SK 50p - Compressed

HYDRAULIC EXCAVATOR
MAINTENANCE SPECIFICATIONS
SHOP
MANUAL model SK50P
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
Book Code No.S5PS0010E01

0-1
GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in mi-
nor or moderate injury. It may also be used to
alert against possible damage to the machine
Do not operate or perform any maintenance on this and its components and is represented as fol-
machine until all instructions found in the OPERA- lows:
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine (4) It is very difficult to forecast every danger that may
may cause accidents and could result in serious in- occur during operation. However, safety can be en-
jury or death. sured by fully understanding proper operating pro-
Always keep the manual in storage. cedures for this machine according to methods
If it is missing or damaged, place an order with an recommended by Manufacturer.
authorized our Distributor for a replacement. (5) While operating the machine, be sure to perform
If you have any questions, please consult an autho- work with great care, so as not to damage the ma-
rized our Distributor. chine, or allow accidents to occur.
(1) Most accidents, which occur during operation, are (6) Continue studying the manual until all Safety, Oper-
due to neglect of precautionary measures and safe- ation and Maintenance procedures are completely
ty rules. Sufficient care should be taken to avoid understood by all persons working with the ma-
these accidents. Erroneous operation, lubrication chine.
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:
2) WARNING- Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
The proper and safe lubrication and maintenance

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
SE Asia INDEX SK50P
Book Code No. Index
Title 1
Distribution Year–Month No. 33 25
MAINTENANCE SPECIFICATIONS
S5PA0105E01
2011-01
OUTLINE 1
S5PS0210E01
2011-01
SPECIFICATIONS 2
S5PS0310E01
ATTACHMENT DIMENSIONS 3 2
2011-01 42 34
S5PJ1131E02
TOOLS 11
2011-01
S5PS1210E01 STANDARD MAINTENANCE
2011-01 TIME TABLE
12
S5PS1310E01 MAINTENANCE STANDARD
13
2011-01 AND TEST PROCEDURE
43 11 3
_ 51
S5PS2210E01
2011-01
HYDRAULIC SYSTEM 22
S5PS2310E01
SYSTEM
2011-01
ELECTRIC SYSTEM 23
44 12
S5PS2410E01
2011-01
COMPONENTS SYSTEM 24
_
AIR-CONDITIONER SYSTEM 25
_
13
S5PA3105E01 GENERAL DISASSEMBLY
DISASSEMBLING
2011-01 & ASSEMBLY

31
S5PS3210E01
ATTACHMENT 32
2011-01
S5PS3310E01 UPPER SLEWING
2011-01
33
STRUCTURE
S5PS3410E01 22
2011-01
TRAVEL SYSTEM 34
E / G TROUBLESHOOTING
S5PS4201E01
2011-01
HYDRAULIC SYSTEM 42
S5PS4301E01
2011-01
ELECTRICAL SYSTEM 43 31 23
S5PW4431E02
ENGINE 44
2011-01
S5PW5131E02
ENGINE 51
2011-01
_
32 24
_
PS02-00101~ APPLICABLE MACHINES
0-5
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
［1. OUTLINE］
１
1. OUTLINE
TABLE OF CONTENTS
1.1 GENERAL PRECAUTIONS FOR REPAIRS …………………………………………………………………1-3

1.1.1 PREPARATION BEFORE DISASSEMBLING …………………………………………………………1-3
1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING …………………………………………………1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ………………………………1-4
1.1.4 ELECTRICAL EQUIPMENT ………………………………………………………………………………1-6
1.1.5 HYDRAULIC PARTS ………………………………………………………………………………………1-7
1.1.6 WELDING REPAIR …………………………………………………………………………………………1-7
1.1.7 ENVIRONMENTAL MEASURE ……………………………………………………………………………1-7
1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS' STANDARD HANDBOOK FOR
MECHANICAL ENGINEERS) …………………………………………………………………………………………1-8
Book Code No. S5PA0105E01
1-1
［1. OUTLINE］
Issue Date of Issue Applicable Machines Remarks

S5PA0105E01
First Edition June, 2009 E10SR : PA03-05001~
(NHK-EUR)
April, 2010 SK50SR-5 : PJ06-09807~

(KCM North America)
CX50B : PJ06-09807~
(CASE-NA)
E50B : PJ06-09807~
(NH-NA)
SK30SR-5 : PW14-46519~
SK35SR-5 : PX15-21105~ (KCM S.E.ASIA&OCE)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-AUS)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-AUS)
CX27B : PV13-33001~
(CASE-Australia)
E27B : PV13-33001~
(NH-AUS)
SK40SR-5 : PH07-06609~
May, 2010
SK50SR-5 : PJ06-09807~ (KCM S.E.ASIA&OCE)
E50B : PJ06-09807~
(NH-AUS)
CX50B : PJ06-09807~
(CASE-AUS)
SK27SR-5 : PV13-33453~
(NA)
CX27B : PV13-33453~
(CASE-NA)
E27B : PV13-33453~
(NH-NA)
SK20SR-5 : PM10-10609~
SK27SR-5 : PV13-33453~ (KCM S.E.ASIA&OCE)
CX27B : PV13-33453~
(CASE-Australia)
E27B : PV13-33453~
(NH-AUS)
September, 2010 SK55SRX : PS02-00101~

(KCM North America)
CX55BMSR : PS02-00101~
(CASE-NA)
E55BX : PS02-00101~
(NH-NA)
December, 2010 SK55SRX : PS02-00101~

(KOR)
January, 2011 SK50P : PS02-00101~

(SE Asia)
1-2
［1. OUTLINE］
1.1 GENERAL PRECAUTIONS FOR REPAIRS
１
1.1.1 PREPARATION BEFORE DISASSEMBLING
(1) Understanding operating procedure

Read OPERATOR'S MANUAL carefully to understand the operating procedure.
(2) Cleaning machines

Remove soil, mud, and dust from the machine before carrying it into the service shop to prevent loss
of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while
reassembling.
(3) Inspecting machines

Identify the parts to be disassembled before starting work, determine the disassembling procedure by
yourself considering the workshop situations etc., and request procurement of necessary parts in
advance.
(4) Recording
Record the following items for communication and prevention of recurring malfunction.
1. Inspection date and place.

2. Model name, applicable machine number, and hour meter read.
3. Trouble condition, place and cause.
4. Visible oil leakage, water leakage and damage.
5. Clogging of filters, oil level, oil quality, oil contamination and loosening of connections.
6. Result of consideration if any problem exists based on the operation rate per month calculated
from hour meter indication after the last inspection date.
(5) Arrangement and cleaning in service shop

1. Tools required for repair work.
2. Prepare space to place the disassembled parts.
3. Prepare oil containers for draining oil etc.
1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING
(1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses.
(2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a
preliminary meeting before starting work.
(3) Stop the engine before starting inspection and maintenance to prevent the operator being caught
in machine.
(4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a
state of emergency.
(5) Choose a hard, level and safe place, and place the attachment on the ground securely.
(6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine.
1-3
［1. OUTLINE］
(7) Use proper tools, and replace or repair defective tools.

(8) Support the machine and attachment with supports or blocks if the work is performed in the lifted
condition.
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT
(1) Removing hydraulic equipment

1. Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side
cover and take out the filter.
2. Carefully drain oil of the removed pipes into a containers without spilling on the floor.
3. Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion.
4. Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear
oil before placing it on the workbench.
(2) Disassembling hydraulic equipment

1. Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the
manufacturer, who is not responsible for the performance and function of the product after
modification.
2. When disassembling and reassembling for unavoidable reason, refer the work to qualified
personnel who have the specific knowledge or completed the parts service training.
3. Provide matching marks to facilitate reassembling work.
4. Before starting the work, read the manual of disassembling procedure, if it is provided, and
decide whether the work can be performed by yourself.
5. Use the special jig and tools without fail if they are specified.
6. If it is hard to remove a part according to the procedure, do not try it by force but investigate the
cause.
7. Place the removed parts in order and attach tags to facilitate the reassembling.
8. Note the location and quantity of parts commonly applied to multiple locations.
(3) Inspecting parts

1. Ensure that the disassembled parts are free from seizure, interference and uneven contact.
2. Measure and record wear condition of parts and clearance.
3. If the problem is found in a part, repair or replace it with a new one.
(4) Reassembling hydraulic equipment

1. Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the
cleaning of parts.
2. Perform rough and finish cleaning before assembling.
3. Remove washing oil by air and apply clean hydraulic or gear oil for assembling.
4. Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease
in advance.
5. Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be
applied.
6. Remove rust preventive agent from the new parts before use.
7. Fit bearings, bushings and oil seals using special jigs.
8. Assemble the parts utilizing matching marks.
9. Ensure all the parts are completely assembled after the work.
1-4
［1. OUTLINE］
(5) Installing hydraulic equipment

1. Ensure hydraulic oil and lubricant are properly supplied.
１
2. Perform air bleeding when :
a. Hydraulic oil changed
b. Parts of suction side piping replaced
c. Hydraulic pump installed
d. Slewing motor installed
e. Travel motor installed
f. Hydraulic cylinder installed
3. Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug,
starting the engine and keep it in low idle condition.
Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug.
4. Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more
than 5 minutes at low speed without load.
5. Perform air bleeding of pilot line by performing a series of digging, slewing and travel.
6. Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if
necessary.
Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air
bleeding will result in damage to the equipment.
Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.
1-5
［1. OUTLINE］
1.1.4 ELECTRICAL EQUIPMENT
(1) Do not disassemble electrical equipment.

(2) Handle it carefully not to drop and give a shock.
(3) Turn the key OFF prior to connecting and disconnecting work.
(4) Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force
to the caulking portion.
(5) Connect the connector and ensure it is completely locked.
(6) Turn the key OFF prior to touching the terminal of starter or generator.
(7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay.
(8) Do not splash water on the electrical equipment and connectors during machine washing.
(9) Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard
to remove moisture from the connector.
If moisture adhesion is found, dry it completely before the connection.
Battery electrolyte is hazardous.

Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or
loss of eyesight.
If the exposure occurs, take the following emergency measures and seek the advice of a medical
specialist.
-When skin exposed :
Wash with water and soap sufficiently.
-When eyes exposed :
Immediately wash away with city water continuously for more than 10 minutes.
-When a large amount of the liquid flows out :
Neutralize with sodium bicarbonate or wash away with city water.
-When swallowed :
Drink a large amount of milk or water.
-When clothes exposed:
Immediately undress and wash.
1-6
［1. OUTLINE］
1.1.5 HYDRAULIC PARTS
１
(1) O-ring
・ Ensure O-rings have elasticity and are not damaged before use.
・ Use the appropriate O-rings. O-rings are made of various kinds of materials having different
hardness to apply to a variety of parts, such as the part for moving or fixed portion, subjected to
high pressure, and exposed to corrosive fluid, even if the size is same.
・ Fit the O-rings without distortion and bend.
・ Always handle floating seals as a pair.
(2) Flexible hose (F hose)

・ Use the appropriate parts. Different parts are used depending on the working pressure even the
size of fitting and the total length of the hose is same.
・ Tighten the fitting at the specified torque.
Ensure no kink, tension, interference nor oil leakage is recognized.
1.1.6 WELDING REPAIR

(1) Refer repair welding to qualified personnel according to the appropriate procedure.
(2) Disconnect the ground (earth) cable of the battery before starting the repair.
Failure to do so will cause damage to the electrical equipment.
(3) Move away the articles in advance that may cause fire if exposed to sparks.
(4) Before starting the repair of the attachment, do not fail to cover the plated surface of the piston
rod with flameproof sheet to prevent it from being exposed to sparks.
1.1.7 ENVIRONMENTAL MEASURE

(1) Run the engine at the place that is sufficiently ventilated.
(2) Industrial waste disposal
Dispose of the following parts according to the relevant regulations :
Waste oil and waste container
Battery
(3) Precautions for handling hydraulic oil
Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling
to avoid an accident. If an eye is exposed to the oil, take the following emergency measures :
-When an eye exposed :
Immediately wash away with city water sufficiently till stimulative feeling vanishes.
-When swallowed :
Do not let vomit, and receive medical treatment immediately.
-When skin exposed:
Wash with water and soap sufficiently.
(4) Others
Use replacement parts and lubricants authorized as the manufacturer's genuine parts.
1-7
［1. OUTLINE］
1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on

MARKS' STANDARD HANDBOOK FOR MECHANICAL
ENGINEERS)
Introduction
Although this manual includes International
System of Unit and Foot-Pound System of
Units, if you need SI unit, refer to the
following international system of units.
Given hereinafter is an excerpt of the units
that are related to this manual.
1. Etymology of SI Unites
French: Le Systeme International d' Unites
English: International System of Units
2. Construction of SI Unit System
1-8
［1. OUTLINE］
1-9
［1. OUTLINE］
1-10
［2. SPECIFICATIONS］
２
2. SPECIFICATIONS
TABLE OF CONTENTS
2.1 COMPONENTS NAME …………………………………………………………………………………………2-3

2.2 MACHINE DIMENSIONS ………………………………………………………………………………………2-4
2.3 SPECIFICATIONS AND PERFORMANCE ……………………………………………………………………2-5
2.4 MACHINE & COMPONENTS WEIGHT (DRY) ………………………………………………………………2-7
2.5 TRANSPORTATION………………………………………………………………………………………………2-9
2.6 TYPE OF CRAWLER SHOES …………………………………………………………………………………2-12
2.7 TYPE OF BUCKET ………………………………………………………………………………………………2-13
2.8 ENGINE SPECIFICATIONS ……………………………………………………………………………………2-14
2.8.1 SPECIFICATIONS …………………………………………………………………………………………2-14
2.8.2 ENGINE PERFORMANCE CURVE ………………………………………………………………………2-15
Book Code No. S5PS0210E01
2-1

S5PS0210E01
First Edition January, 2011 SK50P : PS02-00101~
(SE Asia)
2-2
2.1 COMPONENTS NAME
2-3
2.2 MACHINE DIMENSIONS
(1) SK50P (CANOPY)

Unit: mm (ft-in)
2-4
2.3 SPECIFICATIONS AND PERFORMANCE
SPEED AND GRADEABILITY

Model SK50P
Applicable Machines PS02-00101~
Shoe Type Iron shoe Rubber shoe (OPT)
-1
２
Slewing Speed min {rpm} 8.9 {8.9}
Low (1st) High (2nd) Low (1st) High (2nd)
Travel Speed km/h (mph)
2.7 4.6 2.7 4.6
Gradeability % (degree) 58(30)
ENGINE
Model (YANMAR) 4TNV88-BXPYBE (EDM-4TNV88)
Type Water-cooled, 4-cycle type Swirl chamber type diesel engine
Number of cylinders-Bore X Stroke 4 - 88 dia. mm X 90 mm (3.46 in X 3.54 in)
Total Displacement L 2.189 (134 cu-in)
Output Rating kW/min-1 {PS/rpm} 28.6/2,400 {39/2,400}
-1
Maximum Torque N-m/min (lbf-ft/rpm) 131/1,440 (97/1,440)
Starting Motor V X kW 12 X 2.3
Generator V X A 12 X 55
HYDRAULIC COMPONENTS
Hydraulic Pump Variable displacement axial piston + gear pump
Hydraulic Motor Axial piston
Hydraulic Motor w/Reducer (Travel) 2-Axial piston, 2-Speed motor
Control Valve 11-spool multiple control valve
Cylinder (Boom, Arm, Swing, Bucket, Dozer) Double action cylinder
Return Filter Safety valve containing/Filter Type (30μ)
SIDE DIGGING & DOZER

Type Boom swing by hydraulic cylinder
Right 60 degrees
Boom Swing Angle
Left 70 degrees
Stroke of Dozer (above/below) mm (in) 497 / 373 (19.6/14.7)
2-5
WEIGHT
Iron shoe Rubber shoe (OPT)
Machine Weight kg (lb)
4,660 (10,280) 4,520 (9,970)
Upper slewing body kg (lb) 2,040 (4,500) <--
Travel system kg (lb) 1,875 (4,130) 1,735 (3,830)
Attachment
kg (lb) 550 (1,210)
(Boom+STD Arm+STD Bucket)
Oil & Water kg (lb) 95 (210)
This figure is calculated with Japanese standard bucket.
2-6
2.4 MACHINE & COMPONENTS WEIGHT (DRY)
Unit ; kg (lb)
SK50P
MODEL IRON SHOE RUBBER SHOE (OPT)
CANOPY CANOPY
２
COMPLETE MACHINE 4,660 (10,280) 4,520 (9,970)
UPPER FRAME ASSEMBLY 2,040 (4,500) 2,040 (4,500)
(ASSY OF FOLLOWINGS)
UPPER FRAME 577 (1,272) <--
CANOPY / CAB 100 (220) 100 (220)
ENGINE *170 (375) <--
HYDRAULIC PUMP *35(77) <--
RADIATOR *4 (9) <--
HYDRAULIC TANK *40 (88) <--
FUEL TANK *6 (13) <--
SWING BRACKET 106 (234) <--
SWING CYLINDER *44 (97) <--
SLEWING MOTOR *36 (79) <--
CONTROL VALVE *47 (104) <--
COUNTERWEIGHT 380 (840) <--
GUARD - BONNET 88 (190) <--
BOOM CYLINDER *64 (141) <--
LOWER FRAME ASSEMBLY 1,875 (4,130) 1,735 (3,830)
LOWER FRAME 571 (1,260) <--
SLEWING BEARING 58 (128) <--
TRAVEL MOTOR *65X2 (143X2) <--
UPPER ROLLER 5X2 (11X2) <--
LOWER ROLLER 11X10 (24X10) <--
FRONT IDLER 36X2 (79X2) <--
IDLER ADJUSTER 23X2 (51X2) <--
SPROCKET 14X2 (31X2) <--
RUBBER CRAWLER SHOE - 222X2 (490X2)
400mm (15.7") IRON SHOE 290X2 (640X2) -
SWIVEL JOINT *22 (49) <--
DOZER 180 (397) <--
DOZER CYLINDER *32 (71) <--
ATTACHMENT ASSEMBLY 550 (1,210) <--
BOOM ASSEMBLY 262 (577) <--
BOOM 183 (404) <--
ARM CYLINDER *58 (128) <--
ARM ASSEMBLY 175 (390) <--
ARM 104 (230) <--
BUCKET CYLINDER *31 (68) <--
BUCKET LINK 13 (29) <--
IDLER LINK 4X2 (9X2) <--
BUCKET ASSEMBLY (STD) 111 (250) <--
2-7
Unit ; kg (lb)
SK50P
MODEL IRON SHOE RUBBER SHOE (OPT)
CANOPY CANOPY
FLUIDS (ASSY OF FOLLOWINGS) 100 (221) <--
HYDRAULIC OIL 30 (66) <--
FUEL 63 (139) <--
COOLANT 6 (13) <--
Mark * shows dry weight.
2-8
2.5 TRANSPORTATION
(1) LOADING MACHINE ON A TRAILER

1. Keep trailer bed clean. Put chocks against truck wheels.
2. Use a ramp or loading deck. Ramps must be strong enough, have a low angle, and correct
height. Load and unload machine on a level surface.
3. Travel machine onto ramps slowly. Center the machine over the trailer.
２
4. Lower all attachment.
5. Stop engine. Remove key from switch.
Do not put chains over or against hydraulic lines or hoses.
6. Fasten machine to trailer with chains or cables.

During transportation, the bucket or attachments may hit the cab. Therefore, set the machine in
the transporting position by observing following points:
a. Extend the bucket cylinder fully.

b. Extend the arm cylinder fully.
c. Lower the boom.
d. If machine cannot be transported with arm cylinder fully extended, remove bucket or attachment
and extend arm cylinder.
(2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT

1. BOOM WITH ARM CYLINDER
Model SK50P
L X H X W 3,090 X 1,040 X 286
mm(ft-in) (10'1.7") (3'4.9") (11.3")
Weight w/Arm cyl. kg (lb) 262 (578)
2-9
2. ARM & BUCKET

Model SK50P
L X H X W 2,630 X 510 X 600
mm (ft-in) (8'8") (20.1") (23.6")
Weight kg (lb) 285 (630)
3. ARM
Model SK50P
L X H X W 1,870 X 420 X 250
mm (ft-in) (6'2") (16.5") (9.8")
4. BUCKET
Model SK50P
Heaped capacity m3(cu-yd) 0.14 (0.18)
L X H X W 780 X 690 X 600
mm (ft-in) (30.7") (27.2") (23.6")
2-10
5. DOZER w/o cylinder weight

Model SK50P
L X H X W 1,180 X 327 X 1,960
mm (ft-in) (3'10.5") (12.9") (6'5.2")
2-11
2.6 TYPE OF CRAWLER SHOES
2-12
2.7 TYPE OF BUCKET
2-13
2.8 ENGINE SPECIFICATIONS
2.8.1 SPECIFICATIONS
2-14
2.8.2 ENGINE PERFORMANCE CURVE

SK50P
Model : 4TNV88-BXPYBE
Rated Output : 28.6 kW / 2400 min-1 (39 PS / 2,400 rpm)
2-15
2-16
［3. ATTACHMENT DIMENSIONS］
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
３
3.1 BOOM ………………………………………………………………………………………………………………3-3
3.1.1 BOOM DIMENSIONAL DRAWINGS ……………………………………………………………………3-3
3.1.2 BOOM MAINTENANCE STANDARDS …………………………………………………………………3-4
3.2 ARM ………………………………………………………………………………………………………………3-8
3.2.1 ARM DIMENSIONAL DRAWINGS ………………………………………………………………………3-8
3.2.2 ARM MAINTENANCE STANDARDS ……………………………………………………………………3-10
3.3 BUCKET……………………………………………………………………………………………………………3-14
3.3.1 BUCKET DIMENSIONAL DRAWINGS …………………………………………………………………3-14
3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION……………………………………………3-15
3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION …………………………………………3-15
3.4 DOZER ……………………………………………………………………………………………………………3-17
3.4.1 DOZER DIMENSIONAL DRAWINGS ……………………………………………………………………3-17
3.4.2 DOZER MAINTENANCE STANDARDS …………………………………………………………………3-18
3.5 SWING ……………………………………………………………………………………………………………3-20
3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ………………………………………………………3-20
3.5.2 SWING PORTION MAINTENANCE STANDARDS ……………………………………………………3-21
3-1

S5PS0310E01
(SE Asia)
3-2
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWINGS
３
Boom Dimensional Drawings
DIMENSIONS [mm(ft-in)]
No. NAME
SK50P
A Boom length 2980 (9'9.32")
B Distance between pins of boss R1434 (4'8.46")
C Distance between pins of bracket R1489.5 (4'10.6")
D Height of boom cylinder rod pin 500 (19.7")
E Height of arm cylinder (head side) pin 893.8 (35.2")
F Boom foot width 250 (9.84")
G Inner width of bracket for boom cylinder (rod side) mounting 76 (2.99")
H Boom end inner width 175 (6.89")
J Boom end outer width 265 (10.4")
K Inner width of bracket for arm cylinder (head side) 66 (2.60")
d1 Boom foot pin dia. 50 dia.(1.97")
[Bushing outer dia.] [60 dia.(2.36")]
d2 Boom cylinder (rod side) pin dia. 50 dia.(1.97")
d3 Pin dia. of arm end 60 dia.(2.36")
d4 Arm cylinder (head side) pin dia. 45 dia.(1.77")
3-3
3.1.2 BOOM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing on boom section
Clearance of pin and bushing on boom section
-The tolerance for bushing inside diameter means the dimension after fitting of it into place.
-The part number for pins may be changed owing to improvement, use them only for reference.
3-4
３
This page is blank for editing convenience.
3-5
(2) Clearance in thrust direction on boom and cylinder installation section
Clearance in thrust direction on boom section
3-6
3-7
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWINGS
Arm dimensional drawings
3-8
Dimensions [mm(ft-in)]
No. Name
SK50P
A Arm length 1430 (4'8.3")
B Distance between pins of boss and bracket R405 (15.9")
C Distance between pins of boss and bracket R1118 (3'8.02")
D Distance between pins of boss and boss R230.5 (9.07")
E Height between pins of boss and bracket 311 (12.2")
F Height between pins of boss and bracket 211 (8.3")
G Height between pins of boss and center 12 (0.472")
H Boss width 150 (5.91")
J Boss width 175 (6.89")
K Bracket inner width 61 (2.40")
３
L Bracket inner width 66 (2.6")
M Idler link dimension 320 (12.6")
N Bucket link dimension 310 (12.2")
D1 I.D. of boss 55 dia. (2.17")
D2 I.D. of boss 55 dia. (2.17")
D3 I.D. of boss 75 dia. (2.95")
d1 Pin dia. 45 dia. (1.77")
d2 Pin dia. 45 dia. (1.77")
d3 Pin dia. 60 dia. (2.36")
d4 Pin dia. 45 dia. (1.77")
d5 Pin dia. 45 dia. (1.77")
3-9
3.2.2 ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing
Clearance of pin and bushing on arm section
3-10
３
3-11
(2) Clearance in thrust direction on arm and cylinder installation section
Clearance in thrust direction on arm section
3-12
Clearance X shall be adjusted using shims, if clearance exceeds the standard value.
3-13
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWINGS
Bucket dimensional drawings
Model SK50P
No. 3
Heaped Capacity m 0.14
(cu-yd) (0.18)
A Distance between pin and bracket 228.5 (9")
B Distance between bucket pin and tooth end R800 (31.5")
C Inner width of bucket top end 518.8 (20.4")
D Inner width of lug 197 (7.76")
E Inner width of bracket 151 (5.94")
F Outer width of side cutter 600 (23.6")
G Outer width of bucket bottom plate 461 (18.1")
H Outer tooth distance 450 (17.7")
J Pitch between teeth 150 (5.9")
d1 Pin dia. 45 dia.(1.77")
d2 Pin dia. 45 dia.(1.77")
3-14
3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION
３
Dimension of lug section
3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION
Dimension of boss section
3-15
3-16
3.4 DOZER
3.4.1 DOZER DIMENSIONAL DRAWINGS
３
Dozer dimensional drawings
Dimensions [mm(ft-in)]
No. NAME
SK50P
A Blade width 1960 (6'5.17")
B Blade height 345 (1'1.58")
C Distance from dozer attaching pin center to cutting edge end R1149 (3'9.24")
D Inner width of dozer attaching bracket 531 (20.9")
E Width of dozer attaching bracket 69 (2.72")
F Distance from dozer attaching pin center to attaching pin on dozer R737 (29.0")
cylinder head side
G Attaching bracket inner width on dozer cylinder head side 62 (2.44")
H Horizontal distance from dozer attaching pin center to edge end 1105 (3'7.5")
J Vertical distance from dozer attaching pin center to edge end 313 (12.3")
d1 Dozer attaching pin dia. 40 dia.(1.57")
d2 Attaching pin dia. on dozer cylinder head side 55 dia.(2.17")
3-17
3.4.2 DOZER MAINTENANCE STANDARDS
Dozer maintenance standards
3-18
(2) Clearance in thrust direction on the dozer and cylinder installation section
3-19
3.5 SWING
3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS
Swing bracket dimensional drawings
No. NAME DIMENSION [mm(in)]

A Distance between swing center pin and boom foot pin 85 (3.35)
B Distance between boom foot pin and boom cylinder pin 198 (7.80)
C - ditto - 317.5 (12.5)
D Distance between swing center pin and swing cylinder pin R307.5 (12.1)
E - ditto - 290 (11.4)
F Inside width of swing center 326.7 (12.9)
F1 - ditto - 76.2 (3.00)
F2 - ditto - 76 (2.99)
G Inside width of boom foot 250 (9.84)
H Inside width for installing boom cylinder 77 (3.03)
J Inside width for installing swing cylinder 73 (2.87)
D1 lnner dia. of swing center bushing 90 dia.(3.54)
d1 Pin dia. of swing center 80 dia.(3.15)
d2 Pin dia. of boom foot 50 dia.(1.97)
d3 Pin dia. of boom cylinder 50 dia.(1.97)
d4 Pin dia. of swing cylinder 50 dia.(1.97)
3-20
3.5.2 SWING PORTION MAINTENANCE STANDARDS

３
Clearance of pin and bushing on swing portion
3-21
(2) Clearance in thrust direction on swing bracket and cylinder installation section
Clearance in thrust direction on swing portion
3-22
3-23
3-24
［11. TOOLS］
11. TOOLS
TABLE OF CONTENTS
11
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS………………………………………………11-3
11.1.1 Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all
Capscrews & Nuts to proper torque values. ……………………………………………………………………11-3
11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews
& Nuts to proper torque values. …………………………………………………………………………………11-4
11.2 SCREW AND TOOL SIZES …………………………………………………………………………………11-5
11.2.1 CAPSCREW ………………………………………………………………………………………………11-5
11.2.2 CAPSCREW (SOCKET BOLT) …………………………………………………………………………11-5
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ………………………………………………11-6
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE)……………………………………………………11-6
11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ………………………………………………………11-6
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS …………………………………11-7
11.4.1 SLEEVE TYPE TUBE FITTINGS ………………………………………………………………………11-7
11.4.2 PART NO. …………………………………………………………………………………………………11-7
11.5 PLUGS ……………………………………………………………………………………………………………11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ………………………………………………………………11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT ………………………………………………………………11-9
11.6 SPECIAL SPANNERS FOR TUBES …………………………………………………………………………11-10
11.7 SPECIAL TOOLS ………………………………………………………………………………………………11-11
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ………………………………11-12
11.9 COUNTERWEIGHT LIFTING JIG ……………………………………………………………………………11-13
11.10 UPPER FRAME LIFTING JIG ………………………………………………………………………………11-14
Book Code No. S5PJ1131E02
11-1
［11. TOOLS］

S5PJ1131E01
First Edition April, 2010 SK50SR-5 : PJ06-
(KCM North America)
S5PJ1131E02
Revision June, 2010 SK50SR-5 : PJ06-09807~
(KCM North America)

(KCM North America)
CX55BMSR : PS02-00101~
(CASE-NA)
E55BX : PS02-00101~
(NH-NA)

(KOR)
January, 2011 SK50P : PS02-00101~

(SE Asia)
11-2
［11. TOOLS］
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS
The following Torque Specifications are provided for use when actual torque value of a fastener is not
known. Check the capscrews and nuts for their looseness and dropping off before the start of daily
work and at the periodical maintenance. Retighten the loosened ones, and install new ones for the
dropped off. For the new machine, the check and retightening of them must be carried out at first 50
hours operation. For the replacement of them, make sure to use the same size of manufacturer's
genuine parts.
Refer to the table below for the tightening and retightening of capscrews.
・ The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For
the tightening torque for such capscrews, consult with an authorized our distributor. Over-
tightening may cause damages on the parts to be fixed.
・ In case that the tightening torque is specified in the manual, use such torque values regardless 11
to the table below.
・ Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No
indication is provided for smaller size of capscrews, M 5 or less.
11.1.1 Metric Coarse Thread Standard Tightening Torque Values. Make Certain
to tighten all Capscrews & Nuts to proper torque values.
11-3
［11. TOOLS］
11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to
tighten all Capscrews & Nuts to proper torque values.
11-4
［11. TOOLS］
11.2 SCREW AND TOOL SIZES
11.2.1 CAPSCREW
11
11.2.2 CAPSCREW (SOCKET BOLT)
11-5
［11. TOOLS］
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE)
11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE)
NOTE : The application of the tightening torque is subject to a dry condition.
11-6
［11. TOOLS］
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE

FITTINGS
11.4.1 SLEEVE TYPE TUBE FITTINGS
11
11.4.2 PART NO.
11-7
［11. TOOLS］
11.5 PLUGS
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT

(1) Cap nut (Joint plug)
(2) Plug (Tube plug)
(3) Nut
11-8
［11. TOOLS］
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw
(2) PT screw
11
(3) Plug for (F) flare hose
11-9
［11. TOOLS］
11.6 SPECIAL SPANNERS FOR TUBES
11-10
［11. TOOLS］
11.7 SPECIAL TOOLS
11
11-11
［11. TOOLS］
11.8 APPLICATION OF SCREW LOCKING AND SEALING

COMPOUNDS
Manufacturer
Service Features
Loctite Three-Bond
#242 1360K Low strength
Screw locking
#262 1374 Middle strength
compound
#271 1305 High strength
Sealing compound #515 1215 Sealing
11-12
［11. TOOLS］
11.9 COUNTERWEIGHT LIFTING JIG
11
Counterweight lifting jig
11-13
［11. TOOLS］
11.10 UPPER FRAME LIFTING JIG
Upper frame lifting jig
11-14
［12. STANDARD MAINTENANCE TIME TABLE］
12. STANDARD MAINTENANCE

TIME TABLE
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ………………12-4
12
12-1

S5PS1210E01
(SE Asia)
12-2
PREFACE
(1) Working Conditions
1. Technicians : One or more technicians who are qualified by Manufacturer are needed. The
technicians need five years of more experience, and they have to complete the training in the
operation of this machine.
2. Facilities : General jigs, tools, apparatus, testers to be provided.
The maintenance workshop to be equipped with a good enough capacity of building with crane
and inspection instruments necessary for specific self inspection activities.
3. Place : The workshop to be located on a flat land at which the work is able to perform and to
which a service car or truck crane is accessible.
(2) Applicable Range of Standard Maintenance Time

1. Standard maintenance time : Direct maintenance time plus spare time.
2. Direct maintenance time : Net time actually spent for maintenance.
3. Spare time : Time for transportation of the machine for maintenance, preparation for safety work,
meeting for the work and physiological time for the needs of body.
(3) Excluded Time (not included in the standard maintenance time)

1. Repairing time : Time for machining, sheet metal processing, welding, gas cutting, removing broken
screw, taking care of parts and painting.
12
2. Items excluded from maintenance time because of uncertainty in time :
Receiving the vehicle into shop, transportation, delivery, final inspection and investigation of
causes for trouble, diagnosis and inspection.
3. Indirect time : Time for field work, preparation of required parts, etc., before starting work, going to
and from the site, waiting due to user's convenience at the site and paper work for reports, bills,
etc.
4. Special time : Working time at early morning, at mid night and on holidays shall be separately
calculated.
5. Separate calculation : The cost for service cars, trucks with crane and truck cranes shall be
separately calculated.
(4) Applicable Machine for Estimation of Standard Maintenance Time

1. Standard machine.
2. A well maintained machine combined with standard attachments which has operated in a normal
circumstances.
12-3
12.1 STANDARD WORKING TIME TABLE FOR THE

MAINTENANCE OF EXCAVATOR
(1) Standard maintenance time table
1. Units of working time : 6 minutes = 0.1 hour
2. Calculating method of standard maintenance time :
Maintenance time = Working time × Number of workers
(Working time = Maintenance time / Number of workers)
3. When more than one work are done,
a. Add each standard maintenance time
b. A net time (readily starting) is given except covers easily removed by hand.
c. Assy works include the following works marked with black dot -
4. O / H : The removing and installing time are not included.
5. Abbreviations in the table.
ASSY ; Assembly SOL ; Solenoid Rem. ; Removal

ATT ; Attachment SW ; Switch Inst. ; Installation
BRG ; Bearing V ; Valve O/H ; Overhaul
C/V ; Control valve F hose ; Flexible hose
Cyl ; Cylinder E/G ; Engine
(2) Classification of work code

No. GROUP REMARKS
01 Attachment To indicate removing, installing,
02 Canopy and Guard replacement and overhaul.
03 Upper Structure
04 Undercarriage
01 Attachment(1/2)
WORK TO UNIT :
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
00 Bucket portion Refer to 32.1.2
01 Bucket ASSY Rem.l/Inst. 1 pc. Include adjustment 0.4
02 -Bucket removing / installing position Preparation 1 pc. 0.1
03 -Bucket installing pin Rem./Inst. 1 pc. Include stopper pin. 0.1
04 -Bucket drive pin Rem./Inst. 1 pc. 0.1
05 -Bucket sling and transfer Preparation 1 pc. 0.1
06 -Bucket (Single) O/H 1 pc. Not include removal / inst. 0.6
07 -Bushing Replace 1 pc. 0.5
10 Arm portion Refer to 32.1.3
11 Arm ASSY Rem./Inst. 1 pc. 0.8
12 -Bucket cylinder removing / installing Preparation 1 pc. 0.2
position and piping
13 -Bucket cylinder rod pin Rem./Inst. 1 pc. Include stopper pin. 0.1
14 -Bucket cylinder head pin Rem./Inst. 1 pc. Include stopper pin. 0.1
15 -Bucket cylinder assy Rem./Inst. 1 pc. 0.1
16 -Arm cylinder rod pin Rem./Inst. 1 pc. Include stopper pin. 0.1
17 -Boom top pin Rem./Inst. 1 pc. 0.1
18 -Arm sling and transfer Rem./Inst. 1 pc. 0.1
12-4
01 Attachment(2/2)
WORK TO UNIT :
BE DONE HOUR
20 Boom portion Refer to 32.1.4
21 Boom ASSY Rem./Inst. 1 pc. 1.0
22 -Boom removing / installing position Preparation 1 pc. 0.1
23 -Boom cylinder temporary slinging Preparation 1 pc. 0.1
24 -Boom cylinder rod pin Rem./Inst. 1 pc. Include stopper pin. 0.1
25 -Boom cylinder piping Rem./Inst. 1 pc. 0.1
26 -Arm & Bucket piping Rem./Inst. 1 pc. 0.2
27 -Boom assy temporary slinging Rem./Inst. 1 pc. 0.1
28 -Boom foot pin Rem./Inst. 1 pc. Include stopper pin. 0.1
29 -Boom assy slinging Rem./Inst. 1 pc. 0.1
30 Arm cylinder removing / installing Rem./Inst. 1 pc. 0.3
31 -Arm cylinder piping Rem./Inst. 1 pc. 0.1
32 -Arm cylinder head pin Rem./Inst. 1 pc. Include stopper pin. 0.1
33 -Arm cylinder slinging Rem./Inst. 1 pc. 0.1
40 Boom cylinder removing / installing Rem./Inst. 1 pc. 0.3
41 -Boom cylinder piping Rem./Inst. 1 pc. 0.1
42 -Boom cylinder head pin Rem./Inst. 1 pc. 0.1
43 -Boom cylinder slinging Rem./Inst. 1 pc. 0.1
12
50 Bucket cylinder O / H 1 pc. 2.5
51 -Pin bushing Replace 1 set Include seal. 1.0
60 Arm cylinder O / H 1 pc. 2.5
70 Boom cylinder O / H 1 pc. 2.5
80 Swing portion Refer to 32.1.5
81 Swing bracket assy Rem./Inst. 1 pc. After removing boom. 0.4
82 -Swing cylinder rod pin Rem./Inst. 1 pc. 0.1
83 -Swing bracket slinging Rem./Inst. 1 pc. 0.1
84 -Swing center pin Rem./Inst. 1 pc. 0.1
85 Swing cylinder removing / installing Rem./Inst. 1 pc. After removing swing 0.3
bracket.
86 -Swing cylinder hose Rem./Inst. 2 pcs. 0.2
87 -Swing cylinder head pin Rem./Inst. 1 pc. 0.1
88 Swing cylinder O / H 1 pc. 2.5
89 -Pin bushing Replace 1 pc. Include seal. 1.0
Other necessary works Rem./Inst. 1 set Panel assy (3) 0.1
90 Dozer portion Refer to 32.1.6
91 Dozer ASSY Rem./Inst. 1 pc. 0.6
92 -Dozer cylinder hose Rem./Inst. 2 pcs. 0.2
93 -Dozer cylinder rod pin Rem./Inst. 1 pc. 0.1
94 -Dozer installing pin Rem./Inst. 2 pcs. 0.2
95 Dozer cylinder O / H 1 pc. 2.5
12-5
02 Canopy & Guard (1/1)

WORK TO UNIT :
BE DONE HOUR
10 Canopy portion Refer to 33.1.1
11 Canopy assy Rem./Inst. 1 pc. 0.4
12 -Harness Rem./Inst. 1 pc. 0.1
20 Bonnet & Guard Refer to 33.1.2
21 Cover assy (1) Rem./Inst. 1pc. 0.1
23 Bonnet assy (3) Rem./Inst. 1pc. 0.1
26 Guard assy (B1) Rem./Inst. 1pc. 0.1
27 Cover assy (B2) Rem./Inst. 1pc. 0.1
30 Control stand portion Refer to 33.1.14
31 Control stand ASSY Rem./Inst. 1 pc. 1.6
32 -Air cleaner Rem./Inst. 1 pc. 0.1
33 -E / G control cable Rem./Inst. 1 pc. 0.2
34 -Deceleration motor Rem./Inst. 1 pc. 0.1
35 -Filler neck Rem./Inst. 1 pc. 0.1
36 -Air-con hose Rem./Inst. 2 pcs. 0.4
37 -Heater hose Rem./Inst. 2 pcs. 0.4
38 -Harness Rem./Inst. 1 set 0.3
Other necessary works Rem./Inst. 1 set Canopy 0.2
Rem./Inst. 1 set Floor cover 0.1
Rem./Inst. 1 set Guard (Cover, support) 0.4
Rem./Inst. 1 pc. Counterweight 0.4
Rem./Inst. 1 pc. Negative terminal of battery 0.1
40 Floor plate portion Refer to 33.1.3
41 Floor plate assy Rem./Inst. 1 set 0.5
Other necessary works Rem./Inst. 1 pc. Canopy removal / inst 0.2
50 Counterweight portion Refer to 33.1.5
51 Counterweight ASSY Rem./Inst. 1 pc. 0.4
52 -Lifting tools Preparation 1 set 0.1
53 -Slinging Rem./Inst. 1 pc. 0.1
54 -Counterweight fixing bolt Rem./Inst. 1 set 0.1
Other necessary works Rem./Inst. 3 pcs. Guards 0.3
12-6
03 Upper structure (1/4)

WORK TO UNIT :
BE DONE HOUR
00 Control portion
01 E / G control cable Rem./Inst. 1 pc. 0.2
02 Swing yoke Rem./Inst. 1 pc. 0.1
03 Swing rod Rem./Inst. 1 pc. 0.2
04 Other necessary works Rem./Inst. 1 set Cover and Hose 0.4
10 Intake portion Refer to 33.1.11
11 Air cleaner ASSY Rem./Inst. 1 pc. 0.4
12 -Hose (B1) Rem./Inst. 1 pc. 0.1
13 -Hose (B2) Rem./Inst. 1 pc. 0.1
14 -Element Replace 1 pc. 0.1
20 Exhaust portion Refer to 33.1.13
21 Muffler ASSY Rem./Inst. 1 pc. 0.4
22 -Clamp Rem./Inst. 1 pc. 0.1
23 -Exhaust manifold attaching nuts Rem./Inst. 4 pcs. 0.1
24 -Muffler fixing bolt Rem./Inst. 4 pcs. 0.1
Other necessary works Rem./Inst. 1 set Heat insulation cover 0.1
30 E / G Accessory portion Refer to 33.1.12 & 33.1.15 12
31 Generator Rem./Inst. 1 pc. 0.6
32 -Connector Rem./Inst. 1 pc. 0.1
33 -Generator fixing bolt Rem./Inst. 2 pcs. 0.1
34 -V-belt Rem./Inst. 1 pc. Include tension adjusting 0.3
Other necessary works Rem./Inst. 1 set Covers 0.1
36 Starter Rem./Inst. 1 pc. 0.5
37 -B-terminal Rem./Inst. 1 pc. 0.1
38 -S-terminal connector Rem./Inst. 1 pc. 0.1
39 -Starter fixing bolt Rem./Inst. 2 pcs. 0.2
Other necessary works Rem./Inst. 1 set Cover and Floor plate 0.1
Rem./Inst. 1 set Seat and Stand cover 0.3
40 Fuel portion Refer to 33.1.9
41 Fuel tank ASSY Rem./Inst. 1 pc. 0.6
42 -Fuel Replace 1 pc. 0.2
43 -Hose (Supply ; water separator side) Rem./Inst. 1 pc. 0.1
44 -Hose (Return ; filter side) Rem./Inst. 1 pc. 0.1
45 -Level sensor connector Rem./Inst. 1 pc. 0.1
46 -Fuel tank fixing bolt Rem./Inst. 2 pcs. 0.1
Other necessary works Rem./Inst. 1 pc. Covers 0.6
12-7

WORK TO UNIT :
BE DONE HOUR
50 Hydraulic oil tank portion Refer to 33.1.10
51 Hydraulic oil tank ASSY Rem./Inst. 1 pc. 1.6
52 -Return filter Replace 1 pc. Include pressure releasing 0.2
& replacing O-ring
53 -Hydraulic oil Rem./Inst. 1 pc. 0.2
54 -Suction hose Rem./Inst. 1 pc. 0.2
55 -Strainer Replace 1 pc. Include replacing O-ring 0.1
56 -Pilot return hose Rem./Inst. 1 pc. 0.1
57 -Swivel drain hose Rem./Inst. 1 pc. 0.1
58 -SOL. valve return hose Rem./Inst. 1 pc. 0.1
59 -Slewing, C / V return hose Rem./Inst. 2 pcs. 0.2
60 -Tank fixing bolt Rem./Inst. 4 pcs. 0.2
Other necessary works Rem./Inst. 1 pc. Covers 0.2
Rem./Inst. 1 pc. Control valve 1.6
Rem./Inst. 1 pc. Solenoid valve 0.1
70 Pump portion Refer to 33.1.6
71 Pump ASSY Rem./Inst. 1 pc. After removing 1.3
counterweight
72 -Hydraulic oil Replace 1 pc. Include pressure releasing 0.2
73 -Pilot delivery oil hose Rem./Inst. 1 pc. 0.1
74 -Air conditioner power shift command Rem./Inst. 1 pc. 0.1
hose
75 -Suction hose Rem./Inst. 1 pc. 0.2
76 -Suction tube (pump side) Rem./Inst. 1 pc. 0.2
77 -Main pump delivery hose Rem./Inst. 3 pcs. 0.3
78 -Pump fixing bolt Rem./Inst. 2 pcs. 0.2
79 Pump ASSY O / H 1 pc. 3.0
Other necessary works Feed 1 pc. Hyd. oil in pump 0.1
80 Radiator portion Refer to 33.1.16
81 Radiator ASSY Rem./Inst. 1 pc. 1.3
82 -Coolant (LLC) Replace 1 pc. 0.2
83 --Coolant density Measuring 1 pc. 0.2
84 -Reserve tank hose Rem./Inst. 1 pc. 0.1
85 -Fuel cooler fixing bolt Rem./Inst. 1 pc. 0.1
86 -Radiator hose Rem./Inst. 2 pcs. 0.2
87 -Cooler hose Rem./Inst. 2 pcs. 0.2
88 -Radiator fixing bolt Rem./Inst. 3 pcs. 0.1
89 -Radiator lifting or slinging Rem./Inst. 1 pc. 0.1
Other necessary works Rem./Inst. 1 pc. Counterweight 0.4
Rem./Inst. 1 set Covers 0.2
Rem./Inst. 1 pc. Duct 0.1
12-8

WORK TO UNIT :
BE DONE HOUR
90 Engine (E / G) Installing portion Refer to 33.1.17
91 Engine ASSY Rem./Inst. 1 pc. 1.0
92 -Fuel hose Rem./Inst. 4 pcs. For water separator - 0.2
1pc., For fuel filter - 1 pc.
& For feed pump - 2pcs.
93 -Harness, connector and cable Rem./Inst. 1 set 0.3
94 -Engine fixing nut Rem./Inst. 1 pc. 0.2
95 -Engine slinging Rem./Inst. 1 set 0.2
Rem./Inst. 1 pc. Canopy 0.2
Rem./Inst. 1 set Control stand 1.0
Rem./Inst. 1 pc. Air cleaner 0.2
Rem./Inst. 1 pc. Muffler 0.4
Rem./Inst. 1 pc. Pump 1.3
Rem./Inst. 1 pc. Radiator 1.3
Rem./Inst. 1 pc. Battery negative terminal 0.1
100 Control valve portion Refer to 33.1.7 12
101 Control valve ASSY Rem./Inst. 1 pc. 1.6
102 -Piping connector, hose Rem./Inst. 1 set Include attaching hose's tag 1.0
and plug
104 -Fixing bolt Rem./Inst. 1 set 0.1
105 Control valve ASSY O / H 1 pc. 3.0
Rem./Inst. 1 set Hoses 0.2
110 Slewing motor portion Refer to 33.1.19
111 Slewing motor ASSY Rem./Inst. 1 pc. 1.0
112 -Piping connector, hose Rem./Inst. 8 pcs. Include attaching hose's tag 0.5
and plug
113 -Fixing bolt Rem./Inst. 1 pc. 0.3
114 Slewing motor ASSY O / H 1 pc. 3.0
Other necessary works Rem./Inst. 1 set Floor plate, Covers 0.2
Feed 1 pc. Hyd. oil in motor 0.1
120 Swivel joint portion Refer to 33.1.20
121 Swivel joint ASSY Rem./Inst. 1 pc. After removing slewing 2.5
motor
122 -Under cover Rem./Inst. 1 pc. 0.1
123 -Piping connector, hose Rem./Inst. 1 set Include attaching hose's tag 1.5
and plug
124 -Stopper Rem./Inst. 1 pc. 0.1
125 -Fixing bolt Rem./Inst. 1 set 0.2
126 Swivel joint ASSY O / H 1 pc. 2.0
Other necessary works Preparation 1 pc. Removal / Inst. position. 0.1
(Secure working space.)
1 pc. Cab removal / inst. 0.2
(for easy working)
1 pc. Floor plate cover (4) 0.1
removal / inst.
12-9
03 Upper structure(4/4)
WORK TO UNIT :
BE DONE HOUR
130 Upper frame portion Refer to 33.1.21
131 Upper frame ASSY Rem./Inst. 1 pc. 1.0
132 -Fixing bolt Rem./Inst. 1 set Apply sealant 0.3
133 -Upper frame slinging Rem./Inst. 1 pc. 0.3
134 -Cleaning Cleaning 1 pc. 0.2
Other necessary works Rem./Inst. 1 pc. Canopy 0.2
Rem./Inst. 1 pc. Guard (Cover, support) 1.5
Drain / Feed 1 pc. Hydraulic oil 0.2
Rem./Inst. 1 set Swivel joint hose 0.5
Rem./Inst. 1 set Boom 1.0
12-10
04 Undercarriage
WORK TO UNIT :
BE DONE HOUR
00 Travel portion Refer to 34.1.2
01 Rubber crawler Rem./Inst. One side 0.6
02 -Rubber shoe removing / inst.position. Preparation One side 0.1
03 -Tension adjusting Adjusting One side 0.2
04 -Crawler shoe Rem./Inst. One side 0.2
10 Upper roller portion Refer to 34.1.3
11 Upper roller ASSY Rem./Inst. 1 pc. After removing crawler shoe 0.2
12 Upper roller O / H 1 pc. 1.0
20 Lower roller portion Refer to 34.1.6
21 Lower roller ASSY Rem./Inst. 1 pc. 0.2
22 Lower roller O / H 1 pc. 1.0
30 Front idler & Idler adjuster portion Refer to 34.1.7 & 34.1.8
31 Idler & Idler adjuster ASSY Rem./Inst. One side After removing crawler shoe 0.5
32 Idler & Idler adjuster ASSY O / H One side 0.1
33 Idler ASSY O / H One side 1.0
34 Idler adjuster ASSY Rem./Inst. One side 0.5
40 Sprocket portion Refer to 34.1.9 12
41 Sprocket Replace One side After removing crawler shoe 0.5
50 Travel motor portion Refer to 34.1.10
51 Travel motor ASSY Rem./Inst. One side After removing crawler shoe 1.0
52 -Motor cover Rem./Inst. One side 0.1
53 -Hydraulic connector, hose Rem./Inst. One side Include attaching hose's tag 0.6
and plug
54 -Motor fixing bolt Rem./Inst. One side 0.3
55 -Motor slinging Rem./Inst. One side 0.1
56 Travel motor O / H One side 3.0
57 Travel reduction unit Rem./Inst. One side 3.0
Other necessary works Feed One side Hyd. oil in motor 0.1
60 Slewing bearing portion Refer to 34.1.11
61 Slewing bearing ASSY Rem./Inst. 1 pc. After removing upper frame 0.6
62 -Slewing bearing fixing bolt Rem./Inst. 1 pc. 0.3
63 -Slewing bearing Cleaning 1 pc. Decreasing / Replenishment 0.1
64 -Slewing bearing slinging Rem./Inst. 1 pc. 0.2
12-11
12-12
［13. MAINTENANCE STANDARD AND TEST PROCEDURE］
13. MAINTENANCE STANDARD AND

TEST PROCEDURE
TABLE OF CONTENTS
13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS …………………………………13-3

13.2 PERFORMANCE INSPECTION STANDARD TABLE ……………………………………………………13-5
13.2.1 STANDARD VALUE TABLE ……………………………………………………………………………13-5
13.3 MEASURING ENGINE SPEED ………………………………………………………………………………13-7
13.3.1 ENGINE SPEED MEASUREMENT ……………………………………………………………………13-7
13.4 MEASURING HYDRAULIC OIL PRESSURE ………………………………………………………………13-9
13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT ……………………………13-9
13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT …………………………………………………13-10
13.5 MEASURING TRAVEL PERFORMANCES …………………………………………………………………13-13
13.5.1 TRAVEL ……………………………………………………………………………………………………13-13
13.5.2 TRAVEL DEVIATION ……………………………………………………………………………………13-13 13
13.5.3 MOVEMENT DRIFT DUE TO GRAVITY ………………………………………………………………13-14
13.5.4 DRAIN RATE OF TRAVEL MOTOR …………………………………………………………………13-14
13.6 MEASURING SLEW PERFORMANCES ……………………………………………………………………13-16
13.6.1 SLEW TIME…………………………………………………………………………………………………13-16
13.6.2 OVERRUN WHEN SLEWING STOPS …………………………………………………………………13-16
13.6.3 SLEW DRIFT DUE TO GRAVITY………………………………………………………………………13-16
13.6.4 DRAIN RATE OF SLEW MOTOR………………………………………………………………………13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES …………………………………………13-18
13.7.1 CYLINDER SPEED ………………………………………………………………………………………13-18
13.7.2 GRAVITY DRIFT OF CYLINDERS ……………………………………………………………………13-19
13.8 MEASURING SLEW BEARING PERFORMANCES ………………………………………………………13-20
13.8.1 SLEW BEARING-BUCKET TIP PLAY …………………………………………………………………13-20
13.8.2 SLEW BEARING PLAY …………………………………………………………………………………13-20
13.9 MEASURING CRAWLER TENSION …………………………………………………………………………13-21
13.9.1 CRAWLER TENSION ……………………………………………………………………………………13-21
13-1

S5PS1310E01
(SE Asia)
13-2
13.1 HOW TO USE MAINTENANCE STANDARDS AND

PRECAUTIONS
(1) Application
1. For New Machine;
This manual is to be used to check the actual performance and functions of the machine
compared with the PERFORMANCE STANDARDS.
2. At Specific Self-Inspection (as per LOCAL RULES);
The maintenance standards are used to make them as the criteria to determine the time for
reconditioning, adjustment and replacement.
3. At Deterioration of Performance;
This manual is of the criteria of safe and economical judgment whether the deterioration of
performance on the machine would be caused by any faults or normal deterioration due to
machine operation for a long period.
4. For Replacement of Major Components;
This manual is of the standard to determine the time for replacement to recover the performance
of major components such as pump, etc.
(2) Terminology
1. Standard Values :
These are of the standard values to assemble and regulate a new machine. Where special notes
are not given, these values are based on the machine with standard structure (the machine with
standard attachments and shoes).
2. Standard Values for Repair :
These are of the values at which the reconditioning is required.
In order to ensure the performance and safety, it is strictly prohibited to use the machine with the 13
parts and components being over the standard values.
3. Serviceability Limit :
This is of the service limit for each part and component at which the reconditioning is impossible
and they must be replaced to new ones.
All the parts and components which are estimated to exceed the serviceability limit up to the next
periodical inspection and maintenance, should be also replaced to new ones.
The machine operation with the parts and components which have exceeded the serviceability limit,
causes increase of troubles and down time of the machine, and also causes safety problems.
(3) Precautions for Judgment :

1. Evaluation for Measured Data :
It is inevitable some variation on the measured data due to differences between measuring
conditions, peculiar variability on a new machine, old and new versions of the machine and
measuring characteristics.
The judgment for the measured data should be comprehensively conducted based on the extent of
level of the measured data, instead of mere comparison with the standard values.
2. Determination for Reconditioning, Adjustment or Replacement :
There are two kinds of deterioration of machine performance; one is due to normal wear with
time elapsing of operation, and the other is recoverable to the standard values with the adjustment
for pressure, etc.
Therefore, the determination for reconditioning, adjustment or replacement should be conducted
taking various factors into consideration such as operating hours, working conditions and
maintenance conditions of the machine, so that the machine is able to be operated at the
optimum performance level.
13-3
(4) Other Precautions

1. Parts with Aging Effect :
The rubber products such as hydraulic hoses, O-rings, oil seals, etc. are deteriorated with the
aging effect. It is necessary to replace them to new ones at periodical intervals or at every
overhaul.
2. Parts required Periodical Replacement :
It is recommendable to designate the important hoses critical to secure the safety as Very
Important Parts (V.I.P.), and periodically replace with new ones.
3. Inspection & Replacement of Lubricants :
It is necessary for the user of the machine to fully familiarize himself with the procedures and
precautions to handle the machine in safe and carry out the maintenance, as well as the
procedures for inspection and lubrication. Refer to the OPERATION & MAINTENANCE MANUAL
as well.
13-4
13.2 PERFORMANCE INSPECTION STANDARD TABLE
13.2.1 STANDARD VALUE TABLE
13
*1. The pressure for slew is controlled by the relief valve attached to the slew motor.
Set pressure of this relief valve is 20.1 MPa (2915 PSi)
*2. Measure the both pressures of main relief valve and overload relief valve at pressure measuring
port on main control valve.
13-5
13-6
13.3 MEASURING ENGINE SPEED
13.3.1 ENGINE SPEED MEASUREMENT

(1) Measuring Instruments
1. Diesel Speedometer (Measuring engine
speed by means of applying a pick-up to
one of injection pipes)
2. Surface Thermometer (Measuring the
surface temperature getting contact of the
probe with the surface of hydraulic oil tank
and radiator)
Engine Speed measurement (The above figure

shows concept)
(2) Engine Warming up Operation

Start up the engine, and make the coolant
temperature within the range of 60 to 90C
degrees (140 to 194F degrees).
Check the coolant temperature with the coolant
thermometer on the monitor panel. The white 13
color zone shows approx. 67 to 105C degrees
(153 to 221F degrees) of temperature range.
Therefore, when the indicator is located at
around center of the white zone, it is suitable
for the engine operation.
(3) Engine Speed Measurement

1. Apply the pick up of speedometer to one of convenient injection pipes. (Refer to Fig. "Engine
Speed measurement")
2. Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD
VALUE TABLE.
13-7
(4) Speed Adjustment

1. Low / High Idling Speed is low ;
The proper engine speed is obtained with the length of accelerator wire as shown in the sketch.
When the engine speed is lower than the standard speed, adjust the length of wire with
loosening the capscrew (9) of throttle lever side.
Accelerator wire adjustment
However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer.
13-8
13.4 MEASURING HYDRAULIC OIL PRESSURE
13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT

(1) Hydraulic Instruments
-6.86 MPa (1000 psi) pressure gauge : 1
set
-49 MPa (7100 psi) pressure gauge : 3 sets
-Surface Thermometer : 1 set
-Pressure Measuring Kit and Oil Analyzing
Equipment : 1 set
(2) Measuring cleanliness of hydraulic oil
After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the measured value is over the standard value, replace the
return filter and/or change the hydraulic oil. 13
13-9
13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT

13.4.2.1 MAIN CIRCUIT PRESSURE
(1) Measuring Conditions
Engine speed : High idling
Hydraulic oil temperature : 50 to 60C degrees
(122 to 140F degrees)
Coolant temperature (on radiator surface) :
60 to 90C degrees (140 to 194F degrees)
(2) Pressure Measuring Procedures

1. After releasing pressure in the hydraulic oil
tank, and setting a 49 MPa (7100 psi)
pressure gauge to either of pressure
detecting ports (G1, G2 or G3, PF1/4 with
plug), operate the circuit to be measured to
measure the relief pressure.
2. When the main relief pressure is being
within the standard range, the measurement
for the overload relief pressure may be
omitted.
3. If the main relief pressure is lower than the
standard range, tighten up the main relief
valve by half turn [pressure increase by
12.2 MPa (1770 psi)], then measure the
pressure at overload relief valve.
4. After adjustment for the overload relief Main hydraulic oil pressure measurement
pressure, return back the main relief
pressure within the standard range.
13-10
(3) Pressure Adjustment

1. Control Valve : Main Relief Valve and Overload Relief Valve
a. Loosen the lock nut (2), and adjust the
setting pressure turning the setscrew (1).
Roughly with one full turn :
Main relief valve (MRV1, MRV2) :
Approx. 17.7 MPa (2567 psi)
Main relief valve (MRV3), Overload relief
valve :
Approx. 28.4 MPa (4118 psi)
CW turning : Increasing setting pressure
CCW turning : Decreasing setting pressure
b. After the adjustment, tighten up the lock
nut holding the setscrew not to turn around.
c. Again activate the relief valve to check the
stable setting pressure.
Main relief valve (MRV1, MRV2), Overload
relief valve :
Tightening torque for nut (2) : 30 N-m
(22 lbf-ft)
Main relief valve (MRV3) :
Tightening torque for nut (2) : 70 N-m
(52 lbf-ft)
13
Relief valve
2. Slewing Motor : Relief Valve

a. The adjustment of setting pressure for relief
valve of slewing motor is not available. If
the adjustment is required by fatigue of
spring and so on, replace with the new
relief valve in an assembly.
b. Therefore the port of detecting pressure is
not equipped on the slewing motor.
Relief valve (Slewing motor)
13-11
13.4.2.2 PILOT CIRCUIT PRESSURE

(1) Measuring Conditions
Engine : High idling
Hydraulic oil temp. : 50 to 60C degrees
Coolant temp. : 60 to 90C degrees
at radiator surface
(2) Measurement
Releasing pressure in the hydraulic oil
tank of hydraulic system, and setting a 6.86
MPa (1000 psi) pressure gauge to the
pressure detecting port (G4, PF 1/4 with
plug), measure the pilot relief pressure.
Pressure Detecting Port

Relief Valve
Port Location Size
G4 PF1/4 PR1
(3) Pressure Adjustment

Adjust it with the relief valve attached to the solenoid valve.
1. Loosen the lock nut (2), then turn the

setscrew (1) to adjust the set pressure.
CW screwing : Set pressure is increased.
CCW screwing : Set pressure is decreased.
The pressure rise per one turn of adjuster
is 0.8 MPa.
2. After the adjustment, lock the setscrew
with the lock nut holding the setscrew not
to allow its turning.
3. Again actuate the relief valve, and verify
that the set pressure is being stable.
Tightening Torque :
Lock Nut (2) : 15.7 N-m (11.6 lbf-ft)
Capscrew (3) : 3.9 N-m (2.9 lbf-ft)
Relief valve
13-12
13.5 MEASURING TRAVEL PERFORMANCES
TEST PROCEDURES
Measure 3-time each.
Apply average data of the above for judgement.
13.5.1 TRAVEL
(1) Travel Speed (5 Revolutions)
・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C degrees
・ Measurement Posture : Machine Body is
raised using both hoe attachment and
dozer blade.
・ Set crawler shoes in motion. Starting after
one full revolution, measure the time
required for 5 revolutions. (To measure
speed after it has stabilized.)
(2) Travel Speed (10 m)

・ Engine : Rated r.p.m.
(122 to 140F degrees) 13
・ Measurement Posture : Travel Posture
・ Set machine in motion. Starting after a
running of 5 meters, measure the time
required to travel 10 meters. Do this on
level and hard ground.
・ Travel Posture :
Fully extend the arm and bucket cylinders
and place the hoe attachment so that its
lowest part is even with the machine's
minimum ground clearance level. The hoe
attachment must be in a no-load and the
dozer blade must not touch the ground.
13.5.2 TRAVEL DEVIATION

・ Engine : Rated r.p.m.
・ Measurement Posture : Travel Posture
・ Measure the deviation " X " at the point
of half of 10 m (32.8 ft) travel after 5 m
preliminary running. Measure on level and
hard ground.
13-13
13.5.3 MOVEMENT DRIFT DUE TO GRAVITY

Measure the movement distance of machine on a slope due to machine's own weight, holding the
machine for 5 minutes on the slope.
Measuring Conditions :
・ Engine : Stopped
・ Gradient : 15° (Approx. 1/3.73)
・ Machine posture : Fully extending the
boom, arm and bucket cylinders, and fully
retracting the dozer cylinder.
13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Preparation
1. Apply stopper pins for both travel
sprockets of left and right.
2. Stop the engine, and release air in the
hydraulic oil tank.
3. Connect a hose to the drain port of travel
motor, and receive the drained oil in a
container.
4. Apply a plug to the drain piping at tank
side.
Make sure of the rotating direction of travel motor referring to the figure. Otherwise, the rib "A" may be
broken by the stopper pin.
13-14
(2) Measurement :
・ Engine : At rated speed
・ Hydraulic oil temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Machine posture : Locking the traveling,
and allowing relief on the travel motor
・ Measure the drained volume of oil for 30
seconds of relief.
13
13-15
13.6 MEASURING SLEW PERFORMANCES
TEST PROCEDURES
13.6.1 SLEW TIME

・ Hydraulic Oil Temp. : 50 to 60C
・ Measurement Posture :
Completely retract the arm cylinder, fully
extend the bucket cylinder and place so
that boom foot pin and bucket pin are at
matching height. Place the dozer blade on
the ground.
・ With the hoe attachment in a no-load, drive
1 rotation, then measure the time required
for the next 2 rotations.
13.6.2 OVERRUN WHEN SLEWING STOPS

Same as that for measuring slew time.
・ Prior to measuring, draw matching marks on the outer race of the slew bearing and lower frame
at exactly 180 degrees slew from the starting point. Then with the hoe attachment in a no-load,
slew 180 degrees from starting point. At which point return the operating lever to neutral.
Measure the distance between the position marks and the point the hoe attachment stops.
13.6.3 SLEW DRIFT DUE TO GRAVITY

・ Slew the upper slewing structure and stop
at right angle to the slope, then draw
matching marks on the slew bearing's outer
race and the lower frame. Then measure
the distance that develops between the
marks after 5 minutes. Measure for both
RH and LH directions.
13-16
13.6.4 DRAIN RATE OF SLEW MOTOR

(1) Preparation
1. Stop the engine, and release air inside the
hydraulic oil tank.
2. Disconnect the slew motor drain hose at
the return side to the hydraulic oil tank.
Then receive the drain oil to a container.
Install plug on bore of tank after removing
drain hose.
(2) Measurement :
・ Engine : At rated speed
・ Hydraulic oil temp. : 50 to 60C degrees
・ Machine posture :
Pushing a fixture with the side of bucket,
operating the engine.
・ Measure the drained volume of oil for 30
seconds relieving at full stroke of the
slewing operation.
13
13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES
TEST PROCEDURES
13.7.1 CYLINDER SPEED

(1) Boom Cylinder Speed
・ Measurement Posture : Completely retract
the arm cylinder, fully extend the bucket
cylinder and place the dozer blade on the
ground.
・ Then measure the time required for the
bucket to reach its highest point (lowest
point) from its lowest point (highest point)
placing on the ground. (Do not include the
cushioning time.)
(2) Arm Cylinder Speed

the arm cylinder, fully extend the bucket
cylinder, position the arm horizontally and
place the dozer blade on the ground.
arm cylinder to completely retract (extend)
from a fully extended state (retracted state).
(3) Bucket Cylinder Speed

the arm cylinder, position the arm
horizontally and place the dozer blade on
the ground.
bucket cylinder to completely retract
(extend) from a fully extended state
(retracted state).
13-18
(4) Swing Cylinder Speed

・ Measurement Posture : Same as that for
measuring slew time.
・ While swinging the boom left (right) to
right (left), measure the time required for a
full stroke each way.
(5) Dozer Cylinder Speed

・ Measurement Posture : Using the hoe
attachment lift up the dozer blade side.
・ Then, up and down the dozer blade with
full stroke, measure the time required per
stroke in each direction.
13.7.2 GRAVITY DRIFT OF CYLINDERS

(1) Boom, Arm, Bucket, Dozer, Bucket Tip
・ Engine : Stopped 13
the dozer and arm cylinders, fully extend
the bucket cylinder and position the bucket
pin to the same height as the boom foot
pin.
・ Maintain the position for 10 minutes then
measure the change of rod length and
distance of the bucket tip.
(2) Swing Cylinder

・ Slew the upper slewing structure and stop
at right angle to the slope, then measure
the change in rod length after 5 minutes.
13-19
13.8 MEASURING SLEW BEARING PERFORMANCES
TEST PROCEDURES
13.8.1 SLEW BEARING-BUCKET TIP PLAY

the arm cylinder and fully extend the
bucket cylinder.
・ Move the tips of the bucket teeth from side
to side (left and right) and measure the
play.
13.8.2 SLEW BEARING PLAY

(1) Attach a dial gauge to the bottom face of
the slew bearing's outer-race located in
front of the upper slewing structure.
(2) Raise the crawler on one side off the

ground and set the dial gauge to zero.
(3) Then raise the opposite crawler and read

the dial gauge.
13-20
13.9 MEASURING CRAWLER TENSION
13.9.1 CRAWLER TENSION

・ Raise the machine completely off the
ground using the hoe attachment and dozer
blade.
Then measure the distance (of sag)
between the center point on the crawler
frame and top of the crawler shoe.
In the case of rubber crawlers, measurements should be taken with setting the joint ("M" or "∞"
mark) in the top center position
13
13-21
13-22
［22. HYDRAULIC SYSTEM］
22. HYDRAULIC SYSTEM

TABLE OF CONTENTS
22.1 SUMMARY ………………………………………………………………………………………………………22-3

22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT …………………………………………22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS …………………………………………………22-4
22.2.1 STANDARD SPECIFICATION……………………………………………………………………………22-5
22.3 HYDRAULIC CIRCUIT OPERATION ………………………………………………………………………22-6
22.3.1 COLOR CODING STANDARD FOR HYDRAULIC …………………………………………………22-6
22.3.2 NEUTRAL CIRCUIT ………………………………………………………………………………………22-6
22.3.3 TRAVEL OPERATING CIRCUIT ………………………………………………………………………22-8
22.3.4 SLEW OPERATING CIRCUIT …………………………………………………………………………22-10
22.3.5 BUCKET OPERATING CIRCUIT ………………………………………………………………………22-12
22.3.6 BOOM OPERATING CIRCUIT …………………………………………………………………………22-14
22.3.7 ARM OPERATING CIRCUIT ……………………………………………………………………………22-16
22.3.8 SWING OPERATING CIRCUIT …………………………………………………………………………22-18
22.3.9 DOZER OPERATING CIRCUIT …………………………………………………………………………22-20
22.3.10 TRAVEL / DOZER COMBINED OPERATING CIRCUIT …………………………………………22-22
22.3.11 TRAVEL / BOOM COMBINED OPERATING CIRCUIT ……………………………………………22-24
22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM ………………………………………………………22-26 22
22-1

S5PS2210E01
(SE Asia)
22-2
22.1 SUMMARY
22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT

The hydraulic circuits are built up with the following functions and features in order to achieve easy
operation, safety and high working efficiency.
22
22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS
STANDARD SPECIFICATION PY01Z00032P1 SK50P

No. NAME PART No. MODEL No.
1 PUMP ASSY PH10V00013F1 AP2D25LV1RS7
2 CONTROL VALVE PY30V00074F1 KVSE-72-11
3 SLEWING MOTOR PY15V00014F1 PCR-3B
4 TRAVEL MOTOR PH15V00012F1 GM06VA
5 BOOM CYLINDER PY01V00066F1 Ø100-Ø55-680
6 ARM CYLINDER PY01V00067F1 Ø90-Ø55-735
7 BUCKET CYLINDER PY01V00068F1 Ø75-Ø45-543
8 SWING CYLINDER PY01V00053F1 Ø90-Ø50-574
9 DOZER CYLINDER PY01V00052F1 Ø95-Ø55-200
10 SWIVEL JOINT 24100J12703F1
11 PILOT VALVE (ATT) PX30V00043F4 PV48M2127
12 PILOT VALVE (TRAVEL) PM30V00019F7 PVD6P4044
13 SOLENOID VALVE PY35V00008F1
14 PILOT VALVE (DOZER) PB30V00002F2 PV6P1075
15 SHUTTLE VALVE PH26V00001F1
17 ELEMENT FILTER YR52V01004F1 FZJ3180A001B
18 SUCTION STRAINER PW50V00015F1 SFB12-105-440.5
19 INLINE FILTER YN50V00020F1
20 CHECK VALVE PW21V00003F1 T-2389
22 HYDRAULIC OIL TANK PY33H00008P1
This is for reference only, because the model number might be changed due to improvement.
22-4
22.2.1 STANDARD SPECIFICATION
22
22-5
22.3 HYDRAULIC CIRCUIT generated.

By means of operating the operating lever, the
OPERATION
secondary pressure is generated in accordance
22.3.1 COLOR CODING STANDARD FOR with its motion and led to the control valve (2)
HYDRAULIC from the pilot valve to shift each spool of shifting
Blue : Feed, drain circuit, less than 0.34 MPa (50 psi) valve.
Green : Return, make-up circuit, 0.34 to 0.59 MPa (50
to 86 psi) (2) Main Circuit
Purple : Secondary pilot pressure, 0.59 to 3.5 MPa 1. Variable Pump Circuit
(85 to 508 psi) The delivered oil from A1 and A2 ports on
Red : Primary pilot pressure, 3.5 to 3.9 MPa (508 to variable pump enters into P1 and P2 ports on
566 psi) control valve (2) respectively.
Orange : Main pump drive pressure, 4.9 to 23 MPa All the discharged oil from these two ports finally
(711 to 3340 psi) returns to the hydraulic oil tank (22), through each
valve of travel left, boom and bucket for the P1
Blue tone : At valve selection oil, and through each valve of travel right, swing,
Red valve : When proportional valve (reducing) is service and arm for the P2 oil.
operating 2. Third Pump Circuit
Red solenoid : In active and exciting The oil delivered from A3 port on 3rd pump
Displaying the flow circuit and standby circuit when enters into P3 port on control valve (2).
operating. The whole amount of oil discharged through the
Regarding the electrical symbols in this manual, refer port P3 returns to the hydraulic oil tank (22)
to the electric circuit diagram. through the independent travel dozer, slewing
and flow conflux valves.
22.3.2 NEUTRAL CIRCUIT
(1) Pilot Circuit
1. Pilot Primary Pressure Circuit
The oil delivered from the A4 port on pump assy
(1) enters into the solenoid valve (13) through the
line filter (19).
The pressurized oil from the port B of the
solenoid valve (13) with the safety lock lever
released (in the operating condition) is supplied to
the P ports of the pilot valves for attachment (11),
travel (12) and dozer (14).
Since the operating circuit is fully closed in the
neutral position, the oil delivered by the pump
other than the oil supplied to the Pi2 and Pi3
port of the control valve loses its flowing passage,
and returns to the hydraulic tank (22) through
the relief valve (set pressure : 3.5MPa [508 psi])
built in the solenoid valve (13).
The oil supplied to the Pi2 and Pi3 port is led
to the tank passage through the pilot passages
provided to the service spool and through the
pilot passages provided to the right and left travel
spools.
2. Pilot Secondary Pressure Circuit
While the pilot valves (11),(12) and (14) are being
in neutral, the pilot secondary pressure is not
22-6
22
Neutral circuit
22-7
22.3.3 TRAVEL OPERATING CIRCUIT down to lower pressure, and the counter balance
Pilot oil hydraulic system with operating lever valve [brake valve] (408) spool moves to the
neutral position with the spring force.
22.3.3.1 2nd Speed Operating Circuit As the results, the passage in return oil side is
(Independent-forward travel) throttled, and the motor speed is suppressed by a
(1) Pilot Circuit back-pressure, then the motor is controlled to the
1. Shifting signal for 2nd speed travel speed corresponding to the supplied oil volume
When the "Rabbit and Turtle" mark (at the power of the pump.
cut-off, it automatically takes back for 1st speed) c. The counterbalance valve spool is so designed
on the nob of travel right lever is pushed down, it that it is gradually shifted by a throttle effect to
actuates the 1st and 2nd speed travel shifting stop or start the motor absorbing shock at the
valve of solenoid valve (13). start and stop of the machine.
The pressurized oil signal for 2nd speed is d. When load increases during high speed travel, the
generated from the A port of solenoid valve (13), speed automatically shifts to the 1st speed,
and led to the P port on travel motor (4) through resulting in low speed and high torque.
swivel joint (10), and shifts the 2-speed shifting
valve (404).
2. Changing travel valve spool
The pilot secondary pressure is generated from
pilot valve (12) by the operation for travel forward.
The pressurized oil is led to the Pb3 and Pb4
ports on control valve (2) to shift the travel valve
spool.
(2) Main Circuit

1. Circuit up to Travel Motor (4)
The delivered oil from A1 and A2 ports on
variable pump enters into the P1 and P2 ports
of control valve (2), and led to the B3 and B4
ports through the travel valve.
Then it is led to the A and B ports on left and
right travel motors respectively through the swivel
joint (10).
2. Travel Motor
a. The pressurized oil supplied to the travel motor

shifts the spool of the counterbalance valve (brake
valve) (408), releases the parking brake (403),
opens the hydraulic circuit having closed by the
check valve (407) and rotates the travel motor.
It actuates the speed shifting valve (404) when
the 2nd speed signal is sent. The high pressure
oil pumped through the shuttle valve (406) passes
the speed change valve (404), actuates the
2-speed shifting piston (401) and provides the
motor with high speed and low torque.
b. When the motor reaches near to a self-running
condition (over-running) at going down a slope
and so on, the oil pressure of supply side gets
22-8
22
Travel circuit : Travel foward operation at travel 2nd speed
22-9
22.3.4 SLEW OPERATING CIRCUIT generated in it because of inertia on the slewing

Pilot oil hydraulic system with operating lever mass.
22.3.4.1 Slew (left) Operating Circuit

(1) Pilot Circuit
1. Slew Valve Spool Shifting
With operation for slew (left), the pilot secondary
pressure oil is generated from the pilot valve (11),
and led to the Pa8 port of control valve (2) to
shift the slew valve spool.
2. Releasing Parking Brake
The pilot primary pressure is always led to PB
port on the timer valve (303).
With the slew operation, the operating pilot
secondary pressure is led to PP port on the timer
valve (303) through the shuttle valve (15) to shift
the spool.
It leads the pilot primary pressure 3.5 MPa (508
psi) to the parking brake to release it. (Similarly,
the arm in operation releases the slew brake.)
3. Activating Parking Brake
When the slew operating lever is returned to
neutral position to stop slewing, the pilot
secondary pressure disappears causing to shift
the timer valve (303), then the pressurized oil is
shut down.
The oil in the brake cylinder is discharged due
to spring force, and drained through the throttle in
the timer valve (303).
Thus the braking is activated with some time lag
for 3.0 to 6.0 seconds to smoothly absorb the
slewing inertia at its stop of motion.
(2) Main Circuit

1. Supply Circuit for Slewing Motor (3)
The oil delivered from the A3 port on hydraulic oil
pump (1) is supplied to the A port on slewing
motor (3) through the P3 port on control valve (2)
and slew valve to drive the slewing motor.
2. Slewing Motor (3)
a. The relief valve (304) relieves rapidly increased

pressure at start and stop of the machine to ease
shock.
b. The make-up valve (check valve) (305) has a
function to replenish oil from the return oil circuit
that is led to the tank [T2 port on control valve
(2)] to the slewing motor, to prevent the slewing
motor from the cavitation due to negative pressure
22-10
22
Slewing circuit : Slewing left operation
22-11
22.3.5 BUCKET OPERATING CIRCUIT

Pilot oil hydraulic system with operating lever
22.3.5.1 Bucket Digging Operation Circuit

(1) Pilot Circuit
1. Bucket Spool Shifting
When the operating lever is put at bucket
digging position, the pilot secondary pressure oil
is generated from the pilot valve (11). The
pressurized oil entered into the Pb1 port on
control valve (2) shifts the bucket valve spool.
(2) Main Circuit

1. Supply Circuit for Cylinder (7)
The oil delivered from A1 port on variable pump
of pump assembly (1) enters into P1 port on
control valve (2). The pressurized oil from B1 port
through bucket valve is supplied to the head
side of bucket cylinder (7) to activate the digging
work.
The return oil from the rod side of cylinder (7)
enters into A1 port on control valve (2) and
returns into the tank through bucket valve.
22.3.5.2 Bucket Dumping Operating Circuit

(1) Pilot Circuit
1. Bucket Spool Shifting
When the operating lever is moved to bucket
dumping position, the pilot secondary pressure oil
is supplied from pilot valve (11), and enters into
Pa1 port on control valve (2) to shift the bucket
valve spool.
(2) Main Circuit

Similar to the case for bucket digging, the
pressurized oil delivered from A1 port on variable
pump enters into P1 port on control valve (2).
The oil supplied from A1 port through bucket
valve is entered into the rod side of bucket
cylinder (7) to activate the bucket dumping.
22-12
22
Bucket circuit : Bucket digging operation
22-13
22.3.6 BOOM OPERATING CIRCUIT the boom from lowering due to its own weight
Pilot oil hydraulic system with operating lever while the boom valve is being at neutral position.
22.3.6.1 Boom UP Operating Circuit

(1) Pilot Circuit
1. Boom Spool Shifting
When the operating lever is put at boom up
position, the pilot secondary pressure oil is
generated from pilot valve (11). The pressurized
oil entered into Pb2 port on control valve (2)
shifts the boom valve spool.
(2) Main Circuit

The oil delivered from A1 port on variable pump
of pump assy (1) enters into P1 port on control
valve (2). The oil supplied from B2 port through
boom valve and lock valve is entered into the
head side of boom cylinder (5) to up the boom.
22.3.6.2 Boom Down Operating Circuit

(1) Pilot Circuit
1. Boom Spool Shifting
When the operating lever is put at boom down
position, the pilot secondary pressure oil is
generated from pilot valve (11), and enters into
Pa2 port on control valve (2) to shift the boom
valve spool.
At the same time, the pilot secondary pressure
is led to the boom lock valve (206) to push up
the check valve and open the oil path from
closed condition.
(2) Main Circuit

1. Supply Circuit for Cylinder (5) and Return Oil
Circuit
The pressurized oil delivered from A1 port on
variable pump is led to boom valve provided on
control valve (2), and supplied to the rod side of
boom cylinder (5) to down the boom.
The oil returned from the head side of cylinder
(5) enters into B2 port on control valve (2), and
returns to the tank through the boom lock valve
(206) and boom valve.
Its flow rate is restricted by the throttle effect in
boom valve, accordingly the boom is lowered at a
stable speed.
a. Boom lock valve (206)

This is of a check valve mechanism to prevent
22-14
22
Boom circuit : Boom up operation
22-15
22.3.7 ARM OPERATING CIRCUIT

Pilot oil system with operating lever
With oil flow conflux function for the third pump.
22.3.7.1 Arm In Operating Circuit

(1) Pilot Circuit
1. Shift for Arm Spool
At the arm in operation, the pilot secondary
pressure generated from the pilot valve (11) is led
to the Pa7 port on control valve (2) to shift the
arm valve spool.
Furthermore, the pilot secondary pressure acts to
the PP port on timer valve (303) through the
shuttle valve (15) to release the parking brake.
Since the spool of the arm valve shifts to close
the pilot passage, the pressure of pilot oil thru the
Pi3 port equals to the supply pressure.
Thus the pressure overcomes the spring forces
of the flow conflux valves to shift the valve spool.
(2) Main Circuit

The oil delivered from the A2 port on variable
pump enters into P2 port on control valve (2).
The pressurized oil from the P3 port joins with
the oil from the P2 port through the flow conflux
valve. The joined oil flows out from the A7 port
through the arm valve and is supplied to the
head side of the arm cylinder (6) to perform arm
in work.
2. Return Line from Cylinder (6)
The return oil from the rod side of arm cylinder
enters into the B7 port on control valve (2), and
is led to the return line from the T1 and T2 port
through arm valve, then return to the tank.
22.3.7.2 Operating Circuit for Arm Out

(1) Pilot Circuit
At the operation for arm out, the pilot secondary
pressure is generated from the pilot valve (11),
and led to the Pb7 port on control valve (2) to
shift the arm valve spool.
The flow conflux valves are actuated as in the
arm in operation.
(2) Main Circuit
As in the case of arm in operation, the oil
having flown into the control valve (2) joins with
the pressurized oil from P2 and P3, flows out
from the B7 port and is supplied to the rod side
of the arm cylinder to perform arm out work.
22-16
22
Arm circuit : Arm in operation
22-17
22.3.8 SWING OPERATING CIRCUIT

Cable driving system with operating pedal
22.3.8.1 Swing (left) Operating Circuit

(1) Swing Operation
When depress the left side of swing pedal, the swing
valve spool in control valve (2) is shifted by the
cabling mechanism. Since the pilot oil pressure is not
utilized for it is activated regardless to the safety lock
lever.
(2) Main Circuit

The delivered oil from A2 port on variable pump
enters into P2 port on control valve (2), and
comes out from A5 port through swing valve,
and is supplied to the head side of cylinder (8) to
activate the swing (left).
a. At activation of the swing valve spool for both left

and right swing motions, a part of appropriate
volume of oil is returned to the tank through the
P2 bypass circuit due to the throttle effect on
the spool.
Then supplying volume of oil to the cylinder is
restricted to ensure the slow and stable swing
motions for both leftward and rightward.
22-18
22
Swing circuit : Boom swing left operation
22-19
22.3.9 DOZER OPERATING CIRCUIT

Pilot oil system with operating lever
22.3.9.1 Dozer Down Operating Circuit

(1) Dozer Operation
When the operating lever is pushed forward, the pilot
secondary pressure is generated from the pilot valve
(14) to shift the dozer valve spool through the Pb9
port of the control valve (2).
(2) Main Circuit

The oil delivered from A3 port of the hydraulic
pump (1) enters into P3 port on control valve
(2), and is led to B9 port through dozer valve.
The pressurized oil passed through swivel joint
(10) is supplied to the head side of dozer cylinder
(9) to activate dozer down motion.
22-20
22
Dozer circuit : Dozer down operation
22-21
22.3.10 TRAVEL / DOZER COMBINED

OPERATING CIRCUIT
At the combined operation of travel and dozer at the
same time, the straight traveling is secured with this
function.
22.3.10.1 Travel (1st speed forwarding) / Dozer

Down Operating Circuit
(1) Pilot Circuit
Both the travel and dozer are operated by the lever
using the pilot oil system.
The operation of each lever directly shifts the travel
valve spool and dozer valve spool in the control
valve (2) respectively.
(2) Main Circuit

The oil delivered from A1 and A2 ports on the
variable pump (1) enters into P1 and P2 ports on
control valve (2), and each flow of left and right is led
to swivel joint (10) and travel motor (4) respectively
through each travel valve of left and right.
The oil delivered from A3 port on the third pump
enters into P3 port on control valve (2), then it is led
to the dozer cylinder (9) through dozer valve and
swivel joint (10).
1. The dozer is operated by the pressurized oil

supplied by the third pump which has no relation
with travel circuit. Then there is no variation on
the supply volume of pressurized oil for both
travel motors of left and right even though the
dozer is operated during traveling.
Thus the straight traveling is secured.
(The slewing is operated in the same way as the
dozer.)
2. As the above mentioned, the traveling speed is
not changed from the single operation for traveling
securing the straight traveling.
22-22
22
Combined operation circuit : Travel (forward) 1st speed / Dozer down operation
22-23
22.3.11 TRAVEL / BOOM COMBINED

OPERATING CIRCUIT
At the combined operation of travel and boom at the
same time, the straight traveling is secured with this
function.
22.3.11.1 Travel (1st speed forward) / Boom Up

Operating Circuit
(1) Pilot Circuit
The traveling/boom up is of the pilot oil hydraulic
system with lever operation.
By means of pushing forward of travel operating
lever and pulling this side of boom up operating lever,
the pilot secondary pressure shifts the travel valve
spool and/or boom spool in the control valve (2).
Thus the pilot passage of the boom valve is closed to
make the pressure of the oil from the Pi3 port equal
to the supply pressure. Therefore the hydraulic
pressure overcomes the spring force of the
independent travel valves to shift the valve spool.
(2) Main Circuit

The oil delivered from A1 and A2 ports on the
variable pump enters into P1 and P2 ports on the
control valve (2).
The whole amount of oil from the P1 and P2 ports
is supplied to the travel motor in the same way as
operating the independent travel. The oil flows from
the travel valve through the B3 and B4 ports and the
swivel joint (10) to the right and left travel motor (4).
The oil delivered from the port A3 of the hydraulic
pump (1) is supplied to the boom cylinder.
Pressurized oil that flows out from P3 port of control
valve (2) enters into boom valve through switched
travel independent valve.
The oil from the B2 port through the boom valves is
supplied to the head side of the boom cylinder (5).
1. When the travel and other attachments (boom,

arm, bucket, swing, and service (for N & B) are
operated in combination, the independent travel
and flow conflux valves are actuated. Thus the
attachments are actuated only by oil supplied from
the P3 port. Therefore the oil of the P1 and P2
ports is utilized only by the travel to secure stable
travel in the combined operation.
22-24
22
Combined operation circuit : Travel (forward) 1st speed / Boom up operation
22-25
22.4 SCHEMATIC PIPING FOR

HYDRAULIC SYSTEM
22-26
［23. ELECTRICAL SYSTEM］
23. ELECTRICAL SYSTEM

TABLE OF CONTENTS
23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION ………………………………23-3

23.1.1 ELECTRIC CIRCUIT DIAGRAM …………………………………………………………………………23-3
23.1.2 HARNESS CONNECTION ………………………………………………………………………………23-3
23.2 ELECTRICAL EQUIPMENT & HARNESS …………………………………………………………………23-4
23.2.1 ELECTRICAL EQUIPMENT LIST ………………………………………………………………………23-4
23.2.2 HARNESS & CABLE LIST ………………………………………………………………………………23-6
23.2.3 ELECTRIC CIRCUIT DIAGRAM …………………………………………………………………………23-7
23.2.4 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS ………………………………23-11
23.2.5 DETAIL OF HARNESS & CABLE………………………………………………………………………23-19
23
23-1

S5PS2310E01
(SE Asia)
23-2
23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS

CONNECTION
23.1.1 ELECTRIC CIRCUIT DIAGRAM

(1) In the diagram, the number, size and color of wires are shown on the wiring line.
The size of the wire is to be 0.75 sq (square mm = mm2) unless otherwise specified.
23.1.2 HARNESS CONNECTION

(1) Indication for Connector
1. The figure for the connector pin

arrangement is shown by putting the lock
(nail) to upper portion, and looking from the
fitting face.
2. The numbers in the connector show the
wire No., and alphabetical letters show the
wire color.
3. On the side face of connector, the connector name and serial number of the connector No. are
indicated.
4. At the place indicated as "DOUBLE SPLICE", two wires are connected to one place.
(2) The connector is to be connected with engaging the male (M) and female (F) connectors of the
same number.
Example : CN-101M and CN-101F
Where : M means for Male, and F for Female.
(3) The mark shown the right figure means

the connector with diode. The direction for
23
diode is shown by the arrow.
(4) The AVSS wires are to be used for the size between 0.75 sq and 2 sq. AVS wires between 3 sq
and 5 sq and others are AV wires, unless otherwise specified.
(5) The wire size is 0.75 sq, unless otherwise specified.
(6) The treatment for the harness end is to be as follows :
(7) The length for the above (6)-3) is to be 30±10 mm. (1.2±0.4 in), and the length includes in the
total length of wire shown in the diagram.
23-3
23.2 ELECTRICAL EQUIPMENT & HARNESS
23.2.1 ELECTRICAL EQUIPMENT LIST
Group Code Part Name Part No.

C-4 AIR CONDITIONER (FOR CAB) A/C accessory
Controller
C-7 IT CONTROLLER -
D-1 DIODE YN02D01001P1
D-2 DIODE
D-3 DIODE
D-4 DIODE
Diode D-5 DIODE
D-12 DIODE
D-14 DIODE
D-18 DIODE
D-19 DIODE
E-1 FUSE BOX PY73E00002F1
E-2 GENERATOR (ALTERNATOR) E/G accessory (119626-77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E-7 POWER SOCKET PF81S01001P1
E-8 GLOW PLUG E/G accessory (129008-77800)
E-10 RADIO (OPT) Cab accessory (YN54S00045P2)
Electical
E-11 OVER LOAD BUZZER YJ53S01001D3
Fittings
E-13 BATTERY PH72S00006P1
E-14 SEQUENCE BOX PA24S00002P3
E-18 COMPRESSOR A/C accessory
E-20 TRAVEL ALARM PW53S00002F1
E-26 HOUR METER PA58S00001P1
E-27 RECEIVER DRER PW20M01071F1
E-41 SPEAKER LEFT YT54S00006P1
E-42 SPEAKER RIGHT
L-1 ROOM LAMP (FOR CAB) PW80S00007P1
L-2 BOOM WORKING LIGHT LEFT (55W) PM80S00008F1
Light
L-5 CAB / CANOPY WORKING LIGHT PW80S00003F1
L-9 ROTARY LIGHT PY80S00005P1
M-1 STARTER MOTOR E/G accessory (129136-77011)
M-2 WIPER MOTOR (FOR CAB) Cab accessory (PM76S00001F1)
Motor M-3 WASHER MOTOR (FOR CAB) Cab accessory (PW54C00001P1)
M-4 DECELERATION MOTOR PY20S00003F1
M-6 FUEL PUMP PW22P00001P1
23-4

R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
R-6 TIMER UNIT PH25S00002P1
R-7 E/G STOP RELAY PX24S00003P1
R-8 CHARGE INDICATOR RELAY PA24E01001P1
Relay
R-9 CAB / CANOPY WORKING LIGHT RELAY
R-26 ROTARY LIGHT RELAY PM24S00001P1
R-31 HORN RELAY PA24E01001P1
R-34 NEUTRAL START RELAY PM24S00001P1
R-35 E/G START LOCK RELAY PA24E01001P1
SE-1 FUEL SENSOR PY52S00013F1
Sensor
SE-2 ENGINE THERMO SENSOR PA24S00003P1
SV-1 LEVER LOCK SOL.
PY35V00008F1
SV-2 2-SPEED SELECT SOL.
Solenoid
SV-3 E/G STOP SOL. E/G accessory (119233-77932)
SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
SW-1 KEY SWITCH PW50S00005S001
SW-2 WORKING LIGHT SW. PV24E01001P2
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. (FOR CAB) PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
SW-6 E/G OIL PRESSURE SW. E/G accessory (114250-39450)
SW-7 HORN SW. YN50E01001P1
SW-9 LEVER LOCK SW. PA50S00001P1
Switch SW-11 DECELERATION SW. PM50S00005P1
SW-14 AIR FILTER RESTRICTION SW. PW11P00010S004
SW-23 TRAVEL ALARM SELECT SW. 2479U1190F16
SW-24 TRAVEL RIGHT (FORWARD) PRESSURE SW. GB50S00049F2
SW-25 TRAVEL RIGHT (REVERSE) PRESSURE SW.
SW-26 TRAVEL LEFT (FORWARD) PRESSURE SW.
SW-27 TRAVEL LEFT (REVERSE) PRESSURE SW.
SW-39 OVER LOAD PRESSURE SW. 72117480 (DIN 43650) 23
SW-40 OVER LOAD SW. 2479U1190F33
-The part number may be changed owing to modification, use them only for reference.
-NA : North America, AUST : Australia.
23-5
23.2.2 HARNESS & CABLE LIST
Code Name Part No. Location

H-1 Main Harness PY14E01015P2 Upper Frame Portion
H-2 Right Deck Harness PY14E01014P2 Upper Frame Portion
H-3 Starter Cable (+) PY13E01065P2 Upper Frame Portion
H-4 Battery Ground Cable (-) PY13E01049P1 Upper Frame Portion
H-5 Key Switch Harness PW50E01002P1 Upper Frame Portion
H-6 Boom Work Light Extension Harness PY14E01016P1 Upper Frame Portion
H-7 Engine Harness PY16E01009P3 Engine Portion
H-8 Engine Ground Cable PW13E01043D1 Engine Portion
H-9 Boom Work Light Harness PY15E01004P1 Work Light Portion
The part number may be changed owing to modification, use them only for reference.
23-6
23.2.3 ELECTRIC CIRCUIT DIAGRAM
23
23-7
23-8
23
23-9
23-10
23.2.4 ARRANGEMENT DRAWING FOR

COMPONENTS & HARNESS
23.2.4.1 Upper Frame Portion : PY03E00003F1 (1/5)
23
23-11
23-12
23
23-13
23-14
23
23-15
23.2.4.2 Engine Portion : PY16E00002F1
23-16
23.2.4.3 Fuel Tank Portion : PY20P00002F1
23
23-17
23.2.4.4 Work Light Portion
23-18
23.2.5 DETAIL OF HARNESS & CABLE

23.2.5.1 Main Harness (No. H-1 : PY14E01015P2)
(1/5)
23
23-19

(2/5)
23-20

(3/5)
23
23-21

(4/5)
23-22

(5/5)
23
23-23
23.2.5.2 Right Deck Harness (No. H-2 :

PY14E01014P2)
23-24
23.2.5.3 Starter Cable (+) (No. H-3 : PY13E01065P2)

23.2.5.4 Battery Ground Cable (-) (No. H-4 :
PY13E01049P1)
23.2.5.5 Key Switch Harness (No. H-5 :
PW50E01002P1)
23.2.5.6 Boom Work Light Extension Harness (No.
H-6 : PY14E01016P1)
23
23-25
23.2.5.7 Engine Harness (No. H-7 : PY16E01009P3)
23-26
23.2.5.8 Engine Ground Cable (No. H-8 :

PW13E01043D1)
23.2.5.9 Boom Work Light Harness (No. H-9 :
PY15E01004P1)
23
23-27
23-28
［24. COMPONENTS SYSTEM］
24. COMPONENTS SYSTEM

TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS …………………………………………………………………………………24-3

24.1.1 HYDRAULIC PUMP ………………………………………………………………………………………24-3
24.1.2 PILOT VALVE (ATT)………………………………………………………………………………………24-15
24.1.3 PILOT VALVE (TRAVEL)…………………………………………………………………………………24-19
24.1.4 CONTROL VALVE …………………………………………………………………………………………24-24
24.1.5 SLEWING MOTOR ………………………………………………………………………………………24-31
24.1.6 TRAVEL MOTOR …………………………………………………………………………………………24-40
24.1.7 SWIVEL JOINT ……………………………………………………………………………………………24-51
24.1.8 CYLINDER …………………………………………………………………………………………………24-53
24.2 ELECTRICAL EQUIPMENT ……………………………………………………………………………………24-61
24.2.1 ELECTRICAL EQUIPMENT LIST ………………………………………………………………………24-61
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ………………………………………………………24-63
24
24-1

S5PS2410E01
(SE Asia)
24-2
24.1 HYDRAULIC COMPONENTS
24.1.1 HYDRAULIC PUMP

24.1.1.1 SUMMARY
(1) GENERAL VIEW
General view of hydraulic pump
(2) SPECIFICATIONS
24
24-3
24.1.1.2 CONSTRUCTION - FUNCTION
No. NAME No. NAME

1 Shaft assy 6 Piston assy
2 Swash plate assy 7 Gear pump assy
3 Rotary group 8 Housing assy
4 Cover assy 9 Trochoid pump assy
5 Spring assy
(1) Piston pump

・ This pump is a variable displacement double piston pump which delivers two equal flows with
one cylinder block., and has only one inlet port, but the flow is separated into two flows by the
control plate on the cover and is led to two delivery ports provided on the cover.
・ The hydraulic pressure produced by the delivery oil acts on the hanger, resists the spring force,
and tilts the hanger. As the piston stroke is changed by the tilting of the hanger, the flow rate
varies.
・ Control systems of this pump are two pump simultaneous tilting and constant total power shift.
・ The 3rd pump or pilot pump is installed on the same shaft with a coupling.
24-4
(2) Operation
1. Pump operation
a. The cylinder block is fitted on the spline and rotates with the drive shaft.
b. The piston fitted on the cylinder block follows the sliding surface of the hanger and moves to and
fro.
c. The piston moves to increase the capacity from the bottom dead point to the top dead point, the
pressure oil flows from the inlet port into cylinder block through the control plate. (Suction stroke)
d. But as the piston moves to decrease the capacity from the top dead point to the bottom dead
point, the pressure oil is sent out to the delivery port. (Delivery stroke)
e. By changing the tilting angle of the hanger (sliding surface), the displacement varies.
f. The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside
of the control valve.
g. The oil sucked from the outside port of the cylinder block is delivered from the delivery port
outside of the control plate.
24
24-5
2. Control
a. The delivery pressure P1 and P2 are directed to the piston which slides on the hanger and acts
on the hanger.
b. The spring is provided to act against the delivery pressure.
c. When the oil pressure via piston acting on the hanger is less than the installation load of the
spring, the hanger is fixed to the maximum tilting position.
d. When the oil pressure via piston acting on the hanger exceeds the installation load of the spring,
the hanger is tilted and kept tilted at a position where the oil pressure is balanced with the
spring forces. (Region A in above figure)
e. When the oil pressure acting on the piston rises further to reduce the tilting angle, the spring B
which has been inactive up to now becomes active.
f. To overcome the spring force of two springs, the oil pressure must be higher and the shifting line
becomes more steep. (Regions A + B in the middle of the figure above)
g. When the P3 oil pressure acts on the shift piston, the control shifting line is shifted.
h. When outside oil pressure (Pz=3.4MPa) acts on Z port, air-conditioner mode is available. When Z
port is not in use, the piping is connected to the drain line.
24-6
3. Adjusting procedure of set torque
a. Adjusting procedure
1. Loosen the hexagon nut.
2. Set the power line by tightening or loosening the adjusting screw.
24
24-7
24.1.1.3 INNER CONSTRUCTION

Refer to Fig. 24.1.1.2 regarding the whole pump
(1) Drive shaft
No. NAME Q'TY No. NAME Q'TY

1 Shaft 1 8 Oil seal 1
2 Seal case 1 9 O-ring 1
3 Bearing 1 10 Snap ring 1
6 Snap ring (for Shaft) 1 11 Key 1
7 Snap ring (for Shaft) 1
(2) Swash plate (Hanger)

1 Hanger 1 4 Bearing 2
2 Plate 1 5 Capscrew 4
3 Distance piece 1 6 O-ring 1
24-8
(3) Rotary group

1 Piston 10 7 Spring 1
2 Cylinder block 1 8 Parallel pin 3
4 Retainer 1 9 Spring seat 2
5 Plate 1 10 Snap ring (for hole) 1
6 Guide 1
(4) Control spring

1 Spring seat 1 8 Capscrew 2
2 Spring seat 1 9 Nut 1
3 Cover 1 34 Shim 2
24
4 Setscrew 1 44 Shim 2
5 Spring 1 54 Shim 2
6 Spring 1 64 Shim 2
7 O-ring : 1A P34 1
24-9
(5) Cover

1 Cover 1 9 Orifice 3
2 Control plate 1 10 Bearing 1
3 Parallel pin 2 11 Plug assembly 2
4 Capscrew 3 13 Capscrew 1
5 O-ring 1 16 Plug : M8 2
6 O-ring 4 17 Plug : M5 1
7 Plug : M6 4
24-10
(6) Gear pump

3 Housing 1 12 Coupling 1
4 Cover 1 14 O-ring 2
5 Gear 1 15 O-ring 1
6 Gear 1 16 Square ring 1
7 Side plate assy 2 17 Square ring 2
10 Plate 2 18 O-ring (1B P6) 1
11 Guide 2 19 Capscrew (M12X25) 6
24
24-11
(7) Housing
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

1 Cylinder 1 5 Spring seat 1 9 O-ring 1
2 Piston 1 6 Capscrew 2 11 Piston 1
3 Piston 2 7 Disk spring 3
4 Parallel pin 1 8 O-ring 1
24-12
(8) Trochoid pump

1 Gear 1 6 Capscrew 3
2 Casing 1 7 Side plate (B) 1
3 Side plate (A) 1 8 Spring pin 1
4 O-ring 1 9 Plate 1
5 Spring pin 1
24
24-13
24-14
24.1.2 PILOT VALVE (ATT)

24.1.2.1 SUMMARY
(1) General view
24
24-15
24.1.2.2 CONSTRUCTION
Pilot valve-Sectional view

101 Casing 1 213 Seal 4 241-1 Spring 2
151 Plate 1 214 O-ring; 1B P20 4 241-2 Spring 2
201 Spool 4 216-1 Spring seat 2 301 Joint; M14 1
211 Plug 4 216-2 Spring seat 2 302 Disk 1
212-1 Push rod 2 217 Washer 2 4 312 Adjusting nut; M14 1
212-2 Push rod 2 221 Spring 4 501 Bellows 1
24-16
24.1.2.3 OPERATION
(1) Lever in neutral position
In this case, the force of the secondary
pressure setting spring (241) that
determines the output pressure of the pilot
valve is not transmitted to the spool (201).
Accordingly, the spool (201) is pushed up
by the return spring (221) and spring seat
(216) permitting the output port 2, 4 to
connect with the tank port T. This makes
the output pressure equal to the tank
pressure.
Lever in neutral position
(2) When the Lever is tilted

When the lever is tilted, the push rod (212)
strokes. The spool (201) and spring seat
(216) moves downward to make the port
P to connect with the port 2, 4. With the
result that the oil of the pilot pump flow out
to the port 2, 4, to produce a pressure.
When Lever is tilted
(3) The Lever being held

When the lever is tilted till the pressure of
the port 2, 4 rises to an oil pressure
corresponding to the set spring force, the
hydraulic pressure is balanced with the
spring (241) force. And when the pressure
of the port 2, 4 rises above a set pressure,
the port P are closed and the port T are
opened. When the pressure of the port 2,
4 falls below a set pressure, the port P are 24
caused to open and the port T are
caused to close, thus holding the second
pressure constant.
Lever being held
24-17
24-18
24.1.3 PILOT VALVE (TRAVEL)

24.1.3.1 SUMMARY
(1) General view
(2) Specifications
ITEM SPECIFICATIONS
Model (Type) PVD6P4044
Max. primary pressure 6.9MPa (1000 psi)
Rated flow 10 L/min (2.6 gal/min)
Weight 3.9 kg (8.6 lb)
(3) Performance Characteristics
24
24-19
Pilot valve-Sectional view
Torque Torque
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 6.9 (5.1) 252 Plug 2
102 Casing (Damper) 1 261 O-ring 3
201 Cover 2 8.8 (6.5) 271 Capscrew 4
202 Plug 4 301 Spool 4
203 Grease cup 4 311 Spring seat 4
210 Packing 4 313 Washer 4
211 O-ring 4 324 Spring 4
214 Push rod 4 413 Cam shaft 2
217 Shim 4 414 Bushing 4
218 Spring seat 4 420 Cam 2
224 Piston 4 471 Steel ball 4
225 Steel ball 12 6.9 (5.1) 472 Set screw 2
29.4 (21.7) 251 RO Plug 3 501 Boots (Bellows) 2
24-20
24.1.3.3 OPERATION
1. Reducing valve
(1) When the lever is at neutral position
The spool is pushed up by the return
spring (335) through spring seat (311), and
is positioned at the neutral position in the
right figure. Therefore, the pressure at
delivery ports 1 and 2 is equivalent to that
of port T because the delivery port is
connected to only port T following the
switched spool condition.
(2) In case where the lever is tilted

By rotating cam (420) in clockwise, push
rod (214) on the port 1 side is pushed
down, and the spool moves down by way
of spring seat (311), spring (324) for setting
the secondary pressure, shim (217) and
washer (313) and consequently the port P
is connected to the port 1 and the supplied
oil from the pilot pump flows into port 1
and generates pressure.
When the pressure at port 1 rises to the
pressure equivalent to the spring pressure
for the secondary pressure setting set by
tilting the control section, the hydraulic
pressure applied to the spool balances the
spring force, and maintains port 1 at a
constant delivery pressure.
The spool on the port 2 side is held at
neutral position, and the return oil from the
control valve is discharged through port T.
24
24-21
2. Damping mechanism
(1) In case of neutral position,
Push rod (214) is pushed up by damping spring (336) through piston (224), and holds at the
position shown in Fig. "Pilot valve-Sectional view".
(2) Where the control section is inclined from the neutral position,
By rotating the cam clockwise, the push rod on the port 1 side is pushed down, and the piston
also moves down.
Then, the oil in the damping piston chamber is discharged through the orifice, and the
simultaneously generated pressure produces damping force.
On the other hand, the push rod on the port 2 side moves up by the damping spring through the
piston.
Then, oil is sucked from the tank into the damping piston chamber through three ball check
valves. The oil outside of the piston chamber flows out through the passage leading to port T on
the casing top end.
Operation when the lever is stroked from the neutral position
24-22
(3) Where the control section is inclined in the opposite direction from the full tilting
After tilting the cam clockwise fully, if it is rotated counterclockwise, the push rod on the port 2
side is pushed down and the piston moves down.
Then, the same as above, the oil in the damping piston chamber is discharged through restriction
of piston, and the simultaneously generated pressure produces damping force.
On the other hand, the push rod on the port 1 side is moved up by the force of the return
spring and damping spring.
Similarly oil is sucked from the tank into the damping piston chamber through three ball check
valves.
And the oil in the piston chamber flows out through the passage leading from the casing top end
to the tank port.
That is, either tilting operation from the neutral position to the full tilting position or the full tilting
position to the neutral position is designed to produce the damping force.
24
Operation when the lever is stroked or operated in reverse
24-23
24.1.4 CONTROL VALVE

24.1.4.1 GENERAL VIEW AND HYDRAULIC PORTS NO.
24.1.4.2 SPECIFICATIONS
24-24
(1) Control Valve: Overall composition

1 Nut 8 12 Slewing section 1
2 Tie rod 4 13 Dozer section 1
3 Bucket section 1 14 P3 inlet and travel straight conflux section 1
4 Boom section 1 15 P1, P2 Main relief valve 2
5 Travel (left) section 1 16 P3 Main relief valve 1
6 P1 and P2 inlet section 1 Over load relief valve
17 6
7 Travel (right) section 1 (B1,A2,B2,A7,B7,B9)
8 Swing section 1 18 Anti-void valve (B5) 1

9 Service section 1 19 Plug assy (PF1/2) 2
10 Arm section 1 20 Plug assy (A6,B6) 2
11 Arm conflux section 1
24
24-25
(2) Component Parts

The control valve is roughly classified into the following four sections.
-Manual operation section : Swing

-Pilot operation section : Travel right and left, boom, arm, bucket, slewing, travel straight
and conflux, dozer blade, service(nibbler & breaker)
-Accessory section : P1 and P2 inlets, and P3 inlet (common with independent travel and conflux)
-Accessory section (valve) : P1, P2, P3 main relief, overload relief, anti-void, boom lock
* For respective operation section, only typical example is described.

1. Pilot operation: Swing (No.8)
2. Pilot operation: Slewing (No.12)
24-26
3. Main relief valve (P1, P2)
4. Main relief valve (P3)
5. Anti-void valve
24
24-27
6. Overload relief valve
24-28
24.1.4.4 HYDRAULIC CIRCUIT
24
24-29
24-30
24.1.5 SLEWING MOTOR

24.1.5.1 GENERAL VIEW
24.1.5.2 HYDRAULIC CIRCUIT
Items Specifications
Part No. PY15V00014F1
Slewing motor unit PCR-3B-12A-FP-9093A
Model (Type)
Slewing motor PM-1B-20B-FS2-9093A
3
cm /rev
Displacement 20.0 (1.22)
Hydraulic motor (cu-in/rev)
Rated flow L/min (gal/min) 33.8 (8.93)
Static friction torque N-m (lbf-ft) 68.4 (50.5)
Parking brake
Release pressure MPa (psi) Min 2.5 (363), Max 4.9 (710) 24
Set pressure MPa (psi) 21.0 (3050) at 34l/min (9.0 gal/min)
Relief valve
Cracking pressure MPa (psi) 16.2 (2350) at 1l/min (0.26 gal/min)
Reduction unit Reducting ratio 21.5
Weight (with Reduction unit) kg (lb) Approx. 37 (82)
24-31
24-32

(Reduction assy) 130 Ring 2 3 235 O-ring ; 1B G110 1
101 Casing 1 (Motor assy) 236 O-ring ; 1B G125 1
102 Carrier 1 1 201 Body H 1 241 P/B Timer valve 1
103 Carrier 2 1 202 Plate S 1 242 Socket bolt ; M6X15 4
104 Pinion shaft 1 203 Shaft 1 243 Relief valve 2
105 Internal gear A 1 204 Cylinder barrel 1 246 Check valve 2
106 B1 gear 4 205 Valve plate 1 247 Plug 2
107 B2 gear 3 206 Piston 9 248 Spring 2
108 S1 gear 1 207 Shoe 9 249 O-ring ; 1B P11 2
109 S2 gear 1 208 Shoe holder 1 307 O-ring ; 1B P14 1
111 Needle 1 92 209 Barrel holder 1 308 O-ring ; 1B P18 1
112 Needle 2 72 210 Swash plate 1 309 O-ring ; 1B P22 1
113 Ring seal 1 212 Retainer 2 310 O-ring ; 1B P28 1
114 O-ring 1 213 Pin 3 311 Backup ring ; P14 2
115 Thrust plate 1 1 214 Filter 1 401 Body 1
116 Thrust plate 2 1 215 Spring C 1 402 Spool 1
117 Thrust washer 1 4 216 Ball bearing 1 403 Piston 1
118 Thrust washer 2 3 217 Ball bearing 1 404 Stopper 1
119 Pre-load collar 2 218 O-ring ; 1B G120 1 405 Spring 1
120 Snap ring 4 221 Snap ring 1 406 Spring 1
121 Bearing 1 223 Socket bolt ; M10X35 8 407 Spring holder 1
122 Bearing 1 224 Spring pin 1 408 Plug ; PF1/4 4
123 Oil seal 1 225 Parallel pin 3 409 O-ring ; 1B P11 4
124 Socket bolt ; M8X25 6 226 Pin 1 410 O-ring ; 1B P7 2
126 Pin 4 231 Brake piston 1 411 Metal plug 2
128 Ring 1 232 Spring assy 12 412 Plug ; TPHA-1/8 1
129 Ring 1 4 233 Disk plate 2
24
24-33
24.1.5.5 FUNCTION AND OPERATION

(1) Operating slewing motor
This hydraulic motor, the axial piston (swash
plate) type, converts hydraulic energy delivered
by the pump into rotary motion.
Oil supplied through the control valve from
hydraulic pump is directed to the valve plate
(1). This oil enters port A of the valve plate
and the oil flows into the cylinder bore in the
cylinder (2) aligned with port A and pushes
the piston (3). The force on the piston is
converted by the swash plate (4) into rotary
motion, which is transmitted to the shaft (5)
splined to the cylinder (2).
Return oil from the cylinder bore flows out port
B of the valve plate (1).
In the case of reverse rotation, the oil flows
into port B, and the return oil flows out port A.
Operation of hydraulic motor
(2) Operation of parking brake

The parking brake operates to fix the output shaft of the slewing motor mechanically when the
slewing motor stops.
・ Operation when the brake release

pressure is blocked:
When brake releasing pressure is not
supplied, the brake piston (1) is pressed
in the direction (See Fig. "Operation of
parking brake" above) by the spring (2).
Then the disk plate (4) which is fixed to
the cylinder barrel (3) is held between the
body H (5) and the brake piston (1). As a
result, with the friction of these parts, the
cylinder barrel (3) and the hydraulic motor
are unable to rotate.
・ Operation when the brake release
pressure is continued :
When brake releasing pressure is supplied,
the oil is lead to chamber (6) shown in Fig.
"Operation of parking brake" below. Then
the brake piston (1) is moved to the
direction (See Fig. "Operatioin of parking
brake" below) against the force of spring
(2). As a result, the disk plate (4) is
released from the friction, and the cylinder
barrel (3) can be rotated.
Operation of parking brake
24-34
(3) Operation of hydraulic valve

1. Shockless relief valve
The shockless valve is made up of a
poppet, spring and the piston that changes
two steps stroke.
The IN and OUT ports of the hydraulic
motor are closed when the hydraulic motor
stops. The motor attempts to keep slewing
by inertia of the upper structure. This
produces pressure (braking pressure) on the
OUT port side by the pumping action of
the motor. The shockless relief valve
relieves the braking pressure by the
following two step actions, in order to
absorb the shocks at motor stop and
prevent the motor from breaking down at
the same time. The shockless relief valve
also operates to absorb shocks the same
way when the motor starts up.
a. 1st Stage
As pressure P1 flowing into the hydraulic
motor increases, pressure corresponding to
the spring action F1 causes the poppet
open.
b. 2nd Stage
The pressure P1 flows into "secondary
chamber" through the "orifice" which causes
the piston to push to the stroke end. This
reduces the length of the spring and Operation of shockless relief valve
increases the spring force. The pressure P1
rises to a set value Ps.
The above-mentioned 2-step action
absorbs shocks which occur when the
hydraulic motor starts and stops.
24
24-35
2. Check Valve
When the swing motor is decelerated by
operating the control valve, it continues to
be moved by the inertia of the machine.
Then, it works as pump, and the pressure
of C chamber tends to become nagative.
However, when B port pressure is below
cracking pressure of the relief valve, all
flow in A port goes out from B port through
the motor.
Therefore, if C chamber can get flow only
from the control valve, the flow will not be
enough to prevent the negative pressure;
as a result, cavitation could occur. The
check valve works to supply the flow from
T port to C chamber, and prevents
cavitation.
24-36
3. Action of hydraulic parking brake (P/B) timer

When the parking brake operates as the
upper structure produces inertia, the
hydraulic parking brake timer operates to
delay the operation of the parking brake for
a certain time length.
a. When the parking brake is released ;
If the pressure flows into the brake
release command secondary pilot pressure
port (PP), it overcomes the force of spring
(505) and pushes spool (502) to the
positions in Fig. "Operation of hydraulic
parking brake timer" and in the figure. On
that occasion, the brake release pressure at
the brake releasing primary pressure port
(PB) passes through the arrow in Fig.
"Operation of hydraulic parking brake
timer" is flowed into the chamber of the
parking brake piston, and releases the
parking brake.
b. When the parking brake acts ;
If the pilot pressure at the brake releasing
command secondary pilot pressure port
(PP) is blocked, spool (502) is pushed back
Operation of hydraulic parking brake timer
to the position in the figure by the force
of spring (505). The brake release
pressure at the brake releasing pressure
port (PB) is blocked by spool (502) and
block the pressure supply to the chamber
of the parking brake piston. The pressure
of the parking brake piston chamber is
pushed out by the force of the spring in
the parking brake and flows out to the DR
port through the passage indicated by an
arrow in the figure : On that occasion, the
oil that is flowing out is regulated by the
orifice of piston (503), flows out to the DR
port slowly, and delays the action of the
parking brake for a certain time length.
24
24-37
(4) Reduction Unit (Planetary 2 stage)

This slewing reduction unit for the slewing motor is made up of two stage planetary gear sets. It
converts high-speed rotary motion from the slewing motor into low speed and high-torque motion to
rotate the pinion shaft.
Refer to the Fig. "Operation of slewing reduction", sun gear 2 (S2) is splined on the output shaft of
the slewing motor and the rotation of sun gear 2 (S2) performs primary reduction through gears (S2),
(b2), and (a2).
After primary reduction, rotation performs secondary reduction through gears (S1) (splined to carrier 2),
(b1), and (a1).
After secondary reduction, rotation is transmitted to the pinion shaft splined to carrier 1 creating
slewing force.
The gear ratio of the two-stage planetary gear can generally expressed by :
Operation of slewing reduction
24-38
24
24-39
24.1.6 TRAVEL MOTOR

(1) General View
(2) Specifications
Model (Type) GM06VA
Rated output revolution (1st / 2nd) min-1(rpm) 30.9 / 52.2
Reduction unit Output torque (1st / 2nd) N-m (lbf-ft) 5710 / 3280 (4211 / 1033)
Reduction ratio 1 / 68.6
Displacement (1st / 2nd) cm3/rev (cu-in/rev) 26.4 / 15.3 (1.61 / 0.93)
Rated operating pressure MPa (psi) 23.0 (3340)
-1
Rated output revolution (1st / 2nd) min (rpm) 2119 / 3583
Hydraulic motor
Rated flow L/min (gal/min) 57.1 (15.1)
2-Speed shifting pressure MPa (psi) 3.5 (507)
Automatic 2-speed shifting pressure MPa (psi) 18.5 (2680)
Static friction torque N-m (lbf-ft) 64.7 (47.7)
Parking brake
Releasing pressure MPa (psi) 0.89 (129)
24-40
(1) Construction (Outline)
24
24-41
(2) Sectional view
24-42

1 Hub 1 Piston kit 1
2 Spindle 1 -Piston assembly 1
3 Carrier 1 161 --Piston 1
4 Sun gear (1) 1 162 --Shoe 1
5 Planetary gear (1) 3 163 -Seal ring 1
6 Sun gear (2) 1 102 Shaft 1
7 Planetary gear (2) 4 103 Swash plate 1
9 Thrust washer (1) 2 107 Retainer plate 1
11 Thrust collar (4) 4 108 Thrust ball 1
12 Thrust washer (3) 7 109 Timing plate 1
13 Cover 1 110 Washer 2
14 Coupling 1 112 Piston 1
22 Ring nut 1 113 Spring 8
24 Ball bearing 2 114 Spring 1
27 Needle roller bearing with retainer 3 115 Friction plate 2
28 Needle roller bearing with retainer 4 116 Separator plate 3
29 Inner race 3 132 Oil seal 1
30 Inner race 4 135 O-ring 1
139 O-ring 1
Floating seal kit 1 145 Snap ring 1
31 Floating seal 2 149 Ball bearing 1
150 Ball bearing 1
33 Plug with flange 1 151 Roller 3
35 O-ring 1 167 Pivot 2
37 O-ring 3 177 Parallel pin 2
39 Plug 2 190 Spring 1
40 Hexagon head screw 7
41 Steel ball 1 Rear flange assembly 1
42 Parallel pin 2 -Rear flange kit 1
43 O-ring 2 201 --Rear flange 1
44 O-ring 1 223 --Spool 1
45 Ring 1 -Spool kit 1
47 Hexagon socket set screw 2 263 --Spool 1
264 --Oil stopper 1
Cylinder and piston kit 1 221 -Plug 2
104 -Cylinder block 1 224 -Plug 2
-Piston kit 1 225 -Stopper 2 24
--Piston assembly 9 226 -Plug 2
105 ---Piston 1 227 -Valve 2
106 ---Shoe 1 228 -Spring 2
24-43

230 -Spring 2 275 -Orifice 5
236 -O-ring 2 276 -Orifice 1
237 -O-ring 2 279 -Filter 1
252 -Hexagon socket plug 4 280 -Plug with flange 1
254 -Hexagon socket plug 6 299 -Name plate 1
266 -Spring 1 241 Parallel pin 2
268 -Steel ball 1 243 Capscrew 6
273 -O-ring 2
24-44
24.1.6.3 FUNCTION
24.1.6.3.1 Reduction Unit
(1) Function
This reduction gear unit is composed of two stage planetary gear mechanism.
The reduction gear reduces the high speed of hydraulic motor and converts it low-speed, high-torque
rotation.
(2) Operating Description

The rotation of hydraulic motor shaft is transmitted to sun gear (4) of the first stage which is linked
with shaft (102) in spline.
Sun gear (4) is meshed with three planetary gears (5), and three planetary gears (5) mesh with hub
(1) while rotating on their axis.
At that time, the hub is rotated by the rotation of the planetary gears (5).
The hub rotation is transmitted to carrier (3) which connected to planetary gears (5), and that causes
sun gear (6) rotation of the second stage.
The rotation of sun gear (6) is transmitted to the hub via four planetary gears (7) of the second stage.
The generated rotation of reduction gear is output rotation.
24.1.6.3.2 Hydraulic Motor Section (Brake valve, parking brake, high and low speed change
mechanism)
(1) Function
1. Hydraulic motor: Hydraulic motor is referred to as a swash plate type axial piston motor which
converts the pressure oil power fed by pump into rotary motion.
2. Brake valve
a.
Travel motor controls the force of rotational inertia of the body to brake and stop the rotation
smoothly.
b.
Check valve function to prevent hydraulic motor from cavitation.
c. 24
Open the port to release the parking brake force at travel motor operation, and close the port at a
standstill.
3. Parking brake:
The parking brake is used to the prevent machine from running away or slipping while parking on
a slope using the friction plate type brake mechanism, and is installed on the hydraulic motor.
4. High / Low 2-speed shifting mechanism: By means of changing the tilt angle of the swash plate to
change the stroke volume of piston with help of the function on the shifting valve and control
piston, the speed is shifted to high speed with low torque or low speed with high torque.
24-45
(2) Operation
1. Hydraulic motor
Hydraulic oil fed by pump enters rear flange
(201) of travel motor, and is led from timing
plate (109) to cylinder block (104) through brake
valve mechanism. This pressure oil is led to
only the one side of Y1-Y2 tied between top
dead point and bottom dead point of piston
(105) stroke. And the pressure led to one side
of cylinder block pushes 4 or 5 pistons (105),
generating the power {F (N) = 100 X P (MPa)
X A (cm2)}. This power enters on swash plate
(103), but swash plate (103) is fixed having an
angle (α) against axis of drive shaft (102), and
divided into component of force (F2, F3). And
the radial component of force (F3) generated
various torque (T = F3 X ri) against line Y1-Y2.
The total torque [T = (F3 X ri)] is connected
to turning effort, and rotates cylinder block (104)
through piston (105).
This cylinder block (104) is connected with drive
shaft (102) with spline, and rotates drive shaft
(102) to transmit torque.
2. Brake valve
a. Operation (Brake released)
The pressure oil is led to through port (A),
opens valve (227), and led to port (C) on the
section side of hydraulic motor to rotate
hydraulic motor. At the same time, the
pressure oil enters chamber (b) through
passage (a) from the small hole of spool
(223), and exerts on the end of spool to
generate the force.
Then the force of spring (228) slides the spool
placed on the neutral position leftward.
The sliding of spool forms the space (passage)
between spool and rear flange with spool
groove. This passage is connected to port (D)
and port (B) of the return circuit of the
hydraulic motor, and the return oil returns to
tank side, enabling hydraulic motor to rotate.
Then, the sliding of spool (223) leads pressure
oil to port (P). The pressure oil led to port (P)
moves piston (112) of parking brake, and
releases parking braking force. (For details,
refer to item "Parking brake".) If pressurized oil
is supplied from port (B) the movements of
spool (223) and valve (227) are reversed so
that the hydraulic motor is rotated reversely.
24-46
b. Stop / Stall (braking action)

If pressurized oil supply through the port (A) is
suspended while travelling, the hydraulic force
to push up the spool is lost, and the spool
(223) which is slided to left side, tries to return
to the neutral position through the stopper (225)
due to the spring (228) force. At that time,
through the oil in the chamber (b) tries to flow
out to the port (A) side through the passage (a)
in the spool, its flow is restricted and some
back pressure is generated by the throttle effect
in the passage (a) controlling the return speed
of the spool. At the same time, the hydraulic
motor tries to rotate with its inertia force even
though the pressurized oil is suspended, and
the return oil from the hydraulic motor tries to
return to the port (B) side from the port (D)
through the passages on spool groove and rear
flange.
When the spool entirely return to the neutral
position, the passage on the hydraulic motor of
the oil return side is completely closed by the
spool, and the hydraulic motor ceases its
rotation. While machine working, the brake valve
smoothly stops rotation of the hydraulic motor
which tries to rotate with its inertia force, by
means of throttling the return side passage of
the hydraulic motor, generating back pressure
due to shape of the spool groove and
controlling the return speed of the spool.
On the other hand, when braking is operated,
the hydraulic motor tries to rotate with its inertia
force and to intake oil with its pumping function.
However, because the intake side is closed its
passage with the spool, the oil supply is
suspended. This causes cavitation in the
hydraulic motor. To prevent the cavitation, the
valve (227) is operated by very slight negative
pressure to open the passages of port (A)
side and intake port (C) of the hydraulic motor.
And when pressurized oil is supplied through
the port (B), each motion of the above
mentioned parts becomes symmetrical right 24
and left to stop the hydraulic motor.
24-47
c. Self-traveling
While machine is being operated, as the travel
speed is increased due to steep slope, the oil
flow rate of the hydraulic motor is higher than
the supply flow rate of the hydraulic oil pump.
The rotation of the hydraulic motor in this case
is called a self-traveling (Overrun).
While self-traveling, the oil pressure is lowered
similar to the stopping condition. Then brake
valve is moved similar to the stopping condition,
throttles passage in the return side of hydraulic
motor, and generate backing pressure.
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution having
a balance with the supply flow rate of pump.
3. Parking brake
a. Traveling
The pressure oil led trough brake valve
actuates on spool (223) of brake valve on the
hydraulic motor section, opens passage to
parking brake, and is led to cylinder chamber
(a) compressed of spindle (2) and piston (112)
on the reduction gear section.
If the pressure of oil which is 0.89MPa(129
psi) or higher it exceeds the force of spring
moving piston (112) toward rear flange (201)
side. This movement of piston (112) reduces
the push power to separator plate (116) and
friction plate (115), and makes the movement of
friction plate (115) which is installed to cylinder
block (104) on hydraulic motor section free
releasing the brake power to cylinder block
(104).
24-48
b. Stopping
If pressure oil from brake valve is cut, and the
pressure in cylinder chamber (a) lowers
0.89MPa(129 psi) or less, the piston (112) goes
to rightward by the force of spring (113).
Also, the force of the spring pushes mating
plate (116) and friction plate (115), which is in
a free state because piston (112) is pushed,
against spindle (2) on the reduction gear
section. The frictional force produced by the
push power stops the rotation of cylinder block
(104), and transmits braking torque 64.7N-m
(47.7 lbf-ft) to hydraulic motor shaft. And since
oil is controlled through the proper oil passage,
it results in smooth operation.
4. High / Low 2-speed shifting mechanism

a. Low speed
When the pilot pressure is not supplied through the port (D), the valve (263) is pushed up to the
upper position due to the spring (266) force and pressurized oil through the port (A) or (B), the
pressurized oil is cut off at port (C), and oil in the chamber (P) is released into the drain (motor case)
through the valve (263). Accordingly, the tilt angle of the swash plate (103) becomes the maximum
θ 1 resulting the maximum stroke volume and low speed rotation of the hydraulic motor.
24
24-49
b. High speed
When 3.5MPa (507 psi) of the pilot pressure is supplied through the port (D), it defeats the spring
(263) force and pressurized oil through the port (A) or (B) to push down the valve (263) to lower
position, the pressurized oil at the port (C) is led to the chamber (P) through the valve (263), and the
piston (161) pushes the swash plate (103) up to the plane X and maintain it at its position. At that
time, the tilt angle of the swash plate becomes the minimum θ 2 resulting the minimum stroke
volume and high speed rotation of the hydraulic motor.
c. Automatic shifting to low speed during high speed operation

If the load is increased while high speed operation, the oil pressure at the port (A) or (B) is also
increased. And when the oil pressure reaches to 18.5MPa (2680 psi), it excesses the pilot pressure
of 3.5MPa(507 psi), and the valve (263) is pushed up to upper position, and oil in the chamber (P) is
released into the drain (motor case) through the valve (263). At that time, the swash plate (103) gets
touch with the plane Y of spindle, and the tilt angle of swash plate becomes the maximum θ 1 and
is maintained at its position resulting low speed rotation.
24-50
24.1.7 SWIVEL JOINT

24.1.7.1 GENERAL VIEW
General view
Part No. 24100J12703F1
Port No. A, B, C, D E, F P G (Drain)
Max. working pressure MPa (psi) 22.6 (3280) <-- 3.4 (500) 0.5 (73)
Pressure test MPa (psi) 30.9 (4480) <-- 30.9 (4480) 1.0 (145)
Flow L/min (gal/min) 70 (18.5) 40 (10.6) 10 (2.6) 5 (1.3)
Port size PF1/2 PF3/8 PF1/4 PF3/8
Revolution rpm Less than 15
Weight kg (lb) Approx 22 (49)
24
24-51
Construction

1 STEM 1 10 DUST SEAL 1
2 BODY 1 11 DUST SEAL 1
3 FLANGE 1 12 SNAP RING 1
4 SPACER 1 13 BOLT (M10X30) 4
5 PIN 1 14 PLUG (PF1/4) 3
6 SLIPPER SEAL 7 15 SPRING WASHER 4
7 NAME PLATE 1 16 BACK-UP RING 1
8 O-RING 1 17 CLEVIS 2
9 O-RING 1
24.1.7.4 OPERATION
The swivel joint is installed on the slewing center of the machine, and plays a role to continuously
connect the oil circuit regardless of the slewing angle of the upper frame.
24-52
24.1.8 CYLINDER
(1) General View
General view
Center distance of mounting

Cylinder Bore /
Stroke pins Dry weight
Cylinder Rod Dia. Cushion
mm (ft-in) Full extend B / Full retract A kg (lb)
mm (ft-in)
mm (ft-in)
100 dia. / 55 dia.
Boom 680 (2'2.8") 1757 / 1077 (5'9.2" / 3'6.4") Rod side 64 (141)
(3.94" / 2.17")
90 dia. / 55 dia. Rod &
Arm 735 (2'4.9") 1855 / 1120 (6'1.0" / 3'8.1") 58 (128)
(3.54" / 2.17") Head
75 dia. / 45 dia.
Bucket 543 (1'9.4") 1378 / 835 (4'6.3" / 2'8.9") None 31 (67)
(2.95" / 1.77")
90 dia. / 50 dia. 574
Swing 1451 / 877 (4'9.1" / 2'10.5") None 44 (97)
(3.54" / 1.97") (1'10.6")
95 dia. / 55 dia.
Dozer 200 (7.87") 727 / 527 (2'4.6" / 1'8.7") None 35 (76)
(3.74" / 2.17")
24
24-53
24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1 Construction
(1) Boom cylinder
Construction

1 Cylinder tube 1 9 O-ring 1 17 Slide ring 2
2 Piston rod 1 10 Holder 1 18 Setscrew 1
3 Cylinder head 1 11 Cushion seal 1 19 Steel ball 1
4 Bushing 1 12 Collar 1 24 Pin bushing 2
5 U-ring 1 13 Back-up ring 1 25 Wiper ring 4
6 Wiper ring 1 14 Cushion bearing 1 27 Grease nipple 2
7 O-ring 2 15 Piston 1 32 Spacer 1
8 Back-up ring 1 16 Seal ring assy 1
24-54
(2) Arm cylinder
Construction

1 Cylinder tube 1 10 Holder 1 19 Steel ball 1
2 Piston rod 1 11 Cushion seal 1 20 Cushion bearing 1
3 Cylinder head 1 12 Collar 1 21 Cushion seal 1
4 Bushing 1 13 Back-up ring 1 22 Snap ring 1
5 U-ring 1 14 Cushion bearing 1 23 Stopper 2
6 Wiper ring 1 15 Piston 1 24 Pin bushing 2
7 O-ring 2 16 Seal ring assy 1 25 Wiper ring 4
8 Back-up ring 2 17 Slide ring 2 27 Grease nipple 2
9 O-ring 1 18 Setscew 1 32 Stopper 1
24
24-55
(3) Bucket cylinder
Construction

1 Cylinder tube 1 7 O-ring 1 18 Setscrew 1
2 Piston rod 1 8 Back-up ring 1 19 Steel ball 1
3 Cylinder head 1 9 O-ring 1 24 Pin bushing 1 (2)
4 Bushing 1 15 Piston 1 25 Wiper ring 4
5 U-ring 1 16 Seal ring assy 1 26 Pin bushing 1 (0)
6 Wiper ring 1 17 Slide ring 2 27 Grease nipple 2 (1)
( ) Shows Swing cykinder
24-56
(4) Swing cylinder
Construction

3 Cylinder head 1 9 O-ring 1 24 Pin bushing 1 (2)
5 U-ring 1 16 Seal ring assy 1 26 Pin bushing 1 (0)
6 Wiper ring 1 17 Slide ring 2 27 Grease nipple 2 (1)
( ) Shows Swing cykinder
24
24-57
(5) Dozer cylinder
Construction

3 Cylinder head 1 9 O-ring 1 24 Pin bushing 2
5 U-ring 1 16 Seal ring assy 1 27 Grease nipple 1
6 Wiper ring 1 17 Slide ring 2 28 Grease nipple 1
24-58
24.1.8.2.2 Function (Example for arm cylinder)
Cylinder head assy
(1) Basic function

This is a kind of hydraulic actuator, which works so that the energy of the hydraulic pressure delivered
by the hydrauiic pump is transformed into a large force of rectilinear motion by way of the piston,
and the operating direction is changed in the extending and retracting direction by operating the valve
lever for the pressure oii flowing direction change. These large force and rectilinear motion, and
operating direction change are basic functions.
(2) Functions of other sections

The following are described with the arm cylinders.
1. Cylinder head assembly

The cylinder head assembly plays a role as a bearing in piston rod (2) by press-fitting bushing (4)
in the bore of the cylinder head (3). U-ring (5) is inserted in the bore of cylinder head to prevent
the oil leakage to the outside. And wiperring (6) is press-fitted in the bore of cyiinder head to
protect it from dust entry. The high pressure is produced in the cushion room at the position
where the rod is almost extended to reduce the shock of the cylinder head.
And it has a function to feed and discharge the high pressure oil from the cylinder tube to the
port.
a. Bushing (4)
The bushing (4) is press-filted in the bore of the cyiinder head (3) and is In contact with the
piston rod. And it shares the lateral load to the cylinder with the slide ring around the piston,
moves linearly in high bearing stress to the piston rod, and reduces eccentricity which has a bad
effect on the sealing capacity holding an end of the piston rod.
b. Wiper ring (6)
The wiper ring is fitted on the mouth where the rod cylinder telescopes from cylinder. The rod 24
seal of U-rlng (5) in the cyiinder prevents the entry of dust and water and removes mud adhered
on the piston rod by the movement of the piston rod.
24-59
Piston assy
2. Piston assembly
The piston assembly is prevented from the pressure oil leakage to other sections from the right
or left piston chamber by inserting seal ring (16) in the center of piston (15), and plays the
function as a bearing for the lateral load to the cylinder.
The high pressure is produced in the cushion room at the position where the rod is almost
retracted to reduce the shock of the cylinder piston.
And also, slide ring (17) is used to remove the contamination.
a. Seal ring (16)

The seal ring is fitted at the center of the piston, seals annular space between the piston and the
cylinder tube with the aid of tightness of the O-ring, and forms chambers on the high and low
pressure sides, bordering on the piston.
b. Slide ring (17)
The seal ring is fitted on both sides of the seal ring and is in contact with the inner surface of
the tube. And it shares the lateral load to the cylinder with the bushing located on the bore of the
cylinder head, moves linearly in high surface pressure to the inner surface of the cylinder tube,
and reduces the eccentricity which has a bad effect on the sealing capacity, holding an end of the
piston rod.
c. Cushion bearing (14)
The cushion bearing is placed between the piston and the piston rod step section, forms annular
space with the cylinder head close to the most extended rod position, restricts the oil to reduce
the cylinder impact speed at the most extended position, and consequently absorbs the shock.
d. Cushion bearing (20)
The cushion bearing is placed on tip of the piston rod, forms annular space with the cylinder
bottom close to the most retracted rod position, restricts the oii to reduce the cylinder impact
speed at the most retracted position, and consequently absorbs the shock.
24-60
24.2 ELECTRICAL EQUIPMENT
24.2.1 ELECTRICAL EQUIPMENT LIST

D-1 DIODE YN02D01001P1
D-2 DIODE
D-3 DIODE
D-4 DIODE
Diode D-5 DIODE
D-12 DIODE
D-14 DIODE
D-18 DIODE
D-19 DIODE
E-1 FUSE BOX PY73E00002F1
E-2 GENERATOR (ALTERNATOR) E/G accessory (119626-77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E-7 POWER SOCKET PF81S01001P1
E-8 GLOW PLUG E/G accessory (129008-77800)
E-10 RADIO (OPT) Cab accessory (YN54S00045P2)
Electical
E-11 OVER LOAD BUZZER YJ53S01001D3
Fittings
E-13 BATTERY PH72S00006P1
E-14 SEQUENCE BOX PA24S00002P3
E-18 COMPRESSOR A/C accessory
E-20 TRAVEL ALARM PW53S00002F1
E-26 HOUR METER PA58S00001P1
E-27 RECEIVER DRER PW20M01071F1
E-41 SPEAKER LEFT YT54S00006P1
E-42 SPEAKER RIGHT
L-1 ROOM LAMP (FOR CAB) PW80S00007P1
Light L-2 BOOM WORKING LIGHT LEFT (55W) PM80S00008F1
L-5 CAB / CANOPY WORKING LIGHT PW80S00003F1
M-1 STARTER MOTOR E/G accessory (129136-77011)
M-2 WIPER MOTOR (FOR CAB) Cab accessory (PM76S00001F1)
Motor M-3 WASHER MOTOR (FOR CAB) Cab accessory (PW54C00001P1)
24
M-4 DECELERATION MOTOR PY20S00003F1
M-6 FUEL PUMP PW22P00001P1
R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
Relay
R-6 TIMER UNIT PH25S00002P1
R-7 E/G STOP RELAY PX24S00003P1
24-61

R-8 CHARGE INDICATOR RELAY PA24E01001P1
R-9 CAB / CANOPY WORKING LIGHT RELAY
Relay
R-31 HORN RELAY PA24E01001P1
R-34 NEUTRAL START RELAY PM24S00001P1
SE-1 FUEL SENSOR PY52S00013F1
Sensor
SE-2 ENGINE THERMO SENSOR PA24S00003P1
SV-1 LEVER LOCK SOL.
PY35V00008F1
SV-2 2-SPEED SELECT SOL.
Solenoid
SV-3 E/G STOP SOL. E/G accessory (119233-77932)
SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
SW-1 KEY SWITCH PW50S00005S001
SW-2 WORKING LIGHT SW. PV24E01001P2
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. (FOR CAB) PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
SW-6 E/G OIL PRESSURE SW. E/G accessory (114250-39450)
SW-7 HORN SW. YN50E01001P2
SW-9 LEVER LOCK SW. PA50S00001P1
Switch SW-11 DECELERATION SW. PM50S00005P1
SW-14 AIR FILTER RESTRICTION SW. PW11P00010S004
SW-23 TRAVEL ALARM SELECT SW. 2479U1190F16
SW-24 TRAVEL RIGHT (FORWARD) PRESSURE SW. GB50S00049F2
SW-25 TRAVEL RIGHT (REVERSE) PRESSURE SW.
SW-26 TRAVEL LEFT (FORWARD) PRESSURE SW.
SW-27 TRAVEL LEFT (REVERSE) PRESSURE SW.
SW-39 OVER LOAD PRESSURE SW. 72117480 (DIN 43650)
SW-40 OVER LOAD SW. 2479U1190F33
-The part number may be changed owing to modification, use them only for reference.
-NA : North America, AUST : Australia.
24-62
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT
24
24-63
24-64
24
24-65
24-66
24
24-67
24-68
24
24-69
24-70
24
24-71
24-72
24
24-73
24-74
24
24-75
24-76
24
24-77
24-78
［31. GENERAL DISASSEMBLY AND ASSEMBLY］
31. GENERAL DISASSEMBLY

AND ASSEMBLY
TABLE OF CONTENTS
31.1 GENERAL DISASSEMBLY AND ASSEMBLY ……………………………………………………………31-3

31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY……………………………………31-3
31.1.2 SPECIFICATION OF TIGHTENING TORQUE ………………………………………………………31-3
31
Book Code No. S5PA3105E01
31-1

S5PA3105E01
First Edition June, 2009 E10SR : PA03-05001~
(NHK-EUR)
April, 2010 SK50SR-5 : PJ06-09807~

(KCM North America)
CX50B : PJ06-09807~
(CASE-NA)
E50B : PJ06-09807~
(NH-NA)
SK30SR-5 : PW14-46519~
CX31B : PW14-46519~
E30B : PW14-46519~
E35B : PX15-21105~ (NH-AUS)
SK20SR-5 : PM10-10001~
CX27B : PV13-33001~
(CASE-Australia)
E27B : PV13-33001~
(NH-AUS)
SK40SR-5 : PH07-06609~
May, 2010
E50B : PJ06-09807~
(NH-AUS)
CX50B : PJ06-09807~
(CASE-AUS)
SK27SR-5 : PV13-33453~
(NA)
CX27B : PV13-33453~
(CASE-NA)
E27B : PV13-33453~
(NH-NA)
SK20SR-5 : PM10-10609~
CX27B : PV13-33453~
(CASE-Australia)
E27B : PV13-33453~
(NH-AUS)

(KCM North America)
CX55BMSR : PS02-00101~
(CASE-NA)
E55BX : PS02-00101~
(NH-NA)

(KOR)
January, 2011 SK50P : PS02-00101~

(SE Asia)
31-2
31.1 GENERAL DISASSEMBLY AND ASSEMBLY
31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY

This chapter is consist of three sections as follows.
(1) ATTACHMENT : Index No. : 32

Part I : Removing and Installing Assembly
Part II: Disassembling and Assembling Components
1. Hydraulic cylinder
(2) UPPER SLEWING STRUCTURE : Index No. : 33
1. Hydraulic pump
2. Control Valve
3. Pilot Valve (ATT)
4. Pilot Valve (Travel)
5. Slewing Motor
6. Swivel Joint
(3) TRAVEL SYSTEM : Index No. : 34
1. Travel Motor
31.1.2 SPECIFICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example;
T=100 N-m (73.8 lbf-ft)
Tolerance is ± 10% unless otherwise specified.
・ Refer Index No. 11 TOOLS for standard tightening torque.
31
31-3
31-4
［32. ATTACHMENTS］
32. ATTACHMENTS
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING ………………………………………………………………………………32-3

32.1.1 ATTACHMENT ASSEMBLY AND NAME………………………………………………………………32-3
32.1.2 BUCKET ……………………………………………………………………………………………………32-4
32.1.3 ARM …………………………………………………………………………………………………………32-6
32.1.4 BOOM ………………………………………………………………………………………………………32-10
32.1.5 SWING ………………………………………………………………………………………………………32-14
32.1.6 DOZER ………………………………………………………………………………………………………32-16
32.2 DISASSEMBLING AND ASSEMBLING ……………………………………………………………………32-17
32.2.1 CYLINDER …………………………………………………………………………………………………32-17
32
32-1

S5PS3210E01
(SE Asia)
32-2
32.1 REMOVING AND INSTALLING
32.1.1 ATTACHMENT ASSEMBLY AND NAME
Attachment name and position 32
32-3
32.1.2 BUCKET
32.1.2.1 REMOVAL OF BUCKET
(1) Operate the operating lever and place the
bucket on the ground, so the bucket and
arm connecting pins are not loaded.
(2) Move the O-rings (3) toward the bucket
bosses using a spatula.
(3) In order to remove pin (K) which links arm
and bucket, remove the ring (2) and the
pin (3) by means of straight driver, and
draw out pin (K).
To place Bucket on ground
・ If the pin does not come off easily, the pin is loaded. Take off the load by manipulating the
operating lever.
・ Take care so the dust seal between the arm and the bucket bosses is not damaged.
(4) Adjust the bucket by manipulating the

operating lever so the pin (J) between the
bucket link and the bucket is not loaded.
(5) Remove the ring (2) and pin (1) then pull
out the pin (J).
(6) Remove bucket assembly.
Weight : 111kg (250 lbs) - SK50P
Assembly of pin (SECTION A-A)
32-4
32.1.2.2 INSTALLATION OF BUCKET

Installation is performed in the reverse order of removal, including the following workings :
When aligning the pin position, do not put your finger in the pin holes in any circumstances, but align
them visually.
(1) Clean the welded part of the structures and

check that there is no crack on the part.
(2) Check that the dust seal is not damaged,
and replace a faulty one if necessary.
(3) Replace the worn pins and bushings
according to the Section "ATTACHMENT
DIMENSIONS" of "SPECIFICATIONS".
(4) When inserting the pin, coat the shaft with
grease.
-The bucket can be mounted easily if the
bucket link is installed in the beginning.
Installation of bucket
32
32-5
32.1.3 ARM
32.1.3.1 REMOVAL OF ARM
(1) Making the arm cylinder and bucket
cylinder to the most retracting conditions,
lower the arm tip to the ground.
(2) Shut off the engine and operate the arm
control lever several times, and the
pressure in circuit is released.
(Accumulator is equipped to relieve
pressure in pilot line; therefore, pressure is
released easily from pilot line.) Arm removing posture
Then put the safety lock lever in the
"Locked" position, and depress the air
breather on the hydraulic oil tank, release
the pressure in the tank.
(3) Disconnect the 2 hoses connected to the
bucket cylinder. Then apply plugs to the
openings.
Tools : Spanner : 27mm
(4) Lift up the arm cylinder body with a nylon

sling in order not to exert any load to the
pin (E).
(5) Remove the capscrew and nuts that are
preventing the pin (E) from coming off.
Then remove the pin (E) and shims.
(6) Placing a wood block under the arm
cylinder, get down the cylinder.
(7) Install the pin (E) to the original position,
and install the capscrew and nuts that
prevents the pin (E) from coming off.
Applying a rope to the pin (E) and the
arm tip, slightly lift it up in order not to
Sectional view of Installing Pin
exert any load to the pin (F).
(8) Remove the capscrew that is preventing the

pin (F) connecting the arm and boom,
from coming off. Then pull off the pin (F).
(9) Remove the arm assembly paying
attention to the stability of arm.
Weight of arm assembly : approx.
175kg (390 lbs) - SK50P
Removal of Arm assembly
32-6
(10) Removal of Bucket Cylinder
1. Remove the capscrew that is preventing the

rod pin (H) from coming off, then pull off
the pin (H).
2. Remove the capscrew and nuts that are
preventing the head pin (G) from coming
off, then pull off the pin (G). Sectional view of Installing Pin
3. Apply a nylon sling to the tube of bucket
cylinder, and remove the cylinder.
Weight ; approx. 31kg (68.4 lbs)
32
32-7
32.1.3.2 INSTALLATION OF ARM

Installation is performed in the reverse order of removal, including the following workings.
-At the alignment of pin positions, do not insert your finger into the pin holes.
-Make sure to align them with visual confirmation.
(1) Make the welded area clean to inspect

any cracks there.
(2) Check the dust seal for damages, and
replace the faulty dust seal with new one
(referring to Fig. "Dust seal installation" for
the installing procedures).
(3) Referring to the Section "ATTACHMENT
DIMENSIONS" of Specifications, replace the
worn-out pin and bushing with new ones.
Dust seal installation
(4) Before installing the pin, apply grease to
the shaft area.
(5) Referring to Fig. "Sectional view of
Installing Pin", install the capscrew and nuts
to prevent the pin from coming off.
Tools : Spanner : 19mm, 24mm, 36mm
(6) Make sure to provide an appropriate
clearance for thrust direction at the
installation of pin referring to Fig. "Sectional
view of Installing Pin".
(7) For the adjustment for clearance, insert
resin (plastic) shim first, then adjust the
clearance with steel shims.
32-8
32
32-9
32.1.4 BOOM
32.1.4.1 REMOVAL OF BOOM
(1) Get down the boom from which the arm
was removed, and support the boom end
with a stable stand.
(2) Disconnect all hoses from the bucket
cylinder, arm cylinder and boom cylinder,
and apply plugs to all the openings.
Tools : Spanner : 27 mm
(3) Disconnect the wiring for working light at
the connector.
Removal of Boom Cylinder
(4) Removal of Boom Cylinder
1. Temporarily lift up the boom cylinder with

a nylon sling to prevent the boom cylinder
from falling down.
2. Removing the capscrew and nuts that are
preventing the rod pin (C) from coming off,
remove the pin (C).
3. Retract the rod, then put the cylinder on a
stable stand.
4. Removing the capscrew that is preventing
the head pin (B) from coming off, remove
the pin (B).
5. Remove the boom cylinder.
Weight :
64 kg (141 lbs) - SK50P
(5) Removal of Boom assembly
1. Temporarily lift up the boom assembly in

order not to exert any load on the boom
foot pin (A).
Weight of boom assembly : approx.
262 kg (578 lbs) - SK50P
2. Removing the capscrew that is preventing
the boom foot pin (A) from coming off,
pull off the pin (A).
Tools: Spanner: 19mm
3. Applying a sling to the boom assembly,
remove the boom assembly.
Removal of Boom assembly
32-10
(6) Removal of Arm Cylinder
1. Removing the capscrew and nuts that are

preventing the head pin (D) from coming
off, remove the pin (D).
2. Applying a nylon sling to the tube of arm
cylinder, remove the arm cylinder.
Weight :
58 kg (128 lbs) - SK50P
32
32-11
32.1.4.2 INSTALLATION OF BOOM

Installation is performed in the reverse order of removal, including the following.
-At the alignment of pin positions, do not insert your finger into the bores.
-Make sure to align them with visual check.
(1) Make clean the welded area on each of

structure to inspect any cracks there.
(2) Check the dust seal for damages, and
replace the faulty dust seal with new one
(referring to Fig. "Dust seal installation" for
the installing procedures).
worn-out pin and bush with new ones.
(4) Before inserting the pin, apply grease to Dust seal installation
the shaft area.
(5) Referring to Fig. "Sectional view of
Installing Pin", install the capscrew and nuts
to prevent the pin from coming off.
(6) Make sure to provide an appropriate
clearance for thrust direction at the
installation of pin referring to Fig. "Sectional
view of Installing Pin".
(7) For the adjustment for clearance, insert
resin (plastic) shim first, then adjust the
clearance with steel shims.
32-12
32
32-13
32.1.5 SWING
32.1.5.1 PREPARATION FOR REMOVAL
(1) To make the removing work easy, swing by around 30 degrees leftward.
(2) Disconnect the hoses of bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all
the openings.
32.1.5.2 Removal of Swing Bracket and Cylinder

(1) Removal of swing bracket (A9)
1. Removing the capscrew (C4) that is
preventing the rod side pin (M) of swing
cylinder (C11) from coming off, remove the
pin (M).
Tools : Socket : 19mm
2. Install the boom foot pin (A) to the original
position on swing bracket (A9), then
temporarily lift it up.
3. Removing two capscrews (B7) (B8) those
are preventing the pins (L1) (L2) from
coming off, remove the pins (L1) (L2).
4. Remove the swing bracket (A9).
Weight of Swing Bracket : 106kg (234 lbs).
(2) Removal of Swing Cylinder (C11)

1. Disconnect 2 connecting hoses for the
swing cylinder.
2. Removing the capscrew (C5) that is
preventing the head side pin (N) of swing
cylinder from coming off, remove the pin
(N).
3. Disconnect swing cylinder (C11) grease
hose of head side at connector.
4. Take out the swing cylinder (C11) from

the front side.
Weight of Swing Cylinder : 44kg (97 lbs)
Swing portion
32-14
32.1.5.3 INSTALLATION OF SWING BRACKET AND CYLINDER

Installation is performed in the reverse order of removal, including the following workings.
(1) Check the dust seal for damages, and replace the faulty dust seal with new one.
(2) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the worn-out pin
and bushing with new ones.
(3) Before inserting the pin, apply grease to the shaft area.
(4) Refer to Fig. "Sectional view of Pin Installing" for the shim adjustment at pin installing portion.
Sectional view of Pin Installing
32
32-15
32.1.6 DOZER
32.1.6.1 REMOVAL
(1) Put a support of appropriate height under
the mounting side of dozer body, and make
the dozer at a stable condition not to
exert any load on the pin (P).
(2) Disconnect the hydraulic hoses and apply a
plug to the connecting portions.
(3) Apply a nylon sling to the dozer cylinder
(C1), and lift it up slightly not to exert any
load on the pin (Q) of rod side. Removing/Installing Dozer
(4) Remove the capscrew (C3) and nuts (C4)
that are preventing the pin (Q) from coming
off, of rod side. Remove the pin (Q), and
support the cylinder (C1) with a wood
block, etc.
(5) Remove the capscrew (B2) and nuts (B3)
that are preventing the dozer body fixing
pin (P) from coming off, and remove the
two pins (P).
(6) Gradually move the machine to backward
to remove the dozer.
Weight of dozer assembly :
212kg (467 lbs) - SK50P
(7) If necessary, remove the dozer cylinder by
means of removing the pin (R) of head
side.
Weight of dozer cylinder :
32kg (71 lbs)
32.1.6.2 INSTALLATION
The installation is carried out with the reverse order of the removal paying attention for the following.

worn-out bushings and dust seals with new
ones.
(2) Before installing pin (P), (Q) and (R),
apply grease to their shaft area.
(3) Referring to Fig. "Tightening Procedures
for Nuts", install the nuts for capscrew to
prevent the pin from coming off.
Tightening Procedures for Nuts
32-16
32.2 DISASSEMBLING AND ASSEMBLING
32.2.1 CYLINDER
32.2.1.1 NECESSARY TOOLS
Though the required tools and jigs differ in types of cylinder, as a guide line, tools and jigs to be
prepared are shown in Table "Tools and Jigs".
Tools and Jigs

Tool/Jig Remarks Tool/Jig Remarks
1. Steel hammer A sharp-point tool may be used in
Hammer Gimlet
2. Wooden or plastic hammer place of gimlet
Several kinds of minus driver of small
Screwdriver 1. For installing seal ring
and large sizes
2. For pushing seal ring into groove
Chisel Flat chisel Jig
3. For reforming seal ring
Capable to hold outer dia. of cylinder 4. For pressing bushing
Vise
head and tube installing pin portion.
1. Slide calipers
1. Special wrench Measuring 2. Micrometer
Wrench
2. Extension pipe for wrench Device 3. Cylinder gauge
4. V-block
・ For the details of special jigs, refer to 32.2.1.7 of this section.
32.2.1.2 GENERAL PRECAUTIONS

・ Carry out the disassembly and assembly works in a clean work shop, and always keep
disassembled parts at clean conditions.
・ Prior to disassembly, thoroughly clean the cylinder externally.
・ Use caution not to give any damages to the parts while carrying out the disassembly / assembly
works.
・ Thinly apply grease or hydraulic oil to seals prior to installation.
・ After the installation of O-ring, confirm there is no twist on it.
・ Apply clean hydraulic oil to each sliding portion before the installation.
・ Ensure each sliding portion for no burr and defect, and its smooth sliding operation.
・ This manual describes mainly for the boom cylinder as an typical example.
Refer to 24.1.8 of COMPONENT SYSTEM for the construction of hydraulic cylinders when
disassembling and reassembling the cylinders.
32
32-17
32.2.1.3 CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER)

・ See 24.1.8 CYLINDER for boom.
Construction

1 Cylinder tube 1 9 O-ring 1 17 Slide ring 2
2 Piston rod 1 10 Holder 1 18 Setscrew 1
3 Cylinder head 1 11 Cushion seal 1 19 Steel ball 1
4 Bushing 1 12 Collar 1 24 Pin bushing 2
5 U-ring 1 13 Back-up ring 1 25 Wiper ring 4
6 Wiper ring 1 14 Cushion bearing 1 27 Grease nipple 2
7 O-ring 2 15 Piston 1 32 Spacer 1
8 Back-up ring 1 16 Seal ring assy 1
32.2.1.4 DISASSEMBLY
・ The numbers in ( ) following to each part name are the Items corresponding to those in Fig.
"Construction of boom cylinder" unless otherwise noted.
(1) Disassembly of cylinder assembly

1. Fix the clevis portion of tube with a vice,
and hold the other end with a wooden
stand to hold the cylinder in level.
2. Drain hydraulic oil remained in the cylinder.
-Slowly move the piston rod so that the
hydraulic oil does not spout out.
Disassembling cylinder assembly
32-18
3. Make straight the locking fin for the cylinder

head (4).
-Use cautions bending / straightening of
locking fin, because locking fin and
cylinder tube are made with one-piece.
4. Loosen the cylinder head (4).
-Prior to loosening the cylinder head, pull
out the piston rod (3) by 100 ~ 200 mm (4
~ 8 in).
-Cover the rod with an appropriate material
to prevent it from unexpected dents.
Disassembling cylinder assembly
5. Pull off the piston rod assembly from the

tube.
-Pull the piston rod in straight not to give
any damages on the sliding surface.
Disassembling cylinder head
(2) Disassembly of piston rod assembly

1. Fix the piston rod assembly in level.
2. Disassembly of the piston
Disassembling piston rod
a. Remove the setscrew (20), then remove the

steel ball (21).
-Since the setscrew (20) is caulked at two
positions with a punch, take off the caulked 32
portion with a hand drill.
b. Remove the piston (17) assembly.
c. Remove the cushion bearing (22) (for boom
and arm cylinders only).
Removing piston assembly
32-19
3. Disassembling of cushion bearing of

retraction side (head side) (Only for arm
cylinder)
4. Remove cylinder head (4) and holder (11).

(Only boom and arm cylinders has a holder)
Removing cylinder head and holder
(3) Disassembly of piston assembly :

1. Remove the slide ring (19) from the piston
(17).
-Expand the split on the slide ring (19) as
minimum as required to pull it off for axial
direction. (2 Points)
2. Remove the seal ring assembly (18).
-Cut off the seal ring (18) or remove it
using a minus screw driver.
Disassembling piston assembly
(4) Disassembly of cylinder head assembly :

1. Remove the O-rings (8) and (10) and
back-up ring (9) from the outer periphery of
cylinder head (4).
Disassembling cylinder head assembly
32-20
2. Disassembling holder (Only boom and arm cylinders)
a. Remove collar (14).

b. Remove cushion seal (13).
c. Remove spacer (12).
d. Remove O-ring (8) and back-up ring (16) of
outer diameter.
Disassembling holder
3. Removal of U-ring.
a. Remove the U-ring (6).
Disassembling cylinder head
4. Remove the wiper ring (7).

-Alternately tap inside of the metal ring of
wiper ring at several positions, as shown
in the figure, to push it out step by step
from the groove.
Removing wiper ring
5. Remove the bushing (5) using a removal

jig. 32
Removing bushing
32-21
(5) Disassembly of clevis portion :

1. Remove the dust seal (23) from the clevis
portion of tube (1) and piston rod (3).
Removing dust seal
2. Remove the pin bushing (2).

-Using a metal block, push it out with a
press machine.
Removing pin bushing
32.2.1.5 ASSEMBLY
(1) Assembling Clevis Portion
1. With the installing jig (B) shown Item
32.2.1.7, press the bushings (2) into the
piston rod (3) and tube (1).
-Prior to the work, apply hydraulic oil on
the surface of parts.
Installing pin bushing (2)
2. With the setting tool, install the dust seal

(23).
Installing dust seal
32-22
(2) Assembling Cylinder Head

1. With installing jig (A) shown Item 32.2.1.7,
press-fit the bushing (5).
-Prior to the work, apply hydraulic oil on
inner periphery of the cylinder head (4).
-At press-fitting the bushing (5) into the
cylinder head (4), make the top surfaces
of them in level without step.
Assembling cylinder head
2. Installing U-Ring
a. Install the U-ring (6).
Installing U-ring
3. Assembling holder (Only for boom and arm cylinders)
a. Install spacer (12).

b. Install cushion seal (13).
c. Install collar (14).
d. Install back-up ring (16) and O-ring (8).
Installing holder
32
32-23
4. Using the setting tool, install the wiper ring

(7).
Installing wiper ring
5. Install the back-up ring (9) and O-rings (8)

and (10).
Installing back-up ring and O-ring
(3) Assembly of piston portion :

1. Install the O-ring for the seal ring assembly
(18).
Assembling piston assembly
2. Set the sliding jig (C) on the piston (17),

then quickly push the seal ring (18) with
the pushing jig (D).
Assembling piston assembly
32-24
3. Since the seal ring (18) is extremely

stretched at the installation, reform it with
the reforming jig (E) shown Item 32.2.1.7.
Reforming seal ring
4. Install the slide ring (19).

-Expand the split on the slide ring (19) as
minimum as required to install it toward
the axial direction. (2 points)
Installing slide ring
(4) Installation of piston rod assembly :

1. Fix the piston rod (3) in level, and install
the cylinder head assembly and holder onto
it.
Installing head and holder
2. Installing procedures for cushion bearing of

retraction side. (Only for arm cylinder)
32
32-25
3. Install the piston assembly.
a. Install the cushion bearing (22) (for boom

and arm cylinders only) and piston (17) on
the piston rod (3), and tighten them up.
-Tightening torque for piston :
See Item 32.2.1.6 (4) Tightening torque.
b. Put the steel ball (21) into the threaded
bore, and securely tighten it with the
setscrew (20). And caulk the setscrew with
a punch at two points.
Installing piston assembly
-Tightening torque for setscrew :
(5) Assembly of cylinder :

1. Fix the tube in level, and install the piston
rod assembly into it.
-At the installation, align the center of
piston rod to the center of tube and install
the piston rod in straight, paying attention
not to damage seals.
Inserting piston rod assembly
2. Install the cylinder head (4).

-Apply hydraulic oil on the packings (seals)
prior to install.
-Tightening torque for cylinder head :
Installing cylinder head
3. Bend the locking fin on the tube to lock

the cylinder head.
Assembling cylinder assembly
32-26
32.2.1.6 MAINTENANCE STANDARDS

(1) Inspection after disassembly
1. Inspection item
Parts Name Inspecting Portion Inspection Item Remedy

1. Neck of rod Presence of crack Replace
2. Stepped part to which
Presence of crack Replace
piston is attached
3. Threads Presence of seizure, etc. Recondition or replace
4. Bend Measure amount of bend Refer to Rod Bend
Piston rod
1. Wearing off of plating 1. Replace
5. Plated surface 2. Rust on plating 2. Replace
3. Presence of defect 3. Recondition or replace
6. Rod Wear of outside Recondition or replace
7. Bushing at mounting part Wear of inside Replace
1. Welded part of bottom Presence of crack Replace
2. Tube at mounting part Presence of crack Replace
Cylinder tube
3. Tube inside Presence of defect Replace if oil leak is seen
4. Bushing at mounting part Wear of inside Replace
1. Wear of inside
Cylinder head 1.Bushing Replace
2. Defect of inside
(2) Repair procedure

Replace sliding parts and seal parts according to the followings.
1 Bushing Where 1/4 of circumference is worn in copper color.

2 Seals and slide rings Replace them when cylinder is disassembled.
3 Pin bushing Where severe scuffing is appeared.
4 Piston rod Where the bent 0.5 mm/m (0.02 in/3.3 ft) or more is appeared.
32
32-27
(3) Service limits

Service limits represent the limits of wear on the sliding surfaces of the cylinder tube and the piston
rod that have no such faults as may degrade the sealing effect.
1. Clearance between piston rod and rod bushing :

Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25
mm (0.01 in).
2. Bend of piston rod :
The allowable bend of the rod is maximum 0.5 mm / 1 m (0.02 in / 3.3ft). For measurement,
support both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the
center between the two V-blocks turn the piston rod, and read the difference between the
maximum and minimum values on the dial indicator.
・ Even if the bend is within the allowable limit, the cylinder may not operate smoothly because of
localized bend. Beware of it during function test after installation.
Replace the rod if the cylinder makes a squeaking noise or dose not operate smoothly.
Measuring method
(4) Tightening torque
Unit : N-m (lbf-ft)

Model Cylinder Cylinder head A Piston B Setscrew C
Boom 647 (477) 2263 (1670)
32.6 (24)
Arm 530 (391) 1833 (1350)
SK50P Bucket 422 (311) 873 (644) 16.2 (12)
Swing 530 (391) 1365 (1010) 16.7 (12)
Dozer 647 (477) 1634 (1210) 32.6 (24)
32-28
(5) Inspection after installation

1. Unloaded performance test
a. Put the cylinder horizontally at unloaded condition.
b. Apply pressure slowly and alternately through the ports at both ends to operate the piston rod 5 or
6 times.
c. Check that the cylinder operates normally.
Unloaded test
2. Leakage test
-External leakage
a. Apply test pressure for 3 minutes each to the rod retraction side and to the rod extension side of
the cylinder.
b. Confirm that rod seals, cylinder head tightening part, and each weld are free from abnormalities,
such as external leakage and permanent deformation.
-Internal leakage
a. Disconnect the hose from the rod extension side of the cylinder.
b. Apply test pressure to the rod retraction side of the cylinder for 3 minutes.
c. Measure the leakage from the rod extension side.
-Leakage should be below 1 cc (0.06 cu-in) / 3 min.
Leakage test
(6) Bleeding air from hydraulic cylinder

Bleed air from the cylinder after removing or installing it, or after disconnecting a hydraulic pipe.
1. Start the engine, and let it idling for about 5 minutes. 32

2. Repeat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine.
-Move the piston rod 100 mm (4 in) short of its stroke end.
Do not extend or retract the rod until the end to prevent the relief condition.
3. Perform the above 2) procedures at high idling speed, then move the piston rod to its stroke end
at low idling speed to reach the relief condition.
32-29
32.2.1.7 JIG LIST

(1) Installing Jig (A) for Press Fitting of Head Bushing.
(2) Installing Jig (B) for Press Fitting of Pin Bushing.
32-30
(3) Sliding Jig (C) for Seal Ring
(4) Pushing Jig (D) for Seal Ring (18)
32
32-31
(5) Reforming Jig (E) for Seal Ring (18)
32.2.1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY

Trouble Conditions Major Possible Causes Remedy
Foreign matter is caught by U-ring or
Remove foreign matter.
wiper ring at its inside periphery.
Scuffing or fault on U-ring or wiper ring
Replace each part with new one.
at its inside periphery.
Oil leakage from sliding
Grind sliding face with a fine oil stone.
face of piston rod.
(less than 1.6S)
(A ring shape oil is
If leakage is not stopped by grinding,
formed on piston rod and
Scuffing on sliding face of piston rod. replace seals such as U-ring, etc.
enlarged resulting dripping
with new ones.
down of oil)
If leakage is not stopped by replacing
seals, replace piston rod.
Re-plating of hard chrome on piston
Peeling off of hard chrome plating.
rod.
Oil leakage from outer Damages on O-ring. Replace.

periphery of cylinder head. Damages on back-up ring. Replace.
Oil leakage from welded
Damages on welded portion on tube. Replace.
portion.
Piston movement due to Foreign matter is caught by sliding face
Remove foreign matter.
leakage. of slide ring.
(For the case when static Scuffing or faulty condition on sliding
load that is equivalent to Replace.
face of slide ring.
product of multiplication of
Scuffing on sliding face of seal ring
max. working pressure Replace.
assembly.
and cylinder area, is
applied to rod, max.
movement of piston is
Damages on O-ring. Replace.
larger than 0.5mm (0.02
in)) per 10 minutes.
32-32
［33. UPPER SLEWING STRUCTURE］
33
33. UPPER SLEWING STRUCTURE

TABLE OF CONTENTS

33.1.1 CANOPY ……………………………………………………………………………………………………33-3
33.1.2 GUARD (COVER) …………………………………………………………………………………………33-5
33.1.3 FLOOR PLATE ASSEMBLY ……………………………………………………………………………33-8
33.1.4 BATTERY ……………………………………………………………………………………………………33-11
33.1.5 COUNTERWEIGHT ………………………………………………………………………………………33-12
33.1.6 PUMP ………………………………………………………………………………………………………33-13
33.1.7 CONTROL VALVE …………………………………………………………………………………………33-15
33.1.8 SOLENOID VALVE ………………………………………………………………………………………33-18
33.1.9 FUEL TANK…………………………………………………………………………………………………33-19
33.1.10 HYDRAULIC OIL TANK …………………………………………………………………………………33-21
33.1.11 AIR CLEANER ……………………………………………………………………………………………33-24
33.1.12 GENERATOR ……………………………………………………………………………………………33-25
33.1.13 MUFFLER …………………………………………………………………………………………………33-26
33.1.14 CONTROL STAND ………………………………………………………………………………………33-27
33.1.15 STARTER …………………………………………………………………………………………………33-32
33.1.16 RADIATOR…………………………………………………………………………………………………33-33
33.1.17 ENGINE ……………………………………………………………………………………………………33-35
33.1.18 PILOT VALVE ……………………………………………………………………………………………33-37
33.1.19 SLEWING MOTOR ………………………………………………………………………………………33-39
33.1.20 SWIVEL JOINT……………………………………………………………………………………………33-41
33.1.21 UPPER FRAME …………………………………………………………………………………………33-43
33.2.1 HYDRAULIC PUMP ………………………………………………………………………………………33-45
33.2.2 CONTROL VALVE …………………………………………………………………………………………33-71
33.2.3 PILOT VALVE (ATTACHMENT) …………………………………………………………………………33-97
33.2.4 PILOT VALVE (TRAVEL)…………………………………………………………………………………33-109
33.2.5 SLEWING MOTOR ………………………………………………………………………………………33-114
33.2.6 SWIVEL JOINT ……………………………………………………………………………………………33-145
33-1

S5PS3310E01
(SE Asia)
33-2
33
33.1.1 CANOPY
33.1.1.1 CANOPY REMOVAL
33.1.1.1.1 Canopy removal preparation
(1) Remove the floor mats (7) and (8).
(2) Removing canopy harness connector
1.
Respectively disconnect 18P connectors of
canopy harness and 6P connectors of
air-con harness.
(See ELECTRICAL SYSTEM)
Floor mat removal
Disconnect harness if necessary.
33.1.1.1.2 Canopy removal

(1) Removing canopy.
Loosen 3 sems-bolt and 5 capscrews.
Removing canopy.
1 sems-bolt (3) M10X30
4 capscrews (5) M16X50
1 capscrews (7) M16X100
2 sems-bolts (17) M8X25
Tools: Socket: 13mm, 17mm, 24mm
Outside of canopy
33-3
(2) Lifting canopy

1.
Put slings through the lifting eyes on the
canopy top and lift up.
Canopy weight: 100 kg (221 lbs)
Canopy assembly fastening positions
(3) Installing canopy

Install the canopy in reverse order of the removal.
Tighten screws to the specified torque as follows.
M8: T=23 N-m (17 lbf-ft)
M10: T=46.5 N-m (34.3 lbf-ft)
M16: T=191 N-m (141 lbf-ft)
33-4
33.1.2 GUARD (COVER)

33.1.2.1 REMOVAL 33
・ The right figure shows the method for
removing the cover of the canopy.
Cover removal
(1) Removing bonnet assembly (1)

Unlock and open the bonnet assembly (1).
Loosen 2 sems-bolts M12X35 (27) of the
hinge section (1-2) to remove the bonnet
(1).
Tools: Socket: 19mm
Bonnet assembly (1) removal
(2) Removing cover assembly (4)

Loosen 3 M10X30 sems-bolts (21) to
remove the cover assembly (4).
Tools: Socket: 17mm
Cover assembly (4) removal
33-5
(3) Removing side cover assembly (2)
1. Unlock the lock assy (2-8) to open the side

cover assembly (2).
2. Loosen 2 M12 nut (25) to remove the
side cover assembly (2).
Tools: Socket: 19mm
Side cover assembly (2) removal

Loosen 2 M10X30 sems-bolts (21), a
M10X25 sems-bolt (36) and 3 M10X35
capscrews (34).
Remove guard (31).
Remove the cover assembly (6).
Tools: Socket: 17mm
Loosen 4 M10X30 sems-bolts (21), 5
M10X35 capscrews (34).
Remove guard (32), (33).
Remove the cover assembly (3).
Tools: Socket: 17mm
Cover assemblies (6) and (3) removal
33-6
(6) Removing cover assembly (B2) and (B1)

1) Loosen 2 sems-bolts (7) M10X20 and 3
sems-bolts (8) M10X30 and remove the
33
cover assembly (B2).
Tools: Socket: 17mm
2) Remove 2 grommet (B10) and 2

sems-bolts (B6) M10X20, and remove the
cover assembly (B1).
Tools: Socket: 17mm
Tools: Flat head screwdriver
1) Loosen 2 sems-bolts (26) M10X20 and
remove the cover assembly.
Tools: Socket: 17mm
Cover assemblies (B2), (B1) and (5) removal
33.1.2.2 Installation
Install the above assemblies in reverse order of the removal.
Tighten the capscrews to the specified torque as follows:
M8: T=23 N-m (17 lbf-ft)
M10: T=46.5 N-m (34.3 lbf-ft)
(M10* : T=19.6~24.5 N-m(14.5~18.1 lbf-ft))
M12: T=80 N-m (59 lbf-ft)
33-7
33.1.3 FLOOR PLATE ASSEMBLY

Remove floor plate together with the travel pilot valve assembly and the swing pedal as a unit.
33.1.3.1 FLOOR PLATE REMOVAL PREPARATION

(1) Remove the floor mats (7) and (8). (See Section 33.1.1.)
(2) Remove the canopy. (See Section 33.1.1.)
(3) Loosen 4 M8X20 sems-bolts (9) to remove the floor plate (4).
Tools: Socket: 13mm
(4) Disconnect electrical wiring for travel 2-speed selector switch from the connector portion.
If this machine was equipped with the travel alarm, disconnect the connectors of electric wirings of
four pressure switches on travel pilot valve.
Floor plate removal
In advance, disconnect the minus terminal of the battery to prevent danger of short circuit, etc.
33-8
(5) Removing travel pilot piping (prior to this work, release the pressure in the piping)
Disconnect hoses of the travel pilot valve (A1) at the valve side position marked with * and then
plug their openings.
33
-Attach a tag recording the valve connecting port to each of the disconnected hoses. For
installation, tighten the hose fittings at the following torque :
Pilot piping disconnection
Take care of the tightening torque as the pilot valve is made of aluminum.
(6) Removing cable of swing pedal
1. Loosen 4 M8X20 sems-bolts (B21) to pull

out the support (B1) upward.
Tools: Socket: 13mm
2. Pull out the pin (B6) and loosen the
adjusting nut to disconnect the control cable
(B4).
Swing cable disconnection
33-9
33.1.3.2 FLOOR PLATE REMOVAL

(1) Remove the M8X20 sems-bolt (9).
Tools: Socket: 13mm
(2) Remove the floor plate (3).
Floor plate (3) removal
33.1.3.3 ASSEMBLING FLOOR PLATE

(1) Assemble the floor plate in reverse order of the disassembly.
Sems-bolt (9) M8:
Tools: Socket: 13mm
Tightening torque: 23 N-m (17 lbf-ft)
33-10
33.1.4 BATTERY
33.1.4.1 REMOVAL PREPARATION 33
(1) Unlock and open the side cover assembly (2).
(See Section 33.1.2.1-(3)).
33.1.4.2 REMOVAL
(1) Disconnect the negative side terminal of the
cable.
(2) Then, disconnect the positive side terminal
of the cable
Follow the removal procedure of battery cable. Firstly disconnect the grounding side cable. Connect the
grounding side finally. Failure to do so may result in dangerous situation due to spark.
(3) Loosen the M8 nut (3) to remove the plate (2) and the rod (1).
Tools: Socket: 13mm
(4) Take out the rubber cover (5) and the battery (1) holding the strap attached to it.
Install the battery in reverse order of the removal.
Nut (3) M8:
Tightening torque: 3.5 N-m (2.6 lbf-ft)
33-11
33.1.5 COUNTERWEIGHT
33.1.5.1 REMOVAL PREPARATION
(1) Remove the cover assemblies (2), (3), (4),
(6) as well as the bonnet assembly (1)
(See Section 33.1.2).
(2) Lifting tools preparation
- Lifting jigs for counterweight (see Tool list)
- 2 M20X35 screws (A)
- Wire rope (Nylon sling)
33.1.5.2 REMOVAL
(1) Remove 2 plates (B3) and attach the
lifting jigs for counterweight.
(2) Put a rope through the lifting lugs and
temporarily lift up the counterweight so
that the rope is not slack.
Counterweight weight :
380 kg (838 lbs)
(3) Loosen three M20X80 capscrews (B1).
Tools: Socket: 30mm
(4) Remove the shims (B4), (B5) and (B6).
(5) Remove counterweight (A1).
Counterweight removal
(1) Install the counterweight in reverse order
of the removal.
(2) Reinstall the shims (B4), (B5), and (B6).
(3) Lifting counterweight
Make sure that all the three fixing bolts can
be manually screwed.
(4) Apply Loctite #262 on the capscrews (B1)
and tighten them together with the washer
(B2).
Tools: Socket: 30mm
Tightening torque : 373 N-m (275 lbf-ft)
(5) Remove lifting jigs. Counterweight installation
33-12
33.1.6 PUMP
(1) Remove the cover assembly (1) and (4)
(2) Remove the counterweight
(3) Depressurize the hydraulic oil tank and
drain the hydraulic oil (See Section 33.1.10).
- Spread a vinyl sheet under the pump to
prevent contamination due to oil leakage.
(4) Remove the filler neck (B1) of the fuel
supply port to improve workability.
2 sems-bolts M8X20 (B20)
Tools: Socket: 13mm
Tightening torque : 23.5 N-m (2.4 lbf-ft)
Filler neck removal
33.1.6.2 REMOVAL
(1) Disconnecting hoses and fittings connected
to the pump
- Attach a tag to each hose for
identification.
1.
Loosen 4 M12X35 capscrews (21) to
remove the tube (7).
Tools: Allen wrench: 10mm
2.
Remove the pilot delivery hose (B13).
3.
Remove the main pump delivery hoses
(1), (2) and (3).
Tools: Spanner: 27 mm
(2) Loosen 2 M12X30 capscrews (C4) to
remove the pump.
(See Fig. "Pump installation")
Tools: Allen wrench: Ball joint type 10 mm
Pump weight: 35 kg (78 lbs)
Pump removal
33-13
Install the pump in reverse order of the removal according to the tightening torque and sealant
instructions.
(1) Apply grease to the spline part of the pump input shaft.
Grease : Shell Retinax AM Grease or equivalent (Molybdenum disulfide extreme pressure
multipurpose grease)
(2) Insert the pump spline part to the coupling.
(3) Fix the pump by the capscrew (C4).
Tools: Allen wrench: Ball joint type 10 mm
(4) Install the main pump delivery hoses (6), (7), and (8), and the pilot delivery hose (B25) (See Fig.
"Pump removal").
Pump installation
(5) Tighten the capscrew (21) to install the suction tube (7).
(6) When the suction hose (5) is removed, apply sealant (Permatex #98D equivalent) on the inserted
portion of the hose and fix the tube with the clip (18).
Tools: Minus screwdriver
T=5.39 N-m (4.0 lbf-ft)
(7) Supply the tank with hydraulic oil (approx. 52 liters (14 gal)).
(8) Loosen the air bleed valve of the pump to release air from the casing, and fill it with hydraulic
oil (See Fig. "Pump installation").
(9) Reinstall each component removed in the above removal preparation.
(10) After starting the engine, release air (See Section 33.1.10.3).
33-14

(1) Unlock and open the right upper cover (2).
(2) Remove the right lower cover (6) (See Section 33.1.2.1-(4)).
-Spread a vinyl sheet under the control valve to prevent contamination due to oil leakage.
(3) Release the residual pressure in the circuit and the pressure in the hydraulic oil tank.
33.1.7.2 REMOVAL
(1) Disconnecting hoses
Disconnect all the hoses connecting to the control valve as shown below, and attach blind plugs
and tags recording the installation place.
Control valve ports (1/1)
Pi shows pilot line.
33-15
(2) Disconnecting rod.

Turn the rod end (14) to disconnect the
control valve from the swing cable (4).
Cable disconnection
(3) Removing control valve
1. Loosen a M10X50 capscrew (5) and 2

M12X40 capscrews (4) to remove the
control valve (12) with the bracket (2).
Tools: Socket: 17mm, 19mm
Weight of removed parts : Approx. 57 kg
(126 lbs)
2. Loosen 3 M10X20 capscrews (6) to remove
the control valve (12).
Weight : Approx. 47kg (104 lbs)
Control valve removal
33-16
(1) Install the control valve in reverse order of the removal.
(2) Attach the capscrews (6). (See Section 33.1.7.2.3)
33
Clean the mounting surface and take care to prevent deformation of the valve.

Tightening torque : M10- 65.7 N-m (48 lbf-ft)
(3) Attach the capscrew (5) and 2 capscrews (4). (See Section 33.1.7.2.3)
Tightening torque : M10- 65.7 N-m (48 lbf-ft)
M12- 115 N-m (84.4 lbf-ft)
(4) Tighten the hose fittings to the following torque :
(5) Operate the attachment to check the performance.

(6) Check the tank and piping for oil leakage and oil level.
33-17
33.1.8 SOLENOID VALVE

(1) Unlock and open the side cover assembly (2). (See Section 33.1.2.1-(3))
(2) Remove the cover assembly (6) (See Section 33.1.2.1-(4)).
33.1.8.2 REMOVAL
(1) Disconnecting hoses
Disconnect all the hoses connected to the
solenoid valve (4). Then attach a plug and
a tag recording the connecting port to
each of their openings.
-Item (18) is a drain hose for the hydraulic
oil tank. When disconnecting this hose, take
care of oil leakage.
(2) Disconnecting connector
Disconnect 2 connectors connected to the
main harness.
(3) Removing solenoid valve
Loosen 2 M10X20 sems-bolts (39) to
remove the solenoid valve (4).
Solenoid valve removal
(1) Install the solenoid valve in reverse order of the removal.
Tighten the fittings at the following torque:
33-18
33.1.9 FUEL TANK

33.1.9.1 DISASSEMBLY PREPARATION 33
(1) Remove the floor mats (7) and (8), and the
floor plate (4)
(See Section 33.1.3.1).
(2) Remove the cover assembly (3) on the left
lower side
(See Section 33.1.2.1-(4)).
(3) Remove the cover assembly (4) on the left
side.
(See Section 33.1.2.1-(2)).
(4) Remove the under covers under the fuel
tank and the pump.
Fuel drain & Fuel tank removal
33.1.9.2 DISASSEMBLY PREPARATION

When the canopy is located on support (C4).
(1) Remove a bolt (C26) M12X18.

(2) Remove 2 sems-bolts (C9) M12X40.
(3) Install a sems-bolt (C9) M12X40 in tapped
hole a.
(4) To jack up support (C4), tighten sems-bolt
(C9) M12X40.
(5) Remove shim (C25).
(6) Remove sems-bolt (C9) M12X40 from
tapped hole a.
(7) Remove support (C4).
When assembling support (C24), install shim (C25) securely.
33-19
(1) Open the fuel filler cap (B2) and loosen the
drain cock (B7) to drain fuel.
Tank capacity : 75 liters (19.8 gal)
(2) Disconnect the hoses (8) and (6) for the
fuel inlet and outlet, the hose (B4) for the
fuel supply port.
(3) Loosen the M10X20 sems-bolt (B6) to
remove the boss (B8) together with the
drain hose (B9).
Tools: Socket: 17mm
(4) Disconnect connector (A5) for the level
sensor. Fuel hose disconnection
(5) Remove 2 M8X20 capscrews (B20).
(6) Remove 8 M8 nuts (B18).
(7) Remove 2 plates (B15), 2 rubbers (B16)
and 4 rods (B17).
(8) Remove the fuel tank (A1) together with the
bracket (A10).
Assemble the fuel tank in reverse order of the
removal and tighten the screws to the
specified torque shown in the following table :
33-20
33.1.10 HYDRAULIC OIL TANK

(1) Swing approximately 90 degrees to the right to facilitate to remove the tank.
(2) Unlock and open the side cover assembly (2).
(See Section 33.1.2.1-(3))
(3) Remove the cover assembly (6).
(See Section 33.1.2.1-(4)).
(4) Remove the cover assembly (B2).
(See Section 33.1.2.1-(6)).
(5) After releasing internal pressure of the

hydraulic oil tank, remove the plug (E35)
below the solenoid valve to drain hydraulic
oil.
Tools: Socket: 22mm
Tank capacity : 51.4 liters (13.6 gal)
-Spread a vinyl sheet under the solenoid
valve to prevent contamination around the
valve due to oil leakage.
-Releasing tank pressure
Press the cap boot of breather assembly
(A14) with a finger to release the internal
pressure (See Fig. "Suction hose removal").
Draining hydraulic oil
Press and hold the boot until air-relieving sound stops.
(6) Remove the solenoid valve. (See Section 33.1.8.2)

(7) Remove the control valve. (See Section 33.1.7.2)
(8) In addition, remove the harness and hose clamped on the tank.
33-21
(1) Disconnecting suction hose
1. Remove the clip (18).

2. Remove the hose (4).
Suction hose removal
(2) Removing return oil hose and drain oil

hose.
Disconnect each hose from the position
marked with *.
Tools: Spanner: 19mm, 22mm and 36mm
Return drain oil hose removal
(3) Remove 2 M10X16 sems-bolts (33) and a M12X50 capcsrew (A5).

Tools: Spanner: 17mm and 19mm
33-22
(4) Removing hydraulic oil tank

Loosen 4 M12X30 sems-bolts (B1) to
remove the hydraulic oil tank (C1) and
33
shim (B2).
Record the position of shim (B2).
In some cases, this shim (B2) is not
equipped.
Tools: Socket: 17mm
Weight : about 37 kg (82 lbs)
Hydraulic oil tank removal
33.1.10.3 ASSEMBLY
(1) Clean hydraulic oil tank, hose, and components.
(2) Install the tank in reverse order of the removal.
The specified tightening torque is shown in the following table :
-Apply Loctite #262 to B1.
-Apply "PERMATEX #95D" to inserted inner face of suction hose (4).
(3) After assembling, fill the tank with the specified hydraulic oil and check the oil level with the level
gauge (D8) (See Fig. "Hydraulic oil tank removal").
Oil quantity : about 51.4 liters (13.6 gal)
(4) Air bleeding
1. Start the engine.

2. Run the engine in low idle condition for 2 or 3 minutes. Then extend and retract each cylinder
several times to bleed air in the circuit.
(5) Rechecking oil level

Stop the engine in the posture shown in
Fig. the right figure to recheck oil level. In
addition, ensure no oil leakage is found on
each part.
Posture for stopping engine
33-23
33.1.11 AIR CLEANER

Open the bonnet assembly (1).
(See Section 33.1.2.1-(1))
(1) Pull out 2 connectors of the harness from
the indicator (A3) on the air-cleaner (1).
-If the indicator is not equipped with a
switch, this work is not required.
(2) Loosen the clips (B8), (B9) and (B10) to
remove the air hoses (B2) and (B1).
Tools: Flat head screwdriver
(3) Loosen a sems-bolt M10X20 (B12) to
remove the clip (B7).
(4) Loosen 2 M10X30 sems-bolts (B13), then
remove the air cleaner assembly (1) with
bracket (B4).
(5) Loosen 4 M8X20 (B11) sems-bolts to
remove the air cleaner assembly (1).
Air cleaner removal
33.1.11.3 ASSEMBLY
Assemble the air cleaner in reverse order of the
disassembly.
-Tightening torque
Sems-bolts (B11) : 17.7 N-m (13.1 lbf-ft)
Clip (B8), (B9), (B10) : 5.9 N-m (4.35 lbf-ft)
Air cleaner removal
33-24
33.1.12 GENERATOR
(1) Remove the cover at the lower right of the seat (See Section 33.1.10.1-(5)).
(2) Disconnect the negative side terminal of the battery.
(3) Remove the cover assembly (B2) (See Section 33.1.2.1-(6)).
(1) Disconnect the connector and remove the
nut (M6) for the terminal B.
(2) Remove the capscrews (1), (2), and (3).
(3) Remove the V-belt and the generator.
Generator removal
33.1.12.3 ASSEMBLY
(1) Assemble the generator in reverse order of
the disassembly.
(2) V-belt tension
Press the middle of the V-belt with a
thumb to adjust the deflection within the
following range :
Deflection : 10 to 15 mm (0.39 to 0.59
inch)
Generator terminal
33-25
33.1.13 MUFFLER
(1) Remove the bonnet assembly (3) (See Section 33.1.2.1-(1)).
(2) Remove the cover assembly (4) (See Section 33.1.2.1-(2)).
(1) Loosen 3 M8X20 sems-bolts (10) to remove the cover (5).
(2) Loosen 2 sems-bolts M10X20 (13) to remove the cover (6).
(3) Remove M10 nut (18) to loosen the clamp (3), and loosen 4 M8 nuts (17-1) to remove U bolt
(9) then disconnect the exhaust tube (2).
(4) Loosen 4 M8 nuts (17-2) fastening the exhaust manifold for the engine to remove the muffler.
(5) Loosen 4 M8X20 sems-bolts (11) to remove the muffler (1).
Muffler removal
33.1.13.3 ASSEMBLY
Install the muffler in reverse order of the removal and tighten the screws and nuts to the specified
torque shown in the following table :
33-26
33.1.14 CONTROL STAND

(1) Remove the canopy (See Section 33.1.1).
(2) Remove the floor covers (4) (See Section 33.1.3.1).
(3) Remove the covers (2), (3), (4), (5), (6) and the bonnet (1) (See Section 33.1.2).
(4) Remove the counterweight (See Section 33.1.5).
(5) Remove the negative terminal of the battery.
(1) Remove the air cleaner
(2) Removing throttle cable (2)
1.
Pull out the pin (10) and remove the pin
(6).
2.
Loosen the adjusting nut (M8) to remove
the cable.
(3) Removing deceleration motor
1. Control cable removal
Disconnect the connector.
2.
Loosen the adjusting nut (M8) to remove
the cable.
3.
Loosen 3 M8X20 sems-bolts (12) to remove
the deceleration motor (8).
Tools: Socket: 13mm
(4) Removing filler neck (fuel supply port)

1.
Pull out the hose (B4) connected to the
fuel tank.
2.
Loosen 2 M8X20 capscrews (20) to remove
the filler neck (B1).
Tools: Socket: 13mm
Filler neck removal
33-27
(5) Pilot valve removal for dozer

1.
Disconnecting hoses
Disconnect all the hoses connected to the
Pilot valve (1). Then attach a plug and a
tag recording the connecting port to each
of their openings.
2.
Removing pilot valve
the pilot valve.
Pilot valve removal for dozer
(6) Removing seat

1.
Open cover (B11)
2.
Loosen 4 M8 nuts (5) to remove the seat
assembly (1).
Tools: Socket: 13mm
Seat removal
33-28
(7) Removing the cover in stand

the cover (2).
33
Tools: Socket: 13mm
Cover removal
(8) Removing heat insulation cover

the cover (3).
Tools: Socket: 13mm
Cover removal
(9) Disconnecting pilot hose

1.
Disconnect the hose of the right pilot
valve (R) under the pilot valve
2.
Disconnect the hose of the left pilot valve
(L) from the control valve and solenoid
valve sections (See Sections 33.1.7.2 and
33.1.8.2).
Pilot hose disconnection
33-29
(10) Disconnecting harness

See below drawing to disconnect the harness connected to the main harness.
(For details, see "Section 23 Electric system")
Disconnecting harness
(11) Removing control stand

Remove 2 M8X20 (6) and a M10X30 (5)
sems-bolts for fastening the stand (1) in
addition to the sems-bolts already removed
to disassemble the canopy and floor plate.
Tools: Socket: 13mm and 17mm
Weight of removed stand : approx. 41 kg
(90 lbs)
-Before lifting the control stand, ensure
that harnesses and hoses are already
disconnected.
Control stand removal
33-30
(12) Removing support

Remove the radiator related parts such as
8 bolts (6) M16X50 for support assembly
33
(1) and (2) if necessary.
Tools: Socket: 24mm
Weight : approx. 80 kg (176 lbs)
Support assembly removal
(1) Install the control stand in reverse order of the removal.
Tighten the capscrews and sems-bolts at the torque specified below:
Tightening torque of pilot valve ports. 29.4 N-m {21.7 lbf-ft}
33-31
33.1.15 STARTER
(1) Open the cover (12).
(2) Remove the cover (2) in stand (1).
the cover (2).
Tools: Socket: 13mm
Tightening torque: 23 N-m (17 lbf-ft)
battery.
Seat and cover removal
33.1.15.2 REMOVAL
(1) Remove the M8 nut for the terminal B of the starter.
Tools: Socket: 13mm
(2) Disconnect connector on the terminal S of the starter.
(3) Loosen 2 fastening bolts (1) to remove the starter.
Tools: Socket: 19mm
Starter removal
Install starter in reverse order of the removal.
33-32
33.1.16 RADIATOR
(1) Remove the right side cover assemblies (2), (6), (B2) and (5), and the bonnet assembly (1)
(3) Remove the fan guard (3).
2 M8X16 sems-bolts (17).
(4) Remove the support assembly (1)
(See Section 33.1.14.2-(12)).
-In order to facilitate the work, remove the related covers and components if necessary.
(1) Draining water from radiator
1.
Remove the radiator cap.
2.
Loosen the clip (A9), then remove the plug (A10) to drain water.
Volume : Approx. 2.3 litters (0.61 gal)
Radiator disassembly
33-33
(2) Draining hydraulic oil in oil cooler

1.
Release the pressure in the hydraulic circuit.
2.
Remove the oil cooler hoses (B1) and
(B7) and then plug the inlet/outlet ports of
the oil cooler and the openings of the
hoses.
(3) Disconnect the hose (8) of reservoir (6) by
removing the clip (9).
(4) Loosen 6 sems-bolts (17) M8X16 to remove
the bracket assembly (5) and plate
assembly (4). Draining hydraulic oil in oil cooler
(5) Remove the radiator hoses (1) and (2)
fixed by clip (13), and (14).
Tools : Cutting pliers and minus screwdriver
(6) Removing radiator
Loosen 5 M10X25 sems-bolts (C2) to
remove the radiator assembly.
Tools: Socket: 17mm
Weight : 27 kg (60 lbs)
Radiator assembly removal
33.1.16.3 ASSEMBLY
(1) Assemble the radiator in reverse order of the disassembly.
(2) Apply PERMATEX #98D to the fittings of radiator hoses (1) and (2) prior to the connection.
(3) Install the fan and shroud, adjusting their positions according to the figure.
Tightening torque for related parts
Radiator installation
(4) Feed cooling water (LLC : Long Life Coolant)

See Maintenance section of the OPERATION & MAINTENANCE MANUAL for the mixing ratio of
LLC.
33-34
33.1.17 ENGINE
(1) Remove the side cover and the bonnet (See Section 33.1.2).
(3) Remove the negative side terminal of the battery.
(5) Remove the control stand (See Section 33.1.14).
(6) Remove the air cleaner (See Section 33.1.11).
(7) Remove the muffler (See Section 33.1.13).
(8) Remove the radiator (See Section 33.1.16).
(9) Remove the pump or disconnect the hose connected to the pump (See Section 33.1.6).
33.1.17.2 REMOVAL
(1) Disconnecting fuel hose
Disconnect each hose from the position
marked with *.
(2) Disconnecting cable connector
(for details, see ELECTRICAL SYSTEM)
1.
Disconnect the terminal B of the starter
motor (M-1) on the positive cable of the
battery (See Section 33.1.15.2).
2.
Disconnect the grounding cable of the
engine.
(3) Removing engine
Fuel hose removal
Prepare a worktable capable of enduring the weight of the engine and stably receiving the removed
engine.
1. Loosen 4 M12X120 capscrews (9) fixing the engine on the rubber mount (2) and (3) to remove
the engine.
Tools: Socket: 19mm
2. Lifting engine
Pass a wire rope through the 2 lifting eyes at the top of the engine and lift the engine.
Weight : Approx. 170 kg (370 lbs)
3. Place the engine stably on the worktable.
33-35
(1) Install the engine in reverse order of the removal.
See the following table for the tightening torque and the sealant :
Tightening torque for related parts

Tool Torque
Item Name
(mm) N-m (lbf-ft)
46.1 (34)
8 and 11 Sems-bolt (M10) 19
Apply Loctite #262
79.4 (59)
9 Capscrew (M12) 22
Apply Loctite #262
・ Use the mount rubber (2) with identification color of "blue" (three places).
・ Use the mount rubber (3) with identification color of "black" (one place). : part A
・ Use the mount cover (4) with identification color of "black" (three places).
・ Use the mount cover (5) with identification color of "Plating" (one place). : part A
Engine removal/installation
Mount rubber setting
33-36
33.1.18 PILOT VALVE

33.1.18.1 PREPARATION FOR REMOVAL 33
Since the same method applies to the right-hand and the left-hand pilot valve, only the method for
the right-hand is described.

battery.
(2) Release the residual pressure in the circuit
and the pressure in the hydraulic tank.
(3) Remove the right and left control boxes
and the monitor panel.
(4) Loosen sems-bolts (10) to remove the
cover assembly (A3) and (A4) (See Fig. the
right figure).
Tools: Torx driver (T25)
Cover removal (Right control box)
33.1.18.2 REMOVAL
(1) Disconnect each hose at the position
marked with * and attach a plug and tag to
facilitate installation.
(2) Shift the boot and remove 4 capscrews
(A2).
Tools: Socket: 10 mm
(3) Remove the pilot valve (A1).
Hose removal
33-37
(1) Install the pilot valve in reverse order of the removal according to the following tightening torque :
1. 1. Attaching sems-bolts (20).

Tools: Torx driver (T25)
T=0.27 N-m (0.2 lbf-ft)
2. Installing hoses, etc.
Pilot valve port location
Take care of the tightening torque as the pilot valve is made of aluminum. Tightening torque of pilot
valve ports. 29.4 N-m {22 lbf-ft}
(2) Pressurize the hydraulic tank (See Section 33.1.10.3).

(3) Operate the attachment to check the performance.
(4) Check the tank and piping for oil leakage and oil level.
33-38

(1) Remove the floor mat, the floor plate and the cover (See Section 33.1.3.1).
(2) Release the residual pressure in the circuit and the pressure in the hydraulic tank.
33.1.19.2 REMOVAL
(1) Disconnect 5 hoses (A4), (A8), (4), (5) and (6) connected to the slewing motor.
Main hose disconnection

Main hose disconnection
(2) Remove 2 pilot hoses (B5) and (B11)

connected to the slewing motor.
Pilot hose removal
33-39
(3) Loosen 8 M16X40 capscrews (2) to remove

the slewing motor (1).
Tools: Socket: 24mm [a long type approx.
300 mm (11.8") in length required].
Weight: about 36 kg (79 lbs)
Slewing motor removal
(1) Install the motor in reverse order of the removal according to the tightening torque shown below.
1. Apply Loctite #515 on the entire circumferential surface for mounting the slewing motor (1).
2. Install the capscrews (2) for fixing the motor (1).
Tools: Socket: 24mm
T=279 N-m (206 lbf-ft)
Apply Loctite #262 to the capscrew.
3. Connect the hoses
-Fill the casing with hydraulic oil through the motor drain port prior to connecting drain piping.
Tightening torque N-m (lbf-ft)

Thread Spanner
O-ring type 30°flare type
size used
fitting fitting
(PF) (mm)
1/4 19 36.3 (27) 29.4 (22)
3/8 22 73.5 (54) 49 (36)
1/2 27 108 (80) 78.5 (58)
(2) Check the hydraulic oil tank for the oil level. Supply oil if necessary.
(3) At the start, run the motor in the low idling condition of the engine for a few minutes to check
for oil leakage and abnormal noise.
33-40
33.1.20 SWIVEL JOINT

(1) Lift the machine by approx. 30 cm (1 foot)
and insert support blocks at four places of
the crawler shoes, namely, front, rear, right
and left, to secure working space under the
machine.
(2) Remove the cover (4) of the floor plate
(3) Release the residual pressure in the circuit Lifting machine
and the hydraulic tank.
(4) Disconnect the hose of the slewing motor
-Remove the canopy to facilitate the swivel
joint removal.
33.1.20.2 REMOVAL
(1) Remove the upper-side drain hoses (B5),
connector (B1) and elbow (B2).
Drain hose disconnection
(2) Disconnect all other hoses connected to the swivel joint.

-Attach a plug and tag to each of the openings.
Upper side hose disconnection

Lower side hose disconnection
33-41
(3) Removing stopper

Loosen 2 M12X40 capscrews (D7) to
remove the stopper (D2).
Tools: Socket: 19mm [a long type approx.
300 mm (11.8") in length required].
Stopper removal
(4) Removing swivel joint

Loosen 4 M14X35 capscrews (E2) to
remove the swivel joint (E1) downward.
Tools: Socket: 22mm
Weight: 22 kg (49 lbs)
Swivel joint removal
(1) Install the swivel joint in reverse order of the removal according to the tightening torque shown
below.
1. Install the capscrews (E2).

Tools: Socket: 22mm, T=181 N-m (133 lbf-ft)
Apply Loctite #262 on the capscrews.
2. Install the capscrews (D7).
Tools: Socket: 19mm, T=115 N-m (85 lbf-ft)
Apply Loctite #262 on the capscrews.
3. Connect the hoses.
Connecting port relation
(2) Reinstall all the removed parts.

(3) Pressurize the hydraulic tank.
(4) Check the performance.
33-42
33.1.21 UPPER FRAME

(1) Remove the floor plate and the floor cover (See Section 33.1.3).
(3) Remove the guards (See Section 33.1.2).
(5) Drain hydraulic oil from the hydraulic tank (See Section 33.1.10.2).
(6) Disconnect the upper-side hoses for the swivel joint (See Section 33.1.19.2).
(7) Remove the stopper for the swivel joint

(See Fig. "Stopper removal").
(8) Remove the attachment (See the "BOOM"
section of the Chapter of ATTACHMENT).
(9) Needed Tools
-Lifting device for upper frame. See section
"Tools".
-Two bolts M20X110
-Two nuts M20
-Two washers M20
Slewing bearing and upper frame
33.1.21.2 REMOVAL
(1) Providing match marks to slewing bearing
Provide match marks between the upper
frame and the outer race of slewing
bearing.
(2) Lifting upper frame temporarily
Temporarily lift the upper frame at three
points applying wire ropes on a position of
the swing-bracket mounting hole for the
front side and on 2 places of the rear end
of the upper frame.
(3) Removing bolt for mounting upper frame
Loosen a reamer bolt (6) and twenty 6
capscrews (5) fixing the outer race of the
slew bearing to the upper frame.
Tools: Socket: 19mm
(4) Removing upper frame
Lift the upper frame a little to ensure
safety. Then remove it and place on a
worktable of enduring the weight.
Weight : Approx.
1,470 kg (3,240 lbs)
Lifting upper frame
33-43
(1) Install the upper frame in reverse order of
the removal.
(2) Cleaning contact surface
Clean the bottom surface of the upper
frame and the top surface of the slewing
bearing.
-Apply Loctite #515 over the entire
circumference of the outer race inside of
the capscrew.
Slewing bearing installation
(3) Lifting method

1.
Apply wire ropes to the upper frame and
lift up horizontally.
2.
Check the match marks provided at the
disassembly.
3.
Slowly lower the upper frame while
aligning the match marks and watching the
engaging condition between the slewing
pinion gear and the internal gear of the
inner race of slewing bearing.
(4) Installing slewing bearing and upper frame
1.
Apply Loctite #262 on a reamer bolt (6) Reamer bolt position
and twenty 6 capscrews (5) and temporarily
tighten them.
2.
Tighten the reamer bolt and capscrews to
the specified torque at the front, rear, right
and left positions facing each other in order
alternately.
Tools: Socket: 19mm, T=96 N-m (70.8 lbf-ft)
Apply Loctite #262 to the bolt and
capscrews.
3.
Fill the grease bath portion surrounding
the gear teeth of the slewing bearing with
about 3.6 kg (7.9 lbs) of "NISSEKI NEW
MOLYKNOCK grease."
(5) Install the components removed in the
above removal preparation to the original
position and check the performance.
33-44
33
33.2.1 HYDRAULIC PUMP
No. NAME
1 Shaft assembly
2 Swash plate assembly (Hanger assembly)
3 Rotary group
4 Cover assembly
5 Spring assembly
6 Piston assembly
7 Gear pump assembly
8 Housing assembly
9 Trochoid pump assembly
Refer to section 33.2.1 HYDRAULIC PUMP in COMPONENTS SYSTEM PH24 for detail.
33-45
33.2.1.2 DISASSEMBLY AND ASSEMBLY

33.2.1.2.1 Tools and Jig
(1) Tools
Name Q'ty Size(Nominal) Name Q'ty Size(Nominal)
One Possible to tighten to the
Allen wrench 4, 5, 6, 8 and 10 Torque wrench 1
each specified torque
10 Possible to tighten to the
Plastic hammer 1 Medium type Socket wrench 1
specified torque
For hole Small
Snap ring plier 1 Grease
(for snap ring 72) amount
For shaft Small
Snap ring plier 1 Adhesive agent Loctite high tack sealant #98
(for snap ring 28, 30) amount
(2) Jig
1. Working bench
Plate which is used to place the pump
facing downward
If the shaft end does not contact with
work bench, the wood blocks are available
instead of it.
2. Bearing assembling jig
33.2.1.2.2 Cautions during Assembling and Dissembling

(1) Cautions for disassembling
1. Never attempt operating the adjusting screw unless absolutely necessary.
2. Take utmost care during disassembly not to knock or drop each part.
(2) Cautions for assembling

1. Wash each part thoroughly.
2. During assembling, take utmost care not to damage the part or allow foreign materials to enter.
3. As a rule, the O-ring and oil seal should not be reused.
4. In our assembly work, the torque wrench is used to control the torque. Be sure to use the torque
wrench.
33-46
33.2.1.2.3 Disassembly
(1) Removing gear pump
1. Remove two capscrews (M10X25).
33
2. Remove the coupling.
(2) Removing trochoid pump

1. Remove three M5X12 capscrews.
2. Remove the case.

-Use two M5X50 screws.
33-47
3. Take the gear out of the casing.
4. Remove the side plate (A) from the casing.
5. Remove the side plate (B) from the cover.
6. Remove the key of the shaft
33-48
(3) Disassembling main pump

1. Removing cover
Remove three (M12X30) and one (M12X55)
33
capscrews.
2. Removing the cover in a horizontal

condition.
-Be careful because the control plate is
provided to the back side.
When the cover is difficult to remove,
knock lightly with a plastic hammer.
3. Removing control spring section
a. Remove two springs (inside and outside)

and the guide.
4. Remove the spring seat.
33-49
5. Lay the pump on the side and take out the

rotary group from the shaft.
6. Remove the plate.
7. Remove shaft.
Remove snap ring with plier.
Snap ring plier

(for hole : 72 dia.)
8. Remove oil seal casing using two minus

screwdriver.
33-50
9. Remove O-ring.
33
10. Tap lightly rear end of shaft with plastic

hammer, and remove shaft.
11. Removing hanger.

Remove four socket bolts (M6X16) and
plate.
12. Remove distance piece.
33-51
13. Remove bearing.
14. Remove hanger.
15. Removing cover.

Remove control plate.
16. Removing control piston.

Remove two socket bolts (M8X25).
-Loctite #270 is applied on the threaded
part of socket bolt, so remove it only when
required.
33-52
17. Remove cylinder and parallel pin.

-Take care not miss those O-ring fitted on
cylinder section. (2 pcs)
33
18. Remove piston for air-conditioner mode.
This parts may not to be equipped depending on pump type.
19. Remove piston.
20. Remove three disk springs and spring seats.
33-53
21. Removing control spring seat.

Remove two socket bolts (M8X30) and
remove cover.
22. Remove spring seat.
23. Removing shaft.

Removing bearing.
Remove snap ring from shaft, using snap
ring plier.
Snap ring plier

(for shaft : 28 dia., 30 dia.)
24. Place bearing in the vise, and lightly tap

rear end of shaft with plastic hammer then
remove bearing from shaft.
33-54
(4) Disassembling gear pump (GSP2)

1. Loosen four socket bolts (M10X20).
33
2. Remove the cover.
3. Remove the square ring.
4. Remove plate, guide and O-ring.
33-55
5. Remove the drive gear, idle gear and side

plate.
33.2.1.2.4 Assembly
Assemble the main pump in reverse order of the disassembly.
(1) Assembly of main pump

1. Installing hanger assy.
Install hanger in housing.
2. Install bearing.
3. Install distance piece and check the preload

of bearing is 0.1±0.02mm(0.004±0.0008")
confirming the distance by means of
micrometer and depth micrometer.
33-56
4. Install the plate with four socket bolts

(M6X16).
33
Torque : 1.35 N-m (9.8 lbf-ft)
5. Assembling shaft assy.
a. Place bearing on the pedestal, and press-fit shaft with jig. When there is no press, drive the
shaft with jig and plastic hammer in the same manner as the above.
b. Fix snap rings and bearing.
Snap ring plier

(for shaft : 28 dia., 30 dia.)
c. Install shaft in housing and tap the spline

end with a plastic hammer lightly to fit
outer race of bearing into the hole of
housing completely.
33-57
6. Apply grease on O-ring and fit it.
7. Install seal casing with oil seal in housing

straight along axis.
-Apply grease on oil seal lip.
8. Fix snap ring to housing and fix shaft.
9. Assembling rotary group.

Install ten pistons in retainer of rotary group.
33-58
10. Apply grease on three parallel pins, fit it

in the cylinder block.
33
11. Apply grease on sphere portion of guide.
12. Install guide between retainer and cylinder

block and insert pistons in the holes of
cylinder block.
13. Installing rotary group.

Install plate in hanger. In this case, apply grease on the rear surface of plate to prevent dropping.
33-59
14. Align rotary group with spline of shaft, and

install it to inside of housing.
-Apply grease on sliding surface of piston
shoe and sliding surface to the control
plate of cylinder block.
15. Apply grease on the sphere portion of

spring seat and install it to hanger in
housing.
16. Fit two springs, inner and outer.
17. Fit spring seat and three disk springs to cover assy.
33-60
18. Install control piston.
33
19. Install piston for air-conditioner mode.
This parts may not to be equipped depending on pump type.
20. Apply grease on O-rings, and fit them to

cylinder.
21. Apply grease on two parallel pins (10 dia.)

and one parallel pin (7.5 dia.) and install
them to cylinder.
33-61
22. Install cylinder with two socket bolts

(M8X25).
-Apply Loctite #270 to thread portion.
23. Install spring seat in control spring section.
24. Install cover with two socket bolts (M8X30).

25. Apply grease to rear surface of control

plate and install it on the cover to align the
hole with parallel pins.
33-62
26. Fit five O-rings (2 kinds), on mating face of

cover.
33
27. Install cover parallel to the attaching surface

of housing.
28. Install cover with three socket bolts

(M12X30) and one socket bolt (M12X55).
(2) Assembling trochoid pump

1. Insert the key in the shaft.
-Insert the key directing the round side to the trochoid pump side.
33-63
2. Install side plate (B) on the cover.
3. Install side plate (A) and the plate on the

casing.
4. Place the gear in the casing.

-Install directing the match mark face to side plate (B) side.
5. Install casing to cover.
33-64
6. Install casing with three socket bolts

(M5X12).
33
(3) Assembling gear pump

1. Fit the square ring to the plate on the assembling side of gear pump (GSP2).
Then pay attention to the suction and delivery.
2. Install the drive gear and idle gear in the

side plate.
3. Install the drive gear, idle gear and side

plate into the housing.
33-65
4. Insert O-ring into the guide, and install it to the plate.
5. Install the plate, guide and O-ring into the housing.

Then pay attention to the suction and delivery direction.
6. Fit the square ring.
33-66
7. Install the cover to the housing.
33
8. Fix the housing and the cover with four

M10X20 capscrews.
Tightening torque : 55 to 69 N-m (41 to 51
lbf-ft)
9. Install O-ring on attaching surface of gear

pump.
33-67
(4) Installing gear pump

1. Fit the coupling to the shaft end on the
main pump side.
2. Connect the gear pump to the main pump.

Fix the gear pump with 2 socket bolts
(M10X25).
33-68
33.2.1.3 MAINTENANCE STANDARD

(1) Parts replacement standard
33
33-69
33-70

33.2.2.1 ASSEMBLY DRAWING 33
(1) Outside view

1 Nut 8 12 Slewing section 1
2 Tie rod 4 13 Dozer section 1
3 Bucket section 1 14 P3 inlet and travel straight conflux section 1
4 Boom section 1 15 P1, P2 Main relief valve 2
5 Travel (left) section 1 16 P3 Main relief valve 1
6 P1 and P2 inlet section 1 Over load relief valve
17 6
7 Travel (right) section 1 (B1,A2,B2,A7,B7,B9)
8 Swing section 1 18 Anti-void valve (B5) 1

9 Service section 1 19 Plug assy (PF1/2) 2
10 Arm section 1 20 Plug assy (A6,B6) 2
11 Arm conflux section 1
33-71
(2) Component Parts

The control valve is roughly classified into the following four sections.
-Manual operation section : Swing

-Pilot operation section : Travel right and left, boom, arm, bucket, slewing, travel straight and conflux,
dozer blade, service(nibbler & breaker)
-Accessory section : P1 and P2 inlets, and P3 inlet (common with independent travel and conflux)
-Accessory section (valve) : P1, P2, P3 main relief, overload relief, anti-void, boom lock
* For respective operation section, only typical example is described.
1. Pilot operation : Swing (Item 8)
2. Pilot operation : Slewing (Item 12)
33-72
33
5. Anti-void valve
33-73
33-74
33.2.2.2 PRECAUTIONS FOR DISASSEMBLY
33
Precautions (These precautions must be observed for safety.)
The disassembly and assembly is fundamentally to be carried out at the manufacturer's plant, but
when they are unavoidably necessary, observe the following precautions.
(1) All hydraulic equipment is machined in precision and consequently the clearance of each part is
very small. Therefore when disassembling and assembling, place the machine in the clean area
to prevent it from the entry of dust, earth and sand.
(2) Before disassembly, prepare the valve construction drawing to understand the construction clearly.
(3) When removing the control valve from the machine, never forget to cap every port to prevent dust,
etc. from entering. And before disassembly, recheck that every post is capped and clean the
outer surface of the assembly. The work should be carried out on the appropriate work bench
which is covered by clean paper or rubber mat.
(4) When it is required to leave it in the removed condition, apply rust preventives or seal them to
protect them from rusting.
(5) The control valve should be transported or moved holding the main body. Especially, after
removing the pilot cover, carefully handle it paying attention not to touch the exposed surfaces.
(6) Even when the movement is not smooth, never strike it.
(7) In addition, after assembly of equipment, various tests {relief setting, leak test, flow resistance
(pressure loss) test} are required, but these tests require hydraulic test equipment. Therefore, do
not remove the equipment which is impossible to adjust through respective test, even if the
disassembly is possible technically.
33.2.2.3 REQUIRED TOOLS AND OTHERS

Preliminary preparation of the following tools is required for the disassembly and the assembly of the
control valve. In addition, the following tools are necessary for the disassembly and the assembly of
this valve, but the tools necessary for the disassembly and the assembly of the port connection and
the link joint are not included.
Tools Q'TY Remarks

Allen wrench One each 4, 5, 8, 10 mm
Spanner One each 13, 19, 21, 22, 24, 30, 32 mm
Socket wrench One each 13, 19, 22 mm
Torque wrench 1 1.96 to 19.6 N-m (1.4 to 14 lbf-ft)
Torque wrench 1 19.6 to 117.7 N-m (14 to 87 lbf-ft)
Magnet 1
Pliers 1
Screw driver (-) 1
Tweezer 1
Prepare wash oil, hydraulic oil, grease, Loctite #242, tag and marker (felt-tip pen) beforehand.
33-75
Be careful to the followings when disassembling.
Release the trapped inner pressure of actuator. The disassembling of pressure trapped actuator may
cause spurt out of pressurized oil and coming off of parts.
1. Release the inner air of the tank to prevent squirt out of oil during disassembling work.
2. Clean around the section to disassemble to protect valve from entry of foreign material.
3. The removed parts should be kept with tag to prevent disassembling.
4. Be sure to replace the removed seals (O-ring, backup ring, and wiper) with new ones.
(1) Disassembling access

1. Remove relief valve Assembly (15) (16) (17) (Opposing flats 24, 32mm), anti-void valve (18)
(Opposing flats 24mm)
33-76
(2) Disassembling bucket, travel left, travel right, service, swing and dozer section
1. Loosen socket bolt (13) (Opposing flats 5mm) and remove cap (3). And remove spring seat (4),
spring (6), spring seat (5) and O-ring (12). Then remove spool (2) from valve housing (1).
33
2. Remove caps (3) on other side by the same procedure. And the item number of socket bolts for
travel right and left is (10) and O-ring is (9).
Bucket section
Service section
Slewing / Dozer section
Travel right / left section
Arm section
33-77
Be sure to pull spool straight out to protect it from dent, scratch. The dent, scratch may cause
damaging bore of body in pulling out and resulting in difficult insertion of spool when reassembling.
Even if the spool was inserted in it may cause malfunction. Tag every spool for identification to
prevent wrongly attaching when reassembling. The wrongly attached spool may cause malfunction of
actuator.
(3) Disassembling boom section

spring (6), spring seat (5) and O-ring (13). Then remove spool (2) from valve housing (1).
2. Similarly, loosen socket bolt (20) (Opposing flats 5mm) and remove anti-drift valve Assembly (7).
3. Remove spring seat (4), spring (6), spring seat (5) and O-ring (13).
4. Using screw M4 X 0.7, and remove spacer (17) to remove poppet (15). After removing spacer
(17), remove poppet (15) and spring (16).
Boom section
33-78
(4) Disassembling inlet section

1. Loosen socket bolt (5) (Opposing flats 5mm) and remove cap (3). And remove O-ring (4). Then
remove spool (2) from valve housing (1).
33
2. Remove cap (3) on other side by the same procedure.
Inlet section
33-79
(5) Disassembling swing section / Manual operation

1. Loosen socket bolt (14) (Opposing flats 5mm) and remove cap (6). And remove spool (2) with
subassembly from valve housing (1). Then remove seal plate (3), O-ring (4) and wiper (5) in the
as-attached condition on spool on the cap side as well.
2. Loosen and remove machine screw (13) on other side and remove seal plate (3), O-ring (4) and
wiper (5).
3. In disassembling spool end (2), sandwich it between wood blocks and fix it to vice so as to
protect outside surface from damaging (see Bolow Fig.), and then loosen cap screw (8)
(Opposing flats 5mm), remove spring seat (7) and spring (9), and remove seal plate (3), O-ring (4)
and wiper (5).
Wood block
Special attention must be paid to parts like cap screw so as not to be sprung up by the reaction force
in disassembling.
Swing section
33-80
(6) Disassembling arm conflux section

1. Loosen socket bolt (13) (Opposing flats 5mm) and remove cap (14).
2. Remove spring seat (4), spring (6), spring seat (5) and O-ring (12), and remove spool (2) from
33
valve housing (1).
3. Remove cap (3) on other side by the same procedure. Then, do not disassemble filter attached on
cap (3). (See the "CAUTION" (7) Bypass-valve)
Arm service conflux section
33-81
(7) Disassembling bypass-valve

spring (6), spring seat (5), and O-ring (7). Then remove spool (2) from valve housing (1).
2. Remove cap (8) on other side by the same procedure.
Do not disassemble filter because the filter is caulked to cap (8). If the cap (8) is disassembled, it
could result in malfunction of moving parts. The filter fragment blocks the passage, because the filter
falls, and flows through the passages.
Bypass-valve section
33-82
(8) Removing load check poppet

1. Remove tie rod and remove load check valve and plugs before disassembling valve housing. The
followings show poppet and plugs to be removed.
33
-Bucket (33.2.2.4(2) Fig. "Bucket section") : Plug (10)X2, Spring (9)X2, Poppet (7)X1,
Poppet (8)X1
-Boom (33.2.2.4(3) Fig. "Boom section") : Plug assembly (21)X2, Plug (10)X1,
Spring (9)X1, Poppet (8)X1
-Travel left (33.2.2.4(2) Fig. "Travel right / left section") : Plug (7)X1
-Inlet (33.2.2.4(4) Fig. "Inlet section") : Plug assembly (7)X1
-Travel right (33.2.2.4(2) Fig. "Travel right / left section") : Plug (7)X1
-Swing (33.2.2.4(5) Fig. "Swing section") : Plug (15)X1, Spring (11)X1, Poppet (10)X1
-Service (33.2.2.4(2) Fig. "Service section") : Plug (10)X2, Spring (9)X2, Poppet (7)X2
-Arm (33.2.2.4(2) Fig. "Arm section") : Plug (10)X2, Spring (9)X2, Poppet (7)X2
-Arm service (33.2.2.4(6) Fig. "Arm service conflux section") : Plug (10)X1, Spring (9)X1, Poppet (7)X1,
conflux Plug (8)X1, Plug assembly (16)X2
-Slewing (33.2.2.4(2) Fig. "Slewing / Dozer section") : Plug (10)X1, Spring (9)X1, Poppet (7)X1
-Dozer (33.2.2.4(2) Fig. "Slewing / Dozer section") : Plug (10)X1, Spring (9)X1, Poppet (7)X1
-By-pass valve (33.2.2.4(7) Fig. "Bypass-valve section") : Plug (11)X1
(9) Disassembling valve housing

1. Loosen nut (1) (Opposing flats 8mm) and remove tie rod (2), and then disassemble valve housing
of each section in order.
2. Disassemble parts on mating surfaces of each section.
-Bucket (33.2.2.4(2) Fig. "Bucket section") : No parts

-Boom (33.2.2.4(3) Fig. "Boom section") : O-ring (12)X1
-Travel left (33.2.2.4(2) Fig. "Travel right / left section") : O-ring (11)X1, Poppet (12)X1,
Spring (13)X1
-Inlet (33.2.2.4(4) Fig. "Inlet section") : O-ring (6)X2
-Travel right (33.2.2.4(2) Fig. "Travel right / left section") : O-ring (11)X1, Poppet (12)X1,
Spring (13)X1
-Swing (33.2.2.4(5) Fig. "Swing section") : O-ring (12)X1
-Service (33.2.2.4(2) Fig. "Service section") : O-ring (14)X1
-Arm (33.2.2.4(2) Fig. "Arm section") : O-ring (14)X1
-Arm service (33.2.2.4(6) Fig. "Arm service conflux section") : No parts
conflux
-Slewing (33.2.2.4(2) Fig. "Slewing / Dozer section") : O-ring (14)X1

-Dozer (33.2.2.4(2) Fig. "Slewing / Dozer section") : O-ring (14)X1
-By-pass valve (33.2.2.4(7) Fig. "Bypass-valve section") : O-ring (15)X1
3. Every disassembled part should be kept for each section to clarify the attaching position for
reassembly.
33.2.2.5 CLEANING
Clean all disassembled parts with mineral oil. Dry them with compressed air and put them on clean
paper or cloth for checking.
33-83
33.2.2.6 CHECKING
Check that surfaces of every part are free from bur, scratch, dent and other defects.
1. Check that seal groove surface of valve housing is smooth and is free from dust, dent, rust and
etc.
2. Remove dent and flaw found on the seat surface of valve housing by lapping. Do not leave the
lapping powder inside of valve.
3. Every sliding and fitting parts should be moved smoothly. And every groove and passage is free
from contamination.
4. Replace the damaged and deformed spring with new one.
5. When relief valve moves poorly, replace it in the assembly.
6. Replace every seal, wiper and O-ring with new ones.
33.2.2.7 ASSEMBLING
In assembling, the following attentions must be paid to O-ring.
1. O-ring should be free from deformation and damage.

2. Lubricate O-ring and fitting section adequately with grease or hydraulic oil.
3. Do not extend O-ring as largely as it causes deformation.
4. In fitting O-ring, do not roll and install O-ring because the twisted O-ring is hard to return to
original shape. And the twisted O-ring may cause oil leak.
(1) Assembling valve housing

1. Install the following poppet and spring in the housing.
-Travel left (33.2.2.4(2) Fig. "Travel right / left section") : Poppet (12)X1, Spring (13)X1
-Travel right (33.2.2.4(2) Fig. "Travel right / left section") : Poppet (12)X1, Spring (13)X1
2. Install the following O-rings for mating surface to each specified places.
-Bucket (33.2.2.4(2) Fig. "Bucket section") : No O-ring

-Boom (33.2.2.4(3) Fig. "Boom section") : O-ring (12)X1
-Travel left (33.2.2.4(2) Fig. "Travel right / left section") : O-ring (11)X1
-Inlet (33.2.2.4(4) Fig. "Inlet section") : O-ring (6)X2
-Travel right (33.2.2.4(2) Fig. "Travel right / left section") : O-ring (11)X1
-Swing (33.2.2.4(5) Fig. "Swing section") : O-ring (12)X1
-Service (33.2.2.4(2) Fig. "Service section") : O-ring (14)X1
-Arm (33.2.2.4(2) Fig. "Arm section") : O-ring (14)X1
-Arm service (33.2.2.4(6) Fig. "Arm service conflux section") : No O-ring
conflux
-Slewing (33.2.2.4(2) Fig. "Slewing / Dozer section") : O-ring (14)X1

-Dozer (33.2.2.4(2) Fig. "Slewing / Dozer section") : O-ring (14)X1
-By-pass valve (33.2.2.4(7) Fig. "Bypass-valve section") : O-ring (15)X1
33-84
3. Attach valve housing of each section to tie rod (1) in order. And tighten nut (2) (Opposing flats
8mm) to tie rod (1).
Tightening torque: 26.5 to 29.4N-m
33
33-85
(2) Assembling bucket, travel left, travel right, service, arm, swing, and dozer section
1. Put spring (6) between spring seats (4) and (5), and place spool in valve housing (1) to the
position as it was and in the same direction before disassembling, and attach cap (3) with O-ring
(12) fitted by using socket bolt (13) (Opposing flats 5mm).
2. Attach cap on other side by the same procedure. Then, the socket bolt of travel is (10) and
O-ring is (9).
Bucket section
Service section
Slewing/Dozer section
Travel right/left section
Arm section
33-86
(3) Assembling boom section

1. Put spring (6) between spring seats (5) and (4), and place spool in valve housing (1) to the
position as it was and in the same direction before disassembling, and attach cap (3) with O-ring
33
(13) fitted by using socket bolt (14) (Opposing flats 5mm).
2. On the anti-drift valve, place poppet (15) and spring (16) in and push spacer (17) with O-ring
(18) and backup ring (19) fitted in (Be careful of the fitting positions of O-ring and backup ring.)
3. Then put spring (6) between spring seats (5) and (4), and place spool in valve housing (1) to the
position as it was and in the same direction before disassembling, and attach anti-drift valve
assembly (7) with O-ring (13) fitted by using socket bolt (20) (Opposing flats 5mm).
Tightening torque: 8.8 to 10.8 N-m
Boom section
33-87
(4) Assembling inlet section

1. Place spool (2) in valve housing (1) to the position as it was and in the same direction before
disassembling and attach cap (3) with O-ring (4) fitted by using socket bolt (5) (Opposing flats
5mm).
2. Attach cap (5) on other side by the same procedure.
Inlet section
33-88
(5) Assembling swing section / Manual operation

1. Install O-ring (4), wiper (5), and seal plate (3) in spool (2) in order, and put spring (9) between
spring seats (7), and attach it to spool with cap screw (8) (Opposing flats 5mm). Then be sure to
33
assemble the spool sandwiching it between wood blocks and fixing it to vice so as to protect the
outside surface from damaging (see 33.2.2.4(5) Fig. "Connecting port relation").
Tightening torque: 19 to 22N-m
2. Place previously sub-assembled spool in valve housing (1) and attach O-ring (4), wiper (5) and
seal plate (3) on other side with machine screw (13).
Wiper (5) installing direction
Pay attention to the wiper (5) direction.
Swing section
33-89
(6) Assembling arm conflux section

1. Put spring (6) between spring seats (5) and (4), and place spool (2) in valve housing (1) to the
position as it was and in the same direction before disassembling, and attach cap (14) with
O-ring (12) fitted by using socket bolt (13) (Opposing flats 5mm).
2. Attach cap (3) with filter fitted by using socket bolt (13) (Opposing flats 5mm) by the same
procedure.
Arm service conflux section
33-90
(7) Assembling bypass-valve section

1. Put spring (6) between spring seats (5) and (4), and place spool (2) in valve housing (1) to the
position as it was and in the same direction before disassembling, and attach cap (13) with
33
O-ring (7) fitted by using socket bolt (13) (Opposing flats 5mm).
2. Attach cap (8) with filter fitted by using socket bolt (13) (Opposing flats 5mm) by the same
procedure.
By-pass valve section
33-91
(8) Assembling load check valves and plugs

1. Install the following load check valves, springs, and plugs (with O-ring).
-Bucket (33.2.2.7(2) Fig. "Bucket section") : Plug (10)X2, Spring (9)X2, Poppet (7)X1,
Poppet (8)X1
Plug tightening torque: 30.4 to 32.4N-m
-Boom (33.2.2.7(3) Fig. "Boom section") : Plug assembly (21)X2
Plug tightening torque: 49 to 53N-m
Plug (10)X1, Spring (9)X1, Poppet (8)X1
-Travel left (33.2.2.7(2) Fig. "Travel right/left section") : Plug (7)X1
-Inlet (33.2.2.7(4) Fig. "Inlet section") : Plug assembly (7)X1
Plug tightening torque: 14 to 16N-m
(Opposing flats 5 mm)
-Travel right (33.2.2.7(2) Fig. "Travel right/left section") : Plug (7)X1
-Swing (33.2.2.7(5) Fig. "Swing section") : Plug (15)X1, Spring (11), Poppet (10)X1
-Service (33.2.2.7(2) Fig. "Service section") : Plug (10)X2, Spring (9)X2, Poppet (7)X2
-Arm (33.2.2.7(2) Fig. "Arm section") : Plug (10)X2, Spring (9)X2, Poppet (7)X2
-Arm service (33.2.2.7(6) Fig. "Arm service conflux section") : Plug (10)X1, Spring (9)X1, Poppet (7)X1
conflux Plug tightening torque: 30.4 to 32.4N-m
Plug (8)X1
Plug assembly (16)X2
-Slewing (33.2.2.7(2) Fig. "Slewing/Dozer section") : Plug (10)X1, Spring (9)X1, Poppet (7)X1
-Dozer (33.2.2.7(2) Fig. "Slewing/Dozer section") : Plug (10)X1, Spring (9)X1, Poppet (7)X1
-By-pass valve (33.2.2.7(7) Fig. "Bucket section") : Plug (11)X1
33-92
(9) Assembling accessory

1. Assemble relief valve assembly (15) (16) (17), anti-void valve (18).
Relief valve, anti-void valve: Tightening torque: 69 to 78 N-m (Opposing flats 24, 32mm)
33
Shut-off valve: Tightening torque: 59 to 69N-m (Opposing flats 17mm)
-Insert spool into the bore straight slowly. After insertion of spool, slide spool by hand, and if spool is
inserted with tightness and roughness suspected it could result in malfunction of spool.
-After completion of assembly, check that the disassembled parts are assembled again without missing
and securely tightened. If it is not securely tightened, it may cause oil leak due to looseness of parts.
The tightening torque specified in this Manual is values in wet condition (in hydraulic oil applied
condition).
33-93
33.2.2.8 DISASSEMBLING AND ASSEMBLING OF RELIEF VALVE

(1) Main relief valve
Main relief valve (P1, P2) Main relief valve (P3)
1. Disassembling
This part should be replaced in assembly. In replacing, loosen cap (1) (Opposing flats 24) with
spanner, and remove O-ring (2). And when oil leakage was detected on the adjuster kit section (3),
loosen adjuster kit and replace O-ring (4) with new one.
In disassembling adjuster kit, be careful of spring up of parts and missing of poppet.
2. Assembling
Check that the thread section of cap (1) is free from dust and dirt, and install new O-ring (2). Clean
the relief valve attaching section in valve housing, attach relief valve and tighten cap (1) (Opposing
flats 24) to 50 N-m torque (P1, P2), 70 N-m torque (P3). When adjuster kit is disassembled, clean
the thread section surely, and adjust the pressure.
The said specified tightening torque is values in wet condition (in hydraulic oil applied condition).
(2) Disassembling and Assembling of Over Load Relief valve
1. Disassembling
This part should be replaced in assembly.
In replacing, loosen cap (1) (Opposing flats 24) with spanner, and remove O-ring (2). And when oil
leakage was detected on the adjuster kit section (3), loosen adjuster kit and replace O-ring (4) with
new one.
33-94
33
In disassembling adjuster kit, be careful of spring up of parts and missing of poppet.
2. Assembling
Check that the thread section of cap (1) is free from dust and dirt, and install new O-ring (2).
Clean the relief valve attaching section in valve housing, attach relief valve and tighten cap (1)
(Opposing flats 24) to 69 to 78 N-m torque. When adjuster kit is disassembled, clean the thread
section surely, and adjust the pressure. See (3) for reference.
The said specified tightening torque is values in wet condition (in hydraulic oil applied condition).
(3) Adjusting pressure of relief valve

a. Attach precise pressure gauge to inlet circuit.
b. Operate pump at rated rotation speed.
c. Switch the spool of control valve and read value on pressure gauge at the time of cylinder stroke
end.
Switch the spool of actuator, which has higher set pressure of overload relief valve than the set
pressure of main relief valve.
d. Rotate the adjuster clockwise until the pressure reaches to the specified value.
The pressure rise per one turn of adjuster is 17.7 MPa.
e. When the pressure reaches to the specified value, press adjuster so as not to be rotated and
tighten lock nut.
Tightening torque: 30N-m
f. Increase the pressure again and check that the pressure is maintained to the specified value.
33-95

a. Attach precise pressure gauge to inlet circuit.
b. Operate pump at rated rotation speed.
c. Switch the spool of control valve and read value on pressure gauge at the time of cylinder stroke
end.
Switch the spool of actuator, which has higher set pressure of overload relief valve than the set
pressure of main relief valve.
d. Rotate the adjuster clockwise until the pressure reaches to the specified value.
The pressure rise per one turn of adjuster is 28.4 MPa.
e. When the pressure reaches to the specified value, press adjuster so as not to be rotated and
tighten lock nut.
f. Increase the pressure again and check that the pressure is maintained to the specified value.
When the set value of overload relief valve is higher than that of main relief valve, do not adjust the
overload relief valve but replace the relief valve already set and assembly with new ones.
a. Switch the spool of control valve and read value on pressure gauge at the time of cylinder stroke
end.
b. Rotate the adjuster clockwise until the pressure reaches to the specified value.
The pressure rise per one turn of adjuster is 28.4MPa.
c. When the pressure reaches to the specified value, press adjuster so as not to be rotated and
tighten lock nut.
d. Increase the pressure again and check that the pressure is maintained to the specified value.
33-96
33.2.3 PILOT VALVE (ATTACHMENT)

33.2.3.1 CONSTRUCTION 33
Pilot valve (Attachment)
Tightening Torque Table

Item Thread size
N-m (lbf-ft)
301 M14 47.1 (34.7)
302, 312 M14 68.6 (50.6)
Item NAME Q'TY Item NAME Q'TY Item NAME Q'TY

101 CASING 1 213 SEAL 4 241-1 SPRING 2
151 PLATE 1 214 O-RING; 1B P20 4 241-2 SPRING 2
201 SPOOL 4 216-1 SPRING SEAT 2 301 JOINT; M14 1
211 PLUG 4 216-2 SPRING SEAT 2 302 DISK 1
212-1 PUSH ROD 2 217 WASHER 2 4 312 ADJUSTING NUT; M14 1
212-2 PUSH ROD 2 221 SPRING 4 501 BELLOWS 1
33-97
33.2.3.2 DISASSEMBLY & ASSEMBLY

(1) Tools
(2) Jig
Special jig : for disassembling and assembling
the joint (301)
(See Fig. the right figure).
33.2.3.3 Disassembling procedure

33.2.3.3.1 General cautions for disassembly
(1) Since all the parts are very precisely manufactured, carefully handle them without causing collision
with each other or dropping.
(2) Perform the work carefully without hammering or using excessive force even if the part is
sticking. Otherwise burrs may be produced or the part is damaged, leading to oil leakage or
performance deterioration.
(3) When leaving the parts in the disassembled condition, always take rust preventive and dust
protective measures. Otherwise rust may be produced on the parts due to humidity or dust.
33-98
(1) Remove the handle lever assembly and
boot from the casing (101).
33
(2) Clean the pilot valve with white kerosene.
-Screw a blind plug in each port in
advance.
(3) Hold the pilot valve with a vise by
applying a copper or lead sheet.
Handle lever disassembly
(4) Apply wrenches to the adjusting nut (312)

and the disk (302) across the flats to
loosen and remove them.
Adjusting nut (312) removal
(5) Turn the joint (301) counterclockwise with

a jig to loosen.
Joint (301) removal
When pulling off the joint, be careful that the joint is no sooner loosened than the plate (151), plug
(211) and push rod (212) may pop up if the return spring (221) is too strong.
33-99
(6) Remove the plate (151).
Plate (151) removal
(7) If the return spring (221) is not strong,

use a flat screwdriver to pull out the plug
(221) which remains inside the casing (101)
due to sliding resistance of the O-ring.
-Apply the tip of the flat screwdriver to the
external groove of the plug (211) while
preventing damage to the plug due to
eccentric load.
Spring (221) removal
Be careful that the plug (211) may pop up due to the return spring (221) force when removing the
plug.
(8) Remove the push rod (212), plug (211),

pressure reducing valve section assembly,
and return spring (221) from the casing
(101).
-Record the relation between the casing
hole positions and these parts.
Push rod (212) removal
33-100
(9) In order to disassemble the pressure

reducing valve, shift the spring seat (216)
laterally while pushing in the spring seat
33
(216) to make the secondary pressure
spring (241) deflect, and remove the valve
from the spool (201) through the larger
hole.
-Be careful not to damage the surface of
the spool (201).
-Do not push down the spring seat (216)
by more than 6 mm (0.24").
Pressure reducing valve disassembly
(10) Separate the spool (201), spring seat (216),

secondary pressure spring (241), and
washer 2 (217).
-Handle these parts as an assembly until
assembling.
Pressure reducing valve disassembly
(11) Pull out the push rod (212) from the plug
(211).
Pulling out plug (211)
(12) Remove the O-ring (214) and seal (213)

from the plug (211). Remove the seal (213)
using a small flat screwdriver and so on.
Seal (213) removal
33-101
(13) Cleaning parts
1. Clean the parts in a rough cleaning container containing white kerosene (rough cleaning).
-Immerse the parts in the kerosene to facilitate the removal of dust and oil. Otherwise the parts
may be damaged due to using excessive force.
-Check the white kerosene for contamination and use clean one. Otherwise the parts may be
damaged, leading to performance deterioration after reassembling.
-Do not dry the parts with compressed air. Otherwise the parts may be damaged by dust or
moisture in air or rust may be produced.
2. Put a part in a finish cleaning container containing white kerosene and turn the part slowly to
sufficiently clean the part including its interior (finish cleaning).
Dry parts by wiping off kerosene with clean rag.
3. Rust prevention of parts
Apply rust preventive agent to the parts.
-Do not leave the parts without applying rust preventive agent. Otherwise rust may be produced,
leading to malfunction after assembly.
33-102
33.2.3.4 Assembling procedures

33.2.3.4.1 General cautions for assembling work
(1) General cautions for assembling work are almost similar to that for disassembling work.
33
(2) Remove metal chips or foreign substances from all the parts and ensure that the parts have no
burrs or flaw prior to assembly. Remove burrs or flaw if any, using oil stone.
(3) Replace the O-rings and back-up rings with new ones in principle.
(4) Be careful not to damage the O-rings and back-up rings when fitting them. (Apply a small
amount of grease to fit them smoothly.)
(5) Apply grease to the parts to be installed in order to prevent them from dropping.
(6) Tighten screws at the torque specified in 33.2.3.1 Table "Tightening Torque". Watch the torque
using a torque wrench.
(7) After finishing the assembly, screw blind plugs in all the ports to prevent dust intrusion.
33.2.3.4.2 Assembly
(1) Insert the washer (217), secondary pressure
spring (241), and spring seat (216) to the
spool (201) in this order.
Assembling spool (201)
(2) Shift the spring seat (216) laterally while

pushing in the spring seat (216) to make
the secondary pressure spring (241) deflect,
and install the valve to the spool (201)
through the larger hole.
-Do not push down the spring seat by
more than 6 mm (0.24").
Assembling spool (201)
33-103
(3) Install the return spring (211) into the

casing (101).
Install the pressure reducing valve assembly
into the casing (101).
-Install these parts into the position before
disassembling.
Installing spool (221)
(4) Insert the O-ring (214) and seal (213) into the plug (221).
-Direct the lip of the seal (213) as shown below :
Installing seal (213)
(5) Install the push rod (212) into the plug

(221).
-Apply hydraulic oil to the surface of push
rod.
Installing push rod (212)
33-104
(6) Install the plug assembly into the casing

(101).
If the return spring (221) is not strong, the
33
assembly may stop due to sliding
resistance of the O-ring (214).
-Do not use excessive force with the spool
(201) inclined. Otherwise the casing hole
may be damaged.
Installing plug assembly
(7) If the return spring (221) is too strong,

install four assemblies at the same time
using the plate (151) and temporarily fasten
with the joint (301).
Installing plug assembly
Be careful to popping up of the plug assembly and plate (151).
(8) Install the plate (151).

Install the joint (301) to the casing (101)
and tighten the joint to the specified
torque using a jig.
Installing joint (301)
33-105
(9) Install the disk (302) into the joint (301).

Then install and tighten the adjusting nut
(312) to the specified torque while holding
the disk (302) across the flats with a
wrench.
-Do not change the position of the disk
(302) during tightening.
Installing joint (301)
Screw in until the disk contacts with four push rods (212) equally.
Carefully adjust the screwing position of the disk (302) because excessive screwing may result in
secondary pressure generation at the neutral position of the lever, leading to malfunction of the actual
machine.
(10) Apply grease to the rotating section of the

joint (301) and the push rod (212).
(11) Install the handle lever assembly and boot
to the casing (101).
Applying grease
33-106
33.2.3.5 Maintenance standard
33
Replace seal such as O-ring with new ones after every disassembly.
33-107
33.2.3.6 TROUBLESHOOTING
Phenomenon Possible Cause Corrective action
Secondary pressure 1. 1.
does not rise. Primary pressure is insufficient. Secure primary pressure.
2. 2.
Springs (241-1, 241-2) are broken or Replace with new ones.
fatigued.
3. 3.
Clearance between spool (201-1, 201-2) Replace assembly.
and valve body (101) is abnormally large.
4. 4.
Play of handle portion is too much. Disassembly and reassembly or replace
handle portion.
is unstable. Sliding parts are caught. Correct.
2. 2.
Tank line pressure varies. Return directly to oil tank.
3. 3.
Air has contained into pipeline. Release air.
is high. Tank line pressure is high. Return directly to oil tank.
2. 2.
Sliding parts are caught. Correct.
33-108
33.2.4 PILOT VALVE (TRAVEL)

Pilot valve (Travel)
Torque Torque
N-m (lbf-ft) N-m (lbf-ft)
101 CASING 1 6.9 (5.1) 252 PLUG 2
102 CASING (DAMPER) 1 261 O-RING 3
201 COVER 2 8.8 (6.5) 271 SOCKET BOLT 4
202 PLUG 4 301 SPOOL 4
203 GREASE CUP 4 311 SPRING SEAT 4
210 PACKING 4 313 WASHER 4
211 O-RING 4 324 SPRING 4
214 PUSH ROD 4 413 CAM SHAFT 2
217 SHIM 4 414 BUSHING 4
218 SPRING SEAT 4 420 CAM 2
224 PISTON 4 471 STEEL BALL 4
225 STEEL BALL 12 6.9 (5.1) 472 SET SCREW 2
29.4 (22) 251 RO PLUG 3 501 BELLOWS (BOOTS) 2
33-109

(1) Special jig for disassembly and assembly
Special jig 1 (for removal of bushing)
Special jig 1
(2) Precautions for disassembly and assembly
1. Disassemble and assemble the pilot valve paying attention to dust, dirt, etc. in order not to allow
them to enter in.
2. Handle parts carefully not to damage.
3. Write down the installing positions of respective part during disassembly, and assemble respective
part to the position as they were before.
(3) Disassembly
1. Stop respective port (P, T, 1, 2, 3, and 4) of the valve with plugs and clean the outer surface.
2. Fix the cleaned valve with vise.
3. Remove bellows (501) from cover (201).
4. Remove set screw (472).
Tools: Allen wrench: 6 mm
5. Contact pry bar (7 dia. or less) to one end of cam shaft (413), and strike it lightly with a hammer.
6. Remove cam (420).
7. Remove socket bolt (271).
Tools: Allen wrench: 6 mm
8. Remove cover (201).
9. Remove the casing upper assembly and fix the assembly with vise, again.
10. Draw push rod (214) out of plug (202).
11. Remove plug (202) with grease cup (203), packing (210) and O-ring (212).
12. Remove piston (224).
13. Remove damping spring (336) from the casing.
14. Take out spring seat (218) from casing (102) with tweezers.
15. Take out steel ball (225) using magnet.
16. Fix the lower casing assembly with vise, and take out O-rings (211 and 213) from casing (101).
17. Remove reduction unit valve assembly and return spring (335) from casing (101).
18. Place cover (201) on the flat bench transverse, apply bushing (414) to special jig 1, strike it lightly
with hammer, and pull the bushing out.
19. For disassembly of the reduction unit valve assembly first push spring seat (311) in and shift the
spring seat crosswise making secondary pressure spring (324), remove it from spool (301)
passing through the large hole.
33-110
-Handle the assembled unit as an assembly.
33
20. Separate spool (301), spring (324) for secondary pressure setting, shim (217) and washer.
-Handle the assembled unit as an assembly. And there may be unit on which washer is not
installed.
21. Remove grease cup (203) from plug (202).
22. Remove O-ring (212) from plug (202).
33.2.4.3 ASSEMBLY
(1) Clean all parts before assembly, and dry them by means of compressed air. Don't use rag.
-Repair the parts damaged when being disassembled, clean them, apply oil to the moving
section, and install the same parts on the positions where they are before.
-Replace every O-ring and packing with new ones.
(2) Install washer (313), shim (217), spring (324) for resetting the secondary pressure, and spring
seat on spool (301) in order.
(3) Pass spool (301) through the larger hole of spring seat (311), push the spring seat in, and install
it making the spring for the secondary pressure deflect and shifting the spring seat laterally.
(4) Fix casing (101) with vise, and place spring (335) for return in casing (101).
(5) Place the reduction unit subassembly described above par. 2) and 3) in casing (101).
-Install them on the positions as they were before.
-When placing the reduction unit subassembly in, pay attention to the spool lower end so as not
to bring into contact with the corner of the casing.
33-111
(6) Place O-rings (211, 213) in casing (101).

(7) Fix upper casing (102) with vise and place the steel ball in it.
(8) Place spring seat (218) in casing (102) with tweezers.
(9) Place damping spring (336) in casing (102).
(10) Install piston (224).
(11) Place O-ring (212) in plug (202).
(12) Place packing (210) in plug (202).
-Pay attention to the direction when placing the packing in.
-Apply grease slightly before placing packing in.
(13) Place grease cup (203) in plug (202).

(14) Install push rod (214) on plug (202).
(15) Place the push rod subassembly which is assembled by the procedures in par. 11) to 14) in
casing (102).
(16) Put cover (201) on the flat work bench, press bushing (414) with special jig 1, and press fit the
bushing striking lightly.
(17) Fix the lower cover assembly which is assembled by the procedures in paragraph 2) to 6) with
vise, and install the upper cover assembly which is assembled by the procedures in paragraph 7)
to 15) on it.
(18) Install cover (201) on casing (102).
(19) Tighten socket bolt (271) to the specified torque.
(20) Install cam (420) on cover (201).
(21) Insert cam shaft (413) from the outside pressing cam (420).
(22) Apply Loctite #241 or equivalent to the thread of socket bolt.
(23) Tighten socket set bolt (472) to the specified torque.
(24) Incline cam (420), apply grease to the top end of push rod (214), and fill grease cup (203) of
plug (202) with grease.
(25) After fitting the top end of bellows (501) in cam (402), fit the lower side in the groove of cover
(201).
33-112
Phenomenon Cause Corrective action
Secondary pressure 1. 1. 33
does not rise. Insufficient primary pressure Secure primary pressure.
2. 2.
Permanent set in fatigue of spring (324) for Replace it with new one.
setting of secondary pressure.
3. 3.
The gap between spool and casing is too Replace it with complete remote control
large. valve.
4. 4.
The control section is loosened. Replace parts of control section.
is unstable. Sliding part is not smooth. Repair unsmooth section.
2. 2.
Variation of pressure of tank line Return oil to oil tank directly.
3. 3.
Air contamination in piping Bleed air by operating several times.
is high. Pressure of tank line is high. Return oil to oil tank directly.
2. 2.
Sliding part is not smooth. Repair unsmooth section.
Damping does not 1. 1.
work. Air is accumulated in piston chamber. Bleed air by operating several times.
2. 2.
Sliding part is not smooth. Repair unsmooth section.
3. 3.
Permanent set in fatigue of damping spring Replace it with new one.
(336)
4. 4.
Gap between damping piston (224) and Replace it with complete remote control
casing (damper) (102) is too large. valve.
5. 5.
Malfunction of check valve Disassemble and check on check valve
section.
6. 6.
Orifice of damping piston (224) is too large. Replace damping piston.
Damping torque is 1. 1.
heavy. Sliding part is not smooth. Repair unsmooth section.
2. 2.
Orifice of damping piston (224) is clogged. Repair or replace damping piston.
33-113

33-114

(Reduction assy) 130 Ring 2 3 235 O-ring ; 1B G110 1
101 Casing 1 (Motor assy) 236 O-ring ; 1B G125 1 33
102 Carrier 1 1 201 Body H 1 241 P/B Timer valve 1
103 Carrier 2 1 202 Plate S 1 242 Socket bolt ; M6X15 4
104 Pinion shaft 1 203 Shaft 1 243 Relief valve 2
105 Internal gear A 1 204 Cylinder barrel 1 246 Check valve 2
106 B1 gear 4 205 Valve plate 1 247 Plug 2
107 B2 gear 3 206 Piston 9 248 Spring 2
108 S1 gear 1 207 Shoe 9 249 O-ring ; 1B P11 2
109 S2 gear 1 208 Shoe holder 1 307 O-ring ; 1B P14 1
111 Needle 1 92 209 Barrel holder 1 308 O-ring ; 1B P18 1
112 Needle 2 72 210 Swash plate 1 309 O-ring ; 1B P22 1
113 Ring seal 1 212 Retainer 2 310 O-ring ; 1B P28 1
114 O-ring 1 213 Pin 3 311 Backup ring ; P14 2
115 Thrust plate 1 1 214 Filter 1 401 Body 1
116 Thrust plate 2 1 215 Spring C 1 402 Spool 1
117 Thrust washer 1 4 216 Ball bearing 1 403 Piston 1
118 Thrust washer 2 3 217 Ball bearing 1 404 Stopper 1
119 Pre-load collar 2 218 O-ring ; 1B G120 1 405 Spring 1
120 Snap ring 4 221 Snap ring 1 406 Spring 1
121 Bearing 1 223 Socket bolt ; M10X35 8 407 Spring holder 1
122 Bearing 1 224 Spring pin 1 408 Plug ; PF1/4 4
123 Oil seal 1 225 Parallel pin 3 409 O-ring ; 1B P11 4
124 Socket bolt ; M8X25 6 226 Pin 1 410 O-ring ; 1B P7 2
126 Pin 4 231 Brake piston 1 411 Metal plug 2
128 Ring 1 232 Spring assy 12 412 Plug ; TPHA-1/8 1
129 Ring 1 4 233 Disk plate 2
33-115
33.2.5.2 REMOVAL AND INSTALLATION

(1) General Precautions
1. Work at a clean place and take care so dirt, paint particles and water do not adhere to the
parts. Prepare a container to put in removed parts.
2. Before removing it, clean the outside of the body to be free from dirt and remove paint at joints
with a wire brush.
3. Put markings on jointing parts before removal so all parts are installed where they were.
4. Handle the removed parts carefully so as not to score them.
5. Clean the removed parts thoroughly in cleaning oil.
6. Inspect that the removed parts are not worn or seized abnormally and eliminate fins and burrs,
using emery paper.
7. Replace seals and snap rings with new ones.
(2) Tools
No. Tools required
1 Torque Wrench (Pre-set type) 45N-m {33.2 lbf-ft} (JIS B4650)
2 90N-m {66.4 lbf-ft} (JIS B4650)
3
4 Hexagon Wrench for Torque Wrench Opposing flat 5
5 Opposing flat 6
6 Opposing flat 8
7 Torque Wrench (For single use) T=147.1±14.7N-m {108±10.8 lbf-ft}
Opposing flat 36
8 Allen Wrench Opposing flat 5
9 Opposing flat 6
10 Opposing flat 8
11 Spanner Opposing flat 36
12 Flat-Blade Screwdriver Width 6 to 10
13 Snap Ring Pliers 28 dia. for hole
22 dia. for shaft
14 Hammer
15 Plastic Hammer
20 Others Grease
Oil (Specified hydraulic oil)
Wire brush
Emery paper
Sealant (Three Bond #1305)
33-116
(3) Disassembling of Hydraulic Motor

1. Loose the socket bolts (124), and take out
the hydraulic motor assembly from the
33
reduction gear body.
Tools: Hexagon bar wrench: 6mm
When taking out the hydraulic motor assembly from the reduction gear body, the drain port should be
open.
When it is difficult to take out, insert the minus driver into the binding face to the body and take out
the burr completely.

the timer valve from the hydraulic motor
assembly.
3. Take out the relief valve assembly.
Do not disassemble the relief valve assembly, unless it is necessary.
33-117

it.
5. Take out the plate S (202).
Pay attention not to drop off swash plate (210).
6. Take out the swash plate (210) and the

shaft kit from the plate S (202).
When it is difficult to taka out the shaft, hit the opposite side slightly by the plastic hammer.
As the ball bearing (216) is pressed into the shaft, do not disassemble unless it is necessary to
change the bearing.
33-118
7. Take out the filter (214) and the parallel

pin (225) from the plate S (202).
33
Filter (214) :1 pcs
Parallel pin (225) :3 pcs
8. Take out the spring assembly (232) from

the body H (201).
9. Take out the cylinder barrel kit.
The small parts are easily dispersed. Pay attention not to miss.
The valve plate (205) is sometime attached.
Pay attention not to drop out.
33-119
10. Take out the piston (206) and the shoe

(207) assembly, the shoe holder (208), the
barrel holder (209) and the pin (213).
11. Take out the snap ring (221), the retainer (212) and the spring C (215).
Tools: Snap ring plier: 28 dia. For hole
12. Take out the brake piston (231) and the O-ring (235), (236).
The brake piston is drawn out by the air blowing gradually from the PP port.
Pay attention not to draw out the brake piston rapidly.
33-120
13. Take out the disk plate (233).
33
14. Take out the valve plate (205).
15. Loose the plug (247), and take out the

check valve (246) and the spring (248). (2
locations)
16. Take out the ball bearing (217) and the

spring pin (224).
33-121
(4) Disassembly of Reduction Gear

1. Take out the O-ring (114).
2. Take out the S2 gear (109).
3. Take out the carrier 2 kit.
Pay attention not to scattered each parts as lifting S1 gear up.
33-122
4. Take out the carrier 1 kit.
33
5. Take out the ring (128) and the pre-load collar (119).
Attach the minus driver to the gap of 2pcs pre-load collar, and take out by hitting with the hammer.
As pre-adjusted the gap with the bearing, do not disassemble unless it is necessary.
6. Take out the pinion kit.
33-123
To secure the drawing space of the pinion shaft, attach the approximate 130 mm (5.12") pad to the
flange part, and push out the pinion shaft (104) by the press.
As pre-adjusted the gap with the bearing, do not disassemble unless it is necessary.
7. Take out the outer ring of the bearing

(121), (122) and the oil seal (123).
As the outer ring of the bearing (121), (122) is press-fitting one, do not disassemble unless it is
necessary.
Do not use again the oil seal (123).
8. Take out the thrust plate 2 (116) from the

carrier 2 kit.
9. Take out the B2 gears (107) and the

needles 2 (112) from the carrier 2 kit.
33-124
10. Take out the rings 2 (130) and thrust

washers 2 (118) from the carrier 2 kit.
33
11. Take out the snap ring (120) and the thrust
plate 1 (115) from the carrier 1 kit.
Tools: Snap ring plier: 22 dia. For shaft
12. Take out the b1 gears (106) and needles 1

(111) from the carrier 1 kit.
13. Take out the rings 1 (129) and the thrust

washers 1 (117) from the carrier 1 kit.
33-125
14. Take out the inner ring of the bearing (121)

and the ring seal (113) from pinion kit.
As the inner ring of the bearing (121) is press-fitting one, do not disassemble unless it is necessary.
Do not use again the ring seal (113).
33-126
(5) Assembly of Hydraulic Motor

1. Press-fit the ball bearing (217) and spring
pin (224) into the body H (201).
33
2. Insert the 2 check valves (246) (1pc/side), 2 springs (248) (1pc/side) and 2 plugs (247) (1pc/side)
with O-ring (249) in that order into the body H (201).

Torque wrench
Apply grease slightly to the O-ring and assemble to pay attention not biting the seals.
Plug tightening torque :58.8±2.9 N-m (43.4±2.14 lbf-ft)
33-127
3. Place the valve plate (205) onto the body H (201).
The steel face of the valve plate should be downside and assemble.
4. Assemble the disk plate (233).
33-128
5. Make the brake piston assembly which placed O-rings (235), (236) on brake piston (231), and
place it onto the body H (201).
33
Place the brake piston assembly onto plate S placed 3 pins, then place it onto the body H as
matched pin hole position, After that, press-fit it by tighteing hexagon bolts little by little.
Check no pushed out, scratches and dust on O-ring at this time.
For prevention of brake piston assembly, apply grease on plate S.
Take out the plate S after placed brake piston assembly.
Pay attention to jam seal parts, install them applying grease on O-rings.
6. Place the retainer (212), spring C (215) and retainer (212) in that order into the cylinder barrel
(204), and then secure them with the snap ring (221).
Tools: Snap ring plier: 28 dia. For hole
33-129
7. Make the shoe holder assembly which has

the 9 piston-shoe (206), (207) assemblies
placed on the shoe holder (208).
8. Place the 3 pins (213), barrel holder (209) and the shoe holder assembly onto the cylinder barrel
(204) to make up a cylinder barrel assembly.
9. Insert cylinder barrel assembly along ditch

of disk plate into body H (201).
33-130
10. Insert the spring assembly (232) into the

body H (201).
33
11. Place the filter (214) and the parallel pins

(225) into the plate S (202).
Filter (214) :1 pc
Parallel pin (225) :3 pcs
Pay attention height of pins are 8mm (0.315") from surface after installation.
33-131
12. Press-fit ball bearing (216) with shaft (203).
13. Place the shaft kit into the plate S (202).
14. Place the swash plate (210) onto the plate

S (202).
In case the swash plate drops out, apply grease to the plate S side of it.
33-132
15. Join the body H (201) and the plate S (202).
33
Align the serration of the shaft which is assembled to the plate S to the serration of the cylinder barrel
assembly which is assembled to the body H.
16. Bolt the plate S (202) together with the

socket bolt (223).

Torque wrench
Bolt tightening torque :58.8±2.9 N-m (43.4±2.14 lbf-ft)
33-133
17. Screw up the relief valve assembly.

(Both side)

Torque wrench
Plug tightening torque :147.1±14.7 N-m (109±10.8 lbf-ft)

Once the relief valve is disassembled, replace the O-ring and the back up ring in the above, and
screw the cap with the specified torque.
18. Screw up the timer valve.

Torque wrench
Plug tightening torque :11.8±1 N-m (8.7±0.74 lbf-ft)
33-134
(6) Assembly of Reduction Gear

1. Press-fit the oil seal (123) into the casing (101).
33
Pay attention to the direction of the oil seal, use round steel plate for pressing to prevent misalignment.
Steel plate outer diameter :77.5 dia. (3.05")
2. Place the ring seal (113) onto the pinion shaft (104).
Pay attention to direction of the ring seal.
33-135
3. Press-fit the inner ring of the bearing (121)

to the pinion shaft (104).
After press fitting, apply grease onto the surface of the rollers, and turn them manually so that the
grease can spread to the whole roller surface.
4. Place the 4 rings 1 (129) (1pc/pin) and the 4 thrust washers 1 (117) (1pc/pin) in that order onto
the 4 pins of the carrier 1 (102).
Pay attention to direction of the ring.

Beveling part of the ring should be down side.
33-136
5. Place the 4 B1 gears (106) (1pc/pin) and

the 92 needles 1 (111) (23pcs/pin) in that
order onto the 4 pins of the carrier 1 (102).
33
6. Place the thrust plate 1 (115) and the 4

snap rings (120) (1pc/pin) to make up a
carrier 1 kit.
Tools: Snap ring plier: 22 dia. For shaft
Pay attention to the direction of the snap ring.

The edge side should be uppermost.
Pay attention not to open the snap ring too much.
The snap ring which was opened too much should lose tension and be replaced.
7. Place the 3 thrust washers 2 (118)

(1pc/pin) and the 3 rings 2 (130) (1pc/pin)
in that order onto the 3 pins of the carrier
2 (103).
33-137
8. Place the B2 gears (107) (1pc/pin) and

the 72 needles 2 (112) (24pcs/pin) in that
order onto the 3 pins of the carrier 2 (103).
9. Place the thrust plate 2 (116) and the S1

gear (108) onto the carrer 2 (103) to
make up a carrier 2 kit.
10. Press-fit the outer ring of the bearing

(122) into the casing (101).
11. Press-fit the outer ring of the bearing

(121) into the casing (101).
33-138
12. Fill grease in the bearing (121) section of

the casing (101).
33
Grease amount : approx. 80% of the space inside the outer ring.
13. Insert the pinion shaft (104) into the casing

(101).
Pay attention not to damage the lip of the oil seal.
14. Turn over the casing (101), then press-fit

the inner ring of the bearing (122).
33-139
15. Fix the pinion shaft (104) with the 2 pre-load collars (119).
Thickness of the pre-load collar must be adjusted for the above "L" dimension.
Standard's +0 to +0.05mm (+0 to +0.002")
16. Place the ring (128) over the pre-load

collars.
17. Place the carrier 1 assembly into casing

(101) align spline of carrier to the pinion
shaft (104).
33-140
18. Place the carrier 2 assembly into casing

(101) align spline of S1 gear (108) to the
B1 gear (106).
33
19. Place the S2 gear (109) into the carrier 2

assembly.
20. Place the O-ring (114) onto the casing

(101).
21. Fill casing (101) with hydraulic oil.
33-141
Oil : ISO VG46 or equivalent.

Oil amount : 2 to 3mm (0.079 to 0.118") below top of the thrust plate 2.
Wipe oil off flange surface if it is spilled.
22. Join the hydraulic motor and the body,

and then bolt them together with the 4
socket bolts (124).

Torque wrench
Align the shaft of the motor to the S2 gear.

Apply anti-loose adhesive to the screws.
Plug tightening torque : 29.4±2.9 N-m (21.7±2.14 lbf-ft)
33-142
(7) Troubleshooting
Problem Location Cause Remedy
Not slewing Relief valve Oil pressure is low Replace valve assy 33
(Pressure rises) Malfunction of motion
Hydraulic motor Seizure of sliding surface Replace motor assy
Internal leakage
Reduction unit Damaged gear Replace reduction unit assy
Overload Reduce overload
Insufficient torque Relief valve Pressure setting is low Replace valve assy
(Pressure rises) Malfunction of motion
Hydraulic motor Wear of sliding surface Replace motor assy
Internal leakage
Reduction unit Damaged gear Replace pinion kit or carrier kit
Damaged bearing
Abnormal noise Noise in piping Insufficient flow-rate Correct piping
(Cavitation sound)
Hydraulic motor Damage of sliding surface Replace motor assy
Reduction unit Damaged gear
Damaged bearing Replace pinion kit or carrier kit
Pinion Damaged gear Replace pinion kit
Oil leaks Mating surface Damaged O-ring Replace O-ring
of valve Loose bolt Retighten bolt
Mating surface Damaged O-ring Replace O-ring
of motor Loose bolt Retighten bolt
Mating surface Damaged O-ring Replace O-ring
of reduction unit Loose bolt Retighten bolt
Pinion Damaged oil seal Replace pinion kit
Time-lag of starting Relief valve Malfunction of motion Replace valve assy
and stopping Check valve Internal leakage
Abnormal heat Hydraulic motor Damaged or seized sliding Replace motor assy
surface
Reduction unit Abnormal gear teeth Replace pinion kit or carrier kit
Abnormal bearing
33-143
(8) Maintenance Standards

1. Slewing Motor
Parts Judgment Service limit Remedy
Shaft Abnormal wear of output shaft splines. Wear depth 25μm (0.001") or more Replace
Cylinder Contact surface with valve plate. Wear depth 20μm (0.0008") or more Replace
Valve plate Sliding surface of cylinder. Wear depth 20μm (0.0008") or more Replace
Caulked part of shoe.
Piston and shoe Play 0.3mm (0.012") or more Replace
Sliding surface of shoe.
Swash plate Wear of sliding surface of shoe. Wear depth 0.1mm (0.004") or more Replace
Inside of the
Damage, rust Replace
casing
2. Reduction Gear
33-144
33.2.6 SWIVEL JOINT

Construction
1 STEM 1 10 DUST SEAL 1
2 BODY 1 11 DUST SEAL 1
3 FLANGE 1 12 SNAP RING 1
4 SPACER 1 13 BOLT (M10X30) 4
5 PIN 1 14 PLUG (PF1/4) 3
6 SLIPPER SEAL 7 15 SPRING WASHER 4
7 NAME PLATE 1 16 BACK-UP RING 1
8 O-RING 1 17 CLEVIS 2
9 O-RING 1
33-145

33.2.6.2.1 General precautions
・ For disassembly and assembly, select the clean area.
・ Clean around the port and remove the paints of the joint with wire brush.
・ Clean the removed parts with cleaning solvent, like light oil, etc.
・ Replace seals with new ones every disassembly, and apply hydraulic oil or grease lightly.
・ Check every part for severe wear and seizure, and remove burr, etc. with oil stone.
・ Check that seal groove is free from foreign substances, dust, etc.
(1) Fix the body (2) with vise and loosen bolt
and remove flange (3).
Tools: Socket: 17mm
or
(2) Take out O-ring (9), snap ring (12) and

spacer (4) from the body (2).
(3) Remove stem (1) from the body (2).

-Apply the knock pin to the end face of the
stem, and strike it with hammer.
-Choose the knock pin made of copper,
plastic, etc.
33-146
(4) Remove dust seal (11) from the stem (1).
33
(5) Remove seal, etc. from the inside of the

body.
-Be sure of the position of seal, etc.
referring to the construction drawing.
-Take out O-ring with the pointed tool like
a gimlet.
33.2.6.2.3 Assembling
(1) Insert seals in the body.
-Check the seal position referring to the
construction drawing.
-Ensure that O-rings are free from twisting.
-Do not deform or bend the slipper seal
extremely.
(2) Install dust seal (11) to stem (1).

-Apply enough grease to the lip section of
the dust seal.
33-147
(3) Install stem (1) to body (2).

-Apply hydraulic oil or grease around the
stem lightly.
-Strike the stem with a plastic hammer
carefully not to damage seal.
(4) Fit spacer (4) and snap ring (12).

-Fit the snap ring in the groove correctly.
(5) Fit O-ring (9) and install flange (3).

(6) Install spring washer (15) and bolt (13).
Tools: Socket: 17mm
or
-Tightening torque : 46.5 N-m (34 lbf-ft)
-Put pipe through the locking pin of the
stem, and check that the shaft rotates
smoothly at a torque of approx. 78 to 108
N-m (58 to 80 lbf-ft)
33-148

33.2.6.3.1 Check Procedures and Remedy
Check Interval Place Checked Check Procedure Remedy 33
2000 Hr Seals which Check if oil is leaking out. Replace the O-rings if there is
prevent external leakage.
leakage of hydraulic
oil.
4000 hr All seal parts. Replace all the seal parts
Disassemble and All sliding portion. Check for abnormal wear, Recondition in accordance with
check whether defects, corrosion, etc. due to the service limit.
there is leakage or seizing, foreign material being
not caught, etc.
When All parts. Check for abnormal wear, Recondition in accordance with
disassembling due defects, corrosion, etc. due to the service limit.
to trouble seizing, foreign material being Regarding the seal kit, replace
caught, etc.
33.2.6.3.2 Parts Service Limit

(1) Body and Stem
Portion Judgment Criteria Remedy
Seal Parts and Sliding -Wearing of surface treated with induction hardening, and Replace
Portion coming off of surface due to seizing, foreign material
getting caught, etc.
Body and stem -Abnormal wear or defects by 0.1 mm (0.004 in) deep or Replace
sliding portion other deeper due to seizing or foreign material getting caught,
than seals. etc.
-Defects less than 0.1 mm (0.004 in) deep. Repair with an oil stone.
Portions which slide -Wearing by 0.5 mm (0.020 in) or more, or abnormal wear. Replace.
against the spacer. -Wear less than 0.5 mm (0.020 in). Repair so that is smooth.
-Defects due to seizing or foreign material getting caught, Repair so that is smooth.
etc. which are within the wear limit of 0.5 mm (0.020 in)
and within repairable level.
(2) Flange and Spacer

Portion Judgment Criteria Remedy
-Portions of flange -Wearing by 0.5 mm (0.020 in) or more, or abnormal wear. Replace
which slide against the -Wear less than 0.5 mm (0.020 in). Repair so that is smooth.
stem end.
-Defects due to seizing or foreign material catching, etc., Repair so that is smooth.
-Thrust ring
which are within the wear limit of 0.5 mm (0.020 in) and to
within repairable level.
33-149
(3) Slipper Seal
(4) O-ring
(5) Backup Ring
33-150
33.2.6.3.3 Inspection After Assembly

After assembly is completed, check for leakage of oil in each circuit using the equipment shown below.
33
(1) Connect a pipe (3) between the hydraulic pump (2) and the stem (1) side port.
(2) Connect a pressure gauge (5) to the body (4) side.
(3) Increase the pressure gradually to 22.6 MPa (3270 psi) adjusting the relief valve (6), then perform
1 minute leak test.
-Open the neighboring ports on both sides and check visually for leakage from the ports.
-Check the body for crack, which may cause oil leakage, by a dye check.
Phenomenon Cause Corrective action
External Oil Leakage -O-ring is defective. -Replace all the seal parts.
Internal Oil Leakage -Slipper seal and back-up -Replace all the seal parts.
ring are defective. -Replace the assembly.
-Excessive wear on sliding
surfaces.
Stem Sticks -Stem and body are stuck -Carry out grinding and honing. If excessive looseness
together. cause oil leakage, replace the assembly.
Flange Looseness -Capscrew tightening is -Retighten to the specified torque.
insufficient.
33-151
33-152
［34. TRAVEL SYSTEM］
34
34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1.1 NAME OF TRAVEL SYSTEM PARTS …………………………………………………………………34-3
34.1.2 CRAWLER …………………………………………………………………………………………………34-3
34.1.3 UPPER ROLLER …………………………………………………………………………………………34-11
34.1.4 MAINTENANCE STANDARDS …………………………………………………………………………34-16
34.1.5 TOOLS AND JIGS…………………………………………………………………………………………34-16
34.1.6 LOWER ROLLER …………………………………………………………………………………………34-17
34.1.7 FRONT IDLER ……………………………………………………………………………………………34-24
34.1.8 IDLER ADJUSTER…………………………………………………………………………………………34-30
34.1.9 SPROCKET …………………………………………………………………………………………………34-34
34.1.10 TRAVEL MOTOR…………………………………………………………………………………………34-35
34.1.11 SLEWING BEARING ……………………………………………………………………………………34-38
34.2.1 TRAVEL MOTOR …………………………………………………………………………………………34-41
34-1

S5PS3410E01
(SE Asia)
PREFACE
(1) This manual covers all the procedures required for the dis / re-assembling of the machine in
compilation by items.
(2) This manual consists of 34.1 ; REMOVING AND INSTALLING, and 34.2 ; DISASSEMBLING AND
ASSEMBLING.
(3) Though general dis / re-assembling procedures are able to carry out nearly in the order of Table
of Contents, some items may be omitted because of the circumstances at the actual repair work
or the purpose of time saving.
(4) Please understand that it is impossible to accord the descriptions with all cases of the actual
process for the removal / installation of the assembled components, because of difference in the
field conditions or defective section and the convenience in compilation of this manual.
(5) Please be aware the importance to establish the working order.
Prior to carry out the removal / installation and dis / re-assembling works, select the sections
presumably required, fully understand the description, and itemize the working procedures, then
start up the work.
34-2
34.1.1 NAME OF TRAVEL SYSTEM PARTS
34
Name and location of parts
34.1.2 CRAWLER
34.1.2.1 REMOVAL AND INSTALLATION PROCEDURES (RUBBER)
34.1.2.1.1 Removing Rubber Crawler
(1) Lift the one side of machine with
attachment, as shown in Fig. "Crawler
removing posture", and place support
under lower frame to support machine.
Crawler removing posture
(2) Loosen grease nipple for crawler adjuster,

discharging grease in cylinder, and release
tension of crawler.
-When loosening the grease nipple of the
adjuster, do not loosen it more than one
turn.
-Where grease does not come out well,
drive the crawler forward / reverse. The
Loosing crawler tension
over loosening of grease nipple will cause
it to jump out incurring danger of injury.
So be careful not to over loosen the
grease nipple. Keep body and face away
from the grease nipple for safety.
34-3
(3) Put steel pipes in the rubber crawler, turn

the sprocket in the reverse direction slowly
and when the rubber crawler has floated off
the idler stop the rotating.
(4) Slide the rubber crawler sideways, and
remove it.
Removing rubber crawler
34.1.2.1.2 Installing rubber crawler

Installation work is performed in the reverse order of removal.
(1) Engage the rubber crawler with the

sprocket and mount it on the idler.
(2) Put steel pipes in the rubber crawler, turn
the sprocket in the reverse direction slowly
and then the rubber crawler has floated
off the idler, stop the rotating.
(3) Slide the rubber crawler to the position to
be set on idler exactly.
Installing rubber crawler
(4) Confirm that the rubber crawler is engaged

securely with the sprocket, idler and lower
roller.
(5) Tighten the grease nipple for the crawler
adjuster, and adjust tension by feeding
grease.
Tools : Socket : 17mm,
T=73.5 N-m (54.2 lbf-ft)
Feeding grease
Rubber shoe
Appropriate tension A :
75 to 85mm(2.95 to 3.35 in)
Steel shoe
Appropriate tension A :
130 to 150mm(5.12 to 5.91 in)
Crawler tension
34-4
34.1.2.2 REMOVAL AND INSTALLATION PROCEDURES (STEEL)

(1) Removal
1. The crawler track link includes a set of
master pin(6), which should be placed at
the position front of the front idler.
34
Position of master pin
2. Put wood blocks A and B under the shoe

at the top end of the crawler and between
the crawler and the link over the track
frame to reduce the load to the master pin.
Removing of master pin
3. Loosen grease nipple for track spring

adjustment, discharge grease in the cylinder
and slack the tension of the shoe.
Loosening grease nipple for adjustment
-When loosening grease nipple for adjustment, do not turn it more than one turn to loosen.
-When grease is remained, move the machine forward and backward slightly.
-Be careful that the grease nipple may be popped out.
34-5
4. Straighten the curve of lock pin, and draw

out it striking by hammer.
-Remove lock pin (8) with shoe plate.
Removing lock pin
5. Apply master pin drawing out jig (a) to the

small diameter section of master pin (6),
and draw it out striking by hammer.
Removing master pin
-Especially pay attention to the front idler which may spring out due to the force of spring when
drawing out master pin (6) to repair broken parts relating to the front idler.
-Be careful not to be injured by flying debris, when large hammer is used.
Do not approach the machine because the end of the crawler may drop just before extending the
track link assembly to the ground while rotating the sprocket. Put wood block just in case.
6. Move the machine back slowly, and remove

the crawler extending it to the ground.
Weight of steel crawler (One side) :
SK50P : 290kg (640 lb)
Removing crawler
34-6
(2) Installation
1. Install the crawler to the position where
the end of the track link engages with the
sprocket placing the track link narrowing
toward the end toward the front idler side
as shown in the figure.
34
Direction of crawler
2. Move the machine forward slowly by

inserting the bar in the master pin hole on
the end of the crawler and assisting so that
the sprocket engages with the track link,
and also assist so that the crawler
catches the normal position and engages
with the front idler using pry-bar.
Installing crawler
3. Hook chain block to the upper and lower

parts of the shoe plate, and align the
master pin hole pulling by the chain block.
Alignment of pin holes
4. Align master link holes on the both ends of

the crawler link with the link holes
inserting pry-bar, apply master pin drawing
out jig (a) used when removed and press
fit master pin (6) by hammer.
Press fitting master pin
When large hammer is used, be careful not to be injured by flying debris.

-Apply molybdenum grease to the master pin before press fitting.
34-7
5. After press fitting master pin (6), insert

lock pin (8) and bend the top end in
advance.
6. After completion of installation, adjust the
tension of crawler by the same procedure
of the rubber crawler.
Extension of track link (Example for rubber

crawler)
(1) Construction of rubber crawler
Rubber crawler assy
・ This standard machine provides rubber crawler.
(2) Construction of steel crawler
Construction of steel crawler
34-8

(1) Rubber crawler
34
Rubber crawler shoe
Unit : mm (in)
SERVICEABILITY
ITEM STANDARD VALUE REPAIRABLE LEVEL REMEDY
LIMIT
Sag of rubber crawler L 75~85 (2.95~3.35) - - Adjustment
Where the depth of Where the depth of
Cracks and notch on them does not them reaches to
None Replace
rubber crawler reach to the steel the steel cords.
cords.
Breakage of steel cords None None Exist Replace
Where 10 percent of Where half of
Contact surface of rubber
None cores are visible cores are visible Replace
crawler and lower roller
from outside. from outside.
Height (H) 83.5 (3.29) - 61 (2.4) Replace
Lug projection (h) 22 (0.87) - 0 (0) Replace
34-9
(2) Steel crawler (Track link)
34-10
34.1.3 UPPER ROLLER

34.1.3.1 REMOVAL AND INSTALLATION PROCEDURES
34.1.3.1.1 Removal
(1) Loosen the grease nipple for crawler
adjusting within one turn to discharge
grease and release tension on the crawler.
34
Releasing crawler tension
Turn the grease nipple slowly paying attention not to turn more than one turn, and be careful for the
spouting out grease.
(2) Push up the crawler with a hydraulic jack,

and place suitable wooden block to keep
a clearance between the crawler and lower
frame.
(3) Remove the fixing capscrews and nuts, and
remove the upper roller from the lower
frame.
Tools : Socket : 19mm Supporting with wooden blocks
Weight of upper roller assembly :
5kg (11 lbs)
34-11
34.1.3.1.2 Installation
Before installing the upper roller, make sure that sufficient oil is filled in and that the upper roller
rotates smoothly by hand. If the oil volume is insufficient, refill oil, or if the upper roller does not rotate
smoothly or oil is leaking, check the bearing and the seals and replace them where necessary.
Oil : Engine oil API CD class#30
Volume : 20cc (1.2cu-in)
(1) Insert the shaft of the upper roller assembly

into the lower frame.
(2) Coat mounting capscrews with Loctite
#262 and tighten it to the torque.
Tightening torque : 115 N-m (84.8 lbf-ft)
-Install it so the nut is located on the idler
side.
-At installation, support the crawler with
wooden blocks the same way as it was Removing/Installing upper roller
dismantled so it does not disturb the work.
(3) After installing upper roller, tighten grease
nipple for crawler adjuster, grease it, and
adjust crawler tension.
Construction of upper roller
34-12

34.1.3.3.1 Disassembling
(1) Remove plug (10) and drain out oil.
(2) Place the end face inside upper roller (1)
on stand jig (f) and remove snap ring (9).
(3) Remove cover (4) upwards, using the
threaded hole for the plug.
(4) Remove O-ring (7) from cover (4). 34
(5) Loosen two socket bolts (8) and remove
plate (3).
Preparation for disassembly
(6) Put the extrusion jig (g) against the end

face of shaft (2) and extrude shaft (2) with
retainer for floating seal (6), using a press
or hammer.
Extruding shaft
(7) Remove floating seal (6) from upper roller

(1).
Removing out floating seal
(8) Remove the floating seal (6) from collar (11).
Collar is press fitted into shaft (2). Therefore do not disassemble it.
34-13
(9) When extruding bushing (5), place upper

roller (1) on the stand jig (f), put the
extrusion jig (j) against the end face of
bushing (5) and extrude it by means of a
press.
Extruding bushing
34.1.3.3.2 Installing
Installing of the upper roller is performed in the reverse order of removing.
(1) Place the upper roller (1) on the stand jig

(f), and press the jig (h) against the end
face of the bushing (5), and press it in a
specified position.
Pushing in bushing
If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets
unserviceable. In that case, do not reuse the bushing.
(2) Two floating seals (6) make a pair. Attach

one floating seal to retainer fixed in shaft
(2), and another to the inside of upper
roller (1).
-Prior to placing floating seal (6) in, apply
engine oil lightly to seal surface.
Fixing floating seal
34-14
(3) Put shaft (2) in upper roller (1), and

press-fit it.
34
Pressing shaft
(4) Place upper roller (1) on the stand jig (f)

and attach plate (3) to the end face of the
shaft with socket bolts (8). In that case,
coat the threaded part of socket bolts (8)
with Loctite #242 beforehand.
Tightening torque : 33.3 N-m (24.5 lbf-m)
(5) Fix O-ring (7) in the groove of cover (4).
-Coat grease to O-ring.
(6) Install cover (4) to upper roller (1). Use a
press in this operation as a press fit is
used. Installing cover
(7) Fix snap ring (9) into upper roller (1).
(8) Fill in 20cc (1.2cu-in) of engine oil API CD

class #30 through the plug hole of cover
(4).
(9) Place seal tape around plug (10) and
tighten it into the plug hole of cover (4).
Tightening torque :
9.8~11.8 N-m (7.2~8.7 lbf-m)
Before tightening plug, apply sealant on it
or wind teflon type.
(Plug coated by selant may be used aiso)
-After assembling the upper roller, confirm
that oil is not leaking from it and that it Filling oil
rotates smoothly by hand.
34-15
34.1.4 MAINTENANCE STANDARDS
Sectional view of upper roller
34.1.5 TOOLS AND JIGS

34.1.5.1 Tightening tools
Tools Opposing flats
Socket 17mm
Allen wrench 5mm, 6mm
34.1.5.2 Jig
34-16
34.1.6 LOWER ROLLER

Q'ty on one side : 5 pcs.
34.1.6.1.1 Removing
(1) Slightly loosen capscrews (M16X35)(2)
fastening lower roller assembly (1) to the
lower frame. 34
(2) As same as the case for removal of the
crawler, loosen the grease nipple for
crawler adjusting within one turn to
discharge the grease, and release the
tension on the crawler.
Lower roller assembly
(3) Lift the lower frame good enough to

remove the lower roller, using the
attachment.
(4) After lifting the lower frame to a proper
height, place square lumber under the
lower frame to stabilize the machine.
(5) Remove the capscrews (2) fastening the
lower roller, and remove the lower roller
assembly.
Tools : Socket : 24mm Crawler removing posture
Weight of lower roller assembly :
11 kg (24.3 lbs)
34-17
(1) Installing position of lower roller
Install the lower roller assembly so that
the plug directs outward from the machine.
(2) Coat the mounting capscrews (2) with
Loctite #262 in advance.
Place the roller assembly (1) between the
crawler and lower frame.
Fasten the capscrews (2) temporarily.
(3) Lower the machine in full contact with the
Installing lower roller
ground and tighten the capscrews (2) as
specified.
T=279 N-m (206 lbf-ft)
(4) Tighten the grease nipple of the crawler
adjuster.
Lift the machine, and adjust the crawler
tension by feeding grease.
T=73.5 N-m (54.2 lbf-ft)
Lower roller construction
34-18

(1) Loosen the plug (9) to drain oil.
Tools : Allen wrench : 5mm
(2) Remove the snap ring (8).
(3) Removing collar (2) and O-ring (7)
Place the lower roller on the jig (m) so that
the shaft (4) stands vertically. Apply the
extruding jig (P) to the upper shaft end. 34
Push the shaft (4) with a press or a
hammer until the O-ring comes out from
the collar (2) to remove the upper collar
(with seal) and O-ring (7).
(4) Removing shaft
Push the shaft further to remove the shaft
(4) and the lower collar (with seal) (3) in
one piece.
Removing shaft(4), collar(2) and O-ring(7)
Prior to extruding the shaft, prepare a drain oil container to receive lubricating oil remaining in the
lower roller. Otherwise the lubricating oil flows out to contaminate the work floor.
(5) Removing collar (3) and O-ring (7)

Place the shaft (4) with the collar (3) and
O-ring (7) pulled out according to the above
procedure on the jig (O).
Apply the extruding jig (P) to the shaft to
push it out using a press.
Removing collar (3)
(6) Removing the seal (6)

Remove the seal (6) from the collars (2)
and (3).
Removing the seal (6)
34-19
(7) Removing the seal (6)

Take out the seal (6) from the roller (1).
Removing the seal (6)
(8) Removing bushing (5)

Cut off the bushing (5) having very small
thickness with a lathe or tear it off without
damaging the bore. When an amount of
wear of the bushing is small, place the
roller (1) on the jig (m) and apply the tip of
the extruding jig (n) to the end surface of
the bushing (5) to hammer out the bushing.
Removing bush (5)
In order to avoid damage to the bore of the roller (1), hammer the bushing (5) lightly and change the
jig (n) applying position circumferentially little by little to push out the bushing slowly.
34.1.6.3.2 Assembly
(1) Attach O-ring (7) to one side.
Install O-ring (7) to shaft groove.
-Grease O-ring.
-Replace O-ring with new one without fail
at reassembling. Attach O-ring (7) to one side
34-20
(2) Press fitting bushing (5)

Align the center of the bushing (5) with that
of the bore of the roller (1) with the
bushing press fit jig (q) inserted to the
bushing (5) to push the bushing in with a
press vertically. [Press load : 35300N
(3600kgf)]
Press fit the opposite side bushing (5) too.
-Apply molybdenum disulfide grease to the 34
press fit section of the bushing to press fit Press fitting bushing (5)
the bushing at a normal temperature.
-If the press fit failed due to eccentric
pushing and so on, always replace the
bushing with new one.
(3) Press fitting collar (3)

-Install seal (6) in collar (3) in advance.
Press the collar (3) into the O-ring (7)
side of shaft (4) until groove of snap ring
(8) is flush with end plane of collar (3).
And install snap ring (8) to fix collar (3).
-Avoid damage to O-ring (7) during
press-fitting of shaft (4) into collar (3).
Press fitting collar (3)
(4) Installing snap ring (8)

(5) Attach floating seal (6) of roller side
Fit floating seal (6) to inner holes on both
ends of roller (1).
-Check that the seal surface is free from
flaws, rusts, etc. before reusing the floating
seal.
(6) Inserting shaft (1)
Install shaft (4) into roller (1) from the side
where collar (3) and O-ring (7) are not
there.
Installing roller (1)
34-21
(7) Installing O-ring (7)

Install the O-ring (7) to the shaft groove.
-Apply grease to the O-ring.
-Always replace the O-ring with new one
prior to reassembling.
(8) Installing collar (2)
Insert the collar (2), into which the seal
(6) is built in advance, into the shaft (4).
-Insert it until the snap ring groove of the
shaft (4) is in alignment with the end
surface of the collar (2).
(9) Installing snap ring (8)
Fit the snap ring (8) in the snap ring
groove of the shaft (4).
Installing the collar (2)
(10) Oil supply

Supply 110cc (6.71cu-in) of engine oil (shell
Rimula CT #30) through the plug (9) hole.
(11) Leakage test
Perform leakage test at an air pressure of
2.0 kgf/cm2 (14 psi) prior to tightening the
plug (9).
(12) Installing plug (9)
Apply oil resistant sealing agent to the
plug (9), and screw it in the plug hole in
the end surface of the collar (3).
Tightening torque :
9.8~11.8 N-m (7.2~8.7 lbf-ft)
Installing oil supply plug (9)
After assembling the lower roller as a single unit, ensure that it shows no oil leakage and can be
manually rotated.
34-22
34
Lower roller
34-23
34.1.7 FRONT IDLER

34.1.7.1.1 Removing
(1) Remove the crawler assembly.
(2) Remove idler together with idler adjuster
assembly, rolling it, using a pry-bar or
equivalent.
(3) Loosen capscrews (M10X50) (c), and
separate idler assembly (a) from idler
adjuster assembly (b).
Weight of idler assembly : Removing idler assembly
36 kgf (79 lbs) (one side)
Weight of idler adjuster assembly :
23 kgf (51 lbs) (one side)
Disassembling idler assembly
The separated idler assembly (a) is easy to fall down.

Lay it down so it does not fall down on your feet, utilizing wooden blocks.
(1) Install idler assembly (a) to the idler
adjuster assembly (b) by means of
capscrews (c) in the reverse order of
removing the idler assembly. Coat the
threaded part of capscrews (c) with Loctite
#262 beforehand.
Tools : Spanner : 17mm,
T=66 N-m (48.7 lbf-ft) Installing idler assembly
(2) The assembly of the idler and idler adjuster
is to be installed to the lower frame so that
the grease feeding plug (1) is positioned
to upside, and the grease nipple (2) is
facing to outside.
(3) Following procedures of section 2, install
the crawler assembly, and adjust the
crawler tension.
-On that occasion, confirm the lubrication
through the grease nipple is proper and
that grease is not leaking from the grease
cylinder.
34-24
34
Idler assembly construction

1 Idler 1 4 Shaft 1 7 O-ring 2
2 Collar 1 5 Bushing 2 8 Spring pin 2
3 Collar 1 6 Seal 2 9 Plug : PT 1/8 2

(1) Remove plug (9) on the side of collar (3)
and drain oil.
(2) Apply spring pin push bar (jig R) to the top
of spring pin (8), and take out striking
lightly by hammer.
Extruding pin
(3) Put idler (1) on repair stand (U), apply

pushout jig (S) on shaft (4), push out
shaft (4) with collar (3), then remove collar
(3).
Extruding shaft
34-25
(4) With idler (1) placed on the stand (U), tap

bushing (5) lightly by hammer, while placing
the bushing extruding rod (T) against the
end face of bushing (5) evenly all round, till
it comes out.
(5) Take out floating seals (6) from idler (1),
collar (3). If you intend to reuse floating
seals (6), confirm that there is no scoring
and rusting on the contact surface and
store the floating seals in pairs by placing Removing bushing (5)
thick paper between the sealing faces.
(6) Remove O-ring (7) from shaft (4).
34.1.7.3.2 Assembly
(1) Align inner hole of idler (1) and bushing (5)
and press fit it vertically with press.
Pressing in bushing (5)
(2) Fit O-ring (7) to O-ring groove on shaft (4).

-Apply grease to O-ring
(3) Installing collar (3) (See 32.2.1.3)
Press fit the O-ring installed side of shaft
into collar (3), and drive spring pin (8).
(4) Fit one piece of two (2) pieces type floating
seal (6) on each side of collar (3) and idler
(1).
Pressing in shaft (4)
(5) Insert shaft (4) into idler (1).

-Apply gear oil to shaft.
(6) Fit floating seal (6) on the other side of
idler (1).
Inserting floating seal (6)
34-26
(7) Fit floating seal (6) on the other collar (2),

press fit it in shaft, and drive spring pin
(8) in with mallet.
(8) Filling oil / Inspection
Fill in 65~75cc (4.0~4.6cu-in) of gear oil
SAE 90 GL4 through the plug hole of
collar, place the screwed part of plug (9)
with seal tape and put in plug (9).
Tools: Allen wrench: 5mm 34
-After installing the idler assy to the idler
adjuster assy, make certain that no oil Pressing in collar (2)
leaks from floating seal and plug (9) and
that idler (1) rotates smoothly.
Driving spring pin (8)
34-27
Front idler
34-28
34.1.7.5 TOOLS AND JIGS

(1) Tools
Tools Opposing flats
Socket 17mm, 24mm
Allen wrench 5mm, 6mm
(2) Jigs
34
34-29
34.1.8 IDLER ADJUSTER

34.1.8.1.1 Removing
(1) Idler adjuster assembly assembled with idler
assembly (a) is removed from the lower
frame.
Do this work by referring to 34.1.7.1.1
Removing front idler.
Disassembling idler assembly
(2) Loosen capscrews (c) and separate idler
assembly (a) from idler adjuster assembly
(b).
Weight of idler assembly :
36 kg (79 lbs) (one side)
Weight of idler adjuster assembly :
23 kg (51 lbs) (one side)
The separated idler assembly is easy to fall down. Lay it down so it does not fall down on your feet,
utilizing wooden blocks.
(1) Installation is done in the reverse order of removal :
First of all, assemble idler assembly (a) to idler adjuster assembly (b), and tighten them together
with capscrews (c).
In that case, coat the threaded part of capscrews (c) with Loctite #262 beforehand.
Tools: Spanner: 17mm, T=66 N-m (48.7 lbf-ft)
(2) Before installing the idler adjuster to the crawler frame, assemble it with the idler assembly. For
the procedure, refer to 34.1.7.1.2 Installing front idler.
Idler adjuster assembly
34-30

(1) Disassembly
1. Before disassembling and assembling the
idler adjuster assembly, prepare spring
setting jig (V).
Capacity of hydraulic jack : more than 5
tons (11000 lbf)
34
Spring set special jig (V)
Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.
2. Place a hydraulic jack between the jig base

and the stand.
3. Loosen the holding-down nuts of the jig
and draw out the retainer upward.
4. Draw out piston (1) from grease cylinder (2)
of the idler adjuster assembly.
5. Take out oil seal (7) and O-ring (8) from
grease cylinder (2).
6. Set the idler adjuster assembly on the
stand of the jig (V), with its plate (4) side
facing up.
Slinging work of idler adjuster
7. Fit retainer plate to plate (4) tighten

holding-down nuts alternately, and secure
idler adjuster assembly.
Fixing Holding-down nut
34-31
8. Remove split pin (10), press spring (4)

lifting it with jack so that nut (5) can be
turned freely, and remove nut (5).
Compression of spring
9. Allow the hydraulic jack to retract slowly

till the spring is extended to its free length.
Remove the retainer plate and take off
plate (4).
The free length of the spring :
Approx. 330mm (13.0in)
10. Hook lifting eye nut (W) to screw M30XP3
on grease cylinder (2) top end and hoist it.
Lifting nut : M30XP3
11. Remove the grease cylinder (2) and from
the spring (3).
Removing retainer plate
(2) Assembly
Perform assembly in the reverse order of disassembly.
1. Insert grease cylinder (2) into spring (3)

and erect it in the center of the jig stand
upright.
2. Install the plate (4) on top of spring (3).
Center the rod of grease cylinder (2) and
the holes in plate (4). Attach the retainer
plate and four holding-down nuts. Fasten
the nuts evenly all round fix the idler
adjuster assembly to the jig body.
3. Extend the hydraulic jack, compress spring
(3) to a set length and screw in nut (5) to
the screwed part at the tip of grease
cylinder (2).
Set length of the spring : 265mm (10.4in)
Removing and installing of idler adjuster
assembly
34-32
4. Tighten nut (5) till the holes for locking split

pins (10) are aligned, then fit split pin (10).
Tools: Socket: 46mm
34
Attach idler adjuster assembly to the jig
5. Remove the idler adjuster assembly from the jig.

6. Fit oil seal (7) and O-ring (8) to grease cylinder (2).
-Apply grease on oil seal (7) and O-ring (8).
7. Fill up grease in grease cylinder (2), remove the grease nipple from piston (1) and press the
piston by hand to discharge the inside air.
-Push the piston in while directing the grease nipple hole downward to make it easier to release
air.
8. Tighten grease nipple to piston (1).
Tools: Socket: 17mm

Unit : mm (in)
Code ITEM Rubber crawler / steel shoe
A Installed length of spring 265 (10.4)
B Free length of spring 330 (13.0)
C Stroke 28 (1.1)
D Set length 478 (18.8)
E Outside view of piston No scoring and rusting
F Tightening torque of grease nipple 73.5 N-m (54.2 lbf-ft)
Idler adjuster assembly
34-33
34.1.9 SPROCKET
34.1.9.1.1 Removing
(2) Place wooden block under the lower frame
so the sprocket is off the ground.
(3) Loosen capscrew (M14) for the mounting of
the sprocket by means of an Allen wrench
and remove the sprocket.
Tools: Socket: 22mm
Single weight of sprocket : 14 kg (31 lbs)
Making sprocket free
(1) Check the fixing parts of the travel motor
and the sprocket, eliminate burrs and dirt
thoroughly, and install the sprocket.
(2) Apply Loctite #262 to the threaded portion
of capscrew to mount the capscrew and
fasten the temporarily.
Removing sprocket
(3) Remove the wooden block under the lower

frame and tighten capscrew to specified
torque to fix sprocket and travel motor.
Tools: Socket: 22mm
T=181 N-m (133 lbf-ft)
(4) Install crawler.
Tightening capscrew
Sprocket
Unit:mm(in)
STANDARD REPAIRABLE SERVICE
Code ITEM REMEDY
VALUE LEVEL LIMIT
A Width of sprocket teeth 32 (1.26) 29 (1.14) 27 (1.06) Replace
B O.D. of sprocket φ415.8 (16.37) φ409 (16.1) φ407 (16.0) Welded repair, or replace
34-34
34.1.10 TRAVEL MOTOR

34.1.10.1.1 Removing
(2) Place wooden block under the lower frame
so the sprocket is off the ground.
(3) Remove the capscrews (A4) located inside
the lower frame and remove the covers 34
(A1).
(4) To relieve air from hydraulic tank, remove
cap of air breather located on hydraulic
Making sprocket free
tank. And push air release rod to release
air.
(5) Disconnect the joint of hydraulic piping

connected with the travel motor, and plug
the joints in order to prevent outflow of oil
and entering of dust.
Tools : Spanner : 19mm, 22mm and 32mm
(6) Loosen the capscrew M14X35 (B2) that
fasten the travel motor to the lower frame.
On that occasion, put a matching mark
between the lower frame and the travel
motor.
Tools: Socket: 22mm
Removing cover and travel motor
(7) Apply a wire rope to a part near the

sprocket of the travel motor for balancing,
and remove the unit out of the lower frame.
Weight of travel motor (with sprocket) :
81 kg (179 lbs)
Removing and installing travel motor
34-35
(1) If there are burrs and dirt on fitting part
with which the travel motor are fastened,
eliminate it beforehand. Place a wire sling
in the travel unit with the same way as in
the removing, and install it to the lower
frame.
(2) Coat the threaded part of the mounting
capscrew (B2) with Loctite #262 and tighten
them.
Tools: Socket: 22mm,
T=181 N-m (133 lbf-ft)
Installing travel motor
(3) Reconnect the hydraulic pipings as before, and tighten the joints to the specified torque.
-Fill the casing with hydraulic oil prior to perform drain piping.
Installing hydraulic pipings (LH-travel motor)
(4) Install the covers (A1) located inside the

lower frame, and tighten capscrews (A4).
(See Fig. Removing cover and travel motor)
T : 65.7 N-m (48.7 lbf-ft)
(5) Remove the wooden block supporting the
lower frame and install the crawler.
(6) Check the oil level in the reduction unit of
travel motor [See Item (7) below] and
replace or replenish oil as required.
Oil : GEAR OIL SAE #90 GL4 Checking oil level
Volume of oil : 900cc (55cu-in)
34-36
(7) Checking oil level in reduction unit
1. Stop the machine so that the drain plug of the reduction unit is located in the lowest position.
2. Remove the level plug and check the oil level and contamination. The oil level is proper if it is
close to the plug bore. Replenish oil if necessary.
-When starting operation, operate motor in low idling and at low speed for several minutes, and
check it for possible oil leakage and noise.
34.1.10.2 MAINTENANCE STANDARDS 34

ITEM SPEC.
Sprocket fixing
TIGHTENING Capscrew M14 Apply Loctite #262
TORQUE Travel motor fixing 181 N-m (133 lbf-ft)
Capscrew M14
Spec. and grade Gear oil SAE #90 GL4
OIL
Volume 900cc (55cu-in)
34-37
34.1.11 SLEWING BEARING

34.1.11.1.1 Removing
(1) Remove the upper slewing structure. (See
detail of "Upper Slewing Structure")
(2) Remove capscrews (B) that fix the inner
race of slewing bearing (A)
Tools: Socket: 19mm
Slewing bearing
(3) Remove the grease in the inner race of

slewing bearing.
(4) Screw lifting-bolts in the slewing bearing
(A), and lift it by crane.
Weight of slewing bearing assembly :
58 kgf (128 lbs)
Lifting slewing bearing
(1) Before installing the slewing bearing, clean
thoroughly the bearing and the mating
surface of the lower frame to be free from
dirt, oil and other foreign materials.
(2) Lift up the bearing and place it on the
lower frame, aligning the "S" mark engraved
on the inner race as shown.
(3) Coat the threads of the capscrews (B)
with Loctite #262 and tighten all capscrews
temporarily.
(4) Tighten the capscrews at 180° intervals
alternately, and tighten them up to the
specified torque.
Tools: Socket: 19mm,
T=115 N-m (84.8 lbf-ft)
(5) Replenish 3.6 kg (7.94 lbs) of "Nisseki New
Molyknock Grease NLGI-2 or equivalent
item" to the grease bath.
(6) After installing the slewing bearing on the
lower frame, install upper slewing structure. Location of "S" mark to install slewing
bearing
34-38
Cross-section of slewing bearing

34
(1) Remove seal A (8) fitted in the groove in
the inner circumference on top of outer
race (2) and seal B (9) fitted in the
groove in the outer circumference under
inner race (1), from the bearing, and place
the bearing level on wood block.
(2) Remove taper pin (7), using a hammer and
a push rod.
(3) Remove plug (6) with an puller bolt
Disassembling slewing bearing
making use of the threaded bore in the
center of the plug (6).
(4) After removing plug (6), take out balls (3)
and spacers (4) from the bore in order,
while rotating outer race (2) slightly.
34.1.11.3.2 Assembling
(1) Degrease thoroughly the groove for seal A (8) located in the inner circumference of outer race
(2) and the groove for seal B (9) located in the outer circumference of inner race (1). Coat the
grooves with adhesive (Cyanoacrylate instant glue), fit seal B (9), and place inner race (1) on a
surface plate.
(2) Lift and lower outer race (2) slowly till the top surface of inner race (1) matches the bottom of the
sealing groove of outer race (2). Place an adjusting washer under outer race (2) in order to
support the outer race so the track surface of ball (3) is aligned.
(3) Insert balls (3) and spacers (4) coating with grease (NLGI No.2 Lithium bace with MoS2)
alternately through the hole for plug (6) on outer race (2).
Installing balls
Removing balls / spacers
34-39
When inserting balls (3) and spacers (4), the ball tracks must be aligned completely.
To achieve it, outer race (2) should be adjusted. It is very dangerous to put your finger into the plug
bore directly ; always use a push rod or a hooked rod.
(4) Install plug (6) to outer race (2),

confirming the direction and the position of
the bore for taper pin (7).
(5) Drive taper pin (7) into bore, and caulk
the head of the taper pin with a punch.
(6) Coat seal (8) with adhesive Cyano Bond
P0-1 equivalent and fit it in the groove of
outer race (2).
(7) Confirm that grease nipple (10) is useful.
Apply grease (NLGI-2 EP type) and confirm Installing spacer
that the outer race rotates smoothly and
that the lip of the seal is not scored.
Grease amount : Approx. 95g (3.4oz)

Regarding the maintenance standards for the wear of the slewing bearing, refer to the section 13
Maintenance Standards and Test Procedures, Article Measuring Slewing bearing Performances.
34-40
34.2.1 TRAVEL MOTOR

34.2.1.1 SUMMARY
(1) General View
34
(2) Hydraulic circuit diagram
34-41
(3) EXPLODED VIEW OF TRAVEL MOTOR AND REDUCTION UNIT
34-42

1 Hub 1 Piston kit 1
2 Spindle 1 -Piston assembly 1
3 Carrier 1 161 --Piston 1
4 Sun gear (1) 1 162 --Shoe 1
5 Planetary gear (1) 3 163 -Seal ring 1
6 Sun gear (2) 1 102 Shaft 1
7 Planetary gear (2) 4 103 Swash plate 1 34
9 Thrust washer (1) 2 107 Retainer plate 1
11 Thrust collar (4) 4 108 Thrust ball 1
12 Thrust washer (3) 7 109 Timing plate 1
13 Cover 1 110 Washer 2
14 Coupling 1 112 Piston 1
22 Ring nut 1 113 Spring 8
24 Ball bearing 2 114 Spring 1
27 Needle roller bearing with retainer 3 115 Friction plate 2
28 Needle roller bearing with retainer 4 116 Separator plate 3
29 Inner race 3 132 Oil seal 1
30 Inner race 4 135 O-ring 1
139 O-ring 1
Floating seal kit 1 145 Snap ring 1
31 Floating seal 2 149 Ball bearing 1
150 Ball bearing 1
33 Plug with flange 1 151 Roller 3
35 O-ring 1 167 Pivot 2
37 O-ring 3 177 Parallel pin 2
39 Plug 2 190 Spring 1
40 Hexagon head screw 7
41 Steel ball 1 Rear flange assembly 1
42 Parallel pin 2 -Rear flange kit 1
43 O-ring 2 201 --Rear flange 1
44 O-ring 1 223 --Spool 1
45 Ring 1 -Spool kit 1
47 Hexagon socket set screw 2 263 --Spool 1
264 --Oil stopper 1
Cylinder and piston kit 1 221 -Plug 2
104 -Cylinder block 1 224 -Plug 2
-Piston kit 1 225 -Stopper 2
--Piston assembly 9 226 -Plug 2
105 ---Piston 1 227 -Valve 2
106 ---Shoe 1 228 -Spring 2
34-43

230 -Spring 2 275 -Orifice 5
236 -O-ring 2 276 -Orifice 1
237 -O-ring 2 279 -Filter 1
252 -Hexagon socket plug 4 280 -Plug with flange 1
254 -Hexagon socket plug 6 299 -Name plate 1
266 -Spring 1 241 Parallel pin 2
268 -Steel ball 1 243 Capscrew 6
273 -O-ring 2
34-44
34.2.1.2 TOOLS AND JIGS

(1) Standard tools
No. NAME SIZE Q'TY
1 Allen wrench 3 (For M6), 6 (For M8 & PF1/4), 8 (For PF3/8) 1 each
2 Socket wrench Barrel type 1
(Ratchet handle)
3 Torque wrench Dial type, about 12 N-m (8.7 lbf-ft) 1 each
Dial type, about 90 N-m (65 lbf-ft)
Dial type, about 560 N-m (406 lbf-ft)
34
4 Torque wrench adaptor Nominal socket size 13 and 30 1 each
Nominal rod size 3, 6 and 8
5 Hexagon socket For width across flats of 3 mm 1
6 Extension bar 150 mm (6") 1
7 Hammer Nominal size 12 1
8 Plastic hammer L= about 300 mm (12") 1
9 Flat screwdriver about 150 mm (6"), 50 mm (2") 1
10 Snap ring pliers For shaft 1
For hole 1
11 Cutting pliers (JIS B 4623) 200 mm (8") 2
12 Lifting tool Lifting capacity : 300 kg (660 lbs) or over 1 set
Lifting eye (for M14) (2)
Lifting eye (for PF 3/8) (2)
Wire with hooks (1)
13 Container Vat for general use : W450 X D300 X H120 (W17.7" X D11.8" X H4.7") 2
14 Leather gloves 1 pair
(2) Bolts
No. Name Description Q'TY
Approx. M6 (P1.0)X50 1
Hexagon socket head cap screw
1 Approx. M16 (P2.0)X40 2
(JIS B 1176)
Approx. M16 (P2.0)X150 3
34-45
(3) Tools
APPLICATION ITEM
NAME SIZE REMARKS Q'TY
(Item in cross-sectional or exploded view)
Disassembly and assembly General 1 set

workbench
Parts cleaning Cleaning bath For rough and finish cleaning 1 set
104 and 149 Workbench for Pressing capacity : 1.96 kN 1 set
press [440 lbs] or over
149 Heating bath Heating capacity : 100C 1 set
degrees or over (212F degrees)
Volume 500 X 500 X 500 mm
(20" X 20" X 20")
Drying after cleaning Compressed air Pressure
(294~490 kPa)
(43~71 psi)
34-46
(4) Jigs
34
34-47
34-48
34.2.1.3.1 PREPARATIONS FOR DISASSEMBLY
Prior to disassembling, carry out the following preparations :
(1) Workbench preparation

-Prepare workbench for travel motor.
-Prepare workbench which is rigid enough to disassemble or assemble internal parts of travel
motor and has a wide area for placing them to prevent them from moving or dropping during the
work. 34
-Cover workbench with rubber, vinyl, etc.
(2) Preparations of tools and materials
Prepare materials shown in 34.2.1.2.
34.2.1.3.2 GENERAL PRECAUTIONS FOR WORKING
-Internal parts during disassembly are slippery as they are smeared by hydraulic oil. Handle them with
extreme care not to drop them.
Otherwise, you may be injured or they may be damaged.
-Combustible material such as kerosene is used to clean the parts.
Handle it with extreme care not to cause fire or burns, as it catch fire easily.
(1) Prior to disassembly, make a good judgment on the features etc. of the generated abnormalities to
work according to the disassembling procedure.
(2) All parts are manufactured in high precision. Therefore handle them with care not to bump them
each other or drop them.
(3) Work patiently not to forcibly strike or pry the sticking parts during disassembly. Otherwise it may
result in generating burrs, damages, and performance deterioration.
(4) Be careful not to leave the disassembled parts without appropriate protection. Otherwise they may
be rusted by moisture and or contaminated by dust.
(5) Put a match mark on each mating surface of part during disassembly.
(6) Carry out the work putting every removed part in order, and taking care not to cause damage or
loss.
(7) Sealing parts shall be replaced in principle, even though no damage is found on them. Keep them
on hand prior to disassembly.
(8) Photos and figures of typical models are shown. Any partial difference between them and the
product in use does not affect the disassembling procedure.
34-49
34.2.1.3.3 DISASSEMBLING
(1) Cleaning travel motor
1. Tighten the lifting eyes into the tapped
holes of the spindle (2).
Mounting lifting eye
Screw two lifting eyes into the tapped holes of the spindle diagonally located with each other.
2. Pass a wire sling through the lifting eyes,

lift up the travel motor by hoist, and carry
into the cleaning bath.
3. Clean the travel motor with a car brush.
Cleaning travel motor
Since soil and sand are accumulated in the clearance (where the floating seal is fixed) between the
hub (1) and the spindle (2), clean it with particular care.
34-50
(2) Installing travel motor

1. Place travel motor on a workbench.
34
Placing travel motor on workbench
While aligning the threaded holes of the hub (1) and the workbench, place the travel motor in fixing
holes of the workbench slowly.
2. Fix the travel motor with two socket bolts

on the workbench.
Fixing travel motor on workbench
Tighten the hexagon socket bolts securely.

Failure to do so could result in injury cased by the travel motor falling when it is inverted.
34-51
(3) Draining lubricating oil

1. Turn over the travel motor.
2. Loosen a plug (33) and two socket plugs
(39).
-If the plug (33) and the socket plugs (39)
are removed and the travel motor is
reversed, oil spills. Loosen them to such an
extent that they can be turned by hand.
3. Turn over slowly the travel motor and
extract the lubricating oil. (Turn up the
side of motor)
Removing plug (33)
4. Remove the O-rings (37) from the plug (33)

and two socket plugs (39).
-Do not reuse O-rings (37) which have
been removed.
Draining oil
(4) Removing cover (13)

(The side of reduction gear is turned up.)
2. Remove the ring (45).
3. Loosen two capscrews in the middle of
the cover removal jig in the thread holes
from which the plugs (33) and (39). (Two
places)
4. Apply a block to two capscrews in the
middle of the cover removal jig and tighten
the screws to remove the cover (13).
-If it is difficult to remove the cover (13)
Removing ring (45)
due to resistance of the O-ring (35), lift
the cover while lightly tapping the external
periphery of the cover with a plastic
hammer.
5. Remove the O-ring (35) from the hub (1)
-Do not reuse the removed O-ring (35).
Removing cover (13)
34-52
(5) Removing sun gear 1 (4)

1. Pull out the sun gear 1 (4) by hand.
2. Remove the steel balls (41) from the sun
gear 1 (4).
-The coupling (14) may come off at the
same time.
34
Removing sun gear 1 (4)
(6) Removing carrier assembly

1. Take out the carrier assembly from the hub
(1).
2. Take out the sun gear 2 (6) from the hub.
3. Remove the coupling (14) from the shaft
(102).
Removing carrier assembly
4. Disassembling carrier assembly

a.
Loosen the hexagonal head screws (40)
and remove them from carrier (3).
b.
Remove three thrust washers (12), three
planetary gears 1 (5), three needle roller
bearings with retainers (27) and three
bearing inner races (29) from the carrier (3).
Disassembling carrier assembly
34-53
5. Remove the thrust washer 1 (9) from the

carrier (3).
Removing thrust washer (9)
(7) Removing planetary gear 2 (7)

1. Loosen four hexagonal head screws (40)
and remove them from spindle (2).
Unscrewing hexagonal head screw (40)
2. Remove four planetary gears 2 (7), four

needle roller bearings with cages (28) and
four inner races (30).
3. Remove four thrust collars 4 (11) from the
spindle (2).
4. Remove the thrust washer 1 (9) from the
spindle (2).
Removing planetary gear 2 (7)
34-54
(8) Removing rear flange

1. Turn over the travel motor, so rear flange
(101) is on top.
-Follow the procedures below to make it
easy to remove the plug when
disassembling the interior of the rear flange
(201).
-Do not loosen the plugs unless
disassembling the interior of the rear flange. 34
2. Loosen two plugs (224).
Unscrewing plug (224)
3. Loosen two plugs (226).
Unscrewing plug (226)
4. Loosen six socket bolts (243) and remove

them from the rear flange (201).
Removing socket bolt (243)
5. Remove the rear flange (201) from the

spindle (2).
-Hold the rear flange by both hands, hold it
up gently upright to remove it. Perform the
work with care not to forcibly pry or strike
the flange.
Otherwise it may cause the timing plate
(109) to drop and be damaged.
Removing real flange (201)
34-55
6. Remove the parallel pins (42) from the

spindle (2).
Removing parallel pin (42)
7. Remove the O-rings (43) and (44) from

the spindle (2).
-Do not reuse the removed O-rings (43)
and (44).
Removing O-rings (43) and (44)
(9) Removing rear flange fittings

1. Place the rear flange (201) on the
workbench, with the mating surface for the
spindle (2) facing up.
2. Remove the timing plate (109) from the
rear flange (201).
-It may be hard to remove the rear flange
as the mating surface of it is stuck with oil.
Insert a spatula into the draft groove of
the mating surface on the rear flange side
and hold the timing plate up. Then the rear
flange comes off.
Removing timing plate (109)
If a sharp tool like a screwdriver is put into
the mating surface, the mating surface
may be damaged to cause an oil leakage.
Do not use sharp tools.
34-56
3. Remove the parallel pins (241) from the

rear flange (201).
34
Removing parallel pin (241)
4. Remove bearing (150) from the rear flange

(201).
Removing bearing (150)
(10) Removing brake valve parts from rear flange

1. Remove two plugs (224) from the rear
flange (201).
Removing plug (224)
2. Remove two stoppers (225) and two

springs (228) from the rear flange (201).
3. Remove the spool (223) from the rear
flange (201).
-To remove the spool (223), place your
hand on one part of the plug port of the
rear flange (201) and tilt it down.
Then the spool (223) falls down. Hold the
tip and remove it.
Removing stopper (225), spring (228) and

spool (223)
34-57
4. Remove two plugs (226) from the rear

flange (201).
Remove the plug (226)
5. Remove two springs (230) and two valves

(227) from the rear flange (201).
Removing spring (230) and valve (227)
6. Remove O-ring (236) from plug (224).

Removing O-ring (236)
7. Remove the O-ring (237) from the plug

(226).
Removing O-ring (237)
34-58
(11) Removing two-speed switching spool

1. Remove the plug (221) from the rear flange
(201).
2. Remove the O-ring (273) from the plug
(221).
34
Removing plug (221)
3. Remove the spool (263) and spring (266)

from the rear flange (201).
Removing spool (263)
(12) Removing the parking brake section
Install a protection cover on the piston (112).

Otherwise the piston may fly out suddenly from the spindle (2) due to compressed air to cause injury.
1. Blow compressed air into the passage

hole for the parking brake of the spindle
(2) and take out the piston (112) from the
spindle (2).
Removing piston (112)
34-59
2. Remove the O-rings (135) and (139) from

the piston (112).
-Do not reuse the removed O-rings (135)
and (139).
Removing piston (112)
(13) Disassembling hydraulic motor section

・ When placing the travel motor on its side, place an oil pan under the travel motor to receive oil
flowing out from the travel motor.
1. Incline travel motor 90 degrees.

2. Drain oil out of the travel motor.
3. Remove two separator plates (116) and,
one friction plate (115).
Lifting cylinder block (104)
4. Hold the cylinder block (104) by hand and

turn it 2 or 3 times alternatively to separate
the shoe (106) adhered on the swash plate
(103).
-Note that, if the cylinder block (104) is
pulled out without separating the shoe
(106), the shoe (106) left on the swash
plate (103) may allow the parts (piston,
shoe, etc.) on the cylinder block (104) to
come off and drop into the spindle (2).
Removing cylinder block (104)
34-60
5. Remove the cylinder block (104) from the

drive shaft (102).
6. Remove piston assembly [piston (105) and
shoe (106)] and the retainer plate (107)
from the cylinder block (104).
-When removing the cylinder block, hold the
retainer plate (107) by both hands to
remove it with the piston assembly.
-The piston (105) and the shoe (106) are 34
squeezed at the spherical portion of the Removing retainer plate (107)
piston to make them one piece. It is not
possible to remove the piston from the
shoe without damaging the shoe. When
replacement is required, replace the piston
and shoe by a set (hereafter referred to
as the piston assembly).
7. Remove the retainer plate (107) from piston
assembly (105) and (106) [seven sets].
Removing piston assembly (105) and (106)
8. Remove the thrust ball (108) from the

cylinder block (104).
Removing thrust ball (105)
9. Remove three rollers (151) from the

cylinder block (104).
Removing roller (104)
34-61
(14) Removing spring inside cylinder block

1. Place the cylinder block (104) on the press
bench.
-Remove the spring, only when its
replacement is necessary.
-When removing the spring, align the center
of the retainer metal (I) with the washer
center in order to prevent the cylinder block
from being damaged by contact.
-Put a vinyl sheet over the cylinder block
so as not to damage the surface of the
cylinder block.
Removing spring (114)
2. Place the retainer metal (I) against the

washer (110), remove the snap ring (145)
from the snap ring groove of the cylinder
block (104) with a snap ring plier.
Removing spring (114)
Release pressing force slowly. Otherwise the spring may fly out to cause injury.
3. Remove the snap ring (145), washer

(110), spring (114), and washer (110) out
of the cylinder block.
Removing internals of cylinder block (104)
34-62
(15) Removing swash plate

1. Remove the swash plate (103) from the
drive shaft (102).
-When removing the swash plate (103),
ensure that pivot (167) is not adhered on
the swash plate (103).
34
Removing swash plate (103)
2. Pull the drive shaft (102) out of the

spindle (2).
Then the ball bearing (149) is removed
together.
-Be careful to lightly strike the tip of the
shaft on the reduction side using a plastic
hammer to allow the shaft to come off
easily. Otherwise the shaft may pop out.
3. Remove two pivots (167) and two the
parallel pins (177) from the spindle (2).
4. Take out the 2-speed switching piston kit
(piston assembly and seal ring) and the Removing drive shaft (102)
spring (190) from the spindle (2).
Piston assembly : Piston (161), Shoe (162),
Seal ring (163)
Removing 2-speed switching piston kit
34-63
(16) Removing ball bearing

・ Remove the ball bearing, only when its replacement is necessary.
1. Place the retainer metal (II) on the press

bench and put the drive shaft (102) into it.
2. Hold down the tip of the drive shaft (102)
by a press and remove the bearing (149)
from the shaft.
-Do not reuse the ball bearing.
Removing ball bearing (149)
(17) Removing ring nut

1. Apply the clamp plates to the spindle (2) in
the equally spaced positions, and fasten
three M16×2.0×150 (approx.) to the
workbench.
2. Turn over the travel motor. (Direct the
reduction unit side upward.)
Fixing spindle (2)
3. Remove two hexagon set screws (47).
Removing hexagon set screw (47)
34-64
4. Loosen the ring nut (22) using a tightening

jig.
-Do not reuse the removed ring nut (22)
of which tooth flank may be damaged.
34
Loosen ring nut (22)
Installing jig
5. Remove the ring nut (22) from the spindle

(2).
Removing ring nut (22)
34-65
(18) Removal of spindle

motor side upward.)
2. Remove the clamp plates from the
workbench.
3. Tighten two M12 eyebolts in the mounting
thread holes of the spindle (2) in the
diagonal position.
4. Hook a wire rope with hook to M12
eyebolts, and lift by a crane to remove
the spindle (2) from the hub (1). At this
time, the floating seal (31) and oil seal
Removing spindle (2)
(132) will be removed together with the
spindle (2).
(19) Removing main bearing

1. Remove the floating seal (31) from the hub
(1).
-Do not reuse the removed floating seal
(31).
2. Apply a punch between the inside periphery
of the hub (1) and the main bearing (24) to
remove the main bearing using a hammer.
-When the fit section of the outer race of
ball bearing (24) comes out of hub (1),
the ball bearing drop from the hub.
Therefore place a tray under the workbench
Removing floating seal (31)
and spread a rubber mat on the tray so as
not to damage the parts.

4. Tapping the end face of outer race of ball
bearing (24) with aluminum rod (pin
punch) and hammer, remove the ball
bearing from hub (1)
-To avoid misalignment of the ball bearing,
tap the bearing race end evenly at 3 or 4
points of the hub. And remove the ball
bearing little by little.
Removing ball bearing (24)
34-66
(20) Removing spindle fittings

1. Remove the floating seal (31) from the
spindle (2).
34
Removing floating seal (31)
2. Remove the oil seal (132) from the spindle

(2)
-Do not reuse the removed oil seal (132).
Removing oil seal (132)
(21) Rough washing of parts

1. Separate the four parts, namely the hub
(1), spindle (2), cover (13), and rear flange
(201), from the other parts (hereafter
referred to as built-in parts).
2. Put the hub, spindle, cover, and rear flange
in a cleaning bath and clean them.
-Carefully remove dust accumulated on the
surfaces of parts to make them completely
clean.
-Before cleaning stained parts, immerse
them in kerosene until dust and stain
Cleaning each part
become soft and are floated so as to
prevent damage when cleaning.
Kerosene is combustible. Be careful not to cause fire, burns, and injury.
34-67
3. Put the built-in parts in a rough cleaning

bath containing kerosene and clean them.
Cleaning each section
(22) Finish cleaning

1. Put parts in a finish cleaning bath
containing kerosene and clean them well,
turning them slowly.
2. Wipe off kerosene adhered to the parts
using a clean cloth.
-Dry the inner surfaces of the hub (1) and
the spindle (2) in the dust-free and dry
conditions by blowing compressed air on
them. After drying, apply hydraulic oil to
every part. Finish cleaning
-Dry the inner surface of the rear flange
(201) and the hydraulic motor components
in the dust-free and dry conditions by
blowing compressed air on them. After
drying, apply hydraulic oil to every part.
Finish cleaning
34-68
34.2.1.4 ASSEMBLY
Perform assembly basically in reverse order of disassembly.
34.2.1.4.1 PREPARATION
Prepare a workbench, tools and jigs as in the case of Section 34.2.1.3; DISASSEMBLY.
34.2.1.4.2 GENERAL PRECAUTIONS FOR ASSEMBLY

(1) For assembly also, take the general precautions described in Section 34.2.1.3; DISASSEMBLY.
(2) For assembly, remove any metallic dust or foreign matter from all parts and make sure that the 34
parts are free of burrs and dents which should be ground off using an oilstone.
(3) Replace the O-rings, oil seals, and floating seals with new ones.
(4) Bonding adhesive is applied to the threaded portions and tapped holes of spindle (2) and carrier
(3) when assembling.
Remove their grease by using the tap (M8P1.25), and wash with solvent. After that, degrease
solvent of the holes by spraying with compressed air.
Replace hexagon head bolt (40) with new ones.
(5) Be careful not to damage the O-rings, oil seals, and floating seals at installation (Lightly apply
grease to them for smooth installation).
(6) Prior to assembly, apply clean hydraulic oil (NAS standards class 9 or higher) to movable and
sliding portions of hydraulic motor components and valves.
(7) Use no cloth gloves during assembly to prevent malfunctions due to textile lint.
(8) On completion of assembly, plug every opening to prevent the entry of dirt.
(9) Photos and figures of typical models are shown. Any partial difference between them and the
product in use does not affect the assembling procedure.
34.2.1.4.3 ASSEMBLING PROCEDURE
After replacing any of the following parts with new ones, adjust the preload of the ball bearing without
fail :
(1) Parts requiring preload adjustment of the ball bearing after their replacement : hub (1), the
spindle (2) and ball bearing (24)
When replacing any of the above parts, use the parts previously adjusted.
Otherwise, the travel motor may malfunction resulting in premature breakage.
34-69
(1) Assembling hub section

1. Place the hub (1) on the press workbench.
2. Insert the main bearing (24) in the hub
(1). Place the main bearing press fit jig on
the outer race of the main bearing (24).
Push down the jig by a press to press fit
the bearing into the hub (1).
3. Turn over the hub (1).
4. Press fit the main bearing (24) into the hub
(1) in the same way as the above item 2.
-Be careful not to mistake orientation of the
main bearing (24) when press fitting.
Inserting bearing (24)
5. Apply grease to the O-ring of the floating

seal (31). Build the floating seal into the
floating seal groove of the hub (1).
-Apply a small amount of grease to the
entire surface of the O-ring after removing
it from the floating seal.
-Place the FS inserting tool (I), the floating
seal and the FS inserting tool (II) in this
order, and press in until the FS inserting
tool (II) contacts with the FS inserting tool
(I). Remove the FS inserting tools and
ensure that the end surface of the hub is
Installing floating seal (31)
in alignment with the face of the floating
seal at an accuracy of 1mm (0.04") or less.
6. Attach two lifting eyes to the tapped holes

of the hub (1) in diagonal position.
7. Attach a wire with hooks to the lifting eyes,
lift the hub (1) by a crane and then install
the hub (1) on the workbench.
-While aligning the tapped hole in the hub
(1) with the fixing hole in the workbench,
carefully insert the hub (1) into the fixing
hole in the workbench.
8. Attach the hub (1) to the workbench by
tightening the socket bolts in diagonal Lifting hub (1)
position.
Installing hub (1) to the workbench
34-70
Fully tighten the socket bolts. Otherwise, the travel motor may fall down to cause injury when it is
turned over.
(2) Assembling spindle section

1. Apply grease to the O-ring of the floating
seal (31), and fit the floating seal in the 34
groove of the spindle (2).
-Place the FS inserting tool (III), the floating
seal and the FS inserting tool (II) in this
order, and press in until the FS inserting
tool (II) contacts with the FS inserting tool
(III).
Remove the FS inserting tools and ensure
that the end surface of the hub is in
alignment with the face of the floating seal Installing floating seal (31)
at an accuracy of 1mm (0.04") or less.
2. Attach two lifting eyes to the spindle (2) in

diagonal position.
3. Attach a wire with hooks to lifting eyes, lift
the spindle (2) by crane and then insert the
spindle (2) in the hub (1) slowly.
4. Fix the hub (1) and the spindle (2) with
fixing plate in diagonal position.
(Direct the reduction unit side upward.)
Inserting spindle (2)
6. Apply Loctite #638 to the thread part of

ring nut (22).
Then fasten the ring nut to the spindle with
the bearing preload adjuster.
Tightening torque :
392±39 N-m (289±29 lbf-ft)
Installing ring nut (22)
34-71
7. Tighten two hexagon socket set screws

(47).
Tightening torque :
4.9±1.0 N-m (3.7±0.7 lbf-ft)
8. After tightening up the screws, deform the
entrance of the threaded holes for avoiding
loosening screws.
Attaching hexagon set screw (47)

motor side upward.)
10. Remove the clamp plates from the
workbench.
Removing fixing plate
(3) Assembling motor inner parts of spindle

1. Press fit the oil seal (132) into the spindle
(2) using the oil seal press fit tool and a
hammer.
-Apply lithium grease to the lip of the oil
seal before installing.
-Be careful not to mistake the orientation of
the oil seal.
2. Insert two parallel pins (177) into the pin
holes of the spindle (2).
3. Apply lithium grease to the semi-spherical
surface of two pivots (167) and fit them to
the parallel pins (177) installed to the
Installing Oil seal (132)
spindle (2).
34-72
4. Apply grease to the spring pin (190) to

install to the piston kit consisting of piston
(161), shoe (162) and seal ring (163).
5. Apply grease to the sliding surface of the
piston assembly to install to the piston
hole of the spindle (2).
34
Installing piston kit
(4) Inserting shaft
Carefully carry out the insertion work using leather gloves to prevent possible burns.
1. Put the ball bearing (149) in a heating bath

to heat it at 100±10°C (212±18°F) for 10
minutes and then insert it onto the drive
shaft (102).
Inserting bearing (149)
2. Incline the travel motor by 90 degrees.

3. Insert the shaft (102) into the spindle (2).
-Insert the shaft (102) into the spindle (2)
slowly and carefully. Otherwise the lip of
the oil seal (132) fitted inside the spindle
(2) may be damaged. Damage to the lip
may cause oil leakage, leading to
premature failure of the travel motor.
Inserting shaft
34-73
4. Install the swash plate (103) into the

spindle (2).
-Apply grease to an interface between the
swash plate (103) and the spindle (2).
-Align two pivots (167) installed in the
spindle (2) with the pivot mounting holes
of the swash plate to fit the swash plate
(103) into the spindle (2).
Installing swash plate (103)
(5) Installing cylinder block

1. Place the washer (110), spring (114),
washer (110), and snap ring (145) in this
order, into the cylinder block (104).
-Direct the sharp edge side of the snap
ring (145) toward the inlet side.
-Direct the sharp edge side of the washer
(110) contacting the snap ring (145)
toward the snap ring (145) side.
2. Place the cylinder block (104) on the press Assembling cylinder block
bench.
When mounting the snap ring, if the tip of the pliers slips out of the hole of the snap ring, the snap
ring could jump out.
3. Place the retainer metal (I) against the

washer (110). While holding down the
retainer metal (I) by press, fit the snap
ring (145) into the snap ring groove of the
cylinder block (104) with a snap ring plier.
-Pressing force of the spring (114) is more
than 1180 N-m (265 lbf).
-Cover the cylinder block (104) with a
vinyl sheet to prevent damage to the
contact plane between the cylinder block
(104) and the timing plate (109). Installing snap ring (145)
34-74
(6) Assembling hydraulic motor section

1. Put three rollers (151) into the holes of
the cylinder block (104).
2. Place the thrust ball (108) on the cylinder
block (104).
34
Installing rollers (151)
3. Fit nine piston assemblies to the retainer

plate (107).
-After assembling, immerse the whole unit
in hydraulic oil.
4. Fit the retainer plate (107) and the nine
piston assemblies to the cylinder block
(104).
-Carefully match the retainer plate (107)
with the spherical part of the thrust ball
(108) for installation.
Assembling piston assembly into retainer

plate (107)
5. Insert the cylinder block (104) onto the

drive shaft (102).
-For installation, align the spline hole in
the cylinder block (104) with the spline
shaft of the drive shaft (102).
6. After installing the cylinder block, turn it by
hand to make sure that it fits properly. If
not, inspect it.
-Do not take up the cylinder block (104).
Otherwise the thrust balls (108) may come
off, leading to abnormality in rotation.
Inserting cylinder block (104)
34-75
(7) Installing parking brake

・ Prior to installing, immerse the friction plate (115) in hydraulic oil.
1. Incline the workbench by 90 degrees.

2. Assemble one friction plate (115) and two
separator plates (116) into the cylinder
block (104) alternately one by one.
3. Lightly coat the O-rings (135) and (139)
with grease and install them into the
O-ring grooves of the piston (112).
Installing friction plates (115) and separator

plates (116)
4. Install the piston (112) into the spindle (2).

-If it is hard to fit the piston (112) into the
spindle (2) due to the resistance of the
O-rings (135) and (139), lightly tap the
end face of the piston (112) with a plastic
hammer.
-Take care not to damage the O-rings
when installing the piston (112).
Installing piston (112)
(8) Assembling brake valve parts inside rear flange

1. Fit two O-rings (237) to two plugs (226).
-Coat the O-rings (237) with grease.
2. Install the valve (227) and spring (230) onto
the plug (226), applying grease to them so
as to connect all of them by adhesion of
grease.
3. Insert the plug (226) with the valve (227)
and spring (230) assembled in one piece,
into the rear flange (201).
Inserting plug (226)
34-76
・ For insertion of the plug (226), place the

rear flange (201) on the workbench, facing
the tapped hole for plug mounting of the
rear flange (201) upward and align the
center of tapped hole with the plug center.
This is intended to prevent the O-ring from
being damaged and spring (230) from
coming out of valve (227) due to contact
between the bore of the rear flange and 34
the valve.
Temporarily tightening plug (226)
4. After installing two plugs (226) to the rear

flange (201), temporarily tighten them
using an Allen wrench.
5. Insert the spool (223) into the rear flange
(201).
-Apply hydraulic oil to the spool and insert
the spool into the rear flange.
-To install the spool, align the hole of the
rear flange with the spool shaft center so
as to prevent the inner surface of the rear
flange and the outer surface of the spool
Inserting spool (223)
from being damaged due to interference.
-Otherwise internal leaks will occur after
reassembly, resulting in performance
deterioration of the travel motor.
6. Install the O-ring (236) to the plug (224).

-Apply grease to O-ring (236).
7. Install the spring retainer (225) and spring
(228) into the plug (224).
-When tighten the plugs into the rear
flange, insert carefully so as not to deform
the spring.
8. Tighten two plugs (224) into the rear flange
(201).
Installing O-ring (236)
34-77
9. Temporarily tighten two plugs (224) to the

rear flange (201) with a wrench.
Temporarily tightening plug (224)
(9) Assembling rear flange fittings

1. Installing two-speed switching spool inside
rear flange.
a.
Insert the spring (266) and the spool (263)
into the rear flange (201).
b.
Fix the O-ring (273) to the plug (221).
-Apply grease to the O-ring (273).
c.
Tighten the plug (221) into the rear flange
(201).
Inserting spool (263)
d.
Tighten the plug (221) in the rear flange
(201) at the specified torque with a
hexagonal wrench key.
Tightening torque : 59±9.8 N-m (43±7 lbf-ft)
2. Coat the ball bearing (150) with hydraulic

oil and fit it to the rear flange (201).
3. Put two the parallel pins (241) into the pin
holes in the rear flange (201).
4. Apply grease to the mating face of the
timing plate (109) in contact with the rear
flange (201).
Installing bearing (150)
34-78
5. Install the timing plate (109) into the rear

flange (201), using the parallel pin (241)
as a guide.
-Install the timing plate (109) until it comes
in close contact with the rear flange (201).
This close contact prevents the timing
plate (109) from falling out of the rear
flange (201) when the rear flange (201) is
installed into the spindle (2). 34
6. Install eight springs (113) into the rear
flange (201).
Installing timing plate (109)
-Sufficiently coat the springs (113) with
grease and fix them so as not to allow
them to drop from the rear flange (201).
(10) Connecting rear flange with the spindle

1. Insert the O-rings (43) and (44) into the
O-ring groove of the spindle (2).
-Fit the O-rings (43) without applying
grease. Otherwise grease may ooze out of
the contact face between the rear flange
(201) and the spindle (2) as if oil leakage
occurred.
Installing O-rings (43) and (44)
2. Fix two the parallel pins (42) to the spindle

(2).
3. Fill 0.3 L (0.08 gal) of hydraulic oil into
the spindle (2).
Installing parallel pin (42)
34-79
4. Align two parallel pins (42) set in the

spindle (2) with the pin holes of the rear
flange and install the rear flange (201) into
the spindle (2).
Installing rear flange (201)
5. Screw six hexagonal bolts (243) into the

spindle (2) and tighten them at the
specified torque.
Tightening torque :
29.4±4.9 N-m (22±4 lbf-ft)
Tightening socket bolts (243)
6. Tighten the plug (226) at the specified

torque.
Tightening torque :
78.5±9.8 N-m (58±7 lbf-ft)
Tightening plug (226)
7. Tighten the plug (224) at the specified

torque.
Tightening torque :
196±14.7 N-m (145±11 lbf-ft)
Tightening plug (224)
34-80
(11) Installing carrier assembly

1. Insert three thrust washers (9), three
bearing inner races (29), three needle
roller bearings with cage (27) and three
planetary gears 1 (5) in this order into the
column section of the carrier (3).
34
Installing planetary gear 1 (5)
If the tapped hole of carrier (3) is smeared oil or grease, degrease it by using the tap (M8 P1.25).
After that clean it with solvent, and degrease the solvent of the holes by spraying with compressed air.
Otherwise axial-force dose not produce enough, and it may cause bolt to loosen.
2. Tighten three hexagon head screws (40)

with three thrust washers 3 (12) to fasten
the carrier assembly to the column section
of the carrier to the specified torque.
Tightening torque :
33.3±4.9 N-m (25±4 lbf-ft)
[Carrier assembly finished]
Tightening hexagon head screw (40)
34-81
(12) Tightening planetary gear 2

reduction unit side upward.)
2. Install the thrust washer 1 (9) to the
spindle (2).
3. Insert four thrust collars 4 (11) and four
inner races (30) into the column section of
the spindle (2).
4. Insert four needle roller bearings with
retainer (28) into the column section of the
spindle (2).
5. Make four planetary gears 2 (7) intermesh
Installing planetary gear 2
with the internal teeth of the hub (1) to
insert them into the column section of the
spindle (2).
-If the tapped hole of spindle (2) is
smeared oil or grease, degrease it by using
the tap (M8 P1.25).
After that clean it with slovent, and
degrease the solvent of the holes by
spraying with compressed air.
Otherwise axial-force does not produce
enough, and it may cause bolt to loosen.
6. Tighten four thrust washers 3 (12) into the

column sections of the spindle (2) with
four hexagon screws (40) at the specified
torque.
Tightening torque :
33.3±4.9 N-m (25±4 lbf-ft)
Tightening hexagon head screw (40)
(13) Installing sun gear 2

1. Install the coupling (14) to the shaft (102).
2. Make the sun gear 2 (6) mesh with the
planetary gear 2 (7) to install.
Installing sun gear (102)
34-82
(14) Installing carrier assembly

1. Install the carrier assembly assembled in
Item (11) while making it intermesh with the
sun gear 2 (6) and the internal teeth of the
hub (1).
34
Installing carrier assembly
(15) Installing sun gear 1

1. Insert the sun gear 1 (4) into the coupling
(14). Assemble the steel balls (41) into the
sun gear 1 (4) in advance.
-Apply grease to the steel balls (41) to
prevent them from dropping before
assembling them into the sun gear 1 (4).
2. Install the sun gear 1 (4) while making it
mesh with three planetary gears 1 (5).
Installing sun gear 1 (4)
(16) Installing cover

1. Supply 0.9 liters (0.24 gal) of lubricating
oil to the hub (1).
-Apply grease to the O-ring (35)
2. Fit the O-ring (35) into the O-ring groove of
the hub (1).
3. Install the cover (13) to the hub (1).
-When it is difficult to fit the cover (139)
into the hub (1), tap the periphery of the
cover (13) lightly and uniformly with a
plastic hammer. Otherwise the O-ring (35)
may be damaged to cause oil leakage.
Supplying lubricating oil
Lubricating oil may also gush out through
the thread hole.
34-83
4. Fit the ring (45) into the ring groove of

the hub (1).
-Avoid the position in which the mating port
of the ring (45) faces the notch of the hub
(1).
5. Install the O-rings (37) to two plugs (33)
and (39).
-Apply grease to the O-ring (37) lightly.
6. Tighten the plugs (33) and (39) into the
cover (13) to the specified torque.
Tightening torque :
Installing cover (13)
58.8±9.8 N-m (43±7 lbf-ft)
(17) Removing travel motor

motor side upward.)
2. Remove the travel motor mounting screws
from the workbench.
3. Screw two eyebolts into the thread holes of
the spindle (2).
-Arrange the two eyebolts in the diagonal
position.
4. Hook the wire rope with hook to the
eyebolts to remove the travel motor from
the workbench using a crane.
Removing travel motor
34-84

After disassembling GM motor, follow these standards to perform maintenance. Handle every part with
care and, in particular, avoid damaging the moving and sliding portions.
(1) Replace any seal (O-ring, oil seal, and floating seal) once used even if no damage is found.
(2) Wear parts maintenance standard
1. Replace any part heavily damaged visually.
2. Replace a part that shows the following abnormalities.
34
Standard value
Item Allowable
Part name Phenomenon (Standard
No. value(Criteria)
dimension)
-Severe visual damage

(1) Hub -Pitting recognized on ring gear tooth flank - -
-Abnormal wear such as galling
-Severe visual damage
(2) Spindle - -
-Abnormal wear such as galling.
(3)
Carrier assembly -Abnormal wear such as galling - -
etc.
(4) Sun gear1 -Pitting recognized on tooth flank
(6) Sun gear2 -Flaking recognized on bearing rolling surface
- -
(5) Planetary gear1
(7) Planetary gear 2
(9) Thrust washer 1 -Sliding surface discolored and/or abnormally
(11) Thrust collar 4 worn - -
(12) Thrust washer 3
-Dent recognized
(24) Main bearing -Flaking recognized - -
-Uneven wear recognized
(27) -Pitting recognized on roller
Needle roller bearing - -
(28) -Abnormal wear on cage end surface
(29)
Bearing inner race -Flaking recognized on bearing rolling surface - -
(30)
-Scratch recognized on valve (263) sliding
(201) Rear flange - -
surface
-Oil seal (132) contacting surface worn
(102) Shaft - -
-Spline worn
(103) Swash plate -Seizure is recognized - -
-Spline worn
-Bore severely worn
(104) Cylinder block - -
-Scratch and uneven wear recognized on
timing plate (109) sliding surface
Piston assembly -Clearance exists between piston (105) and
Clearance Clearance
(105) Piston shoe (106)
0.05 mm 0.15 mm
(106) Shoe -Abnormal and uneven wear recognized on
(0.002") (0.006")
shoe surface
-Uneven wear recognized on shoe (106) sliding
surface
(107) Retainer plate - -
-Scratch and uneven wear recognized on
thrust ball (108) sliding surface
34-85
Standard value
Item Allowable
Part name Phenomenon (Standard
No. value(Criteria)
dimension)
-Uneven wear recognized on retainer plate

(108) Thrust ball - -
(107) sliding spherical surface
-Seizure and uneven wear recognized on
(109) Timing plate
sliding surface
(115) Friction plate -Uneven wear recognized on both end surfaces Braking torque Braking torque
(116) Mating plate -Specified torque nor attained 64.7 N-m 64.7 N-m
-Seizure recognized (47.7 lbf-ft) (47.7 lbf-ft)
(105) Piston -Scratch recognized on periphery - -
-Dent recognized
(149)
Ball bearing -Flaking recognized - -
(150)
-Wear recognized
Two-speed piston kit -Abnormal wear recognized on periphery
(161) Piston -Abnormal and/or uneven wear recognized on
- -
(162) Shoe shoe surface
(163) Seal ring -Abnormal wear recognized on Seal ring
(223) -Uneven wear recognized on periphery
Spool - -
(263) -Scratch recognized on periphery
34-86
34.2.1.6 Performance verification test

・ After finishing maintenance of the GM motor, carry out performance verification tests according to
the procedures below :
(1) Measuring instruments to be used

1 Pressure gauge for 35 kgf/cm2 (500 psi) 2
2 Measuring cylinder (for 5 liters) (1.32 gal) 1
3 Stop watch 1
34
(2) Test procedure
34-87
34-88
［42. TROUBLESHOOTING (HYDRAULIC SYSTEM)］
42. TROUBLE SHOOTING

42
(HYDRAULIC SYSTEM)
TABLE OF CONTENTS
42.1 GENERAL PRECAUTIONS ……………………………………………………………………………………42-3

42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE …………………………………………42-3
42.2 TROUBLE DIAGNOSIS : HYDRAULIC ……………………………………………………………………42-5
42.3 TROUBLESHOOTING …………………………………………………………………………………………42-6
42.3.1 ATTACHMENT ……………………………………………………………………………………………42-6
42.3.2 TRAVEL OPERATION ……………………………………………………………………………………42-8
42.3.3 SLEWING OPERATION …………………………………………………………………………………42-10
42.3.4 PUMP ………………………………………………………………………………………………………42-11
42-1

S5PS4201E01
First Edition September, 2010 SK55SRX : PS02-00101~
(KCM North America)
CX55BMSR : PS02-00101~
(CASE-NA)
E55BX : PS02-00101~
(NH-NA)

(KOR)
January, 2011 SK50P : PS02-00101~

(SE Asia)
42-2
42.1 GENERAL PRECAUTIONS
Troubleshooting provides the process to investigate the cause of trouble in order when a trouble
occurred. This manual describes the way how to solve the specific phenomenon systematically as
quick as possible. For the troubleshooting concerning the inside of equipment, refer to the
troubleshooting for each manual of the equipment.
42
42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE
(1) Get to the site as quickly as possible.
Verify the machine model, serial number,
situation of trouble and field, and notify possible
arrival time to the user.
Make field investigation
(2) Verify background of trouble occurred.

1. Model name and serial number.
2. Kind of attachment.
Check that the combination of attachments
was proper and that the operating manner
was not unreasonable.
3. Operating time on the hour-meter.
4. Record of troubles.
First trouble or repeated trouble.
5. History of the trouble and additional
modifications.
Reoccurrence of the same trouble in the Verifying background of trouble occurred.
past or trouble due to additional
modification.
(3) How to diagnose trouble

1. Verify defective part.
2. Reproduce the troubled conditions.
3. Where the defective part can not be
verified, surmise the possible causes
systematically.
4. Verify the surmised cause.
5. Report estimated repairing method,
procedures and term to the user. Diagnosing trouble by means troubleshooting.
42-3
(4) Explanation of the cause of trouble

1. Explain the cause of trouble to the user.
For example, explain the oil leakage through the piston is caused by defect on the piston rod.
And the proper operating manner of the machine should be explained to the user to prevent
reoccurrence of the same kind of trouble.
2. Handling of damaged parts
The damaged parts to be claimed and returned are the evidence, so they should be handled with
care. For example, protect them from invasion of water, soil, etc., into ports on a hydraulic
equipment, etc., at the returning them. And also use care not to give any damages and breakage
for transport.
42-4
42.2 TROUBLE DIAGNOSIS : HYDRAULIC
42
Abbreviation
E/G : Engine
SOL : Solenoid
SW : Switch
ATT : Attachment
C/V : Control valve
R/V : Relief valve
V : Valve
42-5
42.3 TROUBLESHOOTING
42.3.1 ATTACHMENT
42.3.1.1 ATTACHMENT OPERATIONAL FAILURE (Excluding swing operations)
42.3.1.2 ATTACHMNT SPEED IS SLOW
42-6
42.3.1.3 ATTACHMENT OPERATING POWER IS LOW
42
42.3.1.4 MALFUNCTION OF ATTACHMENT
42-7
42.3.2 TRAVEL OPERATION

42.3.2.1 TRAVEL OPERATIONAL FAILURE
42.3.2.2 TRAVEL SPEED IS SLOW
42-8
42.3.2.3 TRAVEL POWER IS LOW
42
42.3.2.4 IT DEVIATES IN TRAVEL INDEPENDENT OPERATION
42-9
42.3.3 SLEWING OPERATION

42.3.3.1 SLEWING OPERATIONAL FAILURE
42.3.3.2 SLEWING SPEED IS SLOW
42.3.3.3 SLEWING POWER IS LOW
42-10
42.3.3.4 MALFUNCTION OF SLEWING OPERATION
42
42.3.4 PUMP
42.3.4.1 ENGINE SPEED IS REDUCED DUE TO PUMP LOAD
42.3.4.2 MALFUNCTION OF PUMP
42-11
42-12
［43. TROUBLESHOOTING (ELECTRICAL SYSTEM)］
43. TROUBLESHOOTING
(ELECTRICAL SYSTEM)
TABLE OF CONTENTS
43
43.1 TROUBLE DIAGNOSIS : ELECTRIC SYSTEM ……………………………………………………………43-3
43.2.1 GENERAL …………………………………………………………………………………………………43-4
43.2.2 ATTACHMENT OPERATION ……………………………………………………………………………43-8
43.2.3 TRAVEL OPERATION ……………………………………………………………………………………43-9
43.2.4 DECELERATION …………………………………………………………………………………………43-10
43-1

S5PS4301E01
First Edition September, 2010 SK55SRX : PS02-00101~
(KCM North America)
CX55BMSR : PS02-00101~
(CASE-NA)
E55BX : PS02-00101~
(NH-NA)

(KOR)
January, 2011 SK50P : PS02-00101~

(SE Asia)
43-2
43.1 TROUBLE DIAGNOSIS : ELECTRIC SYSTEM
43
43-3
43.2.1 GENERAL
43.2.1.1 ENGINE DOES NOT START.
43-4
43
43-5
43.2.1.2 HORN DOES NOT SOUND.
43.2.1.3 WORKING LIGHT DOES NOT LIGHT UP.
43-6
43.2.1.4 HOURMETER DOES NOT ACTUATE.
43
43.2.1.5 FUEL GAUGE DOES NOT ACTUATE.
43.2.1.6 WATER TEMPERATURE METER DOES NOT ACTUATE.
43-7
43.2.2 ATTACHMENT OPERATION

43.2.2.1 ALL CONTROLS DO NOT FUNCTION
43-8
43.2.3 TRAVEL OPERATION

43.2.3.1 TRAVEL 1 & 2 SPEED CHANGE CAN NOT BE CARRIED OUT.
43
43-9
43.2.4 DECELERATION
43.2.4.1 DECEL CHANGE OPERATION CAN NOT BE CARRIED OUT.
43-10
［44. TROUBLESHOOTING (ENGINE)］
44. TROUBLESHOOTING
(ENGINE)
TABLE OF CONTENTS
44.1 TROUBLE DIAGNOSIS : ENGINE …………………………………………………………………………44-3

44.2.1 STARTING TROUBLE ……………………………………………………………………………………44-6
44.2.2 E/G ROTATION TROUBLE ………………………………………………………………………………44-8
44.2.3 OUTPUT DROPS DOWN ………………………………………………………………………………44-9
44.2.4 OTHER TROUBLE…………………………………………………………………………………………44-10
44
Book Code No. S5PW4431E02
44-1

SK30SR-5 : PW14- S5PW4431E01
First Edition March, 2010
SK35SR-5 : PX15- (KCM North America)
SK30SR-5 : PW14-46519~ S5PW4431E02
Revision June, 2010
SK35SR-5 : PX15-21105~ (KCM North America)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-NA)
SK50SR-5 : PJ06-09807~
(KCM North America)
CX50B : PJ06-09807~
(CASE-NA)
E50B : PJ06-09807~
(NH-NA)
SK30SR-5 : PW14-46519~
CX31B : PW14-46519~
E30B : PW14-46519~
E35B : PX15-21105~ (NH-AUS)
SK40SR-5 : PH07-06609~
E50B : PJ06-09807~
(NH-AUS)
CX50B : PJ06-09807~
(CASE-AUS)
SK27SR-5 : PV13-33453~
(NA)
CX27B : PV13-33453~
(CASE-NA)
E27B : PV13-33453~
(NH-NA)
SK20SR-5 : PM10-10609~
CX27B : PV13-33453~
(CASE-Australia)
E27B : PV13-33453~
(NH-AUS)

(KCM North America)
CX55BMSR : PS02-00101~
(CASE-NA)
E55BX : PS02-00101~
(NH-NA)

(KOR)
January, 2011 SK50P : PS02-00101~

(SE Asia)
44-2
44.1 TROUBLE DIAGNOSIS : ENGINE
44
44-3
44-4
44
44-5
44.2.1 STARTING TROUBLE

44.2.1.1 STARTER DOES NOT ROTATE
44-6
44.2.1.2 STARTER ROTATES BUT HARD TO START
44
44-7
44.2.2 E/G ROTATION TROUBLE
44-8
44.2.3 OUTPUT DROPS DOWN

44.2.3.1 ENGINE OUTPUT NOT ENOUGH
44
44.2.3.2 KNOCKING AT HIGH TEMPERATURE
44-9
44.2.4 OTHER TROUBLE

44.2.4.1 EXHAUST TROUBLE
A breather mechanism of blow-by gas reduction system is applied to the engine as shown in the
drawing. Remove and plug the suction manifold to check blow-by gas.
44-10
44.2.4.2 EXCESSIVE OIL CONSUMPTION
44.2.4.3 EXCESSIVE FUEL CONSUMPTION
44
44.2.4.4 ENGINE NOT STOP WHEN KEY TURNED OFF
44-11
44-12
［51. ENGINE］
51. ENGINE
PREFACE
51
This manual explains the engine proper and is a faithful of YANMAR DIESEL ENGINE'S service
manuals.
Book Code No. S5PW5131E02
51-1
［51. ENGINE］

SK30SR-5 : PW14- S5PW5131E01
First Edition March, 2010
SK35SR-5 : PX15- (KCM North America)
SK30SR-5 : PW14-
April, 2010
SK35SR-5 : PX15- (KCM S.E.ASIA&OCE)
CX31B : PW14-
CX36B : PX15- (CASE-AUS)
E30B : PW14-
E35B : PX15- (NH-AUS)
SK40SR-5 : PH07-
May, 2010
SK50SR-5 : PJ06- (KCM S.E.ASIA&OCE)
E50B : PJ06-
(NH-AUS)
CX50B : PJ06-
(CASE-AUS)
SK30SR-5 : PW14-46519~ S5PW5131E02
Revision June, 2010
SK35SR-5 : PX15-21105~ (KCM North America)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-NA)
SK50SR-5 : PJ06-09807~
(KCM North America)
CX50B : PJ06-09807~
(CASE-NA)
E50B : PJ06-09807~
(NH-NA)
SK30SR-5 : PW14-46519~
CX31B : PW14-46519~
E30B : PW14-46519~
E35B : PX15-21105~ (NH-AUS)
SK40SR-5 : PH07-06609~
E50B : PJ06-09807~
(NH-AUS)
CX50B : PJ06-09807~
(CASE-AUS)

(KCM North America)
CX55BMSR : PS02-00101~
(CASE-NA)
E55BX : PS02-00101~
(NH-NA)

(KOR)
January, 2011 SK50P : PS02-00101~

(SE Asia)
51-2
TNV DI Service Manual
TNV series
SERVICE MANUAL
3TNV82A(-B) • 3TNV84 • 3TNV84T(-B) •
3TNV88(-B)(-U)
4TNV84 • 4TNV84T(-Z) •
4TNV88(-B)(-U)
4TNV94L
4TNV98(-Z)(-E) • 4TNV98T(-Z)
4TNV106 • 4TNV106T
P/N: 0BTNV-G00101
INDUSTRIAL
ENGINES
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in
mind and may not contain the necessary detail or safety statements that may be required for a non-
professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar
repair or service professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and /
or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems -
without the written permission of Yanmar Co., Ltd.
© 2005 Yanmar Co. Ltd.
ii TNV DI Service Manual

Section 1
TABLE OF
CONTENTS
Page
Table of Contents ................................................................................... iii
Introduction ......................................................................................... 1-1
Yanmar Warranties.............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Engine .................................................................................................. 6-1
Periodic Maintenance ......................................................................... 5-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Turbocharger ..................................................................................... 10-1
Starter Motor...................................................................................... 11-1
Alternator ........................................................................................... 12-1
Electric Wiring ................................................................................... 13-1
Troubleshooting ................................................................................ 14-1
TNV DI Service Manual iii

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

Section 1
INTRODUCTION
This Service Manual describes the service
procedures for the TNV series direct injection
engines. These engines are certified by the U.S.
EPA, California ARB and/or the 97/68/EC Directive
for industrial use.
Please use this manual for accurate, quick and safe
servicing of the engine. Since the directions in this
manual are for a typical engine, some
specifications and components may be different
from your engine. Refer to the documentation
supplied by the optional equipment manufacturer
for specific service instructions.
Yanmar products are continuously undergoing
improvement. This Service Manual might not
address possible field modifications to the
equipment. Contact an authorized Yanmar
industrial engine dealer or distributor for answers to
any questions relating to field modifications.
TNV DI Service Manual 1-1

INTRODUCTION
1-2 TNV DI Service Manual

Section 2
YANMAR
WARRANTIES
Page
Yanmar Limited Warranty................................................................ 2-3
What is Covered by this Warranty? .......................................... 2-3
How Long is the Warranty Period? ........................................... 2-3
What the Engine Owner Must Do: ............................................ 2-3
To Locate an Authorized Yanmar Industrial Engine
Dealer or Distributor: ................................................................. 2-4
What Yanmar Will Do: ............................................................... 2-4
What is Not Covered by this Warranty? ................................... 2-4
Warranty Limitations: ................................................................ 2-5
Warranty Modifications: ............................................................ 2-5
Questions: ................................................................................. 2-5
Retail Purchaser Registration.................................................... 2-5
Emission System Warranty ............................................................. 2-6
Yanmar Co., Ltd. Limited Emission Control System
Warranty - USA Only....................................................................... 2-6
Your Warranty Rights and Obligations: ..................................... 2-6
Manufacturer’s Warranty Period:............................................... 2-6
Warranty Coverage: .................................................................. 2-7
Warranted Parts: ....................................................................... 2-7
Exclusions: ................................................................................ 2-8
Owner’s Warranty Responsibilities:........................................... 2-8

YANMAR WARRANTIES

Yanmar Limited Warranty YANMAR WARRANTIES
YANMAR LIMITED WARRANTY

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

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

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

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

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

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

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

Yanmar Limited Warranty YANMAR WARRANTIES
Yanmar Limited Warranty - Continued
Warranty Limitations:
The foregoing is Yanmar’s only obligation to you and your exclusive remedy for breach of warranty.
Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all
claims for damages and other relief. In no event shall Yanmar or any authorized industrial engine
dealer or distributor be liable for incidental, special or consequential damages. Such consequential
damages may include, but not be limited to, loss of revenue, loan payments, cost of rental of substitute
equipment, insurance coverage, storage, lodging, transportation, fuel, mileage, and telephone costs. The
limitations in this Warranty apply regardless of whether your claims are based on breach of contract, tort
(including negligence and strict liability) or any other theory. Any action arising hereunder must be brought
within one (1) year after the cause of action accrues or it shall be barred. Some states and countries do not
allow certain limitations on warranties or for breach of warranties. This Warranty gives you specific legal
rights, and you may also have other rights which vary from state to state and country to country.
Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law.
Warranty Modifications:
Except as modified in writing and signed by the parties, this Warranty is and shall remain the complete and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
Yanmar, either orally or in writing.
Questions:
If you have any questions or concerns regarding this Warranty, please call or write to the nearest
authorized Yanmar industrial engine dealer or distributor or other authorized facility.
Retail Purchaser Registration
It is very important for the original retail purchaser to register the Yanmar product. Registration enables
Yanmar to provide the best support for your Yanmar product.
At the time of purchase, Yanmar highly recommends registering the retail purchaser’s information through
the website http://www.yanmar.co.jp as soon as possible.
If it is not possible to access the website, please contact the nearest authorized Yanmar industrial engine
dealer or distributor.

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

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

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

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

Emission System Warranty YANMAR WARRANTIES
Limited Emission Control System Warranty - USA Only - Continued
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair
or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or
distributor.
Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be
warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in
the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, Yanmar is liable for damages to other engine components caused by the failure
of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Add-
on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Electronic Control System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• EGR System
• Positive Crankcase Ventilation System
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.

YANMAR WARRANTIES Emission System Warranty
Limited Emission Control System Warranty - USA Only - Continued
Exclusions:
Failures other than those arising from defects in material and / or workmanship are not covered by this
warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental
or consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or
commercial loss.
Owner’s Warranty Responsibilities:

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

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

SAFETY

Safety Statements SAFETY
SAFETY STATEMENTS
A CAUTION
Yanmar is concerned for your safety and your Caution (the word “CAUTION” is in black
machine’s condition. Safety statements are one of letters with a yellow rectangle behind it)
the primary ways to call your attention to the – indicates a potentially hazardous
potential hazards associated with Yanmar TNV situation which, if not avoided, may
engine operation. Follow the precautions listed result in minor or moderate injury.
throughout the manual before operation, during
0000001en
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the CAUTION
labels from becoming dirty or torn and replace Caution without the safety alert symbol
them if they are lost or damaged. Also, if you need indicates a potentially hazardous
to replace a part that has a label attached to it, situation that can cause damage to the
make sure you order the new part and label at the machine, personal property and / or the
same time. environment or cause the machine to
operate improperly.
This safety alert symbol appears 0000001en
A
with most safety statements. It
means attention, become alert,
your safety is involved! Please read
and abide by the message that
follows the safety alert symbol.
A DANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind
it) - indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en
A WARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en

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

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

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

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

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• If the unit has an electric fuel pump, • Only fill the fuel tank with diesel fuel.
when you prime the fuel system, turn Filling the fuel tank with gasoline may
the key switch to the ON position for result in a fire and will damage the
10 to 15 seconds to allow the electric engine.
fuel pump to prime the system.
• NEVER refuel with the engine running.
• If the unit has a mechanical fuel pump,
when you prime the fuel system, • Wipe up all spills immediately.
operate the fuel priming lever of the • Keep sparks, open flames or any other
mechanical fuel pump several times form of ignition (match, cigarette,
until the fuel filter cup is filled with static electric source) well away when
fuel. refueling.
• Failure to comply will result in death or • NEVER overfill the fuel tank.
serious injury. • Fill the fuel tank. Store any containers
0000010en
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
serious injury.
0000005en

A DANGER A DANGER

• Diesel fuel is flammable and explosive CRUSH HAZARD!
under certain conditions. • When you need to transport an engine
for repair, have a helper assist you to
• Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose • NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. • Failure to comply will result in death or
• NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en
dried grass close to the engine during

engine operation or shortly after
shutdown.
A DANGER
serious injury.
0000014en

• Before you operate the engine, check
for fuel leaks. Replace rubberized fuel
hoses every two years or every 2000
hours of engine operation, whichever
comes first, even if the engine has
been out of service. Rubberized fuel
lines tend to dry out and become
brittle after two years or 2000 hours of
engine operation, whichever comes
first.
serious injury.
0000015en

A DANGER A DANGER

EXPLOSION HAZARD! • Diesel fuel is flammable and explosive
• NEVER check the remaining battery under certain conditions.
charge by shorting out the terminals.
• NEVER use diesel fuel as a cleaning
This will result in a spark and may
agent.
cause an explosion or fire. Use a
hydrometer to check the remaining • Failure to comply will result in death or
battery charge. serious injury.
0000012en
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
serious injury.
0000007en
A DANGER

• NEVER remove the fuel cap with the
engine running.
serious injury.
0000011en

A WARNING A WARNING
SEVER HAZARD! EXHAUST HAZARD!

• Keep hands and other body parts • NEVER operate the engine in an
away from moving / rotating parts enclosed area such as a garage,
such as the cooling fan, flywheel or tunnel, underground room, manhole or
PTO shaft. ship’s hold without proper ventilation.
• Wear tight-fitting clothing and keep • NEVER block windows, vents, or other
your hair short or tie it back while the means of ventilation if the engine is
engine is running. operating in an enclosed area. All
• Remove all jewelry before you operate internal combustion engines create
or service the machine. carbon monoxide gas during
operation. Accumulation of this gas
• NEVER start the engine in gear. within an enclosure could cause
Sudden movement of the engine illness or even death.
and / or machine could cause death or
serious personal injury. • Make sure that all connections are
tightened to specifications after repair
• NEVER operate the engine without the is made to the exhaust system.
guards in place.
• Failure to comply could result in death
• Before you start the engine make sure or serious injury.
that all bystanders are clear of the 0000003en
area.
• Keep children and pets away while the
engine is operating.
A WARNING
• Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
• Failure to comply could result in death ALCOHOL AND DRUG HAZARD!
or serious injury.
0000002en
• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
or serious injury.
0000004en

A WARNING A WARNING
BURN HAZARD!
EXPOSURE HAZARD! • If you must drain the engine oil while it
is still hot, stay clear of the hot engine
• Wear personal protective equipment
oil to avoid being burned.
such as gloves, work shoes, eye and
hearing protection as required by the • ALWAYS wear eye protection.
task at hand. • Failure to comply could result in death
• NEVER wear jewelry, unbuttoned or serious injury.
cuffs, ties or loose-fitting clothing 0000011en
when you are working near

moving / rotating parts such as the
cooling fan, flywheel or PTO shaft.
A WARNING
• ALWAYS tie back long hair when you
are working near moving / rotating
parts such as a cooling fan, flywheel,
or PTO shaft.
• NEVER operate the engine while BURN HAZARD!
wearing a headset to listen to music or • Batteries contain sulfuric acid. NEVER
radio because it will be difficult to hear allow battery fluid to come in contact
the alert signals. with clothing, skin or eyes. Severe
• Failure to comply could result in death burns could result. ALWAYS wear
or serious injury. safety goggles and protective clothing
0000005en
when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area
with a large amount of clean water and
obtain prompt medical treatment.
or serious injury.
0000007en

A WARNING A WARNING
HIGH-PRESSURE HAZARD! ENTANGLEMENT HAZARD!

• Avoid skin contact with the • Stop the engine before you begin to
high-pressure diesel fuel spray caused service it.
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel • NEVER leave the key in the key switch
can penetrate your skin and result in when you are servicing the engine.
serious injury. If you are exposed to Someone may accidentally start the
high-pressure fuel spray, obtain engine and not realize you are
prompt medical treatment. servicing it. This could result in a
serious injury.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood • If you must service the engine while it
or cardboard. Have your authorized is operating, remove all jewelry, tie
Yanmar industrial engine dealer or back long hair, and keep your hands,
distributor repair the damage. other body parts and clothing away
from moving / rotating parts.
or serious injury. • Failure to comply could result in death
0000008en
or serious injury.
0000010en
A WARNING
A WARNING
SHOCK HAZARD! BURN HAZARD!

• Turn off the battery switch (if • Wait until the engine cools before you
equipped) or disconnect the negative drain the engine coolant. Hot engine
battery cable before servicing the coolant may splash and burn you.
electrical system.
• Check the electrical harnesses for or serious injury.
cracks, abrasions, and damaged or 0000016en
corroded connectors. ALWAYS keep
the connectors and terminals clean.
or serious injury.
0000009en

A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
FUME / BURN HAZARD!
• Failure to comply could result in death • Always read and follow safety related
or serious injury. precautions found on containers of
0000006en
hazardous substances like parts
cleaners, primers, sealants and
A WARNING sealant removers.
or serious injury.
0000014en
BURN HAZARD! A WARNING

Never apply over 40 psi (2.8 kgf/cm) to
• Keep your hands and other body parts
the waste gate actuator.
away from hot engine surfaces such
0000026en
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly A WARNING
after you shut the engine down. These • Never inject fuel toward you. Since the
surfaces are extremely hot while the fuel is injected at high pressure from
engine is operating and could the nozzle, it may penetrate the skin,
seriously burn you. resulting in injury.
• Failure to comply could result in death • Never inject fuel toward a fire source.
or serious injury. Atomized fuel is highly flammable and
0000015en may cause a fire or burn skin.
0000028en
A WARNING
To prevent possible eye injury, always

wear SAFETY GLASSES while servicing
the engine.
0000013en

A WARNING A WARNING
• Never use the E-ECU for other • Replacing the fuel injection pump
purposes than intended or in other involves rewriting the fuel injection
ways than specified by Yanmar. Doing data in the E-ECU.
so could result in the violation of Be sure to contact your local Yanmar
emission control regulations and will dealer before replacing the fuel
void the product warranty. injection pump.
• Improper use or misuse of the E-ECU Failure to rewrite the fuel injection
may result in death or serious injury data before replacing the fuel injection
due to an abrupt and unexpected pump will void the engine warranty.
increase in engine speed. • Improper use or misuse of the E-ECU
9999999en may result in death or serious injury
due to an abrupt and unexpected
increase in engine speed.
A WARNING 9999997en
• Be sure to use the E-ECU in
conjunction with the engines whose
models or serial numbers are A WARNING
specified by Yanmar. • Replacing the E-ECU involves
Other E-ECU/engine combinations migrating the fuel injection data to the
than specified will void the engine existing E-ECU to the new unit.
warranty. Be sure to contact your local Yanmar
• Improper use or misuse of the E-ECU dealer before replacing the E-ECU.
may result in death or serious injury Failure to migrate the fuel injection
due to an abrupt and unexpected data before replacing the E-ECU will
increase in engine speed. void the engine warranty.
9999998en • Improper use or misuse of the E-ECU
may result in death or serious injury
9999996en

A CAUTION A CAUTION
COOLANT HAZARD! PINCH HAZARD!

• Wear eye protection and rubber gloves Carefully rotate the alternator toward the
when you handle long life or extended cylinder block while loosening the
life engine coolant. If contact with the V-belt. Failure to comply may result in
eyes or skin should occur, flush eyes minor or moderate injury.
and wash immediately with clean 0000014en
water.
• Failure to comply may result in minor
or moderate injury.
A CAUTION
If any oil pump component clearance
0000005en
exceeds its limit, the oil pump must be
replaced as an assembly.
A CAUTION 0000015en
CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
FLYING OBJECT HAZARD! warranty requirements.
• ALWAYS wear eye protection when • Only use clean diesel fuel.
servicing the engine and when using
compressed air or high-pressure • NEVER remove the primary strainer (if
water. Dust, flying debris, compressed equipped) from the fuel tank filler port.
air, pressurized water or steam may If removed, dirt and debris could get
injure your eyes. into the fuel system causing it to clog.
0000004en
or moderate injury.
0000003en
CAUTION
NEVER attempt to adjust the low or high
A CAUTION idle speed limit screw. This may impair
the safety and performance of the
Be sure to secure the engine solidly to machine and shorten its life. If
prevent injury or damage to parts due to adjustment is ever required, contact
the engine falling during work on the your authorized Yanmar industrial
engine. engine dealer or distributor.
0000009en
0000045en

CAUTION CAUTION
If any problem is noted during the visual Observe the following environmental
check, the necessary corrective action operating conditions to maintain engine
should be taken before you operate the performance and avoid premature
engine. engine wear:
0000021en
• Avoid operating in extremely dusty
conditions.
CAUTION • Avoid operating in the presence of
NEVER hold the key in the START chemical gases or fumes.
position for longer than 15 seconds or • Avoid operating in a corrosive
the starter motor will overheat. atmosphere such as salt water spray.
0000007en
• NEVER install the engine in a
floodplain unless proper precautions
CAUTION are taken to avoid being subject to a
Make sure the engine is installed on a flood.
level surface. If a continuously running • NEVER expose the engine to the rain.
engine is installed at an angle greater 0000003en
than (IDI = 25°, DI = 30°) in any direction
or if an engine runs for short periods of
time (less than three minutes) at an CAUTION
angle greater than (IDI = 30°, DI = 35°) in Observe the following environmental
any direction, engine oil may enter the operating conditions to maintain engine
combustion chamber causing excessive performance and avoid premature
engine speed and white exhaust smoke. engine wear:
This may cause serious engine damage.
• The standard range of ambient
0000010enTNV
temperatures for the normal operation
of Yanmar engines is from +5°F (-15°C)
to +113°F (+45°C).
• If the ambient temperature exceeds
+113°F (+45°C) the engine may
overheat and cause the engine oil to
break down.
• If the ambient temperature is below
+5°F (-15°C) the engine will be hard to
start and the engine oil may not flow
easily.
• Contact your authorized Yanmar
industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en

CAUTION CAUTION
The illustrations and descriptions of • Only use the engine coolant specified.
optional equipment in this manual, such Other engine coolants may affect
as the operator’s console, are for a warranty coverage, cause an internal
typical engine installation. Refer to the buildup of rust and scale and / or
documentation supplied by the optional shorten engine life.
equipment manufacturer for specific • Prevent dirt and debris from
operation and maintenance instructions. contaminating the engine coolant.
0000018en
Carefully clean the radiator cap and
the surrounding area before you
CAUTION remove the cap.
If any indicator illuminates during • NEVER mix different types of engine
engine operation, stop the engine coolants. This may adversely affect the
immediately. Determine the cause and properties of the engine coolant.
repair the problem before you continue 0000006en
to operate the engine.

0000029en
CAUTION
• NEVER overfill the engine with engine
CAUTION oil.
• Only use the engine oil specified. • ALWAYS keep the oil level between the
Other engine oils may affect warranty upper and lower lines on the oil
coverage, cause internal engine cap / dipstick.
components to seize and / or shorten
0000015en
engine life.
• Prevent dirt and debris from
CAUTION
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the For maximum engine life, Yanmar
surrounding area before you remove recommends that when shutting the
the cap. engine down, you allow the engine to
idle, without load, for five minutes. This
• NEVER mix different types of engine will allow the engine components that
oil. This may adversely affect the operate at high temperatures, such as
lubricating properties of the engine oil. the turbocharger (if equipped) and
• NEVER overfill. Overfilling may result exhaust system, to cool slightly before
in white exhaust smoke, engine the engine itself is shut down.
overspeed or internal damage. 0000008en
0000005en
CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en

CAUTION CAUTION
New Engine Break-in:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
• ALWAYS be environmentally engine oil leaks, coolant leaks, and for
responsible. proper operation of the indicators
• Follow the guidelines of the EPA or and / or gauges.
other governmental agencies for the • During the first hour of operation, vary
proper disposal of hazardous the engine speed and the load on the
materials such as engine oil, diesel engine. Short periods of maximum
fuel and engine coolant. Consult the engine speed and load are desirable.
local authorities or reclamation facility. Avoid prolonged operation at
• NEVER dispose of hazardous minimum or maximum engine speeds
materials irresponsibly by dumping and loads for the next four to five
them into a sewer, on the ground, or hours.
into ground water or waterways. • During the break-in period, carefully
• Failure to follow these procedures may observe the engine oil pressure and
seriously harm the environment. engine temperature.
0000013en • During the break-in period, check the
engine oil and coolant levels
CAUTION frequently.
0000011en
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring CAUTION
gear. • NEVER attempt to modify the engine’s
0000012en design or safety features such as
defeating the engine speed limit
control or the fuel injection quantity
control.
• Failure to comply may impair the
engine’s safety and performance
characteristics and shorten the
engine’s life. Any alterations to this
engine may affect the warranty
coverage of your engine. See Yanmar
Limited Warranty in Warranty Section.
0000044enTNVDISM

CAUTION CAUTION
Protect the air cleaner, turbocharger (if If any indicator fails to illuminate when
equipped) and electric components the key switch is in the ON position, see
from damage when you use steam or your authorized Yanmar industrial
high-pressure water to clean the engine. engine dealer or distributor for service
0000014en before operating the engine.
0000028en
CAUTION
NEVER use high-pressure water or CAUTION
compressed air at greater than 28 psi Establish a periodic maintenance plan
(193 kPa; 19 686 mmAq) or a wire brush according to the engine application and
to clean the radiator fins. Radiator fins make sure you perform the required
damage easily. periodic maintenance at the intervals
0000016en indicated. Failure to follow these
guidelines will impair the engine’s safety
and performance characteristics,
CAUTION shorten the engine’s life and may affect
NEVER attempt to adjust the low or high the warranty coverage on your engine.
idle speed limit screw. This may impair
See Yanmar Limited Warranty in
the safety and performance of the
Warranty Section.
machine and shorten its life. If the idle
speed limit screws require adjustment, Consult your authorized Yanmar dealer
see your authorized Yanmar industrial or distributor for assistance when
engine dealer or distributor. checking items marked with a .
0000017en 0000024enTNVDISM
CAUTION CAUTION
The tightening torque in the Standard If the fuel filter / water separator is
Torque Chart (see General Service positioned higher than the fuel level in
Information section) should be applied the fuel tank, water may not drip out
only to the bolts with a “7” head. (JIS when the fuel filter / water separator
strength classification: 7T) drain cock is opened. If this happens,
turn the air vent screw on the top of the
• Apply 60% torque to bolts fuel filter / water separator 2-3 turns
that are not listed. counterclockwise.
• Apply 80% torque when Be sure to tighten the air vent screw
tightened to aluminum alloy. after the water has drained out.
0000023enTNVDISM 0000025en

CAUTION CAUTION
• When the engine is operated in dusty Do not loosen or remove the four bolts
conditions, clean the air cleaner retaining the fuel injection pump drive
element more frequently. gear to the fuel injection pump hub. Do
• NEVER operate the engine with the air not disassemble the fuel injection pump
cleaner element(s) removed. This may drive gear from the hub. Correct fuel
allow foreign material to enter the injection timing will be very difficult or
engine and damage it. impossible to achieve.
0000031en
0000026en
CAUTION CAUTION
The maximum air intake restriction, in The starter motor can be damaged if
terms of differential pressure operated continuously longer than
measurement, must not exceed 0.90 psi 10 seconds while performing the
(6.23 kPa; 635 mmAq). Clean or replace no-load test.
the air cleaner element if the air intake 0000034en
restriction exceeds the above

mentioned value. CAUTION
0000046en
Do not short-circuit the charging system
between alternator terminals IG and L.
CAUTION Damage to the alternator will result.
It is important to perform daily checks. 0000035en
Periodic maintenance prevents

unexpected downtime, reduces the CAUTION
number of accidents due to poor Do not connect a load between
machine performance and helps extend alternator terminals L and E. Damage to
the life of the engine. the alternator will result.
0000060en 0000036en
CAUTION CAUTION
If the oil pump must be replaced, replace Do not remove the positive (+) battery
it as an assembly only. Do not replace cable from alternator terminal B while
individual components. the engine is operating. Damage to the
0000030en alternator will result.
0000037en
CAUTION
Do not turn the battery switch OFF while
the engine is operating. Damage to the
alternator will result.
0000038en

CAUTION CAUTION
Do not operate the engine if the Do not use a high-pressure wash
alternator is producing unusual sounds. directly on the alternator. Water will
Damage to the alternator will result. damage the alternator and result in
0000039en inadequate charging.
0000049en
CAUTION
If the engine coolant pump must be CAUTION
replaced, replace the engine coolant Do not reverse the positive (+) and
pump as an assembly only. Do not negative (-) ends of the battery cable.
attempt to repair the engine coolant The alternator diode and stator coil will
pump or replace individual components. be damaged.
0000041en 0000050en
CAUTION CAUTION
Use a new special O-ring between the When the battery indicator goes out, it
engine coolant pump and the joint. Be should not come on again. The battery
sure to use the special O-ring for each indicator only comes on during
engine model. Although the O-ring operation if the alternator fails. However,
dimensions are the same as a if an LED is used in the battery indicator,
commercially available O-ring, the the LED will shine faintly during normal
material is different. operation.
0000042en 0000051en
CAUTION CAUTION
Remove or install the high-pressure fuel Using a non-specified V-belt will cause
injection lines as an assembly whenever inadequate charging and shorten the
possible. Disassembling the belt life. Use the specified belt.
high-pressure fuel injection lines from 0000052en
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
fuel lines.
CAUTION
0000047en
Agricultural or other chemicals,
especially those with a high sulfur
content, can adhere to the IC regulator.
CAUTION This will corrode the conductor and
After marking the position of the pump result in battery over-charging (boiling)
drive gear, do not rotate the engine and charging malfunctions. Consult
crankshaft. Rotating the crankshaft will Yanmar before using the equipment in
cause the fuel injection pump to become such an environment or the warranty is
misaligned. voided.
0000048en 0000053en

CAUTION CAUTION
Make sure that the combined total Removing the battery cables or the
resistance of the battery cable in both battery while the engine is operating
directions between the starter motor may cause damage to the current limiter
and the battery is within the value depending on the electrical equipment
indicated on the wiring diagram. The being used. This situation could cause
starter motor will malfunction or break loss of control of output voltage. The
down if the resistance is higher than the continuous high voltage of 23-24 volts
specified value. (for 5000 rpm dynamo) will damage the
0000054en current limiter and other electrical
equipment.
CAUTION 0000058en
The starter motor is water-proofed

according to JIS D 0203, R2 which CAUTION
protects the motor from rain or general Reversing the battery cable connections
cleaning. Do not use high-pressure at the battery or on the engine will
wash or submerse the starter motor in destroy the SCR diode in the current
water. limiter. This will cause the charging
0000055en system to malfunction and may cause
damage to the electrical harnesses.
CAUTION 0000059en
Use a specialized battery charger to

recharge a battery with a voltage of CAUTION
8 volts or less. Booster starting a battery Avoid damage to the turbocharger or the
with a voltage of 8 volts or less will engine. Do not spray blower wash fluid
generate an abnormally high voltage or water too quickly.
and destroy electrical equipment. Use short strokes from a spray bottle to
0000056en
inject blower wash fluid or water into the
turbocharger.
CAUTION Spraying too much wash fluid or water,
Make sure that the combined total or spraying too quickly will damage the
resistance of the battery cable in both turbocharger.
directions between the starter motor 0000063en
and the battery is within the value

indicated in the Battery Cable
CAUTION
Resistance chart in the Electric Wiring
Section of this manual. The starter Do not allow any material to fall into the
motor will malfunction and fail if the oil lines or the oil inlet and outlet ports
resistance is higher than the specified of the turbocharger.
value. 0000064en
0000057en

CAUTION CAUTION
If the waste valve does not meet Do not rotate the crankshaft with the
specifications, replace the turbocharger injection pump removed.
or have it repaired by a qualified repair 0000083en
facility.
0000078en
CAUTION
Keep the piston pin parts, piston
CAUTION assemblies, and connecting rod
• NEVER attempt to modify the engine’s assemblies together to be returned to
design or safety features such as the same position during the
defeating the engine speed limit reassembly process. Label the parts
control or the diesel fuel injection using an appropriate method.
quantity control. 0000088en
• Modifications may impair the engine’s

safety and performance CAUTION
characteristics and shorten the
Do not allow the honing tool to operate
engine’s life. Any alterations to this
in one position for any length of time.
engine may void its warranty. Be sure
Damage to the cylinder wall will occur.
to use Yanmar genuine replacement
Keep the tool in constant up-and-down
parts.
motion.
0000079en
0000090en
CAUTION CAUTION
Identify all parts and their location using
Any part which is found defective as a
an appropriate method. It is important
result of inspection or any part whose
that all parts are returned to the same
measured value does not satisfy the
position during the reassembly process.
standard or limit must be replaced.
0000080en
0000119en
CAUTION CAUTION
Each pressure adjusting shim removed
Any part determined to not meet the
or added changes the pressure
service standard or limit before the next
threshold by approximately 275 psi
service, as determined from the state of
(1.9 MPa, 19 kgf/cm2). Adding adjusting
current rate of wear, should be replaced
shims increases the threshold pressure.
even though the part currently meets the
Removing adjusting shims reduces the
service standard limit.
pressure threshold.
0000120en
0000081en

CAUTION CAUTION
• NEVER remove or attempt to remove Shut down the engine if the fault
the tamper-proof devices from the indicator comes on.
full-load fuel adjusting screw or the Continuing running the engine with the
high-speed throttle limit screw on the fault indicator being on may result in a
fuel injection pump and governor serious malfunction of or damage to the
assembly. These adjustments have engine, and will void the engine
been made at the factory to meet all warranty.
applicable emissions regulations and
9999999en
then sealed.
• NEVER attempt to make any
adjustments to these sealed
CAUTION
adjustment screws. If adjustments are Do not energize the starter for a period
required, they can be made only by a of longer than 15 seconds.
qualified fuel injection shop that will Take a pause of at least 30 seconds
ensure the injection pump continues between energization of the starter.
to meet all applicable emissions
regulations and then replace the Otherwise the starter could suffer
tamper-proof seals. damage.
9999998en
• Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.” CAUTION
0000146en • High-pressure washing not
recommended.
CAUTION • Avoid using high-pressure washing for
Never use a steel wire brush to clean electronic or electric devices installed
fuel injectors. Damage to the nozzle and in, on or around the engine, including
other components is likely to result. the E-ECU, relays and harness
couplers.
0000172en
Otherwise such devices may suffer
malfunction due to water ingress into
CAUTION them.
Allow the engine to warm-up for at least 9999997en
five minutes and the idle speed of the
engine to return to normal before
engaging the transmission or any PTOs.
Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the
equipment.
0000159en

CAUTION
• Do not plug or unplug the E-ECU for a
period of at least 6 seconds after
power to the unit has been turned on
or off.
• Do not touch connector pins of the E-
ECU with bare hands.
Doing so may result in corrosion of the
connector pins and/or damage to the
internal circuits of the E-ECU due to
static electricity.
• Do not force a measuring probe into
the female coupler.
Doing so may cause contact failure of
the connector pins, resulting in
malfunction of the E-ECU.
• Take care to prevent water from
entering the couplers when plugging
or unplugging the connector.
Water inside the couplers may cause
corrosion, resulting in malfunction of
the E-ECU.
• Avoid plugging/unplugging the
connector more than approx. 10 times.
Frequent plugging/unplugging of the
connector may cause contact failure of
• Do not use the E-ECU that has ever
suffered drop impact.
9999996en
CAUTION
Always check the battery for proper
charge.
Otherwise the electronically controlled
engines may fail to start.
9999995en


Section 4
GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-5
Engine Nameplate (Typical) ...................................................... 4-6
Emission Control Regulations ......................................................... 4-6
EPA / ARB Regulations - USA Only .......................................... 4-6
Emission Control Labels.................................................................. 4-6
The 97/68/EC Directive Certified Engines....................................... 4-7
Engine Family.................................................................................. 4-7
Function of Major Engine Components ........................................... 4-8
MAIN ELECTRONIC CONTROL COMPONENTS AND
FEATURES ..................................................................................... 4-9
Function of Cooling System Components ..................................... 4-11
Diesel Fuel .................................................................................... 4-12
Diesel Fuel Specifications ....................................................... 4-12
Filling The Fuel Tank ............................................................... 4-13
Priming the Fuel System ......................................................... 4-15
Engine Oil...................................................................................... 4-15
Engine Oil Specifications ........................................................ 4-15
Engine Oil Viscosity................................................................. 4-16
Checking Engine Oil ................................................................ 4-16
Adding Engine Oil.................................................................... 4-17
Engine Oil Capacity (Typical) .................................................. 4-17
Engine Coolant.............................................................................. 4-18
Engine Coolant Specifications................................................. 4-19
Filling Radiator with Engine Coolant........................................ 4-19
Engine Coolant Capacity (Typical) .......................................... 4-20
Specifications ................................................................................ 4-21

GENERAL SERVICE INFORMATION
Description of Model Number................................................... 4-21
Engine Speed Specifications.................................................... 4-21
Engine General Specifications ................................................. 4-22
Principal Engine Specifications ...................................................... 4-23
3TNV82A (~ EPA Tier2) ........................................................... 4-23
3TNV84 (~ EPA Tier2) ............................................................. 4-24
3TNV84T (~ EPA Tier2) ........................................................... 4-25
3TNV88 (~ EPA Tier2) ............................................................. 4-26
4TNV84 (~ EPA Tier2) ............................................................. 4-27
4TNV84T (~ EPA Tier2) ........................................................... 4-28
4TNV88 (~ EPA Tier2) ............................................................. 4-29
4TNV94L (~ EPA Tier2) ........................................................... 4-30
4TNV98 (~ EPA Tier2) ............................................................. 4-31
4TNV98T (~ EPA Tier2) ........................................................... 4-32
4TNV106 (~ EPA Tier2) ........................................................... 4-33
4TNV106T (~ EPA Tier2) ......................................................... 4-34
3TNV82A-B (complies with EPA Interim Tier4)........................ 4-35
3TNV84T-B (complies with EPA Interim Tier4) ........................ 4-36
3TNV88-U (complies with EPA Interim Tier4) .......................... 4-37
3TNV88-B (complies with EPA Interim Tier4) .......................... 4-38
4TNV84T-Z (complies with EPA Interim Tier4) ........................ 4-39
4TNV88-U (complies with EPA Interim Tier4) .......................... 4-40
4TNV88-B (complies with EPA Interim Tier4) .......................... 4-41
4TNV98-E (complies with EPA Interim Tier4) .......................... 4-42
4TNV98-Z (complies with EPA Interim Tier4) .......................... 4-43
4TNV98T-Z (complies with EPA Interim Tier4) ........................ 4-44
Engine Service Standards.............................................................. 4-45
Tightening Torques for Standard Bolts and Nuts ........................... 4-46
Abbreviations and Symbols............................................................ 4-48
Abbreviations............................................................................ 4-48
Symbols.................................................................................... 4-48
Unit Conversions ............................................................................ 4-49
Unit Prefixes ............................................................................. 4-49
Units of Length ......................................................................... 4-49
Units of Volume ........................................................................ 4-49
Units of Mass............................................................................ 4-49
Units of Force ........................................................................... 4-49
Units of Torque......................................................................... 4-49
Units of Pressure...................................................................... 4-49
Units of Power .......................................................................... 4-49
Units of Temperature................................................................ 4-49

Component Identification GENERAL SERVICE INFORMATION
COMPONENT IDENTIFICATION
Figure 4-1 shows where the major engine components are located.
3TNV82A(-B),3TNV84,3TNV84T(-B),3TNV88(-B)(-U),4TNV84,4TNV88(-B)(-U),
4TNV94L,4TNV984TNV106,4TNV106T
(1) (2) (20)

(19)
(3)
(18)
(4)
(17)
(16)
(15)
(5) (21)
(14)
(25)
(6)
(13)
(24)
(22)
(23)
0000015B
(12) (11) (10) (9) (8) (7)
1 – Lifting Eye (Flywheel End) 14 – Governor Lever
2 – Turbocharger* 15 – Intake Manifold
3 – Lifting Eye (Engine Cooling Fan End) 16 – Fuel Filter
4 – Engine Coolant Pump 17 – Fuel Inlet
5 – Engine Cooling Fan 18 – Fuel Return to Fuel Tank
6 – Crankshaft V-Pulley 19 – Top Filler Port (Engine Oil)
7 – V-Belt 20 – Rocker Arm Cover
8 – Side Filler Port (Engine Oil) 21 – Air Intake Port (From Air Cleaner)
9 – Drain Plug (Engine Oil)** 22 – Flywheel
10 – Fuel Injection Pump 23 – Starter Motor
11 – Engine Oil Cooler*** 24 – Exhaust Manifold
12 – Engine Oil Filter 25 – Alternator
13 – Dipstick (Engine Oil)
Figure 4-1
* Only applies to 3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T

** The engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models

GENERAL SERVICE INFORMATION Component Identification
Figure 4-2 shows where the major engine components are located.
4TNV84T-Z, 4TNV98-E, 4TNV98-Z, 4TNV98T-Z
(2) (19) (4) (3) (20) (26)
(18)
(17) (28)
(1)
(16) (27)
(15)
(21)
(14)
(25)
(13) (5)
(22)
(6)
(24)
(23)
(12) (11) (9) (10) (8) (7)
1 – Lifting Eye (Flywheel End) 15 – Intake Manifold

2 – Turbocharger* 16 – Fuel Filter
3 – Lifting Eye (Engine Cooling Fan End) 17 – Fuel Inlet
4 – Engine Coolant Pump 18 – Fuel Return to Fuel Tank
5 – Engine Cooling Fan 19 – Top Filler Port (Engine Oil)
6 – Crankshaft V-Pulley 20 – Rocker Arm Cover
7 – V-Belt 21 – Air Intake Port (From Air Cleaner)
8 – Side Filler Port (Engine Oil) 22 – Flywheel
9 – Drain Plug (Engine Oil)** 23 – Starter Motor
10 – Fuel Injection Pump 24 – Exhaust Manifold
11 – Engine Oil Cooler*** 25 – Alternator
12 – Engine Oil Filter 26 – EGR valve
13 – Dipstick (Engine Oil) 27 – EGR cooler****
14 – Eco-governor 28 – EGR pipe
Figure 4-2
* Only applies to 4TNV84T-Z, 4TNV98T-Z.

** Engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models.
**** Only applies to 4TNV84T-Z, 4TNV98T-Z.

Location of Labels GENERAL SERVICE INFORMATION
LOCATION OF LABELS
Figure 4-3 shows the location of regulatory and safety labels on Yanmar TNV series engines.
(1) (4) (1) (3)

(4) (2)
0000019A-01
Figure 4-3
Location of labels/nameplates on direct injection model engines

EPA/ARB Certification 97/68/EC Emission Control
Model Engine Nameplate
Label Label
3TNV82A,3TNV84,3TNV84T,3TNV88 On the top of the locker On the top of the locker On the exhaust side of the locker
3TNV82A-B,3TNV88-B,3TNV88-U arm cover(cooling fan end) arm cover (flywheel end) arm cover(near the flywheel)
3TNV84T-B Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (2)
On the top of the locker On the top of the locker On the exhaust side of the locker
4TNV84,4TNV88,4TNV84T
arm cover(cooling fan end) arm cover(flywheel end) arm cover(near the flywheel)
4TNV88-B,4TNV88-U,4TNV84T-Z
Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (1)
4TNV94L,4TNV98,4TNV98T On the top of the locker On the top of the locker On the top of the locker arm
4TNV106,4TNV106T arm cover(flywheel end) arm cover(center) cover(fan end)
4TNV98-Z,4TNV98-E,4TNV98T-Z Figure 4-3 right, (4) Figure 4-3 right, (1) Figure 4-3 right, (3)

GENERAL SERVICE INFORMATION Emission Control Regulations
Engine Nameplate (Typical) EMISSION CONTROL LABELS

Since emission control regulations are being issued
on a global basis, it is necessary to identify which
regulations a particular engine complies with. We
have listed several different types of labels you
might find on your engine.
EPA / ARB Labels
" "
0003852
EMISSION CONTROL (EPA) Less than 50 HP SAE (37kW)

REGULATIONS
EPA / ARB Regulations - USA Only
Yanmar TNV engines meet Environmental " US-2D " FUEL
Protection Agency (EPA) (U. S. Federal) emission
control standards as well as the California Air
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA / ARB installation
(page 5-16) and maintenance (page 5-16) in the (EPA) Greater than or Equal to 50 HP SAE (37kW)
Periodic Maintenance Schedule section of this
manual. Also refer to the Emission System
Warranty on page 2-6.
(EPA and ARB) 0000086-01

The 97/68/EC Directive Certified Engines GENERAL SERVICE INFORMATION
THE 97/68/EC DIRECTIVE

CERTIFIED ENGINES 97/68/EC DIRECTIVE
The engines described in this manual have been

certified by the 97/68/EC Directive.
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
(97/68/EC)
the engines.
ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all have an Engine Family field. The following is an
explanation of the Engine Family designation:
5 YDX L 1.33 M 3 N
Method of air aspiration
Number of cylinders
Engine speed specifications
Displacement (liter)
Non-road / Off-road engine
Yanmar Diesel
*2005 Model Year
5*: 2005
6 : 2006
7: 2007
8: 2008
9: 2009

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

Components Functions
The air cleaner prevents airborne contaminants from entering the engine. Since
the air cleaner is application specific, it must be carefully selected by an application
Air Cleaner engineer. It is not part of the basic engine package as shipped from the Yanmar
factory. Periodic replacement of the air cleaner filter element is necessary. See the
Periodic Maintenance Schedule on page 5-17 for the replacement frequency.
The alternator is driven by a V-belt which is powered by the crankshaft V-pulley.
Alternator The alternator supplies electricity to the engine systems and charges the battery
while the engine is running.
The engine oil dipstick is used to determine the amount of engine oil in the
Dipstick (Engine Oil)
crankcase.
The electric fuel pump makes sure there is a constant supply of diesel fuel to the
fuel injection pump. The electric fuel pump is electro-magnetic and runs on
Electric Fuel Pump
12 VDC. It must be installed on every application. This is standard equipment with
every engine.
The engine oil filter removes contaminants and sediments from the engine oil.
Engine Oil Filter Periodic replacement of the engine oil filter is necessary. See the Periodic
Maintenance Schedule on page 5-17 for the replacement frequency.
The engine oil cooler helps to keep the engine oil cool. Engine coolant from the
Engine Oil Cooler
cooling system is circulated through an adapter at the base of the engine oil filter
(If Equipped)
assembly and then returned to the coolant pump inlet.
The fuel filter removes contaminants and sediments from the diesel fuel. Periodic
replacement of the fuel filter is necessary. See the Periodic Maintenance Schedule
Fuel Filter
on page 5-17 for the replacement frequency. Please note that the word “diesel”
is implied throughout this manual when the word “fuel” is used.
The fuel filter / water separator removes contaminants, sediments and water from
the diesel fuel going to the fuel filter. This is a required component of the fuel
Fuel Filter / Water Separator system. This is standard equipment with every engine. The separator is installed
between the fuel tank and the electric fuel pump. Periodically drain the water from
the fuel filter / water separator.
The fuel tank is a reservoir that holds diesel fuel. When the fuel leaves the fuel tank
it goes to the fuel filter / water separator. Next the fuel is pumped to the fuel filter
by the electric fuel pump. Then the fuel goes to the fuel injection pump. Since the
Fuel Tank fuel is used to keep the fuel injection pump cool and lubricated, more fuel than
necessary enters the injection pump. When the injection pump pressure reaches
a preset value, a relief valve allows the excess fuel to be returned back to the fuel
tank. The fuel tank is a required engine component.
You can fill the crankcase with engine oil from either the side or the top filler port
Side and Top Filler Port (Engine Oil)
depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key switch in the
Starter Motor operator’s console to the START position, the starter motor engages with the ring
gear installed on the flywheel and starts the flywheel in motion.
Turbocharger
The turbocharger pressurizes the air coming into the engine. It is driven by a
(Only applies to 3TNV84T, 4TNV84T,
turbine that is energized by exhaust gases.
4TNV98T, 4TNV106T)

MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES GENERAL SERVICE INFORMATION
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES

4TNV84T-Z, 4TNV98-E, 4TNV98-Z,
4TNV98T-Z
Component/Feature Description
Engine controller (E-ECU) Adjusts the rack position of the fuel injection pump
depending on the speed command signal from the
accelerator sensor, thus regulating the engine speed and
power. The engine controller also regulates the opening of
the EGR valve depending on the engine speed and
power. It serves as the master station for the following
components/control features.
Electronic governor (Eco-governor) Consists of the engine speed sensor, rack actuator, etc.,
and is directly connected to the fuel injection pump in
order to regulate the rack position of the fuel injection
pump depending on the signals communicated with the E-
ECU.
Fuel injection pump (for Eco-governor) Is of single plunger type and equipped with a CSD
solenoid valve that allows the fuel injection timing to
advance and the injection quantity to increase, thereby
improving the cold start performance of the engine.
EGR valve Controls the exhaust gas recirculation flow rate
depending on the engine speed/load signals from the E-
ECU. It is installed on the top of the exhaust manifold.
Accelerator sensor Unlike mechanical governors, the Eco-governor has no
governor lever. The accelerator sensor serves as the
governor lever to provide the speed command signal
(voltage signal) to the E-ECU for engine speed control. It
is installed in the operator cabin of the driven machine.
Constant speed engines for e.g. generator use do not
require accelerator sensors because the engine speed
can be shifted via a switch on the operator's console.
Optional CAN communication capability is available as an option.
Fault indicator Is installed on the operator's console. If a fault occurs in
the E-ECU or Eco-governor, the fault indicator flashes
alerting the operator to a fault. The number of flashes
and/or the flashing pattern vary depending on the type or
Optional source of the fault, enabling quick-fix.

GENERAL SERVICE INFORMATION MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
Component/Feature Description
Engine diagnosis tool Allows the operator to troubleshoot the cause of a
problem based on detailed information regarding the
problem occurring in the E-ECU or Eco-governor. This
tool can also be used for data maintenance tasks
including programming and mapping. See
Option for service Troubleshooting Chart on page 7-113.
Engine coolant temperature sensor Allows the CSD and ERG to be controlled in engine cold-
start conditions.
Glow plugs Optional When the key switch is turned to the ON position, the glow
Air heater plugs/air heater are/is energized for up to 15 seconds
(glow plugs) or up to 23 seconds (air heater). The duration
of energization depends on the engine coolant
temperature. The HEAT indicator is on during
energization. When the indicator goes out, turn the key
switch to the START position to start the engine.
After heater Optional In extreme cold start conditions, the after heater is
energized for up to 80 seconds or until the coolant
temperature reaches 10°C after the engine has started, in
order to help ensure the engine continues to run without
stall.This option is not available for glow plug engines.
Droop control Standard with VM series Reduces the engine speed by a certain percentage from
no load to full (rated) load in steady state operation. The
same percentage droop is maintained even when the load
increases at any no-load speed.
Isochronous control Standard with CL series Offers a constant engine speed from no load to full load.
Optional with VM series The engine speed does not decrease even when the load
increases at any no-load speed.
Low-idling speed up Increases the low-idling speed to up to 1000 rpm
depending on the engine coolant temperature. When the
coolant temperature reaches a predetermined value, this
feature returns the engine speed to the normal low idle
setting, thus reducing the warm-up time.
High-idling speed Optional Decreases the high-idling speed depending on the engine
down coolant temperature. When the coolant temperature falls
to a predetermined value, this feature returns the engine
speed to the normal high idle setting, thus minimizing the
emission of white smoke at low temperatures.
Auto deceleration Optional Brings the running engine in low idle mode automatically
when the accelerator pedal is not operated for a
predetermined period of time. When the pedal is
operated, i.e., the accelerator sensor is activated, the low
idle mode is cancelled.

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

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

GENERAL SERVICE INFORMATION Diesel Fuel
DIESEL FUEL • Fuel additives are not recommended. Some fuel

additives may cause poor engine performance.
Diesel Fuel Specifications Consult your Yanmar representative for more
information.
Diesel fuel should comply with the following
specifications. The table lists several worldwide • The ash content must not exceed 0.01% by
specifications for diesel fuels. volume.
• The carbon residue content must not exceed
Diesel Fuel Specification Location 0.35% by volume. Less than 0.1% is preferred.
No. 2-D, No. 1-D, • The total aromatics content should not exceed
USA
ASTM D975-94 35% by volume. Less than 30% is preferred.
European • The PAH (polycyclic aromatic hydrocarbons)
EN590:96
Union content should be below 10% by volume.
ISO 8217 DMX International • The metal content of Na, Mg, Si, and Al should be
United equal to or lower than 1 mass ppm. (Test analysis
BS 2869-A1 or A2 method JPI-5S-44-95)
Kingdom
JIS K2204 Grade No. 2 Japan • Lubricity: The wear mark of WS1.4 should be
KSM-2610 Korea Max. 0.018 in (460 µm) at HFRR test.
GB252 China Bio-Diesel Fuels

In Europe and in the United States, as well as some
Additional Technical Fuel Requirements other countries, non-mineral oil based fuel
• The fuel cetane number should be equal to 45 or resources such as RME (Rapeseed Methyl Ester)
higher. and SOME (Soybean Methyl Ester), collectively
known as FAME (Fatty Acid Methyl Esters), are
• The sulfur content must not exceed 0.5% by
being used as extenders for mineral oil derived
volume. Less than 0.05% is preferred.
diesel fuels.
For electronically controlled engines 4TNV84T-Z,
4TNV98-Z, 4TNV98-E, and 4TNV98T-Z, it is Yanmar approves the use of bio-diesel fuels that do
mandatory to use fuel that does not contain not exceed a blend of 5% (by volume) of FAME with
0.05% or more sulfur content. 95% (by volume) of approved mineral oil derived
In general, using a high sulfur fuel may possible diesel fuel. Such bio-diesel fuels are known in the
result in corrosion inside the cylinder. marketplace as B5 diesel fuels.
• Bio-Diesel fuels. See Bio-Diesel Fuels on These B5 diesel fuels must meet certain
page 4-12. requirements.
• NEVER mix kerosene, used engine oil, or 1. The bio-fuels must meet the minimum
residual fuels with the diesel fuel. specifications for the country in which they are
used.
• The water and sediment in the fuel should not • In Europe, bio-diesel fuels must comply with
exceed 0.05% by volume. the European Standard EN14214.
• Keep the fuel tank and fuel-handling equipment • In the United States, bio-diesel fuels must
clean at all times. comply with the American Standard
ASTM D-6751.
• Poor quality fuel can reduce engine performance
and / or cause engine damage. 2. Bio-fuels should be purchased only from
recognized and authorized diesel fuel suppliers.

Diesel Fuel GENERAL SERVICE INFORMATION
Precautions and concerns regarding the use of Filling The Fuel Tank
bio-fuels:
1. Free methanol in FAME may result in corrosion A DANGER
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures, FIRE AND EXPLOSION HAZARD!
and poor injection nozzle spray atomization.
4. FAME may have adverse effects on some under certain conditions.
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine • Only fill the fuel tank with diesel fuel.
lubricating oil. Filling the fuel tank with gasoline may
result in a fire and will damage the
5. Even bio-diesel fuels that comply with a suitable
engine.
standard as delivered, will require additional
care and attention to maintain the quality of the • NEVER refuel with the engine running.
fuel in the equipment or other fuel tanks. It is • Wipe up all spills immediately.
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system, • Keep sparks, open flames or any other
and / or fuel storage containers, may be form of ignition (match, cigarette,
necessary. static electric source) well away when
refueling.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel • NEVER overfill the fuel tank.
engine manufacturers and the diesel fuel • Fill the fuel tank. Store any containers
injection equipment manufacturers, or bio- containing fuel in a well-ventilated
diesel fuels that have degraded as per the area, away from any combustibles or
precautions and concerns above, may affect sources of ignition.
the warranty coverage of your engine. See
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en

GENERAL SERVICE INFORMATION Diesel Fuel
A DANGER A DANGER

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

serious injury. CAUTION
0000014en
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en

Engine Oil GENERAL SERVICE INFORMATION
Note that a typical fuel tank is shown. The fuel tank 2. NEVER use the starter motor to crank the
on your equipment may be different. engine in order to prime the fuel system. This
may cause the starter motor to overheat and
1. Clean the area around the fuel cap damage the coils, pinion and / or ring gear.
(Figure 4-4, (1)).
2. Remove the fuel cap (Figure 4-4, (1)) from the
fuel tank (Figure 4-4, (2)). ENGINE OIL
3. Observe the fuel level sight gauge
(Figure 4-4, (3)) and stop fueling when the CAUTION
gauge shows the fuel tank is full. NEVER
overfill the fuel tank. • Only use the engine oil specified.
Other engine oils may affect warranty
4. Replace the fuel cap (Figure 4-4, (1)) and hand coverage, cause internal engine
tighten. Over-tightening the fuel cap will components to seize and / or shorten
damage it. engine life.
(1) • Prevent dirt and debris from
clean the oil cap / dipstick and the
surrounding area before you remove
(2) the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
(3)
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
0000002A
overspeed or internal damage.
Figure 4-4 0000005en
Priming the Fuel System Engine Oil Specifications

The fuel system needs to be primed under certain Use an engine oil that meets or exceeds the
conditions: following guidelines and classifications:
• Before starting the engine for the first time. Service Categories
• After running out of fuel and fuel has been added • API Service Categories CD or higher
to the fuel tank. (Grade CF or higher for EGR-equipped engines
4TNV84T-Z, 4TNV98-Z, 4TNV98-E, and
• After fuel system maintenance such as changing 4TNV98T-Z)
the fuel filter and draining the fuel filter / water
separator, or replacing a fuel system component. • ACEA Service Categories E-3, E-4, and E-5
To prime the fuel system: • JASO Service Category DH-1
1. Turn the key to the ON position for 10 - 15 Definitions

seconds. This will allow the electric fuel pump • API Classification (American Petroleum Institute)
to prime the fuel system.
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)

GENERAL SERVICE INFORMATION Engine Oil
• JASO (Japanese Automobile Standards Checking Engine Oil

Organization)
1. Make sure the engine is level.
Notes: 2. Remove the dipstick (Figure 4-6, (1)) and wipe
• Be sure the engine oil, engine oil storage it with clean cloth.
containers, and engine oil filling equipment are 3. Fully reinsert the dipstick.
free of sediment and water. 4. Remove the dipstick. The oil level should be
• Change the engine oil after the first 50 hours of between the upper (Figure 4-6, (2)) and lower
operation and then every 250 hours thereafter. (Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert the dipstick.
• Select the oil viscosity based on the ambient
temperature where the engine is being operated. (4)
See the SAE Service Grade Viscosity Chart
(Figure 4-5).
• Yanmar does not recommend the use of engine
oil “additives.”
Additional Technical Engine Oil

Requirements:
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
mgKOH/g test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI). (4)
Engine Oil Viscosity (5)

Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-5. (2)
(1)
SAE 10W
SAE 20W (3)
SAE 10W-30
0000007C
SAE 15W-40
Figure 4-6
SAE 20
SAE 30
SAE 40
SAE 20W - 50
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F

(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C)
0000005A
Figure 4-5

Engine Oil GENERAL SERVICE INFORMATION
Adding Engine Oil Engine Oil Capacity (Typical)
1. Make sure the engine is level. Note: These are the engine oil capacities
2. Remove the oil cap (Figure 4-6, (4)). associated with a “deep standard” oil
pan. The oil capacity will vary dependant
3. Add the indicated amount of engine oil at the upon which optional oil pan is used.
top or the side engine oil filler port Refer to the operation manual provided
(Figure 4-6, (5)). by the driven machine manufacturer for
4. Wait three minutes and check the oil level. the actual engine oil capacity of your
5. Add more oil if necessary. machine.
6. Reinstall the oil cap (Figure 4-6, (4)) and The following are the engine oil capacities for
hand-tighten. Over-tightening may damage the various Yanmar TNV engines.
cap.
Dipstick Upper
Engine Model
Limit / Lower Limit
5.8 / 3.8 qt
3TNV82A(-B)
(5.5 / 3.6 L)
7.1 / 4.1 qt
3TNV84,3TNV84T(-B)
(6.7 / 3.9 L)
7.1 / 4.1 qt
3TNV88(-B)(-U)
(6.7 / 3.9 L)
7.8 / 4.2 qt
4TNV84,4TNV84T(-Z)
(7.4 / 4.0 L)
7.8 / 4.2 qt
4TNV88(-B)(-U)
(7.4 / 4.0 L)
11.1 / 6.3 qt
4TNV94L
(10.5 / 6.0 L)
4TNV98(-Z)(-E), 11.1 / 6.3 qt
4TNV98T(-Z) (10.5 / 6.0 L)
4TNV106(CL), 14.8 / 5.3 qt
4TNV106T(CL) (14.0 / 5.0 L)
4TNV106(VM), 14.8 / 6.9 qt
4TNV106T(VM) (14.0 / 6.5 L)

GENERAL SERVICE INFORMATION Engine Coolant
ENGINE COOLANT
A CAUTION
A DANGER
COOLANT HAZARD!
• Wear eye protection and rubber gloves
SCALD HAZARD!
when you handle long life or extended
• NEVER remove the radiator cap if the life engine coolant. If contact with the
engine is hot. Steam and hot engine eyes or skin should occur, flush eyes
coolant will spurt out and seriously and wash immediately with clean
burn you. Allow the engine to cool water.
the radiator cap.
or moderate injury.
• Tighten the radiator cap securely after 0000005en
spurt out during engine operation if
the cap is loose. CAUTION
• ALWAYS check the level of the engine • Only use the engine coolant specified.
coolant by observing the reserve tank. Other engine coolants may affect
warranty coverage, cause an internal
• Failure to comply will result in death or buildup of rust and scale and / or
serious injury. shorten engine life.
0000002en
contaminating the engine coolant.
A WARNING Carefully clean the radiator cap and
remove the cap.
coolants. This may adversely affect the
properties of the engine coolant.
BURN HAZARD! 0000006en
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
or serious injury.
0000016en

Engine Coolant GENERAL SERVICE INFORMATION
Engine Coolant Specifications Filling Radiator with Engine Coolant
Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This
Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time
guidelines and specifications: or refilling it after it is flushed. Note that a typical
radiator is illustrated (Figure 4-7).
Additional Technical Coolant
Specifications:
(2)
• ASTM D6210, D4985 (US)
(5)
• JIS K-2234 (Japan)
• SAE J814C, J1941, J1034 or J2036 (3)
(International)
(6) FULL
Alternative Engine Coolant LOW
(4)
If an Extended or Long Life Coolant is not available,
alternatively, you may use an ethylene glycol or
propylene glycol based conventional coolant
(green). (1)
0000029A
Notes:
Figure 4-7
• ALWAYS use a mix of coolant and water.
NEVER use water only. 1. Check to be sure the radiator drain plug is
• Mix the coolant and water per the mixing installed and tightened or the drain cock
instructions on the coolant container. (Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the
• Water quality is important to coolant cylinder block is closed or the oil coolant hoses
performance. Yanmar recommends that soft, (Figure 4-9, (1)) are installed at the oil cooler.
distilled, or demineralized water be used to mix
with coolants.
• NEVER mix extended or long life coolants and
conventional (green) coolants.
• NEVER mix different types and / or colors of
extended life coolants.
• Replace the coolant every 1000 engine hours
or once a year.
(1)
0000027B
Figure 4-8

GENERAL SERVICE INFORMATION Engine Coolant
Engine Coolant Capacity (Typical)

Note: The capacities listed are for the engine
only without a radiator. Refer to the
operation manual provided by the driven
machine manufacturer for the actual
engine coolant capacity on your
machine.
The following are the engine coolant capacities for
various Yanmar TNV engines.
Engine Coolant
Engine Model
(1) 0001579B Capacity
3TNV82A(-B) 1.9 qt (1.8 L)
Figure 4-9
3TNV84,3TNV84T(-B) 2.1 qt (2.0 L)
2. Remove the radiator cap (Figure 4-7, (2)) by 3TNV88(-B)(-U) 2.1 qt (2.0 L)
turning it counter-clockwise about 1/3 of a turn. 4TNV84,4TNV84T(-Z) 2.9 qt (2.7 L)
3. Pour the engine coolant slowly into the radiator 4TNV88(-B)(-U) 2.9 qt (2.7 L)
until it is even with the lip of the engine coolant 4TNV94L 4.4 qt (4.2 L)
filler port. Make sure that air bubbles do not
4TNV98(-Z)(-E),
develop as you fill the radiator. 4TNV98T(-Z)
4.4 qt (4.2 L)
4. Reinstall the radiator cap (Figure 4-7, (2)). 4TNV106, 4TNV106T 6.3 qt (6.0 L)
Align the tabs on the back side of the radiator
cap with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.
5. Remove the cap on the reserve tank
(Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
Reinstall the cap.
6. Check the hose (Figure 4-7, (5)) that connects
the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, the engine coolant will leak out
instead of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at the FULL (HOT) mark (Figure 4-7, (6)). If
the engine coolant is not at the FULL (HOT)
mark (Figure 4-7, (6)), add additional engine
coolant to the reserve tank to bring the level to
the FULL (HOT) mark.

Specifications GENERAL SERVICE INFORMATION
SPECIFICATIONS
Description of Model Number
3 TNV 82 A T - Z 0 00
Customer Code
Rated RPM
Governor Type Symbol (Indicating Conformance to EPA Tier 3/Interim Tier
4 Standards)
Governor Type Symbol Governor Type Applicable engine
Z Electronic Governor (Eco-governor)
Non-derated engine
B Mechanical Governor
E Electronic Governor (Eco-governor)
Derated engine
U Mechanical Governor
Turbocharged (No symbol indicates naturally aspirated)
Engine Sub Series
Cylinder Bore (mm)
Engine Series
No. of Cylinders
Engine Speed Specifications

Notation Available Engine Speed Intended Uses
VH 3200 - 3600 RPM (min-1) Lawn Mower, Construction, Industrial Machine
VM 2000 - 3000 RPM (min-1) Agricultural, Construction, Industrial Machines
-1
CH 3000 or 3600 RPM (min ) 2-pole Generator Sets, Irrigation Pumps
-1
CL 1500 or 1800 RPM (min ) 4-pole Generator Sets, Irrigation Pumps
VH: Variable High Speed CH: Constant High Speed

VM: Variable Medium Speed CL: Constant Low Speed

GENERAL SERVICE INFORMATION Specifications
Engine General Specifications

Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Direct Injection Models Direct Injection
Combustion System
Indirect Injection Models Swirl Chamber (Ball-Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Notes:
1. The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer.
2. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77°F (25°C), Atmospheric pressure 29.53 in. Hg
(100 kPa, 750 mm Hg), Relative humidity 30%
• Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C)
• Fuel Feeding Pressure: 20 ± 10 kPa (net) after engine break-in has been performed with the
cooling fan, air cleaner and muffler installed to the engine.
• With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
• After the Engine Break-In Period. Output Allowable Deviation: ± 3%
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW

Principal Engine Specifications GENERAL SERVICE INFORMATION
PRINCIPAL ENGINE SPECIFICATIONS

3TNV82A (~ EPA Tier2)
Engine Model 3TNV82A
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 82 × 84mm
Displacement 1.331L
min-1 1500 1800
Continuous Rated Output kW 9.9 12.0
PS 13.5 16.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 11.0 13.2 14.6 16.0 17.5 19.0 20.4 21.9
PS 14.9 17.9 19.9 21.8 23.8 25.8 27.8 29.8
1600 1895 2180 2375 2570 2780 2995 3180
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
138kg 128 kg
*with Flywheel Housing
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Normal Oil Pressure at Rated
Engine Speed 0.34 - 0.49 MPa 0.39 - 0.54 MPa
Normal Oil Pressure at Low 0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (1.2 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 55Ah*** (5h rating)
Dimensions (L × W × H)* 553 × 489 × 565 mm 528 × 489 × 565 mm
5.5/3.6L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.8L Engine Only
Standard Cooling Fan 335mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
Fan V-pulley dia. φ120/ φ90mm *** φ110/ φ110mm ***
* Engine specifications without radiator.

** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

GENERAL SERVICE INFORMATION Principal Engine Specifications
3TNV84 (~ EPA Tier2)

Engine Model 3TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 3
Displacement 1.496L
min-1 1500 1800
PS 15.3 18.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 16.8 20.1 22.3 24.6 26.8 29.0 31.3 33.5
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 55 Ah*** (5h rating)
Dimensions (L × W × H)* 589 × 486 × 622mm 564 × 486 × 622mm
Engine Oil Pan Capacity** 6.7/3.9L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

3TNV84T (~ EPA Tier2)
Engine Model 3TNV84T
Version CL VM
Aspiration Turbocharged
No. of Cylinders 3
Displacement 1.496L
min-1 1500 1800
PS 19.0 22.5
min-1 1500 1800 2400 2600 2800 3000
Max. Rated Output (Net) kW 15.8 18.8 25.0 26.8 29.1 30.9
PS 21.5 25.5 34.0 36.5 39.5 42.0
High Idling min-1 1600 1895 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161 kg 155 kg
0.29 - 0.44 MPa 0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V,55 Ah*** (5h rating)
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.


Engine Model 3TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 3
Displacement 1.642L
min-1 1500 1800
PS 16.7 20.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 18.4 22.1 24.5 27.0 29.4 31.9 34.2 36.8
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 55Ah *** (5h rating)
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Engine Model 4TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
PS 20.3 24.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 22.3 26.5 29.8 32.8 35.8 38.7 41.7 44.7
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183kg 170kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Dimensions (L × W × H)* 683 × 498.5 × 617 mm 658 × 498.5 × 617mm
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.


Version CL VM
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
PS 26.0 33.0
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 29.0 36.5 38.0 41.5 45.5 48.5 52.5 56.0
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
0.29 - 0.44 MPa 0.36 - 0.5 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating)
Dimensions (L × W × H)* 683 × 498.5 × 713 mm 649 × 498.5 × 713 mm
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Engine Model 4TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 2.190L
min-1 1500 1800
PS 22.3 26.7
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 24.5 29.4 32.7 36.0 39.2 42.5 45.8 48.1
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating) ***
Dimensions (L × W × H)* 683 × 498.5 × 618 mm 658 × 498.5 × 618 mm
Engine Oil Pan Capacity** 7.4 / 4.0 L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

4TNV94L (~ EPA Tier2)

Engine Model 4TNV94L
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 3.054L
min-1 1500 1800
PS 35.5 42.5
min-1 1500 1800 2000 2200 2400 2500
PS 39.5 47.0 48.0 52.0 56.5 58.5
High Idling min-1 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry) 245 kg 235 kg
Normal Oil Pressure at Rated 0.29 - 0.39 MPa
Engine Speed
0.06 MPa
Idle Speed
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Crank V-pulley dia./ φ130/ φ130mm ***
Fan V-pulley dia.

Engine Model 4TNV98
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
PS 42.0 50.0
min-1 1500 1800 2000 2200 2400 2500
PS 47.0 56.0 57.0 62.0 67.0 69.5
High Idling min-1 1600 ± 25 1895 ±25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Speed
0.06 MPa
Idle Speed
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
Fan V-pulley dia.


Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
PS 51.5 62.0
min-1 1500 1800 2000 2200 2400 2500
PS 57.0 68.5 69.0 75.5 82.0 85.0
High Idling min-1 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 64Ah ***
Dimensions (L × W × H)* 719 × 575 × 804mm
10.5/6.0L
Standard Cooling Fan 430mm O.D., 8 Blade Suction-Type ***
Fan V-pulley dia.

Engine Model 4TNV106
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 4.412L
min-1 1500 1800
PS 56.0 67.0
min-1 1500 1800 2000 2200 2400 2500
PS 62.0 74.0 77.0 83.5 89.0 92.0
High Idling min-1 1600 ± 25 1895 ± 25 2205 ± 25 2420 ± 25 2615 ± 25 2725 ± 25
Engine Weight (Dry) 345kg 330kg
Normal Oil Pressure at Rated 0.31 - 0.49 MPa With balancer: 0.34-0.44 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 88 Ah***
14.0/5.0L 14.0/6.5L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D. 7 Blade Suction-Type ***
Fan V-pulley dia.


Version CL VM
No. of Cylinders 4
Displacement 4.412L
min-1 1500 1800
PS 70.0 84.0
min-1 1500 1800 2000 2200
Max. Rated Output (Net) kW 56.8 68.0 69.9 72.0
PS 77.2 92.5 95.0 97.9
High Idling min-1 1600 ± 25 1875 ± 25 2205 ± 25 2420 ± 25
Normal Oil Pressure at Rated 0.31 - 0.49 MPa With balancer: 0.34-0.44 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
0.06 MPa
Idle Speed
Electric Starting (Starter Motor DC12V (3.0 kW)) ***
Recommended Battery Capacity: 12V, 88 Ah***
14.0/5.0L 14.0/6.5L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D.7 Blade Suction-Type***
Fan V-pulley dia.

3TNV82A-B (complies with EPA Interim Tier4)
Engine Model 3TNV82A-B
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Aspiration Natural aspiration
No. of Cylinders 3
Bore × Stroke φ82 × 84mm
Displacement 1.331L
min-1
Continuous Rated
Output kW
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output kW 16.0 16.8 17.5 18.2 19.0 19.7 20.4 21.9
(Net) PS 21.8 22.8 23.8 24.8 25.8 26.8 27.8 29.8
23.0
High Idling min-1 2375 2485 2570 2675 2780 2890 2995 3180
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
128kg
Governor Mechanical governor (All-speed governor)
Rated Engine 0.36-0.51 (3.7-
Speed 0.31-0.46 (3.2-4.7) MPa 5.2) MPa
Normal Oil
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery
Capacity 12V-55Ah*** (5h rating)
Starting aid device Super-quick Heating Glow plug
5.5L/3.6L
Standard Cooling Fan Resin F type pusher fan - φ335(NF) x 6
Crank V-pulley dia./ φ110/ φ110mm
Fan V-pulley dia.

3TNV84T-B (complies with EPA Interim Tier4)

Engine Model 3TNV84T-B
Version CL VM
No. of Cylinders 3
Displacement 1.496L
min-1
Continuous Rated
Output kW
PS
min-1 2400 2500 2600 2700 2800
Max. Rated Output
(Net) kW 25.0 26.0 26.8 27.9 29.1
PS 34.0 35.3 36.5 38.0 39.5
2590 2700 2810 2920 2995
High Idling min-1
±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 155kg
Governor Electronic governor (All-speed governor)
Rated Engine 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-5.5) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery 12V-55Ah*** (5h rating)
Capacity
Starting aid device Air heater (12V DC 400W)
Dimensions (L × W × H)* 589 × 486 × 564 × 486 × 622mm
622mm
6.7L/3.9L
Standard Cooling Fan Resin F type pusher fan - φ350(QF) x 6
Fan V-pulley dia.

3TNV88-U (complies with EPA Interim Tier4)
Engine Model 3TNV88-U
Version CL VM
No. of Cylinders 3
Displacement 1.642L
min-1
Continuous Rated
Output kW
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 18.1 18.9 19.7 20.5 21.3 22.2 23.0 24.6
PS 24.6 25.7 26.8 27.9 29.0 30.2 31.3 33.5
2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
Rated Engine 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-
Normal Oil Speed 5.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
6.7L/3.9L
φ110/ φ110mm
Fan V-pulley dia.

3TNV88-B (complies with EPA Interim Tier4)

Engine Model 3TNV88-B
Version CL VM
No. of Cylinders 3
Displacement 1.642L
min-1 1500 1800
Continuous Rated
Output kW 12.3 14.8
PS 16.7 20.1
min-1 1500 1800 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 13.5 16.3 19.9 20.7 21.6 22.6 23.5 24.3 25.2 27.1
PS 18.4 22.1 27.0 28.2 29.4 30.7 31.9 33.1 34.2 36.8
1600 1895 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 161kg 155kg
Rated Engine 0.29-0.44 (3.0- 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-
Normal Oil Speed 4.5) MPa 5.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
622mm
6.7L/3.9L
Crank V-pulley dia./ φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV84T-Z (complies with EPA Interim Tier4)
Engine Model 4TNV84T-Z
Version CL VM
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
Continuous Rated
Output kW 19.1 24.3
PS 26.0 33.0
min-1 1500 1800 2400 2500 2700 2800 3000
Max. Rated Output
(Net) kW 21.3 26.9 33.5 34.5 37.1 38.6 41.2
PS 29.0 36.5 45.5 47.0 50.5 52.5 56.0
1600 1895 2590 2700 2850 2950 3150
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
Rated Engine 0.29-0.44 (3.0- 0.36-0.51 (3.7-5.2) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW) ***
Capacity
Starting aid device Air heater (12V DC 400W)
713mm
7.4L/4.0L
Standard Cooling Fan Resin F type pusher fan - φ370(EF) x 6
Crank V-pulley dia./ φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV88-U (complies with EPA Interim Tier4)

Engine Model 4TNV88-U
Version CL VM
No. of Cylinders 4
Displacement 2.190L
min-1
Continuous Rated
Output kW
PS
min-1 2700 2800
Max. Rated Output
(Net) kW 29.6 30.7
PS (40.2) (41.7)
2920 2995
High Idling min-1
±25 ±25
Engine Weight (dry)
Rated Engine 0.32-0.47 (3.3-4.8) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV88-B (complies with EPA Interim Tier4)
Engine Model 4TNV88-B
Version CL VM
No. of Cylinders 4
Displacement 2.190L
min-1 1500 1800
Continuous Rated
Output kW 16.4 19.6
PS 22.3 26.7
min-1 1500 1800 2000 2100 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 18.0 21.6 24.1 25.3 26.5 27.7 28.8 30.1 31.3 32.5 33.7 35.4
PS 24.5 29.4 32.7 34.4 36.0 37.6 39.2 40.9 42.5 44.2 45.8 48.1
1600 1895 2180 2290 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
Rated Engine 0.29-0.44 (3.0- 0.32-0.47 (3.3-4.8) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
φ120/ φ90 φ110/ φ110
Fan V-pulley dia.

4TNV98-E (complies with EPA Interim Tier4)

Engine Model 4TNV98-E
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1
Continuous Rated
Output kW
PS
min-1 2100 2200 2300 2400 2500
Max. Rated Output
(Net) kW 36.8 38.2 39.7 41.6 43.0
PS 50.0 52.0 54.0 56.5 58.5
High Idling min-1 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 240kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed 0.06 (0.6) MPa
Recommended Battery
12V-64Ah*** (5h rating)
Capacity
Starting aid device Air heater (12VDC/500W)
Engine Oil Pan Capacity** 10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
Fan V-pulley dia. φ130/ φ130mm


4TNV98-Z (complies with EPA Interim Tier4)
Engine Model 4TNV98-Z
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
Continuous Rated
Output kW 30.9 36.8
PS 42.0 50.0
min-1 1500 1800 2000 2100 2200 2300 2400 2500
Max. Rated Output
(Net) kW 34.6 41.2 41.9 43.8 45.6 47.4 49.3 51.1
PS 47.0 56.0 57.0 59.5 62.0 64.5 67.0 69.5
High Idling min-1 1530 ± 25 1830 ± 25 2150 ± 25 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 248kg 235kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed 0.06 (0.6) MPa
Recommended Battery
Capacity
Engine Oil Pan Capacity** 10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
Fan V-pulley dia. φ130/ φ130mm


4TNV98T-Z (complies with EPA Interim Tier4)

Engine Model 4TNV98T-Z
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
Continuous Rated
Output kW 37.9 45.6
PS 51.5 62.0
min-1 1500 1800 2200 2300 2400 2500
Max. Rated Output
(Net) kW 41.9 50.4 55.5 58.0 60.3 62.5
PS 57.0 68.5 75.5 78.8 82.0 85.0
High Idling min-1 1530 ± 25 1830 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 258kg 245kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed ≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ430(UX) x 6
Fan V-pulley dia.

Engine Service Standards GENERAL SERVICE INFORMATION
ENGINE SERVICE STANDARDS

Reference
Inspection Item Standard Limit
page
All models
except 0.006 - 0.010 in. See Measuring
-
4TNV106 and (0.15 - 0.25 mm) and Adjusting
Intake / Exhaust Valve Clearance 4TNV106T Valve Clearance
4TNV106 and 0.010 - 0.014 in. on page 6-66
-
4TNV106T (0.25 - 0.35 mm)
Fuel Injection
See Checking and Adjusting Fuel Injection Timing on page 7-30.
Timing
Fuel Injection
See Test and Adjustment Specifications on page 7-12.
Pressure
443 - 473 psi 340 - 370 psi
3TNV82A (3.06 - 3.26 MPa; (2.35 - 3.55 MPa;
30 - 32 kgf / cm²) 24 - 26 kgf / cm²)
455 - 485 psi 355 - 385 psi See
Compression 3TNV84, 4TNV84 (3.14 - 3.34 MPa; (2.45 - 2.65 MPa; Troubleshooting
Pressure at 32 - 34 kgf / cm²) 25 - 27 kgf / cm²) By Measuring
250 rpm 411 - 441 psi 340 - 370 psi Compression
(250 min¯¹) 3TNV84T, 4TNV84T (2.84 - 3.04 MPa; (2.35 - 2.55 MPa; Pressure on
29 - 31 kgf / cm) 24 - 26 kgf / cm²) page 15-187
3TNV88, 4TNV88, 4TNV94L, 483 - 513 psi 384 - 414 psi
4TNV98, 4TNV98T, 4TNV106, (3.33 - 3.53 MPa; (2.65 - 2.85 MPa;
4TNV106T 34 - 36 kgf / cm²) 27 - 29 kgf / cm²)
29 - 43 psi
Deviation Between Cylinders All Models (0.2 - 0.3 MPa; - -
2 - 3 kgf/cm²)
5.8 - 8.8 psi
Oil Pressure Switch Operating Pressure (0.04 - 0.06 MPa; - -
0.4 - 0.6 kgf / cm²)
Valve Opening Full Opening Lift
Temperature Temperature
0.32 in (8 mm) or
157°F - 163°F
All Models above See Thermostat
Thermostat (70°C - 73°C)
185°F (85°C) on page 8-11
0.39 in (10 mm) or
All Models 176°F - 183°F
above
Option (80°C - 84°C)
203°F (95°C)
See
225°F - 235°F Temperature
Coolant Temperature Switch -
(107°C - 113°C) Switch on
page 8-10

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

Use the correct amount of torque when you tighten
the fasteners on the machine. Applying excessive CAUTION
torque may damage the fastener or component and The tightening torque in the Standard
not enough torque may cause a leak or component Torque Chart (see General Service
failure. Information section) 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.
0000023enTNVDISM
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
7 - 9 ft-lb
(87 -104 in.-lb,
M6 x 1.0 mm
9.8 -11.8 N·m,
1.0 -1.2 kgf·m)
17 - 21 ft-lb
M8 x 1.25 mm (200 - 251 in.-lb,
22.6 - 28.4 N·m,
2.3 - 2.9 kgf·m)
33 - 40 ft-lb Use 80% of the value at left
M10 x 1.5 mm (44.1 - 53.9 N·m, when the tightening part is
Hexagon Bolt (7T) and
Nut 4.5 - 5.5 kgf·m) aluminum.
Use 60% of the value at left for
58 - 72 ft-lb 4T bolts and lock nuts.
M12 x 1.75 mm (78.4 - 98.0 N·m,
8.0 - 10 kgf·m)
94 - 108 ft-lb
M14 x 1.5 mm (127.5 - 147.1 N·m,
13 - 15 kgf·m)
159 - 174 ft-lb
M16 x 1.5 mm (215.7- 235.4 N·m,
22 - 24 kgf·m)
1/8 mm 7 ft-lb
(87 in.-lb, 9.8 N·m, 1.0 kgf·m)
14 ft-lb
1/4 mm
(173 in.-lb, 19.6 N·m, 2.0 kgf·m)
PT PLug -
22 ft-lb
3/8 mm (29.4 N·m, 3.0 kgf·m)
1/2 mm 43 ft-lb
(58.8 N·m, 6.0 kgf·m)

Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
9 - 12 ft-lb
(112 - 148 in.-lb,
M8
12.7 - 16.7 N·m,
1.3 - 1.7 kgf·m)
14 - 19 ft-lb
M10 (173 - 225 in.-lb,
19.6 - 18.734 N·m,
2.0 - 3.5 kgf·m)
Pipe Joint Bolt 18 - 25 ft-lb -
M12 (24.5 - 34.3 N·m,
2.5 - 3.5 kgf·m)
29 - 36 ft-lb
M14 (39.2 - 49.0 N·m,
4.0 - 5.0 kgf·m)
36 - 43 ft-lb
M16 (49.0 - 58.8 N·m,
5.0 - 6.0 kgf·m)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

GENERAL SERVICE INFORMATION Abbreviations and Symbols
ABBREVIATIONS AND JASO Japanese Automobile Standards

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

Unit Conversions GENERAL SERVICE INFORMATION
UNIT CONVERSIONS Units of Torque

ft-lb x 1.3558 = N·m
Unit Prefixes ft-lb x 0.1383 = kgf/m
Prefix Symbol Power in.-lb x 0.1130 = N·m
mega M x 1,000,000 in.-lb x 0.0115 = kgf/m
kilo k x 1,000 kgf/m x 7.2330 = ft-lb
centi c x 0.01 kgf/m x 86.8000 = in.-lb
milli m x 0.001 kgf/m x 9.8070 = N·m
micro μ x 0.000001 N·m x 0.7376 = ft-lb
N·m x 8.8510 = in.-lb
Units of Length N·m x 0.1020 = kgf/m
mile x 1.6090 = km Units of Pressure
ft x 0.3050 =m
in. x 2.5400 = cm psi x 0.0689 = bar
in. x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm²
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in. bar x 100.0000 = kPa
mm x 0.0394 = in. bar x 29.5300 = inHg (60°F)
kPa x 0.1450 = psi
Units of Volume kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm²
gal (U.S.) x 3.78540 =L
kg/cm² x 98.0700 = psi
qt (U.S.) x 0.94635 =L
kg/cm² x 0.9807 = bar
cu in. x 0.01639 =L
kg/cm² x 14.2200 = kPa
cu in. x 16.38700 = mL
in.Hg (60°) x 0.0333 = bar
fl oz (U.S.) x 0.02957 =L
in.Hg (60°) x 3.3770 = kPa
fl oz (U.S.) x 29.57000 = mL
in.Hg (60°) x 0.0344 = kg/cm²
cm³ x 1.00000 = mL
mmAq x 0.0394 = in.Aq
cm³ x 0.03382 = fl oz (U.S.)
Units of Mass Units of Power

hp (metric x 0.9863201 = hp SAE
lb x 0.45360 = kg
or PS)
oz x 28.35000 =g
hp (metric x 0.7354988 = kW
kg x 2.20500 = lb
or PS)
g x 0.03527 = oz
hp SAE x 1.0138697 = hp (metric or PS)
Units of Force hp SAE x 0.7456999 = kW
kW x 1.3596216 = hp (metric or PS)
lbf x 4.4480 =N kW x 1.3410221 = hp SAE
lbf x 0.4536 = kgf
N x 0.2248 = lbf Units of Temperature
N x 0.1020 = kgf
°F = (1.8 x °C) + 32
kgf x 2.2050 = lbf
°C = 0.556 x (°F - 32)
kgf x 9.8070 =N

GENERAL SERVICE INFORMATION Unit Conversions

Section 5
PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ............................................................ 5-3
Introduction.................................................................................... 5-16
The Importance of Periodic Maintenance................................ 5-16
Performing Periodic Maintenance ........................................... 5-16
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance -USA Only........................ 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule.................................................... 5-17
Periodic Maintenance Procedures ................................................ 5-20
After Initial 50 Hours of Operation ........................................... 5-20
Every 50 Hours of Operation ................................................... 5-24
Every 250 Hours of Operation ................................................. 5-27
Every 500 Hours of Operation ................................................. 5-32
Every 1000 Hours of Operation ............................................... 5-36

PERIODIC MAINTENANCE

Before You Begin Servicing PERIODIC MAINTENANCE
BEFORE YOU BEGIN

A DANGER
SERVICING
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
EXPLOSION HAZARD! engine is hot. Steam and hot engine
coolant will spurt out and seriously
• NEVER check the remaining battery burn you. Allow the engine to cool
charge by shorting out the terminals. down before you attempt to remove
This will result in a spark and may the radiator cap.
hydrometer to check the remaining • Tighten the radiator cap securely after
battery charge. you check the radiator. Steam can
• If the electrolyte is frozen, slowly warm the cap is loose.
the battery before you recharge it.
• ALWAYS check the level of the engine
• Failure to comply will result in death or coolant by observing the reserve tank.
serious injury.
0000007en
serious injury.
0000002en
A DANGER

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

PERIODIC MAINTENANCE Before You Begin Servicing
A DANGER A DANGER

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

• NEVER remove the fuel cap with the
engine running.
serious injury.
0000011en

A DANGER A DANGER

• Diesel fuel is flammable and explosive CRUSH HAZARD!
under certain conditions. • When you need to transport an engine
for repair, have a helper assist you to
• Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose • NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. • Failure to comply will result in death or
• NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en
dried grass close to the engine during

engine operation or shortly after
shutdown.
serious injury.
0000014en
A DANGER

agent.
serious injury.
0000012en

A DANGER A DANGER

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

A WARNING A WARNING
EXHAUST HAZARD! SEVER HAZARD!

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

A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
ALCOHOL AND DRUG HAZARD!
or serious injury. • NEVER operate the engine while you
0000006en
are under the influence of alcohol or
drugs.
A WARNING • NEVER operate the engine when you

are feeling ill.
or serious injury.
0000004en
BURN HAZARD!
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.
or serious injury.
0000015en

A WARNING A WARNING
BURN HAZARD!
EXPOSURE HAZARD! • Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
• Wear personal protective equipment
with clothing, skin or eyes. Severe
such as gloves, work shoes, eye and
burns could result. ALWAYS wear
hearing protection as required by the
safety goggles and protective clothing
task at hand.
• NEVER wear jewelry, unbuttoned fluid contacts the eyes and / or skin,
cuffs, ties or loose-fitting clothing immediately flush the affected area
when you are working near with a large amount of clean water and
moving / rotating parts such as the obtain prompt medical treatment.
cooling fan, flywheel or PTO shaft.
• ALWAYS tie back long hair when you or serious injury.
are working near moving / rotating 0000007en
parts such as a cooling fan, flywheel,
or PTO shaft.
A WARNING
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
HIGH-PRESSURE HAZARD!
or serious injury.
0000005en
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
or serious injury.
0000008en

A WARNING A WARNING
BURN HAZARD!
SHOCK HAZARD!
• If you must drain the engine oil while it
• Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system. • ALWAYS wear eye protection.
• Check the electrical harnesses for • Failure to comply could result in death
cracks, abrasions, and damaged or or serious injury.
corroded connectors. ALWAYS keep 0000011en

• Failure to comply could result in death A WARNING
or serious injury.
0000009en
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
ENTANGLEMENT HAZARD! • Failure to comply could result in death
• Stop the engine before you begin to or serious injury.
service it. 0000016en
• NEVER leave the key in the key switch

when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away
or serious injury.
0000010en

A CAUTION CAUTION
warranty requirements.
COOLANT HAZARD! • Only use clean diesel fuel.
• Wear eye protection and rubber gloves • NEVER remove the primary strainer (if
when you handle long life or extended equipped) from the fuel tank filler port.
life engine coolant. If contact with the If removed, dirt and debris could get
eyes or skin should occur, flush eyes into the fuel system causing it to clog.
and wash immediately with clean 0000004en
water.
• Failure to comply may result in minor CAUTION
or moderate injury. • Only use the engine oil specified.
0000005en
coverage, cause internal engine
A CAUTION components to seize and / or shorten
engine life.
the cap.
FLYING OBJECT HAZARD! • NEVER mix different types of engine
• ALWAYS wear eye protection when oil. This may adversely affect the
servicing the engine and when using lubricating properties of the engine oil.
compressed air or high-pressure • NEVER overfill. Overfilling may result
water. Dust, flying debris, compressed in white exhaust smoke, engine
air, pressurized water or steam may overspeed or internal damage.
injure your eyes. 0000005en

or moderate injury.
0000003en

CAUTION CAUTION
• Only use the engine coolant specified. Observe the following environmental
Other engine coolants may affect operating conditions to maintain engine
warranty coverage, cause an internal performance and avoid premature
buildup of rust and scale and / or engine wear:
shorten engine life. • Avoid operating in extremely dusty
• Prevent dirt and debris from conditions.
contaminating the engine coolant. • Avoid operating in the presence of
Carefully clean the radiator cap and chemical gases or fumes.
remove the cap. • Avoid operating in a corrosive
atmosphere such as salt water spray.
coolants. This may adversely affect the • NEVER install the engine in a
properties of the engine coolant. floodplain unless proper precautions
0000006en
are taken to avoid being subject to a
flood.
CAUTION • NEVER expose the engine to the rain.

0000003en
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit CAUTION
control or the diesel fuel injection Observe the following environmental
quantity control. operating conditions to maintain engine
• Modifications may impair the engine’s performance and avoid premature
safety and performance engine wear:
characteristics and shorten the • The standard range of ambient
engine’s life. Any alterations to this temperatures for the normal operation
engine may void its warranty. Be sure of Yanmar engines is from +5°F (-15°C)
to use Yanmar genuine replacement to +113°F (+45°C).
parts.
• If the ambient temperature exceeds
0000079en
+113°F (+45°C) the engine may
overheat and cause the engine oil to
break down.
• If the ambient temperature is below
+5°F (-15°C) the engine will be hard to
start and the engine oil may not flow
easily.
• Contact your authorized Yanmar
industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en

CAUTION CAUTION
NEVER hold the key in the START New Engine Break-in:
position for longer than 15 seconds or • On the initial engine start-up, allow the
the starter motor will overheat. engine to idle for approximately 15
0000007en
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
CAUTION engine oil leaks, coolant leaks, and for
proper operation of the indicators
For maximum engine life, Yanmar
and / or gauges.
recommends that when shutting the
engine down, you allow the engine to • During the first hour of operation, vary
idle, without load, for five minutes. This the engine speed and the load on the
will allow the engine components that engine. Short periods of maximum
operate at high temperatures, such as engine speed and load are desirable.
the turbocharger (if equipped) and Avoid prolonged operation at
exhaust system, to cool slightly before minimum or maximum engine speeds
the engine itself is shut down. and loads for the next four to five
0000008en hours.
• During the break-in period, carefully
CAUTION observe the engine oil pressure and
engine temperature.
NEVER use an engine starting aid such
as ether. Engine damage will result. • During the break-in period, check the
0000009en
engine oil and coolant levels
frequently.
0000011en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
CAUTION
engine is installed at an angle greater NEVER engage the starter motor while
than (IDI = 25°, DI = 30°) in any direction the engine is running. This may damage
or if an engine runs for short periods of the starter motor pinion and / or ring
time (less than three minutes) at an gear.
angle greater than (IDI = 30°, DI = 35°) in 0000012en
any direction, engine oil may enter the

combustion chamber causing excessive CAUTION
engine speed and white exhaust smoke.
This may cause serious engine damage. It is important to perform daily checks.
0000010enTNV Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en

CAUTION CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
• ALWAYS be environmentally 0000016en
responsible.
• Follow the guidelines of the EPA or CAUTION
other governmental agencies for the NEVER attempt to adjust the low or high
proper disposal of hazardous idle speed limit screw. This may impair
materials such as engine oil, diesel the safety and performance of the
fuel and engine coolant. Consult the machine and shorten its life. If the idle
local authorities or reclamation facility. speed limit screws require adjustment,
• NEVER dispose of hazardous see your authorized Yanmar industrial
materials irresponsibly by dumping engine dealer or distributor.
them into a sewer, on the ground, or 0000017en
into ground water or waterways.

• Failure to follow these procedures may CAUTION
seriously harm the environment. Establish a periodic maintenance plan
0000013en according to the engine application and
make sure you perform the required
CAUTION periodic maintenance at the intervals
indicated. Failure to follow these
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
shorten the engine’s life and may affect
high-pressure water to clean the engine.
the warranty coverage on your engine.
0000014en
Warranty Section.
CAUTION
Consult your authorized Yanmar dealer
• NEVER overfill the engine with engine or distributor for assistance when
oil. checking items marked with a .
• ALWAYS keep the oil level between the 0000024enTNVDISM
upper and lower lines on the oil
cap / dipstick.
0000015en

CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
CAUTION
• When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
• NEVER operate the engine with the air
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
CAUTION
The maximum air intake restriction, in
terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
mentioned value.
0000046en

PERIODIC MAINTENANCE Introduction
INTRODUCTION Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
This section of the Service Manual describes the perform the procedures indoors to prevent
procedures for proper care and maintenance of the environmental conditions, such as rain, wind, or
engine. snow, from damaging the machine.
The Importance of Periodic Yanmar Replacement Parts
Maintenance Yanmar recommends that you use genuine Yanmar
Engine deterioration and wear occurs in proportion parts when replacement parts are needed.
to length of time the engine has been in service and Genuine replacement parts help ensure long
the conditions the engine is subject to during engine life.
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of Required EPA / ARB Maintenance -
accidents due to poor machine performance and USA Only
helps extend the life of the engine.
To maintain optimum engine performance and
Performing Periodic Maintenance compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
A WARNING California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-17 and
Periodic Maintenance Procedures on page 5-20.
EPA / ARB Installation

EXHAUST HAZARD! Requirements - USA Only
• NEVER operate the engine in an The following are the installation requirements for
enclosed area such as a garage, the EPA / ARB. Unless these requirements are met,
tunnel, underground room, manhole or the exhaust gas emissions will not be within the
ship’s hold without proper ventilation. limits specified by the EPA and ARB.
• NEVER block windows, vents, or other Maximum Exhaust Gas Restriction shall be:
means of ventilation if the engine is
• 3TNV84T(-B): 1.42 psi (9.81 kPa; 1000 mm
operating in an enclosed area. All
Aq) or less
internal combustion engines create
carbon monoxide gas during • 4TNV98T(-Z): 1.71 psi (11.77 kPa; 1200 mm
operation. Accumulation of this gas Aq) or Iess
within an enclosure could cause • 3TNV82A(-B),3TNV84,3TNV88(-B)(-U),
illness or even death. 4TNV94L,4TNV98(-Z)(-E): 2.22 psi (15.3 kPa;
• Make sure that all connections are 1560 mm Aq) or Iess
tightened to specifications after repair Maximum air intake restriction shall be 0.90 psi
is made to the exhaust system. (6.23 kPa; 635 mm Aq) or less. Clean or replace
• Failure to comply could result in death the air cleaner element if the air intake restriction
or serious injury. exceeds the above mentioned value.
0000003en

Periodic Maintenance Schedule PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
SCHEDULE
Daily and periodic maintenance is important to
keep the engine in good operating condition. The
following is a summary of maintenance items by
periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
application, loads, diesel fuel and engine oil used
and are hard to establish definitively. The following
should be treated only as a general guideline.
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at the intervals
indicated. Failure to follow these
shorten the engine’s life and may affect
the warranty coverage on your engine.
Warranty Section.
Consult your authorized Yanmar dealer
or distributor for assistance when
checking items marked with a .
0000024enTNVDISM

PERIODIC MAINTENANCE Periodic Maintenance Schedule
: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Check and Refill Engine Coolant

Check and Clean Radiator Fins
Check and Adjust Cooling Fan V-belt 1st time 2nd and
after
Cooling
System or
every 1
year
Drain, Flush and Refill Cooling System With New Coolant which-
ever
comes
first
Cylinder Adjust Intake / Exhaust Valve Clearance

Head Lap Intake / Exhaust Valve Seats. If necessary
Electrical Check Indicators

Equipment Check Battery
Check Engine Oil Level
Engine Oil Drain and Fill Engine Oil 2nd and

1st time
after
Replace Engine Oil Filter
Engine
Check and Adjust Governor Lever and
Speed Engine Speed Control
Control
Inspect, Clean And Test Fuel Injectors
Inspect Turbocharger
(Blower Wash as Necessary)
3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T,
3TNV84T-B, 4TNV84T-Z, 4TNV98T-Z
Emission Inspect, Clean and Test EGR Valve

Control 4TNV84T, 4TNV98T
Warranty
Clean EGR Lead Valve
4TNV84T, 4TNV98T
Clean EGR Cooler
(Clean to Blow Water/Air Passages)
4TNV84T, 4TNV98T
Inspect Crankcase Breather System
Check and Refill Fuel Tank Level
Drain Fuel Tank
Drain Fuel Filter / Water Separator
Fuel
Check Fuel Filter / Water Separator
Clean Fuel Filter / Water Separator
Replace Fuel Filter
Replace Fuel System and

Hoses Cooling System Hoses or every
2 yrs.

Periodic Maintenance Schedule PERIODIC MAINTENANCE
: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Intake and
Clean or Replace Air Cleaner Element
Exhaust
Complete
Engine Overall Visual Check Daily
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

PERIODIC MAINTENANCE Periodic Maintenance Procedures
PERIODIC MAINTENANCE CAUTION

PROCEDURES • Only use the engine oil specified.
After Initial 50 Hours of Operation coverage, cause internal engine
Perform the following maintenance after the initial engine life.
50 hours of operation. • Prevent dirt and debris from
• Replace Engine Oil and Engine Oil Filter contaminating the engine oil. Carefully
• Check and Adjust Cooling Fan V-Belt surrounding area before you remove
the cap.
Replace Engine Oil and Engine Oil Filter
A WARNING oil. This may adversely affect the
0000005en
BURN HAZARD!
• If you must drain the engine oil while it CAUTION
• ALWAYS wear eye protection.
or serious injury.
0000011en
• ALWAYS be environmentally
responsible.
A WARNING • Follow the guidelines of the EPA or

other governmental agencies for the
SUDDEN MOVEMENT HAZARD! proper disposal of hazardous
• Engaging the transmission or PTO at materials such as engine oil, diesel
an elevated engine speed could result fuel and engine coolant. Consult the
in unexpected movement of the local authorities or reclamation facility.
equipment. • NEVER dispose of hazardous
• Failure to comply could result in death materials irresponsibly by dumping
or serious injury. them into a sewer, on the ground, or
0000006en
• Failure to follow these procedures may
seriously harm the environment.
0000013en

Periodic Maintenance Procedures PERIODIC MAINTENANCE
The engine oil in a new engine becomes 7. After all oil has been drained from the engine,
contaminated from the initial break-in of internal reinstall the oil drain plug (Figure 5-2, (1)) and
parts. It is very important that the initial oil and filter tighten to 139.8 - 47.0 ft·lb (53.9 - 63.7 N·m;
change is performed as scheduled. 5.5 - 6.5 kgf·m).
Note: The oil drain plug may be in another 8. Dispose of used oil properly.
location if an optional oil pan is used. Remove the engine oil filter as follows:
Drain the engine oil as follows: 1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
1. Make sure the engine is level.
wrench.
2. Start the engine and bring it up to operating
temperature. (3)
3. Stop the engine.
(4)
4. Remove one of the oil filler caps
(Figure 5-1, (1)) to vent the engine crankcase
and allow the engine oil to drain more easily.
5. Position a container under the engine to collect
waste oil.
(2)
(1)
(1)
0000062B
Figure 5-2
(1) 0000084 2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (4)) until it contacts the mounting
surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5
N·m; 2.0 - 2.4 kgf·m) or one additional turn
using the filter wrench.
0000084B
Figure 5-1
6. Remove the oil drain plug (Figure 5-2, (1)) from
the engine oil pan. Allow oil to drain.

Engine Oil Filter Part No. (4)

Standard Dust proof *
3TNV82A
3TNV84
- 4TNV98
3TNV82A-B 129150-35153
3TNV88-B
- 4TNV98-Z 119005-35151
4TNV98-E
4TNV98T
4TNV98T-Z (4)
119005-35151
4TNV106,
4TNV106T (5)
* Consult the operation manual for the driven

machine for applicability of the dust proof
filter. (2)
(1)
4. Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-17.
(3)
CAUTION 0000007C
• NEVER overfill the engine with engine Figure 5-3

oil.
9. Reinstall the oil filler cap (Figure 5-3, (4)). If
• ALWAYS keep the oil level between the any engine oil is spilled, wipe it away with a
upper and lower lines on the oil clean cloth.
cap / dipstick.
0000015en Check and Adjust Cooling Fan V-Belt
The V-belt will slip if it does not have the proper
5. Warm up the engine by running it for five
tension. This will prevent the alternator from
minutes and check for any engine oil leaks.
generating sufficient power. Also, the engine will
6. After engine is warm, shut it off and let it sit for overheat due to the engine coolant pump pulley
10 minutes. slipping.
7. Recheck the engine oil level.
Check and adjust the V-belt tension (deflection) as
8. Add engine oil (Figure 5-3, (5)) as needed until follows:
the level is between the upper (Figure 5-3, (2))
and lower lines (Figure 5-3, (3)) shown on the 1. Press the V-belt down with your thumb with a
dipstick (Figure 5-3, (1)). force of approximately 22 ft·lb (98 N·m; 10 kgf)
to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-4, (A), (B) and (C)). You can
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is:

Used V-Belt Tension

A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
(2)
Note: A “Used V-Belt” refers to a V-belt which (1)

has been used on a running engine for
five minutes or more. 0000584
(B) Figure 5-6
(A)
(C)
0000063B
Figure 5-4
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Figure 5-5, (1)) and move
the alternator (Figure 5-5, (2)) with a pry bar
(Figure 5-5, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting bolt.
(3)
(1)
(2) 0000064B
Figure 5-5
3. Tighten the V-belt to the proper tension. There
must be clearance (Figure 5-6, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.

4. Check the V-belt for cracks, oil or wear. If any of

these conditions exist, replace the V-belt. Every 50 Hours of Operation
5. Install the new V-belt. Refer to the table for
proper tension. After you complete the initial 50 hour maintenance
procedures, perform the following procedures every
New V-Belt Tension 50 hours thereafter.
A B C
• Drain Fuel Filter / Water Separator
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm) • Check Battery
6. After adjusting, run the engine for 5 minutes or Drain Fuel Filter / Water Separator
more. Check the tension again using the
specifications for a used V-belt. A DANGER
Used V-Belt Tension
A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
• Wipe up any spills immediately.
is under pressure and fuel could spray
out when you remove any fuel system
component.
serious injury.
0000009en

The cup of the separator is made from semi-
CAUTION transparent material. In the cup is a red colored
If the fuel filter / water separator is float ring. The float ring will rise to the surface of the
positioned higher than the fuel level in water to show how much needs to be drained. Also,
the fuel tank, water may not drip out some optional fuel filter / water separators are
when the fuel filter / water separator equipped with a sensor to detect the amount of
drain cock is opened. If this happens, contaminants. This sensor sends a signal to an
turn the air vent screw on the top of the indicator to alert the operator.
fuel filter / water separator 2-3 turns
Drain the fuel filter / water separator as follows:
counterclockwise.
Be sure to tighten the air vent screw 1. Position an approved container under the fuel
after the water has drained out. filter / water separator (Figure 5-7, (1)) to
0000025en
collect the contaminants.
CAUTION (2)
(3)
(1)
responsible.
• Follow the guidelines of the EPA or (4) 0000012C
proper disposal of hazardous Figure 5-7
materials such as engine oil, diesel 2. Close (Figure 5-7, (2)) the fuel cock
fuel and engine coolant. Consult the (Figure 5-7, (3)).
local authorities or reclamation facility.
3. Loosen the drain cock (Figure 5-7, (4)) at the
• NEVER dispose of hazardous bottom of the fuel filter / water separator. Drain
materials irresponsibly by dumping any water collected inside.
them into a sewer, on the ground, or
into ground water or waterways. 4. Hand-tighten the drain cock.
• Failure to follow these procedures may CAUTION

If the fuel filter / water separator is
0000013en
positioned higher than the fuel level in
Drain the fuel filter / water separator whenever the fuel tank, water may not drip out
there are contaminants, such as water, collected in when the fuel filter / water separator
the bottom of the cup. NEVER wait until the drain cock is opened. If this happens,
scheduled periodic maintenance if contaminants turn the air vent screw on the top of the
are discovered. fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en

5. Open the fuel cock (Figure 5-7, (3)).

6. Be sure to prime the diesel fuel system when
A WARNING
you are finished. See Priming the Fuel System
on page 4-15.
7. Check for leaks.
Check Battery
BURN HAZARD!
A DANGER • Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
fluid contacts the eyes and / or skin,
EXPLOSION HAZARD! immediately flush the affected area
• NEVER check the remaining battery with a large amount of clean water and
charge by shorting out the terminals. obtain prompt medical treatment.
This will result in a spark and may
or serious injury.
hydrometer to check the remaining
0000007en
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it. CAUTION
serious injury.
0000007en
responsible.
• Follow the guidelines of the EPA or
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
• NEVER dispose of hazardous
materials irresponsibly by dumping
0000013en

• When the amount of fluid nears the lower limit
(Figure 5-8, (1)), fill with distilled water Every 250 Hours of Operation
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with Perform the following maintenance every 250 hours
insufficient battery fluid, the battery life is of operation.
shortened, and the battery may overheat and
explode. During the summer, check the fluid • Drain Fuel Tank
level more often than specified. • Replace Engine Oil and Engine Oil Filter
• Check and Clean Radiator Fins
(3) • Check and Adjust Cooling Fan V-Belt
(2) • Check and Adjust the Governor Lever and
Engine Speed Control
• Clean Air Cleaner Element
(1)
Drain Fuel Tank
A DANGER
0000067A
Figure 5-8
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery. FIRE AND EXPLOSION HAZARD!
• If the engine still will not start after charging, • Diesel fuel is flammable and explosive
have your authorized Yanmar industrial engine under certain conditions.
dealer or distributor check the battery and the • When you remove any fuel system
engine’s starting system. component to perform maintenance
• If operating the machine where the ambient (such as changing the fuel filter) place
temperature could drop to 5°F (-15°C) or less, an approved container under the
remove the battery from the machine at the end opening to catch the fuel.
of the day. Store the battery in a warm place • NEVER use a shop rag to catch the
until the next use. This will help start the engine fuel. Vapors from the rag are
easily at low ambient temperatures. flammable and explosive.
• Wipe up any spills immediately.
component.
serious injury.
0000009en

4. Drain the tank until clean diesel fuel with no

CAUTION water and dirt flows out. Reinstall and tighten
the drain plug firmly.
5. Reinstall the fuel cap.
6. Check for leaks.
Replace Engine Oil and Engine Oil Filter

responsible. CAUTION
• Follow the guidelines of the EPA or • Only use the engine oil specified.
other governmental agencies for the Other engine oils may affect warranty
proper disposal of hazardous coverage, cause internal engine
materials such as engine oil, diesel components to seize and / or shorten
fuel and engine coolant. Consult the engine life.
• NEVER dispose of hazardous contaminating the engine oil. Carefully
materials irresponsibly by dumping clean the oil cap / dipstick and the
them into a sewer, on the ground, or surrounding area before you remove
into ground water or waterways. the cap.
• Failure to follow these procedures may • NEVER mix different types of engine
seriously harm the environment. oil. This may adversely affect the
0000013en lubricating properties of the engine oil.
Note that a typical fuel tank is illustrated. • NEVER overfill. Overfilling may result
1. Position an approved container under the diesel overspeed or internal damage.
fuel tank (Figure 5-9, (1)) to collect the 0000005en
contaminates.
2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.
(3)
(1)
(2)
0000065A
Figure 5-9

Check and Clean Radiator Fins
CAUTION
A CAUTION
responsible.
• Follow the guidelines of the EPA or FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
• NEVER dispose of hazardous injure your eyes.
or moderate injury.
0000003en
seriously harm the environment. Dirt and dust adhering to the radiator fins reduce
0000013en
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
Change the engine oil every 250 hours of operation clean as needed.
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace Note that a typical radiator is shown in Figure 5-10
Engine Oil and Engine Oil Filter on page 5-20. for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa; 2 kgf/cm2) or less of
compressed air (Figure 5-10, (1)). Be careful
not to damage the fins with the compressed air.
• If there is a large amount of contamination on
the fins, apply detergent, thoroughly clean and
rinse with tap water.
CAUTION
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en

Checking and adjusting the governor lever:

1. Check that the governor lever (Figure 5-11, (1))
makes uniform contact with the high idle
(Figure 5-11, (2)) and low idle
(1) (Figure 5-11, (3)) speed limit screws when the
FULL
LOW
engine speed control is in the high idle speed or
low idle speed position.
0000085A
(2) (3)
Figure 5-10
Check and Adjust Cooling Fan V-Belt

(1)
Check and adjust the cooling fan V-belt every 250
hours of operation after the initial 50 hour V-belt
maintenance. See Check and Adjust Cooling Fan
V-Belt on page 5-22.
(4)
Check and Adjust the Governor Lever and
Engine Speed Control
0000069A
(This does not apply to the following
electronically controlled engines: 4TNV84T- Figure 5-11
Z, 4TNV98-E, Z, and 4TNV98T-Z.) 2. If the governor lever does not make contact with
The governor lever and engine speed control the high idle or low idle speed limit screw, adjust
(throttle lever, pedal, etc.) of the machine are the throttle cable.
connected together by a throttle cable or rod. If the 3. In some engine speed control applications,
cable becomes stretched, or the connections loosen the throttle cable lock nut
loosen, the governor lever may not respond to (Figure 5-11, (4)) and adjust the cable so the
change of engine speed control position. This may governor lever makes proper contact with the
make operation of the machine unsafe. Check the high / low idle speed limit screw.
cable periodically and adjust if necessary.
NEVER force the throttle cable or pedal to move. CAUTION
This may deform the governor lever or stretch the NEVER attempt to adjust the low or high
cable and cause irregular operation of the engine idle speed limit screw. This may impair
speed control. the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en

Clean Air Cleaner Element 3. Blow air (Figure 5-12, (3)) through the element
Note that a typical air cleaner is shown in from the inside out using 42 - 71 psi
Figure 5-12 and Figure 5-13 for illustrative (0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2)
purposes only. compressed air to remove the particulates. Use
the lowest possible air pressure to remove the
The engine performance is adversely affected dust without damaging the element.
when the air cleaner element is clogged with dust. 4. If the air cleaner is equipped with a double
Be sure to clean the air filter element periodically. element, only remove and replace the inner
1. Unlatch and remove the air cleaner cover element (Figure 5-13, (1)) if the engine lacks
(Figure 5-12, (1)). power or the dust indicator actuates (if
equipped).
(6) (4)
(2)
(5)
(3)
(1)
(1)
0000070A
Figure 5-12 0000071A
2. Remove the element (Figure 5-12, (2)) (outer Figure 5-13

element if equipped with two elements). 5. The inner element should not be removed when
cleaning or replacing the outer element. The
A CAUTION inner element is used to prevent dust from
entering the engine while servicing the outer
element.
FLYING OBJECT HAZARD!

injure your eyes.
or moderate injury.
0000003en

6. Replace the element with a new one if the

element is damaged, excessively dirty or oily. Every 500 Hours of Operation
7. Clean inside of the air cleaner cover.
Perform the following maintenance every 500 hours
8. Install the element into the air cleaner case of operation.
(Figure 5-12, (4)).
9. Reinstall the air cleaner cover making sure you • Replace Air Cleaner Element
match the arrow (Figure 5-12, (5)) on the cover • Replace Fuel Filter
with the arrow on the case (Figure 5-12, (6)). • Clean Fuel Filter / Water Separator
10. Latch the air cleaner cover to the case.
Replace Air Cleaner Element
CAUTION
• When the engine is operated in dusty
CAUTION
conditions, clean the air cleaner The maximum air intake restriction, in
element more frequently. terms of differential pressure
measurement, must not exceed 0.90 psi
• NEVER operate the engine with the air
(6.23 kPa; 635 mmAq). Clean or replace
cleaner element(s) removed. This may
the air cleaner element if the air intake
allow foreign material to enter the
engine and damage it.
mentioned value.
0000026en
0000046en
Replace the air cleaner element (Figure 5-12, (2))

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

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

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

component. Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
• Failure to comply will result in death or diesel fuel flow.
serious injury.
0000009en
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
CAUTION separator.
For maximum engine life, Yanmar 3. Remove the fuel filter with a filter wrench,
recommends that when shutting the turning it to the left (Figure 5-14, (1)). When
engine down, you allow the engine to removing the fuel filter, carefully hold it to
idle, without load, for five minutes. This prevent the fuel from spilling. Wipe up all spilled
will allow the engine components that fuel.
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en

Clean Fuel Filter / Water Separator
A DANGER

(1) (2) • Diesel fuel is flammable and explosive
0000072A
agent.
Figure 5-14 • Failure to comply will result in death or
4. Clean the filter mounting surface and apply a serious injury.
small amount of diesel fuel to the gasket of the 0000012en
new fuel filter.

5. Install the new fuel filter. Turn to the right A DANGER
(Figure 5-14, (2)) and hand-tighten it only until
it comes in contact with the mounting surface.
Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m;
2.0 - 2.4 kgf·m) or one additional turn using the
filter wrench.
Applicable Fuel Filter Part No. • Diesel fuel is flammable and explosive
Standard Dust proof * under certain conditions.
3TNV82A, • When you remove any fuel system
-4TNV98 component to perform maintenance
119802-55801 (such as changing the fuel filter) place
3TNV82A-B,
-4TNV98-B 129907-55801 an approved container under the
4TNV98T,
4TNV98T-Z, 123907-55801 • NEVER use a shop rag to catch the
-4TNV106T fuel. Vapors from the rag are
* Consult the operation manual for the driven • Wipe up any spills immediately.
machine for applicability of the dust proof
filter. • Wear eye protection. The fuel system
6. Open the fuel cock of the fuel filter / water out when you remove any fuel system
separator. component.
7. Prime the fuel system. See Priming the Fuel • Failure to comply will result in death or
System on page 4-15. serious injury.
8. Check for leaks. 0000009en

Periodically clean the fuel filter / water separator
CAUTION element and inside cup.
1. Position an approved container under the cup
(Figure 5-15, (1)) of the fuel filter / water
separator to collect the contaminants.
(5) (9)
responsible.
(2)
other governmental agencies for the (10)
proper disposal of hazardous (6)
(3)
(8)
• NEVER dispose of hazardous (1)
materials irresponsibly by dumping (4)
0000013en
(7)
0000073A
Figure 5-15
2. Close (Figure 5-15, (2)) the fuel cock
(Figure 5-15, (3)).
3. Loosen the drain cock (Figure 5-15, (4)) and
drain the contaminants. See Drain Fuel
Filter / Water Separator on page 5-24.
4. Turn the retaining ring (Figure 5-15, (5)) to the
left (Figure 5-15, (10)) and remove the cup
(Figure 5-15, (6)). If equipped, disconnect the
sensor wire (Figure 5-15, (7)) from the cup
before removing the cup.
5. Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.

6. Remove the float ring (Figure 5-15, (8)) from

the cup. Pour the contaminants into the Every 1000 Hours of Operation
container and dispose of it properly.
7. Clean the element (Figure 5-15, (9)) and inside Perform the following maintenance every 1000
cup. Replace the element if it is damaged. hours of operation.
• Drain, Flush and Refill Cooling System With
Applicable Element Part No.
New Coolant
All Models 119802-55710
• Adjust Intake / Exhaust Valve Clearance
8. Install the element and O-ring in the bracket. Drain, Flush and Refill Cooling System With
9. Position the float ring in the cup. New Coolant
10. Check the condition of the cup O-ring. Replace
if necessary. A DANGER
11. Install the cup to the bracket by tightening the
retaining ring to the right (Figure 5-15, (6)) to a
torque of 11 - 15 ft·lb (15 - 20 N·m;
1.5 - 2.0 kgf·m).
12. Close the drain cock. Reconnect the sensor
wire if equipped. SCALD HAZARD!
13. Open the fuel cock (Figure 5-15, (3)). • NEVER remove the radiator cap if the
14. Prime the fuel system. See Priming the Fuel engine is hot. Steam and hot engine
System on page 4-15. coolant will spurt out and seriously
15. Check for leaks. burn you. Allow the engine to cool
the radiator cap.
the cap is loose.
coolant by observing the reserve tank.
serious injury.
0000002en

A WARNING CAUTION
BURN HAZARD! • ALWAYS be environmentally

• Wait until the engine cools before you responsible.
drain the engine coolant. Hot engine • Follow the guidelines of the EPA or
coolant may splash and burn you. other governmental agencies for the
• Failure to comply could result in death proper disposal of hazardous
or serious injury. materials such as engine oil, diesel
0000016en fuel and engine coolant. Consult the
A CAUTION • NEVER dispose of hazardous
0000013en
COOLANT HAZARD!
• Wear eye protection and rubber gloves Engine coolant contaminated with rust or scale
when you handle long life or extended reduces the cooling effect. Even when extended life
life engine coolant. If contact with the engine coolant is properly mixed, the engine
eyes or skin should occur, flush eyes coolant gets contaminated as its ingredients
and wash immediately with clean deteriorate. Drain, flush and refill the cooling
water. system with new coolant every 1000 hours or once
a year, whichever comes first.
or moderate injury. 1. Allow engine and coolant to cool.
0000005en
2. Remove the radiator cap (Figure 5-16, (1)).
3. Remove the drain plug or open the drain cock
(Figure 5-16, (2)) at the lower portion of the
radiator and drain the engine coolant.

(1)
FULL
LOW
(2) 0000074A
Figure 5-16
4. Drain the coolant from the engine block.
• On models not equipped with an oil cooler,
remove the coolant drain plug
(Figure 5-17, (1)) from the engine block.
(1)
0000027B
Figure 5-17

• On models equipped with an oil cooler, remove
the coolant hose (Figure 5-18, (1)) at the oil Every 1500 Hours of Operation
cooler.
Perform the following maintenance every 1500
hours of operation.
• Inspect, Clean and Test Fuel Injectors
• Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV84T, 4TNV98T
and 4TNV106T, 3TNV84T-B, 4TNV84T-Z,
4TNV98T-Z
• Inspect, Clean and Test EGR Valve
4TNV84T-Z, 4TNV98T-E, 4TNV98-Z,
4TNV98T-Z
• Inspect and Clean EGR Lead Valve
4TNV84T-Z, 4TNV98T-Z
(1) 0001579B
• Clean EGR Cooler
Figure 5-18 4TNV84T-Z, 4TNV98T-Z
5. After draining the engine coolant, flush the • Inspect Crankcase Breather System
radiator and engine block to remove any rust,
Inspect, Clean and Test Fuel Injectors
scale and contaminants. Then reinstall and
tighten the drain plug or close the drain cock in
the radiator. Reinstall and tighten the cylinder A WARNING
block drain plug or reconnect the coolant hose
at the oil cooler.
6. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-19. HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
Adjust Intake / Exhaust Valve Clearance high-pressure diesel fuel spray caused
Proper adjustment is necessary to maintain the by a fuel system leak such as a broken
correct timing for opening and closing the valves. fuel injection line. High-pressure fuel
Improper adjustment will cause the engine to run can penetrate your skin and result in
noisily, resulting in poor engine performance and serious injury. If you are exposed to
engine damage. See Intake / Exhaust Valve and high-pressure fuel spray, obtain
Guide on page 6-7. prompt medical treatment.
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
or serious injury.
0000008en

Proper operation of the fuel injectors is required to Clean EGR Cooler

obtain the optimum injection pattern for full engine 4TNV84T-Z, 4TNV98T-Z
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every The EGR cooler is apt to be contaminated with rust
1500 hours. See Testing of Fuel Injectors on and scale that deteriorate the cooling performance.
page 7-38. Carbon accumulation in the exhaust gas passage
of the cooler hinders circulation of exhaust gas,
This procedure is considered normal maintenance resulting in deterioration in exhaust gas cleanup
and is performed at the owner’s expense. This performance.
procedure is not covered by the Yanmar Limited
Warranty. To prevent such a problem, clean the cooler at least
every 1500 hours.
Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV98T, 4TNV84T, Consult your local Yanmar dealer for this service.
and 4TNV106T, 3TNV84T-Z, 4TNV84T-Z,
EGR cooler
4TNV98T-Z
Turbocharger service is required by the EPA / ARB
every 1500 hours. Inspect, clean and blower wash
the unit if necessary (see Periodic Inspection on
page 10-13). If you notice that the engine seems
sluggish or the exhaust color is abnormal NEVER
wait until the next service interval.
Inspect, Clean and Test EGR Valve

4TNV84T-Z, 4TNV98T-E, 4TNV98-Z, 4TNV98T-Z
The EGR valve is a key component for cleaning
exhaust gas.
EGR valve
To prevent the valve from deteriorating in exhaust EGR lead valve
gas recirculation performance due to carbon
accumulation, inspect, clean and test the valve at
least every 1500 hours.
Figure 5-19
Consult your local Yanmar dealer for this service.
Inspect Crankcase Breather System
Inspect and Clean EGR Lead Valve
Proper operation of the crankcase breather system
4TNV84T-Z, 4TNV98T-Z is required to maintain the emission requirements
The EGR lead valve is located in the passage of of the engine. The EPA / ARB requires that the
recirculated gas. crankcase breather system is inspected every 1500
hours.
To prevent carbon accumulation in or clogging of
the lead valve, inspect and clean the lead valve at There are three different crankcase breather
regular intervals. systems used on the TNV engines. Only the non-
turbo TNV engines crankcase breather system
Consult your local Yanmar dealer for this service. requires periodic maintenance.

The non-turbo TNV engines use a crankcase Failure of the diaphragm and / or spring will cause
breather system that has a spring-backed the loss of pressure control and allow an excessive
diaphragm (Figure 5-20, (1)) in the valve cover amount of crankcase fumes to be routed to the
(Figure 5-20, (2)). When the crankcase pressure intake manifold. This could result in excessive
reaches a predetermined value, the diaphragm deposits in the intake system, high engine exhaust
opens a passage that allows crankcase fumes to smoke levels, excessive engine oil consumption,
be routed to the intake manifold. and / or engine run-on due to the burning of the
engine oil.
To inspect the diaphragm and spring
(Figure 5-20, (3)):
1. Remove the bolts retaining the diaphragm cover
(Figure 5-20, (4)).
(4)
(3)
(5)
(1)
(2)
0002135
Figure 5-20
2. Remove the diaphragm cover, spring,
diaphragm plate (Figure 5-20, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.

Lap the Intake and Exhaust Valves

Every 2000 Hours of Operation
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
Perform the following maintenance every 2000 and Exhaust Valves on page 6-42.
hours of operation.
• Check and Replace Fuel Hoses and Engine
Coolant Hoses
• Lap the Intake and Exhaust Valves.
If necessary
Check and Replace Fuel Hoses and Engine

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

system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years.

Section 6
ENGINE
Page
Introduction...................................................................................... 6-6
Cylinder Head Specifications .......................................................... 6-6
Adjustment Specifications ......................................................... 6-6
Cylinder Head............................................................................ 6-6
Intake / Exhaust Valve and Guide ............................................. 6-7
Push Rod................................................................................... 6-9
Rocker Arm and Shaft ............................................................... 6-9
Valve Spring ............................................................................ 6-10
Camshaft and Timing Gear Train Specifications........................... 6-11
Camshaft ................................................................................. 6-11
Idler Gear Shaft and Bushing .................................................. 6-13
Timing Gear Backlash ............................................................. 6-13
Crankshaft and Piston Specifications............................................ 6-14
Crankshaft ............................................................................... 6-14
Thrust Bearing ......................................................................... 6-15
Piston....................................................................................... 6-16
Piston Ring .............................................................................. 6-18
Connecting Rod....................................................................... 6-22
Tappet ..................................................................................... 6-23
Cylinder Block Specifications ........................................................ 6-24
Cylinder Block.......................................................................... 6-24
Special Torque Chart .................................................................... 6-25
Torque for Bolts and Nuts........................................................ 6-25
Special Service Tools.................................................................... 6-28
Measuring Instruments.................................................................. 6-32
2-Valve Cylinder Head .................................................................. 6-34
2-Valve Cylinder Head Components ....................................... 6-34

ENGINE
Components of a two-valve cylinder head ............................... 6-35
Disassembly of 2-Valve Cylinder Head .................................... 6-36
Cleaning of Cylinder Head Components .................................. 6-40
Inspection of Cylinder Head Components................................ 6-40
Reassembly of Cylinder Head.................................................. 6-44
4-Valve Cylinder Head ................................................................... 6-49
4-Valve Cylinder Head Components ........................................ 6-49
Disassembly of 4-Valve Cylinder Head .................................... 6-50
Cleaning of Cylinder Head Components .................................. 6-55
Inspection of Cylinder Head Components................................ 6-56
Reassembly of Cylinder Head.................................................. 6-61
Measuring and Adjusting Valve Clearance .................................... 6-66
2-Valve Cylinder Heads............................................................ 6-67
4-Valve Cylinder Heads............................................................ 6-68
Crankshaft and Camshaft Components ......................................... 6-71
Disassembly of Engine............................................................. 6-72
Disassembly of Camshaft and Timing Components ................ 6-73
Disassembly of Crankshaft and Piston Components ............... 6-78
Inspection of Crankshaft and Camshaft Components.............. 6-82
Honing and Boring.................................................................... 6-88
Reassembly of Crankshaft and Piston Components................ 6-89
Reassembly of Camshaft and Timing Components ................. 6-95
Final Reassembly of Engine..................................................... 6-99
EGR system ................................................................................. 6-100
EGR system ........................................................................... 6-100
EGR system ........................................................................... 6-102
Inspecting/cleaning EGR related components ....................... 6-105

Before You Begin Servicing ENGINE
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
To prevent possible eye injury, always cleaners, primers, sealants and
wear SAFETY GLASSES while servicing sealant removers.
the engine.
0000013en
or serious injury.
A WARNING
0000014en
A CAUTION
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch FLYING OBJECT HAZARD!
when you are servicing the engine. • ALWAYS wear eye protection when
Someone may accidentally start the servicing the engine and when using
engine and not realize you are compressed air or high-pressure
servicing it. This could result in a water. Dust, flying debris, compressed
serious injury. air, pressurized water or steam may
• If you must service the engine while it injure your eyes.
is operating, remove all jewelry, tie • Failure to comply may result in minor
back long hair, and keep your hands, or moderate injury.
other body parts and clothing away 0000003en
• Failure to comply could result in death A CAUTION
or serious injury.
Be sure to secure the engine solidly to
0000010en
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en

ENGINE Before You Begin Servicing
CAUTION CAUTION
• Only use the engine oil specified. Any part which is found defective as a
Other engine oils may affect warranty result of inspection or any part whose
coverage, cause internal engine measured value does not satisfy the
components to seize and / or shorten standard or limit must be replaced.
engine life. 0000119en

contaminating the engine oil. Carefully CAUTION
the cap.
• NEVER mix different types of engine current rate of wear, should be replaced
oil. This may adversely affect the even though the part currently meets the
lubricating properties of the engine oil. service standard limit.
• NEVER overfill. Overfilling may result 0000120en

overspeed or internal damage. CAUTION
0000005en
Remove or install the high-pressure fuel
injection lines as an assembly whenever
CAUTION possible. Disassembling the
• Only use the engine coolant specified. high-pressure fuel injection lines from
Other engine coolants may affect the retainers or bending any of the fuel
warranty coverage, cause an internal lines will make it difficult to reinstall the
buildup of rust and scale and / or fuel lines.
shorten engine life. 0000047en

contaminating the engine coolant. CAUTION
Carefully clean the radiator cap and Do not loosen or remove the four bolts
the surrounding area before you retaining the fuel injection pump drive
remove the cap. gear to the fuel injection pump hub. Do
• NEVER mix different types of engine not disassemble the fuel injection pump
coolants. This may adversely affect the drive gear from the hub. Correct fuel
properties of the engine coolant. injection timing will be very difficult or
0000006en
impossible to achieve.
0000031en
CAUTION
an appropriate method. It is important
0000080en

Before You Begin Servicing ENGINE
CAUTION
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
CAUTION
motion.
0000090en

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

Adjustment Specifications
Valve Bridge Clearance
Model Valve Clearance
(4-Valve Head Only)
0.006 - 0.010 in.
All except 4TNV106, 4TNV106T 0
(0.15 - 0.25 mm)
0.010 - 0.014 in.
4TNV106, 4TNV106T 0
(0.25 - 0.35 mm)
Cylinder Head
Reference
Page
0.0020 in. 0.0059 in.
Combustion Surface Distortion (Flatness)
(0.05 mm) or less (0.15 mm)
0.0138 - 0.0217 in.
Intake 0.0315 in. (0.8 mm)
3TNV82A (0.35 - 0.55 mm)
(2-Valve Head) 0.0118 - 0.0197 in.
Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm)
3TNV84, 3TNV84T, 0.0118 - 0.0197 in.
Intake 0.0315 in. (0.8 mm)
3TNV88, 4TNV84, (0.30 - 0.50 mm)
4TNV84T, 4TNV88 See Valve
(2-Valve Head) 0.0118 - 0.0197 in. Recession on
4TNV84T (4-Valve Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm) page 6-42
Valve Recession Head) and 6-58.
0.0142 - 0.0220 in.
4TNV94L, 4TNV98, Intake 0.0315 in. (0.8 mm)
(0.36 - 0.56 mm)
4TNV98T
(4-Valve Head) 0.0138 - 0.0217 in.
(0.35 - 0.55 mm)
0.0197 - 0.0276 in.
Intake 0.0394 in. (1.0 mm)
4TNV106, 4TNV106T (0.50 - 0.70 mm)
(4-Valve Head) 0.0276 - 0.0354 in.
(0.70 - 0.90 mm)
Intake 120° - See Valve
Seat Angle Face and
Valve Seat Exhaust 90° -
Valve Seat
(2-Valve, 4-Valve)
Seat Correction Angle 40°, 150° - on page 6-43
and 6-59.

Cylinder Head Specifications ENGINE
Intake / Exhaust Valve and Guide
Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter
(7.000 - 7.015 mm) (7.08 mm)
Valve Stem Outside 0.2734 - 0.2740 in. 0.2717 in.
Intake
Diameter (6.945 - 9.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0071 in. See
Valve Stem Bend Inspection of
3TNV82A (0.040 - 0.070 mm) (0.18 mm)
Valve Guides
(2-Valve Head) 0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter on
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.3154 - 0.3159 in. 0.3189 in.
(8.010 - 8.025 mm) (8.10 mm)
Intake
Diameter (7.955 - 7.975 mm) (7.90 mm)
0.0014 - 0.0028 in. 0.0071 in. See
4TNV84, Valve Stem Bend
(0.035 - 0.070 mm) (0.18 mm) Inspection of
3TNV84, 3TNV84T,
Valve Guides
4TNV88, 4TNV88 0.3156 - 0.3161 in. 0.3189 in.
(2-Valve Head) (8.015 - 8.030 mm) (8.10 mm) page 6-41.
Valve Stem Outside 0.3132 -.3134 in. 0.3110 in.
Exhaust
Diameter (7.955 - 7.960 mm) (7.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm)
Intake
Diameter (5.960 - 5.975 mm) (5.90 mm)
0.0010 - 0.0022 in. 0.0059 in. See
4TNV84T (0.025 - 0.055 mm) (0.15 mm)
Valve Guides
(4-Valve Head) 0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm) page 6-41.
Exhaust
Diameter (5.945 - 5.960 mm) (5.90 mm)
0.0016 - 0.0028 in. 0.0067 in.
Valve Stem Bend
(0.040 - 0.070 mm) (0.17 mm)

ENGINE Cylinder Head Specifications
(Intake / Exhaust Valve and Guide Cont.)
Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
(7.000 - 7.015 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0067 in. See
4TNV94L Oil Clearance Inspection of
(0.040 - 0.070 mm) (0.17 mm)
4TNV98, 4TNV98T Valve Guides
(4-Valve Head) 0.2756 - 0.2762 in. 0.2787 in. on
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0067 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.17 mm)
0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.92 mm)
0.0019 - 0.0030 in. 0.0063 in. See
4TNV106T (0.048 - 0.075 mm) (0.16 mm)
Valve Guides
(4-Valve Head) 0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.960 - 6.975 mm) (6.90 mm)
0.0013 - 0.0024 in. 0.0071 in.
Valve Stem Bend
(0.033 - 0.060 mm) (0.18 mm)
0.4606 - 0.4724 in.
3TNV82A -
(11.70 - 12.00 mm)
3TNV84, 3TNV84T, 0.5791 -0.5905 in.
-
4TNV84, 4TNV88 (14.71 - 15.00 mm) See
Valve Guide Projection From 0.3228 - 0.3346 in. Reassembly
4TNV84T - of Valve
Cylinder Head (8.20 - 8.50 mm)
Guides on
4TNV94L, 4TNV98, 0.3819 - 0.3937 in. page 6-44
-
4TNV98T (9.70 - 10.00 mm) and 6-61.
0.5276 - 0.5354 in.
4TNV106, 4TNV106T -
(13.40 - 13.60 mm)
Valve Guide Installation Method Cold-fitted -

Cylinder Head Specifications ENGINE
Reference
Page
Valve Stem Seal Projection From Cylinder Head
0.618 - 0.629 in.
3TNV82A -
(15.7 - 16.0 mm)
2 Valves 4TNV84 -
0.736 - 0.748 in. See
3TNV84 (T) - Reassembly
(18.7 - 19.0 mm)
4TNV88 - of Intake and
0.389 - 0.401 in. Exhaust
4TNV84T - Valves on
(9.9 - 10.2 mm)
page 6-45.
4TNV94L 0.460 - 0.472 in. -
4 Valves
4TNV98 (T) (11.7 - 12.0 mm) -
0.606 - 0.614 in.
4TNV106 (T) -
(15.4 - 15.6 mm)
Push Rod
Reference
Page
See Push
Less than 0.0012 in. Rod Bend on
Push Rod Bend - All Models
0.0012 in. (0.03 mm) (0.03 mm) page 6-41
and 6-56.
Rocker Arm and Shaft

Reference
Model Inspection Item Standard Limit
Page
0.6299 - 0.6307 in. 0.6327 in.
Arm Shaft Hole Diameter
3TNV82A, 3TNV84, (16.000 - 16.020 mm) (16.07 mm)
3TNV84T, 3TNV88, 0.6286 - 0.6293 in. 0.6276 in.
Shaft Outside Diameter
4TNV84, 4TNV84T, (15.966 - 15.984 mm) (15.94 mm)
See
4TNV88 0.0006 - 0.0021 in. 0.0051 in.
Oil Clearance Inspection of
(0.016 - 0.054 mm) (0.13 mm) Rocker Arm
0.7283 - 0.7291 in. 0.7311 in. Assembly on
Arm Shaft Hole Diameter page 6-41
(18.500 - 18.520 mm) (18.57 mm)
4TNV94L, 4TNV98, and 6-56.
0.7272 - 0.7280 in. 0.7260 in.
4TNV98T, 4TNV106, Shaft Outside Diameter
(18.470 - 18.490 mm) (18.44 mm)
4TNV106T
0.0004 - 0.0020 in. 0.0051 in.
Oil Clearance
(0.010 - 0.050 mm) (0.13 mm)

ENGINE Cylinder Head Specifications
Valve Spring
Reference
Inspection Item Model Standard Limit
Page
1.7480 in. 1.7283 in.
3TNV82A (2-Valve Head)
(44.4 mm) (43.9 mm)
4TNV84, 3TNV84, 3TNV84T, 4TNV88 1.6535 in. 1.6339 in.
(2-Valve Head) (42.0 mm) (41.5 mm)
1.4724 in. 1.4528 in.
Free Length 4TNV84T (4-Valve Head)
(37.4 mm) (36.9 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 1.5630 in. 1.5433 in.
Head) (39.7 mm) (39.2 mm)
See
1.9921 in. 1.9724 in. Inspection of
4TNV106, 4TNV106T (4-Valve Head)
(50.6 mm) (50.1 mm) Valve
0.0551 in. Springs on
3TNV82A (2-Valve Head) - page 6-44
(1.4 mm)
and 6-60.
4TNV84, 3TNV84, 3TNV84T, 0.0551 in.
-
4TNV88 (2-Valve Head) (1.4 mm)
0.0551 in.
Squareness 4TNV84T (4-Valve Head) -
(1.3 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 0.0551 in.
-
Head) (1.4 mm)
0.0551 in.
4TNV106, 4TNV106T (4-Valve Head) -
(1.5 mm)

Camshaft and Timing Gear Train Specifications ENGINE
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Page
See Removal
0.0020 - 0.0079 in. 0.0118 in. of Camshaft
End Play
(0.05 - 0.20 mm) (0.030 mm) on
page 6-76.
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
3TNV82A, 3TNV84,
1.5197 - 1.5276 in. 1.5098 in. See
3TNV84T, 3TNV88, 4TNV84,
4TNV84T, 4TNV88
Camshaft on
Cam Lobe Height 4TNV94L, 4TNV98, 1.7087 - 1.7165 in. 1.6988 in. page 6-87.
4TNV98T (43.400 - 43.600 mm) (43.150 mm)
2.0039 - 2.0118 in. 1.9941 in.
4TNV106, 4TNV106T
(50.900 - 51.100 mm) (50.650 mm)
Shaft Outside Diameter / Bearing Inside Diameter
1.7713 - 1.7738 in. 1.7768 in.
Bushing Inside Diameter
(44.990 - 45.055 mm) (45.130 mm)
1.7687 - 1.7697 in. 1.7673 in.
Gear End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
3TNV82A, 1.7716 - 1.7726 in. 1.7756 in.
3TNV84, Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm) See
3TNV84T,
1.7681 - 1.7691 in. 1.7667 in. Inspection of
3TNV88, Intermediate Camshaft Outside Diameter
(44.910 - 44.935 mm) (44.875 mm) Camshaft on
4TNV84,
0.0026 - 0.0045 in. 0.0089 in. page 6-87.
4TNV84T, Oil Clearance
4TNV88 (0.065 - 0.115 mm) (0.225 mm)
1.7716 - 1.7726 in. 1.7756 in.
Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm)
1.7687 - 1.7697 in. 1.7673 in.
Flywheel End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil Clearance
(0.050 - 0.100 mm) (0.210 mm)

ENGINE Camshaft and Timing Gear Train Specifications
(Camshaft Cont.)
Reference
Page
1.9681 - 1.9707 in. 1.9736 in.
(49.990 - 50.055 mm) (50.130 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
4TNV94L,
1.9650 - 1.9659 in. 1.9636 in.
4TNV98, Intermediate Camshaft Outside Diameter
(49.910 - 49.935 mm) (49.875 mm)
4TNV98T
0.0026 - 0.0045 in. 0.0089 in;
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0020 - 0.0039 in. 0.0083 in. See
Oil Clearance
2.2827 - 2.2854 in. 2.2876 in. Camshaft on
Bushing Inside Diameter page 6-87.
(57.980 - 58.050 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0016 - 0.0055 in. 0.0098 in.
Oil Clearance
(0.040 - 0.140 mm) (0.250 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
4TNV106, 2.2793 - 2.2805 in. 2.2779 in.
Intermediate Camshaft Outside Diameter
4TNV106T (57.895 - 57.925 mm) (57.860 mm)
0.0030 - 0.0053 in. 0.0096 in.
Oil Clearance
(0.075 - 0.135 mm) (0.245 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0020 - 0.0047 in. 0.0091 in.
Oil Clearance
(0.050 - 0.120 mm) (0.230 mm)

Camshaft and Timing Gear Train Specifications ENGINE
Idler Gear Shaft and Bushing
Reference
Page
1.8091 - 1.8100 in. 1.8071 in.
Shaft Outside Diameter See
(45.950 - 45.975 mm) (45.900 mm)
Inspection of
1.8110 - 4.8120 in. 1.8140 in.
Bushing Inside Diameter Idler Gear
(46.000 - 46.025 mm) (46.075 mm)
and Shaft on
0.0010 - 0.0030 in. 0.0069 in. page 6-87.
Oil Clearance
(0.025 - 0.075 mm) (0.175 mm)
Timing Gear Backlash

Reference
Page
3TNV82A
3TNV84, 3TNV84T, Crank Gear, Cam Gear, Idler Gear,
0.0028 - 0.0059 in. 0.0067 in.
3TNV88, 4TNV84, Fuel Injection Pump Gear and PTO
(0.07 - 0.15 mm) (0.17 mm)
4TNV84T, Gear
4TNV88 See
Crank Gear, Cam Gear, Idler Gear, Checking
0.0031 - 0.0055 in. 0.0063 in. Timing Gear
Fuel Injection Pump Gear and PTO
4TNV94L (0.08 - 0.14 mm) (0.16 mm) Backlash on
Gear
4TNV98, 4TNV98T, page 6-73.
0.0035 - 0.0059 in. 0.0067 in.
4TNV106, Lubricating Oil Pump Gear
(0.09 - 0.15 mm) (0.17 mm)
4TNV106T
Balancer Drive Gear 0.0047 - 0.0071 in. 0.0079 in.
(Only for 4TNV106T) (0.12 - 0.18 mm) (0.20 mm)

ENGINE Crankshaft and Piston Specifications
CRANKSHAFT AND PISTON SPECIFICATIONS

Crankshaft
Note: Check appropriate parts catalog for various sizes of replacement main bearing inserts.
Reference
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
Journal Outside 1.6910 - 1.6914 in. 1.6891 in.
Diameter (42.952 - 42.962 mm) (42.902 mm)
Bearing Inside 1.6929 - 1.6946 in.
-
Diameter (43.000 - 43.042 mm)
3TNV82A
Bearing Insert 0.0585 -.0591 in.
-
Thickness (1.487 - 1.500 mm)
0.0015 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.038 - 0.090 mm) (0.150 mm)
Diameter (47.952 - 47.962 mm) (47.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.8898 - 1.8909 in.
-
3TNV88, Diameter (48.000 - 48.026 mm)
4TNV84, Bearing Insert 0.0587 - 0.0591 in.
4TNV84T - See
Thickness (1.492 - 1.500 mm)
4TNV88 Inspection of
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance Crankshaft
Connecting Rod (0.038 - 0.074 mm) (0.150 mm)
on
Journals Journal Outside 2.2816 - 2.2820 in. 2.2796 in. page 6-86.
Diameter (57.952 - 57.962 mm) (57.902 mm)
4TNV94L, -
Diameter (58.000 - 58.026 mm)
4TNV98,
4TNV98T Bearing Insert 0.0587 - 0.0591 in.
-
Thickness (1.492 - 1.500 mm)
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance
(0.038 - 0.074 mm) (0.150 mm)
Diameter (63.952 - 63.962 mm) (63.902 mm)
-
4TNV106, Diameter (64.016 - 64.042 mm)
-
Thickness (1.984 - 1.992 mm)
0.0021 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.054 - 0.090 mm) (0.150 mm)

Crankshaft and Piston Specifications ENGINE
(Crankshaft Cont.)
Reference
Page
Diameter (46.952 - 46.962 mm) (46.902 mm)
-
Diameter (47.000 - 47.032 mm)
3TNV82A
Bearing Insert 0.0782 - 0.0787 in.
-
Thickness (1.987 - 2.000 mm)
0.0015 - 0.0031 in. 0.0059 in.
Oil Clearance
(0.038 - 0.080 mm) (0.150 mm)
Journal Outside 1.9666-1.9670 in. 1.9646 in.
Diameter (49.952-49.962 mm) (49.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.9685 - 1.9693 in.
-
3TNV88, Diameter (50.000 - 50.020 mm)
4TNV84, Bearing Insert 0.0785 - 0.0791 in.
4TNV84T -
Thickness (1.995 - 2.010 mm)
4TNV88 See
0.0015 - 0.0027 in. 0.0059 in.
(0.038 - 0.068 mm) (0.150 mm)
Main Bearing Journal Crankshaft
Journal Outside 2.5572 - 2.5576 in. 2.5552 in. on
Diameter (64.952 - 64.962 mm) (64.902 mm) page 6-86.
4TNV94L, -
Diameter (65.000 - 65.020 mm)
4TNV98,
-
Thickness (1.995 - 2.010 mm)
0.0015 - 0.0027 in. 0.0059 in.
Oil Clearance
(0.038 - 0.068 mm) (0.150 mm)
Diameter (75.952 - 75.962 mm) (75.902 mm)
-
4TNV106, Diameter (76.014 - 76.034 mm)
-
Thickness (2.488 - 2.503 mm)
0.0020 - 0.0032 in. 0.0059 in.
Oil Clearance
(0.052 - 0.082 mm) (0.150 mm)
Thrust Bearing
Reference
Page
See Removal
0.0051 - 0.0091 in. 0.0110 in. of Crankshaft
Crankshaft End Play - All Models
(0.13 - 0.23 mm) (0.28 mm) on
page 6-80.

Piston
Reference
Page
3.2264 - 3.2275 in. 3.2246 in.
3TNV82A
(81.950 - 81.980 mm) (81.905 mm)
3TNV84, 3TNV84T, 3.3047 - 3.3059 in. 3.3029 in.
4TNV84, 4TNV84T (83.940 - 83.970 mm) (83.895 mm)
3.4622 - 3.4634 in. 3.4604 in.
3TNV88,4TNV88
Piston Outside Diameter (87.940 - 87.970 mm) (87.895 mm)
(Measure at 90° to the Piston Pin.) 3.6982 - 3.6994 in. 3.6968 in.
4TNV94L
(93.935 - 93.965 mm) (93.900 mm)
3.8555 - 3.8567 in. 3.8541 in.
4TNV98, 4TNV98T
(97.930 - 97.960 mm) (97.895 mm) See
4TNV106, 4TNV106T Pistons,
(105.930 - 105.960 mm) (105.880 mm)
Piston Rings
0.6299 in. and Wrist Pin
3TNV82A -
(16 mm) on
3TNV84, 3TNV84T, 0.9449 in. page 6-83.
-
4TNV84, 4TNV84T (24 mm)
0.9449 in.
Piston Diameter Measure Location 3TNV88,4TNV88 -
(24 mm)
(Upward From the Bottom of the
Piston.) 0.8661 in.
4TNV94L -
(22 mm)
0.8661 in.
4TNV98, 4TNV98T -
(22 mm)
1.1811 in.
4TNV106, 4TNV106T -
(30 mm)

(Piston Cont.)
Reference
Page
0.9055 - 0.9059 in. 0.9070 in.
Hole Inside Diameter
(23.000 - 23.009 mm) (23.039 mm)
0.9053 - 0.9055 in. 0.9041 in.
3TNV82A Pin Outside Diameter
(22.995 - 23.000 mm) (22.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil Clearance
(0.000 - 0.014 mm) (0.074 mm)
3TNV84, 1.0236 - 1.0240 in. 1.0252 in.

3TNV84T, (26.000 - 26.009 mm) (26.039 mm)
3TNV88, 1.0234 - 1.0236 in. 1.0222 in.
Pin Outside Diameter
4TNV84, (25.995 - 26.000 mm) (25.965 mm) See
4TNV84T 0.0000 - 0.0006 in. 0.0029 in. Inspection of
4TNV88 Oil Clearance Pistons,
(0.000 - 0.014 mm) (0.074 mm)
Piston Pin Piston Rings
1.1811 - 1.1815 in. 1.1826 in. and Wrist Pin
(30.000 - 30.009 mm) (30.039 mm) on
4TNV94L,
1.1807 - 1.1811 in. 1.1795 in. page 6-83.
4TNV98, Pin Outside Diameter
(29.989 - 30.000 mm) (29.959 mm)
4TNV98T
0.0000 - 0.0008 in. 0.0031 in.
Oil Clearance
(0.000 - 0.020 mm) (0.080 mm)
1.4567 - 1.4571 in. 1.4582 in.
(37.000 - 37.011 mm) (37.039 mm)
4TNV106, 1.4563 - 1.4567 in. 1.4551 in.
Pin Outside Diameter
4TNV106T (36.989 - 37.000 mm) (36.959 mm)
0.0000 - 0.0009 in. 0.0031 in.
Oil Clearance
(0.000 - 0.022 mm) (0.080 mm)

Piston Ring
Reference
Page
0.0813 - 0.0819 in.
Ring Groove Width -
(2.065 - 2.080 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0030 - 0.0043 in.
Side Clearance -
(0.075 - 0.110 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.0801 - 0.0807 in. 0.0846 in.
Ring Groove Width
(2.035 - 2.050 mm) (2.150 mm) See
3TNV82A, 0.0776 - 0.0783 in. 0.0768 in. Inspection of
3TNV84, Ring Width Pistons,
(1.970 - 1.990 mm) (2.150 mm)
3TNV84T, Second Ring Piston Rings
4TNV84, 0.0018 - 0.0031 in. 0.0079 in. and Wrist
Side Gap
4TNV84T (0.045 - 0.080 mm) (0.200 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 - 0.1571 in. 0.01555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

(Piston Ring Cont.)
Reference
Page
0.0811 - 0.0817 in.
Ring Groove Width -
(2.060 - 2.075 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0028 - 0.0041 in.
Side Clearance -
(0.070 - 0.105 mm)
0.0079 - 0.157 in. 0.0193 in.
End Gap
(0.200 -.0400 mm) (0.490 mm)
0.0797 - 0.0803 in. 0.0843 in.
Ring Groove Width
(2.025 - 2.040 mm) (2.140 mm) See
0.0776 -- 0.0783 in. 0.0768 in. Inspection of
Ring Width Pistons,
3TNV88, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV88 0.0014 - 0.0028 in. 0.0075 in.
Side Clearance and Wrist
(0.035 - 0.070 mm) (0.190 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 -.1571 in. 0.1555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

(Piston Ring Cont.)
Reference
Page
0.0803 - 0.0811 in.
Ring Groove Width -
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0756 in.
Ring Width
(1.940 - 1.960 mm) (1.920 mm)
Top Ring
0.0031 - 0.0047 in.
Side Clearance -
(0.080 - 0.120 mm)
0.0098 - 0.0177 in. 0.0213 in.
End Gap
(0.250 - 0.450 mm) (0.540 mm)
0.0819 - 0.0825 in. 0.0864 in.
Ring Groove Width
(2.080 - 2.095 mm) (2.195 mm) See
4TNV94L, Ring Width Pistons,
(1.970 - 1.990 mm) (1.950 mm)
4TNV98, Second Ring Piston Rings
4TNV98T 0.0035 - 0.0049 in. 0.0096 in. and Wrist
Side Clearance
(0.090 - 0.125 mm) (0.245 mm) Pin on
0.0177 - 0.0256 in. 0.0287 in. page 6-83.
End Gap
(0.450 - 0.650 mm) (0.730 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0098 - 0.0177 in. 0.0217 in.
End Gap
(0.250 - 0.450 mm) (0.550 mm)

(Piston Ring Cont.)
Reference
Page
0.0992 - 0.1000 in.
Ring Groove Width -
(2.520 - 2.540 mm)
0.0961 - 0.0969 in. 0.0953 in.
Ring Width
(2.440 - 2.460 mm) (2.420 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0118 - 0.0177 in. 0.0213 in.
End Gap
(0.300 - 0.450 mm) (0.540 mm)
0.0815 - 0.0821 in. 0.0860 in.
Ring Groove Width
(2.070 - 2.085 mm) (2.185 mm) See
Ring Width Pistons,
4TNV106, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV106T 0.0031 - 0.0045 in. 0.0093 in.
Side Clearance and Wrist
(0.080 - 0.115 mm) (0.235 mm) Pin on
0.0177 - 0.0236 in. 0.0268 in. page 6-83.
End Gap
(0.450 - 0.600 mm) (0.680 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0118 - 0.0197 in. 0.0236 in.
End Gap
(0.300 - 0.500 mm) (0.600 mm)

Connecting Rod
Connecting Rod Small End
Reference
Page
Wrist Pin Bushing 0.9065 - 0.9070 in. 0.9082 in.
Inside Diameter (23.025 - 23.038 mm) (23.068 mm)
Wrist Pin Outside 0.9053 - 0.9055 in. 0.9042 in.
3TNV82A
Diameter (22.995 - 23.000 mm) (22.967 mm)
0.0010 - 0.0017 in. 0.0040 in.
Oil Clearance
(0.025 - 0.043 mm) (0.101 mm)
3TNV84, 3TNV84T, 3TNV88, Wrist Pin Outside 1.0234 - 1.0236 in. 1.0223 in.
4TNV84, 4TNV84T, 4TNV88 Diameter (25.995 - 26.000 mm) (25.967 mm)
0.0010 - 0.0017 in. 0.0040 in. See
(0.025 - 0.043 mm) (0.101 mm)
Connecting
Wrist Pin Bushing 1.1821 - 1.1826 in. 1.1838 in. Rod on
Inside Diameter (30.025 - 30.038 mm) (30.068 mm) page 6-85.
4TNV94L, 4TNV98, 4TNV98T
Diameter (29.987 - 30.000 mm) (29.959 mm)
0.0010 - 0.0020 in. 0.0043 in.
Oil Clearance
(0.025 - 0.51 mm) (0.109 mm)
4TNV106, 4TNV106T
Diameter (36.989 - 37.000 mm) (36.961 mm)
0.0010 - 0.0019 in. 0.0042 in.
Oil Clearance
(0.025 - 0.049 mm) (0.107 mm)
Connecting Rod Big End

Reference
Page
See
Inspection of
0.0079 - 0.0157 in.
Side Clearance - All Models - Connecting
(0.20 - 0.40 mm)
Rod on
page 6-85.
See Special Torque Chart on page 6-25 for other specifications.

Tappet
Reference
Page
Tappet Bore (Block) Inside 0.4724 - 0.4734 in. 0.4742 in.
3TNV82A, 3TNV84, Diameter (12.000 - 12.025 mm) (12.045 mm)
3TNV84T, 3TNV88, 0.4715 - 0.4720 in. 0.4707 in.
Tappet Stem Outside Diameter
4TNV84, 4TNV84T, (11.975 - 11.990 mm) (11.955 mm)
4TNV88 0.0004 - 0.0020 in. 0.0035 in.
Oil Clearance
(0.010 - 0.050 mm) (0.090 mm)
Diameter (12.000 - 12.018 mm) (12.038 mm) See
4TNV94L, 4TNV98, 0.4715 - 0.4720 in. 0.4707 in. Inspection of
Tappet Stem Outside Diameter
4TNV98T (11.975 - 11.990 mm) (11.955 mm) Tappets on
0.0004 - 0.0017 in. 0.0033 in. page 6-85.
Oil Clearance
(0.010 - 0.043 mm) (0.083 mm)
Diameter (14.000 - 14.018 mm) (14.038 mm)
0.5498 - 0.5505 in. 0.5491 in.
4TNV106, 4TNV106T Tappet Stem Outside Diameter
(13.966 - 13.984 mm) (13.946 mm)
0.0006 - 0.0020 in. 0.0036 in.
Oil Clearance
(0.015 - 0.052 mm) (0.092 mm)

ENGINE Cylinder Block Specifications
CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection Item Model Standard Limit
Page
3.2283 - 3.2295 in. 3.2362 in.
3TNV82A
(82.000 - 82.030 mm) (82.200 mm)
3TNV84, 3TNV84T, 3.3071 - 3.3083 in. 3.3150 in.
4TNV84, 4TNV84T (84.000 - 84.030 mm) (84.200 mm)
3.4646 - 3.4657 in. 3.4724 in.
3TNV88, 4TNV88
(88.000 - 88.030 mm) (88.200 mm) See
Cylinder Inside Diameter Inspection of
3.7008 - 3.7020 in. 3.7059 in.
4TNV94L Cylinder
(94.000 - 94.030 mm) (94.130 mm)
Block on
3.8583 - 3.8594 in. 3.8634 in. page 6-83.
4TNV98, 4TNV98T
(98.000 - 98.030 mm) (98.130 mm)
4.1732 - 4.1744 in. 4.1783 in.
4TNV106, 4TNV106T
(106.000 - 106.030 mm) (106.130 mm)
Roundness 0.0004 in. (0.01 mm) 0.0012 in.
Cylinder Bore
Taper or less (0.03 mm)

Special Torque Chart ENGINE
SPECIAL TORQUE CHART

Torque for Bolts and Nuts
Lubricating Oil
Thread Diameter Application
Component Model Torque
and Pitch (Thread Portion and
Seat Surface)
46 - 49 ft·lb
3TNV82A M9 x 1.25 mm (61.7 - 65.7 N·m;
6.3 - 6.7 kgf·m)
3TNV82A, 3TNV84,
63 - 67 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (85.3 - 91.1 N·m;
4TNV84, 4TNV84T,
Cylinder 8.7 - 9.3 kgf·m)
4TNV88 Applied
Head Bolt
76 - 83 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (103.1 - 112.9 N·m;
4TNV98T
10.5 - 11.5 kgf·m)
139 - 146 ft·lb
4TNV106, 4TNV106T M13 x 1.5 mm (188.0 - 112.9 N·m;
19.0 - 20.0 kgf·m)
27 - 30 ft·lb
3TNV82A M8 x 1.0 mm (37.2 - 41.2 N·m;
3.8 - 4.2 kgf·m)
3TNV82A, 3TNV84,
33 - 36 ft·lb
3TNV84T, 3TNV88,
M9 x 1.0 mm (44.1 - 49.0 N·m;
4TNV84, 4TNV84T,
Connecting 4.5 - 5.0 kgf·m)
4TNV88 Applied
Rod Bolt
40 - 43 ft·lb
4TNV94L, 4TNV98,
M10 x 1.0 mm (53.9 - 58.8 N·m;
4TNV98T
5.5 - 6.0 kgf·m)
58 - 62 ft·lb
4TNV106, 4TNV106T M11 x 1.0 mm (78.5 - 83.4 N·m;
8.0 - 8.5 kgf·m)
3TNV82A, 3TNV84,
61 - 65 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (83.3 - 88.2 N·m;
4TNV84, 4TNV84T,
Flywheel 8.5 - 9.0 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 137 - 152 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (186.2 - 205.8 N·m;
4TNV106T 19 - 21 kgf·m)
83 - 91 ft·lb
EPA Flange
4TNV106, 4TNV106T M8 x 1.5 mm (113 - 123 N·m; Not Applied
Bolt
11.5 - 12.5 kgf·m)

ENGINE Special Torque Chart
(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
56 - 60 ft·lb
3TNV82A M10 x 1.25 mm (76.4 - 80.4 N·m;
7.8 - 8.2 kgf·m)
3TNV84, 3TNV84T, 69 - 72 ft·lb
3TNV88, 4TNV84, M12 x 1.5 mm (93.2 - 98.1 N·m;
Main Bearing Cap 4TNV84T, 4TNV88 9.5 - 10.5 kgf·m)
Applied
Bolt 80 - 87 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (108.1 - 117.9 N·m;
4TNV98T
11.0 - 12.0 kgf·m)
137 - 152 ft·lb
4TNV106, 4TNV106T M14 x 1.5 mm (186.2 - 205.8 N·m;
19 - 21 kgf·m)
3TNV82A, 3TNV84,
83 - 91 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (112.7 - 122.7 N·m;
4TNV84, 4TNV84T,
Crankshaft Pulley 11.5 - 12.5 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 80 - 94 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (107.9 - 127.5 N·m;
4TNV106T 11.0 - 13.0 kgf·m)
3TNV82A, 3TNV84,
18 - 21 ft·lb
3TNV84T, 3TNV88,
M8 x 1.25 mm (24.4 - 28.4 N·m;
4TNV84, 4TNV84T,
Fuel Injector 2.5 - 2.9 kgf·m)
4TNV88 Not Applied
Bolt
4TNV94L, 4TNV98, 17 - 21 ft·lb
4TNV98T, 4TNV106, M8 x 1.25 mm (22.6 - 28.4 N·m;
4TNV106T 2.3 - 2.9 kgf·m)
3TNV82A, 3TNV84,
58 - 65 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (78 - 88 N·m;
4TNV84, 4TNV84T,
Fuel Pump Drive 8 - 9 kgf·m)
4TNV88 Not Applied
Gear Nut
4TNV94L, 4TNV98, 83 - 90 ft·lb
4TNV98T, 4TNV106, M18 x 1.5 mm (113 - 123 N·m;
4TNV106T 11.5 - 12.5 kgf·m)
3TNV82A, 3TNV84,
22 - 25 ft·lb
3TNV84T, 3TNV88,
M12 x 1.5 mm (29.4 - 34.3 N·m;
4TNV84, 4TNV84T,
High-Pressure 3.0 - 3.5 kgf·m)
4TNV88 Not Applied
Fuel Lines Bolt
4TNV94L, 4TNV98, 174 - 217 in·lb
4TNV98T, 4TNV106, M12 x 1.5 mm (19.6 - 24.5 N·m;
4TNV106T 2.0 - 2.5 kgf·m)

Special Torque Chart ENGINE
(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
4TNV94L, 4TNV98, 70 - 86 in·lb
Fuel Return Line
4TNV98T, 4TNV106, M6 x 1.0 mm (7.8 - 9.8 N·m; Not Applied
Joint Bolt
4TNV106T 0.8 - 1.0 kgf·m)
Rocker Arm 148 - 199 in·lb
Cover 4TNV106, 4TNV106T M8 x 1.25 mm (16.7 - 22.5 N·m; Not Applied
Bolt 1.7 - 2.3 kgf·m)
3TNV82A-B, 133 - 177 in·lb
Glow Plug 3TNV88-B,-U, M10 x 1.25 mm (15 - 20 N·m Not Applied
4TNV88-B,-U 1.53 - 2.04 kgf·m)
3TNV82A-B,
Glow Connector 9 - 13 in·lb
3TNV88-B,-U, M4 x 0.7 mm Not Applied
Nut (1 - 1.5 N·m)
4TNV88-B,-U
See Tightening Torques for Standard Bolts and Nuts on page 4-46 for standard hardware torque values.

ENGINE Special Service Tools
SPECIAL SERVICE TOOLS

No. Tool Name Applicable Model and Tool Size Illustration
Model L1 L2 d1 d2
3TNV82A
4TNV94L,
4TNV98, 0.787 in. 2.953 in. 0.256 in. 0.394 in.
0000827
4TNV98T (20 mm) (75 mm) (6.5 mm) (10 mm)
4TNV106,
Valve Guide Tool 4TNV106T
1 (For Removing
Valve Guide) 4TNV84,
3TNV84,
0.787 in. 2.953 in. 0.295 in. 0.433 in.
3TNV84T,
(20 mm) (75 mm) (7.5 mm) (11 mm)
3TNV88,
4TNV88
0.787 in. 2.953 in. 0.217 in. 0.354 in.
4TNV84T
(20 mm) (75 mm) (5.5 mm) (9 mm)
Locally Manufactured
Model L1 L2 d1 d2
0.472 in. 2.362 in. 0.512 in. 0.748 in.
3TNV82A
(12 mm) (60 mm) (13 mm) (19 mm)
4TNV84,
3TNV84,
0.591 in. 2.559 in. 0.551 in. 0.787 in.
3TNV84T, 0000828
(15 mm) (65 mm) (14 mm) (20 mm)
Valve Guide Tool 4TNV88,
2 (For Installing 4TNV88
Valve Guide) 0.335 in. 2.362 in. 0.433 in. 0.669 in.
4TNV84T
(8.5 mm) (60 mm) (11 mm) (17 mm)
4TNV94L,
0.276 in. 2.362 in. 0.512 in. 0.630 in.
4TNV98,
(7 mm) (60 mm) (13 mm) (16 mm)
4TNV98T
4TNV106, 0.535 in. 2.559 in. 0.512 in. 0.630 in.
4TNV106T (13.6 mm) (65 mm) (13 mm) (16 mm)
Fuel Injector
3 Removal Tool Yanmar Part No. 129470-92305
(2-Valve Head)

Special Service Tools ENGINE
(Special Service Tools Cont.)
Model L1 L2 d1 d2
0.984 in. 3.346 in. 0.906 in. 1.024 in.
3TNV82A
(25 mm) (85 mm) (23 mm) (26 mm)
3TNV84,
Connecting Rod
3TNV84T,
Bushing
3TNV88, 0.787 in. 3.937 in. 1.024 in. 1.142 in.
Replacer 0000829
4TNV84, (20 mm) (100 mm) (26 mm) (29 mm)
4 (For Removal/
4TNV84T,
Installation of
4TNV88,
Connecting Rod
Bushing) 4TNV94L,
0.787 in. 3.937 in. 1.181 in. 1.299 in.
4TNV98,
(20 mm) (100 mm) (30 mm) (33 mm)
4TNV98T
4TNV106, 0.787 in. 3.937 in. 1.457 in. 1.575 in.
4TNV106T (20 mm) (100 mm) (37 mm) (40 mm)
Valve Spring
Compressor
Yanmar Part No.
5 (For Removal/
129100-92630
Installation of 0000830
Valve Spring)
Model d1 d2 d3 L1 L2 L3
0.598 0.827 0.472 0.622 2.559 0.157
in. in. in. in. in. in.
3TNV82A
(15.2 (21 (12 (15.8 (65 (4
mm) mm) mm) mm) mm) mm)
3TNV84,
0.638 0.866 0.531 0.740 2.559 0.157
3TNV84T,
3TNV88,
(16.2 (22 (13.5 (18.8 (65 (4
4TNV84,
Stem Seal 4TNV88
Installer 0.508 0.748 0.453 0.394 2.559 0.157
6
(for Installing in. in. in. in. in. in.
Valve Stem Seal) 4TNV84T
(12.9 (19 (11.5 (10 (65 (4
0.598 0.827 0.472 0.465 2.559 0.157
4TNV94L, 0000820
4TNV98,
(15.2 (21 (12 (11.8 (65 (4
4TNV98T
0.598 0.827 0.472 0.610 2.559 0.157
4TNV106, in. in. in. in. in. in.
4TNV106T (15.2 (21 (12 (15.5 (65 (4

ENGINE Special Service Tools

Filter Wrench
(For Removal /
7 Available Locally
Installation of
Engine Oil Filter) 0000821
Model L1 L2 d1 d2
3TNV82A,
3TNV84,
3TNV84T,
0.709 in. 2.756 in. 1.772 in. 1.890 in.
3TNV88,
Camshaft (18 mm) (70 mm) (45 mm) (48 mm)
4TNV84,
Bushing Tool 0000822
4TNV84T,
8 (For Extracting 4TNV88
Camshaft
4TNV94L,
Bushing) 0.709 in. 2.756 in. 1.968 in. 2.087 in.
4TNV98,
(18 mm) (70 mm) (50 mm) (553 mm)
4TNV98T
4TNV106, 0.709 in. 2.756 in. 2.283 in. 2.402 in.
4TNV106T (18 mm) (70 mm) (58 mm) (61 mm)
Allowance: d1 d2
Model Yanmar Part No. Cylinder Bore

3.071 - 3.307 in.
3TNV82A 129400-92420
(78 - 84 mm)
3TNV88,
Flex-Hone 3.268 - 3.740 in.
4TNV88, 129400-92430
9 (For Preparation (83 - 95 mm)
4TNV94L
of Cylinder Walls) 0000823
3.504 - 3.976 in.
4TNV98 129400-92440
(89 - 101 mm)
4TNV106, 3.740 - 4.252 in.
129400-92450
4TNV106T (95 - 108 mm)
Piston Ring
Yanmar Part No. 95550-002476
Compressor
10 The Piston Insertion Tool is Applicable for
(For Installing
2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons
Piston)
0000824
Piston Ring
Expander
11 (For Removal / Available Locally
Installation of
Piston Ring) 0000825

Special Service Tools ENGINE
Locally Manufactured 0000826

(1)
Crankshaft Pulley
12 (4TNV94L, 4TNV98(T) series)
Installing Tool
(Knurl knob (1))
0002134
6.3
0.05 A 0.1 A
(16) 36
20
5 M14 x 1.5
0.
C
0.
16 C
5
Pulley Installing 3TNV82A - 4TNV88 1

13 C
ø 35.4 -0.05
-0.15
Tool For all series

ø6
1
C
A
3
52
Knurling

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

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

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

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

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

8 Square Locally Available
straightness of parts
0000838

Measuring Instruments ENGINE
9 V-Block Locally Available For measuring shaft bend
0000839
For tightening nuts and bolts to the specified

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

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

ENGINE 2-Valve Cylinder Head
2-VALVE CYLINDER HEAD

2-Valve Cylinder Head Components
(3)
(1)
(2) (4)
(5)
(6) (7)
(34)
(8)
(32)
(33)
(9) (10)
(11)
(12)
(29)
(17) (13)
(30) (18) (14)
(28) (31) (15)
(19)
(20) (16)
(27)
(21)
(22)
(23)
(26)
(24)
(25) 0001919
Figure 6-1

2-Valve Cylinder Head ENGINE
1 – Valve Cover Nut Components of a two-valve cylinder
2 – Valve Cover Nut O-Ring
3 – Crankcase Breather Cover
head
4 – Diaphragm Spring Cylinder head with glow plugs (two-valve
5 – Diaphragm Plate type)Applicable Model
6 – Crankcase Breather Diaphragm 3TNV82A-B, 3TNV88-B,-U, 4TNV88-B,-U
(non-turbocharged engines only)
7 – Oil Fill Cap
8 – Valve Cover Gasket (3)
9 – Rocker Arm Shaft Spring
10 – Valve Adjusting Screw Lock Nut
11 – Valve Adjusting Screw
12 – Rocker Arm
13 – Rocker Arm Shaft (2)
14 – Rocker Arm Shaft Aligning Stud
15 – Support Bolt
16 – Rocker Arm Shaft Support
17 – Valve Cap
18 – Valve Keepers
19 – Spring Retainer
20 – Valve Spring (1)
21 – Valve Stem Seal
22 – Valve Guide
23 – Cylinder Head
Figure 6-2
24 – Intake Valve
25 – Exhaust Valve 1 – Cylinder Head
26 – Cylinder Head Gasket 2 – Glow plug
27 – Fuel Injector Retainer 3 – Harness, Glow plug
28 – Washer
29 – Fuel Injector Retainer Bolt
30 – Fuel Injector Nozzle Protector
31 – Fuel Injector Nozzle Seat
32 – Push Rod
33 – Crankcase Breather Components
34 – Valve Cover

Disassembly of 2-Valve Cylinder

Head
Prepare a clean, flat working surface on a (1)
workbench large enough to accommodate the
cylinder head assembly. Discard all gaskets,
O-rings and seals. Use new gaskets, O-rings and
seals on reassembly of the cylinder head.
1. Drain the coolant from the engine into a suitable
container. See Drain, Flush and Refill Cooling
System With New Coolant on page 5-36.
CAUTION
0002087A
an appropriate method. It is important Figure 6-4
position during the reassembly process. 4. Remove the intake manifold bolts
(Figure 6-5, (1)). Remove the intake manifold
0000080en
(Figure 6-5, (2)). Discard the intake manifold
2. Disconnect the electrical wire from the intake air gasket (Figure 6-5, (3)).
heater (Figure 6-3, (1)).
(5)
(4)
(1) (5)
(6)
(7)
(2) (3)
0001682
(1)
Figure 6-5
Figure 6-3
5. Remove the exhaust manifold bolts
3. Disconnect the coolant hoses from the cold (Figure 6-5, (4)) and nuts (Figure 6-5, (5)).
start device (Figure 6-4, (1)) on the fuel Remove the exhaust manifold (Figure 6-5, (6))
injection pump. and the exhaust manifold gasket
(Figure 6-5, (7)).
6. Remove the coolant pump. See Disassembly of
Engine Coolant Pump on page 8-10.
7. Remove the high-pressure lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 7-35.

Removing the glow plugs Removal of Valve Cover
1. Remove the glow plug harness 1. Remove the valve cover nuts (Figure 6-7, (1)).
(Figure 6-6, (2)) from each glow plug 2. Remove the O-ring (Figure 6-7, (2)) on each
(Figure 6-6, (1)). valve cover nut.
2. Remove the glow plug from the cylinder head.
(1)
(2)
(2)
(1) (3)
(4)
0001920
Figure 6-7
3. Remove the valve cover (Figure 6-7, (3)) and
the valve cover gasket (Figure 6-7, (4)).
Figure 6-6
Note: Removing the cylinder head from the
engine requires that the glow plugs be
removed in advance.
Failure to remove the glow plugs in
advance could result in damages to the
glow plugs because their tips are
protruding from the cylinder head
combustion chamber surface.

Removal of Rocker Arm Assembly

(7)
1. Remove the bolts (Figure 6-8, (1)) that retain (6)
the rocker arm shaft supports. (1)
(2)
2. Remove the rocker arm shaft assembly from
the cylinder head.
Note: Identify the push rods so they can be (3)
(4)
reinstalled in their original locations.
3. Remove the push rods and identify for
installation. (5)
0001951
Figure 6-9
(1)
3. Remove the valve adjusting screw
(Figure 6-9, (6)) and the lock nut
(Figure 6-9, (7)) from the rocker arms.
Removal of Cylinder Head

1. Loosen the cylinder head bolts following the
sequence shown in (Figure 6-10).
(2)
8 14 5
0001950 2 12 9 3
(1)
Figure 6-8 4 10 11 1
6 13 7
Disassembly of Rocker Arm Assembly

1. Remove the rocker arm shaft alignment stud (2)
(Figure 6-9, (4)) from support (Figure 6-9, (5)).
7 16 14 6
1 9 18 12 4
Note: The rocker arm shaft fits tightly in the
(1)
rocker arm supports. Clamp the support 3 11 17 10 2
in a padded vise. Twist and pull out on 5 13 15 8
the rocker arm shaft to remove. Reverse 0001864
this process when you reinstall the 1 – Cooling Fan End

rocker arm shaft into the supports. 2 – Camshaft Side
2. Slide the rocker arm shaft (Figure 6-9, (3)) out Figure 6-10
of the rocker arm supports (Figure 6-9, (5)),
springs (Figure 6-9, (1)), and rocker arms
(Figure 6-9, (2)).
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.

2. Remove the cylinder head bolts Removal of Intake / Exhaust Valves
(Figure 6-11, (1)). 1. Place the cylinder head on the work bench with
3. Lift the cylinder head away from the cylinder the combustion side down.
block. Discard the cylinder head gasket 2. Remove the valve cap (Figure 6-13, (1)) and
(Figure 6-11, (2)). Position the cylinder head on keep with the valve it was installed on.
the work bench to prevent damage to the
combustion surface. 3. Using the valve spring compressor tool,
compress one of the valve springs
(Figure 6-12).
(1)
0000191
Figure 6-12
4. Remove the valve keepers (Figure 6-13, (2)).
(2) 5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 6-13, (3))
and valve spring (Figure 6-13, (4)).
(1)
(2)
(3)
(4)
0001690 (5)
Figure 6-11
(6)
0001684
Figure 6-13
7. Repeat the procedure with all remaining valves.

Note: If the valves are to be reused, identify Cleaning of Cylinder Head

them so they can be installed in their
Components
original location.
8. Turn the cylinder head so the exhaust port side A WARNING
faces down. Remove the intake and exhaust
valves (Figure 6-13, (6)) from the cylinder
head.
9. Remove the valve stem seals
(Figure 6-13, (5)).
FUME / BURN HAZARD!
Removal of Valve Guides
Note: Removal of the valve guides should be precautions found on containers of
postponed until inspection and hazardous substances like parts
measurement procedures have been cleaners, primers, sealants and
performed. See Inspection of Valve sealant removers.
Guides on page 6-41.
1. If the valve guides were not within or serious injury.
specifications, use a drift pin and hammer to 0000014en
drive the valve guides (Figure 6-14, (1)) out of
the cylinder head. Thoroughly clean all components using a non-
metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other
debris.
(1)
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 limit.
001689 CAUTION
Figure 6-14 Any part which is found defective as a
0000119en

Inspect the contact areas (Figure 6-16, (1)) for
CAUTION excessive wear or damage.
service standard limit.
0000120en
(1)
Inspection of Push Rods (1)
Push Rod Bend

Determine if the bend of the push rods are within 0001916
the specified limit.

Figure 6-16
1. Place the push rods on a flat inspection block or
layout bed. Rocker Arm Shaft Outside Diameter
2. Roll the push rods until a gap can be observed Use a micrometer to measure the rocker arm shaft
between a portion of the push rod and the diameter. Measure at each rocker arm location in
surface of the block or layout bed. two directions 90° apart (Figure 6-17). See Rocker
Arm and Shaft on page 6-9 for the service limit.
3. Use a feeler gauge to measure the gap
(Figure 6-15). See Push Rod on page 6-9 for
the service limit.
0001952
0000204
Figure 6-15 Figure 6-17
Inspection of Rocker Arm Assembly Inspection of Valve Guides

Visually inspect the valve guides for distortions,
Rocker Arm Shaft Hole Diameter scoring or other damage.
Use a test indicator and micrometer to determine if
the inside diameter of all the rocker arm support Note: Measure the valve guides while they are
brackets and the rocker arms (Figure 6-16) are installed in the cylinder head.
within the specified limits. See Rocker Arm and
Shaft on page 6-9 for the service limit.

Use a telescoping gauge and micrometer to Valve Stem Diameter

measure the inside diameter at each end of the Use a micrometer to measure the valve stem
valve guide. Measure in three places and 90° apart diameter. Measure the valve stem near the
(Figure 6-18). See Intake / Exhaust Valve and combustion end and near the opposite end
Guide on page 6-7 for the service limit. Replace (Figure 6-20, (1)). See Intake / Exhaust Valve and
valve guides if not within specification. Guide on page 6-7 for the service limit.
(1)
0001869 0000197

Inspection of Cylinder Head Valve Stem Bend
Cylinder Head Distortion Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
Place the cylinder head flat and inverted
observed between a portion of the valve stem and
(combustion side up) on the bench. Use a straight
the surface of the block or bed. Use a feeler gauge
edge and a feeler gauge to measure cylinder head
to measure the gap (Figure 6-21). See
distortion (Figure 6-19). Measure diagonally and
Intake / Exhaust Valve and Guide on page 6-7 for
along each side. See Cylinder Head on page 6-6
the service limit.
for the service limit.
0000199
Figure 6-21
0000192
Valve Recession
Figure 6-19
Note: The valve guides must be installed to
If distortion exceeds the service limit, resurface or perform this check.
replace the cylinder head. Remove only enough
material to make the cylinder head flat, but do not Insert the valves into their original locations and
remove more than 0.008 in. (0.20 mm). press them down until they are fully seated. Use a
depth micrometer (Figure 6-22) to measure the
Inspection of Intake and Exhaust Valves difference between the cylinder head gasket
surface and the combustion surface of each
Visually inspect the intake and exhaust valves.
exhaust and intake valve (Figure 6-23). See
Replace any valves that are obviously discolored,
Cylinder Head on page 6-6 for the service limit.
heavily pitted or otherwise damaged.

Coat the valve seat with a thin coat of bluing
compound. Install the valve and rotate it to
distribute bluing onto the valve face. The contact
pattern should be approximately centered on the
valve face (Figure 6-24, (1)) and even in width.
0000193
Figure 6-22
(1)
0001691B
Figure 6-24
Also visually inspect the valve seat for even
0001755 contact.
Figure 6-23
Light cutting can be performed by the use of a
Valve Face and Valve Seat hand-operated cutter (Figure 6-25, (3)).
Always check the clearance between the valve and
valve guide before grinding or lapping the valve (1)
seats. See Intake / Exhaust Valve and Guide on 150° 40°
page 6-7 for the service limit. If the clearance
exceeds the limit, replace the valve and / or valve (3)
guide to bring the clearance within the limit. (2)
Roughness or burrs will cause poor seating of a

valve. Visually inspect the seating surfaces of each 0001862
valve and valve seat to determine if lapping or Figure 6-25

grinding is needed.
The valve seat diameter can be adjusted by top-
Visually inspect all valve faces and valve seats for grinding with a 150° stone to make the seat
pitting, distortion, cracking, or evidence of diameter smaller, and bottom-grinding using a 40°
overheating. Usually the valves and the valve seats stone to make the seat diameter larger. Once the
can be lapped or ground to return them to seat location has been corrected, grind and lap the
serviceable condition. Severely worn or damaged seat angle (Figure 6-25, (1)) to specification. See
components will require replacement. Cylinder Head on page 6-6 for specifications.

Grind the valve face and / or valve seat only Free Length
enough to return them to serviceable condition. Use a caliper to measure the length of the spring
Grinding is needed if the valve and the valve seat (Figure 6-27). See Valve Spring on page 6-10 for
do not contact correctly. Check the recession after the service limit.
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.
2
3
1
4
Be sure to thoroughly wash all parts to remove all
5
9
6
grinding powder or compound.
8
7
Inspection of Valve Springs
Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
limits, replace the springs. 0000200
Figure 6-27
Fractures
Check for fractures on the inside and outside Reassembly of Cylinder Head
portions of the springs. If the valve spring is
fractured, replace the valve spring. Use new gaskets, O-rings and seals for the
reassembly of the cylinder head.
Corrosion
IMPORTANT
Check for corrosion of the spring material caused Liberally oil all components during
by oxidation. reassembly to prevent premature wear or
Squareness damage.
Use a flat surface and a square to check each Reassembly of Valve Guides
spring for squareness (Figure 6-26). See Valve
Spring on page 6-10 for the service limit. 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,
making it easier to install the valve guides into
place.
0000201
Figure 6-26

2. Immediately after removing the valve guides Reassembly of Intake and Exhaust Valves
from the freezer, insert the valve guides
(Figure 6-28, (1)) in their proper positions. IMPORTANT
Always install new valve stem seals.
The exhaust valve stem seals are different
than the intake valve stem seals and can be
(1) identified by either the paint marks on the
outside of the seals or by the color of the
seal spring (Figure 6-30, (4)). Ensure they
are installed in the correct locations.
Marking
Engine Model
Intake Exhaust
3TNV84, 3TNV88, Yellow (Paint
3TNV84T, 4TNV84, None on outside of
001689 4TNV88 seal)
Figure 6-28 Black (Seal
3TNV82A None
Spring)
3. Finish installing the valve guides
(Figure 6-29, (1)) into the cylinder head to the 1. Oil the lip of the valve stem seal
proper height (Figure 6-29, (3)) using the valve (Figure 6-30, (2)). Using the valve stem seal
guide installation tool (Figure 6-29, (2)). See installation tool (Figure 6-30, (1)), install a new
Valve Guide Projection specification starting on valve stem seal on each of the valve guides
page 6-7. (Figure 6-30, (3)).
(2)
(1)
(3)
(4)
(1) (2)
0001756A
(3)
Figure 6-29
0001873B
Figure 6-30
2. Measure the distance (Figure 6-31, (1)) from
the cylinder head to valve stem seal to ensure
proper clearance (Figure 6-31, (2)) between
the guide and the seal. See Valve Stem Seal
Projection specification on page 6-9.

7. Insert the valve keepers (Figure 6-32, (2)) and

slowly release the tension on the valve spring.
Install the valve cap (Figure 6-32, (1)). Repeat
the steps on all the remaining valves.
(2) Reassembly of Cylinder Head
(1)
1. Carefully clean both the combustion surface of
the cylinder head and the top surface of the
cylinder block. Then place a new cylinder head
gasket (Figure 6-33, (2)) on the cylinder block.
0001874
2. Position the cylinder head on the cylinder head
Figure 6-31 gasket.
3. Place the cylinder head assembly on its
exhaust port side. (1)
4. Place all the valves (Figure 6-32, (6)) in their
proper location in the cylinder head.
(1)
(2)
(3)
(4)
(5)
(2)
(6)
0001684
0001690
Figure 6-32
5. Place the cylinder head on the workbench with Figure 6-33
the combustion side down to install the valve
springs. Install the valve spring
(Figure 6-32, (4)) and the spring retainer
(Figure 6-32, (5)).
6. Using the valve spring compressor tool,
compress the valve spring.

3. Lightly oil the threads of the cylinder head bolts 1. Lubricate the rocker arm shaft. Slide the rocker
(Figure 6-33, (1)). Tighten the bolts to the arm supports (Figure 6-36, (5)), springs
specified torque in two steps as shown in the (Figure 6-36, (1)) and rocker arms
chart below. Tighten in the sequence shown in (Figure 6-36, (2)) onto the shaft.
(Figure 6-34). See Special Torque Chart on Note: The rocker arm shaft fits tightly in the
page 6-25 for specification. rocker arm supports. Clamp the support
First Step 1/2 of final torque
in a padded vise. Twist and push on the
rocker arm shaft to reinstall.
Second Step Final torque
Note: To properly align the rocker arm shaft
4. Insert the push rods in their respective with the rocker arm shaft supports, first
positions. reinstall a rocker arm support
(Figure 6-36, (5)) having a hole for the
(2) shaft alignment stud (Figure 6-36, (4)).
13
7
3
1
6
10
12
Align the hole in the rocker arm shaft and
(1) the hole in the rocker arm support.
11 5 4 14
Reinstall the alignment stud.
9 2 8
(7)
(6)
(2)
(1)
12 3 5 13 (2)
18 10 1 7 15
(1)
16 8 2 9 17
14 6 4 11 (3)
(4)
0001875
1 – Fan End
2 – Camshaft Side
(5)
Figure 6-34
Reassembly of Rocker Arm Reassembly

0001951
Note: Ensure the lubrication holes
(Figure 6-35, (1)) in the rocker arm shaft Figure 6-36
are oriented correctly with respect to the
Note: Figure 6-36 shows components for one
rocker arms (Figure 6-35, (2)).
cylinder. Components for all remaining
cylinders are assembled in the same
(2)
order.
2. Place the rocker arm shaft assembly onto the
(1)
cylinder head.
3. If removed, reinstall the valve adjusting screws
(Figure 6-36, (6)) and the lock the nuts
(Figure 6-36, (7)).
4. Align the push rods with their respective rocker
arms.
(1) 0001914
5. Reinstall and tighten the rocker arm shaft
Figure 6-35 retaining bolts to the specified torque.

6. Tighten the rocker arm shaft alignment studs. 6. Install each glow plug (Figure 6-38, (1)), and
7. Adjust the valve clearance. See Measuring and tighten it with the specified torque. Install each
Adjusting Valve Clearance on page 6-66. electrical harness (Figure 6-38, (1)), and
tighten it with the specified torque.
Reassembly of the Valve Cover
1. Lightly grease a new valve cover gasket (2)
(Figure 6-37, (4)). Place the gasket in the
groove of the valve cover (Figure 6-37, (3)).
2. Place the valve cover on the cylinder head. (1)
3. Be sure new O-rings (Figure 6-37, (2)) are
installed on the valve cover nuts. Reinstall and
tighten the valve cover nuts (Figure 6-37, (1)).
4. Reinstall the exhaust manifold using a new
gasket. Tighten the bolts to the specified
torque.
(1)
(2)
Figure 6-38
7. Reinstall the fuel injectors. See Installation of
the Fuel Injectors on page 7-42.
(3) 8. Reinstall the high pressure and the return fuel
injection lines. See Installation of the Fuel
Injectors on page 7-42
9. Reinstall the engine coolant pump. See
(4)
Reassembly of Engine Coolant Pump on
0001920 page 8-11.
Figure 6-37 10. Reinstall the coolant hoses on the cold start
5. Reinstall the intake manifold using a new device on the fuel injection pump.
gasket. Tighten the bolts to the specified 11. Reinstall the alternator. See Installation of
torque. Alternator on page 12-16.

4-VALVE CYLINDER HEAD

4-Valve Cylinder Head Components
(1)
(2)
(3)
(4) (5)
(36)
(6)
(7)
(35)
(8)
(34)
(9)
(11) (12)
(10)
(33)
(14) (15)
(31) (13)
(30) (32)
(29)
(28)
(27) (16)
(26)
(24)
(25)
(23) (17)
(18)
(22)
(19)
(21)
(20) 0001861
Figure 6-39

1 – Crankcase Breather Cover Disassembly of 4-Valve Cylinder

2 – Diaphragm Spring
3 – Diaphragm Cup Head
4 – Crankcase Breather Diaphragm Prepare a clean, flat working surface on a
5 – Oil Fill Cap workbench large enough to accommodate the
6 – Valve Cover Nut cylinder head assembly. Discard all gaskets,
7 – Valve Cover Nut O-Ring
O-rings and seals. Use new gaskets, O-rings and
8 – Valve Cover Gasket
9 – Support Bolt
seals on reassembly of the cylinder head.
10 – Rocker Arm Shaft Support 1. Drain the coolant from the engine into a suitable
11 – Wave Washer container. See Drain, Flush and Refill Cooling
12 – Fuel Injector Retainer Bolt
System With New Coolant on page 5-36.
13 – Valve Adjusting Screw (Primary)
14 – Valve Adjusting Screw Lock Nut (Primary)
15 – Rocker Arm Shaft Aligning Stud CAUTION
16 – Fuel Injector Retainer Identify all parts and their location using
17 – Valve Stem Seal an appropriate method. It is important
18 – Valve Guide that all parts are returned to the same
19 – Cylinder Head position during the reassembly process.
20 – Intake Valve
0000080en
21 – Exhaust Valve
22 – Cylinder Head Gasket 2. Remove the high pressure fuel injection lines
23 – Fuel Injector Nozzle Protector
(Figure 6-40, (1)). See Removal of Fuel
24 – Fuel Injector Nozzle Seat
25 – Valve Spring
Injectors on page 7-35.
26 – Valve Bridge Guide
27 – Spring Retainer
28 – Valve Keepers
29 – Valve Bridge (1)
30 – Valve Bridge Seat
31 – Valve Adjusting Screw Lock Nut
(Secondary)
32 – Valve Adjusting Screw (Secondary)
33 – Push Rod
34 – Rocker Arm Shaft
35 – Crankcase Breather Components
36 – Valve Cover (3)
(2)
0001876
Figure 6-40

CAUTION (2)
possible. Disassembling the (3) (6)
(1)
high-pressure fuel injection lines from (7)
the retainers or bending any of the fuel (5)
(4)
fuel lines.
0000047en
3. Disconnect the fuel return hose

(Figure 6-40, (2)) from the cylinder head. (12)
4. Disconnect the hoses (Figure 6-40, (3)) from
the cold start device on the fuel injection pump. (11) (8)
This cooling water pipe is not used in (10) (9)
0001860
electronically controlled engines 4TNV84T-Z,

Figure 6-41
4TNV98-Z, 4TNV98-E and 4TNV98T-Z.
Instead, these engines use a solenoid valve 10. Remove the engine coolant pump. See
and connecting coupler but, when removing the Disassembly of Engine Coolant Pump on
cylinder head only, it is not necessary to remove page 8-10.
the connecting coupler.
5. Remove the turbocharger-to-intake manifold
hose (Figure 6-41, (1)) (if equipped).
6. Disconnect the electrical wire from the intake air
heater (Figure 6-41, (12)).
7. Remove the intake manifold bolts
(Figure 6-41, (11)). Remove the intake
manifold (Figure 6-41, (10)). Discard the intake
manifold gasket (Figure 6-41, (9)).
8. Disconnect the turbocharger oil supply
(Figure 6-41, (2)) and the return lines
(Figure 6-41, (4)) (if equipped).
9. Remove the exhaust manifold bolts
(Figure 6-41, (7)). Remove the exhaust
manifold (Figure 6-41, (6)) with the
turbocharger attached. Discard the exhaust
manifold gasket. (Figure 6-41, (5)).

Removal of Valve Cover

Note: The high pressure fuel injection lines and (3)
valve cover grommets must be removed
prior to removing the valve cover. See (4)
Removal of Fuel Injectors on page 7-35.
(5)
1. Remove the high-pressure fuel lines.
2. Use a flat-blade screwdriver (Figure 6-42) to
remove the fuel injection line grommets
(Figure 6-43, (1)) from the valve cover
(Figure 6-43, (3)) and fuel injectors (2)
(6)
(Figure 6-43, (2)). There is a notch at the 3 (1)
o’clock position in the valve cover opening to
insert the screwdriver.
Figure 6-42
3. Remove the valve cover nuts (Figure 6-43, (4)). 0001877
4. Remove the O-ring (Figure 6-43, (5)) on each Figure 6-43

valve cover nut.
5. Remove the valve cover (Figure 6-43, (3)).
Discard the valve cover gasket
(Figure 6-43, (6)).
6. Inspect and clean the crankcase breather
assembly. See Inspect Crankcase Breather
System on page 5-40.

Removal of Rocker Arm Assembly Disassembly of Rocker Arm Assembly
1. Remove the fuel injectors from the cylinder Note: Identify the rocker arms so they can be
head. See Removal of Fuel Injectors on reinstalled with the original matching
page 7-35. valve and pushrod.
2. Remove the bolts (Figure 6-44, (1)) that retain 1. Remove the rocker arm shaft alignment studs
the rocker arm shaft supports to the cylinder (Figure 6-45, (5)) from the rocker arm shaft
head. supports (Figure 6-45, (6)).
3. Remove the rocker arm and shaft assembly 2. Slide the supports, wave washers
from the cylinder head. (Figure 6-45, (7)), rocker arms
Note: Identify the push rods and valve bridges (Figure 6-45, (8)), and fuel injector retainers
so they can be installed in their original (Figure 6-45, (4)) off the rocker shaft
locations. (Figure 6-45, (1)), leaving these parts in order
on the bench surface.
4. Remove the push rods (Figure 6-44, (2)).
5. Remove the valve bridge assemblies (1)
(Figure 6-44, (3)). Remove the seat
(Figure 6-44, (4)) from each valve bridge. (3)
6. Identify all parts so that they will be reinstalled (2)
(4) (5)
in their original locations.
(1)
(8)
(7)
(6)
0001866
(4)
(3) Figure 6-45
(2)
Note: Figure 6-45 shows components for one
order.
3. Remove the valve adjusting screw
(Figure 6-45, (2)) and the lock nut
000187
(Figure 6-45, (3)) from the rocker arms.
Figure 6-44

Removal of Cylinder Head

1. Loosen the cylinder head bolts following the (1)
sequence shown in (Figure 6-46).
(2)
8 14 5
2 12 9 3
(1)
4 10 11 1
6 13 7
(2)
7 16 14 6
1 9 18 12 4
(1)
3 11 17 10 2
5 13 15 8 (2)
0001864
1 – Cooling Fan End

2 – Camshaft Side
Figure 6-46 0001872
2. Remove the cylinder head bolts Figure 6-47

(Figure 6-47, (1)).
Removal of Intake and Exhaust Valves
3. Lift the cylinder head away from the cylinder
block. Discard the cylinder head gasket 1. Place the cylinder head on the work bench with
(Figure 6-47, (2)). Place the cylinder head on the combustion side down.
the work bench to prevent damage to the 2. Using the valve spring compressor tool,
combustion surface. compress one of the valve springs
(Figure 6-48).
0000191
Figure 6-48

3. Remove the valve keepers (Figure 6-49, (1)). Removal of Valve Guides
4. Slowly release the tension on the valve spring. Note: Removal of the valve guides should be
5. Remove the spring retainer (Figure 6-49, (2)), postponed until inspection and
valve spring (Figure 6-49, (3)). measurement procedures have been
performed. See Inspection of Valve
(1) Guides on page 6-57.
(7) (2) 1. Using a drift pin and hammer, drive the valve
(6) guides (Figure 6-50, (1)) out of the cylinder
(3) head.
(4)
(1)
(5)
0001867
0001868
Figure 6-49
Figure 6-50
6. Repeat the procedure with all the remaining
valves. Cleaning of Cylinder Head
Note: If the valves are to be reused, identify Components
them so they can be installed in their
original location.
A WARNING
7. Remove the injector nozzle protectors
(Figure 6-49, (6)) and the seats
(Figure 6-49, (7)).
8. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
valves (Figure 6-49, (5)) from the cylinder FUME / BURN HAZARD!
head. • Always read and follow safety related
9. Remove the valve stem seals precautions found on containers of
(Figure 6-49, (4)). hazardous substances like parts
sealant removers.
or serious injury.
0000014en

Thoroughly clean all components using a non- Inspection of Push Rods

metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other Push Rod Bend
debris. 1. Place the push rods on a flat inspection block or
layout bed.
Inspection of Cylinder Head 2. Roll the push rods until a gap can be observed
Components between a portion of the push rod and the
Visually inspect the parts. Replace any parts that surface of the block or layout bed.
are obviously discolored, heavily pitted or otherwise 3. Use a feeler gauge to measure the gap
damaged. Discard any parts that do not meet its (Figure 6-51). See Push Rod on page 6-9 for
specified limit. the service limit.
CAUTION
Any part which is found defective as a
0000119en
CAUTION
Any part determined to not meet the 0000204
service, as determined from the state of Figure 6-51
Inspection of Rocker Arm Assembly
service standard limit. Rocker Arm Shaft Hole Diameter
0000120en
1. Use a telescoping gauge and micrometer to
determine if the inside diameter of all the rocker
arm support brackets and the rocker arms
(Figure 6-52) are within the specified limits.
See Rocker Arm and Shaft on page 6-9 for the
service limit.
2. Inspect the contact areas (Figure 6-52, (1)) for
excessive wear or damage.

Inspection of Valve Guides
Valve Guide Inside Diameter
Visually inspect the valve guides for distortions,
scoring or other damage.
Note: Measure the valve guides while they are
(1) installed in cylinder head.
(1)
Use a telescoping gauge and micrometer to
measure the inside diameter at each end of the
0001916 valve guide. Measure in three places and 90° apart
(Figure 6-54). See Intake / Exhaust Valve and
Figure 6-52 Guide on page 6-7 for the service limit. Replace the
valve guides if not within specification.
Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm shaft
diameter (Figure 6-53). Measure at each rocker
arm location in two directions 90° apart
(Figure 6-53). See Rocker Arm and Shaft on
page 6-9 for the service limit. 0001869
Figure 6-54
Inspection of Cylinder Head

Cylinder Head Distortion
Place the cylinder head flat and inverted
(combustion side up) on the bench. Use a straight
edge and feeler gauge to measure cylinder head
distortion (Figure 6-55). Measure diagonally and
along each side. See Cylinder Head on page 6-6
for the service limit.
0001952
Figure 6-53
0000192
Figure 6-55

If distortion exceeds the service limit, resurface or Valve Stem Bend

replace the cylinder head. Remove only enough Place the valve stem on a flat inspection block or
material to make the cylinder head flat, but do not layout bed. Roll the valve until a gap can be
remove more than 0.008 in (0.20 mm). observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
Inspection of Intake and Exhaust Valves to measure the gap (Figure 6-57). See
Visually inspect the intake and exhaust valves. Intake / Exhaust Valve and Guide on page 6-7 for
Replace any valves that are obviously discolored, the service limit.
heavily pitted or otherwise damaged.
Valve Stem Diameter

Use a micrometer to measure the valve stem
diameter. Measure the valve stem near the
combustion end and near the opposite end
(Figure 6-56, (1)). See Intake / Exhaust Valve and
Guide on page 6-7 for the service limit.
(1) 0000199
Figure 6-57
0000197 Valve Recession
Note: The valve guides must be installed to
Figure 6-56 perform this check.
Insert the valves into their original locations and
press them down until they are fully seated. Use a
depth micrometer (Figure 6-58) to measure the
difference between the cylinder head gasket
surface and the combustion surface of each
exhaust and intake valve (Figure 6-59). See
Cylinder Head on page 6-6 for the service limit.
0000193
Figure 6-58
Note: 2-Valve cylinder head is shown. 4-Valve
cylinder head is similar.

Coat the valve seat with a thin coat of bluing
compound. Install the valve and rotate to distribute
bluing onto the valve face. The contact pattern
should be approximately centered on the valve face
(Figure 6-60, (1)) and even in width.
0001755
Figure 6-59
Valve Face and Valve Seat

Always check the clearance between the valve and
(1)
valve guide before grinding or lapping the valve
seats. See Intake / Exhaust Valve and Guide on
page 6-7 for the service limit. If the clearance
exceeds the limit, replace the valve and/or valve 0001691B
guide to bring the clearance within the limit.
Figure 6-60
Roughness or burrs will cause poor seating of a
Also visually inspect the valve seat for even
valve. Visually inspect the seating surfaces of each
contact.
valve and valve seat to determine if lapping or
grinding is needed. Light cutting can be performed by the use of a
hand-operated cutter (Figure 6-61).
Visually inspect all valves faces and valve seats for
pitting, distortion, cracking, or evidence of
overheating. Usually the valves and valve seats can (1)
be lapped or ground to return them to serviceable 150° 40°
condition. Severely worn or damaged components
will require replacement. (3)
(2)
0001862
Figure 6-61
Valve seat diameter can be adjusted by top-
grinding with a 150° stone to make the seat
diameter smaller, and bottom-grinding using a 40°
stone to make the seat diameter larger. Once the
seat location has been corrected, grind and lap the
seat angle (Figure 6-61, (1)) to specification. See
Cylinder Head on page 6-6 for specifications.

Grind the valve face and/or valve seat as necessary Free Length
to return them to serviceable condition. Grinding is Use a caliper to measure the length of the spring
needed if the valve and valve seat do not contact (Figure 6-63). See Valve Spring on page 6-10 for
correctly. Check the valve margin and valve the service limit.
recession 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.
2
3
1
4
Be sure to thoroughly wash all parts to remove all
5
9
6
grinding powder or compound.
8
7
Inspection of Valve Springs
Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
limits, replace the springs. 0000200
Figure 6-63
Fractures
Check for fractures on the inside and outside Inspection of Valve Bridges
portions of the springs. If the valve spring is
Visually inspect the contact surface at both ends of
fractured, replace the valve spring.
the valve bridge (Figure 6-64, (2)) for excessive
Corrosion wear or mushrooming.
Check for corrosion of spring material caused by Remove and inspect the seat (Figure 6-64, (1)).
oxidation.
Measure the diameter of the valve bridge guide pin
Squareness bore in the valve bridge and guide pin
Use a flat surface and a square to check each (Figure 6-64, (3)). See Rocker Arm and Shaft on
spring for squareness (Figure 6-62). See Valve page 6-9 for the service limit.
Spring on page 6-10 for the service limit.
(1)
(2)
(3)
0000201
Figure 6-64
Figure 6-62

Reassembly of Cylinder Head 3. Finish installing the valve guides
(Figure 6-66, (1)) into the cylinder head to the
Use new gaskets, O-rings, and seals on proper height (Figure 6-66, (3)) using the valve
reassembly of the cylinder head. guide installation tool (Figure 6-66, (2)). See
IMPORTANT Intake / Exhaust Valve and Guide on page 6-7.
Liberally oil all components during
reassembly to prevent premature wear or (2)
damage.
Reassembly of Valve Guides

1. The valve guides are installed into the cylinder (3)
head with an extremely tight press fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes (1)
0001756A
This will cause the valve guides to contract,
making it easier to install the valve guides into Figure 6-66
place.
2. Immediately after removing the valve guides Reassembly of Intake and Exhaust Valves
from the freezer, insert the valve guides IMPORTANT
(Figure 6-65, (1)) in their proper positions. When installing valve stem seals, use new
ones instead of reusing removed seals.
(1)
Exhaust valve and intake valve stem seals
are different. They can be distinguished
based on the paint marks on the outer side
of the seal or the color of the seal spring
(Figure 6-67, (4)). When installing each
stem seal, take care to correctly position it.
Marking
Engine Model
Intake Exhaust
0001868 White (Seal Black (Seal
4TNV84
Spring) Spring)
Figure 6-65
4TNV94L,4TNV98,
Black (Seal
4TNV98T,4TNV106, None
Spring)
4TNV106T
1. Oil the lip of the valve stem seal

(Figure 6-67, (2)). Using the valve stem seal
installation tool (Figure 6-67, (1)), install a new
valve stem seal on each of the valve guides
(Figure 6-67, (3)).

(1)
(7) (2)
(6)
(1) (3)
(4)
(2)
(3)
(5)
0001873
Figure 6-67 0001867
2. Measure the distance (Figure 6-68, (1)) from Figure 6-69

the cylinder head to the valve stem seal to
ensure proper clearance (Figure 6-68, (2)) 5. Place the cylinder head on the workbench with
between the guide and seal. See the combustion side down. Install the valve
Intake / Exhaust Valve and Guide on page 6-7. spring (Figure 6-69, (3)) and spring retainer
(Figure 6-69, (2)).
6. Using the valve spring compressor tool,
compress the valve spring.
7. Insert the valve keepers (Figure 6-69, (1)) and
slowly release the tension in the valve spring.
(2)
(1) Repeat the steps on all the remaining valves.
Reassembly of Cylinder Head

1. Carefully clean both the combustion surface of
the cylinder head and the top surface of the
0001874 cylinder block. Then place a new cylinder head
Figure 6-68 gasket (Figure 6-70, (2)) on the cylinder block.
2. Position the cylinder head on the on the cylinder
3. Place the cylinder head assembly on its head gasket.
exhaust port side.
4. Place all the valves (Figure 6-69, (5)) in their
proper location in the cylinder head.

(2)
(1) 7 1 10
13 3 6 12
(1)
11 5 4 14
9 2 8
(2)
12 3 5 13
18 10 1 7 15
(1)
16 8 2 9 17
14 6 4 11
0001875
1 – Fan End
2 – Camshaft Side
Figure 6-71
(2)
Reassembly of Rocker Arm Assembly
1. Reinstall the valve bridges (Figure 6-72, (3)) in
their original locations and ensure each seat
0001872 (Figure 6-72, (4)) is in place.
Figure 6-70 2. Insert the push rods (Figure 6-72, (2)) in their
original locations.
3. Lightly oil the threads of the cylinder head bolts
(Figure 6-70, (1)). Tighten the bolts to the
specified torque in two steps as shown in the (1)
chart below. Tighten in the sequence shown in
(Figure 6-71). See Special Torque Chart on
page 6-25 for specification.
First Step 1/2 of final torque
Second Step Final torque
(4)
(3)
(2)
0001871
Figure 6-72

IMPORTANT Note: To properly align the rocker arm shaft

The wave washers (Figure 6-73, (2)) must with the rocker arm shaft supports, first
be installed with the bow facing the rocker reinstall one of the end rocker arm
arms (Figure 6-73, (1)). supports (Figure 6-75, (6)) with a hole
for the shaft alignment stud
(Figure 6-75, (5)). Align the hole in the
(1)
(2) rocker arm shaft and the hole in the
rocker arm support bracket. Reinstall the
alignment stud.
(1)
(3)
0001878
(2)
(4) (5)
Figure 6-73
IMPORTANT
Ensure the lubrication holes
(Figure 6-74, (1)) in the rocker arm shaft
are oriented correctly with respect to the
rocker arms (Figure 6-74, (2)). (8)
(7)
(6)
(2) 0001866
Figure 6-75
(1) Note: Figure 6-75 shows components for one
order.
4. Position the rocker arm assembly on a flat
surface. Reinstall the alignment studs
(1) 0001914 (Figure 6-75, (5)).
Figure 6-74 5. Place the rocker arm shaft assembly onto the
cylinder head.
3. Lubricate the rocker arm shaft. Slide the rocker
6. If removed, reinstall the valve adjusting screws
arm supports (Figure 6-75, (6)), wave washers
(Figure 6-75, (2)) and lock nuts
(Figure 6-75, (7)), rocker arms
(Figure 6-75, (3)).
(Figure 6-75, (8)), and fuel injector retainers
(Figure 6-75, (4)) onto the shaft. 7. Align the push rods with their respective rocker
arms.
8. Reinstall and tighten the rocker arm shaft
retaining bolts to the specified torque.
9. Tighten the rocker arm shaft alignment studs.
10. Adjust the valve clearance.
11. Reinstall the fuel injectors. See Installation of
the Fuel Injectors on page 7-42.

Reassembly of the Valve Cover 9. Reinstall the high pressure and fuel return lines.
1. Lightly grease a new valve cover gasket See Installation of the Fuel Injectors on
(Figure 6-76, (6)). Place the gasket in the page 7-42.
groove of the valve cover (Figure 6-76, (3)). 10. Reinstall the coolant pump. See Reassembly of
2. Place the valve cover on the cylinder head. Engine Coolant Pump on page 8-11.
3. Be sure new O-rings (Figure 6-76, (5)) are 11. Reinstall the alternator. See Installation of
installed on the valve cover nuts. Reinstall and Alternator on page 12-16.
tighten the valve cover nuts (Figure 6-76, (4)). 12. Reconnect the turbocharger oil supply and
drain lines.
13. Reconnect the air intake hose.
(3)
(4)
(5)
(2)
(6)
(1)
0001877
Figure 6-76
4. Reinstall the fuel injector grommets
(Figure 6-76, (1)).
5. Reinstall the exhaust manifold using a new
gasket. Tighten the bolts to specification.
6. Reinstall the intake manifold using a new
gasket. Tighten the bolts to specification.
7. Reconnect the fuel injector return hose and fuel
injection pump coolant hoses.
8. Reinstall the high-pressure fuel line grommets
into the valve cover.

ENGINE Measuring and Adjusting Valve Clearance
MEASURING AND ADJUSTING • If there is no valve clearance, and the cylinder

is at TDC of the compression stroke, extreme
VALVE CLEARANCE wear, or damage to the cylinder head or valves
Measure and adjust while the engine is cold. may be possible.
• If adjusting each cylinder individually, the
Notes:
cylinder to be adjusted first does not have to be
• The No. 1 piston position is on the flywheel end the No. 1 cylinder. Select and adjust the
of the engine, opposite the radiator. The firing cylinder where the piston is nearest to the top
order is 1-3-2 for 3-cylinder engines and dead center after turning. Make adjustment for
1-3-4-2 for 4-cylinder engines. the remaining cylinders in the order of firing by
• 3-cylinder engines fire every 240° of crankshaft turning the crankshaft each time.
rotation. • To decrease the number of rotations required
• 4-cylinder engines fire every 180° of crankshaft to check all cylinders, other cylinders can also
rotation. be checked as indicated in the chart below.
• Valve clearance of both the intake and exhaust Example: On a 3-cylinder engine, with the No. 1
valves can be checked with the piston for that piston at TDC on the compression stroke (both
cylinder at top dead center (TDC) of the valves closed), the valves indicated on the top line
compression stroke. When a piston is at TDC of the chart can be adjusted without rotating the
of the compression stroke, both rocker arms crankshaft. To adjust the remaining two valves,
will be loose and the cylinder TDC mark on the rotate the crankshaft until the No. 1 piston is at TDC
flywheel will be visible in the timing port of the on the exhaust stroke (exhaust valve only open).
flywheel housing.
3-Cylinder Engines
Cylinder No. 1 2 3
Valve Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 Cylinder at TDC
• • • •
Compression
No. 1 Cylinder at TDC Exhaust • •
4-Cylinder Engines
Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
• • • •
Compression
• • • •
Compression

Measuring and Adjusting Valve Clearance ENGINE
2-Valve Cylinder Heads
1. Remove the valve cover. See Removal of Valve (2)
Cover on page 6-52.
Note: If adjusting each cylinder individually, the
cylinder to be adjusted first does not
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is
nearest to the top dead center after
turning, and make adjustment for other
cylinders in the order of firing by turning
the crankshaft.
(1)
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to Figure 6-78
TDC on the compression stroke while watching
6. Insert a feeler gauge of the correct thickness
the rocker arm motion and timing grid on the
(Figure 6-79, (1)) (see Adjustment
flywheel. (Position where both the intake and
Specifications on page 6-6) between the rocker
exhaust valves are closed.)
arm and valve cap. Turn the valve adjustment
3. Insert a feeler gauge (Figure 6-77, (1)) screw to adjust the valve clearance so there is a
between the rocker arm and valve cap, and slight “drag” on the feeler gauge when sliding it
record the measured valve clearance. (Use the between the rocker arm and the valve cap. Hold
data for estimating the wear.) the adjusting screw while tightening the valve
adjusting screw lock nut (Figure 6-78, (1)).
(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 you make
the initial clearance adjustment slightly
on the “loose” side before tightening the
lock nut.
(1)
0001782A
Figure 6-77
4. If adjustment is required, proceed to the next
step.
Figure 6-79
5. Loosen the valve adjusting screw lock nut
(Figure 6-78, (1)) and valve adjusting screw 7. Apply oil to the contact surface between the
(Figure 6-78, (2)) on the rocker arm and check adjusting screw and push rod.
the valve for inclination of the valve cap,
8. Rotate the crankshaft. Measure and adjust the
entrance of dirt, or wear.
valves on the next cylinder. Continue until all
the valves have been measured and adjusted.

4-Valve Cylinder Heads IMPORTANT

Do not loosen or tighten the valve adjusting
The 4-valve cylinder head operates two valves with
screw lock nut without holding the valve
a single rocker arm by employing a valve bridge
bridge. Always hold the valve bridge using a
(Figure 6-80, (1)) between the two valves
wrench to prevent bending of the valve
(Figure 6-80, (2)). Clearance (Figure 6-80, (4))
stems.
between the valve bridge and valves must be set
before adjusting the clearance (Figure 6-80, (5)) 4. Loosen the valve bridge adjusting screw lock
between the rocker arm (Figure 6-80, (3)) and nut (Figure 6-81, (1)) while holding the bridge
valve bridge. (Figure 6-81, (3)) with a wrench
(Figure 6-81, (2)).
(5) (3)
(1) (1)
(4)
(3)
(2) (2) (2) 0001917A
Figure 6-81
0001918B
5. To assure the valve bridge contacts the rear

Figure 6-80
valve, apply light, downward (Figure 6-82, (4))
1. Remove the valve cover. See Removal of Valve finger pressure on the valve bridge
Cover on page 6-52. (Figure 6-82, (3), and loosen the valve bridge
adjusting screw (Figure 6-82, (1)), until there is
Note: If adjusting each cylinder individually, the
visible clearance (Figure 6-84, (2)) between the
cylinder to be adjusted first does not
adjusting screw and the front valve.
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is 6. To assure the valve bridge has equal contact
nearest to the top dead center after with the front and rear valves, apply light
turning, and make adjustment for other downward (Figure 6-82, (4)) pressure on the
cylinders in the order of firing by turning valve bridge (Figure 6-82, (3), adjust the valve
the crankshaft 180° each time. bridge adjusting screw ((Figure 6-82, (1)),
(Figure 6-84, (1))) so there is zero
2. Rotate the crankshaft clockwise as seen from “0” clearance (Figure 6-84, (2)) between the
the coolant pump end, to bring No. 1 piston to adjusting screw and the front valve.
TDC on the compression stroke while watching
the rocker arm motion and the timing grid on the (1)
flywheel. (Position where both the intake and (4)
exhaust valves are closed.)
3. Make sure there is clearance (Figure 6-80, (5))
between the valve bridge (Figure 6-80, (1)) and
the rocker arm (Figure 6-80, (3)). (3)
(2) 0001917C
Figure 6-82

Measuring and Adjusting Valve Clearance ENGINE
7. Tighten the lock nut (Figure 6-83, (1)), while
(2)
holding the valve bridge (Figure 6-83, (3)) with
a wrench (Figure 6-83, (2)). Verify that the
valve clearance (Figure 6-84, (2) is zero “0”.
(1)
(3)
.006 (1)
(2) 0001917A .152 m
m
Figure 6-83
(1) 0003566
(3)
Figure 6-85
9. If adjustment is required, proceed to the next
step.
(2)
10. Loosen the valve adjusting screw lock nut
(Figure 6-86, (5)) and valve adjusting screw
(Figure 6-86, (4)) on the rocker arm
0001918D (Figure 6-86, (3)) and check the clearance gap
Figure 6-84 (Figure 6-86, (2)) for evidence of dirt or wear.
Note: There is a tendency for the clearance to
Note: There is a tendency for the clearance to decrease slightly when the lock nut is
decrease slightly when the lock nut is tightened. It is suggested that you make
tightened. It is suggested that you make the clearance adjustment is made
the initial clearance adjustment is made slightly on the “loose” side before
slightly on the “loose” side before tightening the lock nut.
tightening the lock nut.
11. Adjust the valve clearance (Figure 6-86, (2)) by
8. To adjust the actual valve clearance between turning the adjusting screw (Figure 6-86, (4))
the rocker arm and the valve bridge, insert a until there is a slight “drag” on the feeler gauge
feeler gauge (Figure 6-85, (1)) of the correct when sliding it between the rocker arm and the
thickness (See Adjustment Specifications on valve bridge.
page 6-6) between the rocker arm
(Figure 6-85, (2)) and valve bridge
(Figure 6-85, (3)). Record the results and use
this value as an indication of wear.

(3)
(4)
(1) (2) (5)
0001918
Figure 6-86
12. Hold the adjusting screw (Figure 6-86, (4))
while tightening the valve adjusting screw lock
nut (Figure 6-86, (5)). Recheck the clearance.
13. Apply oil to the contact surface between the
adjusting screw and push rod.
14. Rotate the crankshaft to measure and adjust
the set of valves. Continue until all valves are
measured and adjusted.

Crankshaft and Camshaft Components ENGINE
CRANKSHAFT AND CAMSHAFT COMPONENTS

(6)
(1)
(5)
(7)
(3) (4)
(2)
(41)
(40)
(8)
(9)
(39) (10)
(8)
(38)
(37) (11)
(35) (12)
(36) (13)
(34) (14)
(32)
(33) (17)
(29) (16)
(31) (15)
(30) (18)
(19)
(20)
(21)
(22)
(28) (23)
(24)
(25)
(27) (26)
0001963
Figure 6-87

ENGINE Crankshaft and Camshaft Components
1 – Cylinder Block
2 – Camshaft Bushing CAUTION
3 – Gear Case (3TNV94 - 4TNV106) Identify all parts and their location using
4 – Dowel (2 used) an appropriate method. It is important
5 – O-Ring
6 – Front Plate (3TNV82 - 4TNV88)
7 – Gear Case Cover (3TNV82 - 4TNV88)
0000080en
8 – Front Crankshaft Seal
9 – Gear Case Cover (3TNV94 - 4TNV106)
If the engine will be completely disassembled, the
10 – Tappets
11 – Camshaft
following preliminary steps should be performed:
12 – Camshaft Gear Key 1. Disconnect the battery cables at the battery.
13 – Camshaft End Plate
Always disconnect the negative (-) cable first.
14 – Camshaft Gear
15 – Idler Gear Shaft 2. Remove the throttle cable, electrical
16 – Idler Gear Bushing connections, intake and exhaust system
17 – Idler Gear connections, and fuel supply lines from the
18 – Oil Pickup O-Ring engine.
19 – Oil Pickup
3. Remove the alternator. See Removal of
20 – Crankshaft
21 – Parallel Pin
Alternator on page 12-12.
22 – Crankshaft Gear Key 4. Drain the engine coolant from the radiator and
23 – Crankshaft Gear cylinder block. See Drain, Flush and Refill
24 – Crankshaft Pulley Cooling System With New Coolant on
25 – Main Bearing Inserts page 5-36. Remove the cooling system
26 – Main Bearing Cap components from the engine.
27 – Oil Pan
28 – Thrust Bearings 5. Remove the engine from the machine. Mount
29 – Flywheel the engine to a suitable engine repair stand
30 – Connecting Rod Cap having adequate weight capacity.
31 – Connecting Rod Bearing Inserts
32 – Connecting Rod A CAUTION
33 – Wrist Pin Bushing
34 – Circlip Be sure to secure the engine solidly to
35 – Wrist Pin prevent injury or damage to parts due to
36 – Piston the engine falling during work on the
37 – Oil Ring engine.
38 – Second Compression Ring 0000009en
39 – Top Compression Ring
40 – Crankshaft Rear Seal 6. Clean the engine by washing with solvent, air or
41 – Crankshaft Rear Seal Housing steam cleaning. Carefully operate so as to
prevent any foreign matter or fluids from
Disassembly of Engine entering the engine or any fuel system or
Prepare a clean, flat working surface on a electrical components remaining on the engine.
workbench large enough to accommodate the 7. Drain the engine oil into a suitable container.
engine components. Discard all used gaskets, Remove the oil filter.
O-rings and seals. Use new gaskets, O-rings and 8. Remove the cylinder head. See 2-Valve
seals on reassembly of engine. Cylinder Head on page 6-34 or 4-Valve Cylinder
Head on page 6-49.

9. Remove the fuel injection pump from the gear
case / front plate only if it must be sent out for
repair, or will interfere with other procedures
such as “hot tank” cleaning. If the fuel injection
pump does not need to be repaired, leaving it
mounted to the timing gear case or plate will
eliminate the need to re-time it during
reassembly. See Fuel Injection Pump on
page 7-19.
10. Remove the starter motor. See Removal of
Starter Motor on page 11-10.
Disassembly of Camshaft and Timing (1)
Components 0001641A
Discard all gaskets, O-rings and seals. Use new Figure 6-88
gaskets, O-rings and seals on reassembly of the
camshaft and timing components. Checking Timing Gear Backlash
Prior to removing the timing gears, measure the
Removal of Timing Gear Case Cover gear backlash and determine the gear wear.
1. Remove the bolt and washer retaining the Check the backlash between each pair of mating
crankshaft pulley. gears (Figure 6-89). If not within specification,
IMPORTANT replace both mating gears. See Timing Gear
Use care not to damage the threads in the Backlash on page 6-13 for service limits.
end of the crankshaft when removing the Note: Do not allow the gear being checked to
crankshaft pulley. move axially as excess end play could
2. Remove the crankshaft pulley using a gear cause a false reading.
puller.
3. Remove the bolts that retain the gear case
cover to the cylinder block and oil pan.
4. Remove the gear case cover (Figure 6-88, (1)).

Measuring Idler Gear-to-Camshaft Gear

(1)
(2) Backlash
1. Drive a small wooden wedge between the
crankshaft gear and idler gear to prevent the
B B
C C idler gear from rotating.
(7)
A 2. Install the dial indicator to read the camshaft
A
(3) gear backlash. Rotate the camshaft drive gear
against the idler gear to measure the backlash.
(6) (4)
(5) 0001709A
Record the measurement.
3. Check the idler gear-to-fuel injection pump
1 – Fuel Injection Pump Drive Gear drive gear backlash in the same manner as the
2 – Camshaft Drive Gear camshaft drive gear. Record the measurement.
3 – Auxiliary Drive Gear (Optional)
4 – Crankshaft Drive Gear Removal of Timing Gears
5 – Direction of Rotation 1. Remove the bolts from the idler gear shaft
6 – Oil Pump Drive Gear (4TNV94L - 4TNV106) (Figure 6-91, (1)). Remove the idler gear shaft,
7 – Idler Gear idler gear (Figure 6-91, (2)) and bushing
Figure 6-89 (Figure 6-91, (3)).
Note: 3TNV82A - 4TNV88: The oil pump is

driven directly by flats on the crankshaft
drive gear hub.
Measuring Idler Gear-to-Crankshaft Gear

Backlash (2)
1. Install a dial indicator as shown in Figure 6-90. (3)

(1)
0001728A
Figure 6-91
2. Do not remove the crankshaft gear unless it is
damaged and requires replacement. If the gear
must be removed, remove it using a gear puller.
3. Removal of the camshaft gear requires the
0002086
camshaft be removed and placed in a press. Do
not remove the camshaft gear unless it or the
Figure 6-90 camshaft is damaged and requires
2. Rotate the idler gear back and forth to check replacement. See Removal of Camshaft on
the idler gear-to-crankshaft gear backlash. The page 6-76.
total indicator reading is the backlash. Record
the measurement.

CAUTION
Do not loosen or remove the four bolts
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
drive gear from the hub. Correct fuel
injection timing will be very difficult or
0000031en
4. Do not remove the fuel injection pump drive

gear unless absolutely necessary to avoid
damage to the gear or pump. Do not loosen or
remove the four bolts (Figure 6-92, (3))
retaining the pump drive gear to the hub. Only
remove the nut (Figure 6-92, (1)) and washer
(1)
(Figure 6-92, (2)), leaving the hub attached to
the gear. Remove the pump drive gear and hub
as an assembly using a gear puller.
0001695A
Figure 6-93
(3)
(1)
(2)
0000162A
Figure 6-92
Removal of Oil Pan

1. Invert the engine (oil pan up) on the engine
stand.
2. Remove the oil pan (Figure 6-93, (1)).

3. Remove the oil pickup tube (Figure 6-94, (1)) (2)

and O-ring (Figure 6-94, (2)).
60
50 70
40 80
30 90
20 0
10
(1)
0002085A
Figure 6-95
• Method B: Use a feeler gauge to measure the
(2)
clearance between the thrust plate
(1) (Figure 6-96, (1)) and front camshaft bearing
(Figure 6-96, (2)). See Thrust Bearing on
page 6-15 for the service limit.
0001696A (1)
Figure 6-94
(2)
Removal of Camshaft
1. Before removing the camshaft, check the
camshaft end play.
• Method A: Install a dial indicator
(Figure 6-95, (1)) on the cylinder block. Move
the camshaft (Figure 6-95, (2)) back and forth
to measure the end play. Record the
measurement. See Camshaft on page 6-11 for 0001710B
the service limit.
Figure 6-96

2. Remove the two bolts (Figure 6-97, (3)) Removal of Gear Case or Front Plate
retaining the camshaft thrust plate Note: The camshaft must be removed before
(Figure 6-97, (1)). the gear case / front plate can be
removed. See Inspection of Camshaft on
page 6-87.
(2) (5) 1. TNV94 - TNV106: Remove the oil pump.

Note: It is not necessary to remove the fuel
(1) injection pump from the gear case / front
plate to remove the gear case / front
(3) (4) plate. If the fuel injection pump does not
need to be repaired, leaving it mounted
to the timing gear case / front plate will
eliminate the need to re-time it during
0001966
assembly. See Fuel Injection Pump on
page 7-19.
Figure 6-97
2. Remove the bolts (Figure 6-98, (4)).
3. Rotate the engine in the engine stand so that
3. Remove the gear case (Figure 6-98, (1)) or
gravity causes the tappets (Figure 6-97, (5)) to
front plate from the cylinder block. Thoroughly
drop away from the camshaft lobes.
clean all old sealant from the mating surfaces.
Note: Rotate the camshaft at least two turns to
4. Inspect and measure the camshaft bushing.
“bump” any sticking tappets away from
See Camshaft on page 6-11 for the service
the camshaft.
limit. If damaged or worn beyond service limits,
4. Slowly pull the camshaft (Figure 6-97, (2)) remove the camshaft bushing
assembly out of the engine being careful not to (Figure 6-98, (3)).
damage the front camshaft bushing. 5. TNV94 - TNV106: Remove two O-rings
Note: If the engine is not installed on an engine (Figure 6-98, (2)).
repair fixture, stand the engine upright on
the flywheel end mounting flange. Rotate
the camshaft at least two turns to bump
the tappets out of the way to prevent the
tappets from interfering with the removal
of the camshaft.
(3) (1)
Note: The tappets are “mushroom” shaped and
must be removed from inside the engine
crankcase.
(4)
5. Remove the tappets. Mark the tappets so they
can be reinstalled in the same location.
6. Remove the camshaft drive gear
(2)
(Figure 6-97, (4)) only if the gear or camshaft 0001737B
require replacement. Use a knife-edge puller
and a press to remove the gear. The gear is a Figure 6-98
shrink-fit and will need to be heated to
356° - 392°F (180° - 200°C) to remove.

6. TNV84 - TNV88: Remove the O-ring 1. Using a feeler gauge, measure the connecting
(Figure 6-99, (2)) and dowels rod side clearance as shown (Figure 6-100).
(Figure 6-99, (5)). See Connecting Rod on page 6-22 for the
standard limit. If the measurement is out of
specification, replace the crankshaft,
connecting rod, or both.
(3)
(1)
(2) (4)
(5 )
0002016
Figure 6-99
0000219
Disassembly of Crankshaft and Figure 6-100

Piston Components 2. Measure bearing oil clearance prior to removing
the pistons and connecting rods to determine
Removal of Pistons extent of wear. Record the measurements.
CAUTION
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
IMPORTANT
Engines with high operating hours may
have a ridge near the top of the cylinders
that will catch the piston rings and make it
impossible to remove the pistons. Use a
suitable ridge reamer to remove ridges and
carbon prior to removing the pistons.
Note: Pistons can fall from cylinder block if the
engine is inverted. Rotate the engine so
the connecting rods are horizontal before
removing the connecting rod caps.

IMPORTANT (g) Repeat with remaining connecting rods.
Mark the connecting rod caps and
connecting rods so the caps and connecting IMPORTANT
rods stay together. Do not allow the connecting rod to contact
the crankshaft journal during piston
(a) Remove the bearing cap. Do not remove the removal. Damage to the bearing journal
bearing inserts at this time. may result.
(b) Wipe oil from the bearing insert and 3. Use a wooden dowel against the connecting
crankshaft journal surfaces. rod and tap the piston / connecting rod
(c) Place a piece of PLASTIGAGE® assembly out of the cylinder.
(Figure 6-101, (1)) along the full width of the 4. Mark the cylinder number on the piston and
bearing insert. connecting rod.
5. Remove the bearing inserts (Figure 6-103, (2)).
(1)
6. Remove the compression rings
(Figure 6-103, (3)) from the piston using a
piston ring expander.
7. Remove the oil ring (Figure 6-103, (4)) from the
piston using a piston ring expander.
0001898
(3)
Figure 6-101
(4)
IMPORTANT
(5)
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result. (9) (6)
(5)
(d) Reinstall bearing cap and tighten to
specification. See Special Torque Chart on
page 6-25. (8)
(e) Remove bearing cap. (7)
(f) Compare the width of the flattened
PLASTIGAGE to the graduation marks on (2)
the package (Figure 6-102, (1)). The mark
that most closely matches the width of the (1)
flattened PLASTIGAGE will indicate the
bearing oil clearance.
0001960
Figure 6-103
8. Remove the circlips (Figure 6-103, (5)) from
(1) the wrist pin.
9. Remove the wrist pin (Figure 6-103, (6)) and
connecting rod (Figure 6-103, (8)) from the
piston (Figure 6-103, (9)).
0001899
10. Repeat the steps until all pistons are removed
Figure 6-102 and dissembled.

Removal of Crankshaft • Method B: Use a feeler gauge to measure the

1. Remove the flywheel (Figure 6-104, (1)) from clearance (Figure 6-106, (3)) between the
the crankshaft. thrust bearing (Figure 6-106, (1)) and
crankshaft (Figure 6-106, (2)). Record the
2. Remove the bolts from the rear oil seal measurement. See Thrust Bearing on
assembly (Figure 6-104, (2-3)). Remove the page 6-15 for the service limit.
assembly from the engine.
(2)
(3)
(1)
(1)
(2)
(3) 0001962
Figure 6-106
0001707A
Figure 6-104
3. Before removing the main bearing caps,
measure the crankshaft end play. Use either of
the following two methods.
• Method A: Install a dial gauge
(Figure 6-105, (1)) on the cylinder block. Move
the crankshaft (Figure 6-105, (2)) in and out to
measure the end play. Record the
measurement.
(1)
(2)
0001961
Figure 6-105

4. Remove the main bearing caps
(Figure 6-107, (3)). Be sure to note the (1)
markings on the main bearing caps, or mark
them yourself, so they can be reinstalled in the
same order as they were removed. Do not
remove the bearing inserts at this time.
Note: The “arrows” on the main bearing caps
point to the flywheel end of the engine. 0001898
Figure 6-108
IMPORTANT
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result.
(c) Reinstall bearing caps and tighten to
specification. See Special Torque Chart on
page 6-25.
(d) Remove bearing caps.
(e) Compare the width of the flattened
(2) PLASTIGAGE to the graduation marks on
the package (Figure 6-109, (1)). The mark
that most closely matches the width of the
flattened PLASTIGAGE will indicate the
bearing oil clearance.
(1)
(1)
(3)
0001752A
Figure 6-107 0001899
5. Measure bearing oil clearance prior to removing Figure 6-109

the crankshaft to determine extent of wear. 6. Remove the crankshaft from the engine.
Record the measurements.
7. Remove the bearing inserts (Figure 6-107, (1))
(a) Wipe oil from the bearing insert and and thrust bearings (Figure 6-107, (2)).
crankshaft journal surfaces.
Note: Do not remove the crankshaft gear
(b) Place a piece of PLASTIGAGE unless the gear or crankshaft are
(Figure 6-108, (1)) along the full width of damaged and require replacement.
each bearing insert.

8. If necessary, remove the crankshaft gear 2. Apply a continuous bead of ThreeBond Liquid
(Figure 6-110, (1)), parallel pin Gasket No. 1212, Yanmar Part No. 977770-
(Figure 6-110, (2)) and key (Figure 6-110, (3)). 01212 to the outside diameter of a new oil seal
If using a gear puller, be careful not to damage (Figure 6-111, (2)), and install in the gear case
the threads in the end of the crankshaft. cover. Apply lithium grease to the lip of the seal.
(2)
(3)
(1)
0001731A
(1)
Figure 6-110
Inspection of Crankshaft and

Camshaft Components (2)
A WARNING 0001735A
Figure 6-111
3. Remove the rear oil seal (Figure 6-112, (3))
from the seal housing (Figure 6-112, (2)).
4. Apply a continuous bead of ThreeBond Liquid
FUME / BURN HAZARD! Gasket No. 1212, Yanmar Part No. 977770-
• Always read and follow safety related 01212 to the outside diameter of a new oil seal
precautions found on containers of (Figure 6-112, (2)), and install in the housing.
hazardous substances like parts Apply lithium grease to the lip of the seal.
sealant removers.
(2)
or serious injury.
0000014en (3)
Thoroughly clean all components using a brush (1)

and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
debris.
Replacement of Crankshaft Oil Seals

1. Remove the seal (Figure 6-111, (2)) from the
cover (Figure 6-111, (1)). 0001707A
Figure 6-112

Measure Crankshaft Bearing Oil Clearance • On an engine with high hours, the pistons rings
Oil clearance should be checked during should be replaced and the cylinder honed
disassembly to determine the extent of wear, and (See Honing and Boring on page 6-88) or
during assembly to ensure long engine life. The replaced. The piston should be replaced as
same procedure is done for both connecting rods necessary.
and main bearings. 1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s
Inspection of Cylinder Block instructions for correct operation.
1. Ensure that oil passages are clear and 2. Wash the pistons in an appropriate solvent
unobstructed. using a soft brush.
2. Check for discoloration or evidence of cracks. If 3. Visually inspect each piston for cracks. Pay
a fracture is suspected, use the color check particular attention to the ring lands between
method or the Magnaflux method to determine the piston ring grooves.
if the cylinder block is fractured. 4. Measure the diameter of the piston skirt at 90°
3. Inspect cylinders for roundness, taper, or to the wrist pin bore as shown (Figure 6-114).
evidence of scoring. Collect and record the Measurements must be taken at a specified
measurements. Consider honing, reboring or distance (Figure 6-114, (1)) from the bottom of
replacing the cylinder block if the the piston, based on engine model. Record the
measurements are not within specification. measurements. See Piston on page 6-16 for
• Take measurements at three places specifications.
(Figure 6-113) (a, b, c), and in two directions (d
and e) in each cylinder.
a 20 mm
(0.75 in.)
d
e
b
(1)
c
20 mm
(0.75 in.) 0000230B
0000235
Inspection of Pistons, Piston Rings and 5. Subtract the piston measurement from the
greatest measurement acquired during cylinder
Wrist Pin
inspection (see Inspection of Cylinder Block on
Notes: page 6-83) to obtain piston-to-cylinder
• On an engine with low hours, the pistons, clearance. Record the measurements. See
piston rings may be reused if they are found to Piston on page 6-16 for specifications.
be within specifications. The pistons and piston 6. Measure the diameter of the wrist pin bore on
rings must be reinstalled in the same cylinders both sides of the piston (Figure 6-115). See
from which they were originally removed. Piston on page 6-16 for specifications. Record
the measurements.

0000237
0001892
Figure 6-115
7. Measure the outside diameter of the wrist pin in Figure 6-117
three places and at 90° (Figure 6-116). See
Piston on page 6-16 for specifications. Record
the measurements.
0001889
Figure 6-116
8. Using a micrometer, measure the thickness of
each piston ring. See Piston on page 6-16 for
specifications. Record the measurements.
Notes:
• On an engine with low hours, the pistons,
piston rings and cylinders may be reused if 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 6-88) or
replaced. The piston should be replaced as
necessary.
9. Place each compression piston ring in the
groove as shown (Figure 6-117). Use a feeler
gauge to measure the clearance between the
piston ring and the piston ring land. Record the
measurements. See Piston Ring on page 6-18
for specifications. Replace the piston if not
within specification.

10. To measure piston ring end gap, insert each
compression piston ring (Figure 6-118, (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 6-118, (2)) from the
bottom of the bore. Remove the piston.
Measure the end gap (Figure 6-118, (3)) of
each piston ring. Record the measurements.
See Piston Ring on page 6-18 for (1)
specifications.
(2)
0001724A
Figure 6-119
2. Place the connecting rod bearing inserts into
the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
(1) specified torque.
(2) 3. Measure the inside diameter. See Crankshaft
on page 6-14 for specifications.
Inspection of Tappets
(3) 1. Inspect the tappet contact surfaces for
0001964 abnormal wear (Figure 6-120, (1)). Normal
Figure 6-118 wear will be even as shown in
(Figure 6-120, (2)). Slight surface defects can
Note: Always check the piston ring end gap
be corrected using an oilstone.
when installing new piston rings. See
Piston Ring on page 6-18 for
specifications. Use a piston ring end gap
filing tool to adjust the piston ring end
gap on new piston rings.
11. Repeat the above steps for each cylinder and
piston assembly.
Inspection of Connecting Rod

1. Measure the wrist pin bushing bore using a (1) (2) 0001725
bore gauge (Figure 6-119, (1)). Replace the
Figure 6-120
bushing if not within specifications. If the
bushing has been removed, measure the inside
diameter of the connecting rod small end
(Figure 6-119, (2)). See Connecting Rod on
page 6-22 for specifications.

2. Measure the outside diameter of the tappet 4. Use the color check method or Magnaflux® to
stem (Figure 6-121, (1)). See Tappet on inspect the crankshaft for cracks. Replace the
page 6-23 for the service limit. crankshaft if evidence of fractures are found.
5. Measure the outside diameter of each crankpin
(Figure 6-123, (2)) and main bearing journal
(Figure 6-123, (1)). See Crankshaft on
page 6-14 for specifications. Take
measurements at several places around each
bearing surface. If not within specification, grind
the journals and install undersize bearings, or
replace the crankshaft.
(1)
0001726A
Figure 6-121
3. Measure the tappet bores in the cylinder block.
See Tappet on page 6-23 for the service limit.
Inspection of Crankshaft
1. Place the crankshaft end journals
(Figure 6-122, (4)) on V-blocks.
2. Place a dial indicator (Figure 6-122, (3)) on a
center main bearing surface.
(2) R
(1)
R
(1)
(3) (2) 0001733A
Figure 6-123
(4) (4) 0000232A
Figure 6-122
3. Rotate the crankshaft and observe runout. See
Crankshaft on page 6-14 for specifications.

Inspection of Camshaft (3)
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 6-124). Place the
indicator on the center bearing journal. (2)
(1)
0001713A
Figure 6-126
0001711
Inspection of Camshaft Bushing and Bores
Figure 6-124 1. Measure the I.D. of the front bushing and the
remaining bores in the cylinder block. See
2. Rotate the camshaft and observe the runout. Camshaft on page 6-11 for specifications.
See Camshaft on page 6-11 for specifications.
2. If the camshaft bushing is not within
3. Measure the height of each lobe specification, replace it using the appropriate
(Figure 6-125, (1)). See Camshaft on service tool. If the remaining bores are not
page 6-11 for specifications. within specification, the cylinder block will
require replacement as there are no bearing
inserts used.
(1)
Inspection of Idler Gear and Shaft
1. Measure the outside diameter
(Figure 6-127, (1)) of the idler gear shaft
(Figure 6-127, (2)). See Idler Gear Shaft and
Bushing on page 6-13 for specifications.
0001712A
2. Measure the inside diameter
Figure 6-125 (Figure 6-127, (3)) of the idler gear bushing
(Figure 6-127, (4)). See Idler Gear Shaft and
4. Measure the diameter of the gear end
Bushing on page 6-13 for specifications.
(Figure 6-126, (1)), intermediate
(Figure 6-126, (2)), and flywheel end
(Figure 6-126, (3)) bearing journals. See (4)
Camshaft on page 6-11 for specifications.
(1) (3)
(2)
0001714A
Figure 6-127

Honing and Boring

CAUTION
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
motion.
condition. Slight imperfections can be corrected by
0000090en
honing alone.
1. Boring - Significant cylinder damage may be (1)
corrected by boring the cylinder to an oversize
dimension. Refer to the appropriate parts
catalog for available oversize pistons and piston
rings.
• Boring a cylinder should always be done in a
properly equipped machine shop.
• A bored cylinder should always be finished with
a hone to properly prepare the cylinder surface
so the new piston rings will seat properly.
• After the cylinder has been bored and honed, 0000248A
install the appropriate oversize pistons and Figure 6-128
piston rings.
2. Honing - Minor cylinder imperfections may be • Use a 50:50 mixture of diesel fuel and engine
corrected by using a rigid cylinder hone oil as a honing fluid.
(Figure 6-129, (1)). Be sure not to exceed the • Use a 300-grit hone at 300 - 1200 rpm
maximum cylinder bore specification. (Figure 6-129).
Deglazing - A used cylinder that did not require
(1)
boring or honing, should always be deglazed with
a ball hone (Figure 6-129, (2)) before installing (2)
new piston rings. This will properly prepare the
cylinder surface to allow new piston rings to seat
properly.
Note: When honing a cylinder, with either a
ridged hone or a ball hone 0000249B
(Figure 6-128, (1)), move the rotating
hone up and down in the cylinder bore to Figure 6-129
accomplish a 30° to 40° crosshatch
pattern (Figure 6-128). This will provide IMPORTANT
the ideal surface for the proper seating of Solvents will not adequately remove honing
new piston rings. residue, resulting in premature piston and
ring wear. Always wash cylinders using hot,
soapy water.

• When honing is completed, wash the cylinder
block with hot water and soap. The cylinder wall (3)
is adequately cleaned when a white rag wiped
(4)
in cylinder comes out clean. Use brushes to
clean all passages and crevices. Rinse with hot (5)
water and dry with compressed air. Apply clean (9) (6)
engine oil to all steel surfaces to prevent (5)
rusting.
Reassembly of Crankshaft and (8)

Piston Components (7)
Notes:
(2)
• Proceed slowly. Make no forced assemblies
unless a pressing operation is called for. All (1)
parts must be perfectly clean and lightly
lubricated when assembled.
0001960
• Use new gaskets, seals and O-rings during
assembly. Figure 6-130
• Liberally apply clean engine oil to all internal 3. Reinstall one circlip (Figure 6-130, (5)) into the
parts during assembly. piston. Ensure the circlip is securely seated in
• All fasteners should be tightened to a given the groove.
torque. If a special torque is not provided in the
Special Torque Chart on page 6-25, tighten to IMPORTANT
standard torque specifications. See Tightening The piston and connecting rod must be
Torques for Standard Bolts and Nuts on assembled together in the correct
page 4-46. orientation. The orientation of the piston
and connecting rod are different depending
Reassembly of Pistons on engine model.
1. Select the parts needed to reassemble the
Piston to Connecting Rod Orientation - By Model
piston and connecting rod for one cylinder.
All TNV models - 82,
2. If removed, install a new wrist pin bushing Only TNV models - 106(T)
84(T), 88, 94, and 98(T)
(Figure 6-130, (7)) using a press and the Orient the piston Orient the piston
appropriate service tool. Be sure to align the oil identification mark identification mark
holes. stamped on top of the stamped on top of the
piston on the same side as piston on the opposite
the rod and cap match side as the rod and cap
marks stamped on the match marks stamped on
connecting rod. the connecting rod.

Note: The actual appearance of the match Piston Assembly - All TNV models - 82, 84(T),
marks on the piston and connecting rod 88, 94, and 98(T)
may vary, but they will always be in the When correctly assembled, the piston
same locations. identification mark (Figure 6-132, (2)) stamped
into the top of the piston will be on the same side
of the connecting rod as the match marks
(1) (Figure 6-132, (4)) stamped into the connecting
rod and connecting rod cap.
When installed in the cylinder, the piston
ML↓844V
identification mark (Figure 6-132, (2)) stamped

on the top of the piston must face the fuel
injection pump side (Figure 6-132, (1)) of the
engine and the embossed mark on the
(2) connecting rod (Figure 6-132, (3)) must face the
flywheel end (Figure 6-132, (5)) of the engine.
E106 R
(6) (1)
0002090
(2)
(3)
(5)
80 80 (3)
0002089 (4)
1 – Piston Identification Mark
2 – Embossed Mark on Connecting Rod
0001967
3 – Rod and Cap Match Marks
1 – Fuel Injection Pump Side of Engine
Figure 6-131 2 – Piston Identification Mark
5 – Flywheel End of Engine
6 – Camshaft Side of Engine
Figure 6-132

Piston Assembly - Only TNV models 106(T)
(3)
When correctly assembled, the identification mark
(Figure 6-133, (2)) stamped into the top of the (4)
piston will be on the opposite side of the connecting
(5)
rod as the match marks (Figure 6-133, (4))
stamped into the connecting rod and connecting (9) (6)
rod cap. (5)
When installed in the cylinder, the piston
identification mark (Figure 6-133, (2)) stamped on (8)
the top of the piston must face the camshaft side (7)
(Figure 6-133, (6)) of the engine and the
embossed mark on the connecting rod
(2)
(Figure 6-133, (3)) must face the flywheel end
(Figure 6-133, (5)) of the engine. (1)
(6) (1)
0001960
Figure 6-134
(2)
(5) Note: If installing new piston rings the end gap
must be checked and adjusted as
necessary. See Inspection of Pistons,
(3) Piston Rings and Wrist Pin on page 6-83
for specifications. Use a piston ring end
gap filing tool to adjust the piston ring
(4)
end gap on new piston rings.
0001967A
Note: Reinstall the top and second piston rings
with the stamped “makers mark”
1 – Fuel Injection Pump Side of Engine (Figure 6-135, (1)) facing the top of the
2 – Piston Identification Mark piston. The “makers mark” may vary in
appearance but will always be located on
the top surface of the piston ring
6 – Camshaft Side of Engine adjacent to the piston ring gap. The oil
ring and oil ring expander can be
Figure 6-133 installed either side up.
1. Lubricate and reinstall the wrist pin
(1)
(Figure 6-134, (3)) through the piston and
connecting rod.
2. Reinstall the second circlip (Figure 6-134, (4))
and ensure it is securely seated in the groove.
0000225A
Figure 6-135

IMPORTANT (1)
Always use a piston ring installation tool
(expander) when installing piston rings.
Never attempt to install piston rings by
hand. (2)
3. Reinstall the oil ring expander
(3)
(Figure 6-136, (4)). Reinstall the oil ring
(Figure 6-136, (3)) with the end gap at 180°
from the expander end gap.
4. Reinstall the second compression ring
(Figure 6-136, (2)). This ring is identified by its
dark color and tapered face profile.
5. Reinstall the top compression ring
(Figure 6-136, (1)). This ring is identified by its
silver color and barrel-shaped face profile.
0001968
IMPORTANT 1 – Top Compression Ring End Gap

The oil ring expander (Figure 6-136, (4)) 2 – Second Compression Ring End Gap
end gap must be located 180° from the oil 3 – Oil Ring End Gap
ring (Figure 6-136, (3)) end gap.
Figure 6-137
(1) Installation of Crankshaft

1. If removed, reinstall the keys and timing gear on
the crankshaft.
(2) 2. Reinstall new bearing inserts
(Figure 6-138, (1)) and thrust bearing
(Figure 6-138, (2)) in the cylinder block and
(3)
main bearing caps. Apply a liberal coat of clean
engine oil to the bearings and crankshaft
journals.
(4)
3. Place the crankshaft into the engine.
0001722B
Figure 6-136 IMPORTANT

The main bearing caps are numbered and
6. Stagger the piston ring end gaps at 120° have arrows for proper positioning. The
intervals (Figure 6-137, (1, 2, 3)). Do not No. 1 cap is at the flywheel end. The arrows
position the top piston ring end gap in line with point toward the flywheel end of the engine.
the wrist pin.
4. Reinstall the main bearing caps
(Figure 6-138, (3)).

5. Apply a light coat of clean engine oil to the Installation of Pistons
bearing cap bolts and tighten the bolts to the
specified torque in two stages (1/2 then full IMPORTANT
torque). See Special Torque Chart on Do not allow the connecting rod to contact
page 6-25 for specifications. the crankshaft journal during piston
installation. Damage to the crankshaft
bearing journal may result.
1. Lubricate the piston, piston rings, and cylinder
with clean engine oil or assembly lubricant.
2. Rotate the crankshaft so the crankpin for the
(2) piston being installed is near bottom dead
center.
IMPORTANT
Ensure the piston ring gaps are located
(1) correctly (Figure 6-140).
(1)
(3)
0001752A
(2)
Figure 6-138
(3)
6. Rotate the crankshaft to assure it turns freely.
7. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212 to the mounting
flange of the seal housing (Figure 6-139, (2)). 1 – Top Compression Ring End Gap
2 – Second Compression Ring End Gap
8. Align the seal housing with the two dowel pins.
3 – Oil Ring End Gap
9. Reinstall seal housing and seal assembly.
Figure 6-140
10. Reinstall the flywheel (Figure 6-139, (1)) and
tighten the bolts to the specified torque. See 3. Using a piston ring compressor, compress the
Special Torque Chart on page 6-25 for piston rings.
specifications.
IMPORTANT
The piston and connecting rod must be
installed in the correct orientation. The
(2) orientation of the piston to the cylinder is
different depending on engine model.
(3)
Piston Orientation to Cylinder - By Model
(1)
All TNV models - 82,
Only TNV models - 106(T)
84(T), 88, 94, and 98(T)
Figure 6-139

Orient the piston Orient the piston Piston Installation - Only TNV models 106(T)
identification mark identification mark When correctly assembled, the identification
stamped on top of the stamped on top of the mark (Figure 6-142, (2)) stamped into the top of
piston on the fuel injection piston on the camshaft
pump side of the engine side of the engine
the piston will be on the opposite side of the
connecting rod as the match marks
Piston Installation - All TNV models - 82, 84(T), (Figure 6-142, (4)) stamped into the connecting
88, 94, and 98(T) rod and connecting rod cap.
When correctly assembled, the piston When installed in the cylinder, the piston
identification mark (Figure 6-141, (2)) stamped identification mark (Figure 6-142, (2)) stamped
into the top of the piston will be on the same side on the top of the piston must face the camshaft
of the connecting rod as the match marks side (Figure 6-142, (6)) of the engine and the
(Figure 6-141, (4)) stamped into the connecting embossed mark on the connecting rod
rod and connecting rod cap. (Figure 6-142, (3)) must face the flywheel end
When installed in the cylinder, the piston (Figure 6-142, (5)) of the engine.
identification mark (Figure 6-141, (2)) stamped
(6) (1)
on the top of the piston must face the fuel
injection pump side (Figure 6-141, (1)) of the
engine and the embossed mark on the
connecting rod (Figure 6-141, (3)) must face the (2)
(5)
flywheel end (Figure 6-141, (5)) of the engine.
(6) (1)
(3)
(4)
(2)
(5)
(3) 3 – Embossed Mark on Connecting Rod
(4) 5 – Flywheel End of Engine
Figure 6-142
Figure 6-141

4. Reinstall the bearing inserts (Figure 6-143, (1)) Reassembly of Camshaft and Timing
in the connecting rod and cap.
Components
5. Apply a liberal coat of clean engine oil to the
bearing inserts and crankshaft journal. Installation of Gear Case or Front Plate
6. Apply a light coat of clean engine oil to the rod 1. If removed, install a new camshaft bushing
cap bolts. Reinstall the connecting rod cap (Figure 6-144, (3)) using the appropriate
(Figure 6-143, (2)). Tighten the connecting rod service tool.
bolts to the specified torque in two stages (1/2
then full torque). See Special Torque Chart on
Gasket No. 1212, Yanmar Part No. 977770-
page 6-25 for specifications.
01212 to the mounting area of the gear case or
front plate. Be sure to circle each bolt hole.
3. 4TNV94 - 4TNV106: Install two new O-rings
(Figure 6-144, (2)) in the cylinder block.
(1)
(2) (1)
(3)
(4)
0001965
Figure 6-143
7. Reinstall the remaining pistons in their (2)
respective cylinders. 0001737B
Figure 6-144

4. TNV84 - TNV88: Reinstall the dowels Note: The tappets are “mushroom” shaped and
(Figure 6-145, (5)) and a new O-ring must be installed from inside the engine
(Figure 6-145, (2)). crankcase.
3. Lubricate the tappets with clean oil or assembly
lube. Reinstall the tappets in their respective
(3) locations in the cylinder block. Push the tappets
fully into the tappet bores so they will not
(1) interfere with the installation of the camshaft.
4. Lubricate the camshaft (Figure 6-146, (2)) with
clean engine oil or assembly lube. Slowly insert
the camshaft through the front of the engine.
5. Reinstall and tighten the cap screws
(2) (Figure 6-146, (3)).
(4)
(5 )
0002016 (2) (5)

Figure 6-145
(1)
5. Reinstall the gear case (Figure 6-144, (1)) or
front plate (Figure 6-145, (1)). Tighten the bolts (3) (4)
to the specified torque.
Installation of Camshaft
Note: The gear housing or front plate must be 0001966
reinstalled prior to installing the
camshaft. See Installation of Gear Case Figure 6-146
or Front Plate on page 6-95. 6. If removed, reinstall the fuel injection pump.
1. If removed, reinstall the camshaft end plate Adjust the fuel injection timing the engine after
(Figure 6-146, (1)), key, and timing gear installation. See Adjusting Fuel Injection Timing
(Figure 6-146, (4)) onto the camshaft using a on page 7-34.
press.
Note: Heat the gear to 356 - 392°F
(180 - 200°C) and press onto the end of
the camshaft.
2. Rotate the cylinder block so that gravity will
keep the tappets (Figure 6-146, (5)) in place
and out of the way of the camshaft lobes when
the camshaft is being reinstalled.
Note: If the engine is not installed on an engine
repair fixture, stand the engine upright on
the flywheel end mounting flange.

Installation of Timing Gears 5. Reinstall the idler gear and idler gear shaft. Be
1. Set the No. 1 piston to top dead center. sure the oil hole in the bushing is facing toward
the top of the engine.
2. Rotate the camshaft until the mark
(Figure 6-147, (C)) is approximately at the 6. Ensure all three timing marks
9 o’clock position. (Figure 6-147, (A, B, C)) are aligned.
7. When all gears are properly aligned, tighten the
(1) idler gear retaining bolts to specified torque.
(2)
See Special Torque Chart on page 6-25 for
specifications.
B B
C C
Installation of Gear Case Cover
A
(7) 1. Apply a continuous bead of ThreeBond Liquid
A
(3) Gasket No. 1212, Yanmar Part No. 977770-
(4) 01212 to the mounting area of the gear case
(6)
(5) 0001709A cover (Figure 6-149, (1)). Be sure to circle the
bolt holes.
1 – Fuel Injection Pump Gear
2 – Camshaft Gear IMPORTANT
3 – Optional Accessory Drive Gear 3TNV84 - 4TNV88 engines: Be sure to
4 – Crankshaft Gear align the flats on the oil pump with the flats
5 – Direction of Rotation on the crankshaft gear when installing the
6 – Oil Pump Gear gear case cover.
7 – Idler Gear
2. Reinstall and tighten the gear case cover bolts.
Figure 6-147
3. Lubricate the idler gear (Figure 6-148, (2)),
bushing (Figure 6-148, (3)) and idler gear shaft
(Figure 6-148, (1)) with clean engine oil.
(2)
(3)
(1)
(1)
0001641A
Figure 6-149
0001728A 3. Reinstall the crankshaft pulley.
Figure 6-148
4. Align the timing gears as shown in
(Figure 6-147).

IMPORTANT Installation of Oil Pan

3TNV82A, 3TNV84, 3TNV84T, 3TNV88, 1. Reinstall the oil pickup tube (Figure 6-151, (1))
4TNV84, 4TNV84T, 4TNV88, 4TNV94L, using a new O-ring (Figure 6-151, (2)).
4TNV98, 4TNV98T: Use the crankshaft
pulley installation tool (Figure 6-150, (3))
when reinstalling the pulley
(Figure 6-150, (1)). The tool will guide the
pulley hub and protect the front seal
(Figure 6-150, (2)) from damage.
(1)
(2)
(2)
(1)
0001696A
Figure 6-151
(3)
Gasket No. 1212, Yanmar Part No.
977770-01212 to the mounting surface of the oil
0002133
pan (Figure 6-152, (1)). Be sure to circle each
bolt hole.
Figure 6-150
3. Reinstall the oil pan and tighten the bolts
4. Reinstall the washer and bolt. Tighten the bolt securely.
to the specified torque. See Special Torque
Chart on page 6-25 for specifications.
(1)
0001695A
Figure 6-152

Final Reassembly of Engine
1. Reinstall the starter motor.
2. Reinstall the cylinder head. See Reassembly of
Cylinder Head on page 6-46 for the 2-valve
cylinder head or 6-62 for the 4-valve cylinder
head.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
5. Reinstall the alternator.
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.

ENGINE EGR system
EGR SYSTEM
EGR system
Applicable engines : 4TNV98-E, 4TNV98-Z
(8) (11) (12)
(1) (4) (5)
Figure 6-153

EGR system ENGINE
Applicable engines : 4TNV84T-Z, 4TNV98T-Z
(11) (12)
(13)
(1) (8)
(6)
(7)
(2) (9) (3) (10) (4) (5)
Figure 6-154
1 – Exhaust manifold 8 – Intake manifold

2 – Elbow, EGR cooler inlet 9 – Cooling water hose, EGR cooler inlet
3 – EGR cooler 10 – Cooling water hose, EGR cooler outlet
4 – EGR pipe 11 – Cooling water hose, EGR valve inlet
5 – EGR valve 12 – Cooling water hose, EGR valve outlet
6 – Spacer, EGR lead valve 13 – Turbocharger
7 – Lead valve, EGR

ENGINE EGR system
EGR system
A WARNING
A DANGER
BURN HAZARD!
SCALD HAZARD! away from hot engine surfaces such
• NEVER remove the radiator cap if the as the muffler, exhaust pipe,
engine is hot. Steam and hot engine turbocharger (if equipped) and engine
coolant will spurt out and seriously block during operation and shortly
burn you. Allow the engine to cool after you shut the engine down. These
down before you attempt to remove surfaces are extremely hot while the
the radiator cap. engine is operating and could
seriously burn you.
you check the radiator. Steam can • Failure to comply could result in death
spurt out during engine operation if or serious injury.
the cap is loose. 0000015en

coolant by observing the reserve tank. A WARNING
serious injury.
0000002en
service it.
serious injury.
or serious injury.
0000010en

EGR system ENGINE
A WARNING A CAUTION
FUME / BURN HAZARD!

COOLANT HAZARD!
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the
eyes or skin should occur, flush eyes
sealant removers.
and wash immediately with clean
• Failure to comply could result in death water.
or serious injury.
0000014en
or moderate injury.
0000005en
A CAUTION
CAUTION
When it is necessary to replace an EGR
valve, be sure to replace the entire EGR
valve assembly. Neither attempt to
disassemble and repair the EGR valve,
nor replace its individual components.
• ALWAYS wear eye protection when CAUTION
compressed air or high-pressure The EGR system uses steel gaskets at
water. Dust, flying debris, compressed the joints between its
air, pressurized water or steam may components/parts. These steel gaskets
injure your eyes. are specific to the respective joints.
When you remove the system's
• Failure to comply may result in minor components/parts and reinstall them,
or moderate injury. replace the steel gaskets between them
0000003en with new correct ones.

ENGINE EGR system
1. Drain the engine cooling water. 4TNV84T-Z, 4TNV98T-Z

2. Remove the battery cable from the battery's 1. Disconnect the cooling water inlet and outlet
minus (-) terminal. hoses from the EGR cooler by loosening the
3. If there is any additional equipment (such as an hose clips.
air cleaner) installed above the EGR valves, When loosening the clips, put waste cloth or the
remove it in advance. like beneath the hose joints in case water leaks.
4. Remove the EGR valve connectors. 2. Loosen the nuts used to connect the exhaust
manifold with the EGR cooler elbow.
5. Disconnect the cooling water inlet and outlet
hoses from each EGR valve by loosening the 3. Loosen the bolts in the coupling flanges of the
hose clips. When loosening the clips, put waste EGR cooler and EGR pipe, and remove the
cloth or the like beneath the hose joints in case EGR cooler.
water leaks. 4. Remove the elbow from the EGR cooler.
5. Remove the EGR pipe from the EGR valve.
4TNV98-E, 4TNV98-Z
6. Remove the EGR valve.
1. Loosen the nuts in the coupling flanges of the
exhaust manifold and the EGR pipe. 7. Remove the spacer (for the lead valve).
2. Loosen the bolts in the coupling flanges of the 8. Remove the lead valve.
EGR pipe and EGR valve, and remove the EGR
pipe.
(1)
(2) (3)
(1)
1 – Elbow
1 – EGR pipe 2 – EGR cooler
3 – EGR pipe
Figure 6-155
Figure 6-156
3. Remove the EGR valve.

EGR system ENGINE
Inspecting/cleaning EGR related EGR valve operation checks
components 1. After removing each EGR valve from the
engine, connect the valve with the connector.
EGR Valve 2. Connect the valve to the battery's minus (-)
Each EGR valve has four built-in coils. The power terminal.
to each of the four coil is either ON or OFF at any 3. Turn on the key switch.(Note that turning on the
given time. Depending on which coil is ON and key switch causes the E-ECU to check whether
which coil is OFF, the step motor rotates to the valve functions properly by opening and
determine the valve lift. The power to each coil is shutting it.)
turned ON/OFF by the E-ECU based on the engine
4. From the exhaust gas inlet, visually check
speed and fuel injection rate. The resistances of
whether the valve operates correctly.
these coils should be as specified below when
measured between each pair of pins shown. If any Note: If the EGR valve fails to smoothly
of the actually measured values is beyond the operate, replace the entire valve
standard range, replace the entire EGR valve assembly with new one.
assembly. Note: If the EGR valve does not respond at all,
check whether there exists a voltage
(1) (EGR valve signal) between the
connector pins. If the voltage is within the
standard range, then replace the entire
valve assembly with new one.
IMPORTANT
Alternatively, you can remove the EGR pipe
from the engine and check the valve
operation through the gas inlet window,
instead of removing the EGR valve from the
1 – EGR valve connectors engine.
Figure 6-157
Standard value
Terminal Resistance (Ω)
1-2
2-3 15 ± 2
4-5 at 20 °C
5-6
Note: The higher the temperature, the higher

the coil resistance. Therefore, wait for the
EGR valve to return to normal state
before measuring the resistances.

ENGINE EGR system
Cleaning the EGR valves To remove deposited carbon, use compressed air
(0.19MPa(2kg/cm2) or lower). If the valves are
A WARNING heavily fouled, use carbon cleaner, kerosene, or
some other liquid capable of removing carbon as
well as a soft brush to clean the valves, taking care
not to damage their parts.
When cleaning the valves, take extreme care to
prevent water, solvent, cleaner, and other liquid
FUME / BURN HAZARD! from entering into the motor and coupler terminals;
• Always read and follow safety related otherwise, failure may result.
hazardous substances like parts CAUTION
sealant removers.
• Failure to comply could result in death (193 kPa; 19 686 mmAq) or a wire brush
or serious injury. to clean the radiator fins. Radiator fins
0000014en damage easily.
0000016en
A CAUTION Lead valves

Similarly to the EVR valves, the lead valves must
be periodically cleaned every 1500 hours because,
as exhaust gas circulates through them for a
prolonged time, carbon is deposited on their inner
surfaces, possibly deteriorating the EGR ratio.
FLYING OBJECT HAZARD! To remove carbon deposited inside the lead valves,
disassemble and clean them.
(1)
injure your eyes.
(2)
or moderate injury. (3) (4)
0000003en
1 – Case
The EGR valves must be periodically cleaned every 2 – Stopper
1500 hours because, as exhaust gas circulates 3 – Valve
through them for a prolonged time, carbon is 4 – Machine screw
deposited on their inner surfaces, possibly
Figure 6-158
deteriorating the EGR ratio.

EGR system ENGINE
To remove deposited carbon, use carbon cleaner, EGR cooler
kerosene, or some other liquid capable of removing The EGR cooler must be periodically cleaned every
carbon as well as a soft brush or cloth to clean the 1500 hours because the exhaust gas passage is
valves, taking care not to damage their parts. subject to carbon deposition and the cooling water
Upon completion of carbon removal, wipe off water transit portion to scale deposition and these
and liquid, make sure that the case, valve, and depositions gradually deteriorate the cooling of
stopper are free of foreign matter, and then reinstall recirculated gas, thus resulting in higher gas
the valve and related parts. temperatures and lower effective circulation
amounts (EGR ratio).
To remove deposited carbon from the gas passage,
use compressed air (0.19MPa(2kg/cm2) or lower).
Stopper chamfer Then dip the gas passage in carbon cleaner,
kerosene, or some other liquid capable of removing
Exhaust gas
passage hole 17.5
carbon; leave it dry and blow it with compressed air
again.
To clean the water transit portion, dip it in a solution
Assemble without of descaling detergent diluted with water and wash
misalignment.
it.
20 Valve plate
EGR pipe and other connecting elbows
Figure 6-159
The exhaust gas passage is subject to carbon
Precautions for installation deposition when used over time. To remove
deposited carbon from the gas passage, use
1. The valve and stopper must be installed in their compressed air (0.19MPa(2kg/cm2) or lower). If the
specific orientations. As shown in the figure exhaust gas passage is heavily fouled, clean it by
above, install the valve and stopper so that they dipping it in carbon cleaner, kerosene, or some
are located on the left-hand side of the lead other liquid capable of removing carbon.
valve.
2. Install the valve by tightening the machine
screw while ensuring that it is evenly positioned
inside the case window.
3. The machine screw must be tightened with
torque of 1.37±0.2N•m(14±2kgf•cm).
4. After tightening the machine screw, mark it with
a marker to indicate that it has already been
tightened.

ENGINE EGR system
Installing EGR related components/parts

CAUTION
To install these components/parts, reverse the
disassembly procedure described above: thus
install the lead valve, spacer, EGR valve, EGR pipe,
EGR cooler, elbow, cooler cooling water hose, and
EGR cooling water hose exactly in this order.
• ALWAYS be environmentally The EGR system uses steel gaskets at the joints
responsible. between its components/parts. When you remove
the system's components/parts and reinstall them,
• Follow the guidelines of the EPA or replace the steel gaskets between them with new
other governmental agencies for the correct ones.
0000013en

Section 7
FUEL SYSTEM
Page
Introduction...................................................................................... 7-8
Fuel Injection Pump................................................................... 7-8
Stop Solenoid ............................................................................ 7-9
Cold Start Device....................................................................... 7-9
Trochoid Fuel Pump ................................................................ 7-10
Electronically controlled governor............................................ 7-10
Fuel System Specifications ........................................................... 7-11
Special Torque Chart............................................................... 7-11
Test and Adjustment Specifications ........................................ 7-12
Special Service Tools.................................................................... 7-13
Measuring Instruments.................................................................. 7-13
Fuel System Diagram.................................................................... 7-14
Fuel System Components ............................................................. 7-15
2-Valve Cylinder Head............................................................. 7-15
4-Valve Cylinder Head............................................................. 7-17
Fuel Injection Pump....................................................................... 7-19
Removal of Fuel Injection Pump.............................................. 7-19
Installation of Fuel Injection Pump........................................... 7-24
Checking and Adjusting Fuel Injection Timing .............................. 7-30
Determining the Fuel Injection Timing Specification................ 7-30
Checking Fuel Injection Timing ............................................... 7-31
Adjusting Fuel Injection Timing................................................ 7-34

FUEL SYSTEM
Fuel Injectors.................................................................................. 7-35
Removal of Fuel Injectors......................................................... 7-35
Testing of Fuel Injectors ........................................................... 7-38
Disassembly and Inspection of Fuel Injectors .......................... 7-39
Adjusting Fuel Injector Pressure .............................................. 7-41
Reassembly of Fuel Injectors ................................................... 7-41
Installation of the Fuel Injectors................................................ 7-42

Before You Begin Servicing FUEL SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING • Never inject fuel toward you. Since the
fuel is injected at high pressure from
A WARNING the nozzle, it may penetrate the skin,
resulting in injury.
• Never inject fuel toward a fire source.
Atomized fuel is highly flammable and
may cause a fire or burn skin.
0000028en
service it. A WARNING
serious injury. FUME / BURN HAZARD!
sealant removers.
or serious injury.
or serious injury.
0000014en
0000010en
A WARNING A WARNING
• Never use the E-ECU for other
SUDDEN MOVEMENT HAZARD! purposes than intended or in other
• Engaging the transmission or PTO at ways than specified by Yanmar. Doing
an elevated engine speed could result so could result in the violation of
in unexpected movement of the emission control regulations and will
equipment. void the product warranty.
• Failure to comply could result in death • Improper use or misuse of the E-ECU
or serious injury. may result in death or serious injury
0000006en due to an abrupt and unexpected
9999999en

FUEL SYSTEM Before You Begin Servicing
A WARNING A WARNING
• Be sure to use the E-ECU in • Replacing the E-ECU involves
conjunction with the engines whose migrating the fuel injection data to the
models or serial numbers are existing E-ECU to the new unit.
specified by Yanmar. Be sure to contact your local Yanmar
Other E-ECU/engine combinations dealer before replacing the E-ECU.
than specified will void the engine Failure to migrate the fuel injection
warranty. data before replacing the E-ECU will
• Improper use or misuse of the E-ECU void the engine warranty.
may result in death or serious injury • Improper use or misuse of the E-ECU
due to an abrupt and unexpected may result in death or serious injury
increase in engine speed. due to an abrupt and unexpected
9999998en increase in engine speed.
9999996en
A WARNING
• Replacing the fuel injection pump
involves rewriting the fuel injection
data in the E-ECU.
Be sure to contact your local Yanmar
dealer before replacing the fuel
injection pump.
Failure to rewrite the fuel injection
data before replacing the fuel injection
pump will void the engine warranty.
• Improper use or misuse of the E-ECU
9999997en

A CAUTION CAUTION
• NEVER remove or attempt to remove
the tamper-proof devices from the
full-load fuel adjusting screw or the
high-speed throttle limit screw on the
fuel injection pump and governor
assembly. These adjustments have
FLYING OBJECT HAZARD! been made at the factory to meet all
• ALWAYS wear eye protection when then sealed.
compressed air or high-pressure • NEVER attempt to make any
water. Dust, flying debris, compressed adjustments to these sealed
air, pressurized water or steam may adjustment screws. If adjustments are
injure your eyes. required, they can be made only by a
qualified fuel injection shop that will
• Failure to comply may result in minor ensure the injection pump continues
or moderate injury. to meet all applicable emissions
0000003en regulations and then replace the
tamper-proof seals.
A CAUTION • Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.”
0000146en
CAUTION
PINCH HAZARD! Never use a steel wire brush to clean
Carefully rotate the alternator toward the fuel injectors. Damage to the nozzle and
cylinder block while loosening the other components is likely to result.
V-belt. Failure to comply may result in 0000172en
minor or moderate injury.

0000014en CAUTION
Allow the engine to warm-up for at least
five minutes and the idle speed of the
engine to return to normal before
Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the
equipment.
0000159en

FUEL SYSTEM Before You Begin Servicing
CAUTION CAUTION
Remove or install the high-pressure fuel Shut down the engine if the fault
injection lines as an assembly whenever indicator comes on.
possible. Disassembling the Continuing running the engine with the
high-pressure fuel injection lines from fault indicator being on may result in a
the retainers or bending any of the fuel serious malfunction of or damage to the
lines will make it difficult to reinstall the engine, and will void the engine
fuel lines. warranty.
0000047en
9999999en
CAUTION CAUTION
After marking the position of the pump Do not energize the starter for a period
drive gear, do not rotate the engine of longer than 15 seconds.
crankshaft. Rotating the crankshaft will
cause the fuel injection pump to become Take a pause of at least 30 seconds
misaligned. between energization of the starter.
0000048en Otherwise the starter could suffer
damage.
CAUTION 9999998en

retaining the fuel injection pump drive CAUTION
gear to the fuel injection pump hub. Do • High-pressure washing not
not disassemble the fuel injection pump recommended.
drive gear from the hub. Correct fuel
• Avoid using high-pressure washing for
electronic or electric devices installed
in, on or around the engine, including
0000031en
the E-ECU, relays and harness
couplers.
CAUTION Otherwise such devices may suffer
Do not rotate the crankshaft with the malfunction due to water ingress into
injection pump removed. them.
0000083en 9999997en
CAUTION
Each pressure adjusting shim removed
or added changes the pressure
threshold by approximately 275 psi
shims increases the threshold pressure.
pressure threshold.
0000081en

CAUTION
• Do not plug or unplug the E-ECU for a
period of at least 6 seconds after
power to the unit has been turned on
or off.
• Do not touch connector pins of the E-
ECU with bare hands.
Doing so may result in corrosion of the
connector pins and/or damage to the
internal circuits of the E-ECU due to
static electricity.
• Do not force a measuring probe into
the female coupler.
Doing so may cause contact failure of
• Take care to prevent water from
entering the couplers when plugging
or unplugging the connector.
Water inside the couplers may cause
corrosion, resulting in malfunction of
the E-ECU.
• Avoid plugging/unplugging the
connector more than approx. 10 times.
Frequent plugging/unplugging of the
connector may cause contact failure of
• Do not use the E-ECU that has ever
suffered drop impact.
9999996en
CAUTION
Always check the battery for proper
charge.
Otherwise the electronically controlled
engines may fail to start.
9999995en

FUEL SYSTEM Introduction
INTRODUCTION
This section of the Service Manual describes the
procedures necessary to remove, install, and time
the MP fuel injection pump and its associated
system components. This fuel injection pump is
representative of the fuel injection pumps used on
other TNV DI model engines. The descriptions
given in this section basically apply also to fuel
injection pumps used for electronically controlled
engines unless otherwise described herein.
Fuel Injection Pump 0000038
Note: If the MP fuel injection pump itself Figure 7-1

requires servicing, it must be taken to an The following describes the features of the MP fuel
authorized Yanmar FIE (Fuel Injection injection pump, manufactured by Yanmar.
Equipment) repair facility.
The fuel injection pump is a very important
component of the engine. It is capable of making
CAUTION
very precise fuel delivery adjustments according to
• NEVER remove or attempt to remove the varied loads applied to the engine.
full-load fuel adjusting screw or the All of the fuel injection pump components are very
high-speed throttle limit screw on the precisely machined. It is extremely important to
fuel injection pump and governor follow good service practices and maintain
assembly. These adjustments have cleanliness when servicing the fuel injection pump.
been made at the factory to meet all
The Yanmar MP “Mono-Plunger” Fuel Injection
Pump is a distributor type pump which consists of a
then sealed.
single fuel supply plunger, a distributor shaft, a
• NEVER attempt to make any hydraulic head and a pump housing. The hydraulic
adjustments to these sealed head has a delivery valve for each cylinder. The
adjustment screws. If adjustments are fuel injection pump housing contains a governor
required, they can be made only by a and an internal camshaft.
ensure the injection pump continues The fuel is pressurized by the up and down motion
to meet all applicable emissions of the camshaft-driven single plunger. It is then
regulations and then replace the distributed to the proper fuel injector by the rotating
tamper-proof seals. distributor shaft.
• Tampering with or removing these There are two versions and sizes of the MP Fuel
devices may void the “Yanmar Limited Injection Pump. The smaller of the two pumps, the
Warranty.” MP2 pump, is used on the 3TNV82A - 4TNV88
0000146en model engines. The larger pump, the MP4 pump,
which has a larger single plunger and a more
aggressive cam profile, is used on the
4TNV94L - 4TNV106T model engines.

Introduction FUEL SYSTEM
Stop Solenoid Electronically controlled engines 4TNV84T-Z,
4TNV98-Z, 4TNV98-E, and 4TNV98T-Z are
The MP fuel injection pumps are equipped with a designed so that, when the key is turned on or off,
stop solenoid that controls the fuel flow inside the the corresponding signal is sent to the E-ECU.
fuel injection pump. Thus the E-ECU controls the rack actuator to
With the starter switch in the OFF position, no provide a sufficient injection rate when the engine is
current flows to the stop solenoid and the solenoid started up (the key is turned on) or cut the fuel
plunger is extended holding the fuel injection pump supply and stop then engine when the key is turned
fuel rack in the “closed” position and not allowing off. Therefore, these electronically controlled
fuel to flow through the injection pump and to the engines does not have a stop solenoid.
engine.
Cold Start Device
When the starter switch is turned to the start
The Yanmar TNV model engines are equipped with
position, the “pull coil” (36.5 Amp draw / white wire)
a cold start device (CSD).
inside the solenoid is activated and pulls the
solenoid plunger into the solenoid. This releases The cold start device is located in the upper section
the fuel injection pump fuel rack, allowing fuel to of the fuel injection pump and is connected to the
flow through the injection pump and allowing the engine’s cooling system.
engine to start and run.
• The cold start device improves engine starting at
When the starter switch is returned to the ON or lower temperatures. At engine cooling system
RUN position, the “pull coil” no longer receives temperatures below 41°F (5°C), the cold start
current and the “hold coil” (0.5 Amp draw / red wire) device advances the fuel injection timing and
inside the solenoid is activated. The “hold coil” slightly increases the fuel injection volume.
holds the solenoid plunger in the RUN position,
allowing fuel to continue flowing and he engine to • For approximately the first 5 minutes of operation,
continue running. the idle speed of the engine will be slightly
elevated.
To stop the engine, the key switch is turned to the
OFF position. Current no longer flows to the stop
CAUTION
solenoid “hold coil”, and the solenoid plunger
extends and moves the injection pump fuel rack to Allow the engine to warm-up for at least
the “closed” position, shutting off the fuel flow and five minutes and the idle speed of the
stopping the engine. engine to return to normal before
Failure of the stop solenoid could result in the Engaging the transmission or PTO at an
engine not starting, the engine stopping suddenly, elevated engine speed could result in an
the engine not continuing to run with the key switch unexpected movement of the
returned to the ON or RUN position, or the engine equipment.
failing to stop when the key switch is turned to the 0000159en
OFF position. Use a multimeter or continuity light to
check for 12V at the stop solenoid connector in the • When the cold start device is activated, you may
correct sequence. notice a slight increase in the exhaust smoke of
the engine during engine warm-up.
Electronically controlled engines 3TNV84T-Z,
4TNV84T-Z, 4TNV98-Z, 4TNV98-E, and
4TNV98T-Z use a cold start device (CSD) that
consists of a fuel injection pump complete with a
solenoid valve (Figure 7-2, (1)).

FUEL SYSTEM Introduction
(2) (1) Electronically controlled governor

Electronically controlled engines 4TNV84T-Z,
(4) 4TNV98-Z, 4TNV98-E, and 4TNV98T-Z are
quipped with an electronically controlled governor
called "Eco Governor". Combined with the rack
(3) actuator (Figure 7-2, (3)), engine speed sensor
(Figure 7-2, (5)), and other parts, the electronically
controlled governor communicates with the engine
controller (E-ECU), whereby the engine speed and
fuel injection rate are controlled.
(6)
(5)
Figure 7-2
• When the engine is started with the cooling water
sensor detecting a low water temperature of 10Åé
or lower and the E-ECU receives the
corresponding signal, then the E-ECU causes the
CSD's solenoid valve to increase the injection
rate and advance the injection timing.
• Because of this, the engine speed increases by
approximately 75 min-1 while the CSD is
operating. When the water temperature becomes
10°C or higher, the CSD is turned off and the
engine returns to the normal speed.
Trochoid Fuel Pump

Note: The trochoid fuel pump located on the
side of the MP fuel injection pump is not
a “fuel supply” pump. The function of this
pump is to raise the pressure of the fuel
supplied by the electric fuel supply pump
to the internal fuel pressure required by
the MP fuel injection pump.
The use of an electric fuel supply pump is required
on all TNV model engines with the MP fuel injection
pump.

Fuel System Specifications FUEL SYSTEM
FUEL SYSTEM SPECIFICATIONS

Special Torque Chart
Lubricating Oil Application
Component Tightening Torque
(Thread Portion and Seat Surface)
29 ft·lb
Fuel Injector Retainer Bolt Not Applied
(39.2 N·m; 4 kgf·m)
3TNV82A
58 - 65 ft·lb
to Not Applied
(78 - 88 N·m; 8 - 9 kgf·m)
Fuel Pump Drive 4TNV88
Gear Nut 83 - 91 ft·lb
4TNV94 to
(113 - 123 N·m; Not Applied
4TNV106T
11.5 - 12.5 kgf·m)
22 - 25 ft·lb
High-Pressure Fuel Injection Line Nuts (29 - 34 N·m; Not Applied
3.0 - 3.5 kgf·m)
69 - 87 in·lb
Fuel Return Line Bolts (7.8 - 9.8 N·m; Not Applied
0.8 - 1.0 kgf·m)
17 - 21 ft·lb
Fuel Injection Pump Mounting Nuts (23 - 28 N·m; Not Applied
2.3 - 2.9 kgf·m)
30 - 33 ft·lb
Fuel Injector Nozzle Case Nut (39.2 - 44.1 N·m; Not Applied
4 - 4.5 kgf·m)
3TNV82A 22 - 26 ft·lb
to (30 - 35 N·m; Not Applied
Fuel Injection Pump Plunger 4TNV88 3.1 - 3.6 kgf·m)
Plug 30 - 33 ft·lb
4TNV94 to
(40 - 45 N·m; Not Applied
4TNV106T
4.1 - 4.6 kgf·m)

FUEL SYSTEM Fuel System Specifications
Test and Adjustment Specifications

Engine Injector ID
Model Fuel Injector Pressure Fuel Injection Timing
Class mark*
2843 - 2988 psi
3TNV82A - 4TNV88 CL W (19.6 - 20.6 MPa;
200 - 210 kgf/cm2)
2843 - 2988 psi
W** (19.6 - 20.6 MPa;
200 - 210 kgf/cm2)
3TNV82A - 4TNV88 See Checking and Adjusting Fuel
VM or or
3TNV84T - 4TNV84T Injection Timing on page 7-30
3133 - 3278 psi
V** (21.6 - 22.6 MPa;
220 - 230 kgf/cm2)
3133 - 3278 psi
4TNV94L - 4TNV106 CL
V (21.6 - 22.6 MPa;
4TNV98T - 4TNV106T VM
220 - 230 kgf/cm2)
Note: Fuel injection pressure of a new fuel injector is reduced approximately 72.5 psi (0.5 MPa; 5.0
kgf/cm2) after about 5 hours of operation due to the initial break in of the engine. When adjusting a
new fuel injector or after it has been disassembled for service, adjust the fuel injector 72.5 psi (0.5
MPa; 5.0 kgf/cm2) higher than the above standard.
Note: All fuel injectors have a three character identification mark (Figure 7-3, (1)). The first character
starts with “V” or “W”.
(1)
0004105
Figure 7-3
** Fuel injector identification is critical as each engine has a unique fuel injection pressure. The fuel
nozzle is specifically matched to the fuel injector by engine model and / or engine speed.

Special Service Tools FUEL SYSTEM

No. Tool Name Application Illustration
For tightening nuts and bolts to the specified

1 Torque Wrench Locally Available
torque
0000840
Used in conjunction with a slide hammer to

Fuel Injector Yanmar Part No.
2 remove the fuel injectors (2-valve cylinder
Removal Tool 129470-92305
heads)
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
Mituotoyo 2050SB -
Dial Indicator* Check and adjust fuel injection timing
Locally Available
2
0000831
Mituotoyo 303613 -
Extension Rod*
Locally Available
(M14) TNV82-88 -
Yanmar Part No.
158090-51831
Fuel Injection Pump
3 Mount dial indicator to fuel injection pump
Plunger Adapter* (M16) TNV94-106 -
Yanmar Part No.
158090-51841
0002690
Plunger Adapter Yanmar Part No.

4 Clamps stem of dial indicator in plunger adapter.
Clamp 23000-013000
0002691
* These special service tools may also be available as an “MP Fuel Injection Pump Special Tool Set”, under a
different part number, in territories serviced by Yanmar America and Yanmar Europe. Contact your authorized
Yanmar dealer or distributor for details.

FUEL SYSTEM Fuel System Diagram
FUEL SYSTEM DIAGRAM

(5) (20)
(21)
(4)
(18)
(17)
(19)
(16)
(3) (22)
(15)
(2)
(17)
(13) (14)
(11)
(1) (12)
(10)
(6)
(9)
(8)
(7)
0000034B
1 – Diesel Fuel Tank 12 – Engine Crankcase

2 – Fuel Filter / Water Separator 13 – Tappet
3 – Electric Fuel Pump 14 – High Pressure Gallery
4 – Fuel Filter 15 – Overflow Orifice
5 – Air Bleed Orifice 16 – Accumulator
6 – Fuel Supply Line 17 – Timer Piston
7 – Low Pressure Gallery 18 – Mono-Plunger
8 – Pressure Control Valve 19 – Distributor Shaft
9 – Trochoid Pump 20 – Fuel Return Line
10 – Oil Seal 21 – High-Pressure Fuel Injection Lines
11 – Fuel Injection Pump Cam 22 – Fuel Injector
Figure 7-4

Fuel System Components FUEL SYSTEM
FUEL SYSTEM COMPONENTS

2-Valve Cylinder Head
(16 )
(1)
(2)
(3)
(15 )
(14 )
(4)
(13)
(18)
(12) (10)
(17)
(9)
(8)
(11) (5)
(7)
(19) (6)
0002128
Figure 7-5

FUEL SYSTEM Fuel System Components
1 – High-Pressure Fuel Injection Lines 9 – Coolant Lines for Cold Start Device
2 – Fuel Return Line 10 – Fuel Injection Pump Insulator
3 – Fuel Injector 11 – Fuel Injection Pump
4 – Front Plate or Timing Gear Case 12 – Rear Fuel Injection Pump Support
5 – Gear Case Cover 13 – Fuel Filter / Water Separator
6 – Fuel Injection Pump Drive Gear Nut 14 – Electric Fuel Supply Pump
7 – Lock Washer 15 – Fuel Filter
8 – Fuel Injection Pump Drive Gear Assembly 16 – Fuel Filter Housing
(DO NOT remove or loosen the four bolts 17 – Stop Solenoid
that fasten the injection pump drive gear to 18 – Cold Start Device (CSD)
the injection pump drive gear hub!) 19 – Trochoid Fuel Pump

Fuel System Components FUEL SYSTEM
(18)
(1)
(2)
(3)
(5)
(4)
(17)
(16)
(6)
(15)
(12)
(20)
(14)
(19)
(11)
(10) (7)
(13)
(21) (9)
(8)
0002017
Figure 7-6

FUEL SYSTEM Fuel System Components
1 – High-Pressure Fuel Injection Lines 11 – Coolant Lines for Cold Start Device *
2 – Fuel Return Line 12 – Fuel Injection Pump Insulator
3 – Return Line-to-Cylinder Head Bolt 13 – Diesel Fuel Injection Pump
4 – Fuel Injector 14 – Rear Fuel Injection Pump Support
5 – Injection Line Grommet 15 – Fuel Filter / Water Separator
6 – Front Plate or Timing Gear Case 16 – Electric Fuel Supply Pump
7 – Gear Case Cover 17 – Fuel Filter
8 – Fuel Injection Pump Drive Gear Nut 18 – Fuel Filter Housing
9 – Lock Washer 19 – Stop Solenoid *
10 – Fuel Injection Pump Drive Gear Assembly 20 – Cold Start Device (CSD) **
(DO NOT remove or loosen the four bolts 21 – Trochoid Fuel Pump
that fasten the injection pump drive gear to
the injection pump drive gear hub!)
*: Not used for electronically controlled engines.
**: Electronically controlled engines are equipped with a solenoid valve. As shown in the following
figure, electronically controlled engines use an electronically controlled governor combined with a
solenoid valve (CSD), rack actuator, engine speed sensor, and other parts.
(2) (1)
(4)
(3)
(6)
(5)
Figure 7-7

Fuel Injection Pump FUEL SYSTEM
FUEL INJECTION PUMP CAUTION

Removal of Fuel Injection Pump Remove or install the high-pressure fuel
1. Loosen the cooling fan V-belt. possible. Disassembling the
2. Remove the engine coolant fan guard (if high-pressure fuel injection lines from
equipped), engine coolant fan (Figure 7-8, (2)), the retainers or bending any of the fuel
spacer (Figure 7-8, (3)) if equipped, V-pulley lines will make it difficult to reinstall the
(Figure 7-8, (4)) and cooling fan V-belt fuel lines.
(Figure 7-8, (1)). 0000047en
7. 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 covering all open
(3) (2) connections.
8. Disconnect the coolant lines from the cold start
device (Figure 7-9, (3)) on the fuel injection
pump. Plug the open ends of the lines to
minimize leakage and prevent contamination.
(1)
This cooling water pipe is not used in
electronically controlled engines 4ÇsNV84T-Z,
4TNV98-Z, 4TNV98-Z, and 4TNV98T-Z.
(4) 9. Disconnect the fuel return lines from the fuel
0000163A
return fitting (Figure 7-9, (2)). Plug the open
ends of the lines to minimize leakage and
Figure 7-8
prevent contamination.
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. Remove the high-pressure fuel injection lines
as an assembly (Figure 7-9, (1)).
(1)
Note: To prevent “rounding” the fuel line nuts
always use a “line” or “flare nut” wrench. (4)
When loosening the fuel line nuts,
(3)
always hold the fuel injection pump
delivery valves with a “back up” wrench
to prevent loosening of the delivery
(2)
valves.
6. First loosen the fuel line nuts at the fuel
injectors and then at the fuel injection pump.
0002094
Figure 7-9

FUEL SYSTEM Fuel Injection Pump
10. Remove the fuel supply line (Figure 7-9, (4)).

Plug the open end of the line to minimize
leakage and prevent contamination.
(2) (1)
(4) (1)
(3)
(2)
(6) 0000153A
Figure 7-11
(5)
14. Disconnect the lube oil line (Figure 7-12, (1))
Figure 7-10 and the clamp (Figure 7-12, (2)) from the
11. Remove the throttle cable from the fuel injection pump.
pump. IMPORTANT
12. Separate the stop solenoid wiring connector Take care to not damage or bend the oil
(Figure 7-11, (2)). line. In some applications, it may be
For electronically controlled engines 4TNV84T- preferable to remove the complete oil line
Z, 4TNV98-Z, 4TNV98-E, and 4TNV98T-Z, assembly from the engine before
remove the solenoid valve connector proceeding.
(Figure 7-10, (2)), rack actuator connector
(Figure 7-10, (4)), and engine speed sensor Note: On models 3TNV82-4TNV88, the fuel
connector (Figure 7-10, (6)). injection pump drive gear cover is
retained to the gear case cover by 4
13. Remove the rear fuel injection pump bracket(s) bolts. On models 4TNV94-4TNV106, the
(Figure 7-11, (1)) from the fuel injection pump. cover is larger and retained by 7 bolts.
Note: Configuration of the fuel injection pump
rear brackets may vary depending upon
engine model.

16. To position the fuel injection pump for easier
removal and installation, install a dial indicator
(see Checking and Adjusting Fuel Injection
Timing on page 7-30) into the injection pump
(1) plunger opening. Using a wrench on the
crankshaft pulley bolt, rotate the crankshaft until
the dial indicator shows that injection pump
plunger is at the bottom of it's stroke.
17. To aid in reassembly, make reference marks on
the fuel injection pump drive gear, and on either
the gear case cover or idler gear.
CAUTION
(2) 0000593B
After marking the position of the pump
Figure 7-12 drive gear, do not rotate the engine
crankshaft. Rotating the crankshaft will
15. Remove the fuel injection pump drive gear cause the fuel injection pump to become
cover (Figure 7-13, (1)) from the gear case misaligned.
cover (Figure 7-13, (2)).
0000048en
Note: The fuel injection pump drive gear cover
is secured with an adhesive sealant. Use • On TNV82-88 model engines, the idler gear is
a gasket scraper to separate the fuel not visible. Make a reference mark on the fuel
injection pump cover from the gear case injection pump drive gear (Figure 7-14, (1))
cover. and a matching mark on the bore of the gear
case opening (Figure 7-14, (2)).
(2)
(2)
(1)
0002039 (1)
0000575
0000575A
Note: TNV82-88 shown.

• On TNV94 - 106 model engines, the idler gear

is visible. Make a reference mark
(Figure 7-15, (1)) across both the fuel injection
pump drive gear and the idler gear.
(3)
(1)
(1) (2)
0000162A
Figure 7-16
Figure 7-15 19. Hold the gear train using a large socket wrench
on the crankshaft pulley nut. Loosen the fuel
CAUTION injection pump drive gear retaining nut
(Figure 7-16, (1)) and turn it out to the end of
the fuel injection pump shaft.
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do 20. Remove the pump drive gear and hub as an
not disassemble the fuel injection pump assembly using an appropriate two-bolt gear
drive gear from the hub. Correct fuel puller (Figure 7-17).
0000031en
18. Do not loosen or remove the four bolts

(Figure 7-16, (3)) retaining the pump drive gear
to the hub. Only remove the single drive gear
nut (Figure 7-16, (1)) and washer
(Figure 7-16, (2)), leaving the hub attached to
the gear.
0000574
Figure 7-17

Note: On TNV82 - 88 models the injection Note: Some model engines may require the
pump drive gear will remain “captured” in intake manifold and fuel injection pump
the gear case. On TNV94 - 106 models, insulator (Figure 7-20, (2)) be removed
the injection pump drive gear can be to access the inner fuel injection pump
removed through the gear case cover (Figure 7-20, (1)) retaining nuts.
opening.
21. Once the fuel injection pump drive gear and
hub assembly has “popped” loose from the
tapered fuel injection pump drive shaft, carefully
remove the drive gear nut (Figure 7-18, (1)) (2)
and lock washer (Figure 7-18, (2)).
(1)
(1)
0000263A
Figure 7-20
(2)
0000162B
23. If required, remove the intake manifold and fuel
pump insulator to access the fuel injection
Figure 7-18 pump mounting nuts.
22. Locate the mark stamped into the upper outside Note: The MP2 fuel injection pumps
mounting boss of the fuel injection pump. (TNV82 - 88 model engines) are
Highlight this mark and make a corresponding fastened to the gear case with three (3)
mark on the gear case or front plate studs and nuts. The MP4 fuel injection
(Figure 7-19, (1)). pumps (TNV94 - 106 model engines) are
fastened to the gear case with four (4)
studs and nuts.
24. Remove the fuel injection pump
(Figure 7-20, (1)). For purposes of future
injection timing purposes, record the fuel
injection pump timing index number located on
the boss on the engine side (back) of the of the
fuel injection pump (Figure 7-21, (1)).
(1)
0000593
0000593A
Figure 7-19

(1) CAUTION
• NEVER remove or attempt to remove
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
then sealed.
• NEVER attempt to make any
adjustments to these sealed
0002047 adjustment screws. If adjustments are
Figure 7-21 required, they can be made only by a
ensure the injection pump continues
CAUTION to meet all applicable emissions
Do not rotate the crankshaft with the regulations and then replace the
injection pump removed. tamper-proof seals.
0000083en
• Tampering with or removing these
25. If the fuel injection pump requires servicing, it devices may void the “Yanmar Limited
must be sent to an authorized Yanmar FIE Warranty.”
repair facility for repair and calibration, or 0000146en
replaced with a new fuel injection pump.

Installation of Fuel Injection Pump
For electronically controlled engine
A WARNING
• Replacing the fuel injection pump
involves rewriting the fuel injection
data in the E-ECU.
Be sure to contact your local Yanmar
dealer before replacing the fuel
injection pump.
Failure to rewrite the fuel injection
data before replacing the fuel injection
pump will void the engine warranty.
• Improper use or misuse of the E-ECU
9999997en

IMPORTANT
If installing a new or recalibrated fuel
injection pump, locate and record the timing
index number located on the pump housing
boss on the engine side of the new or
recalibrated fuel injection pump
(Figure 7-22, (1)). This number will be used
(1)
to calculate and adjust the final fuel injection
timing.
Note: If either or both of the fuel injection
pumps do not have a timing index
number, note the injection pump ID
(example: XK42) on the injection pump
ID label.
To locate the timing index number for the engine
0000575
0000575B
being serviced use the Timing Index Chart under
“FIE Specs” on the Yanmar Distributor Website Figure 7-23
(http://distributor.yanmar.co.jp).
If additional assistance is needed in locating the
engine timing index number See To Locate an
Authorized Yanmar Industrial Engine Dealer or
Distributor: on page 2-4 and follow the instructions
to locate an authorized Yanmar industrial engine
dealer or distributor for assistance.
Note: Treat the timing index number as if it has
a decimal point (68 = 6.8).
(1)
(1)
0002096
Figure 7-24
2. If installing the fuel injection pump on an engine
with the front gear case cover removed, the fuel
injection pump drive gear can be aligned with
the idler gear by aligning the stamped marks
Figure 7-22
(A, B, C) on the fuel injection pump drive gear,
1. Align the pump drive gear with the idler gear idler gear, and crankshaft drive gear. Ensure all
using the reference marks made earlier. three timing marks (Figure 7-25, (A, B, C)) are
TNV82 - 88 model engines (Figure 7-23, (1)). aligned.
TNV94 - 106 model engines (Figure 7-24, (1)).

(1)
(2)
B B
C C
A
(7) A
(3)
(6) (4)
(5) 0001709A
1 – Fuel Injection Pump Drive Gear (1)

2 – Camshaft Drive Gear
3 – Auxiliary Drive Gear (Optional)
4 – Crankshaft Drive Gear
5 – Direction of Rotation
(2)
6 – Oil Pump Drive Gear (4TNV94L - 4TNV106)
7 – Idler Gear 0000162B
3. Install a new O-ring on the pump mounting If reinstalling the original fuel injection pump:
flange. Apply grease to the O-ring to hold it in
• Align the reference marks (Figure 7-27, (1))
place during installation of the injection pump.
previously made on both the fuel injection
Note: Ensure the tapered surface of the fuel pump mounting flange and gear case or front
injection pump shaft is clean and dry. plate.
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. Reinstall the pump retaining nuts
finger tight.
5. Reinstall the fuel injection pump drive gear lock
washer (Figure 7-26, (2)) and nut
(Figure 7-26, (1)). Do not lubricate the threads
of the nut or shaft. Hold the crankshaft pulley
bolt with a socket wrench and tighten the drive
(1)
gear nut to the specified torque. See Special
Torque Chart on page 7-11.
0000593
0000593A
Figure 7-27
• Tighten the fuel injection pump retaining nuts
to specification. See Special Torque Chart on
page 7-11.

If installing a new fuel injection pump: • Calculate the difference between the timing
index numbers (Figure 7-29, (1)) of the fuel
• Reinstall the timing grid sticker, provided with injection pump that you removed and the
the new fuel injection pump, onto the back of replacement fuel injection pump. See
the gear case / front plate (Figure 7-28). Align Calculation Example below.
the “standard mark” (Figure 7-28, (1)) with the
reference mark (Figure 7-28, (2)) made on the (1)
gear case during disassembly.
0002047
Figure 7-29
Adjusting the fuel injection timing to
compensate for the difference in pump timing
index numbers:
(2)
Calculation Example
Timing Index Number
(1) Original injection pump= 6.8
Replacement injection pump= 7.3
Difference= +0.5
• If the difference between the timing index

numbers is a positive number, the fuel injection
pump mounting position must be advanced
(Figure 7-30, (2)) (rotated away from the
engine) as compared to the “standard mark”
(Figure 7-30, (1)) by the calculated positive
amount, adjust the fuel injection pump to the
calculated value.
• If the difference between the timing index
numbers is a negative number, the
0002139 replacement injection pump must be retarded
(Figure 7-30, (3)) (rotated toward the engine)
Figure 7-28 by the calculated negative amount.
• Each mark on the timing sticker represents
0.5° timing change.

The above calculated difference indicates that Tighten the fuel injection pump mounting nuts to
the replacement fuel injection pump is to be specification. See Special Torque Chart on
installed at +0.5° (advanced) from the “Standard page 7-11.
Mark” (Figure 7-30, (1)) on the timing sticker.
6. Reinstall the rear bracket(s) (Figure 7-32, (1))
to the fuel injection pump. Tighten the rear
support bolts.
Note: Configuration of the fuel injection pump
rear brackets may vary depending on the
(3) model.
(1)
+0.5°
(1)
+1.0°
(2)
0002124A
(2)
Figure 7-30
0000153A
In this case, rotate the top of the fuel injection
pump away from the cylinder block until the mark Figure 7-32
on the outside upper mounting boss 7. Reconnect the throttle linkage and the stop
(Figure 7-31, (1)) of the fuel injection pump solenoid connector (Figure 7-33, (2)).
aligns with the +0.5° mark on the timing sticker.
8. Reconnect the lube oil line (Figure 7-33, (1))
and clamp (Figure 7-33, (2)).
(1) 0002125A
Figure 7-31

12. If equipped, verify the fuel injection pump
insulator (Figure 7-34, (2)) is not damaged.
Reinstall the insulator and intake manifold if
previously removed.
(1)
(2)
(1)
(2) 0000593B
Figure 7-33
0000263A
9. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212, or equivalent
Figure 7-34
sealant to the sealing surface of the pump
cover. Install the pump cover and tighten the 13. Reinstall the coolant pump V-pulley
cover bolts. (Figure 7-35, (4)), spacer (Figure 7-35, (3)) (if
10. Reconnect the fuel return lines, fuel supply line equipped) and engine coolant fan
and coolant lines to the fuel injection pump. (Figure 7-35, (2)).
11. Reinstall the fuel injection high-pressure lines.
Tighten the nuts to specification. See Special
Torque Chart on page 7-11.
(3) (2)
IMPORTANT
When reinstalling a new or repaired fuel
injection pump, it is important to add engine
oil to the fuel injection pump to provide
lubrication for initial start-up. Add 5-7 oz
(1)
(150-200 cc) of clean engine oil to the fuel
injection pump at the fill plug located in the
upper outside section of the governor
housing.
(4) 0000163A
Figure 7-35
14. Reinstall the cooling fan V-belt
(Figure 7-35, (1)). Adjust it as described in
Check and Adjust Cooling Fan V-Belt on
page 5-22.
15. Reinstall the cooling fan guard (if equipped).

FUEL SYSTEM Checking and Adjusting Fuel Injection Timing
16. Prime the fuel system. See Priming the Fuel 2. Using the FIR number for the engine being
System on page 4-15. serviced use the Fuel Injection Reference (FIR)
17. Operate the engine and check for fuel and Chart under “FIE Specs” on the Yanmar
coolant leaks. Distributor Website
(http://distributor.yanmar.co.jp).
The FIR number is determined by the complete
CHECKING AND ADJUSTING engine model number. The engine model
number is located on the engine nameplate
FUEL INJECTION TIMING (Figure 7-38).
Determining the Fuel Injection Timing

Specification
1. Locate and record the fuel injection pump
timing index number (Figure 7-37, (1)) stamped
into the boss on the engine side of the fuel
injection pump housing (Figure 7-36, (1)). Treat
this number as though there is a decimal point
between the two digits. i.e. 68 = 6.8
(1)
0003852
Figure 7-38
EXAMPLE: The following example is for an engine
model 3TNV82A-DSA.
0000040B
• Find the engine model number in the FIR chart.
Figure 7-36 Locate and record the FIR number (The FIR
number for this engine is 4).
(1) • Insert the numbers you have recorded into the
following equation:
(Fuel Injection Pump Timing Index Number X 2)
+ FIR Number = FIT° (Fuel injection Timing in
Degrees)
(6.8 X 2) = 13.6 + 4 = 17.6° Fuel injection

Timing
• Record the calculated fuel injection timing
specification.
0002047
Figure 7-37

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
Checking Fuel Injection Timing Note: Use the Yanmar part no. 158090-51831
M14 adapter for the MP2 fuel injection
Note: Some fuel may drain from the fuel pumps (TNV82 - 88 model engines) or
injection pump during this process. Make Yanmar part no. 158090-51841 for the
provisions to contain any such spillage. M16 adapter used on the MP4 fuel
1. Turn off the fuel valve in the fuel supply hose injection pumps (TNV94 - 106 model
and the fuel return hose. engines) and Yanmar part no. 23000-
013000 plunger adapter clamp
2. Clamp shut the fuel injection pump fuel return
(Figure 7-40, (1)).
hose leading to fuel filter (Figure 7-39, (1)).
(1)
(1)
(2)
0002068A
Figure 7-40
0002087
5. Install a dial indicator (Figure 7-41, (1)),
Figure 7-39 Mitutoyo No. 2050SB or equivalent, with a
30 mm extension, Yanmar part no.
IMPORTANT 158090-51870 or Mitutoyo No. 303613, into the
Clean the top of the fuel injection pump to adapter. Secure with the Yanmar part no.
prevent any contamination when the fuel 23000-013000 plunger adapter clamp
injection pump plunger plug is removed. (Figure 7-40, (1)) at approximately the mid-
3. Remove the forward fuel injection pump plunger point of its travel.
plug (Figure 7-39, (2)) on the top of the fuel
injection pump.
4. Install a dial indicator adapter and clamp into
the pump plunger opening.

The flywheel shown in Figure 7-43 is for a

(1) Yanmar “Standard Specification” DI engine.
Flywheels used on some “OEM Specific” DI
engines may be marked differently. You should
contact that specific OEM for information on the
identification of the timing marks.
(3)
(2)
(4)
(1)
14
(5)
0002069
Figure 7-41 0002071
Note: The following references to the direction- 1 – 10° BTDC (Before Top Dead Center)
of-rotation are facing the coolant pump 2 – 15° BTDC
end of the engine and are adjusted by 3 – 20° BTDC
turning the crankshaft pulley. 4 – Direction of Rotation
5 – TDC (Top Dead Center)
6. Using a wrench on the crankshaft pulley bolt,
rotate the crankshaft in a clockwise direction Figure 7-43
while looking through the flywheel inspection
port (Figure 7-42, (1)). Rotate the crankshaft Note: The TDC (Top Dead Center) mark can
until the injection timing marks on the flywheel be identified by the cylinder numbers
are visible. stamped near the TDC mark on the
flywheel.
If you are uncertain as to the timing degree
designation of the timing marks on the flywheel
timing grid, you can determine the timing degree
designation by measuring the timing grid.
• First measure the distance between two of the
“longer” marks on the timing grid. (They are 5°
apart.) Then measure the distance from the
TDC mark to the first “longer” mark on the
(1) 00020 timing grid. Divide that measurement by the
distance between the two “longer” marks. The
Figure 7-42 resulting answer will tell you how many
degrees there are between the TDC mark and
7. Typical flywheel markings are as shown in
the first “longer” mark.
(Figure 7-43, (1)).
Note: A typical flywheel will have multiple
timing grids depending on the number of
cylinders. Any grid can be used to check
the fuel injection timing.

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
• EXAMPLE: If the distance between the two
“longer” marks is approximately 2.0 cm and the
distance from the TDC mark is approximately
(1)
4.0 cm, the answer is approximately 2. This
(2)
indicates there is 10° (2 x 5°) between the TDC
mark and the first “longer” mark on the timing
grid. That means the first “longer” mark on the
timing grid indicates 10° BTDC, the second
“longer” mark indicates 15° BTDC and the third
timing mark indicates 20° BTDC. If the answer
is 3, that indicates there is 15° (3 x 15°)
between the TDC mark and the first “longer”
mark and that the first “longer” mark indicates 0002066
15° BTDC with the second and third “longer”
marks indicating 20° BTDC and 25° BTDC
respectively.
8. Highlight the timing reference mark (2)
(Figure 7-44, (2)) on the flywheel housing or (1)
engine back plate (Figure 7-45, (2)). Highlight
the TDC (Top Dead Center) mark
(Figure 7-44, (1)) on the flywheel.
9. Highlight the target timing mark
(Figure 7-45, (1)) on the flywheel as calculated
in Determining the Fuel Injection Timing
Specification on page 7-30.
0002142
Figure 7-45
(1)
(2) 10. Rotate the crankshaft counter-clockwise until
the dial indicator shows that the injection pump
plunger is at the bottom of its stroke. Rock the
1 4
crankshaft back and forth slightly to confirm a

point where the dial indicator shows no
movement. Zero the dial indicator.
11. Slowly rotate the crankshaft clockwise until the
dial indicator shows a pump plunger lift of
2.5 mm (0.098 in.).
0002065
12. Check the position of the flywheel target timing
Figure 7-44 mark (previously determined) (Figure 7-45, (1))
in relation to the timing reference mark
(Figure 7-45, (2)) on the flywheel housing or
engine 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 7-34.

13. If the injection timing is correct, remove the dial 3. Note the reading on the dial indicator
indicator and adapter. Replace the pump (Figure 7-47, (1)). If the reading is less than
plunger plug and its copper gasket and tighten 2.5 mm (0.098 in.), the fuel injection timing is
to specifications. Replace the flywheel “retarded.” If the dial indicator reading is greater
inspection port cover. Open the fuel supply than 2.5 mm (0.098 in.), the fuel injection timing
valve and remove the clamp from the fuel is “advanced.”
supply hose and the fuel return hose.
(1)
14. Prime the fuel system. Operate the engine and
check for leaks.
Adjusting Fuel Injection Timing

If the timing marks did not align when performing
the Checking Fuel Injection Timing on page 7-31,
the following steps must be performed to properly
time the engine.
1. Leave the dial indicator installed in the fuel
injection pump. Do not disturb the reading on
the dial indicator.
2. Rotate the flywheel until the target timing mark
(Figure 7-46, (1)) and the timing reference 0002069
mark (Figure 7-46, (2)) on the flywheel housing Figure 7-47

or back plate are aligned.
Note: Some model engines require the intake
IMPORTANT manifold and fuel injection pump
Do not rotate the crankshaft during the insulator be removed to access the inner
remainder of this procedure. fuel injection pump retaining nuts.
4. Loosen the nuts fastening the fuel injection
pump to the gear case or front plate. Loosen
(1) the rear bracket(s) on the fuel injection pump.
(2) Note: Loosening the high-pressure injection
line nuts on the fuel injection pump may
make rotating the pump easier.
5. Rotate the fuel injection pump until the dial
indicator reads 2.5 mm (0.098 in.).
6. To “advance” the injection timing, rotate the top
of the fuel injection pump away from the engine.
7. To “retard” the injection timing, rotate the top of
0002066
the fuel injection pump toward the engine.
Figure 7-46
8. When the dial indicator reads 2.5 mm
(0.098 in.) of pump plunger lift and the target
timing mark on the flywheel aligns with the
reference mark on the flywheel housing or
engine back plate, the injection timing is
correct.

Fuel Injectors FUEL SYSTEM
9. Tighten the fuel injection pump mounting nuts Note: To prevent “rounding” the fuel line nuts
and rear bracket(s). always use a “line” or “flare nut” wrench.
10. Remove the dial indicator and adapter. Replace When loosening the fuel line nuts,
the plug in the pump plunger opening and always hold the fuel injection pump
tighten it to specification. If removed, install the delivery valves with a “back up” wrench
intake manifold and pump insulator. Tighten the to prevent loosening.
high-pressure injection line nuts to • Loosen the fuel line nuts at the fuel injectors
specification. Open the fuel supply valve, and then at the fuel injection pump.
remove the clamp from the fuel return line and
prime the fuel system. Operate the engine and CAUTION
check it for leaks.
possible. Disassembling the
FUEL INJECTORS high-pressure fuel injection lines from
Removal of Fuel Injectors lines will make it difficult to reinstall the
fuel lines.
2-Valve Cylinder Head 0000047en

• Finish loosening all the fuel line nuts and
2. Remove the high-pressure fuel injection lines remove the high-pressure fuel lines as an
as an assembly (Figure 7-48, (1)). assembly being careful not to bend any of the
(1) fuel lines. Be sure to protect the fuel system
from contamination by covering all open
connections.
3. Remove the return fuel hoses (Figure 7-49, (1))
from one side of each fuel injector.
4. Remove the bolts and washers that secure the
fuel injector retainers (Figure 7-49, (2)) to the
cylinder head.
5. Remove the fuel injector retainer.
0000154A
Figure 7-48

FUEL SYSTEM Fuel Injectors
(3)
(1)
(4)
(2) 0002092A
Figure 7-49
0000815
6. Remove the fuel injector.
Figure 7-50
Note: The fuel injectors can usually be
removed by manually pulling them out of • Tap the fuel injector out of the cylinder head
the fuel injector wells. If the fuel injectors using the slide hammer.
cannot be manually removed, use the 7. Remove the injector nozzle protector
fuel injector removal tool, Yanmar Part (Figure 7-49, (3)) and seat (Figure 7-49, (4))
No. 129470-92305, and a slide-hammer from the cylinder head.
puller (Figure 7-50).
8. Repeat the steps to remove the remaining fuel
• Attach a slide-hammer puller to the fuel injector injectors.
removal tool using a 3/8-16 puller rod.
2. Remove the valve cover. See Removal of Valve
Cover on page 6-37.
3. Remove the injector return line
(Figure 7-51, (1)). Be careful not to bend the
line.
4. Remove the fuel injector mounting clamp bolts
(Figure 7-51, (2)). Lift the injector mounting
clamps (Figure 7-51, (3)) away from injector.
5. Remove the fuel injector (Figure 7-51, (4)) from
the cylinder head.

(2)
(1)
(3)
(4)
(5)
(6)
Figure 7-51
Note: The fuel injectors can be removed by
manually pulling them out of the fuel
injector wells.
6. Remove the injector nozzle protector
(Figure 7-51, (5)) and seat (Figure 7-51, (6))
from the cylinder head. Discard both items.
7. Repeat steps to remove the remaining fuel
injectors.

Testing of Fuel Injectors

A CAUTION
CAUTION
Never use a steel wire brush to clean
fuel injectors. Damage to the nozzle and
other components is likely to result.
0000172en
1. Thoroughly clean the fuel injector nozzle using FLYING OBJECT HAZARD!
clean diesel fuel and a brass wire brush. • ALWAYS wear eye protection when
2. Visually inspect the fuel injectors and nozzle servicing the engine and when using
protectors for deposits or damage. Clean, repair compressed air or high-pressure
or replace as necessary. water. Dust, flying debris, compressed
Note: Test the fuel injector using an injection air, pressurized water or steam may
nozzle tester. Operate the tester injure your eyes.
following the information provided by the • Failure to comply may result in minor
tester manufacturer. Use clean, filtered or moderate injury.
fuel or FIE calibration fluid for the test. 0000003en
3. Using the correct adapter, connect a fuel

injector to a nozzle tester. Aim the fuel injector
into a suitable container to catch the fuel spray.
A WARNING ON AG
OFF
E-
OFF
P-
-G
• Never inject fuel toward you. Since the

fuel is injected at high pressure from
the nozzle, it may penetrate the skin,
resulting in injury.
• Never inject fuel toward a fire source. Figure 7-52
Atomized fuel is highly flammable and
may cause a fire or burn skin. 4. Pump the operating lever of the tester slowly,
0000028en observing the pressure reading at the point
where the fuel injector begins spraying fuel
(Figure 7-52).
See Figure 7-55 for injector ID location.
See Test and Adjustment Specifications on
page 7-12 for correct pressure readings.
Note: The opening pressure of a new fuel
injector will be approximately 725 psi
(5 MPa; 51 kgf/cm2) higher than one that
has been operated for five hours or
longer.

5. Pump the operating lever slowly to hold the Disassembly and Inspection of Fuel
pressure steady at a point just below the
Injectors
opening pressure and hold it for 5 seconds.
Observe the injector to see that it is sealing
properly and is not “dripping”. If fuel leaks from CAUTION
the return line fitting, check that the nozzle case Never use a steel wire brush to clean
nut is tight. Service or replace the injector if fuel fuel injectors. Damage to the nozzle and
continues to leak from either the return line other components is likely to result.
fitting or nozzle. 0000172en
6. Pump the operating lever more rapidly to

1. Clean carbon from used injectors using clean
repeatedly “pop” the injector and observe the
diesel fuel. Hardened deposits or varnish can
spray pattern. The pattern should be a very fine
be cleaned using a brass wire brush.
uniform spray (Figure 7-53). If a dripping or an
uneven pattern is seen (Figure 7-54), service (1)
or replace the injector.
(2)
(3)
(4)
0001336A
(5)
Figure 7-53
(6)
(7)
(8)
(9)
(10)
0001337A
Figure 7-54
1 – Fuel Return Passage
If the fuel injector fails any of these tests, it should 2 – Injector ID Location
be serviced or replaced as necessary. If the 3 – Injector Body
pressure is outside specified limits, adjust the 4 – Pressure Adjusting Shims
5 – Spring
pressure. See Adjusting Fuel Injector Pressure
6 – Spring Seat
on page 7-41. 7 – Valve Stop Spacer
8 – Nozzle Valve
9 – Nozzle Body
10 – Nozzle Case Nut
Figure 7-55

2. Place the fuel injector in a soft-jawed vise with

the nozzle pointing up.
3. Remove the nozzle case nut.
4. Carefully remove the injector from the vise.
5. Turn the injector over and remove the nozzle
body, nozzle valve, valve stop spacer, nozzle
spring seat, nozzle spring, and shims.
6. Inspect the sealing surfaces (Figure 7-56, (2))
between the valve stop spacer and nozzle body
for nicks or scratches. Check the contact area 0001332A
between the valve stop spacer and the nozzle

Figure 7-57
valve (Figure 7-56, (1)) for scoring, or pitting.
Use a magnifier glass to inspect the area. 8. Replace the fuel injector assembly if it fails any
inspection.
(1)
(2)
0001333A
Figure 7-56
7. Perform a nozzle valve slide test:
(a) Wash nozzle body and valve in clean diesel
fuel.
(b) While holding the nozzle body vertical, pull
the nozzle valve about 2/3 of the way out
(Figure 7-57).
(c) Release the valve. It should fall smoothly to
its seat by it’s own weight.

Adjusting Fuel Injector Pressure See the parts catalog for available shims.
The fuel injectors open when pressure reaches a
predetermined pressure threshold. They close CAUTION
when the pressure is reduced below that threshold. Each pressure adjusting shim removed
The pressure threshold can be adjusted by adding or added changes the pressure
or removing shims (Figure 7-58, (3)). threshold by approximately 275 psi
(1) shims increases the threshold pressure.
(2) pressure threshold.
0000081en
(3) 1. Disassemble the fuel injector assembly. See

Disassembly and Inspection of Fuel Injectors
on page 7-39.
2. Remove or add adjusting shims as needed.
(4)
3. Reassemble the fuel injector assembly. See
Reassembly of Fuel Injectors on page 7-41.
(5)
0002093 4. Retest the fuel injector. See Testing of Fuel
(6) Injectors on page 7-38. If the injector cannot be
(7) adjusted to the appropriate pressure, discard
the fuel injector.
(8)
Reassembly of Fuel Injectors
(9) 1. Secure the injector in a soft-jawed vise with the
nozzle end up.
2. Reinstall the shims, nozzle spring, nozzle
(10) spring seat, valve stop spacer, nozzle valve,
and nozzle body.
0002093 3. Reinstall the nozzle case nut. Tighten it to
1 – Fuel Return Passage specification. See Special Torque Chart on
2 – Injector ID Location page 7-11.
3 – Injector Body
4 – Pressure Adjusting Shims
5 – Spring
6 – Spring Seat
7 – Valve Stop Spacer
8 – Nozzle Valve
9 – Nozzle Body
10 – Nozzle Case Nut
Figure 7-58
The injection pressure will change by
approximately 275 psi (1.9 MPa; 19 kgf/cm2) for
every 0.1 mm (0.004 in.) in shim thickness.

Installation of the Fuel Injectors 4-Valve Cylinder Head

1. Reinsert a new nozzle seat (Figure 7-60, (6))
2-Valve Cylinder Head and nozzle protector (Figure 7-60, (5)) in the
1. Reinsert a new nozzle seat (Figure 7-59, (4)) cylinder head for each injector.
and nozzle protector (Figure 7-59, (3)) in the 2. Reinstall a O-ring on to each injector body.
cylinder head for each injector.
3. Reinsert each fuel injector (Figure 7-60, (4))
2. Reinstall a O-ring on to each injector body. into the cylinder head.
3. Reinsert each fuel injector into the cylinder 4. Reinstall the fuel injector retainers
head. (Figure 7-60, (3)) and torque the retaining bolts
4. Reinstall the fuel injector retainers (Figure 7-60, (2)) to specification.
(Figure 7-59, (2)) and torque the retaining bolts 5. Reinstall the fuel injector return line assembly
to specification. using new gaskets on each side of the injector
5. Reinstall the fuel return hoses line screws.
(Figure 7-59, (1)), one on each side of each 6. Reinstall the fuel high-pressure fuel lines to
injector. each injector and tighten the nuts using a “line”
6. Reinstall the fuel high-pressure fuel line or “flare nut” wrench.
assembly and tighten the nuts using a “line” or
“flare nut” wrench. (2)
(1)
(3)
(1)
(4)
(3)
(4)
(5)
(6)
(2) 0002092A
Figure 7-59
7. Prime the fuel system. See Priming the Fuel Figure 7-60
7. Prime the fuel system. See Priming the Fuel
8. Operate the engine and check for fuel and
coolant leaks.
8. Operate the engine and check for fuel and
coolant leaks.

Fuel injection system (for a four-valve
cylinder head)
The fuel injection system for a four-valve cylinder
head is different, not only in the nozzle valve
specifications, but also in the nozzle holder
specifications. Therefore, it is marked as follows;
take care not to install a wrong part when replacing
it with new one.
Identifying the fuel injector assembly

107.8
107.8
106.8
4TNV84T 4TNV94L,98,98T 4TNV98-Z,-E,98T-Z

Identification Identification Identification
groove: one groove: none groove: two
Figure 7-61


Section 8
COOLING SYSTEM
Page
Introduction...................................................................................... 8-6
Cooling System Diagram................................................................. 8-6
Engine Coolant Pump Components ................................................ 8-7
Engine Coolant System Check........................................................ 8-8
Engine Coolant Pump ..................................................................... 8-8
Removal of Engine Coolant Pump ............................................ 8-8
Disassembly of Engine Coolant Pump .................................... 8-10
Cleaning and Inspection .......................................................... 8-10
Reassembly of Engine Coolant Pump..................................... 8-11
Installation of Engine Coolant Pump ....................................... 8-12

COOLING SYSTEM

Before You Begin Servicing COOLING SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING
A DANGER
service it.
SCALD HAZARD! • NEVER leave the key in the key switch

• NEVER remove the radiator cap if the Someone may accidentally start the
engine is hot. Steam and hot engine engine and not realize you are
coolant will spurt out and seriously servicing it. This could result in a
burn you. Allow the engine to cool serious injury.
the radiator cap. • If you must service the engine while it
• Tighten the radiator cap securely after back long hair, and keep your hands,
you check the radiator. Steam can other body parts and clothing away
spurt out during engine operation if from moving / rotating parts.
the cap is loose.
• ALWAYS check the level of the engine or serious injury.
coolant by observing the reserve tank. 0000010en

serious injury.
0000002en
A WARNING
A WARNING
FUME / BURN HAZARD!

BURN HAZARD! hazardous substances like parts
• Wait until the engine cools before you cleaners, primers, sealants and
drain the engine coolant. Hot engine sealant removers.
• Failure to comply could result in death or serious injury.
or serious injury. 0000014en
0000016en

COOLING SYSTEM Before You Begin Servicing
A WARNING A CAUTION
BURN HAZARD!
• If you must drain the engine oil while it
PINCH HAZARD!
is still hot, stay clear of the hot engine Carefully rotate the alternator toward the
oil to avoid being burned. cylinder block while loosening the
V-belt. Failure to comply may result in
• ALWAYS wear eye protection. minor or moderate injury.
• Failure to comply could result in death 0000014en
or serious injury.
0000011en
CAUTION
• Only use the engine coolant specified.
A CAUTION Other engine coolants may affect
buildup of rust and scale and / or
shorten engine life.
FLYING OBJECT HAZARD! the surrounding area before you
• ALWAYS wear eye protection when remove the cap.
servicing the engine and when using • NEVER mix different types of engine
compressed air or high-pressure coolants. This may adversely affect the
water. Dust, flying debris, compressed properties of the engine coolant.
air, pressurized water or steam may 0000006en
injure your eyes.
• Failure to comply may result in minor CAUTION
or moderate injury.
If the engine coolant pump must be
0000003en
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant
pump or replace individual components.
0000041en

Before You Begin Servicing COOLING SYSTEM
CAUTION
Use a new special O-ring between the
engine coolant pump and the joint. Be
sure to use the special O-ring for each
engine model. Although the O-ring
dimensions are the same as a
commercially available O-ring, the
material is different.
0000042en

COOLING SYSTEM Introduction
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 4TNV84 engine
coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model
engines. For specific part detail, see the parts catalog for the engine you are working on.
COOLING SYSTEM DIAGRAM

(1)
(2)
(3)
(4)
(7)
FULL
LOW
(6)
(5)
0000573A
1 – Cylinder Head 5 – Coolant Recovery Tank

2 – Thermostat 6 – Engine Oil Cooler*
3 – Engine Coolant Pump 7 – Cylinder Block
4 – Radiator
* Not standard on all models.
Figure 8-1

Engine Coolant Pump Components COOLING SYSTEM
ENGINE COOLANT PUMP COMPONENTS
(1)
(2)
(3)
(5)
(4)
(8) (14)
(7)
(6)
(9)
(12)
(10)
(11)
(13)
0000031A-01
1 – Thermostat Cover 8 – Gasket

2 – Thermostat Cover Gasket 9 – Engine Coolant Pump Gasket
3 – Thermostat 10 – V-Belt
4 – Thermostat O-Ring 11 – Engine Coolant Pump V-Pulley
5 – Special O-Ring 12 – Spacer
6 – Engine Coolant Pump 13 – Engine Coolant Fan
7 – Temperature Switch 14 – Water temperature sensor
(Electronically controlled engine)
Figure 8-2

COOLING SYSTEM Engine Coolant System Check
ENGINE COOLANT SYSTEM 1. Before removing the engine coolant pump or

thermostat, it will be necessary to drain the
CHECK engine coolant. Drain the coolant into a clean
Check the engine coolant system for leakage. container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
1. With the radiator properly filled, install a cooling
2. Remove the radiator cap (Figure 8-4, (1)).
system tester (Figure 8-3, (1)).
3. Remove the drain plug or open the drain cock
(Figure 8-4, (1)) at the lower portion of the
radiator and drain the coolant.
(1)
(1)
0000577A
Figure 8-3
FULL
LOW
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05

kgf/cm²) to the cooling system. If the pressure
reading drops, the engine coolant system is
leaking. Identify the source of the leak and
repair it.
(2) 0000074A
ENGINE COOLANT PUMP Figure 8-4

Removal of Engine Coolant Pump 4. Drain the coolant from the engine block.
Verify the condition of the engine coolant pump • On models equipped with an oil cooler, remove
before disassembling it from the engine. Check the the coolant hose (Figure 8-5, (1)) at the oil
engine coolant pump shaft bearing for abnormal cooler.
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these conditions
are present.
CAUTION
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant
pump or replace individual components.
0000041en
IMPORTANT
Make sure the engine and engine coolant (1) 0001579B
are not hot. Figure 8-5

Engine Coolant Pump COOLING SYSTEM
• On models not equipped with an oil cooler,
remove the coolant drain plug (Figure 8-6, (1))
from the engine block.
(2) (1)
(4)
(1)
(3)
0000163B
0000027B
Figure 8-7
Figure 8-6
7. Disconnect the coolant hoses and the
5. Loosen the alternator mounting bolts. Loosen temperature switch lead wire from the engine
and remove the V-belt and rotate the alternator coolant pump.
away from the engine and out of the way.
8. Remove the engine coolant pump
A CAUTION (Figure 8-7, (4)). Discard the gasket.
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the
0000014en
6. Remove the engine coolant fan guard (if

equipped), engine coolant fan (Figure 8-7, (1)),
spacer (Figure 8-7, (2)) and engine coolant
pump V-pulley (Figure 8-7, (3)).

COOLING SYSTEM Engine Coolant Pump
Disassembly of Engine Coolant

Pump (3) (1)
1. Remove the thermostat cover (Figure 8-8, (1)).
Discard the gasket.
(2)
(1)
(4) (2)
(3) 0000577A
Figure 8-9
2. Place the temperature switch and an accurate
thermometer (Figure 8-9, (3)) in engine
coolant.
3. Slowly increase temperature of the fluid using
an external heat source.
4. The temperature switch is operating properly if
the continuity light or ohmmeter indicates
continuity when the fluid temperature reaches
225°F - 235°F (107°C - 113°C).
0000267A
Water temperature sensor
Figure 8-8 1. Inspect the water temperature sensor to make
2. Remove the thermostat (Figure 8-8, (2)). sure that it is properly operating. As shown in
Discard the O-ring. Remove the temperature the following figure, connect an electric resistor
switch (Figure 8-8, (3)) and gasket to the coupler of the water temperature sensor
(Figure 8-8, (4)). Discard the gasket. (Figure 8-10, (1)).
Cleaning and Inspection

Temperature Switch (1)
1. Check for proper operation of the temperature
(2)
switch. Connect a continuity light or ohmmeter
to the temperature switch. Connect one lead to
the terminal of the switch (Figure 8-9, (1)) and
the other lead to the metal portion of the switch
(Figure 8-9, (2)).
Figure 8-10

2. Dip the water temperature sensor and an Radiator Cap
accurate thermometer (Figure 8-10, (2)) into 1. Check for proper operation of the radiator cap.
the cooling water. Install the radiator cap (Figure 8-12, (1)) on a
3. Measure the electric resistance value while cooling system tester.
slowly raising the cooling water temperature
using an external heat source.
4. The resistance value at each of the following
temperatures is within the permissible range
specified, the water temperature sensor is
correctly operating.
(1)
Cooling water
Resistance (kΩ)
temperature (°C) 0000577A
20 2.45 +0.14
-0.13 Figure 8-12
80 0.318 ± 0.008 2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05
100 (0.1836) kgf/cm²) to the radiator cap. The radiator cap
relief valve must open within the specified
Thermostat range.
1. Check for proper operation of the thermostat.
Place the thermostat (Figure 8-11, (1)) and an Reassembly of Engine Coolant Pump
accurate thermometer (Figure 8-11, (2)) in 1. Reinstall the thermostat (Figure 8-13, (1)) and
warm water. a new O-ring.
(2)
(2)
(5) (1)
(1)
(4)
(3)
0000577A
Figure 8-11
2. Slowly increase the temperature of the water
using an external heat source.
3. The thermostat is operating properly if it starts
to open at the temperature value stamped on
the flange of the thermostat, and fully opens as 0001623A
the temperature of the water is increased.
Figure 8-13

2. Reinstall the thermostat cover

(Figure 8-13, (2)) and a new gasket. Tighten
the thermostat cover bolts.
3. Reinstall the temperature switch
(Figure 8-13, (3)) and a new gasket
(2) (3)
(Figure 8-13, (4)).
Installation of Engine Coolant Pump

1. Position the engine coolant pump on the engine
and install a new gasket. Install a new special
O-ring (Figure 8-13, (5)) on assembly between
the engine coolant pump and the joint.
CAUTION (1)
0000163C
Use a new special O-ring between the
engine coolant pump and the joint. Be Figure 8-14
sure to use the special O-ring for each
engine model. Although the O-ring 5. Inspect the condition of the V-belt. There must
dimensions are the same as a be clearance (Figure 8-15, (1)) between the
commercially available O-ring, the V-belt and the bottom of the pulley groove. If
material is different. there is no clearance (Figure 8-15, (2))
between the V-belt and the bottom of the pulley
0000042en
groove, replace the V-belt.
2. Reinstall the engine coolant pump bolts.
Tighten the bolts.
3. Inspect and reinstall the coolant hoses and the
temperature switch lead wire.
4. Reinstall the engine coolant pump V-pulley (2)
(Figure 8-14, (1)), spacer (Figure 8-14, (2))
(1)
engine coolant fan (Figure 8-14, (3)) and
engine coolant fan guard (if equipped).
0000584
Figure 8-15
6. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and Adjust Cooling
Fan V-Belt on page 5-30.
7. Reinstall and tighten the drain plug or close the
drain cock in the radiator. Reinstall and tighten
the engine block drain plug or reconnect the
coolant hose at the oil cooler.
8. Fill the radiator and engine with engine coolant.
See Drain, Flush and Refill Cooling System
With New Coolant on page 5-36.

CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
buildup of rust and scale and / or
shorten engine life.
remove the cap.
coolants. This may adversely affect the
properties of the engine coolant.
0000006en


Section 9
LUBRICATION
SYSTEM
Page
Introduction...................................................................................... 9-5
Oil Pump Service Information.......................................................... 9-5
Lubrication System Diagram ........................................................... 9-8
Checking Engine Oil Pressure ........................................................ 9-9
Trochoid Oil Pump........................................................................... 9-9
3TNV82A to 4TNV88 Oil Pump Components............................ 9-9
Disassembly of Oil Pump ........................................................ 9-10
Reassembly of Oil Pump ......................................................... 9-12
Trochoid Oil Pump......................................................................... 9-13
3TNV82A-B, 3TNV88-B, 3TNV88-U, 4TNV88-B4TNV88-U,
3TNV84T-Z, 4TNV84T-Z Oil Pump Components.................... 9-13
Cleaning and inspection .......................................................... 9-14
Trochoid Oil Pump......................................................................... 9-17
4TNV94L/98/106 Oil Pump Components ................................ 9-17

LUBRICATION SYSTEM

Before You Begin Servicing LUBRICATION SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
BURN HAZARD!
ENTANGLEMENT HAZARD! as the muffler, exhaust pipe,
• Stop the engine before you begin to turbocharger (if equipped) and engine
service it. block during operation and shortly
seriously burn you.
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000015en
back long hair, and keep your hands, A WARNING
or serious injury.
0000010en
FUME / BURN HAZARD!

sealant removers.
or serious injury.
0000014en

LUBRICATION SYSTEM Before You Begin Servicing
A CAUTION CAUTION
• Only use the engine oil specified.
coverage, cause internal engine
engine life.
• ALWAYS wear eye protection when clean the oil cap / dipstick and the
servicing the engine and when using surrounding area before you remove
compressed air or high-pressure the cap.
oil. This may adversely affect the
injure your eyes.
or moderate injury.
0000003en
0000005en
A CAUTION
If any oil pump component clearance CAUTION
If the oil pump must be replaced, replace
it as an assembly only. Do not replace
0000015en
individual components.
0000030en

Introduction LUBRICATION SYSTEM
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 3TNV82A to
4TNV88, and 4TNV94L/98/106 Trochoid oil pumps.
See Replace Engine Oil and Engine Oil Filter on page 5-28 for engine oil and engine oil filter replacement
procedures.
OIL PUMP SERVICE INFORMATION

Engine Oil Pressure
At Rated Engine RPM
Model 1500 - 1800 2000 - 2500 2600 2700 2800 2900 - 3000 At Low Idle Speed
min-1 min-1 min-1 min-1 min-1 min-1
0.34 - 0.49MPa 0.39 - 0.54MPa
3TNV82A
(3.5 - 5.0kgf/cm2) (4.0 - 5.5kgf/cm2)
0.31 - 0.46MPa 0.36 - 0.51MPa
3TNV82A-B -
(3.2 - 4.7kgf/cm2) (3.7 - 5.2kgf/cm2)
3TNV84
3TNV88 0.34 - 0.49MPa 0.39 - 0.54MPa
4TNV84 (3.5Å`5.0kgf/cm2) (4.0 - 5.5kgf/cm2)
4TNV88
3TNV88-B 0.29 - 0.44MPa 0.34 - 0.49MPa 0.39 - 0.54MPa
3TNV88-U (3.0 - 4.5kgf/cm2) (3.5 - 5.0kgf/cm2) (4.0 - 5.5kgf/cm2)
4TNV88-B 0.29 - 0.44MPa 0.32 - 0.47MPa
4TNV88-U (3.0 - 4.5kgf/cm2) (3.3 - 4.8kgf/cm2) 0.06MPa
3TNV84T 0.29 - 0.44MPa 0.34 - 0.49MPa 0.39 - 0.54MPa (0.6kgf/cm2)
3TNV84T-Z (3.0 - 4.5kgf/cm2) (3.5 - 5.0kgf/cm2) (4.0 - 5.5kgf/cm2) or greater
4TNV84T 0.29 - 0.44MPa 0.36 - 0.51MPa

4TNV84T-Z (3.0 - 4.5kgf/cm2) (3.7 - 5.2kgf/cm2)
4TNV94L
4TNV98
4TNV98-Z 0.29 - 0.39MPa
4TNV98-E (3.0 - 4.0kgf/cm2)
4TNV98T
4TNV98T-Z
With balancer: Without balancer:
4TNV106 0.31 - 0.49MPa
0.34 - 0.44MPa 0.39 - 0.49MPa
4TNV106T (3.2 - 5.0kgf/cm2)
(3.5 - 4.5kgf/cm2) (4.0 - 5.0kgf/cm2)

LUBRICATION SYSTEM Oil Pump Service Information
Outer Rotor Outside Clearance

Reference
Model Standard Limit
Page
Check Outer
3TNV82A, 3TNV84, 3TNV84T
0.0047 - 0.0083 in. 0.0118 in. Rotor Outside
3TNV88, 4TNV84, 4TNV88,
(0.12 - 0.21 mm) (0.30 mm) Clearance on
4TNV84T
page 9-11
3TNV82A-B Check Outer
3TNV88-B, 3TNV88-U 0.0035 - 0.0063 in. 0.0098 in. Rotor Outside
4TNV88-B, 4TNV88-U (0.09 - 0.16 mm) (0.25 mm) Clearance on
3TNV84T-Z, 4TNV84T-Z page 9-14
0.0039 - 0.0061 in. 0.0098 in. Check Outer
4TNV98-Z, 4TNV98-E
(0.100 - 0.155 mm) (0.25 mm) Rotor Outside
4TNV98T-Z
Clearance on
0.0039 - 0.0065 in. 0.0098 in. page 9-18
4TNV106, 4TNV106T
(0.100 - 0.165 mm) (0.25 mm)
Outer Rotor Side Clearance

Model Standard Limit Reference Page
3TNV82A, 3TNV84, 3TNV84T
0.0008 - 0.0028 in. 0.0047 in. Check Outer Rotor Side
3TNV88, 4TNV84, 4TNV88,
(0.02 - 0.07 mm) (0.12 mm) Clearance on page 9-12
4TNV84T
3TNV82A-B
3TNV88-B, 3TNV88-U 0.0020 - 0.0039 in. 0.0059 in. Check Outer Rotor Side
4TNV88-B, 4TNV88-U (0.05 - 0.10 mm) (0.15 mm) Clearance on page 9-15
0.0020 - 0.0039 in. 0.0059 in.
4TNV98-Z, 4TNV98-E
(0.05 - 0.10 mm) (0.15 mm) Check Outer Rotor Side
4TNV98T-Z
Clearance on page 9-18
0.0012 - 0.0047 in. 0.0067 in.
4TNV106, 4TNV106T
(0.03 - 0.12 mm) (0.17 mm)
Outer Rotor to Inner Rotor Tip Clearance

Model Standard Limit Reference Page
3TNV82A, 3TNV84, 3TNV84T Outer Rotor to Inner
0.0063 in.
3TNV88, 4TNV84, 4TNV88, - Rotor Tip Clearance on
(0.16 mm)
4TNV84T page 9-11
3TNV82A-B
Outer Rotor to Inner
3TNV88-B, 3TNV88-U 0.0063 in.
- Rotor Tip Clearance on
4TNV88-B, 4TNV88-U (0.16 mm)
page 9-15
0.0063 in.
4TNV98-Z, 4TNV98-E - Outer Rotor to Inner
(0.16 mm)
4TNV98T-Z Rotor Tip Clearance on
0.0063 in. page 9-18
4TNV106, 4TNV106T -
(0.16 mm)

Oil Pump Service Information LUBRICATION SYSTEM
Inner Rotor and Gear Boss Clearance
<Multiple tooth trochoid type 3TNV82A - 4TNV88>
Standard
Standard Standard Reference
Item Parts Clearance
Dimension Clearance Page
Limit
2.0886 - 2.0925 in.
Gear Boss Diameter
Inside Clearance of (53.05 - 53.15 mm) 0.012 - 0.020 in. 0.024 in.
Inner Rotor 2.1043 - 2.1083 in. (0.3 - 0.5 mm) (0.6 mm) Check Inner
Rotor Diameter Rotor and
(53.45 - 53.55 mm)
Gear Boss
Width Across Flat of 1.9468 - 1.9587 in. Clearance on
Inner Rotor Width Gear Boss (49.45 - 49.75mm) 0.008 - 0.020 in. 0.028 in. page 9-12
Across Flat
Width Across Flat of 1.9665 - 1.9705 in. (0.2 - 0.5 mm) (0.7 mm)
Clearance
Rotor (49.95 - 50.05 mm)
Rotor Shaft Clearance

<Trochoid type 3TNV82A-B - 4TNV88-B, 4TNV94L - 4TNV106T>
Reference
Page
0.3937 - 0.3943 in. 0.3953 in.
3TNV82A-B ÉvÉåÅ[ÉgéðéÛì‡åa
(10.000 - 10.015 mm) (10.040 mm) Check Rotor
3TNV88-B, 3TNV88-U
0.3919 - 0.3924 in. 0.3913 in. Shaft
4TNV88-B, 4TNV88-U Rotor Shaft O.D.
(9.955 - 9.967 mm) (9.940 mm) Clearance on
3TNV84T-Z, 4TNV84T-
0.0013 - 0.0024 in. 0.0039 in. page 9-15
Z Rotor Clearance
(0.033 - 0.060 mm) (0.100 mm)
0.5110 - 0.5126 in. 0.5138 in.
ÉMÉÑÉPÅ[ÉXéðéÛì‡åa
4TNV94L, 4TNV98, (12.980 - 13.020 mm) (13.050 mm)
4TNV98T 0.5100 - 0.5104 in. 0.5096 in.
Rotor Shaft O.D.
4TNV98-Z, 4TNV98-E (12.955 - 12.965 mm) (12.945 mm)
4TNV98T-Z 0.0006 - 0.0026 in. 0.0041 in.
Rotor Clearance Check Rotor
(0.015 - 0.065 mm) (0.105 mm) Shaft
0.5118 - 0.5126 in. 0.5138 in. Clearance on
ÉMÉÑÉPÅ[ÉXéðéÛì‡åa page 9-19
(13.000 - 13.020 mm) (13.050 mm)
0.5100 - 0.5104 in. 0.5096 in.
4TNV106, 4TNV106T Rotor Shaft O.D.
(12.955 - 12.965 mm) (12.945 mm)
0.0014 - 0.0026 in. 0.0041 in.
Rotor Clearance
(0.035 - 0.065 mm) (0.105 mm)

LUBRICATION SYSTEM Lubrication System Diagram
LUBRICATION SYSTEM DIAGRAM
Oil Filter
Turbocharger*
Bypass Valve
Oil Cooler* Fuel

Injection Pump
Oil Pressure
Switch
Cylinder Body - Main Gallery

Pressure
Regulator Valve
Idle Gear Camshaft Crank
Oil Pump Shaft Bearing Journal
Piston Cooling Rocker Arm Crank Pin

Oil Suction Pipe Nozzles* Bearing
Strainer
Rocker Arm
Tappet
Cam Face
Oil Pan
0000042
Figure 9-1
Note: Items marked * are not standard equipment on all models.

Checking Engine Oil Pressure LUBRICATION SYSTEM
CHECKING ENGINE OIL TROCHOID OIL PUMP

PRESSURE
3TNV82A TO 4TNV88 Oil Pump
Perform an engine oil pressure check if there is any
indication of low oil pressure such as the oil
Components
pressure indicator is on or the oil pressure gauge On these model engines, the oil pump is located
indicates low oil pressure. See Engine Oil Pressure inside the front gear case cover and is driven by a
on page 9-5. boss on the front crankshaft gear. You must remove
the front gear case cover to gain access to the oil
1. Disconnect the wire lead from the oil pressure pump.
switch or sending unit (Figure 9-2, (1)).
(1)
(2) (5) (6)
(1) (3)
(4)
0000028B
0000075A
Figure 9-2
2. Remove the oil pressure switch. 1 – Crankshaft
2 – Oil Pump Cover
3. Install a mechanical oil pressure gauge in the 3 – Oil Pressure Regulator
oil pressure switch port. 4 – Gear Case Cover
4. Start the engine: 5 – Outer Rotor
6 – Inner Rotor
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty Figure 9-3
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 Failure Diagnosis Table
on page 15-191. Repair as necessary.

LUBRICATION SYSTEM Trochoid Oil Pump
Disassembly of Oil Pump (1) (2)
CAUTION
0000030en
1. Remove the engine cooling fan guard (if

equipped), engine cooling fan (Figure 9-4, (3)),
spacer (Figure 9-4, (2)), engine coolant pump
V-pulley (Figure 9-4, (1)) and V-belt.
0001625
Figure 9-5
4. Remove the oil pump cover (Figure 9-5, (1))
(2) (3)
from the gear case cover.
5. Remove the outer rotor (Figure 9-6, (2)) and
inner rotor (Figure 9-6, (1)) from the gear case
cover.
(2)
(1)
(1)
0000163C
Figure 9-4
2. Remove the crankshaft pulley and gear case
cover. See Removal of Timing Gear Case
Cover on page 6-73.
3. Remove the seven oil pump cover
(Figure 9-5, (1)) screws (Figure 9-5, (2)). 0001626
Note: The oil pump cover screws are installed

Figure 9-6
using a liquid thread lock. It may be
necessary to use a “localized heat”
(small propane torch) and an
impact-type screwdriver or air tool to
remove these screws.

Trochoid Oil Pump LUBRICATION SYSTEM
6. Remove the oil pressure regulator valve Record the measurement(s) and see Outer
(Figure 9-7, (1)) from the oil pump cover Rotor Outside Clearance on page 9-6 for the
(Figure 9-7, (2)). service limits.
(1)
(2)
(2)
(1) 0001151A
Figure 9-8
0001642
Figure 9-7
Determine the outer rotor to inner rotor tip
Cleaning and Inspection clearance. Insert a feeler gauge between the top of
an inner rotor tooth (Figure 9-9, (1)) and the top of
Wash the oil pump cover, the oil pressure regulator
an outer rotor tooth (Figure 9-9, (2)) and measure
valve, the oil pump cavity and the inner and outer
the clearance.
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.
A CAUTION
(1)
If any oil pump component clearance
0000015en
(2) 0001150A
Check Outer Rotor Outside Clearance
Figure 9-9
1. Reinstall the outer and inner rotors. The dots on
the rotor faces must face “up.” Make sure that Record the measurement(s) and see Outer Rotor
the pilot on the back of the inner rotor fits into to Inner Rotor Tip Clearance on page 9-6 for the
the bore of the oil pump cavity and the top service limits.
surface of the inner rotor is flush with the top
surface of the outer rotor.
2. Determine the outside clearance of the outer
rotor. Insert a feeler gauge between the outer
rotor (Figure 9-8, (1)) and the gear case oil
pump cavity (Figure 9-8, (2)).

Check Outer Rotor Side Clearance Record the measurement(s) and see Inner Rotor
Determine the side clearance of the outer rotor and Gear Boss Clearance <Multiple tooth trochoid
across the pump cavity. While pressing down on type 3TNV82A - 4TNV88> on page 9-7 for the
the outer rotor, measure the depression using a service limits.
depth micrometer (Figure 9-10).
Reassembly of Oil Pump
1. Lubricate the outer rotor (Figure 9-12, (1)),
10
25 20 15
inner rotor (Figure 9-12, (2)) and pump bore in

the gear case cover with clean engine oil.
(5)
(3)
0001152 (1)
(2)
Figure 9-10
Record the measurement(s) and see Outer Rotor
Outside Clearance on page 9-6 for the service
limits.
Check Inner Rotor and Gear Boss (4)

Clearance 0000044A
Using appropriate measuring instruments, measure Figure 9-12

the outside dimensions of the crankshaft gear boss
and the inside dimensions of the inner rotor 2. Reinstall the outer rotor in the gear case. The
(Figure 9-11). dot mark on the face of the outer rotor must
face up toward the oil pump cover.
(5) 3. Reinstall the inner rotor into the gear case cover
with the dot mark also facing up. Make sure that
(3) the pilot on the back side of the inner rotor fits
into the bore in the gear case cover and the top
surface of the inner rotor is flush with the top
surface of the outer rotor.
4. Reinstall the oil pressure regulator valve into
the oil pump cover. Apply LOCTITE® 242 (red)
(1) (6) to the valve plug. (Follow LOCTITE package
(4)
(2) instructions.)
0000076A
5. Reinstall the oil pump cover (Figure 9-12, (3)).
1 – Crank Gear Apply LOCTITE 290 (green) or LOCTITE 262
2 – Inner Rotor (red) to the oil pump cover screws. (Follow
3 – Inside Width Across Flats of Inner Rotor
LOCTITE package instructions.) Tighten the
4 – Overall Inside Diameter of Inner Rotor
pump cover screws to 61 ± 13 in·lb
5 – Outside Width Across Flats of Gear Boss
6 – Overall Outside Diameter of Gear Boss (6.9 ± 1.5 N·m, 0.7 ± 0.15 kgf·m).
Figure 9-11

6. Reinstall the gear case cover and crankshaft TROCHOID OIL PUMP
pulley. See Installation of Gear Case Cover on
page 6-97. 3TNV82A-B, 3TNV88-B, 3TNV88-
7. Reinstall the engine coolant pump V-pulley
(Figure 9-13, (1)), spacer (Figure 9-13, (2)),
U, 4TNV88-B4TNV88-U,
engine cooling fan (Figure 9-13, (3)) and 3TNV84T-Z, 4TNV84T-Z Oil Pump
engine cooling fan guard (if equipped). Components
The oil pump on these model engines is located in
the front gear case and is driven by the same gear
train that drives the camshaft and fuel injection
(2) (3) pump. You must remove the front gear case cover
to gain access to the oil pump.
(3) (7) (1) (2) (6)
(1)
0000163C
Figure 9-13
8. Reinstall the V-belt. Tighten the V-belt to the (5) (4)
proper tension as described in Check and
Adjust Cooling Fan V-Belt on page 5-22.
1 – Body
2 – Shaft
3 – Inner rotor
4 – Outer rotor
5 – Cover
6 – Drive gear
7 – Pressure regulator valve
Figure 9-14

Disassembly of Oil Pump
CAUTION
0000030en
Remove the cooling water fan guard (if equipped),

cooling fan (Figure 9-15, (3)), spacer
(Figure 9-15, (2)), cooling water pump V-pulley
(Figure 9-15, (1)), and V-belt.
(1)
(2) (3)
(2)
Figure 9-16
Cleaning and inspection

Clean the lubricating oil pump, pressure regulator
(1) valve (Figure 9-14, (7)), and rotor inserting portion.
0000163C
Check the parts for wear or flaw. Replace the parts
Figure 9-15 with new ones as needed.
1. Remove the crank shaft pulley and gear case
cover. See Removal of Timing Gear Case CAUTION
Cover on page 6-73. • NEVER overfill the engine with engine
2. Remove the lubricating oil pump assembly oil.
mounting bolts. Remove the lubricating oil • ALWAYS keep the oil level between the
pump assembly (Figure 9-16, (1)) from the upper and lower lines on the oil
gear case flange (Figure 9-16, (2)). cap / dipstick.
3. You can remove by hand the lubricating oil 0000015en
pump cover (Figure 9-14, (5)) and outer rotor

(Figure 9-14, (4)). Check Outer Rotor Outside Clearance
Inspect the outside diameter clearance of the outer
rotor. To inspect this, insert a feeler gauge between
the outer rotor (Figure 9-17, (1)) and the lubricating
oil pump body (Figure 9-17, (2)).

to Inner Rotor Tip Clearance on page 9-6 for the
(1) service limits.
Check Outer Rotor Side Clearance

Inspect the side clearance between the lubricating
oil pump body and the outer rotor. To measure the
side clearance, use a straight edge and feeler
gauge (as shown in Figure 9-19) or a depth
(2) micrometer.
Figure 9-17
limits.

Inspect the tip clearance between the outer and
inner rotors. To inspect this, insert a feeler gauge
between the inner rotor tooth tip (Figure 9-18, (1))
and the outer rotor tooth tip (Figure 9-18, (2)), and
measure the clearance. Figure 9-19
limits.
(1)
Check Rotor Shaft Clearance
Inspect the rotor shaft clearance. Measure the
outside diameter of the rotor shaft
(Figure 9-20, (1)) and the inside diameter of the
cover.
Determine the clearance by subtracting the outside
diameter of the rotor from the inside diameter of the
(2) cover.
Figure 9-18

(1)
(2) (3)
(2)
Figure 9-20
Record the measurement(s) and see Rotor Shaft (1)
0000163C
Clearance <Trochoid type 3TNV82A-B - 4TNV88-B,
4TNV94L - 4TNV106T> on page 9-7 for the service Figure 9-21
limits. 8. Install the V-belt. Adjust the belt to uniform
tensile strength in accordance with the
Reassembly of Oil Pump instructions given in Check and Adjust Cooling
1. Apply clean lubricating oil to the lubricating oil Fan V-Belt on page 5-22.
pump body and inner rotor assembly as well as
to the outer rotor.
2. Insert the outer rotor into the lubricating oil
pump body and inner rotor assembly and install
the cover.
3. Replace the packing with new one.
4. Install the lubricating oil pump assembly to the
gear case flange by tightening the bolts with
the specified torque.
5. Install the gear case cover. For more
information, See Installation of Gear Case
Cover on page 6-97.
6. Install the crank shaft pulley.
7. Install the cooling water pump V-pulley
(Figure 9-21, (1)), spacer (Figure 9-21, (2)),
cooling water fan (Figure 9-21, (3)), and fan
guard (if equipped).

TROCHOID OIL PUMP Disassembly of Oil Pump
4TNV94L/98/106 Oil Pump CAUTION

Components If the oil pump must be replaced, replace
The oil pump on these model engines is located in individual components.
the front gear case and is driven by the same gear
0000030en
train that drives the camshaft and fuel injection
pump. You must remove the front gear case cover Remove the engine cooling fan guard (if equipped),
to gain access to the oil pump. engine cooling fan (Figure 9-23, (3)), spacer
(Figure 9-23, (2)), engine coolant pump V-pulley
(Figure 9-23, (1)) and V-belt.
(1)
(2)
(5)
(2) (3)
(3)
(4) 0000043A
1 – Gear Case Housing

2 – Outer Rotor
3 – Inner Rotor
4 – Cover Plate
5 – Drive Gear (1)
0000163C
Figure 9-22
Figure 9-23
1. Remove the crankshaft pulley and the gear
case cover. See Removal of Timing Gear Case
Cover on page 6-73.
2. Remove the oil pump assembly bolts. Remove
the oil pump assembly (Figure 9-24, (1)) from
the gear case housing (Figure 9-24, (2)).


Determine the outer rotor to inner rotor tip
clearance. Insert a feeler gauge between the top of
an inner rotor tooth (Figure 9-26, (1)) and the top
of an outer rotor tooth (Figure 9-26, (2)) and
measure the clearance.
(1)
(1)
(2)
(2) 0000049D
Figure 9-24

Wash the oil pump, oil pressure regulator and oil
pump cavity. Inspect for wear or damage. Replace 0001153A
as necessary.
Figure 9-26
A CAUTION Record the measurement(s) and see Outer Rotor

If any oil pump component clearance to Inner Rotor Tip Clearance on page 9-11 for the
exceeds its limit, the oil pump must be service limits.
Check Outer Rotor Side Clearance
0000015en
Determine the side clearance of the outer rotor
Check Outer Rotor Outside Clearance across the pump cavity. Measure the depression
using a depth micrometer (Figure 9-27, (1)).
Determine the outside clearance of the outer rotor.
Insert a feeler gauge between the outer rotor
(Figure 9-25, (1)) and gear case oil pump cavity (1)
(Figure 9-25, (2)).
(1)
(2)
0000045A
Figure 9-25 0001615A
Figure 9-27
Record the measurement(s) and see Check Outer
Rotor Outside Clearance on page 9-11 for the Record the measurement(s) and see Check Outer
service limits. Rotor Side Clearance on page 9-12 for the service
limits.

Check Rotor Shaft Clearance 3. Reinstall the oil pump assembly
Determine the rotor shaft clearance. Measure the (Figure 9-30, (1)) into the gear case housing
outside diameter of the rotor shaft (Figure 9-30, 2). Tighten the bolts to specified
(Figure 9-28, (1)) and the bore diameter in the gear torque.
case housing (Figure 9-28, (2)).
Calculate the difference between the two
measurements to determine the clearance.
(1)
(1)
(2) 0000049D
Figure 9-30
(2) 4. Reinstall the gear case cover and crankshaft
0000047A pulley. See Installation of Gear Case Cover on
Figure 9-28 page 6-97.
5. Reinstall the engine coolant pump V-pulley
Record the measurement(s) and see Rotor Shaft (Figure 9-31, (1)), spacer (Figure 9-31, (2)),
Clearance <Trochoid type 3TNV82A-B - 4TNV88-B, engine cooling fan (Figure 9-31, (3)) and
4TNV94L - 4TNV106T> on page 9-7 for the service engine cooling fan guard (if equipped).
limits.
Reassembly of Oil Pump

1. Lubricate the outer rotor and pump bore in the
gear case with clean engine oil. (2) (3)
2. Reinstall the outer rotor in the gear case
housing. The punch mark (Figure 9-29, (1)) on
the end of the outer rotor must face away from
the gear case housing (Figure 9-29, (2)).
(1)
0000163C
Figure 9-31
1
0000048A Adjust Cooling Fan V-Belt on page 5-22.
Figure 9-29


Section 10
TURBOCHARGER
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-5
Specifications ................................................................................ 10-5
Turbocharger Service Information ........................................... 10-5
Troubleshooting............................................................................. 10-6
Excessive Exhaust Smoke ...................................................... 10-6
Generates White Smoke ......................................................... 10-7
Sudden Oil Decrease .............................................................. 10-7
Decrease in Output.................................................................. 10-7
Poor (Slow) Response (Starting) of Turbocharger .................. 10-7
Abnormal Sound or Vibration .................................................. 10-7
Turbocharger Components ........................................................... 10-8
Turbocharger Component Functions........................................... 10-10
Theory of Operation............................................................... 10-11
Compressor Side Sealing Mechanism .................................. 10-11
Waste Gate Modulation ......................................................... 10-11
Washing Procedure..................................................................... 10-12
Periodic Inspection ...................................................................... 10-13
Visual Inspection ................................................................... 10-13
Inspection of Rotor Rotation .................................................. 10-13
Inspection of Rotor Play ........................................................ 10-13
Removal of Turbocharger...................................................... 10-13
Checking Rotor Play.............................................................. 10-14
Waste Gate Valve Test.......................................................... 10-14
Waste Gate Actuator Leak Test ............................................ 10-15
Installation of Turbocharger................................................... 10-15

TURBOCHARGER

Before You Begin Servicing TURBOCHARGER
BEFORE YOU BEGIN

A WARNING
SERVICING Never apply over 40 psi (2.8 kgf/cm) to
the waste gate actuator.
A WARNING 0000026en
A CAUTION
service it.
Someone may accidentally start the • ALWAYS wear eye protection when
engine and not realize you are servicing the engine and when using
servicing it. This could result in a compressed air or high-pressure
serious injury. water. Dust, flying debris, compressed
injure your eyes.
back long hair, and keep your hands, • Failure to comply may result in minor
other body parts and clothing away or moderate injury.
from moving / rotating parts. 0000003en

or serious injury. CAUTION
0000010en For maximum engine life, Yanmar
recommends that when shutting the
A WARNING engine down, you allow the engine to
idle, without load, for five minutes. This
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
FUME / BURN HAZARD!
0000008en
sealant removers.
or serious injury.
0000014en

TURBOCHARGER Before You Begin Servicing
CAUTION
Avoid damage to the turbocharger or the
engine. Do not spray blower wash fluid
or water too quickly.
Use short strokes from a spray bottle to
inject blower wash fluid or water into the
turbocharger.
Spraying too much wash fluid or water,
or spraying too quickly will damage the
turbocharger.
0000063en
CAUTION
Do not allow any material to fall into the
oil lines or the oil inlet and outlet ports
of the turbocharger.
0000064en
CAUTION
If the waste valve does not meet
specifications, replace the turbocharger
or have it repaired by a qualified repair
facility.
0000078en

Introduction TURBOCHARGER
INTRODUCTION
This section of the Service Manual describes the servicing of the RHF5, RHB31 and RHB51 model
turbochargers.
SPECIFICATIONS
Turbocharger Service Information
3TNV84T (CL,
4TNV106T
Applicable Engine Model (application) VM) 3TNV84T (VM) 4TNV98T
(CL, VM)
4TNV84T (CL)
Turbocharger Model RHB31 RHB51 RHF5 RHF5
Turbocharger Specification Standard (w/waste gate)
Turbine Type Radial flow
Blower (Compressor) Type Centrifugal
Lubrication External lubrication
Maximum Continuous Allowable Speed 250,000 180,000
Maximum Continuous Allowable Gas Inlet
750°F (399°C)
Temperature
5.4 lb 9.2 lb 10.3 lb 10.3 lb
Weight (Dry)
(24 N; 2.4 kgf) (41 N; 4.2 kgf) (46 N; 4.7 kgf) (46 N; 4.7 kgf)
Note: VM application is provided with the waste gate.

TURBOCHARGER Troubleshooting
TROUBLESHOOTING
The following troubleshooting procedures apply to problems identified as turbocharger related. Consider all
other troubleshooting possibilities before cleaning or removing the turbocharger.
Excessive Exhaust Smoke

Cause Corrective action
Clogged air cleaner element Clean or replace the air cleaner element
Blocked air intake port Correct the condition
Leak from a joint in intake line Correct the condition

1. Compressor impeller dirty
1. Wash the impeller blades.
2. Deposit of impurities in oil sticking on the turbine side seal
2. Repair the turbocharger. Send to a qualified repair facility.
portion to make turbine revolution heavy
3. Sticking bearing:
3a. Repair turbocharger. Send to qualified repair facility.
3a. Insufficient lubrication or clogged lubrication piping
3b. Inspect the lubricating oil line for problem. Correct the
3b. Excessively high oil temperature
condition and replace lubricating oil.
3c. Repair the turbocharger. Send to a qualified repair
3c. Unbalanced rotating part
facility.
3d. Improper operation of the machine. Refer to the
3d. Insufficient warming up or sudden stop from loaded
Operation Manual.
operation (no-load operation)
4. Contact or breakdown of turbine wheel or blower vane: 4a. Inspection and repair of each engine part
4a. Excessive revolution 4b. Inspection and repair of each engine part
4b. Excessive exhaust temperature rise 4c. Clean the air cleaner and engine compartment. Repair
4c. Foreign matter within turbocharger the turbocharger. Send to a qualified repair facility.
4d. Repair the turbocharger. Send to a qualified repair
4d. Worn bearing facility.
4e. Repair the turbocharger. Send to a qualified repair
4e. Incorrect assembly of turbocharger facility.

Exhaust system gas leak prior to the turbocharger. Condition
Inspect the exhaust system for leaks. Correct the condition.
will decrease turbocharger revolutions.
Deformed or clogged exhaust pipe. Condition will decrease
Correct the condition.
turbocharger revolutions.

Troubleshooting TURBOCHARGER
Generates White Smoke
Clogged or deformed oil return pipe causing oil flow to the Correct the condition
blower on the turbine side
Excessive bearing wear causing abnormal wear or damage of
the seal ring Repair the turbocharger. Send to a qualified repair facility.
Sudden Oil Decrease

Excessive bearing wear causing abnormal wear or damage of
Repair turbocharger. Send to qualified repair facility.
the seal ring
Decrease in Output
Gas leak from any part in exhaust piping Correct the condition
Air leak from discharge side of blower Correct the condition
Clogged air cleaner element Clean or replace the air cleaner element
Damaged turbocharger Repair the turbocharger. Send to a qualified repair facility
Poor (Slow) Response (Starting) of

Turbocharger
Hard carbon deposit on the turbine side (wheel sealing portion)
Repair the turbocharger. Send to a qualified repair facility
causing abnormal revolution of the turbine shaft
Incomplete combustion Correct the condition
Abnormal Sound or Vibration

Excessively narrowed gas path due to clogged nozzle in the
turbine wheel chamber or reverse flow of blower discharge in Repair the turbocharger. Send to a qualified repair facility
acceleration (generally called surging)
Contact rotating part Repair the turbocharger. Send to a qualified repair facility

Loosened intake, exhaust or oil pipe connection with the
Correct the condition
turbocharger
Damaged bearing, contact between rotating part and adjacent
part, or chipping of the turbine wheel or blower vane due to Repair the turbocharger. Send to a qualified repair facility
foreign matter within the turbocharger
Unbalanced rotating part Repair the turbocharger. Send to a qualified repair facility

TURBOCHARGER Turbocharger Components
TURBOCHARGER COMPONENTS
Note: The following illustration is provided for informational purposes only. Yanmar does not offer individual
service parts for turbochargers. If the turbocharger is worn or damaged, it should be replaced or
repaired by a qualified repair facility.
(12)
(15)
(14) (8) (7)
(13) (9)
(4)
(5)
(11) (3) (22)
(2) (23)
(20) (21)
(28)
(10) (29)
(24)
(27)
(6)
(19)
(1) (29)
(14)
(13)
(17)
(18) (26)
(16) (32)
(25) (31) (30)
0000078A
Figure 10-1

Turbocharger Components TURBOCHARGER
1 – Turbine Shaft 17 – Bolt
2 – Thrust Bearing 18 – Lock Plate
3 – Oil Thrower 19 – Bearing Housing
4 – Seal Ring 20 – Retaining Ring
5 – Seal Ring 21 – Bolt
6 – Seal Ring (Turbine Side) 22 – Bolt
7 – Lock Nut 23 – Lock Washer
8 – Impeller 24 – Heat Protector
9 – Seal Plate 25 – Liquid Gasket
10 – Journal Bearing 26 – Waste Gate Actuator
11 – Thrust Bearing 27 – Hose
12 – Compressor Housing 28 – Adapter
13 – Flanged Bolt 29 – Clip
14 – Spring Washer 30 – Retaining Ring
15 – Clamp 31 – Waste Gate Valve
16 – Turbine Housing 32 – Link Plate

TURBOCHARGER Turbocharger Component Functions
TURBOCHARGER COMPONENT FUNCTIONS

D
(13) (14) (12) (15) (8) (9) (10) (17)
B C
(19)
(18)
F
(2)
(11) (1) (20) (3) (5) (16) (6) (4) (7)
A 0000077A
1 – Turbine Shaft 11 – Turbine Housing

2 – Oil Thrower 12 – M6 Hex Bolt
3 – Turbine Side Seal Ring 13 – Turbine Side Clamp
4 – Seal Plate 14 – Lock Washer
5 – Journal Bearing 15 – Bearing Housing
6 – Thrust Bearing 16 – Retaining Ring
7 – Compressor Housing 17 – M3 Countersunk Flat-Head Bolt
8 – M5 Hex Bolt 18 – Compressor Wheel
9 – M5 Spring Washer 19 – Shaft End Nut
10 – Compressor Side Clamp 20 – Heat Protector
A. Exhaust Gas Inlet D. Air Outlet

B. Exhaust Gas Outlet E. Oil Inlet
C. Air Inlet F. Oil Outlet
Figure 10-2

Turbocharger Component Functions TURBOCHARGER
Theory of Operation Bearings
Normally aspirated engines produce horsepower Thrust Bearing
that is limited by the atmospheric pressure of the A thrust force is continuously imposed on the
induction air. The turbocharger is an exhaust gas turbine shaft during engine operation. A thrust
pressure driven device that adds to the bearing prevents the shaft from moving laterally
atmospheric pressure, resulting in a boost in under this thrust force.
pressure at the combustion chambers. This
substantially increases the amount of fuel that can Radial Bearing
be injected into the combustion chambers, while A floating radial bearing moves with the turbine
maintaining the proper fuel-to-air ratio. A slight shaft as oil films form on the inside and outside
parasitic loss is imposed on the engine because of bearing surfaces. The bearing slipping speed is
added back pressure in the exhaust system. That slower than the turbine shaft speed, resulting in
loss is offset by horsepower gains. The net result is higher dynamic stability and reduced mechanical
substantially increased overall horsepower over noise.
normally aspirated engines.
Lubrication
The turbocharger consists of two main
components: The oil pump delivers oil from the engine to the
turbocharger for cooling and lubrication of the
• Turbine bearings. As oil leaves the turbocharger, it is
• Compressor returned to the engine.
Turbine Compressor Side Sealing Mechanism

The turbine is driven by exhaust gas pressure from A seal ring and a seal plate form a double wall
the engine and is coupled to a shaft on the structure at the rear of the compressor impeller.
compressor side of the turbocharger. The seal ring and seal plate prevent Intake air and
oil leakage.
Exhaust gas velocity is accelerated at the nozzle
portion in the turbine housing where the Waste Gate Modulation
cross-sectional area is reduced. As exhaust passes
Excessive boost pressure that cannot be
over the turbine impeller at high linear velocity, the
accommodated by the engine can damage the
turbine shaft is rotated at proportionally high rpm.
turbocharger. The waste gate is a component that
Compressor monitors intake boost pressure on the compressor
side and diverts exhaust gases around the
The compressor is driven by a shaft on the turbine turbocharger turbine. The amount of exhaust gas
side of the turbocharger and increases the diverted is varied to limit turbine rpm and maintain
induction air pressure at the intake manifold. the intake pressure equal to, or less than the
The compressor impeller draws induction air into specified maximum level. This improves the
the turbocharger, compresses it and directs it into response to load variation in the low to medium rpm
the engine at high pressure. range and minimizes black smoke.
A seal ring and heat insulating plate thermally Waste Gate Control
isolate heat energy, at the turbine side, from the A mechanical pressure sensor in the outlet of the
bearings and the induction air, at the compressor compressor side of the turbocharger opens and
side. closes the waste gate to maintain the specified
intake pressure at the intake manifold.

TURBOCHARGER Washing Procedure
WASHING PROCEDURE
Note: Inspection, cleaning and repair of the
internal turbocharger components must
be performed by a qualified repair facility.
The washing procedure described in this section is
intended to clean the impeller on the compressor
only if the engine loses rpm, seems sluggish or has
insufficient boost pressure. The process does not
require disassembling any portion of the
turbocharger.
Since washing is quick and easy, perform this
procedure before considering replacement.
1. Start the engine and allow it to reach the
0000860
normal operating temperature.
Figure 10-3
CAUTION
3. Continue to operate the engine under the same
Avoid damage to the turbocharger or the
load for three to four minutes.
engine. Do not spray blower wash fluid
or water too quickly. 4. While the engine is still operating at normal load
(75 - 80% of maximum), slowly and evenly
Use short strokes from a spray bottle to spray 2 - 3 oz (60 - 90 cc) of clean water over a
inject blower wash fluid or water into the period of ten to fifteen seconds into the air inlet.
turbocharger.
5. Continue to operate the engine under the same
Spraying too much wash fluid or water, load for at least ten minutes to completely dry
or spraying too quickly will damage the the air intake system and turbocharger.
turbocharger.
6. Test the engine performance. If engine
0000063en
performance has not improved, repeat steps 2
2. While the engine is operating at normal load through 6. If the engine performance does not
(75 - 80% of maximum), slowly and evenly improve after executing the washing process
spray 2 - 3 oz (60 - 90 cc) of blower wash fluid three times, replace the turbocharger or have it
over a period of ten to fifteen seconds into the repaired by a qualified repair facility.
air inlet (Figure 10-3).

Periodic Inspection TURBOCHARGER
PERIODIC INSPECTION
Inspect the turbocharger at regularly scheduled intervals.
Inspection interval
Application
200 hours 400 hours 500 hours 800 hours 1000 hours 2000 hours
First 6 First 12 Every 24
Construction Equipment months months months
or 500 hrs or 1000 hrs or 2000 hrs
First 6 First 12 Every 24
Farm Equipment months months months
or 200 hrs or 400 hrs or 800 hrs
Engine Oil and Filter Replacement Based on engine operation manual
Visual Inspection Inspection of Rotor Play

1. Check for indications of oil leaks at the oil inlet To inspect the rotor, the turbocharger must be
and outlet lines. Repair or replace the oil lines removed. Inspect for maximum rotor end play and
as needed. run-out limits before reinstalling.
2. Inspect the air inlet connection to the
turbocharger’s turbine side for cracks or broken
Removal of Turbocharger
hardware. Repair or replace the connection as 1. Shut down the engine and allow the
needed. turbocharger to cool. Remove the exhaust
3. Inspect the exhaust outlet connection to the outlet connection from the turbocharger
turbocharger’s compressor side for cracks or housing.
broken hardware. Repair or replace the 2. Remove the air inlet connection from the
connection as needed. turbocharger housing.
Inspection of Rotor Rotation CAUTION

1. With the engine cool and not operating, Do not allow any material to fall into the
manually rotate the rotor. Smooth rotation is oil lines or the oil inlet and outlet ports
normal. Any catching or resistance to rotation is of the turbocharger.
an indication of abnormal operation. Replace 0000064en
the turbocharger or have it repaired by a
qualified repair facility. 3. Remove the inlet and outlet oil lines from the
turbocharger. Plug the lines and ports with tape
2. Start the engine.
to prevent contamination. Discard the sealing
3. After the engine reaches normal operating washers and O-rings. Inspect the oil lines and
temperature, place a stethoscope firmly against replace if damaged.
the turbocharger case.
4. Remove the turbocharger mounting nuts from
4. Increase the rpm gradually. A high-pitched the mounting studs. Lift the turbocharger from
sound, occurring at intervals of two or three the engine and place it on a clean, level working
seconds, is an indication of abnormal operation. surface.
Replace the turbocharger or have it repaired by
5. Discard the turbocharger exhaust manifold
a qualified repair facility.
gasket.

TURBOCHARGER Periodic Inspection
Checking Rotor Play

Note: If rotor play measurements are not within specification, replace the turbocharger assembly or have it
repaired by a qualified facility.
Standard Dimension Wear Limit

Rotor Play
RHF5 RHB31 RHB51 RHF5 RHB31 RHB51
0.0011 - 0.0024 in. 0.0009 - 0.0021 in. 0.0012 - 0.0024 in. 0.0044 in. 0.0028 in. 0.0035 in.
End Play
(0.03 - 0.06 mm) (0.022 - 0.053 mm) (0.03 - 0.06 mm) (0.09 mm) (0.07 mm) (0.09 mm)
0.0031 - 0.0051 in. 0.0024 - 0.0037 in. 0.0031 - 0.0051 in. 0.007 in. 0.0047 in. 0.0067 in.
Run-out
(0.08 - 0.13 mm) (0.061 - 0.093 mm) (0.08 - 0.13 mm) (0.17 mm) (0.12 mm) (0.17 mm)
To Check Rotor End Play:

1. Set up a dial indicator as shown (Figure 10-4). (1)
(2)
2. Manually move the rotor end-to-end while
observing indicated readings. Replace the (4)
turbocharger if end play measurements are
outside specified limits. See table above.
(1)
(2)
(3)
(3)
0000081A
Figure 10-5
Waste Gate Valve Test

0000080A
Before reinstalling the turbocharger, verify the
operation of the waste gate valve. Poor waste gate
Figure 10-4 operation will adversely affect the engine
To Check Rotor Run-out: performance.
1. Set up a dial indicator as shown (Figure 10-5).

CAUTION
2. Manually rotate the rotor while observing
indicated limits. Replace the turbocharger if If the waste valve does not meet
run-out measurements are outside specified specifications, replace the turbocharger
limits. See table above. or have it repaired by a qualified repair
facility.
0000078en

Periodic Inspection TURBOCHARGER
1. Connect a hand-operated air pump to the waste • If the pressure reading is equal to or greater
gate actuator pipe (Figure 10-6, (1)). The pump than 15.9 psi (0.11 MPa; 1.1 kgf/cm2), the
should be equipped with a 30 psi (0.21 MPa; waste gate actuator is not leaking and is
2.21 kgf/cm2) pressure gauge operating properly.
(Figure 10-6, (2)), and a pressure release valve • If the pressure reading is less than 15.9 psi
to release any pressure pumped into the (0.11 MPa; 1.1 kgf/cm2), the waste gate
system. (Similar pumps are used to check for actuator is leaking. Replace the turbocharger
leaks in marine gear cases.) or have it repaired by a qualified repair facility.
A WARNING Installation of Turbocharger

Never apply over 40 psi (2.8 kgf/cm) to 1. Pour 2 oz (60 cc) of clean engine oil in the oil
the waste gate actuator. inlet port at the top of the turbocharger. Rotate
0000026en the compressor wheel to ensure the shaft
bearings are lubricated.
2. Flush the oil lines to ensure that they are free of
containments.
3. Put a new turbocharger exhaust manifold
gasket in place and reinstall turbocharger on
the exhaust manifold.
(1 4. Apply anti-seize compound to the turbocharger
(2) mounting studs.
5. Reinstall the mounting nuts. Torque the nuts to
the specified torque.
6. Install new sealing washers and O-rings and
reinstall the inlet and outlet oil lines to the
turbocharger.
(3) 00001617 CAUTION

Figure 10-6 Do not allow any material to fall into the
oil lines or the oil inlet and outlet ports
2. Apply 17 psi (0.12 MPa; 1.2 kgf/cm2) to the of the turbocharger.
waste gate actuator (Figure 10-6, (3)) circuit. 0000064en
Observe if the waste gate valve is open fully. If
the waste valve does not open fully, replace the 7. Reinstall the air inlet connection to the
turbocharger or have it repaired by a qualified turbocharger turbine housing.
repair facility. 8. Reinstall the exhaust connection to the
turbocharger compressor housing.
Waste Gate Actuator Leak Test
Allow the pressure, 17 psi (0.12 MPa; 1.2 kgf/cm2)
to remain in the circuit for one minute. After one
minute, observe the pressure reading.

TURBOCHARGER Periodic Inspection

Section 11
STARTER MOTOR
Page
Introduction.................................................................................... 11-5
Starter Motor Information .............................................................. 11-5
3TNV82A to 4TNV88 - Standard and Optional........................ 11-5
Starter Motor Specifications .......................................................... 11-7
Starter Motor Troubleshooting....................................................... 11-8
Starter Motor Components ............................................................ 11-9
Starter Motor ............................................................................... 11-10
Removal of Starter Motor ...................................................... 11-10
Disassembly of Starter Motor ................................................ 11-10
Cleaning and Inspection ........................................................ 11-12
Reassembly of Starter Motor................................................. 11-17
Check Pinion Projection Length ............................................ 11-18
No-Load Test......................................................................... 11-19
Installation of Starter Motor ................................................... 11-20

STARTER MOTOR

Before You Begin Servicing STARTER MOTOR
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
SHOCK HAZARD!
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
• Check the electrical harnesses for
cracks, abrasions, and damaged or
0000009en
or serious injury.
0000010en
FUME / BURN HAZARD!
sealant removers.
or serious injury.
0000014en

STARTER MOTOR Before You Begin Servicing
A CAUTION CAUTION
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general
cleaning. Do not use high-pressure
wash or submerse the starter motor in
water.
FLYING OBJECT HAZARD! 0000055en

servicing the engine and when using CAUTION
compressed air or high-pressure Use a specialized battery charger to
water. Dust, flying debris, compressed recharge a battery with a voltage of
air, pressurized water or steam may 8 volts or less. Booster starting a battery
injure your eyes. with a voltage of 8 volts or less will
• Failure to comply may result in minor generate an abnormally high voltage
or moderate injury. and destroy electrical equipment.
0000056en
0000003en
CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated on the wiring diagram. The
starter motor will malfunction or break
down if the resistance is higher than the
specified value.
0000054en

Introduction STARTER MOTOR
INTRODUCTION
This section of the Service Manual covers the servicing of the starter motor. Yanmar Part No. 129900-
77010 is standard equipment on 4TNV94-98 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 you are working on.
STARTER MOTOR INFORMATION

3TNV82A to 4TNV88 - Standard and Optional
YANMAR Mfg. No Load Loaded
Part Mfg. Part Specification Terminal Amperag Terminal Amperag
Number Number rpm Torque rpm
Voltage e Draw Voltage e Draw
87 in.-lb
129129- 228000- DC12V-1.6 hp
Denso 11.5 90A MAX 3000 8 280 Max (9.81N·m; 900
77010 0251 (1.2 kW)
1.0 kgf·m)
117 in.-lb
129407- 228000- DC12V-1.9 hp
Denso 11.5 90A MAX 3000 8.5 350 Max (13.2 N·m; 1000
77010 3732 (1.4 kW)
1.4 kgf·m)
74 in.-lb
129608- S114- DC12V-1.9 hp
Hitachi 11 90A MAX 2700 8.4 250 Max (8.3 N·m; 1000
77010 817A (1.4 kW)
0.9 kgf·m)
134 in.-lb
129242- S114- DC12V-2.3 hp
Hitachi 11 90A MAX 2300 8 370 Max (15.1 N·m; 880
77010 883 (1.7 kW)
1.5 kgf·m)
97 in.-lb
129136- DC12V-3.1 hp 140A
Hitachi S13-332 11 4100 7.7 400 Max (11.0 N·m; 1400
77011 (2.3 kW) MAX
1.1 kgf·m)
269 in.-lb
129612- S25- DC24V-5.3 hp 100A
Hitachi 24 3500 18 400 Max (30.4 N·m; 1000
77011 166A (4.0kW) MAX
3.1 kgf·m)

STARTER MOTOR Starter Motor Information
4TNV94L to 4TNV106T - Standard and Optional

YANMAR Mfg. No Load Loaded
Part Mfg. Part Specification Terminal Amperag Terminal Amperag
Number Number rpm Torque rpm
Voltage e Draw Voltage e Draw
97 in.-lb
129900- DC12V-3.1 hp 140A
Hitachi S13-204 11 4100 7.7 400 Max (11.0 N·m; 1400
77010 (2.3 kW) MAX
1.1 kgf·m)
60 in.-lb
129940- DC12V-4.0 hp 160A
Hitachi S14-102 12 3600 10.85 300 Max (6.9 N·m; 2000
77010 (3.0 kW) MAX
0.7 kgf·m)
130 in.-lb
119131- DC24V-4.8 hp
Hitachi S24-13 23 90A MAX 3100 20.2 250 Max (14.7 N·m; 1300
77010 (3.5 kW)
1.5 kgf·m)
130 in.-lb
129900- DC24V-4.8 hp
Hitachi S24-14 23 90A MAX 3100 20.2 250 Max (14.7 N·m; 1300
77030 (3.5 kW) Wet
1.5 kgf·m))
97 in.-lb
129910- S13- DC12V-3.1 hp 140A
Hitachi 11 4100 7.7 400 Max (11.0 N·m; 1400
77022 2050 (2.3 kW) Wet MAX
1.1 kgf·m)

Starter Motor Specifications STARTER MOTOR
STARTER MOTOR SPECIFICATIONS

Yanmar Part Number 129900-77010
Nominal Output 3.0 hp (2.3 kW)
12.1 lb
Weight
(5.5 kg)
Revolution Direction (As Viewed From Pinion) Clockwise
Engagement System Magnetic Shift
Terminal Voltage / Current 11 V / 140 A max
No-load
Revolution 4100 rpm (min-1)
Terminal Voltage / Current 2.5 V / 1050 A max
Loaded 18 ft-lb
Torque
(24.5 N·m; 2.5 kgf·m) minimum
Clutch System Overrunning
Pinion Projection Voltage at 212°F (100 °C) 8.6 V max
Pinion DP or Module / Number of Teeth M3/9
Difference (O-ring, Oil Seal) Dry (none)
Application Standard
Spring Force 7.868 lbf (35 N; 3.6 kgf)
Brush Standard 0.591 in. (15 mm)
Height
Limit 0.354 in. (9 mm)
Magnetic Series Coil Resistance 0.27 W at 68°F (20°C)
Switch Shunt Coil Resistance 0.60 W at 68°F (20°C)
Standard 1.437 in. (36.5 mm)
Outside Diameter
Limit 1.398 in. (35 mm)
Commutator Run-Out
Limit 0.008 in. (0.2 mm)
Standard 0.020 - 0.031 in. (0.5 - 0.8 mm)
Insulation Depth
Limit 0.008 in. (0.2 mm)
Armature Run-Out
Limit 0.008 in. (0.02 mm)
Armature Front 6903DDU
Bearing Armature Rear 608DDU
Nominal Number
Type Pinion Front 60004DDU
Pinion Rear 6904DDU
Pinion Projection Length (Length L) 0.012 - 0.059 in. (0.3 - 1.5 mm)

11-8
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
STARTER MOTOR
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,
Pinion and ring gear NO return spring for fatigue and pinion
meshing normal? for sliding.
YES • Repair meshing between pinion and
ring gear or replace as needed.
YES
Connect M terminal of starter NO • Inspect brush and replace if worn.
Pinion roller clutch or motor directly to battery. • If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.
YES
Solenoid switch assembly If starter motor becomes wet, replace solenoid switch
contact defective. Repair assembly even if function is normal.
NO or replace.
STARTER MOTOR TROUBLESHOOTING
(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
Starter Motor Troubleshooting
Starter Motor Components STARTER MOTOR
STARTER MOTOR COMPONENTS

(13)
(12) (14)
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(23)
(3)
(2)
(1) (15)
(18)
(22)
(21)
(19)
(20)
(17)
(16) 0000103A
1 – Pinion Shaft 13 – Magnetic Switch Assembly (Solenoid)

2 – M4 Bolts (3 used) 14 – Cover
3 – Bearing Retainer 15 – M6 Bolts (2 used)
4 – Pinion Clutch Assembly 16 – Armature Assembly
5 – Return Spring 17 – Field Coil Assembly
6 – Pinion Stop 18 – Positive (+) Brushes
7 – Retaining Ring 19 – Negative (-) Brushes
8 – Gear Housing 20 – Brush Holder Assembly
9 – Shift Lever 21 – Rear Cover
10 – Torsion Spring 22 – M5 Through Bolts (2 used)
11 – Plunger 23 – M4 Bolts (2 used)
12 – Dust Covers (Shims)
Figure 11-1

STARTER MOTOR Starter Motor
STARTER MOTOR (1)
A WARNING
SHOCK HAZARD!
equipped) or disconnect the negative 0002126
battery cable before servicing the Figure 11-2

electrical system.
• Check the electrical harnesses for Disassembly of Starter Motor
cracks, abrasions, and damaged or 1. Loosen the M8 nut from the magnetic switch
corroded connectors. ALWAYS keep (solenoid) assembly (Figure 11-3). Disconnect
the connectors and terminals clean. the wire from the magnetic switch.
or serious injury.
0000009en
Note: While starter motor design varies

between models, the basic repair
procedures are the same. The following
procedures are typical and may differ
from the stater being serviced.
Removal of Starter Motor

1. Disconnect the battery cables at the battery,
negative (-) cable first. 0000104
2. Remove the electrical wires from the magnetic Figure 11-3

switch assembly. 2. Remove the two M4 bolts (Figure 11-4, (1))
3. Remove the starter mounting bolts securing the rear cover (Figure 11-4, (2)) to the
(Figure 11-2, (1)). Remove the starter motor brush holder assembly (Figure 11-4, (3)).
from the flywheel housing.

Starter Motor STARTER MOTOR
(7) (1)
(4)
(1)
(2) (3)
0000107A
Figure 11-6
(6) (5) (3) (2) 6. Pull the armature assembly (Figure 11-6, (3))
0000105A
out from the field coil assembly
Figure 11-4 (Figure 11-6, (2)).
3. Remove the two M5 through bolts 7. Remove the two M6 bolts (Figure 11-7, (1))
(Figure 11-4, (4)). Separate the rear cover retaining the magnetic switch assembly
(Figure 11-4, (2)), field coil assembly (Figure 11-7, (2)) to the gear housing. Remove
(Figure 11-4, (5)) with the armature assembly the magnetic switch assembly, dust cover(s)
(Figure 11-4, (6)) from the gear housing (Figure 11-7, (3)) and torsion spring
(Figure 11-4, (7)). (Figure 11-7, (4)) from the gear housing.
4. Pull the brush springs up using a brush spring (1)
puller. On the negative (-) side, bring the brush
spring into contact with the side of the brush for
lifting from the commutator surface. On the
positive (+) side, remove the brush from the (2) (4)
brush holder assembly (Figure 11-5, (1)).
(3)
0000108A
Figure 11-7
8. Disassemble the dust cover (Figure 11-8, (3))
and shift the lever (Figure 11-8, (4)) from the
(1) gear housing.
0000106A
(1)
Figure 11-5
5. Remove the brush holder assembly
(Figure 11-6, (1)) from the armature assembly
(Figure 11-6, (3)).
(2)
0000109A
Figure 11-8

9. Remove the three M4 bolts (Figure 11-9, (1))

(4)
securing the bearing retainer assembly (1)
(Figure 11-9, (2)) to the gear housing. Remove
the bearing retainer assembly from the gear (5)
housing. (2)
(3)
(2)
0000112A
Figure 11-11
(3)
Armature
(1)
Commutator Surface Inspection
0000110A If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth
Figure 11-9
(Figure 11-12).
10. Remove the pinion clutch assembly
(Figure 11-9, (3)) from the bearing retainer
assembly.
11. Using a flat-blade screwdriver, remove the
retaining ring (Figure 11-10, (1)) from the shaft
of the pinion.
(1)
0000117
Figure 11-12
Measure Commutator Outside Diameter

0000111A Measure the commutator outside diameter
(Figure 11-13). Replace the armature if the
Figure 11-10
measurement is less than the limit.
12. Disassemble the pinion stop
(Figure 11-11, (3)), return spring
(Figure 11-11, (4)), pinion clutch assembly
(Figure 11-11, (1)), and pinion shaft
(Figure 11-11, (5)).

Armature Coil Continuity Test
Check for continuity between the commutator
segments using a multimeter (Figure 11-15). The
multimeter should indicate continuity.
0000113
Figure 11-13
See Starter Motor Specifications on page 11-7 for
the service limit.
0000114
Measure Commutator Insulation Depth
Figure 11-15
Measure the depth of the insulating material
(Figure 11-14, (1)) between commutator segments If the multimeter does not indicate continuity,
(Figure 11-14, (2)). If the depth measures less replace the armature.
than the limit, use a hacksaw blade
(Figure 11-14, (3)) to remove the insulating Armature Coil Insulation Test
material until the depth is within the limit. Check for continuity between a commutator
segment and the shaft or armature using a
A normal commutator condition is indicated in multimeter (Figure 11-16). The multimeter should
(Figure 11-14, (4)). An abnormal commutator not indicate continuity.
condition is indicated in (Figure 11-14, (5)).
(3)
(2)
(1)
0000115
Figure 11-16
(5) (4) If the multimeter indicates continuity, replace the
0000118
armature.
Figure 11-14
the service limit.

Measure Armature and Commutator Run-Outs Field Coil Insulation Test

Measure the armature core run-out and the Check for continuity between the field coil terminal
commutator run-out using a dial indicator and the yoke using a multimeter (Figure 11-19).
(Figure 11-17). Replace the armature if either of The multimeter should not indicate continuity.
the measurements is less than the limit.
If the multimeter indicates continuity, replace the
field coil assembly.
0000116
Figure 11-17
See Starter Motor Specifications on page 11-7 for 0000120
the service limit.
Figure 11-19
Field Coil
Measure Brush Length
Field Coil Continuity Test Measure the length of the brush (Figure 11-20).
Check for continuity between the field coil terminals Replace the brush if the length is less than the limit.
using a multimeter (Figure 11-18). The multimeter
should indicate continuity.
If the multimeter does not indicate continuity,
replace the field coil assembly.
0000121
Figure 11-20
0000119 the service limit.
Figure 11-18

Magnetic Switch Series Coil Continuity Test
If the starter motor becomes wet, replace the Check for continuity between the “S” and “M”
magnetic switch even if the magnetic switch terminals using a multimeter (Figure 11-22). The
assembly function is normal. multimeter should indicate continuity.
Shunt Coil Continuity Test If the multimeter does not indicate continuity,
replace the magnetic switch.
Check for continuity between the “S” terminal and
the switch body using a multimeter (Figure 11-21).
The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
0000125
Figure 11-22
Coil Resistance Test

0000124 the service limit.
Figure 11-21

Contact Continuity Test Slide the pinion clutch assembly on the shaft. It
Depress the plunger at the bottom of the magnetic should slide smoothly on the shaft (Figure 11-25).
switch. Check for continuity between the “B” and Rust, too much grease or damage could prevent
“M” terminals using a multimeter (Figure 11-23). the pinion clutch from sliding smoothly. If the pinion
The multimeter should indicate continuity. clutch assembly does not slide smoothly, clean the
shaft and pinion clutch assembly or replace the
If the multimeter does not indicate continuity, damaged component.
0000128
Figure 11-25
0000126 Ball Bearing Inspection
Figure 11-23 Rotate each ball bearing while holding the pinion
clutch assembly (Figure 11-26). Replace the ball
Pinion Clutch Assembly bearing if it does not rotate smoothly or has
excessive play.
Pinion Clutch Assembly Inspection
Manually rotate the pinion clutch assembly in the
drive direction (Figure 11-24). It should rotate
freely in the drive direction and is locked by turning
it in the opposite direction. Replace the pinion
clutch assembly if the results are different.
0000129
Figure 11-26
0000127
Figure 11-24

Reassembly of Starter Motor (3)
1. Apply the appropriate starter bendix grease
(obtain locally) to the pinion shaft. Reassemble
the pinion shaft (Figure 11-27, (5)), pinion (2)
(1)
clutch assembly (Figure 11-27, (1)), return
spring (Figure 11-27, (4)) and pinion stop
(Figure 11-27, (3)). Reinstall the retaining ring
(Figure 11-27, (2)) in the groove in the pinion
shaft. Slide the piston stop over the retaining (5)
ring.
(4)
(4)
0000268
(1)
(5) Figure 11-28
(2) 5. Reassemble the magnetic switch assembly to
(3) the gear housing. Pry the pinion away from the
gear housing to allow installation of the
0000112A magnetic switch assembly (Figure 11-29).
Figure 11-27
2. Reinstall the pinion clutch assembly into the
bearing retainer assembly.
3. Reinstall the bearing retainer assembly and
pinion assembly to the gear housing. Reinstall
and tighten the three M4 bolts.
4. Apply a small amount of high temperature
lithium grease (obtain locally) to the sliding
portions of the shift lever (Figure 11-28, (1)). 0000131
Reassemble the torsion spring
Figure 11-29
(Figure 11-28, (2)), shift lever and dust cover(s)
(Figure 11-28, (3)), plunger (Figure 11-28, 4) 6. Secure the magnetic switch assembly to the
and magnetic switch assembly gear housing using the two M6 bolts.
(Figure 11-28, (5)).

7. Carefully install the armature assembly 12. Reinstall the two M4 through bolts
(Figure 11-30, (1)) into the field coil assembly (Figure 11-32). Securely tighten the through
(Figure 11-30, (2)). bolts. Reconnect the wire to the magnetic
switch assembly. Tighten the M8 nut. Reinstall
the cover over the connection.
(1)
(2)
0000269
Figure 11-30
8. Position the brush springs in brush holders
(Figure 11-31). Reinstall the brushes in the
brush holders. Reversing the brushes will cause 0000104
the starter motor to turn backwards.

Figure 11-32
Check Pinion Projection Length

1. Connect the positive (+) lead from a battery to
the “S” terminal.
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
0000106 moving distance L in the thrust direction
Figure 11-31 (Figure 11-33). Perform this test within 10
seconds. See Starter Motor Specifications on
9. Carefully install the brush holder assembly to page 11-7 for the service limit.
the armature assembly.
10. Reinstall the field coil assembly with the
armature assembly to the gear housing.
11. Reinstall the rear cover to the brush holder
assembly. Securely tighten the two bolts.
0000132
Figure 11-33

5. If the measured L dimension is outside the
standard range, adjust the dust covers to obtain
the standard range. Dust covers (3)
(Figure 11-34, (1)) are available in 0.020 in (0.5 (6) (1)
mm) and 0.031 in (0.8 mm) thicknesses.
M (8)
(2)
(7)
(1)
(5)
(4)
0002127A
Figure 11-35
3. Connect a wire lead between the mounting
base of the starter motor (Figure 11-35, (4))
and the battery negative terminal
0000133
(Figure 11-35, (5)).
Figure 11-34 4. Connect a voltmeter (Figure 11-35, (7)) to the
battery negative (-) terminal (Figure 11-35, (5))
No-Load Test and the main positive (+) battery terminal
(Figure 11-35, (3)) on the starter motor.
Test the characteristics of the starter motor by
performing a no-load test. 5. Install a switch (Figure 11-35, (6)) in a circuit
between the battery positive (+) terminal
(Figure 11-35, (2)) and the starter magnetic
CAUTION switch (solenoid) terminal (Figure 11-35, (8))
The starter motor can be damaged if on the starter motor.
operated continuously longer than 6. Use a suitable tachometer to monitor the rpm of
10 seconds while performing the the starter.
no-load test.
7. Turn the switch to the ON position. Monitor the
0000034en
rpm, amperage draw and voltage. For test
1. Secure the starting motor in a vise or other specifications, see 3TNV82A to 4TNV88 -
suitable fixture. Standard and Optional and 4TNV94L to
4TNV106T - Standard and Optional on
2. Connect an ammeter (Figure 11-35, (1)) in
page 11-5 for the appropriate starter motor.
series between the battery positive (+) terminal
(Figure 11-35, (2)) and the main positive (+)
terminal (Figure 11-35, (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.

Installation of Starter Motor

1. Reinstall the starter motor to the flywheel
housing.
2. Reinstall the starter mounting bolts
(Figure 11-36, (1)). Tighten the bolts to
specification. See Tightening Torques for
Standard Bolts and Nuts on page 4-46.
(1)
0002126
Figure 11-36
3. Reconnect the electrical wires to the magnetic
switch assembly (solenoid). Be sure to place
the cover over the battery positive (+) cable
connection.
4. Reconnect the battery cables at the battery.

Section 12
ALTERNATOR
Page
Introduction.................................................................................... 12-6
Dynamo and Alternator Information .............................................. 12-6
3TNV82A to 4TNV106T - Standard and Optional Dynamos ... 12-6
3TNV82A to 4TNV106T - Standard and Optional Alternators . 12-6
Alternator Specifications................................................................ 12-7
Dynamo Specifications.................................................................. 12-7
Alternator Troubleshooting ............................................................ 12-8
Alternator Components ................................................................. 12-9
Alternator Wiring Diagram ........................................................... 12-10
Alternator Standard Output ........................................................ 12-11
Alternator .................................................................................... 12-12
Removal of Alternator............................................................ 12-12
Disassembly of Alternator...................................................... 12-12
Reassembly of Alternator ...................................................... 12-14
Installation of Alternator......................................................... 12-16
Dynamo Component Location..................................................... 12-17
Dynamo Wiring Diagram ............................................................. 12-18
Operation of Dynamo .................................................................. 12-18
Dynamo Standard Output ........................................................... 12-19
Testing of Dynamo ...................................................................... 12-20
Testing Stator Coil Continuity ................................................ 12-20
Testing Stator Coil Short-to-Ground ...................................... 12-20
Testing Dynamo Regulated Output ....................................... 12-20

ALTERNATOR
Dynamo........................................................................................ 12-20
Removal of Dynamo............................................................... 12-20
Disassembly of Dynamo......................................................... 12-21
Reassembly of Dynamo ......................................................... 12-21
Installation of Dynamo............................................................ 12-22

Before You Begin Servicing ALTERNATOR
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
SHOCK HAZARD!
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
cracks, abrasions, and damaged or
0000009en
or serious injury.
0000010en
BURN HAZARD!
block during operation and shortly
seriously burn you.
or serious injury.
0000015en

ALTERNATOR Before You Begin Servicing
A WARNING A CAUTION
FUME / BURN HAZARD!

PINCH HAZARD!
precautions found on containers of Carefully rotate the alternator toward the
hazardous substances like parts cylinder block while loosening the
cleaners, primers, sealants and V-belt. Failure to comply may result in
sealant removers. minor or moderate injury.
0000014en
or serious injury.
0000014en
CAUTION
A CAUTION
NEVER permit anyone to operate the

engine or driven machine without proper
training.
FLYING OBJECT HAZARD! • Read and understand this Operation

Manual before you operate or service
• ALWAYS wear eye protection when the machine to ensure that you follow
servicing the engine and when using safe operating practices and
compressed air or high-pressure maintenance procedures.
air, pressurized water or steam may • Machine safety signs and labels are
injure your eyes. additional reminders for safe operating
and maintenance techniques.
or moderate injury. • See your authorized Yanmar industrial
engine dealer or distributor for
0000003en
additional training.
0000002en
CAUTION
Do not short-circuit the charging system
between alternator terminals IG and L.
Damage to the alternator will result.
0000035en

Before You Begin Servicing ALTERNATOR
CAUTION CAUTION
Do not connect a load between Using a non-specified V-belt will cause
alternator terminals L and E. Damage to inadequate charging and shorten the
the alternator will result. belt life. Use the specified belt.
0000036en 0000052en
CAUTION CAUTION
Do not remove the positive (+) battery Agricultural or other chemicals,
cable from alternator terminal B while especially those with a high sulfur
the engine is operating. Damage to the content, can adhere to the IC regulator.
alternator will result. This will corrode the conductor and
0000037en result in battery over-charging (boiling)
and charging malfunctions. Consult
Yanmar before using the equipment in
CAUTION such an environment or the warranty is
Do not turn the battery switch OFF while voided.
the engine is operating. Damage to the 0000053en
alternator will result.
0000038en
CAUTION
Do not use a high-pressure wash
CAUTION directly on the alternator. Water will
Do not operate the engine if the damage the alternator and result in
alternator is producing unusual sounds. inadequate charging.
Damage to the alternator will result. 0000049en
0000039en
CAUTION
Do not reverse the positive (+) and
negative (-) ends of the battery cable.
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
When the battery indicator goes out, it
should not come on again. The battery
indicator only comes on during
operation if the alternator fails. However,
if an LED is used in the battery indicator,
the LED will shine faintly during normal
operation.
0000051en

ALTERNATOR Introduction
INTRODUCTION
This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part
No. 129423-77200 alternator is used in this section to show the service procedures for the representative
alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures
for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working
on.
DYNAMO AND ALTERNATOR INFORMATION

3TNV82A to 4TNV106T - Standard and Optional Dynamos
YANMAR Part Number Mfg. Mfg. Part Number Specification
171301-77201 Kokusan GP8138 DC12V-15A
119910-77200 Kokusan GP9191 DC12V-20A
3TNV82A to 4TNV106T - Standard and Optional Alternators

YANMAR Part Number Mfg. Mfg. Part Number Specification
119620-77201 Denso 100211-4531 DC12V-40A
129423-77200 Denso 101211-1170 DC12V-40A with Pulse
129961-77200 Denso 101211-2591 DC12V-55A
119626-77210 Denso 101211-2951 DC12V-55A with Pulse
129612-77290 Hitachi LR180-772 DC12V-80A with Pulse
129900-77240 Hitachi LR235-705 DC24V-35A with Pulse

Alternator Specifications ALTERNATOR
ALTERNATOR SPECIFICATIONS
Nominal Output (13.5 Volts Heat) 40 Amps
Weight 6.17 lb (2.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 5000 rpm (min-1)
Operating Range 1350 - 18000 rpm (min-1)
Grounding Characteristics Negative (-) Side of Circuit
Integrated Regulator IC Regulator
Outside Diameter of Pulley 2.724 in. (69.2 mm)
Belt Shape Type A
DYNAMO SPECIFICATIONS
Nominal Output 20 Amps
Weight 3.97 lb (1.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 3500 rpm
Operating Range 1400 - 6600 rpm
Grounding Characteristics Negative (-) Side of Circuit
Current Limiter (Yanmar Part No.
Regulator
119653-77710)
A-Belt 2.56 in. (65 mm)
Outside Diameter of Pulley
Special M-Belt 2.28 in. (58 mm)
Belt Shape Type A or Type Special M

12-8
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF Replace the battery indicator.
Does battery indicator and IG terminal at alternator L terminal. Does battery Battery indicator is available from
ALTERNATOR
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.
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.
ALTERNATOR TROUBLESHOOTING
Battery voltage minus

L terminal voltage is Excessive voltage drop between
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.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500

rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.
Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?
OFF

Notes: Not abnormal.
1) Use a fully charged battery
2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test
Alternator Troubleshooting
Alternator Components ALTERNATOR
ALTERNATOR COMPONENTS
Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.
14
12 13
10 11
8 9
6
5
29
4
3 7 19
2
16 18
1 17
25
15 28
27
26
24
23
22 0000255
21
20
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 12-1

ALTERNATOR Alternator Wiring Diagram
ALTERNATOR WIRING DIAGRAM
IG 1
IG P
B
PI P L
2
F
IC
L
0.5μF 3 3
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 12-2
CAUTION CAUTION
Do not short-circuit the charging system Do not remove the positive (+) battery
between alternator terminals IG and L. cable from alternator terminal B while
Damage to the alternator will result. the engine is operating. Damage to the
0000035en alternator will result.
0000037en
CAUTION
Do not connect a load between
alternator terminals L and E. Damage to
the alternator will result.
0000036en

Alternator Standard Output ALTERNATOR
ALTERNATOR STANDARD OUTPUT
Output Current
60
Cold
50
13.5 Volts, Constant Ambient
Temperature at 77˚F (25˚C) Hot
40
30
20
10
0 1 2 3 4 5 6 7 8
Alternator RPM (x10³ min¯¹)
Figure 12-3

ALTERNATOR Alternator
ALTERNATOR 4. Remove the nut (Figure 12-4, (2)) from the

gear case stud. Remove the alternator.
A WARNING
SHOCK HAZARD!
2 1
0000264
equipped) or disconnect the negative
battery cable before servicing the Figure 12-4
electrical system.
Disassembly of Alternator
cracks, abrasions, and damaged or 1. Remove the nut (Figure 12-5, (1)) from the
corroded connectors. ALWAYS keep shaft of the rotor assembly. Remove the pulley
the connectors and terminals clean. (Figure 12-5, (2)).
or serious injury.
0000009en
Removal of Alternator
1. Disconnect the electrical wires from the
alternator.
2. Loosen the V-belt.
A CAUTION
2
1 0000256
PINCH HAZARD! Figure 12-5

Carefully rotate the alternator toward the
cylinder block while loosening the
0000014en
3. Remove the V-belt adjuster from the alternator

bolt (Figure 12-4, (1)).

Alternator ALTERNATOR
2. Remove the three bolts (Figure 12-6, (1)) 5. Remove the bolts retaining the holder
retaining the rear cover (Figure 12-6, (2)) to the (Figure 12-7, (2)) to the rear frame housing.
rear frame assembly. Remove the holder.
6. Remove the nut (Figure 12-7, (3)) retaining the
insulation bushing (Figure 12-7, (4)). Remove
the insulation bushing.
7. Remove the two bolts (Figure 12-8, (1)) and
3 1 two nuts (Figure 12-8, (2)) securing the rear
frame housing to the front frame housing.
4 2
5
1
0000257A
Figure 12-6
3. Remove the brush holder (Figure 12-6, (3)).
0000265A
Remove the brush springs (Figure 12-6, (4))
and brushes (Figure 12-6, (5)). Figure 12-8
4. Remove the bolt retaining the regulator 8. Using a press, remove the rotor assembly
assembly (Figure 12-7, (1)) to the holder (Figure 12-9, (1)) from the front frame housing
(Figure 12-7, (2)). (Figure 12-9, (2)) and rear frame housing
(Figure 12-9, (1)).
3 3
1
4
1
2
100266A
Figure 12-9
0000258A
Figure 12-7

9. Remove the stator assembly

(Figure 12-10, (1)) from the front frame
housing.
4
3
2
3 1
0000260A
1 Figure 12-11
Reassembly of Alternator
0000259A
1. If removed, reinstall the two trust washers
(Figure 12-12, (3)) and bearing cover
Figure 12-10 (Figure 12-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new bearing
10. If it is necessary to replace the bearing (Figure 12-12, (1)). Press the bearing into the
(Figure 12-10, (2)) in the front frame housing, rear frame housing.
remove the four bolts (Figure 12-10, (3))
securing the plate (Figure 12-10, (4)) to the
front frame housing. Remove the plate. Use a
puller to remove the bearing. Discard the
bearing.
11. If it is necessary to replace the bearing
(Figure 12-11, (1)) in the rear frame housing, 3
use a puller to remove. Discard the bearing. 2
Remove the bearing cover (Figure 12-11, (2)) 1
and two thrust washers (Figure 12-11, (3)).
0000260A
Figure 12-12

Alternator ALTERNATOR
2. If removed, lubricate the outside diameter of a 5. Align the front frame housing with the rear
new front frame housing bearing. Press the frame housing. Reinstall the two bolts
bearing (Figure 12-13, (2)) into the front frame (Figure 12-15, (1)) and two nuts
housing. Reinstall the plate (Figure 12-13, (4)) (Figure 12-15, (2)).
to the front housing. Tighten the four bolts
(Figure 12-13, (3)). 2
1
3
0000265A
1 Figure 12-15
6. Reinstall the insulation bushing
0000259A (Figure 12-16, (4)) and nut (Figure 12-16, (3)).
Figure 12-13
3. Position the stator assembly (Figure 12-13, (1)) 3
on the front frame housing studs. 1
4
4. Lubricate the shaft of the rotor assembly
(Figure 12-14, (1)). Press the rotor assembly
into the front frame housing (Figure 12-14, (2))
and rear frame housing (Figure 12-14, (3)).
1
2
2
0000258A
Figure 12-16
7. Reassemble the regulator assembly
(Figure 12-16, (1)) to the holder
100266A
(Figure 12-16, (2)).
Figure 12-14

8. Reinstall the brush holder (Figure 12-17, (3)), Installation of Alternator

springs (Figure 12-17, (4)) and brushes
(Figure 12-17, (5)). 1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 12-19, (2)) on
9. Reattach the regulator assembly and holder to the gear case stud and the V-belt adjuster bolt
the rear frame housing. (Figure 12-19, (1)).
3 1
2 1
0000264
Figure 12-19
4 2
5 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).
0000257A
Figure 12-17 Adjust Cooling Fan V-Belt on page 5-22.
4. Start the engine. Listen for any unusual sounds
10. Reinstall the rear cover (Figure 12-17, (2)) to from the alternator.
the rear frame housing with three bolts
(Figure 12-17, (1)). CAUTION
11. Reassemble the pulley (Figure 12-18, (2)) and Do not operate the engine if the
nut (Figure 12-18, (1)) to the shaft of the rotor alternator is producing unusual sounds.
assembly. Tighten the nut. Damage to the alternator will result.
0000039en
5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
2
1 0000256
Figure 12-18

Dynamo Component Location ALTERNATOR
DYNAMO COMPONENT
LOCATION
Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on.
(1)
(2)
(3)
(4)
(7)
(5)
(8) (9)
(6) (10)
(11) (12)
(13)
(14)
0002140
1 – Rear Cover 8 – Spacer

2 – Nut 9 – Stator Assembly
3 – Lock Washer 10 – Front Bearing (2 used)
4 – Flat Washer 11 – Flat Washer
5 – Rear Bearing 12 – Flywheel Assembly
6 – Output Wire and Connector 13 – Pulley Half
7 – Plate 14 – Through Bolt
Figure 12-20

ALTERNATOR Dynamo Wiring Diagram
DYNAMO WIRING DIAGRAM
(3)
(5) (6)
(2) (4)
(1)
0002137
1 – Dynamo
2 – Current Limiter
3 – Key Switch
4 – Charge Lamp (3.4 Watts Max.)
5 – Battery
6 – Load
Figure 12-21
OPERATION OF DYNAMO
The dynamo consists of a series of permanent
magnets that rotate around a stationary stator coil.
The magnets are attached to the flywheel which is
rotated via the engine cooling fan drive belt. The
resultant output is an AC (alternating current)
signal. The AC is converted to DC (direct current)
by the current limiter. The current limiter outputs
charging DC current to the battery.

Dynamo Standard Output ALTERNATOR
DYNAMO STANDARD OUTPUT
0002138
Figure 12-22

ALTERNATOR Testing of Dynamo
TESTING OF DYNAMO DYNAMO

Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo
1. Disconnect the output wire connector from the
Testing Stator Coil Continuity dynamo.
1. Disconnect the dynamo output wire connector. 2. Loosen the V-belt.
2. Connect one meter lead to each of the stator
wire terminals and read the meter. A CAUTION
Results: The meter reading should indicate
continuity. If continuity is not indicated, the windings
are open and the stator must be replaced.
Testing Stator Coil Short-to-Ground

1. Disconnect the dynamo output wire connector. PINCH HAZARD!
2. Test continuity between each stator wire Carefully rotate the alternator toward the
terminal and engine ground. cylinder block while loosening the
Results: The meter reading should infinity. If the V-belt. Failure to comply may result in
meter reading indicates continuity, the windings are minor or moderate injury.
shorted to ground and the stator must be replaced. 0000014en
Testing Dynamo Regulated Output 3. Remove the V-belt adjuster from the dynamo
bolt (Figure 12-23, (1)).
1. Test and record the battery voltage with the
engine not running. 4. Remove the nut (Figure 12-23, (2)) from the
gear case stud. Remove the dynamo.
2. Start the engine and operate it at normal
operating rpm.
3. Again, check the battery voltage with the engine
running.
Results: The meter reading with the engine
running must be higher than with the engine not
running.
• If results are not correct, test the stator for
(1) 0002141
continuity and shorts to the ground. (2)
• Check the charging system wiring. Figure 12-23
• If no problems are found in previous checks,
replace the IC regulator.

Dynamo ALTERNATOR
Disassembly of Dynamo 4. Remove the screws (Figure 12-26, (1)) and the
stator assembly (Figure 12-26, (2)).
1. Remove the rear cover (Figure 12-24, (1)).
5. Remove the rear bearing (Figure 12-26, (3)).
2. Remove the nut (Figure 12-24, (2)), lock
washer (Figure 12-24, (3)), and flat washer
(3)
(Figure 12-24, (4)).
(1)
(2)
(3)
(4)
(2)
(1)
0002145
Figure 12-26
0002143
Figure 12-24 Reassembly of Dynamo

1. Reinstall the rear bearing (Figure 12-27, (3)).
3. Remove the through bolt (Figure 12-25, (1)),
pulley half (Figure 12-25, (2)), flywheel 2. Reinstall the stator (Figure 12-27, (2)) and
(Figure 12-25, (3)), flat washer screws.
(Figure 12-25, (4)), bearings
(Figure 12-25, (5)), and spacer (3)
(Figure 12-25, (6)).
(6) (2)
(5)
(4) (1)
(3)
(2)
(1)
0002145
Figure 12-27
0002144
Figure 12-25

ALTERNATOR Dynamo
3. Reinstall the front bearings (Figure 12-28, (5)) Installation of Dynamo

and spacer (Figure 12-28, (6)).
1. Position the dynamo on the gear case. Loosely
4. Reinstall the flat washer (Figure 12-28, (4)), reinstall the nut (Figure 12-30, (2)) on the gear
flywheel (Figure 12-28, (3)), pulley half case stud and the V-belt adjuster bolt
(Figure 12-28, (2), and through bolt (Figure 12-30, (1)).
(Figure 12-28, (1)).
(6)
(5)
(4)
(3)
(2) (1) 0002141
(2)
(1)
Figure 12-30
2. Reconnect the dynamo output wire connector.
0002144 3. Reinstall the V-belt. Tighten the V-belt to the
Figure 12-28
Adjust Cooling Fan V-Belt on page 5-22.
5. Reinstall the flat washer (Figure 12-29, (4)), 4. Start the engine. Listen for any unusual sounds
lock washer (Figure 12-29, (3)), and nut from the alternator.
(Figure 12-29, (2)). Tighten the nut to the
specified torque. CAUTION
6. Reinstall the rear cap (Figure 12-29, (1)). Do not operate the engine if the
alternator is producing unusual sounds.
(1) Damage to the alternator will result.
(2)
(3) 0000039en
(4)
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.
0002143
Figure 12-29

Section 15
TROUBLESHOOTING
Page
Special Service Tools................................................................ 15-186
Troubleshooting By Measuring Compression Pressure ............ 15-187
Compression Pressure Measurement Method .................... 15-187
Quick Reference Table For Troubleshooting ............................ 15-190

TROUBLESHOOTING Special Service Tools
For measuring compression pressure

Yanmar Gauge Set Part No. TOL-97190080
0000849
Adapter for direct injection 2-valve cylinder head

Yanmar Adapter Part No. 119802-92950
130
Compression Gauge Kit
0000850
Adapter for direct injection 4-valve cylinder head for

4TNV94L/98/98T
165
0000851
Adapter for direct injection 4-valve cylinder head for

4TNV106(T)
179
0000852

Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING
TROUBLESHOOTING BY For engines with 4 valve cylinder heads
MEASURING COMPRESSION 4. Remove the valve cover assembly. See

Removal of Valve Cover on page 6-52. Remove
PRESSURE the fuel injector from the cylinder to be tested.
Compression pressure drop is one of the major See Removal of Fuel Injectors on page 7-35.
causes of increasing blow-by gas (engine oil 5. Turn off the fuel supply valve in the fuel supply
contamination or increased engine oil consumption line. Disconnect the fuel injection pump stop
as a resultant phenomenon) or starting failure. The solenoid at the connector. This prevents the fuel
compression pressure is affected by the following injection pump from injecting fuel during
factors: compression testing.
1. Degree of clearance between the piston and 6. Before installing the compression gauge
cylinder ((Figure 15-1, (1)) 2 valve engine,
(Figure 15-2, (1)) 4 valve engine) adapter,
2. Degree of clearance at the intake / exhaust crank the engine with the stop solenoid
valve seat disconnected for a few seconds to clear the
3. Gas leak from the nozzle gasket or cylinder cylinder of any residual fuel.
head gasket 7. Install a nozzle seat at the tip end of the
The pressure will drop due to increased parts wear. compression gauge adapter. Install the
Pressure drop reduces the durability of the engine. compression gauge and the compression
gauge adapter at the cylinder to be measured.
A pressure drop may also be caused by a
scratched cylinder or piston, dust entrance from the 8. Crank the engine until the compression gauge
dirty air cleaner element or a worn or broken piston reading is stabilized.
ring. Measure the compression pressure to
(1)
determine the condition of the engine.
Compression Pressure Measurement

Method
1. Warm up the engine.
2. Stop the engine. Remove the high-pressure fuel
injection lines as an assembly from the engine.
For engines with 2 valve cylinder heads
3. Remove the fuel injector from the cylinder to be
measured. See Removal of Fuel Injectors on
page 7-35. Figure 15-1
CAUTION
possible. Disassembling the
high-pressure fuel injection lines from
fuel lines.
0000047en

TROUBLESHOOTING Troubleshooting By Measuring Compression Pressure
(1)
Figure 15-2
9. After performing the compression check
remove the compression gauge and
compression gauge adapter from the cylinder.
10. Reinstall the fuel injector, high-pressure fuel
injection lines, and reconnect the stop solenoid.
See Reassembly of Fuel Injectors on
page 7-41.
11. Install the fuel valves. See Installation of the
Fuel Injectors on page 7-42. See Inspection of
Valve Guides on page 6-57. Then install the
valve covers and injection high pressure lines. .
Then connect the stop solenoid..
12. Turn on the fuel supply valve and reconnect the
injection pump stop solenoid.
13. Prime the fuel system. Check for leaks. Test the
engine.

Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING
Standard Compression Pressure (Reference Value)
Compression Pressure
Engine Model at 250 rpm (250 min-1) Deviation Between Cylinders
Standard Limit
443 - 473 psi 340 - 370 psi
3TNV82A
(3.06 - 3.26 MPa; 30 - 32 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²)
3TNV84 455 - 485 psi 355 - 385 psi
4TNV84 (3.14 - 3.34 MPa; 32 - 34 kgf/cm²) (2.45 - 2.65 MPa; 25 - 27 kgf/cm²)
3TNV84T 411 - 441 psi 340 - 370 psi
4TNV84T (2.84 3.04 MPa; 29 - 31 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²) 29 - 43 psi
3TNV88 (0.2 - 0.3 MPa; 2 - 3 kgf/cm²)
4TNV88
4TNV94L
483 - 513 psi 384 - 414 psi
4TNV98
(3.33 - 3.53 MPa; 34 - 36 kgf/cm²) (2.65 - 2.85 MPa; 27 - 29 kgf/cm²)
4TNV98T
4TNV106
4TNV106T
Engine Speed and Compression Pressure (Use for Reference)
3TNV88
4TNV88
4TNV94L
4TNV98
569 psi 4TNV98T
(4 MPa)
(40 KgF/cm2) 3TNV84
4TNV106
4TNV106T
498 psi 4TNV84
(35 KgF/cm2)
427 psi
(30 KgF/cm2) (3 MPa)
356 psi
(25 KgF/cm2) 3TNV82A
3TNV84T
284 psi
4TNV84T (2 MPa)
(20 KgF/cm2)
200 250 300 350 400

Engine speed (min-1)
Figure 15-3

TROUBLESHOOTING Quick Reference Table For Troubleshooting
Measured Value and Troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective Action

Clogged element Clean the element.
1 Air Cleaner Element Broken element
Replace the element.
Defect at element seal portion
2 Valve Clearance Excessive or no clearance Adjust the valve clearance.
3 Valve Timing Incorrect valve clearance Adjust the valve clearance.
Replace the gasket.
4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake / Exhaust Valve Sticking valve Replace the intake / exhaust valve.
5 Gas leak due to worn valve seat

Valve Seat or foreign matter trapped in Lap the valve seat.
valve
Piston
Gas leak due to scratching or
6 Piston Ring Perform honing and use an oversized part.
wear
Cylinder
QUICK REFERENCE TABLE

FOR TROUBLESHOOTING
The following table summarizes the general trouble
symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a
serious problem so as not to shorten the engine
service life.

TNV DI Service Manual TROUBLESHOOTING
Failure Diagnosis Table
Starting failure Engine stall Speed control error Engine Noise and Lubricating oil Cooling Intake air Exhaust gas Fuel Electrical parts
Symptoms and conditions of failure after start up output low vibration water
Starter does Starter
ECU failure lamp stops flashing immediately (within 2 seconds) after turning off the key
not rotates rotates Smoke No load Workload Smoke color Workload
Revolution speed cannot be changed with accelerator (stays at a constant speed)

ECU failure lamp goes on immediately (within 2 seconds) after turning on the key
ECU failure lamp does not go on immediately after turning on the key
Engine does not start up (it stops immediately after initial ignition)
Abnormal sound (other than combustion sound) from engine
Fuel mixed with water (oil-water separator warning lamp lit)

Corrective Action Referenced page number
Engine does not start up (without initial ignition)
Oil pressure low (oil pressure warning lamp lit)
Overheat (water temperature warning lamp lit)

It takes longer than before to start up engine
Pressure low (air cleaner warning lamp lit)

High knocking sound at combustion time
Fuses get blown or broken (repeatedly)

Does not smoothly return to low speed
Battery charge error (charge lamp lit)

Too much lubricating oil consumed
Specific ECU control functions fail.

Cannot be set to particular speed
Lubricating oil mixed with water

Lubricating oil diluted with fuel
Exhaust gas temperature high

Uneven combustion sound
Too much fuel consumed
ECU failure lamp flashes

Engine vibrates heavily
Water temperature low
Fuel filter fouled shortly

Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
Intake/exhaust valves with improper See "Measuring and Adjusting Valve

Adjust the valve clearances.
clearances Clearances" (on page 6-50).
See "Correcting the Valve Seats" (on
Compressed air leaks from a valve seat Lap the valve seat. page 6-30) for two-valve head or
"Correcting The Valve Seats" (on page 6-
44) for four-valve head.
Repair or replace the intake/exhaust See "Removing the Intake/Exhaust
Intake/exhaust valve seized
valves. Valves" (on page 6-26).
See "Removing the Cylinder Head" (on
Cylinder head gasket blown Replace the gasket.
page 6-40).
See "Installing the Pistons" (on page 6-
Piston ring stuck or broken Replace the piston rings.
70).
Piston rings piston, or cylinder worn Apply honing, and use oversized parts. See "Honing and Boring" (on page 6-69).
See "Inspecting the Crank Shaft" (on
Crank pin metal and bearing seized Repair or replace.
page 6-67).
Engine system

Piston ring joint not correctly positioned Correct the joint position.
70).
Piston ring reverse-installed Reinstall.
70).
See "Inspecting the Crank Shaft" (on
Crank pin metal and journal metal worn Measure and replace.
page 6-67).
See "Tightening Torques for Main Bolts
Connecting rod bolt loose Tighten with specified torque.
and Nuts" (on page 6-15).
See "Disassembling the Engine" (on
Foreign matter in a combustion chamber Disassemble and repair.
page 6-55).
See "Inspecting the Timing Gear
Gear backlash too large Adjust the gear engagement.
Backlash" (on page 6-70).
See "Inspecting the Valve Guide" (on
Intake/exhaust valve guide worn Measure and replace.
page 6-29).
See "Inspecting and Adjusting Governor
Governor not properly adjusted Adjust.
Lever and Accelerator" (on page 5-27).
Intake/exhaust valves with improper See "Measuring and Adjusting Valve
Adjust the valve clearances.
opening/closing timings Clearances" (on page 6-50).
Engine's mounting loosened or damaged Repair or replace the faulty part(s).

TROUBLESHOOTING Failure Diagnosis Table
Smoke No load Workload Smoke color Workload
not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
See "Cleaning Procedures" (on page 10-

Supercharger
Floor fouled Clean the floor.

11).
See "Testing the Waste Gate Valve" (on
Waste gate malfunctioning Disassemble and inspect.
page 10-14).
Radial metal worn Disassemble and inspect. See "Radial Metal" (on page 10-10).
See "Disassembling the Cooling Water
Radiator overcooling Replace the thermostat.
Pump" (on page 8-9).
Replace the thermostat. Pump" (on page 8-9) or
Cooling water system
Radiator cooling insufficient Or check the fan belt for looseness. "Adjusting the Cooling Fan V-belt
Tension" (on page 5-21).
Check the cooling water system for water See "Inspecting the Cooling Water
Cooling water low
leakage. System" (on page 8-7).
Water jacket cracked Repair or replace.
See "Adjusting the Cooling Fan V-belt
Fan belt elongated Adjust the belt tension.
Tension" (on page 5-21).
Thermostat faulty Inspect or replace.
See "Engine Oil Standards" (on page 4-
Improper lubricating oil Use the proper lubricating oil.
13).
See "Disassembling the Lubricating Oil
Leakage from lubricating oil system Repair.
Lubricating oil system

Trochoid pump discharge rate insufficient Inspect and repair.
See "Replacing the Engine Oil and
Lubricating oil filter clogged Clean or replace.
Engine Oil Filter" (on page 5-19).
Pressure regulator valve faulty Clean, adjust, or replace.
See "Filling the Engine Oil" (on page 4-
Lubricating oil low Fill the proper lubricating oil. 14).
See "Inspecting the Engine Oil" (on page
Crank case excessively lubricated Inspect the engine oil. 4-14).

Failure Diagnosis Table TROUBLESHOOTING
not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
Stop solenoid faulty Inspect and replace. See "Stop Solenoid" (on page 7-7).
Fuel injection pump's injection timing See "Inspecting and Adjusting Fuel
Inspect and adjust.
advanced excessively Injection Timing" (on page 7-25).
Fuel injection pump's injection timing See "Inspecting and Adjusting Fuel
Inspect and adjust.
delayed excessively Injection Timing" (on page 7-25).
See "Diesel Fuel Standards" (on page 4-
Improper fuel oil Use the proper fuel oil. 9).
See "Draining the Oil-Water Separator"
Water flown into the fuel system Drain the fuel filter. (on page 5-22).
"Cleaning the Oil-Water Separator" (on
Fuel filter clogged Clean or replace.
page 5-31).
See "Oil Feed to the Fuel System" (on
Air contained in the fuel system Bleed.
page 4-12).
Fuel pipe clogged or cracked Clean or replace.
Fuel system
Insufficient fuel supply to the fuel injection Inspect the fuel tank cock, fuel filter, fuel
pump pipe, and fuel feed pump.
Uneven injection by the fuel injection pump Inspect and adjust. See "Testing the Fuel Injectors" (on page
7-32).
See "Testing the Fuel Injectors" (on page
Fuel injected excessively Inspect and adjust.
7-32).
Fuel injection nozzle spray failure Inspect and adjust. See "Testing the Fuel Injectors" (on page
7-32).
Remove dirt caught in the priming pump
See "Fuel System Components" (on page
Priming fails internal valve
7-12).
(disassemble and clean).
Feed pump inlet strainer clogged Clean the strainer.
Replace the pump.
CSD valve malfunctioning
Replace the CSD valve.
Inspect the fuel tank and lid;
Fuel tank airtightness deteriorated replace with the genuine parts if
necessary.
See "Cleaning the Air Cleaner Element"
Intake/exhaust
Air filter clogged Clean the air filter.

(on page 5-28).
gas system
Engine used at high temperatures or high Examine the relationship between output
altitudes reduction and load
Exhaust pipe clogged Clean the exhaust pipe.

not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
Fuse blown or broken Replace the fuse.

Starter faulty Repair or replace the starter. See "Starter" (on page 11-9).
See "Removing the Alternator" (on page
Alternator faulty Repair or replace the alternator.
12-12).
Repair or replace the disconnected
Wires disconnected
wire(s) of the harness.
Wires short-circuited (sheathing broken); Inspect, repair, or replace the harnesses
overloaded by the power consumption by and wires as needed.
additional devices Reexamine the additional devices.
See "Inspecting the Electrolyte Level and
Battery voltage low – Inspect and charge the battery.
Charging the Battery" (on page 5-23).
Repair or replace the harness.
Key switch faulty or disconnected
Replace the key switch.
Key switch instantly cut off Replace the key switch.
Starter relay faulty, disconnected, or short- Repair or replace the harness.
circuited Replace the starter relay.
Electrical system
Main relay faulty Repair or replace the harness.

(except for sticking of the contact, which is
Replace the main relay.
undetectable by ECU)
Actuator relay faulty
? ? Replace the actuator relay.
(contact failure undetectable by ECU)
Start assist relay faulty
∆ Replace the start assist relay.
(contact failure undetectable by ECU)
Accelerator sensor signal error
(an error undetectable by ECU) Repair or replace the accelerator sensor.
Water temperature sensor signal error

Replace the water temperature sensor.
(an error undetectable by ECU)
Speed sensor signal error (an error
Monitor the engine speed using the
undetectable by ECU, such as caused by Repair or replace the fuel injection pump.
noise) diagnosis tool.
Rack position sensor signal error Monitor the rack position sensor signal
Repair or replace the fuel injection pump.
(an error undetectable by ECU) using the diagnosis tool.
Rack actuator malfunctioning Monitor the rack actuator using the
(an error undetectable by ECU) diagnosis tool.
Replace the lamp.
ECU failure lamp disconnected
ECU faulty (ECU self diagnosis failure) Replace the ECU.

Failure Diagnosis Table TROUBLESHOOTING
not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
This is not a failure.

ECU control function active Refer to the control manual.
Switch to the normal mode.
Water temperature sensor disconnected or Repair or replace the harness.
Engine stopped or restricted by ECU failure diagnosis function
short-circuited Replace the water temperature sensor.

Accelerator sensor disconnected or short- Repair or replace the harness.
circuited Replace the accelerator sensor.
Speed sensor signal error Repair or replace the harness.

Rack position sensor signal error Repair or replace the harness.

Rack actuator malfunctioning
Check for idle rotations caused by the
Engine overspeed occurs working machine.
Check the speed sensor signal.
CAN Communication error
Replace the ECU.
The EGR valve motor disconnected or short- Repair or replace the harness.
circuited. Replace the EGR valve.
CSD solenoid valve disconnected or short- Repair or replace the harness.
circuited. Replace the CSD valve solenoid.
Start assist relay disconnected or short- Repair or replace the harness.
∆
circuited. Replace the relay.
Main relay cannot be turned off Replace the relay.
Rack actuator relay disconnected or short- Repair or replace the harness.
?
circuited Replace the relay.
Error detected by ECU self diagnosis ? Replace the ECU.


Electrical Wiring TNV DI Service Manual WIRING DIAGRAM
ELECTRICAL WIRING
Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine
manufacturer for specific information.
KEY SWITCH* 30A

FUSE*
EMERGENCY
STOP
SWITCH*
Items marked with * are

not provided by Yanmar.
0000864A

WIRING DIAGRAM Electrical Wiring

SK 50p - Compressed

Uploaded by

Document Information

Original Description:

Original Title

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

SK 50p - Compressed

Uploaded by

Copyright:

Available Formats

HYDRAULIC EXCAVATOR

Book Code No.S5PS0010E01

2) WARNING- Indicates a potentially hazardous

The proper and safe lubrication and maintenance

2011-01 & ASSEMBLY

PS02-00101~ APPLICABLE MACHINES

1.1 GENERAL PRECAUTIONS FOR REPAIRS …………………………………………………………………1-3

Book Code No. S5PA0105E01

Issue Date of Issue Applicable Machines Remarks

April, 2010 SK50SR-5 : PJ06-09807~

September, 2010 SK55SRX : PS02-00101~

December, 2010 SK55SRX : PS02-00101~

January, 2011 SK50P : PS02-00101~

1.1 GENERAL PRECAUTIONS FOR REPAIRS

(1) Understanding operating procedure

(2) Cleaning machines

(3) Inspecting machines

1. Inspection date and place.

(5) Arrangement and cleaning in service shop

1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING

(7) Use proper tools, and replace or repair defective tools.

1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

(1) Removing hydraulic equipment

(2) Disassembling hydraulic equipment

(3) Inspecting parts

(4) Reassembling hydraulic equipment

(5) Installing hydraulic equipment

1.1.4 ELECTRICAL EQUIPMENT

(1) Do not disassemble electrical equipment.

Battery electrolyte is hazardous.

1.1.5 HYDRAULIC PARTS

(2) Flexible hose (F hose)

1.1.6 WELDING REPAIR

1.1.7 ENVIRONMENTAL MEASURE

1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on

2.1 COMPONENTS NAME …………………………………………………………………………………………2-3

Book Code No. S5PS0210E01

Issue Date of Issue Applicable Machines Remarks

2.1 COMPONENTS NAME

2.2 MACHINE DIMENSIONS

(1) SK50P (CANOPY)

2.3 SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY

SIDE DIGGING & DOZER

This figure is calculated with Japanese standard bucket.

2.4 MACHINE & COMPONENTS WEIGHT (DRY)

Mark * shows dry weight.

(1) LOADING MACHINE ON A TRAILER

Do not put chains over or against hydraulic lines or hoses.

6. Fasten machine to trailer with chains or cables.

a. Extend the bucket cylinder fully.

(2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT

2. ARM & BUCKET

5. DOZER w/o cylinder weight

2.6 TYPE OF CRAWLER SHOES

2.7 TYPE OF BUCKET

2.8 ENGINE SPECIFICATIONS

2.8.2 ENGINE PERFORMANCE CURVE

Book Code No. S5PS0310E01

Issue Date of Issue Applicable Machines Remarks

3.1.1 BOOM DIMENSIONAL DRAWINGS

3.1.2 BOOM MAINTENANCE STANDARDS