Takeuchi Tb108 Service Sec Wat

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FOREWORD
This manual is intended for persons who engage in maintenance operations, and explains
procedures for disassembly and reassembly of the machine, check and maintenance procedures,
maintenance reference values, troubleshooting and outline specifications, etc. Please use this
manual as a reference in service activities to improve maintenance techniques.
Further, please be advised that items contained in this manual are subject to change without notice
due to design modifications, etc.
MACHINE FRONT AND REAR, LEFT AND RIGHT

The end where the dozer blade is mounted is the front and the end with the travel motors is the
rear. Also the right and left sides of the operator when he is seated in the operator’s seat are the
right and left sides of the machine.
MACHINE SERIAL NUMBER

The machine serial number is stamped on the identification plate. When sending reports and
inquiries, and when ordering parts, etc., be sure to include this number.
MANUAL CONTROL
Information on those to whom this manual is distributed is recorded in the ledger in the section
in charge at this company, so please decide on a person to be in charge of it and control it. When
there are updates or additions, etc., we will notify the person in charge.
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FOOT OF THE PAGE
6. Bleed the air from the cylinders.

a. With the engine running at slow, extend and contract the
cylinders 4 or 5 times.
• Move the piston rods to 100 mm before the stroke end.
DO NOT extend them completely.
b. Repeat step “a” above with the engine running at full,
then run it at slow and extend the piston rods completely
to the stroke end.
L4A100E
1. Page number
The following page numbers are assigned to each respective page. And if there are additional pages, the addition
codes are supplied. Please file the sheets in the order of the page numbers.
Page No.
X–XX
Page number within chapter
Chapter Number
Page Addition
X–XX–X
Addition Code
Example: II-8
II-9
II-9-1 ............... A page is added between page 9 and page 10.
II-10
2. Revision number
Indicates the number of revisions made to this manual. This number is printed on the page that reflects this
revision.
If a page has been revised, it is to be used in place of the page used before revision and it is not necessary to keep
the old page.
3. Model(s)
SYMBOLS
means “Please refer to the section quoted.”
Indicates the tightening torque at the specific section that requires special attention in designing.
Indicates the mass of a part or device.
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TB108 0-6
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I . GENERAL
II . SPECIFICATIONS
III . MACHINE CONFIGURATION
IV . HYDRAULIC UNITS
V. TROUBLESHOOTING
VI . ENGINE
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I . GENERAL
I-1 TB108
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GENERAL
CONTENTS
Safety Precautions ................................................................................................................................................. 3

Cautions during Disassembly and Assembly ........................................................................................................ 9
Cautions during Removal and Installation of the Hydraulic Units ....................................................................... 9
Cautions during Removal and Installation of Piping .......................................................................................... 10
Handling of Seals ................................................................................................................................................ 10
Tightening Torques ............................................................................................................................................. 11
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GENERAL
SAFETY PRECAUTIONS
SAFETY ALERT SYMBOL

This symbol means Attention! Be Alert! Your Safety Is Involved.
The message that follows the symbol contains important information about safety.
Read and understand the message to avoid personal injury or death.
■ SIGNAL WORDS
Safety messages appearing in this manual and on machine decals are identified by the words “DANGER”,
“WARNING” and “CAUTION”. These signal words mean the following:
DANGER WARNING CAUTION

The word “DANGER” indicates The word “WARNING” indi- The word “CAUTION” indi-
an imminently hazardous situ- cates a potentially hazardous cates a potentially hazardous
ation which, if not avoided, can situation which, if not avoided, situation which, if not avoided,
result in serious injury or death. could result in serious injury or may result in minor or moder-
death. ate injury.
IMPORTANT: The word “IMPORTANT” is used to alert against operators and maintenance personnel
about situations which can result in possible damage to the machine and its components.
This manual is intended for trained and qualified personnel only. Warnings or cautions described in this manual do
not necessarily cover all safety measures. For maintenance work, each person must take adequate safety precautions
against possible hazards present in the respective working environment.
Observe all safety rules
• Operation, inspection and maintenance of this ma-

chine must be performed only by a trained and
qualified person.
• All rules, regulations, precautions and safety pro-
cedures must be understood and followed when
performing operation, inspection and maintenance
of this machine.
• Do not perform any operation, inspection and
maintenance of this machine when under the ad-
verse influence of alcohol, drugs, medication, fa-
tigue, or insufficient sleep.
• Wear a hard hat, safety shoes, safety glasses, filter

Wear appropriate clothing and personal mask, heavy gloves, ear protection and other pro-
protective equipment tective equipment as required by job conditions.
Wear required appropriate equipment such as safety
• Do not wear loose clothing or any accessory that glasses and filter mask when using grinders, ham-
can catch on controls or in moving parts. mers or compressed air, as metal fragments or
• Do not wear oily or fuel stained clothing that can other objects can fly and cause serious injury.
catch fire. • Use hearing protection when operating the ma-
chine. Loud prolonged noise can cause hearing
impairments, even the total loss of hearing.
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GENERAL
Provide a fire extinguisher and first aid Anti-explosive lighting
kit
Use anti-explosive electrical fixtures and lights when

• Know where a fire extinguisher and first aid kit are inspecting fuel, oil, coolant, battery fluid, etc. If
located and understand how to use them. lighting that is not anti-explosive should break, the
• Know how to contact emergency assistance and substance could ignite, resulting in serious injury or
first aid help. death.
Attach a “DO NOT OPERATE” tag Do not allow unauthorized personnel in

the work area
Severe injury could result if an unauthorized person
should start the engine or touch controls during in-
spection or maintenance.
• Stop the engine and remove the key before per-
forming maintenance.
• Attach a “DO NOT OPERATE” tag to the starter
switch or control lever.
Use the correct tools

Do not allow unauthorized personnel in the work
area. Chips or other debris can fly off machine parts
when grinding, welding or using a hammer.
Prepare the work area
• Select a firm, level work area. Make sure there is

adequate light and, if indoors, ventilation.
• Clear obstacles and dangerous objects. Eliminate
Do not use damaged or weakened tools or tools slippery areas.
designed for other purposes. Use tools suited for the
operation at hand.
Replace important safety parts

periodically
• Replace fuel hoses periodically. Fuel hoses be-

come weaker over time, even if they appear to be
in good shape.
• Replace important safety parts whenever an ir-
regularity is found, even if it is before the normal
time for replacement.
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GENERAL
Always clean the machine Securely block the machine or any
component that may fall
• Clean the machine before performing maintenance.

• Cover electrical parts when washing the machine. • Before performing maintenance or repairs under
Water on electrical parts could cause short-circuits the machine, set all working equipment against the
or malfunctions. ground or in the lowermost position.
Do not use water or steam to wash the battery, • Securely block the tracks.
sensors, connectors or the operator’s seat area. • If you must work beneath the raised machine or
equipment, always use wood blocks, jack-stands
or other rigid and stable supports. Never get under
Stop the engine before performing the machine or working equipment if they are not
maintenance sufficiently supported. This procedure is espe-
cially important when working on hydraulic cylin-
• Avoid lubrication or mechanical adjustments with ders.
the machine in motion or with the engine running
while stationary.
• If maintenance must be performed with the engine
running, always work as a 2-person team with one
person sitting in the operator’s seat while the other Securely block the working equipment
works on the machine.
• When performing maintenance, be sure to keep To prevent unexpected movement, securely block the
your body and clothing away from moving working equipment when repairing or replacing the
parts. cutting edges or bucket teeth.
Stay clear of moving parts
Secure the engine hood or cover when

opened
Be sure to secure the engine hood or cover when

opening it. Do not open the engine hood or cover on
slopes or in strong wind.
• Stay clear of all rotating and moving parts. Wrap-

ping or entanglement may result in serious injury Cautions on tilting up the platform
or death.
• Keep hands, clothing and tools away from the • Raising or lowering the platform while the engine
rotating fan and running fan belts. is running may cause the machine to move, and
cause serious injury or death.
Stop the engine before raising or lowering the
platform.
• When the floor is tilted up, support it firmly with
the stopper to prevent it from falling.
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GENERAL
Place heavy objects in a stable position Handling of hoses
Fuel, oil or hydraulic fluid leaks can cause a fire.

• Do not twist, bend or hit the hoses.
• Never use twisted, bent or cracked hoses, tubes and
pipes. They may burst.
• Retighten loose connections.
Be careful with hot and pressurized

components
When removing or installing the hoe attachment,
place it in a stable position so that it does not tip over.
Use caution when fueling
Stop the engine and allow the machine to cool down

before performing inspection and maintenance.
• The engine, muffler, radiator, hydraulic lines, slid-
ing parts and many other parts of the machine are
hot directly after the engine is stopped. Touching
these parts will cause burns.
• The engine coolant, oil and hydraulic fluid are also
hot and under high pressure.
Be careful when loosening caps and plugs. Work-
• Do not smoke or permit open flames while fueling ing on the machine under these conditions could
or near fueling operations. result in burns or injuries due to the hot oil spurting
• Never remove the fuel cap or refuel with the engine out.
running or hot. Never allow fuel to spill on hot
machine components.
• Maintain control of the fuel filler nozzle when Be careful with hot cooling systems
filling the tank.
• Do not fill the fuel tank to capacity. Allow room for
expansion.
• Clean up spilled fuel immediately.
• Tighten the fuel tank cap securely. Should the fuel
cap be lost, replace it only with the original
manufacturer’s approved cap. Use of a non-ap-
proved cap without proper venting may result in
pressurization of the tank.
• Never use fuel for cleaning purposes.
• Use the correct fuel grade for the operating season. Do not remove the radiator cap or drain plugs when
the coolant is hot. Stop the engine, let the engine and
radiator cool and loosen the radiator cap or drain plugs
slowly.
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GENERAL
Be careful with fluids under pressure Be careful with grease under pressure
The track adjuster contains highly pressurized grease.

If the tension is adjusted without following the pre-
Pressure can be maintained in the hydraulic circuit scribed procedure, the grease discharge valve may fly
long after the engine has been shut down. off, resulting in injury.
• Release all pressure before working on the hydrau- • Loosen the grease discharge valve slowly. Do not
lic system. unfasten it more than one full turn.
• Hydraulic fluid under pressure can penetrate the • Do not put your face, arms, legs or body in front of
skin or eyes and cause injury, blindness or death. the grease discharge valve.
Fluid escaping from a small hole can be almost
invisible. Wear a safety goggles and heavy gloves
and use a piece of cardboard or wood to search for Disconnect the battery
suspected leaks.
If fluid is injected into the skin, it must be removed
within a few hours by a doctor familiar with this
type of injury.
Release all pressure before working on

the hydraulic system
Oil may spurt out if caps or filters are removed or

pipes disconnected before releasing the pressure in Disconnect the battery before working on the electri-
the hydraulic system. cal system or doing any welding. Remove the nega-
• Gradually loosen the vent plug to relieve tank tive (–) battery cable first. When reconnecting the
pressure. battery, connect the negative (–) battery cable last.
• Move all the control levers and pedals several
times in all directions to release the pressure from
the working equipment circuitry. (For link type
controls)
• When removing plugs or screws or disconnecting
hoses, stand to the side and loosen slowly to gradu-
ally release the internal pressure before removing.
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GENERAL
Avoid battery hazards Checks after maintenance
• Batteries contain sulfuric acid which will damage • Gradually raise the engine speed from a low idle to
eyes or skin on contact. maximum speed and check that no oil or air is
• If acid contacts eyes, flush immediately with leaking from serviced parts.
clean water and get prompt medical attention. • Move the controls and check that the machine is
• If acid is accidentally swallowed, drink large operating properly.
quantities of water or milk and call a physician
immediately.
• If acid contacts skin or clothing, wash off imme-
diately with clean water.
• Wear safety glasses and gloves when working with Disposing of wastes
batteries.
• Batteries generate flammable and explosive gases.
Keep arcs, sparks, flames and lighted tobacco
away.
• Use a flashlight to check battery electrolyte level.
• Stop the engine and shut off electrical equipment
while inspecting or handling the battery.
• Do not short circuit the battery posts with metal
items.
• Always unfasten the negative (–) battery cable first
when disconnecting the battery cable. Always con- • Funnel spent fluids from the machine into contain-
nect the negative (–) battery cable last when fasteners. Disposing of fluids improperly destroys the
ing the battery cable. environment.
• Loose battery terminals may result in sparks. Be • Follow the prescribed regulations when disposing
sure to fasten terminals tightly. of oil, fuel, engine coolant, refrigerant, solvents,
• Make sure the vent caps are tightened securely. filters, batteries or other harmful substances.
• Do not charge a battery or jump-start the engine if
the battery is frozen. Warm to 15°C (60°F) or the
battery may explode.
Have a Takeuchi service agent repair

welding cracks or other damage
Ask a Takeuchi service agent to repair any welding

problems which are detected. If not feasible, make
sure the welding is done by a qualified person in a
properly equipped workplace.
Safety signs
• Keep all safety signs clean and legible.

• Replace all missing, illegible or damaged safety
and warning signs.
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GENERAL
CAUTIONS DURING DISASSEMBLY AND CAUTIONS DURING REMOVAL AND
ASSEMBLY INSTALLATION OF THE HYDRAULIC UNITS
1. Clean the machine before disassembly operation. 1. Make sure that the temperature of the hydraulic
oil has dropped.
2. Before disassembly, check the machine condi-
tions and record them. 2. To prevent a loss of flow of the hydraulic oil, the
• Model, Machine Serial Number, Hourmeter residual pressure in the piping and the internal
• Reason for Repairs, Repair History pressure in the hydraulic tank should be released.
• Dirtiness of Filters
• Fuel and Oil Conditions 3. Be sure to install caps or plugs on all openings in
• Damage to each parts, etc. the hydraulic unit to prevent dirt from getting into
the unit through the openings.
3. To make reassembly operations easy, make match-
PLUG
ing marks at the necessary points.
4. Clean all disassembled parts and new parts, then

arrange them in the proper sequence.
5. Be sure to replace all seals and cotter pins, etc.,

with new parts.
PLUG
6. Keep parts which should not come in contact with
oil and water separate from parts with oil on them.
• Electrical Parts, Rubber, V-Belts, etc.
7. When installing bearings, bushings and oil seals,

as a rule, use a press. When a hammer, etc., is 4. It is easy to mistake hydraulic oil adhering to the
used, it leaves bruises. hydraulic unit for an oil leak, so wipe the unit off
thoroughly.
8. Wipe all joining surfaces clean so that there is no
dirt or dust adhering to them. 5. Be sure that no damage is done to the plating on
the rod in the hydraulic cylinder.
9. Wrap seal tape from the front end, Wrapping it
tight and leaving 1 or 2 threads bare, Overlap the 6. As a rule, removal and installation of the hydrau-
tape by about 10 mm. lic cylinder should be done with the rod fully
retracted.
SEALING TAPE
7. Be sure to bleed the air after replacing the hydrau-
lic oil or removing any of the hydraulic devices.
“III. Machine Configuration, Hydraulic Sys-
tem”
8. After installation of the hydraulic unit, be sure to

pressurize the hydraulic tank. If this operation is
LEAVE 1 OR 2 THREAD MARGIN
forgotten, it could cause cavitation of the hydrau-
lic pump. Also, it could have a drastic effect on
the life of the hydraulic pump.
10. When fitting the snap rings, the bigger, rounder “III. Machine Configuration, Hydraulic Sys-
side of their circumferences should face the mat- tem”
ing surfaces.
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GENERAL
CAUTIONS DURING REMOVAL AND HANDLING OF SEALS
INSTALLATION OF PIPING
1. Clean the grooves for O-rings and if there is any
1. When hydraulic hoses are installed, tighten them burr, etc., remove it.
once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed
torque.
• Tighten the fittings after the installation sur- BURR
faces fit snugly together.
• Pieces wrapped with seal tape are excluded.
2. Use 2 spanners, each on an opposite side, to DIRT

remove and tighten fittings so that the hoses or
steel pipes are not twisted.
2. Be careful not to twist O-rings. If an O-ring is

twisted, remove the twist with the fingertips.
3. During insertion, be careful not to damage the

seal.
4. Handling of Floating Seals

• Wipe all oil off the O-ring and housing of the
floating seal.
• When assembling, apply a thin coating of gear
3. After installation of hydraulic hoses or steel pipes, oil to the contact surface of the housing.
apply the maximum working pressure 5 or 6 times • After assembly, turn the seal 2 or 3 times to get
and confirm that there is no leakage. it to fit snugly.
5. Apply grease to the lip of the oil seal.

• This is to prevent wear when it is first started up
after assembly.
GREASE
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GENERAL
TIGHTENING TORQUES
Hydraulic Hoses
Torque
UNION NUT
Hose Fitting Size Union Nut (G) Taper Thread (R)
N·m ft-lb N·m ft-lb
1/8 9.8 +4.9
0 7.3 +3.5
0 11.8 ±1.2 8.7 ±0.8
1/4 24.5 +4.9
0 18.1 +3.5
0 29.4 ±2.9 21.7 ±2.1 TAPER THREAD
3/8 49 +4.9
0 36.2 +3.5
0 53.9 ±5.4 39.8 ±3.9
1/2 58.8 +4.9
0 43.4 +3.5
0 88.3 ±8.8 65.1 ±6.4
3/4 117.7 +4.9
0 86.8 +3.5
0 147.1 ±14.7 108.5 ±10.7
1 137.3 +4.9
0 101.3 +3.5
0 196.1 ±19.6 144.7 ±14.3
Bite Type Pipe Fitting for Steel Pipe
Pipe Outer Diameter Torque

(mm) N·m ft-lb
8 34.3 ±4.9 25.3 ±3.5
10 41.7 ±2.5 30.7 ±1.7
12 58.8 ±4.9 43.4 ±3.5
15 88.3 ±4.9 65.1 ±3.5
16 93.2 ±4.9 68.7 ±3.5
18 132.4 ±4.9 97.6 ±3.5
22 205.9 ±9.8 151.8 ±7.2
27.2 245.2 ±9.8 181.0 ±7.2
28 313.8 ±19.6 231.4 ±14.3
32 313.8 ±19.6 231.4 ±14.3
35 411.9 ±19.6 303.7 ±14.3
I-11 TB108
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GENERAL
Joints for Piping
Torque
Nominal Thread
Diameter Steel Cast Steel
(R) N·m ft-lb N·m ft-lb
1/8 11.8 ±1.2 8.7 ±0.8 10.8 ±1.1 8.0 ±0.7
1/4 29.4 ±2.9 21.7 ±2.1 24.5 ±2.5 18.1 ±1.7
3/8 53.9 ±5.4 39.8 ±3.9 49 ±4.9 36.2 ±3.5
1/2 88.3 ±8.8 65.1 ±6.4 73.5 ±7.4 54.3 ±5.3
3/4 147.1 ±14.7 108.5 ±10.7 127.5 ±12.7 94.1 ±9.3
1 196.1 ±19.2 144.7 ±14.3 171.6 ±17.2 126.6 ±12.5
Joints for Piping (O-ring Seal Type)

Nominal Thread Torque
Diameter
(G) N·m ft-lb
1/8 19.6 ±2.0 14.5 ±1.4
1/4 34.3 ±4.9 25.3 ±3.5
3/8 53.9 ±4.9 39.8 ±3.5
1/2 63.7 ±4.9 47.0 ±3.5
3/4 93.2 ±4.9 68.7 ±3.5 O-RING
1 107.9 ±9.8 79.5 ±7.2

1-1/4 117.7 ±9.8 86.8 ±7.2
1-1/2 137.3 ±9.8 101.2 ±7.2
Nominal Thread Torque

Diameter
(UNF) N·m ft-lb
7/16–20 16.7 ±2.0 12.3 ±1.4
1/2–20 22.6 ±2.0 16.6 ±1.4
9/16–18 31.4 ±2.9 23.1 ±2.1
3/4–16 59.8 ±4.9 44.1 ±3.5
1-1/16–12 102.0 ±5.9 75.2 ±4.4
1-5/16–12 135.3 ±7.8 99.8 ±5.8
1-5/8–12 181.4 ±9.8 133.8 ±7.2
TB108 I-12
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GENERAL
Bolts and Nuts (for ISO Strength Category 10.9)
Torque
Thread Size × Pitch General Tightening Points Special Tightening Points
N·m kgf·m ft-lb N·m kgf·m ft-lb
M6 × 1.0 9.8 ±0.5 1.0 ±0.05 7.2 ±0.4 11.8 ±0.6 1.2 ±0.06 8.7 ±0.4
M 8 × 1.25 22.6 ±1.1 2.3 ±0.11 16.6 ±0.8 26.5 ±1.3 2.7 ±0.13 19.5 ±0.9
M10 × 1.5 47.1 ±2.4 4.8 ±0.24 34.7 ±1.7 54.9 ±2.7 5.6 ±0.28 40.5 ±2.0
Coarse M12 × 1.75 83.4 ±4.1 8.5 ±0.42 61.5 ±3.0 97.1 ±4.8 9.9 ±0.49 71.6 ±3.5
M14 × 2.0 134.4 ±6.7 13.7 ±0.68 99.1 ±4.9 155.9 ±7.7 15.9 ±0.79 115.0 ±5.7
M16 × 2.0 207.9 ±10.4 21.2 ±1.06 153.3 ±7.7 241.2 ±12.1 24.6 ±1.23 177.9 ±8.9
M20 × 2.5 410.9 ±20.5 41.9 ±2.09 303.1 ±15.1 475.6 ±23.7 48.5 ±2.42 350.8 ±17.5
M8 × 1.0 24.5 ±1.2 2.5 ±0.12 18.1 ±0.9 28.4 ±1.4 2.9 ±0.14 21.0 ±1.0
M10 × 1.25 50.0 ±2.5 5.1 ±0.25 36.9 ±1.8 58.8 ±2.9 6.0 ±0.30 43.4 ±2.2
M12 × 1.5 87.3 ±4.3 8.9 ±0.44 64.4 ±3.2 102.0 ±5.1 10.4 ±0.52 75.2 ±3.8
Fine
M14 × 1.5 135.3 ±6.8 13.8 ±0.69 99.9 ±5.0 157.9 ±7.8 16.1 ±0.80 116.5 ±5.8
M16 × 1.5 220.6 ±11.0 22.5 ±1.12 162.7 ±8.1 256.0 ±12.7 26.1 ±1.30 188.8 ±9.4
M20 × 1.5 452.1 ±22.6 46.1 ±2.30 333.4 ±16.6 524.7 ±26.1 53.5 ±2.66 387.0 ±19.2
1. General Tightening Points (Non-lubricated) 4. If tightening torque values are provided in this
• All securing points other than the special tight- manual, then tightening should be done accord-
ening points. ing to those values.
(This indicates that the tightening torque differs
2. Special Tightening Points (Grease with molyb- from the values given in this table.)
denum disulfide applied.)
• Points where particularly necessary due to 5. In order to tighten bolts and nuts evenly, they
function. should be tightened alternately top, bottom, left,
Special tightening positions and associated right.
instructions are given in the text.
3. Points where thread-locking compound is used

(Three Bond #1324 is applied.)
Thread-locking compound positions and associ-
ated instructions are given in the text.
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GENERAL
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II . SPECIFICATIONS
II-1
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SPECIFICATIONS
CONTENTS
Names of Components .......................................................................................................................................... 3

Dimensions ............................................................................................................................................................ 4
Lifting Capacities .................................................................................................................................................. 5
Specification Tables .............................................................................................................................................. 8
Mass Tables ......................................................................................................................................................... 12
Recommended Lubricants ................................................................................................................................... 13
Servicing Standards ............................................................................................................................................. 14
Standards for Judging Performance ..................................................................................................................... 17
Reference Value Table .................................................................................................................................. 17
Methods for Inspecting Performance ............................................................................................................ 19
In regard to Standard Values and Allowable Values

The terms used in the items “Servicing Standards” and “Standards for Judging Performance” have the following
meanings.
Standard Value ......... This indicates the standard value for the new machine at the time of shipping from the factory.
It should be used as the target value for maintenance work after operation.
Allowable Value ....... The dimensions of parts change during use because of wear and deformation. Also, the
performance of pumps, motors, and other hydraulic equipment drops, and this is the
estimated value indicating the use limit for the respective part. It is decided under reference
to the standard at the time of shipping, the results of various tests, etc. As the use conditions,
the degree of repairs, etc., differ for each machine, these should be combined and used as
reference for servicing standards and standards for judging performance.
* Do not use the standard values and the allowable values as standards for customer claims.
TB108 II-2
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NAMES OF COMPONENTS SPECIFICATIONS

NAMES OF COMPONENTS
3
11
7
10
8 2
6
9
25
24 4
23
5
26 12
22
16
20
15 28
21
27 14
19 18
17 13 B5B000
1. Canopy 11. Engine 21. Bucket

2. Engine Hood 12. Crawler Belt 22. Bucket Cylinder
3. Fuel Tank 13. Idler 23. Arm
4. Hydraulic Tank 14. Track Roller 24. Arm Cylinder
5. Hydraulic Pump 15. Swing Cylinder 25. Boom
6. Slew Motor 16. Travel Motor 26. Boom Cylinder
7. Right Operating Lever 17. Dozer Blade 27. Swing Bracket
8. Battery 18. Track Adjuster 28. Spanner Cylinder
9. Control Valve 19. Dozer Blade Cylinder
10. Left Operating Lever 20. Swivel Joint
II-3 TB108
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SPECIFICATIONS DIMENSIONS
DIMENSIONS
Machine Dimensions
T Unit: mm
L Standard Arm Long Arm
A 2710 2740
N
X P B 740 @
M
Y C 2110/2195* @
D D 800 @
Z
U E 385 @
F 900 @
B
X G 1220 @
H 900 @
J 180 @
K 160 @
L 790 825
C
M 440 @
V N 340 @
P 900 @
E
K S Q 1920 1955
J F R 740 @
W G
H Q R S 200 @
A T 90° @
B5B001
U 90° @
V 1375 @
W 680 @
X 680 @
Y 1080 1125
Z 880 915
* Option: With Lift Eyes
Operating Range
Unit: mm
Standard Arm Long Arm
E A 2825 2970
F B 2730 2880
C 1530 1680
G D 1220 1370
J E 2860 2975
F 2030 2145
K G 900 760
H 1890 1915
D
C J 155 @
K 120 @
H
B
A
B5B002
TB108 II-4
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LIFTING CAPACITIES SPECIFICATIONS

LIFTING CAPACITIES
Rated Lift Capacity Chart
• The loads in the charts do not exceed 87% of
hydraulic lift capacity or 75% of tipping load.
• Rated lift capacities limited by rated hydraulic lift
capacity are identified by an asterisk(*)
• The mass of slings and any auxiliary lifting devices
shall be deducted from the rated load to determine
the net load that may be lifted.
• The load point is the bucket hinge pin, and the
bucket posture is with the standard bucket com-
pletely retracted under the arm.
• Units: daN (lbs.)
Load Hooking System

A load hooking system with all of the following
capacities must be provided and used.
1. A system which can withstand a weight of two
times the rated lift capacity no matter at what
position the load is applied.
2. A system in which there is no risk of the lifted load
falling from the hooking device, for example one
equipped with a hook slippage prevention device.
3. A system in which there is no risk of the hooking
system slipping from the hoe attachment.
WARNING
• DO NOT attempt to lift or hold any load that is
greater than these rated values at their speci-
fied load radii and height.
• All rated lift capacities are based on the ma-
chine being level and on a firm supporting
surface. For safe working loads, the user is
expected to make due allowance for the par-
ticular job conditions such as soft or uneven
ground, non-level condition, side loads, haz-
ardous conditions, experience of personnel,
etc. The operator and other personnel should
fully acquaint themselves with the operator’s
manual furnished by the manufacturer before
operating this machine, and rules for safe
operation of equipment shall be adhered to at
all times.
II-5 TB108
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SPECIFICATIONS LIFTING CAPACITIES
Equipped with Standard Arm Unit: daN (lbs.)
Over Front; Dozer Blade Up
Over Rear Over Side Upper Crawler width 900 mm

Lower Crawler width 680 mm
B5B004
TB108 II-6
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LIFTING CAPACITIES SPECIFICATIONS

Equipped with Long Arm Unit: daN (lbs.)
Over Front; Dozer Blade Up
Over Rear Over Side Upper Crawler width 900 mm

Lower Crawler width 680 mm
B5B006
II-7 TB108
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SPECIFICATIONS SPECIFICATION TABLES
SPECIFICATION TABLES
SPECIFICATIONS
Serial Number 10820001~

Machine Type With Canopy Canopy Less
Machine Mass (not including operator)
Rubber Crawler kg 855 810
Steel Crawler kg ± ±
Engine Rated Output kW/min–1 7.1/2400 @
Bucket Capacity (Standard Bucket)
Rated Capacity m3 0.018 @
Struck Capacity m3 0.013 @
Performance
Slew Speed min–1 9.3 @
Travel Speed: Rubber Crawler 1st/2nd km/h 2.0/3.9 @
Steel Crawler 1st/2nd km/h ± ±
Gradeability % (degree) 47 (25) @
Ground Pressure: Rubber Crawler kPa 25.1 23.8
Steel Crawler kPa ± ±
Noise Level: Sound-power level dB (A) LwA 93 @
Sound-pressure level dB (A) LpA 80 @
Auxiliary Hydraulic Flow Rate L/min 21.4 @
Dimensions
Overall Length in Transport Position mm 2710 @
Overall Width mm 900 @
Overall Height mm 2110 1375
Dimensions of Base Machine
Tail Swing Radius mm 800 @
Distance of Rearmost Upper Structure from Axis of Rotation mm 790 @
Clearance Height under Upper structure mm 385 @
Crawler base mm 900 @
Crawler: Overall Length mm 1220 @
Overall Width mm 900/680 @
Crawler Shoe Width mm 180 @
Minimum Ground Clearance mm 160 @
TB108 II-8
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SPECIFICATION TABLES SPECIFICATIONS

Machine Type Standard Arm Long Arm
Working Equipment (Hoe Attachment)
Boom Swing Angle: L.H. degree 90 @
R.H. degree 90 @
Maximum Reach mm 2825 2970
Maximum Reach at GRP mm 2730 2880
Minimum Level Cut Radius with Bucket Flat on GRP mm 930 845
Maximum Digging Depth mm 1530 1680
Radius at Maximum Digging Depth mm 1210 @
Vertical Digging Depth mm 1220 1370
Maximum Digging Height mm 2860 2975
Radius at Maximum Digging Height mm 1330 1425
Maximum Dumping Height mm 2030 2145
Radius at Maximum Dumping Height mm 1260 1360
Minimum Dumping Height mm 900 760
Minimum Front Swing Radius mm 1080 1125
Minimum Front Swing Radius at Boom Offset mm 790 825
Overall Height at Minimum Front Swing Radius mm 2160 @
Overall Height at Minimum Front Swing Radius at Boom Offset mm 2160 @
Maximum Bucket Offset Volume: Left mm 440 @
Right mm 340 @
Digging Force: Bucket kN 10.2 @
Arm kN 6.6 5.8
Working Equipment (Dozer Blade)
Dozer Blade: Width mm 680/900 @
Height mm 200 @
Dozer Blade: Lift Height mm 155 @
Depth of Cut mm 120 @
II-9 TB108
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SPECIFICATIONS SPECIFICATION TABLES
SPECIFICATIONS OF DEVICE
Engine
Model Yanmar 2TNV70-PTB
Type 4-Cycle, vertical, water-cooled, in-line, 2-cylinder diesel engine
Number of Cylinders-Bore × Stroke mm 2-70 × 74
Total Displacement L 0.569
Compression Ratio 23.4 : 1
Performance
Maximum Torque N·m/min-1 31.4~34.3/1800 ±100
Maximum No-load R.P.M. min-1 2570 ±25
Minimum No-load R.P.M. min-1 1100 ±25
Specific Fuel Consumption g/kW·h <
= 287
Starter V–kW 12–1.0
Generator V–kW 12–0.18
Battery V–A·h 12–34
Hydraulic Pump
Model DDG05A4.5·4.5F2H1-R256
Type Double gear
Delivery: P1 L/min 10.7
P2 L/min 10.7
Rated Pressure:P1 MPa 15.7
P2 MPa 15.7
Control Valve (9-Section)

Model NSC10
Number of Circuits 9
Main Relief Valve Pressure Setting MPa 15.7
Port Relief Valve Pressure Setting MPa 18.6
Boom Cylinder
Bore Diameter × Rod Diameter mm 50 × 25
Stroke mm 300
Fully Retracted Length (Pitch) mm 560
Cushion Mechanism Rod Side
Arm Cylinder
Stroke mm 320
Cushion Mechanism ±
TB108 II-10
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SPECIFICATION TABLES SPECIFICATIONS
Bucket Cylinder
Stroke mm 285
Swing Cylinder
Stroke mm 370
Dozer Blade Cylinder

Stroke mm 75
Spanner Cylinder
Stroke mm 220
Travel Motor
Model PHK-80-25B-1-8032A
Type Piston Motor
Total Displacement cm3/rev 288
Motor Displacement cm3/rev 11.4
Reduction Gear Ratio 1/25.26
Parking Brake Torque N·m 17.6
Parking Brake Release Pressure MPa 1.5
Amount of Reduction Gear Lubricant L 0.33
Slew Motor
Model 2-200DOS-E3792
Type Orbit Motor
Total Displacement cm3/rev 195
Relief Valve Pressure Setting MPa 6.4
Swivel Joint
Model YV-7108B
II-11 TB108
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SPECIFICATIONS MASS TABLES
MASS TABLES
UNIT MASS (Dry Mass)
Unit: kg
Upper Machinery
Engine 84
Radiator 3.2
Gear Pump 3.6
Hydraulic Tank 13
Fuel Tank 8
Control Valve 11
Slew Motor 15
Canopy 40
Counterweight 36
Swing Bracket 16
Swing Cylinder 9
Lower Machinery
Swivel Joint 13
Slew Bearing 18
Crawler Belt 24
Travel Motor 14
Track Roller 2.2
Idler 6.4
Sprocket 3.9
Track Adjuster 1.4
Dozer Blade 33
Dozer Blade Cylinder 5.5
Hoe Attachment
Boom 33
Arm: Standard/Long 14/16
Bucket: Standard 15
Boom Cylinder 9
Arm Cylinder 9.3
Bucket Cylinder 7.5
TB108 II-12
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RECOMMENDED LUBRICANTS SPECIFICATIONS

RECOMMENDED LUBRICANTS
Use different fuels, lubricants and greases according to the temperature, referring to the chart below.
• Change the lubricant earlier than as show in the table if it is extremely dirty or its performance has deteriorated
severely.
• Whenever possible, use the same brand of lubricant as before. If changing with a different brand, replace the entire
quantity – do not mix different brands.
Type by temperature
Replacement
Part Type -22 -4 14 32 50 68 86 104°F Capacity
interval
-30 -20 -10 0 10 20 30 40°C
Diesel engine Upper limit:

SAE 5W-20 After first 50
oil 1.7 L
Engine oil pan SAE 10W-30 hrs.
API class. Lower limit:
SAE 15W-40 Every 250 hrs.
CD 1.0 L
Total system:
ISO VG68
Antiwear 14 L
Hydraulic tank ISO VG46 Every 2000 hrs.
hydraulic oil Tank level:
ISO VG32 7.3 L
Use a clean, Quality fuel for performance and optimum engine life.
• To prevent fuel flow problems in cold weather, use diesel
fuel with a pour point of at least -12°C (10°F) below the
Fuel tank Diesel fuel lowest expected ambient temperature. 8L
• Minimum cetane number is 45. Low temperature or high
altitude operation may require the use of fuel with a
higher cetane number.
Engine cooling Coolant 30% coolant mixture

Every 1000 hours 2.8 L
system (water*+Coolant**) 50% coolant mixture
Travel reduc- After first 250 hrs.
0.33 L each
tion gear Gear oil Every 1000 hrs.
SAE 90
Track Roller API GL-4 ± 20 mL
Idler ± 17 mL
Slew motor pinion ±± Every 50 hrs.
Slew bearing Lithium grease ±± Every 50 hrs.

EP-2 As required
Working NLGI No. 2 Daily or every
equipment ±± 10 hrs.
Levers ±± When required
* For water, use tap water (soft). Do not use well or river water.
** When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the coolant manufacture’s
instructions to determine the mixture ratio.
II-13 TB108
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SPECIFICATIONS SERVICING STANDARDS
SERVICING STANDARDS
TRAVEL SYSTEM
Track Roller
Unit: mm
Code Designated Standard
Basic Dimension Allowable Value

A
130 124 A B
B 25 ±±
B5B007
Drive Sprocket *
Unit: mm

A
249 243 )
B 19 16
."*!
Idler
Unit: mm

A
249 243 B A
B 25 ±±
B5B008
TB108 II-14
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SERVICING STANDARDS SPECIFICATIONS

ATTACHMENTS
Pin and Bushing Clearances
O L M B
D A
N C
P
Q
E
G
F
T
S
R
B5B014
II-15 TB108
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SPECIFICATIONS SERVICING STANDARDS
Unit: mm
Servicing
Code Item Designated Standard Procedure
Basic Allowable Tolerance Standard Allowable
Dimensions Shaft Hole Clearance Clearance
A Connection Between Bucket & 25 -0.02 +0.15 0.12~0.20 1.0
Arm -0.05 +0.10
B Connection Between Bucket & 25 -0.02 +0.15 0.12~0.20 1.0
Link -0.05 +0.10
C Connection Between Arm & 25 -0.02 +0.15 0.12~0.20 1.0
Link -0.05 +0.10
D Connection Between Bucket 25 -0.02 +0.15 0.07~0.20 1.0
Cylinder & Link -0.05 +0.05
E Connection Between Bucket 25 -0.02 +0.15 0.07~0.20 1.0
Cylinder & Arm -0.05 +0.05
F Connection Between Arm & 25 -0.02 +0.15 0.12~0.20 1.0
Boom -0.05 +0.10
G Connection Between Arm Cyl- 25 -0.02 +0.15 0.07~0.20 1.0
inder & Arm -0.05 +0.05
H Connection Between Arm Cyl- 25 -0.02 +0.15 0.07~0.20 1.0
inder & Boom -0.05 +0.05
I Connection Between Boom & 25 -0.02 +0.15 0.12~0.20 1.0
Swing Bracket -0.05 +0.10
J Connection Between Boom Cyl- 25 -0.02 +0.15 0.07~0.20 1.0
inder & Boom -0.05 +0.05
Replace
K Connection Between Boom Cyl- 35 -0.02 +0.15 0.07~0.20 1.0
inder & Swing Bracket -0.05 +0.05
L Connection Between Swing 45 -0.02 +0.15 0.12~0.20 1.0
Bracket & Turntable -0.05 +0.10
M Connection Between Swing 25 -0.02 +0.15 0.12~0.20 1.0
Bracket & Link -0.05 +0.10
N Connection Between Swing 25 -0.02 +0.15 0.12~0.20 1.0
Arm & Link -0.05 +0.10
Connection Between Swing -0.02 +0.15
O 25 +0.10 0.12~0.20 1.0
Arm & Turntable -0.05
P 30 +0.05 0.07~0.20 1.0
Cylinder & Swing Arm -0.05
Q 25 -0.05 +0.05 0.07~0.20 1.0
Cylinder & Turntable
Connection Between Dozer -0.02 +0.15
R 25 -0.05 +0.10 0.12~0.20 1.0
Blade & Lower Frame
S 25 -0.05 +0.05 0.07~0.20 1.0
Blade Cylinder & Dozer Blade
T Blade Cylinder & Lower Frame 25 -0.05 +0.05 0.07~0.20 1.0
TB108 II-16
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STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS

STANDARDS FOR JUDGING PERFORMANCE
REFERENCE VALUE TABLE

Item Unit Standard Values Allowable Values
Hydraulic Oil Pressure
Boom MPa 15.7 +1.2
-0.5 ±
Arm MPa 15.7 +1.2
-0.5 ±
Dozer Blade MPa 15.7 +1.2
-0.5 ±
Slew MPa 9.8 +3.9
0 ±
Pilot Pressure MPa ± ±
Travel
Travel Speed (5 rev.)
Steel Crawler Low Speed s ± ±
High Speed s ± ±
Rubber Crawler Low Speed s 23.6 ±1.7 27.7
High Speed s 12.6 ±1.7 16.1
Travel Speed (10m)
Steel Crawler Low Speed s ± ±
High Speed s ± ±
Rubber Crawler Low Speed s 17.5 ±1.5 20.8
High Speed s 9.3 ±1.2 11.8
Travel Curve mm 125-0125 500
Natural Travel drop mm 0 ±
Slew
Slew Time s 12.8 ±1.0 15.1
Overrun When Slewing Stops mm 30 ±18 55
Natural Slew Drop mm 120-0120 240
Cylinders
Cylinder Speed
Boom Extended s 1.9 ±0.4 2.5
Retracted s 2.1 ±0.4 2.7
Arm Extended s 4.2 ±0.5 5.1
Bucket Extended s 3.2 ±0.5 4.0
Dozer Blade Extended s 2.0 ±0.4 2.6
Swing Extended s 4.2 ±0.7 5.3
Spanner Extended s 5.5 ±0.8 6.9
II-17 TB108
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SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE

Item Unit Standard Values Allowable Values
Cylinders
Natural Cylinder Drop
0
Boom mm 14 -14 28
0
Arm mm 8 -8 16
Bucket mm 5 -50 10
Dozer Blade mm 5 -50 10
Swing mm 5 -50 10
0
Bucket Tip mm 125 -125 500
Levers
Lever Operating Force
Boom N 9.8 ±4.9
Arm N 9.8 ±4.9
Bucket N 9.8 ±4.9
Slew N 9.8 ±4.9
Travel N 12.8 ±5.9
Auxiliary N 49.0 ±19.6
Dozer Blade N 18.6 ±9.8
Swing N 49.0 ±19.6
Lever Play
0
Boom mm 20 -20
0
Arm mm 20 -20
0
Bucket mm 20 -20
0
Slew mm 20 -20
0
Travel mm 15 -15
0
Dozer Blade mm 15 -15
Slew Bearing
Backlash mm 20 ±15 75
Slew Bearing Play mm 0.3 ±0.1 1.0
Crawler Belt
Crawler Tension Steel mm ± ±
Rubber mm 53~58 ±
TB108 II-18
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METHODS FOR INSPECTING PERFORMANCE
Hydraulic Oil Pressure (Main Relief Valve Set

Pressure)
Boom, Arm, Dozer Blade
WARNING
When inspecting the performance of the ma-
chine that has an extendible crawler, it should be
done with the crawler fully extended.
Measuring Method
• Engine : Rated r.p.m.
• Hydraulic Oil Temp. : 50~60°C
• Mount the pressure gauge on the pressure detec-
tion port, operate the desired hydraulic circuit
and measure the relief pressure.
R1 R2
B5B009
Pressure Detection Port

Circuit Relief Valve A
Port Position Size
Boom A G1/4 R1
Arm B G1/4 R2
Dozer Blade B G1/4 R2 B
B5B010
Adjusting Method
1
1. Loosen locknut (2), then begin adjusting pressure
by turning setting screw (1). 2
Turning clockwise ................ raises the set pressure.
Turning counterclockwise .... lowers the set pressure.
2. In order to keep the setting screw from turning
after pressure has been adjusted, tighten the lock-
nut while at the same time holding the setting
screw firmly in place.
3. Operate the relief valve once more to confirm that
the pressure that has been set it stabilized.
B5B011
II-19 TB108
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Hydraulic Oil Pressure (Slewing Relief Valve

Set Pressure)
WARNING
Make absolute sure that the slew lock pin is
securely in place before relieving pressure.
Measuring Method R1
• Engine : Rated r.p.m. Av
• Connect the pressure gauge to the pressure de- A1
tection port. Fully retract the arm cylinder and R2
B1 Bv
turn it to the right or left to measure the relief
pressure. Before measurement, allow the relief
pressure to become stable by the actuation of the
slewing relief valve.
B5B012
Pressure Detection Port

Circuit Relief Valve A
Port Position Size
Right Slew B G1/4 R1
Left Slew B G1/4 R2
B
B5B010
Adjusting Method
1. Loosen locknut (2), then begin adjusting pressure
by turning setting screw (1).
Turning clockwise ................ raises the set pressure.
Turning counterclockwise .... lowers the set pressure.
2. In order to keep the setting screw from turning
after pressure has been adjusted, tighten the lock- 2 1
nut while at the same time holding the setting
screw firmly in place.
3. Operate the relief valve once more to confirm that
the pressure that has been set it stabilized.
B5B013
TB108 II-20
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Travel Speed (5 Revolutions)
• Measurement Posture : Excavator body raised
using both hoe attachment and dozer blade.
• Set crawler belts in motion. Starting after one
full revolution, measure the time required for 5
revolutions. (To measure speed after it has sta-
bilized.)
Travel Speed (10m)

• Measurement Posture : Travel Posture
• Set excavator in motion. Starting after a distance MEASURED
APPROACH
of 5 meters, measure the time required to travel STRETCH
START
10 meters. Do this on level ground.
■ Travel Posture
Fully extend the arm and bucket cylinders and
adjust the hoe attachment so that its lowest part
is even with the excavator’s minimum ground
clearance level. The hoe attachment, of course, MIN. GROUND
should be in a no-load state and the dozer blade CLEARANCE
should not be touching the ground.
Travel Curve
• Measurement Posture : Travel Posture
• Starting after an approach of 5 meters, drive the
excavator in a turn for 10 meters, then measure
the distance of X (5 m point). Do this on level
ground.
II-21 TB108
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Natural Travel Drop

• Engine : Stopped
• Grade : 15°
• Measurement Posture : Fully extend the boom,
arm and bucket cylinders and completely retract
the dozer blade cylinder.
• With the excavator parked at angle for 5 min-
utes, measure the extent of natural drop.
Slew Time
• Engine : Rated r.p.m. BUCKET PIN BOOM FOOT PIN
• Measurement Posture : Completely retract the
arm cylinder, fully extend the bucket cylinder
and adjust so that boom foot pin and bucket pin
are at matching height. Rest the dozer blade on
the ground.
• With the hoe attachment in a no-load state, wait
1 rotation, then measure the time required for
the next 2 rotations.
Overrun When Slewing Stops

• Measurement Posture : Same as that for mea-
suring slew time. LEVER BACK
START TO NEUTRAL
• Draw matching marks on the outer race of the
slew bearing and lower frame at an exactly 180 OVER RUN
degrees rotation from the starting point. With
the hoe attachment in a no-load state, rotate 180
degrees at, which point return the operation
lever to neutral. Measure the differential be-
tween the position marks and the point the hoe
attachment stops.
Natural Slew Drop

TION
• Engine : Stopped DEVIA
• Grade : 15°
suring slew time.
• Rotate the upper machinery so that it is directly
abeam of the grade, then draw positional marks
on the slew bearing’s outer race and the lower
frame. Then measure the distance that develops
between the marks after 5 minutes.
TB108 II-22
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Boom Cylinder Speed
arm cylinder, fully extend the bucket cylinder
and rest the dozer blade on the ground.
• Then measure the time required for the bucket to
reach its highest elevation point (lowest point)
from its lowest point (highest point) resting on
the ground. (Do not include the cushioning
time.)
Arm Cylinder Speed

arm cylinder, fully extend the bucket cylinder,
position the arm horizontally and rest the dozer
blade on the ground.
• Then measure the time required for the arm
cylinder to completely retract (extend) from a
fully extended state (retracted state).
Bucket Cylinder Speed

FULLY
• Engine : Rated r.p.m. RETRACTED
arm cylinder, position the arm horizontally and
rest the dozer blade on the ground.
• Then measure the time required for the bucket
cylinder to completely retract (extend) from a
fully extended state (retracted state). FULLY EXTENDED
Dozer Blade Cylinder Speed

• Measurement Posture : Using the hoe attach-
ment, lift up the dozer blade end of the excava-
tor.
• Then, raising and lowering the dozer blade full
stroke, measure the time required per stroke in
each direction.
II-23 TB108
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Swing Cylinder Speed

suring slew time.
• While swinging the boom left (right) to right
(left), measure the time required for a full stroke
each way.
(Do not include the cushioning time.)
Spanner Cylinder Speed

• Measurement Posture : Excavator body raised
using both hoe attachment and dozer blade.
• Measure the time required for the spanner cylin-
der to completely retract (extend) from a fully
extended state (retracted state).
Natural Cylinder Drop

Boom, Arm, Bucket, Dozer Blade, Bucket Tip
dozer blade and arm cylinders, fully extend the
bucket cylinder and adjust the bucket pin posi-
tion to the same height as the boom foot pin.
• Maintain this position for 10 minutes, then mea-
sure the change in rod length and the distance the
bucket tip falls.
Swing Cylinder
• Engine : Stopped
• Hydraulic Oil Temp. : 50~60˚C
• Grade : 15˚
suring slew time.
• Rotate the upper machinery so that it is directly
abeam of the grade, then measure the change in
rod length after 5 minutes.
TB108 II-24
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Lever Operating Force
• With the engine stopped, attach a push-pull
scale to the center of the operation lever’s handle
grip, or in the case of a pedal, position a push-
pull scale to its tip and record the measurement
at the point the lever/pedal reaches full stroke.
Lever Play
• Measure any discernible play at the tip of the
lever (pedal).
Backlash
arm cylinder and fully extend the bucket cylin-
der.
• Move the tips of the bucket teeth from side to
side (left and right) and measure the play.
Slew Bearing Play

1. Attach a dial gauge to the bot- 2. Raise the crawler on one side 3. Then raise the opposite
tom face of the slew bearing’s off the ground and set the dial crawler and read the dial
race located near the front of gauge to zero. gauge.
the upper machinery.
II-25 TB108
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Crawler Tension
• Raise the excavator completely off the ground
using the hoe attachment and dozer blade.
Then measure the distance (of droop) between
the center point on the crawler frame and top of
the crawler shoe.
Note: For the rubber crawler, the measuring
should be performed after placing the
joint portion with “M” mark to the top
center.
TB108 II-26
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III . MACHINE CONFIGURATION
III-1 TB108
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MACHINE CONFIGURATION
CONTENTS
Drive System ......................................................................................................................................................... 3

Slew System ........................................................................................................................................................ 11
Travel System ...................................................................................................................................................... 15
Upper Frame ........................................................................................................................................................ 21
Control System .................................................................................................................................................... 27
Attachments ......................................................................................................................................................... 31
Hydraulic System ................................................................................................................................................ 37
Electrical System ................................................................................................................................................. 43
TB108 III-2
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DRIVE SYSTEM MACHINE CONFIGURATION

DRIVE SYSTEM
CONSTRUCTION
Engine Mount
A: 66 N·m
Apply thread-locking compound. 1. Engine Foot 9. Air Cleaner
B: 26 N·m
2. Engine Foot RR 10. Pipe
C: 21 N·m
3. Engine Foot RL 11. Pipe
4. Bracket 12. Muffler Pipe
5. Plate 13. Pipe
6. Cushion Rubber 14. Fuel Filter
7. Cushion Rubber 15. Water Separator
8. Ground Cable
III-3 TB108
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MACHINE CONFIGURATION DRIVE SYSTEM
Radiator
A: 9.8 N·m
1. Plate 5. Radiator 9. Plate

2. Bracket 6. Radiator Hose (Top) 10. Plate
3. Fan Guard 7. Radiator Hose (Bottom)
4. Cushion Rubber 8. Cushion Rubber
Pump Coupling
2
C
A
B
3
B5C103
A: Supply molybdenum disulfide grease.

B: 54.9 N·m 1. Plate 2. Coupling 3. Hydraulic Pump
C: 55 N·m
TB108 III-4
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The pump coupling connects the engine flywheel and
the hydraulic pump’s drive shaft. It is constructed so
that it absorbs vibrations, torsions, impact and out of
center of the engine and hydraulic pump.
• Refer to the table concerning the responsibility

of each of the pumps shown in the drawing at
right. P2 P1
Boom, Bucket, Right Travel, Auxiliary,

P1
Swing
Arm, Slew, Left Travel, Dozer Blade
P2 B5C104
Auxiliary
Fuel Tank and Lines
1. Fuel Tank 4. Strainer 7. Fuel Filter

2. Drain Valve 5. Level Gauge
3. Cover 6. Water Separator
III-5 TB108
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Engine Control
A: Aupply molybdenum disulfide grease.

1. Lever
2. Pin
3. Control Cable
4. Pin
5. Boot
6. Bolt
TB108 III-6
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DISASSEMBLY AND ASSEMBLY
Removing the Engine

1. Disconnect the battery ground cable (1) from the
battery.
2. Remove the canopy.

1
3. Remove the engine hood, center cover, side cover
L and R.
“Removing the Covers” 3
4. Remove the radiator.
5
“Removing the Radiator” B5C107
5. Remove the fuel tank.

“Removing the Fuel Tank”
6. Remove the hydraulic pump.

“Removing the Hydraulic Pump”
7. Disconnect the control cable (2) from the engine.
8. Disconnect the battery cable (3) and all the con-

nections on the engine side of the electric wirings
(4).
• Attach identification labels to individual wir-
ings.
• Disconnect the wirings from the clamp and the
band.
9. Disconnect the engine ground cable (5).
10. Remove the muffler pipe (6).
11. Remove the cushion rubber tightening double

nuts at the three feet of the engine foot, engine
foot RR and RL.
Nut (9): 26 N·m
Nut (10): 21 N·m
12. Suspend the engine (8) remove it.
Installing the Engine

Follow the same procedure as for removal in the
reverse order.
III-7 TB108
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Removing the Radiator

2. Remove the engine hood, center cover, side cover

L and R.
“Removing the Covers”
3. Loosen the drain cock to bleed out the engine

coolant.
• Engine coolant volume: Approx. 2.8 L
4. Take out the bolts and remove the counterweight.

“Removing the Upper Frame”
5. Disconnect the radiator hoses (1) and (2).
6. Remove the fan guard (3).
7. Remove the cushion rubber tightening nuts (4).
8. Remove the radiator from the plate (5).
Installing the Radiator

reverse order.
• The radiator should be mounted at right angles to PARALLEL
the main body frame and parallel to the cooling fan.
RIGHT ANGLE
TB108 III-8
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Removing the Hydraulic Pump
2. Open the engine hood and remove the center 3 1

cover.
3. Drain out the oil from the hydraulic tank.

“Removing the Hydraulic Tank”
4. Disconnect the suction hose (1) from the pump.

4 2
5. Disconnect the discharge hoses (2) from the pump.
B5C111
6. Remove the fixing bolts (3) and take out the

hydraulic pump (4).
Bolt: 55 N·m
• Apply molybdenum disulfide grease to the
spline section.
Installing the Hydraulic Pump

reverse order.
Cautions when starting the hydraulic pump

1. Fill the pump housing with clean hydraulic oil
before starting the pump.
2. After starting the engine, let it run at a low idling

speed for a while to completely bleed out the air
within the circuit.
III-9 TB108
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Removing the Fuel Tank

2. Remove the engine hood center cover and side

cover R.
3. Loosen the drain cock (1) to drain out the fuel.

• Fuel tank capacity: 8 L

5. Remove the panel (2), them remove the battery

(3).
6. Disconnect the hydraulic hoses (4) and (5).
7. Suspend the fuel tank (6) temporarily and remove

the fixing bolts. 6
8. Suspend the fuel tank (6) and remove it.
Installing the Fuel Tank

Follow the same procedure as for removal in the 1
reverse order.
B5C113
TB108 III-10
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SLEW SYSTEM MACHINE CONFIGURATION

SLEW SYSTEM
CONSTRUCTION
5 6 2 3 9
A,D
D
RIGHT OF
MACHINE
A B,D
A,C
A,D
4 7 8 1
B5C200E
A: Apply thread-locking compound.

B: Apply molybdenum disulfide grease. 1. Slew Bearing 6. Rod
C: 27 N·m 2. Stopper 7. Lock Pin
D: 55 N·m
3. Swivel Joint 8. Grease Cover
4. Lock Boss 9. Slew Motor
5. Lever
III-11 TB108
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MACHINE CONFIGURATION SLEW SYSTEM
Slew Bearing
1. Outer Race 4. Spacer

2. Inner Race 5. Seal
3. Ball
The slew bearing is a ball type bearing, with balls (3)

and spacers (4) aligned alternately in the groove
between the outer race (1) and inner race (2). The slew
bearing is installed by attaching the outer race to the
turntable and the inner race to the lower frame using
hex bolts.
The slew speed reducer’s pining, mounted on the
turntable, engages with the gear formed on the inside
of the inner race and rotates, slewing the machine’s
frame during operation.
TB108 III-12
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SLEW SYSTEM MACHINE CONFIGURATION

3
Removing the Slew Motor
1. Open the engine hood and remove the center 1
cover.
2. Disconnect the hydraulic hoses (1) from the slew

motor.
3. Disconnect the grease pipe (2) from the slew

motor.
2
4. Remove the slew motor fixing bolts.
Bolt: 55 N·m B5C201
• Apply thread lock to the bolts.
5. Suspend the slew motor (3) and remove it.

Slew Motor: 15 kg
Installing the Slew Motor

reverse order.
Removing the Slew Bearing

1. Remove the hoe attachment
“Attachments, Disassembly and Assembly”
2. Remove the upper frame.

3. Remove the inner race fixing bolts.

Bolt: 55 N·m
4. Suspend the slew bearing and remove it.

Slew Bearing: 18 kg
III-13 TB108
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MACHINE CONFIGURATION SLEW SYSTEM
Installing the Slew Bearing

reverse order.
• Apply grease to the teeth on the inner part of the
slew bearing.
• Install the slew bearing’s outer race so that place
where the “S” mark is stamped on it is on the right
side or the left side of the turntable.
S MARK B5C202E
Removing the Swivel Joint

1. Remove the upper frame.
2. Disconnect the hydraulic hoses from the hub side 1

of the swivel joint.
3. Remove the swivel joint fixing bolts (1).

Bolt: 27 N·m
4. Suspend the swivel joint (2) and remove it.

Swivel Joint: 13 kg
2
B5C203
Installing the Swivel Joint

reverse order.
• When mounting the swivel joint, tighten it tempo-
rarily with the fixing bolts, and center the swivel
joint by using a dial gauge.
• Adjust the centering so that the deviation from the
center is within 0.25 mm.
TB108 III-14
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TRAVEL SYSTEM MACHINE CONFIGURATION

TRAVEL SYSTEM
CONSTRUCTION
Track Roller
1 1. Roller
3 4 2 2. Shaft
3. Bearing
4. Oil Filler Plug
B5C300
Idler
1. Idler
1 2. Shaft
3. Bearing
4. Oil Filler Plug
4 5. Slide
B5C301
III-15 TB108
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MACHINE CONFIGURATION TRAVEL SYSTEM
Track Adjuster
7,6 1 4 5 3 2
B5C302
1. Cylinder 5. O-ring
2. Piston 6. Packing
3. Oil Seal 7. Check Valve
4. Backup Ring
Travel Motor
1. Sprocket
1
2. Travel Motor
A,B
A,B
B5C303

B: 55 N·m
TB108 III-16
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1
Removing the Rubber Crawler
1. Loosen the tension of the crawler (1). 4
When loosening the check valve (2), turn it slowly.
Do not loosen it beyond the point where grease
starts to ooze out. If it is difficult for the grease to 2
come out, move the machine forward and in
reverse.
Check Valve: 177 N·m
2. Raise the body and after engaging pieces of iron C4C308

pipe (3) in the crawler, rotate the sprocket in the
reverse direction.
3. When the iron pipes reach a point just to the side

of the idler (4), stop rotating the sprocket.
4. Slide the crawler to the side to remove it.

Crawler Belt: 24 kg
Installing the Rubber Crawler

1. Raise the machine body and set the crawler (1) on
the frame.
• The Crawler should engage in the sprocket.
2. Engage pieces of iron pipe (3) in the crawler, then

rotate the sprocket in the reverse direction.
3. When the iron pipes reach a point just to the side

of the idler, stop rotating the sprocket.
4. Slide the crawler to a position where it will fit

snugly with the idler.
5. Engage the crawler fully with the sprocket and the

idler, then adjust the crawler tension.
“II. Specifications, Standards for Judging
Performance”
III-17 TB108
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Removing the Track Roller

1. Loosen the crawler tension.
2. Loosen the roller installation bolt (1) slightly

(approximately 1 turn).
3. Raise the machine body, take out the installation

bolt (1) and remove the roller (2).
Installing the Track Roller 1

1. Tighten the roller (2) installation bolt (1) tempo-
rarily.
2 B5C304
2. Bring the machine body in full contact with the

ground, then tighten the bolt.
• Apply thread lock to the threads of the instal-
lation bolts.
3. Raise the machine body, then adjust the tension of

the crawler.
Removing the machine body, then adjust the
tension of the crawler.
Removing the Idler and Track Adjuster

1. Remove the Crawler.
“Removing the Crawler”
2. Take out the idler and track adjuster.
Installing the Idler and Track Adjuster

Follow the procedure used for removal in reverse
order.
• Apply grease to the rubbing surfaces of the track
adjuster piston and cylinder.
B5C305
TB108 III-18
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Removing the Travel Motor
1. Remove the crawler.
“Removing the Crawler”
2. Remove the installation bolts (1) and remove the

sprocket (2).
Bolt: 55 N·m
3. Remove the motor cover and disconnect the hy-

draulic piping (4).
4. Suspend the travel motor (3) temporarily and

remove the fixing bolts (5).
Bolt: 55 N·m
4
5. Suspend the travel motor (3) and remove it.
Travel Motor: 14 kg
4
B5C306
Installing the Travel Motor

order.
III-19 TB108
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TB108 III-20
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UPPER FRAME MACHINE CONFIGURATION

UPPER FRAME
CONSTRUCTION
Turntable
A: 102 N·m
Apply thread-locking compound. 1. Turntable
2. Counterweight
3. Bushing
III-21 TB108
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MACHINE CONFIGURATION UPPER FRAME
Cover
1. Engine Hood 5. Side Cover R

2. Rear Cover 6. Hook
3. Center Cover 7. Rod
4. Side Cover L
TB108 III-22
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Grease Piping
1. Nipple 5. Tube
2. Connector 6. Tube
3. Elbow 7. Grease Nipple
4. Tube 8. Elbow
III-23 TB108
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Removing the Upper Frame

1. Remove the hoe attachment.
“Attachments, Disassembly and Assembly”
1
3. Remove the engine hood and center cover.

4. Disconnect the lever joint (1) from the swivel

joint selector portion. 2
B5C403
5. Disconnect the hydraulic hoses from the swivel

joint.
• Make match marks on the hose at the connec-
tion position before disconnecting it.
6. Take off the fixing bolts and remove the stopper

(2).
Bolt: 55 N·m
7. Disconnect the grease pipe (3) from the slew

bearing.

• Attach and tighten the hoisting cable to the
counterweight.
Bolt: 102 N·m
Counterweight: 36 kg
9. Remove the fixing bolts (4) from the outer race of

the slew bearing, leaving only two bolts each on
the front and the rear of the machine.
• When mounting the slew bearing, be careful of
the positions of the grease hole.
“Installing the Slew Bearing”
Bolt: 55 N·m
• Apply molybdenum disulfide grease to the
threads and the bolt holes. 4
B5C405
10. Suspend the upper frame temporarily and remove

the remaining fixing bolts while keeping the
frame well balanced.
11. Suspend the upper frame and remove it.
Installing the Upper Frame

reverse order.
TB108 III-24
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Removing the Covers
3
2
2. Remove the engine hood (1). 1

a. Open the engine hood and suspend it tempo-
rarily.
b. Take off the E-ring and remove the stay (2).
c. Remove the hinge fixing bolts (3). 7
B5C406
3. Take off the bolts and remove the rear cover (4).
4. Take off the bolts and remove the center cover

(5). 4
B5C407
5. Take off the bolts and remove the side cover L (6).
6. Take off the bolts and remove the side cover R (7).
6
5 B5C408
Installing the Covers

reverse order.
III-25 TB108
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TB108 III-26
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CONTROL SYSTEM MACHINE CONFIGURATION

CONTROL SYSTEM
CONSTRUCTION
Travel Lever
1. Lever 4. Plate 7. Bracket 10. Lever 13. Rod

2. Lever 5. Shaft 8. Bracket 11. Shaft
3. Lever 6. Lever 9. Spring 12. Rod
Operating Lever
1. Lever 3. Bracket 5. Rod

2. Lever 4. Bracket
III-27 TB108
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MACHINE CONFIGURATION CONTROL SYSTEM
Swing and Auxiliary Pedal
1. Lever 3. Lever 5. Pedal

2. Lever 4. Pedal
Dozer Blade Lever
1. Lever 4. Lever 7. Pipe 10. Lever

2. Lever 5. Shaft 8. Plate 11. Lever
3. Lever 6. Plate 9. Stopper 12. Spring
TB108 III-28
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CONTROL SYSTEM MACHINE CONFIGURATION

Lever Stand
1. Lever Stand 5. Plate 9. Starter Switch

2. Cover 6. Water Temperature Gauge 10. Hour Meter
3. Cover 7. Battery Charge Warning Lamp 11. Horn
4. Cover 8. Engine Oil Pressure Warning Lamp
III-29 TB108
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MACHINE CONFIGURATION CONTROL SYSTEM
INSPECTION AND ADJUSTMENT
Adjusting Stroke STROKE CENTER

Adjust the lever’s stroke to correspond to the control VALVE SPOOL NEUTRAL
valve spool stroke using the setscrew.
1. The control valve’s spool should be in the neutral

position.
2. Turn the rod and position the lever in the center of
the stroke, then fasten the rod with the nut.
3. Move the lever and hold it at the stroke end of the
valve spool.
4. Set the setscrew.
B5C505E
TB108 III-30
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ATTACHMENTS MACHINE CONFIGURATION

ATTACHMENTS
CONSTRUCTION
11
8
7
9
5
4
2 13
1
10
12
14 B5C600
1. Bucket 8. Boom
2. Bucket Link 9. Boom Cylinder
3. Guide Link R 10. Swing Bracket
4. Guide Link L 11. Swing Cylinder
5. Bucket Cylinder 12. Dozer Blade Cylinder
6. Arm 13. Dozer Blade
7. Arm Cylinder 14. Extension Blade
III-31 TB108
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MACHINE CONFIGURATION ATTACHMENTS
General Cautions Air Bleeding Operation

• When disconnecting hydraulic hoses, be sure to 1. Start the engine and let it idle for about 5 minutes.
bleed off any residual pressure in the hoses and in 2. With the engine running at slow speed, extend
the Hydraulic Tank. and retract the cylinders 4 or 5 times.
• Plug openings which are opened up when piping is • Move the piston rods to a position 100 mm
disconnected to prevent dust and mud, etc. from before the end of the stroke, taking care not to
getting in. allow any relief whatsoever.
• During assembly, be sure to adjust all the parts with 3. Perform the operation in (2) with the engine at top
shims so that there will be no looseness in the speed, then with the engine at slow speed, move
mounts. the piston rods to the stroke end, allowing relief.
• When aligning pin hole positions, absolutely do
not insert a finger in any pin holes.
• When all the hydraulic equipment such as hydrau-
lic cylinders and piping have been removed and the
hydraulic cylinders are being operated for the first
time after reassembly, be sure the bleed the air out
of the hydraulic circuits by the following proce-
dure. 0.5~1.0mm C4C601
• Keep the clearance at the pin connecting section
(excluding the bucket connecting section) to 0.5
mm or less by using the shim.
• When fastening the lock bolt with double nuts,
maintain a clearance between the nuts and the
bushing of 0.5~1.0 mm when tightening the double
nuts.
Removing the Bucket 5 6

• Move the back side of the bucket so that it is down, 2
then lower it fully to the ground.
4
1. Pull out the pin (2) over the ring (1), then take out
the bucket link side pin (3). 1
3
2. Pull out the pin (5) over the ring (4), then take out
the bucket hinge pin (6).
3. Remove the bucket.

Bucket: 15 kg C4C602
Installing the Bucket

order.
TB108 III-32
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Removing the Link
• Fully retract the bucket cylinder and lower the 6
front end of the arm to the ground.
2
1. Suspend the bucket link (2) temporarily and take
out the pin (3).
• Place pillow blocks under the bucket cylinder
to support it.
• Since the end of the guide link will drop when 3
the pin is taken out, exercise caution.
2. Take out the pin (4), then remove the guide link L
(5), R (6). 5
4 B5C601
Installing the Link

order.
Removing the Arm

1. Disconnect the hydraulic hoses (1) from the bucket 4
cylinder (2). Next, disconnect hydraulic hoses
from the auxiliary ports (3).
2
2. Suspend the bucket cylinder (2) temporarily, take
out the pin (4) and remove the bucket cylinder.
3. Place pillow blocks under the arm cylinder (5),

then take out the pin (6). 1
4. Take out the split pin and remove the castle nut 3
(7). B5C602
5. Suspend the arm (8) temporarily, take out the pin 5 6

(9) and remove the arm.
Arm: 14 kg
Installing the Arm 8

order.
9
7
B5C603
III-33 TB108
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Removing the Boom

• Lower the front end of the boom so that it is in full
1
contact with the ground.
2
1. Disconnect the hydraulic hoses (1) from the arm
cylinder (2).
3
2. Suspend the arm cylinder (2) temporarily, then
take out the pin (3) and remove the arm cylinder.
3. Remove the clamp from the boom (5), and dis-

connect the hydraulic hose (6) from the boom
cylinder (7).
B5C604
4. Suspend the boom cylinder (7) temporarily and

take out the pin (8).
9
5. Disconnect the wiring to the boom light.
6. Disconnect the hydraulic hoses (9) from the pipes. 8
7. Suspend the boom (5) temporarily, take out the 5

pin (10) and remove the boom.
Boom: 33 kg
6
Installing the Boom 7
Follow the procedure used for removal in reverse 10 B5C605
order.
TB108 III-34
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Removing the Swing Bracket
1. Disconnect the hydraulic hoses from the boom
cylinder.
2. Take out the head side pin and remove the boom 1
cylinder (1).
• The cylinder should be suspended temporarily 6
before it is removed.
3. Take out the rod side pin and disconnect the 2

swing cylinder (2) rod side.
4. Take out the pin and disconnect the swing arm (3)
and link (4). B5C606
5. Take out the pin and remove the swing arm (3).
5
6. Take out the pin and remove the link (4).
7. Take out the pivot pins (5) and remove the swing
bracket (6).
• The bracket should be suspended temporarily
before being removed.
• Be careful not to damage the hoses in any way.
Swing Bracket: Approx. 16 kg
Installing the Swing Bracket 3 4 B5C607

order.
III-35 TB108
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Removing the Dozer Blade

• Lower the dozer blade fully to the ground.
3
1. Disconnect the hydraulic hoses (1) from the dozer
blade cylinder (2).
2. Suspend the dozer blade cylinder (2) temporarily,

take out the pins (3), (4) and remove the cylinder.
1 6
3. Suspend the dozer blade (5) temporarily, take out 2
the pins (6), and remove the dozer blade.
Dozer Blade: 33 kg 4
5 B5C608
Installing the Dozer Blade

order.
TB108 III-36
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HYDRAULIC SYSTEM MACHINE CONFIGURATION

HYDRAULIC SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
III-37 TB108
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MACHINE CONFIGURATION HYDRAULIC SYSTEM
TB108 III-38
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CONSTRUCTION
Hydraulic Tank
A: 47 N·m
Apply thread-locking compound.
1. Hydraulic Tank 6. Strainer
2. Flange 7. O-ring
3. Adapter 8. Valve
4. Plug 9. Cover
5. Sight Gauge 10. Cartridge
III-39 TB108
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Function
1. This tank stores the quantity of hydraulic oil
necessary to operate the cylinders and hydraulic
motors.
2. It keeps air, moisture and dirt out of the hydraulic

oil.
3. It dissipates heat and lowers the oil temperature.
4. Volume of Hydraulic Oil.

Check the oil level with the arm cylinder and
bucket cylinder both fully retracted and with the
bucket and dozer blade both lowered to the ground.
Reference
If the amount of hydraulic oil is insufficient, the
disturbances in the flow of oil can not be calmed, and
this will result in air bubbles getting in the hydraulic
oil. If these bubbles are sucked into the hydraulic
pumps, they could cause cavitation. Heat dissipation
time would also become shorter and would result in a
rise in the oil temperature.
If more than the specified amount of hydraulic oil is
supplied, the amount of air in the tank will become
small and changes in the oil level could cause the
pressure fluctuation in the tank to become severe.
TB108 III-40
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Removing the Hydraulic Tank 1

4
2. Remove the covers around the tank.
6
3. Drain out the oil from the tank.
a. Slowly loosen the filler plug (1) and bleed out 2
the tank’s inner pressure completely in ad-
vance.
b. Loosen the drain plug (2) and drain out the oil. 5
• Tank level capacity: 7.3 L B5C702

5. Disconnect the four low pressure hoses (4) from

the tank.
6. Disconnect the four hydraulic hoses (5) from the

tank.
• Attach identification labels to individual hoses
for easy reassembling.
7. Take off the fixing bolts (6), and suspend the tank
and remove it.
Bolt: 47 N·m
Tank: 13 kg
Installing the Hydraulic Tank

reverse order.
III-41 TB108
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Filling with Hydraulic Oil

1. Fill the tank with the specified amount of hydrau-
lic oil through the filler inlet.
2. Run the engine for 2~3 minutes at low speed.
3. Retract the arm and bucket cylinders fully, lower

the boom and lower the bucket to the ground.
4. Lower the dozer blade to the ground.
5. Check if the oil level is proper using a level gauge.
Tank Pressurization
1. Extend all the cylinders fully, then in that condi-
tion, close the filler inlet. (The dozer blade should
be lowered to the ground.)
• When filling of the hydraulic tank is com-
pleted, be sure to pressurize the tank.
Bleeding the Air

Bleed the air after replacing the hydraulic oil or
reassembling hydraulic devices or hoses.
1. Start the engine and run the engine at low idle.
B5C704
2. Slowly operate the cylinders until the air is bled.
3. Bleed the air from the cylinders.

a. With the engine running at slow, extend and
contract the cylinders 4 or 5 times.
• Move the piston rods to 100 mm before the
stroke end. DO NOT extend them com-
pletely.
b. Repeat step “a” above with the engine running
at full, then run it at slow and extend the piston
rods completely to the stroke end.
TB108 III-42
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ELECTRICAL SYSTEM MACHINE CONFIGURATION

ELECTRICAL SYSTEM
ELECTRICAL WIRING DIAGRAM
III-43 TB108
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MACHINE CONFIGURATION ELECTRICAL SYSTEM
TB108 III-44
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ELECTRICAL SYSTEM MACHINE CONFIGURATION

Travel Alarm
III-45 TB108
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MACHINE CONFIGURATION ELECTRICAL SYSTEM
TB108 III-46
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IV . HYDRAULIC UNITS
IV-1 TB108
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HYDRAULIC UNITS
CONTENTS
Gear Pump ............................................................................................................................................................. 3

Control Valve ...................................................................................................................................................... 11
Cylinders .............................................................................................................................................................. 23
Travel Motor ........................................................................................................................................................ 41
Slew Motor .......................................................................................................................................................... 59
Swivel Joint ......................................................................................................................................................... 77
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GEAR PUMP HYDRAULIC UNITS

GEAR PUMP
CONSTRUCTION
14
4 15 16 3 8 5 13 12
1 7
9 10 11 B5D100
1. Flange 5. Drive Gear 9. Bushing 13. Gasket

2. Cover 6. Driven Gear 10. Bushing 14. Oil Seal
3. Housing 7. Driven Gear 11. Bushing 15. Snap Ring
4. Drive Gear 8. Bushing 12. Gasket 16. Ball
Gear Pump
The gear pump consists of a single gear case, inside of
which is a drive gear (1) and a driven gear (2) engaged
with each other. By turning the drive shaft (3), the
space between the case and the gears is filled with oil.
This oil is thus sent through the pump from the inlet
to the outlet.
INLET OUTLET
Y1-D101E
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HYDRAULIC UNITS GEAR PUMP
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
the disassembled parts in. • Check each part to make sure there is no abnormal
• Before disassembly, clean around the ports and wear or seizing and use sandpaper, etc. to remove
remove the paint from each joint using a wire any burrs, sharp edges, etc.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
assembled in the same positions when assembled.
Following is an explanation of the gear pump disas-

sembly procedure.
Follow the procedure used to disassemble the gear
pump in reverse order when reassembling it.
1. Remove the bolts.

Bolt: 48.1~51.0 N·m
2. Remove the flange.

2
1
3. Remove gasket (2) from flange (1).
4
3
4. Remove snap ring (3) and oil seal (4) from flange
(1).
• Be careful not to scratch or otherwise damage
the flange.
• When re-assembling, install the oil seal using *#,#
the jigs A and B.
4 1
T7D152
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5. Remove the rear cover (5).
6. Remove the gasket (6) from the reae cover (5).

5
6
B5D101
7. Disassrmble the front pump.

DISCHARGE SIDE
a. Remove bushing A (7), bushing B (8), drive
gear (9), and driven gear (10) from the hous- 12
8
ing.
• Be careful to keep the bushings separated 9
and in their original places. 7
SUCTION 11
8. Remove the gasket (11), (12) from bushing A (7) SIDE
and bushing B (8).
10
B5D102E
9. Disassemble the rear pump using the same proce-

dure as for the front pump.
B5D103
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Checking Parts
After checking the disassembled parts for dirt or
discoloration, clean them with diesel fuel. However,
do not let diesel fuel get on rubber parts. Check each
part for the following points and if there is any trouble,
repair or replace the part.
Housing
SUCTION SIDE
SUCTION SIDE DISCHARGE SIDE

CONTACT MARKS
CONTACT MARKS DISCHARGE SIDE DEPTH OF CONTACT MARKS:

T8D154E A 0.15mm T7D158E
The gear pump is made so that the crests of the gear

teeth make light contact with the housing walls as a
means of increasing its efficiency. Therefore, contact
marks can be seen near the suction side in any pump
that has been operated. These contact marks are
normal if they have a depth within 0.1 mm. If they
exceed the use limit given in the figure above, replace
the gear pump.
Bushings
The ideal situation is for the sliding surface of the
bearing inner diameter to have no roughness and for
the suction side half to be lustrous. Also, it is satisfac-
tory if strong contact marks can be seen on the side
surface on the suction side and minute contact marks
can be seen on the discharge side.
Replace the bushings if their condition is as follows. DISCHARGE SIDE
• Contact marks can be seen on the sliding surface of
the entire bearing inner diameter and it is so rough
that it looks like it has been clawed.
• There is a large number of scratches around the
circumference of the side surface and it is so rough
that it looks like it has been clawed. GEAR SIDE SUCTION SIDE
• There are marks from foreign matter biting into the
sliding surface of the bearing inner diameter and
the side surface. CONTACT MARKS
Dirty hydraulic oil is one likely cause of such wear. In B5D104E
such a case, replace the hydraulic oil and flush out

affected hydraulic circuit completely.
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Other likely causes are as follows.
• Excessive load due to damage to the relief valve.
• Cavitaion or aeration.
• Hydraulic oil temperature is too high.
• Hydraulic oil is deteriorated.
• Hydraulic oil’s viscosity is low.
If it is necessary to replace the bushings, this means
that the gear shaft and gear side surfaces are also
rough or worn severely, so replace the gears at the
same time as the bushings are replaced.
Gear
Replace a gear if it is in the following condition.
1. The shaft or the gear side surfaces ar so rough that
they look like they have been clawed.
2. There are cracks in the tooth roots and there is
extreme abnormal wear in the tooth surfaces.
Seals
• Check oil seals for scratches in the seal surface,
wear, deformation or deterioration of the rubber’s
elasticity. If a seal is abnormal, replace it.
• Replace seals when the hydraulic pump is disas-
sembled.
• Check the backup ring for scaling and cutting. If it
is abnormal, replace it.
Test Operation
The best method for testing the pump’s operation is to 4. Next, run the pump so that it reaches the rated
mount it in a test stand. However, if that cannot be pressure ( “II. Specifications, Specification
done, test it under the conditions it would be subjected Tables”) for 5 minutes at a time for each addi-
to if it were installed in the machine. tional 1.96~2.94 kPa of pressure.
Also, if any abnormal wear is discovered during Afterward, after operating each ciruit for about 5
disassembly, be sure to replace the hydraulic oil and minutes, replace the return filter or clean it.
return filter. In addition, during the process of raising the pressure,
1. Install a pressure gauge in the high pressure pay careful attention to the oil temperature, the pump’s
piping near the pump. surface temperature and the operating noise. If the oil
2. Run the engine at 500~1,000 min-1 and set the temperature or the pump’s surface temperature be-
control valve in the neutral position. come abnormally high, eliminate the load from the
3. Run the pump for 10 minutes under the conditions pump and let the temperature drop before resuming
in (2), then increase the engine’s speed to the test.
1,500~2,000 min-1 and run it for another 10 min-
utes.
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Measuring the Discharge Volume

After completing the test operation, measure the
discharge volume.
1. Connect a tester (1) to the discharge side of the
pump (2).
• There should be no mistakes made in the
tester’s pipe installation.
2. Open the tester’s loading valve and start the
engine.
3. Run the engine at the rated speed.
4. Gradually close the loading valve and apply the
rated pressure to the pump (2).
5. Measure the discharge volume and the pump’s
speed (engine speed).
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TROUBLESHOOTING
Symptom Probable Causes Remedy

Pump won’t discharge. • Direction of rotation is reversed. • Run the pump in the specified direc-
tion.
• Oil level in the tank is low. • Replenish the oil to the specified level.
• Suction side pipe or suction filter is • Clean the pipes.
clogged.
• Hydraulic oil’s viscosity is too high. • Replace the hydraulic oil with oil of the
proper viscosity.
• Speed is low. • Run the pump at the specified speed.
Noise level is high. • Suction side hose is crushed, the suc- • Remove the dirt or eliminate the crushed
Abnormal noise is tion filter is clogged or cavitation is condition of the hose.
generated. occurring.
• Suction side joint is loose and air is • Tighten all the joint.
being sucked in.
• Hydraulic oil’s viscosity is too high, • Replace the hydraulic oil with oil of the
and cavitation is occurring. proper viscosity.
• Pump and engine are out of center with • Correct the centering between the pump
respect to each other. and engine.
• There are bubbles in the hydraulic oil. • Investigate the cause of the bubbles
and correct it.
Oil leaks from oil seals. • Oil seal is worn, damaged or deformed. • Replace the oil seal.
Oil leaks from mating sur- • Body seal is damaged or worn by rub- • Replace with a new part.
faces between housing and bing.
flange and between hous-
ing and cover.
Discharge volume is low. • Bushing seal is damaged. • Replace the bushing.
• Cavitation is occurring. • Clean the suction filter and suction side
piping.
• Aeration is occurring. • Check for insufficient tightening of
pipes, etc. and repair.
• Viscosity of the hydraulic oil is too • Replace the hydraulic oil with oil of the
low. proper viscosity.
IV-9 TB108
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TB108 IV-10
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CONTROL VALVE HYDRAULIC UNITS

CONTROL VALVE
CONSTRUCTION
14,15
1 16,17 9 10 11
19
20,21
18
P1 P2
12,13 2 3 4 6 7 5 8 14,15 12,13

B5D200
1. Inlet Housing 12. Main Relief Valve

2. Slew Block Assembly 13. O-ring
3. Arm Block Assembly 14. Port Relief Valve
4. Left Travel Block Assembly 15. O-ring
5. Right Travel Block Assembly 16. Anti Cavitation Valve
6. Dozer Blade Block Assembly 17. O-ring
7. Auxiliary Block Assembly 18. O-ring
8. Swing Block Assembly 19. O-ring
9. Boom Block Assembly 20. Bolt
10. Bucket Block Assembly 21. Nut
11. Housing
IV-11 TB108
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HYDRAULIC UNITS CONTROL VALVE
Left Travel, Right Travel Block

11 10 1. O-ring
2. Backup Ring
3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
12
7. O-ring
8. Backup Ring
9. Seal Holder
10. O-ring
11. Plug
12. Cover
13. O-ring
14. O-ring
6 5 4 3 2 1 13,14 7 8 9 B5D201
Swing Block 1. O-ring

13 10 12 11 2. Backup Ring
3. Seal Holder
15,16 4. Spring Holder
5. Spring
6. Screw
7. O-ring
8. Backup Ring
9. Seal Holder
10. Poppet
11. Spring
14 12. O-ring
13. Plug
14. Cover
15. O-ring
6 16. Plug
9 8 7 17,18 1 2 3 4 5 B5D202 17. O-ring
18. O-ring
Dozer Blade
13 10 12 11 1. O-ring
2. Backup Ring
3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
14 7. O-ring
8. Backup Ring
9. Seal Holder
10. Poppet
11. Spring
12. O-ring
13. Plug
14. Cover
15. O-ring
6 5 4 3 2 1 15,16,17 7 8 9 B5D203 16. O-ring
17. O-ring
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Boom Block, Bucket Block
1. O-ring
13 10 12 11 15 2. Backup Ring
16 3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
7. O-ring
8. Backup Ring
9. Seal Holder
14 10. Poppet
11. Spring
12. O-ring
13. Plug
14. Cover
7 8 9 15. O-ring
6 5 4 3 2 1 17,18 B5D204 16. Plug
17. O-ring
18. O-ring
Slew Block
13 10 12 11 1. O-ring
2. Backup Ring
3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
14 7. O-ring
8. Backup Ring
9. Seal Holder
10. Poppet
11. Spring
12. O-ring
13. Plug
14. Cover
15. O-ring
6 5 4 3 2 1 15,16 7 8 9 B5D205 16. O-ring
Arm Block 1. O-ring

2. Backup Ring
13 10 12 11 3. Seal Holder
15 4. Spring Holder
16 5. Spring
6. Screw
7. O-ring
14 8. Backup Ring
9. Seal Holder
10. Poppet
11. Spring
12. O-ring
13. Plug
14. Cover
15. O-ring
6 5 4 3 2 1 17,18 7 8 9 16. Plug
B5D206 17. O-ring
18. O-ring
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Auxiliary Block
1. O-ring
13 10 12 11 2. Backup Ring
3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
7. O-ring
8. Backup Ring
9. Seal Holder
10. Poppet
14 11. Spring
12. O-ring
13. Plug
14. Cover
15. O-ring
1 2 3 4 5 6
9 8 7 15,16 B5D207 16. O-ring
Main Relief Valve, Port Relief Valve

8 13 15 1 12 2 9 1. Housing 9. Lock Nut
2. Plug 10. Spring
3. Sleeve 11. Spring
7 4. Main Poppet 12. O-ring
5. Piston 13. Backup Ring
6. Needle Valve 14. O-ring
7. Set Screw 15. O-ring
8. O-ring
3 4 11 5 6 14 10
G4D211
Anti-Cavitation Valve
2 1 7 6 8 3 4 5 1. Sleeve
2. Poppet
3. Spring
4. O-ring
5. Plug
6. Backup Ring
7. O-ring
8. O-ring
G4D212
TB108 IV-14
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OPERATION
When the Spool is in the Neutral Position

When the control valve spool is not moving, hydrau-
lic oil flows through the center bypass passage (1) and
then through the tank passage (T) in the arrow direc-
tion, returning to the tank.
When the Spool is Actuated

Explanation is given for the case where the spool is
moved to the right.
When the spool (2) is moved to the right, the center
bypass passage (3) is closed and hydraulic oil entering
from the pump passes through the load check valve
(5) from the parallel passage (4), flowing from the A
port to the actuator. On the other hand, oil returning
from the B port flows through the tank circuit (T) and
returns to the tank.
Load Check Valve

This valve prevents oil from flowing backward due to
the load pressure (C) from the actuator port during
switching of the spool.
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Straight travel capability while the dozer blade is

in operation
Since the center bypass passage (1) is blocked by the P1 2
4
spools of the left travel block (2) and the right travel 7
block (3), oils from the pumps P1 and P2 are supplied
to the left and right travel motors through the parallel 6
passages P1 (4) and P2 (5), respectively. Oil from the
parallel passage P1 (4) passes through the orifice (7) 1
of the dozer blade block (6) and is supplied to the 8
dozer blade cylinder. Oil from the parallel passage P2 9 1
(5) passes through the orifice (9) of the auxiliary block
(8) to the dozer blade block (6) and is supplied to the
dozer blade cylinder. At this time, the flows at the 5 3
orifices (7) and (9) are controlled so that the same P2 B5D208
amount of oil to be supplied from the parallel passages

P1 (4) and P2 (5) to the dozer blade cylinder. As a
result, the vehicle can travel straight while operating
the dozer blade.
Main Relief Valve, Port Relief Valve

A main relief valve is mounted between the pump
circuit and tank circuit of each inlet housing and
serves to maintain the circuit pressure at the set value.
A port relief valve is located between the actuator port

and the tank circuit and when abnormal pressure due
to shock pressure or external pressure generated when
the actuator port is suddenly blocked by the spool or
when there is an overload occurs, these valves act to
protect the actuator.
Relieving Operation B A A1 5
When the pressure in the circuit is low with respect to
the set value, the relief valve is maintained at equilib-
rium. Pressure from the pump passes from chamber B
to the orifice in piston (4), then reaches chamber C and
the needle valve (5). On the other hand, forces F and
F1 are acting in the arrow directions on both sides of
the main poppet (6).
F = P × A F1 = P × A1 6 4 C
P: Pressure A, A1: Sectional Area
Since the sectional area of A is less than that of A1, the G4D214
main poppet (6) is pushed by the force “F1-F” to the

seat surface on the left side.
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If the pressure in the circuit becomes higher than the
force of the spring (7), the needle valve (5) is pushed T 7 5
to the right by hydraulic pressure, opening. Oil then
flows around the circumference of the needle valve
(5) and passes through the slits, flowing into the tank
passage (T).
G4D215
Compared to the chamber B side, the pressure in T

chamber C is low and there is no equilibrium in
pressure. For this reason, the main poppet (6) opens
and pressurized oil flows to the tank passage (T).
6 C
G4D216
Suction Operation A A1
When the cylinder is operated at high speed, and the T
supply of oil cannot keep up with it, creating a vacuum
in chamber B, oil is supplied from the tank side,
preventing the occurrence of cavitation.
When the pressure in chamber B is lower than the
pressure in the tank passage (T), the differences in the
sectional areas A and A1 cause the main poppet (6) to B
open. Thus, sufficient oil from the tank passage (T)
enters chamber B, filling the empty space. 6
G4D217
Anti-Cavitation Valve 1
When a cylinder is operated at high speed and when
the supply of hydraulic oil can't keep up with it, T
causing a vacuum to form at the cylinder port, this
valve supplies oil from the tank, preventing cavitation
from occurring. In the normal cylinder port, pressure
is brought to bear, so the poppet (1) is closed. If a
vacuum is generated at the cylinder port (P) and the
pressure in the tank passage (T) drops as a result, it
pushes on the poppet (1) and oil flows from the tank
P
passage to the cylinder port.
G4D218
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General Cautions
• Since all parts in control valves are precision • Replace all seals with new ones each time the
machined, carry out disassembly and assembly valves are disassembled.
operations in a clean place. • Spools and section bodies are specially selected for
• Before disassembly, clean the outside surfaces a precise fit. Therefore, if any damage is found in
around the valves. either of these parts, replace the section assembly
• Clean all disassembled parts in cleaning solvent. as a unit.
Use a lint free cloth, or air dry the parts. • Be sure to number each section and spool to avoid
• Apply hydraulic oil to sliding surfaces and apply a mistakes during assembly.
thin coating of grease to seals when assembling • Do not turn adjusting screws if not required.
them.
Following is an explanation of the control valve

disassembly procedure.
Follow the procedure used to disassemble the control
valve in reverse order when reassembling it.
Disassembly
Valve Assembly
1. Loosen the nuts and remove the tie rods, then
remove the sections.
Nut: 13.7~14.7 N·m
2. Remove the O-ring.

• The mating surfaces are metal seals, so be
careful not to scratch, bruise or otherwise dam-
age them.
• When assembling, do not apply any oil or
grease to the O-rings used on the mating sur-
faces.
3. Remove the main relief valves and the port relief

valves, then remove the O-rings from the relief
valves.
• Do not disassemble the relief valves unless it is
necessary.
• When using a spanner or adjustable wrench, be
sure to attach it in the place shown in the figure
at right.
Relief valve: 39.2 N·m
G4D223
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4. Remove the anti-cavitation valve (1) and remove
the O-ring (2) from the valve.
Valve: 39.2 N·m
2
1
B5D209
5. Remove the load check valve.

a. Remove the plug (3) and the spring (4), then 3
remove the poppet (5).
Plug: 24.5~29.4 N·m
6
b. Remove the O-ring (6) from the poppet.
G4D224
6. Remove the cap screws, the cover (7) and the

spool assembly (8).
• Remove the spool assembly while turning it
gently.
• Be careful not to scratch or bruise the outside
surface.
Cap screw: 5.88~6.86 N·m
7
7. Remove the seal holder, backup ring and O-ring.
8
B5D210
8. Remove the screws on the spool yoke end side of

the section, then remove the seal holder, backup
ring and O-ring.
When assembling, temporarily fasten the seal
holder with the screw and confirm that the spool
turns smoothly, and then fasten the screw at the
stipulated torque.
Screw: 1.96~2.94 N·m
IV-19 TB108
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Checking the Parts
Parts Judgment Criteria Treatment

Housing, • Scratches, rust, corrosion of the portion which slides • Replace
Section Body against the spool.
• Scratches, rust, corrosion of the seal pocket portion of • Replace
the part that enters the spool.
• Scratches, rust, corrosion of the port seal portion which • Replace
is in contact with the O-ring.
• Scratches, rust, corrosion of the seal portion of the relief • Replace
valve, etc.
• Other damage which could be a hindrance to correct • Replace
function.
Spool • Scratch marks like being clawed around the outer cir- • Replace
cumference sliding portion.
• Scratches on the portion that slides against the seals on • Replace
both ends.
• Spool not operating smoothly. • Repair or replace.
Load Check Valve • Imperfect sealing due to damage to the valve or spring. • Repair or replace.
• Does not catch, but operates lightly when inserted in the • Normal
section body and operated.
Around Springs • Rust, corrosion, deformation, breakage or other marked • Replace
damage to the spring, holder or cover.
Around Spool Seal • Oil leaking to the outside. • Repair or replace.
• Rust, corrosion or deformation of the seal holder. • Repair or replace.
Main Relief Valve, • External rust, damage. • Replace
Port Relief Valve, • Damage to valve seat contact surface. • Replace
Anti-Cavitation Valve • Damage to poppet contact surface. • Replace
• Abnormality in the spring. • Replace
• O-rings, backup rings, seals • As a rule, all these
should be replaced.
Adjusting the Main Relief Valve Pressure

1. Install a pressure gauge in the following pressure
sensor port.
• Control valve pressure sensor port.
Performance”
2. Run the pump at the rated speed.
3. Operate the control valve’s cylinder spool over its 1
full stroke and read the value indicated by the 2
pressure gauge.
4. Turn the set screw (1) while watching the pres-
sure gauge to adjust.
Turning it to the right increases the set pressure.
Turning it to the left decreases the set pressure.
5. After completing the pressure adjustment, tighten
the lock nut (2) while holding the set screw (1) so
it won’t turn.
Operate the relief valve again and check if the
pressure is stabilized. B5B011
TB108 IV-20
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TROUBLESHOOTING
The following items are a list of all the problems that compound the trouble. It is therefore desirable to
might occur individually, but in actual practice, 2 or proceed so that the causes can be eliminated one at a
3 of these problems might occur simultaneously to time.

Oil leaks from spool seal. • Seal is scratched or the seal lip is worn • Replace with a new part.
due to long use.
• Spool’s seal sliding portion was dam- • Repair or replace the spool.
aged by some external cause (bruise,
scratch, etc.).
• Seal bulged out and the cover was in- • Return to the correct shape and check
stalled in a warped state. for eccentric wear of the seal lip.
• Paint adhered to the sliding portion of • Remove paint with paint thinner or re-
the spool’s seal portion during painting. move it mechanically. However, at this
time, be careful not to damage the spool
surface or the seal lip.
• Tank circuit’s pressure became high • Eliminate the factors causing excessive
and exceeded the pressure level that the flow resistance.
seal was capable of withstanding.
Spool’s sliding is not • Foreign matter is biting into the spool’s • Overhaul and repair or replace.
smooth. sliding surface.
• Oil film between the spool and body • Use some method to lower the oil tem-
disappears due to abnormally high oil perature or if the relief valve is operat-
temperature. ing frequently, investigate the cause
and reduce the frequency.
• Lubrication is improper due to deterio- • This could be alleviated by simply re-
rating oil. placing the hydraulic oil, or it could
require an overhaul of the circuit.
• Spool is worn from long use or due to • Check the spool’s diameter and con-
pressure bearing on one side only. sider the necessity of replacement.
• Spool is bent from externally applied • Check the spool’s straightness and other
pressure. factors, then repair or replace.
• Entire valve is strained due to strain in • Loosen the installation bolts, then cut
the installation face. the installation face and edge and check.
• Valve was used at a pressure or a flow • In the case of pressure, check with a
volume which was out of specification. pressure gauge. In the case of flow
volume, check by the actuator’s speed
of movement and the capacity.
• Bolts used to assemble the valve were • Check if the assembly bolts are tight-
tightened excessively. ened to the specified torque. If the torque
deviates markedly from the specified
torque, tighten them again.
• Oil is accumulating in the cover (the • The spool is leaking oil, so when the
side with a spring or a detent) opposite spool moves, oil leaks from the cover.
the side where the spool operates. After confirming this, replace the seal.
Cylinder drops while • Foreign matter is biting into the load • Disassemble and check, then overhaul
shifting to a lift operation. check valve seat or large scratches were or replace.
made by foreign matter biting into the
valve's seat previously.
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Can’t be held in the spool • Could be mistaken for a great amount of • Check if it isn't just the cylinder’s natu-
neutral position (cylinder leakage in the cylinder. ral drop when the cylinder is held. If the
drops). problem is in the cylinder, disassemble
and repair it.
• The gap between the spool and body is • Replace the spool or replace the valve
large, so the amount of oil leaking from block assembly.
the spool is great.
• Spool won’t return completely to the • Manually Operated :
neutral position. Check if there is something interfering
with the link mechanism.
Pilot Operated:
Check the pilot pressure.
• Foreign matter is biting into the port • Disassemble and check, then overhaul
relief valve seat or the anti-cavitation or replace.
valve seat and oil is bypassing. Or a seat
is damaged.
The load won’t move. • Foreign matter is biting into the relief • Disassemble and check, then overhaul
(Pressure won’t increase.) valve seat and oil is bypassing. Or the or replace.
seat is damaged.
• The relief valve’s adjustment screw is • Try tightening the adjustment screw. If
loose. it is loose, correct the setting and tighten
the lock nut securely.
• Foreign matter is biting into the port • Disassemble and check, then overhaul
relief valve seat or the anti-cavitation or replace.
valve seat and oil is bypassing. Or a seat
is damaged.
• Spool stroke is not the specified stroke. • Manually Operated:
Check if there is something interfering
with the link mechanism. Check if a pin
or a pin hole in the link connection is
worn.
Pilot Operated:
Check the pilot pressure.
• Pump is damaged and no oil is dis- • Check if the pump is abnormal or not. If
charged. the pump is bad, replace it. Check if the
cause of the abnormality is air being
sucked in, deterioration of hydraulic oil
or shafts not centered, etc.
Load doesn’t move. (Pres- • The load is too heavy. • Compare with an object of the specified
sure rises.) weight.
• Mechanical resistance of connecting • Check and replenish hydraulic oil, etc.,
parts is great regardless of the hydraulic modify or repair.
pressure in the operating unit.
• A large piece of foreign matter is trapped • Find the affected place and repair it.
in the circuit or a pipe is bent, causing
great resistance.
• Spool stroke is not the specified stroke. • Check if there is something interfering
with the link mechanism. Check if a pin
or a pin hole in the link connection is
worn or not.
TB108 IV-22
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CYLINDERS HYDRAULIC UNITS

CYLINDERS
CONSTRUCTION
Boom Cylinder
22 23 21 1 21 20 24 7 5 6 5 8 15 3
12 13 14
11 10 9 19 18 17 16 2 4 B5D400
1. Piston Packing 7. O-ring 13. Bushing 19. Stopper

2. Rod Packing 8. O-ring 14. Grease Nipple 20. Piston
3. Dust Seal 9. Tube 15. Rod Cover 21. Wear Ring
4. Backup Ring 10. Bushing 16. Bushing 22. Ball
5. Backup Ring 11. Grease Nipple 17. Cushion Seal 23. Set Screw
6. O-ring 12. Piston Rod 18. Spacer 24. Cushion Bearing
Arm Cylinder
17 18 16 1 16 15 5 4 6 13 3
9 8 7 2 14 10 12 11
B5D401
1. Piston Packing 6. O-ring 11. Bushing 16. Wear Ring

2. Rod Packing 7. Tube 12. Grease Nipple 17. Ball
3. Dust Seal 8. Bushing 13. Rod Cover 18. Set Screw
4. Backup Ring 9. Grease Nipple 14. Bushing
5. O-ring 10. Piston Rod 15. Piston
IV-23 TB108
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HYDRAULIC UNITS CYLINDERS
Bucket Cylinder
18 17 16 1 16 15 5 4 6 13 3 11 12 10
9 8 7 2 14
B5D402

2. Rod Packing 7. Tube 12. Grease Nipple 17. Set Screw
3. Dust Seal 8. Bushing 13. Rod Cover 18. Ball
Dozer Blade Cylinder
8 9 7 18 17 16 1 16 15 5 4 6 13 3 11 12 10
2 14
B5D403

2. Rod Packing 7. Tube 12. Grease Nipple 17. Set Screw
3. Dust Seal 8. Bushing 13. Rod Cover 18. Ball
TB108 IV-24
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Swing Cylinder
17 16 15 1 15 14 5 4 6 12 3
8 7 2 13 9 11 10 B5D404
1. Piston Packing 6. O-ring 11. Grease Nipple 16. Set Screw

2. Rod Packing 7. Tube 12. Rod Cover 17. Ball
3. Dust Seal 8. Bushing 13. Bushing
4. Backup Ring 9. Piston Rod 14. Piston
5. O-ring 10. Bushing 15. Wear Ring
Spanner Cylinder
14 13 12 1 12 11 7 8 5 4 6 9 3
2 10 B5D405
1. Piston Packing 5. O-ring 9. Rod Cover 13. Set Screw

2. Rod Packing 6. O-ring 10. Bushing 14. Ball
3. Dust Seal 7. Tube 11. Piston
4. Backup Ring 8. Piston Rod 12. Wear Ring
IV-25 TB108
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OPERATION
Hydraulic oil flowing alternately in and out of the oil

outlet and inlet on both sides (head and rod sides) of
the piston acts on the piston and its force causes the
piston to move back and forth.
In cylinders equipped with a cushion mechanism, the
shock resulting from the piston colliding with the
cover at the stroke end acts on that mechanism and is
dampened by it.
Cushion Mechanism
PORTION A
DETAIL OF
PORTION A
B5D406E
Before the piston (1) nears the stroke end and collides
with the cover (2), the cushion bearing (3) which
precedes it enters the cushion seal (4), shutting off the
return passage for the hydraulic oil on the rear end of
the piston and making it possible for oil to be expelled
only along the groove provided in the cushion bearing
(3). This causes the piston (1) back pressure to be-
come high, slowing the speed of the piston.
TB108 IV-26
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Special Tools
See the table of special tools at the back of this section
for the jigs and tools used for disassembly and assem-
bly.
General Cautions
In this manual, the procedure for the boom cylinder is

described. When necessary, the points which are
different in other cylinders are mentioned.
Disassembly
Cylinder Assembly
1. Fasten the clevis of the tube in a vice and place the
other end on a support black made of wood to
fasten the cylinder in a horizontal condition.
2. Drain out hydraulic oil remaining in the cylinder.

• Move the piston rod gently to prevent the
hydraulic oil from spraying out and scattering
all over.
3. Free the locked portion of the rod cover.

• Since the lock is integrated with the cylinder
tube, be careful not to bend it or to scratch it
when the lock is being freed.
IV-27 TB108
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4. Loosen the rod cover.

• The piston rod should be pulled out approxi-
mately 200 mm beforehand.
• Measures should be taken to prevent the piston
rod from being hit.
5. Take the piston rod assembly out of the tube.

• Pull it out straight to prevent the sliding surface
from being scratched.
Piston Rod Assembly

1. Fasten the piston rod assembly securely in a level
position.
2. Remove the piston.

a. Take out the set screw (10) and remove the ball
(11).
• The set screw is staked at 2 place with a
punch, so grind off the staked portions using
a hand drill.
b. Remove the piston assembly (12) and remove
the cushion assembly (13).
3. Remove the rod cover assembly.
TB108 IV-28
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Piston
1. Remove the wear ring (27), then remove the
piston packing (28).
• Spread the wear ring at the cut portion the
minimum amount necessary for it to be re-
moved. Remove it in the direction of the shaft.
• Either cut the piston packing off or use a flat
bladed screwdriver, etc. to take it off.
Rod Cover
1. Remove the O-ring (34) from the outer diameter
of the rod cover, then remove the backup ring
(35).
2. Remove the rod packing.

a. Remove the stopper (37).
b. Remove the spacer (38).
c. Remove the cushion seal (39).
d. Remove the rod packing (40).
e. Remove the backup ring (41).
3. Remove the dust seal (42).

• Tap alternately on several points around the
circumference on the inside of the metal ring,
pushing it out a little at a time to remove it.
IV-29 TB108
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4. Remove the bushing.

• Since the bushing has been pressure fitted
tightly in the rod cover, it is impossible to take
it out. First use a lathe to grind down the inside
portion until only a thin piece remains, then
insert a copper spatula strongly and pry it out
to remove it.
Clevis
1. Remove the bushings using a setting tool (43).
TB108 IV-30
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Assembly
Clevis
1. Using a setting tool (45), pressure fit the bushings
(44) in the piston rod and tube.
45
44
B5D407
Rod Cover
1. Using an installation jig (A), pressure fit the
bushing.
• Hydraulic fluid should be applied to the inside
surface of the rod cover before assembly.
• After installation, make sure there are no level
differences with the bushing.
2. Install the rod packing.

a. Install the backup ring (41).
b. Install the rod packing (40), being careful of its
installation direction.
c. Install the cushion seal (39).
d. Install the spacer (38).
e. Install the stopper (37).
3. Install the dust seal (42).

• In the case of a dust seal with a metal ring
around the outer circumference, use a setting
tool (46) to install it.
IV-31 TB108
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4. Install the backup ring (35) and fit the O-ring (34).
• The cut portions of the backup ring should
overlap correctly.
Piston
1. Assemble the piston assembly.
a. Fit the O-ring (50).
• If the O-ring is twisted after it is fitted,
correct it.
b. Cover the piston with the sliding jig (C), then

using the fitting jig (D), insert the slipper ring
(51) rapidly.
c. Since the slipper ring (51) is extended when it

is installed, correct it using the corrective jig
(E).
TB108 IV-32
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2. Install the wear ring (27).
a. Spread the wear ring (27) at the cut portion the
minimum amount necessary, installing it on
the piston from the shaft direction.
Piston Rod Assembly

1. Insert the rod cover assembled above into the
piston rod.
2. Install the piston unit.

a. Fit the cushion bearing (13) and piston (12)
and tighten them.
• Piston Tightening Torque: Refer to the table
below.
b. Insert the ball (11), tighten the set screw (10)
and stake at 2 points with a punch.
• Set Screw Tightening torque: Refer to the
table below.
Piston, Set Screw

Unit: N·m
Piston Set Screw
Boom 157 6.8
Arm 265 6.8
Bucket 157 6.8
Dozer Blade 157 6.8
Swing 157 6.8
Spanner 157 6.8
IV-33 TB108
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Cylinder Assembly
1. Fasten the tube in a horizontal position, then
insert the piston rod assembly in the tube.
• During insertion, align the center of the piston
rod with the center of the tube, inserting it
straight so that the seals will not be scratched.
2. Tighten the rod cover.

Rod Cover
Unit: N·m
Boom 255
Arm 265
Bucket 255
Dozer Blade 255
Swing 255
Spanner 255
3. Bend the lock rib on the tube down in a notch of

the rod cover to lock it.
TB108 IV-34
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Inspection after Disassembly

Clean each part thoroughly with cleaning oil, then
carry out the following checks. When a cylinder has
been disassembled, replace all the seals with new
ones.
1. Piston Rod
• Replace the rod if there are cracks. Measuring the Bend
• If the threads are damaged, repair them or
replace it.
• If the plating layer of the plated portion is
broken, rusted or scratched, replace it.
• If the rod is bent more than the limit of 1 mm
in 1 m, replace it. (Measure by the method
shown in the figure at right.
If the bending of the rod is within the above
limit, yet is bent a lot in a small distance so that a. Support the portion of the rod with the same
it won’t move smoothly, replace the rod if it diameter at both ends on V-blocks.
makes a squeaking sound in the operation test b. Set a dial gauge at the center between the two
after reassembly or if it catches during move- blocks.
ment. c. Rotate the rod and take a reading of the maxi-
• If the inner diameter of the clevis bushing is mum and minimum runout indicated by the
worn, replace the bushing. dial gauge.
2. Tube
• If there are cracks in the welded portion, re-
place it.
• Replace the tube if the inside surface is scratched
or if it leaks hydraulic oil.
• If the inner diameter of the clevis bushing is
worn, replace the bushing.
3. Rod Cover
• If the bushing inner diameter is worn and the
clearance with the piston rod is greater than
0.25 mm, replace the bushing.
• If the inside surface of the bushing is scratched,
and the scratches are deeper than the depth of
the coating layer, replace the bushing.
IV-35 TB108
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Inspection after Assembly

No Load Operation Test
1. Place the cylinder in a horizontal position with no
load.
2. Apply gentle pressure alternately to the ports at
both ends, operating the piston rod 5 or 6 times.
3. Make sure there is no abnormality in the operat-
ing condition.
Leak Test
• External Leakage
1. Apply test pressure for 3 minutes each to the
retraction side and the extension side.
2. Make sure there are no abnormalities such as
external leakage or permanent deformation, etc.
in the rod seal, the rod cover mount, or in any
welded portion.
• Internal Leakage
1. Disconnect the extension side hose.
2. Apply test pressure to the retraction side for 3
minutes.
3. Measure the amount of oil that has leaked from
the extension side.
• The amount of leakage should be 1 cm3 / 3min
or less.
Bleeding Air from the Hydraulic Cylinder

Bleed the air out of the cylinder when the cylinder is
removed or when the hydraulic piping, etc. is discon-
nected.
1. Start the engine and let it idle for approximately
5 minutes.
2. With the engine running at slow speed, extend
and retract the cylinder 4 or 5 times.
• Move the piston rod to a position 100 mm
before the end of the stroke, being careful not
to apply any relief at all.
3. With the engine at top speed, repeat the operation
in (2), then with the engine running at slow speed,
move the piston rod to the stroke end and apply
relief.
TB108 IV-36
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TROUBLESHOOTING

Oil leaks from piston rod • Foreign matter is caught in the inner • Remove the foreign matter.
sliding surface (an oil ring diameter portion of the rod packing,
forms on the piston and backup ring or dust seal.
this enlarges and drips off). • The inner diameter lip of the rod packing, • Replace the affected parts.
backup ring or dust seal is damaged or
abnormal.
• Piston rod sliding surface is scratched. • Smooth the sliding surface with an oil
stone (1.6 S or lower)
• If it leaks after the sliding surface has
been smoothed, replace the rod pack-
ing and other seals.
• If it leaks after the seals have been
replaced, replace the piston rod.
• The hardened chrome plating is separat- • Repair the hardened chrome plating.
ing from the piston rod.
Oil leaks from the outer • O-ring is damaged. • Replace the affected parts.
circumference of the rod • Backup ring is damaged. • Replace the affected parts.
cover.
Oil leaks from welded por- • The tube’s welds are damaged. • Replace the affected parts.
tion.
Cylinder natural drop (this • Foreign matter is caught in the wear ring • Remove the foreign matter.
is the maximum amount sliding surface.
of movement of the piston • The sliding surface of the wear ring is • Replace the affected parts.
in 10 minutes when a static scratched or abnormal.
weight corresponding to • The piston packing sliding surface is • Replace the affected parts.
the maximum use pressure scratched.
multiplied by the • The O-ring is damaged. • Replace the affected parts.
cylinder’s surface area) is
0.5 mm or greater.
IV-37 TB108
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TABLE OF SPECIAL TOOLS
Installation Jig (A)
MATERIAL : SS41 B5D408E
Unit: mm
Installation Jig (A)
A B C D E F
Boom 29.0 24.9 10.0 30.0 ± ±
Arm 34.0 29.9 10.0 12.0 20.0 45.0
Bucket 29.0 24.9 10.0 12.0 20.0 40.0
Dozer Blade 29.0 24.9 10.0 12.0 20.0 40.0
Swing 29.0 24.9 10.0 12.0 20.0 40.0
Spanner 29.0 24.9 10.0 12.0 20.0 40.0
Sliding Jig (C) Fitting Jig (D)
MATERIAL : STKM13C B5D409E MATERIAL : NYLON B5D410E
Unit: mm
Sliding Jig (C) Fitting Jig (D)
A B C D E A B C
Boom 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Arm 12.3 55.5 53.0 35.0 15.0 60.0 58.0 50.0
Bucket 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Dozer Blade 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Swing 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Spanner 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
TB108 IV-38
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Corrective Jig (E)
Unit: mm
A B
Boom 65 50
Arm 70 55
Bucket 65 50
Dozer Blade 65 50
Swing 65 50
Spanner 65 50
MATERIAL : STKM13C B5D411E
IV-39 TB108
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TB108 IV-40
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TRAVEL MOTOR HYDRAULIC UNITS

TRAVEL MOTOR
CONSTRUCTION
Hydraulic Motor
3
1
14
2
10 15 26
27
21
17
22
18 28
24
16
23
20 19
13
12
13 4
25 9 8
6
5
11
7 B5D500
1. Body 11. Pin 21. O-ring

2. Flange Holder 12. Spring 22. O-ring
3. Shaft 13. Retainer 23. O-ring
4. Cylinder Block 14. Bearing 24. Friction Disc
5. Valve Plate 15. Pin 25. Center Disc
6. Piston 16. Pin 26. Oil Seal
7. Shoe 17. Brake Piston 27. Backup Ring
8. Shoe Holder 18. Spring 28. Backup Ring
9. Guide 19. Snap Ring
10. Swash Plate 20. O-ring
IV-41 TB108
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HYDRAULIC UNITS TRAVEL MOTOR
Reduction Gears
29
19 3
6
9 2
7 16 5
11
28
25
27
26
25
24
15
23 18
14 21 4
13 17
1 8
12
10 20
22
B5D501
1. O-ring 9. Gear S2 17. Plug 25. Thrust Washer

2. O-ring 10. Seal Ring 18. Washer 26. Needle
3. O-ring 11. Snap Ring 19. Plug 27. Gear B2
4. O-ring 12. Plate 20. Snap Ring 28. Pin
5. Cover 13. Needle 21. Ring 29. Carrier 2
6. Snap Ring 14. Floating Seal 22. Housing
7. Spring Pin 15. Snap Ring 23. O-ring
8. Gear B1 16. Snap Ring 24. Snap Ring
TB108 IV-42
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Counterbalance Valve
2
5
1
3
4
3
1
5
2 B5D502
1. Spring 5. O-ring
2. Plug 6. Bearing
3. Ring 7. Spring Pin
4. O-ring 8. Spool
IV-43 TB108
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OPERATION
3 1 2 5 4
Hydraulic Motor
7 pistons (2) are fitted in the cylinder block (1) and
there is a valve plate (3) with two half moon ports, B
and C in the end. Also, the cylinder block (1) rotates
freely and is joined to the shaft (4) via the spline. On
the other band, the swash plate (5) is fastened to the
A
housing.
When high pressure oil is introduced into port B, one
piston (2) makes contact and force F bears on the
swash plate (5).
F = P × A P: Pressure A: Piston Sectional Area
The force F which the piston (2) applies to the swash F1
F2
plate (5) is divided into force F1, which pushes the
plate, and force F2, which rotates the cylinder block F
(1). The total sum of the components in the direction F
of rotation of the high pressure side piston generates
a rotational force in the cylinder block (1) and via the F2
spline, torque is transmitted to the shaft (4), turning it. B F C
Conversely, if high pressure oil is introduced to port
C, rotation is the reverse of the above. F2
F F2
VIEW A
E5D503E
If high pressure oil is introduced to port P1, the oil
pushes the check valve (6) up. This causes oil to flow
through the motor port M1 and to flow into chamber
B of the pilot portion and fill it. When hydraulic oil
flows the motor from port M1 and acts to turn the
motor, even if oil returns from the motor and flows
into port M2, since the flow is cut off by the check
valve (6), the pressure at port P1 and in chamber B
rises. If the pressure in chamber B becomes higher
than the set valve of the spring (7), the spool (8) moves
to the left side and ports M2 and P2 open up, causing B C4D554
the motor to turn.
If the motor’s turning becomes too fast, and the B

amount of oil flowing out of port M2 is greater than
the amount of oil flowing into port M1, the pressure
D
in port P1 and chamber B drops. When the pressure in
chamber B drops below the set valve of the spring (7),
the spool (8) attempts to return to the right side. As a
result, since the resuming oil is constricted at portion
D, back pressure is generated at port M2 and the
motor’s turning is slowed.
C4D555
TB108 IV-44
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When the motor is slowed, the pressure in port P1 and
chamber B rises again and the spool (8) moves to the B
left aide, eliminating the back pressure generated at
port M2. In this way, the motor is controlled so that it
rotates at a speed appropriate for the amount of oil
flowing into it.
If the high pressure hydraulic oil introduced into port

P1 is cut off, the pressure at ports P1 and P2 becomes
the same and the spool (8) returns to the neutral
position by spring force. For this reason, the oil in
chamber B is pushed out at port P1. At this time, the
flow of oil is restricted by the orifice (9) as it is C4D556
returning to port P1, so the spool (8) returns to the
neutral position slowly. In this way, the motor is
stopped while the shock during stopping is absorbed.
Parking Brake
The center disc (1) are connected to the flange holder
and the friction disc (2) are connected to the cylinder
block (3) via the spline, respectively. The center disc
(1) and friction disc (2) are pressed against the flange
holder (6) by the springs (4) via the brake piston (5).
The friction force between these discs generates the
brake torque to prevent the cylinder block (3) from
rotating.
When the pressure oil is introduced into the motor, the

spool of the counterbalance valve moves and the oil
flows from the parking brake release port (7) into the 3 6 2 1 5 4 B5D503
brake piston chamber (8). The oil pressure overpow-

ers the spring force and moves the brake piston (5) to
the right. This generates a clearance between the
center disc (1) and friction disc (2) to release the
parking brake. When the motor stops, the spool re-
turns to the neutral position to close the parking brake
release port (7). The pressure oil in the brake piston
chamber (8) is introduced into the motor case and the
spring (4) operates the parking brake.
2 1 87 5 4 B5D504
IV-45 TB108
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Reduction Gears
The reduction gear has a simple planetary two-stage a1,a2
configuration. It decelerates the high speed rotary
motions of the hydraulic motor, converts them into B1 B2
low speed high torque, and rotates the case. The
output shaft of the hydraulic motor is connected to the
gear S2 via the spline. The rotation of the gear S2 is S1 1
decelerated by one stage among the gears S2, B2 and S2
a2. This one-stage decelerated rotation is further
decelerated by two stages among the gears S1, B1 and
a1 that are connected to the carrier 2 (1) via the spline.
This rotation is conveyed to the rotary main body via
the inner gears a1 and a2 as the driving force of the
motor. C4D560
TB108 IV-46
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General Cautions
The following describes the assembly procedure. For

disassembly, follow the procedure in the reverse
order referring to the construction diagram.
Assembly
Counterbalance Valve and Hydraulic Motor
1. Fix the body with a vise and mount the spool on
the body.
• To prevent the outer surface of the body from
being damaged, insert a protector such as an
aluminum plate between the body and the vise.
• Do not disassemble the spool assembly into
parts. B5D505
2. Mount the rings (1) and springs (2) on both sides

of the spool.
1
2
B5D506
3. Fit the O-ring to the plug, and tighten the plug on

both sides of the body.
Plug: 167~169 N·m
B5D507
IV-47 TB108
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4. Press fit the oil seal (6) into the flange holder.
• As the oil seal is to be inserted, do not disas-
semble it unless necessary. 6
• Fill between the lips of the oil seal with grease.
B5D508
5. Mount the shaft on the flange holder.

• The bearing has been inserted and cannot be
disassembled.
• Be careful not to damage the oil seal by the
shaft.
C4D567
6. Mount the swash plate on the flange holder.

• The positioning pin has been inserted and
cannot be disassembled.
C4D568
7. Mount the retainer (7), spring (8) and retainer (7)

on the cylinder block and fix them with the snap
ring (9).
9 7
8
C4D570
C4D569
TB108 IV-48
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8. Fit the three pins (10) to the cylinder block.
10
C4D571
9. Mount the piston (12) and guide (13) on to the 11

shoe holder (11) to assemble the shoe holder
assembly. 13
12
C4D572
10. Mount the shoe holder assembly on the cylinder

block to assemble the cylinder block assembly.
C4D573
11. Mount the cylinder block assembly on the flange

holder.
• Mount the cylinder block assembly in such a
manner that the shoe will touch the swash
plate.
C4D575
IV-49 TB108
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12. Install the center disc (14) in the groove of the

flange holder and then install the friction disc (15) 14
in the groove of the cylinder block, alternately
15
one by one.
C4D576
13. Mount two O-rings and two backup rings on the

brake piston.
• Be sure to position the backup rings on the
outer side.
C4D577
14. Mount the brake piston assembly on the flange

holder.
• Apply grease to the O-ring and be careful not
to let it bite the seal.
C4D578
15. Mount the large and small O-rings on the body.
B5D512
TB108 IV-50
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16. Mount the valve plate (16) on the body and insert
ten springs into the spring holes.
• The dot in the figure shows the spring installa- 16
tion positions.
• Assemble the valve plate in such a manner that
the copper surface is on the cylinder block side.
• Apply grease to the valve plate and springs,
and be careful not to drop them.
B5D513
17. Supply 100 mL of hydraulic oil into the flange

holder and mount the valve body on the flange
holder.
C4D581
18. Fix the flange holder with a vise and tighten it

with the screws.
Screw: 28.4~30.4 N·m
• Insert a protector such as an aluminum plate
between the flange holder and the vise to
prevent the outer surface of the body from
being damaged.
B5D514
19. Mount the floating seal (17) and O-ring on the

flange holder.
• Apply grease to the O-ring.
17
B5D515
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20. Mount the flange holder on the bearing inner ring

(18).
18
18
17
B5D517
B5D516
21. Mount the flange holder on the bearing (19).

19
19
B5D519
B5D520
22. Fit the O-ring to the seal ring and install them in
the housing.
• Install the seal ring with the seal faced upward.
B5D521
23. Mount the housing on the flange holder.

• Tighten the housing of the reduction gear and
the flange of the hydraulic motor with a C-
clamp or hydraulic press, and fix them with the
snap ring.
C4D588 B5D522
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24. Mount the housing on bearing (19) and the bear-
ing inner ring (18).
19
18
19
B5D524
B5D523
25. Mount the snap ring.
B5D525
26. Mount the ring, the thrust washer, gear B1 and

needle on the pin.
B5D526
27. Mount the thrust plate and fix them with the snap
ring.
• Be careful not to expand the snap ring more
than necessary.
• Install the snap ring with its edge positioned
upside (cover side).
B5D527
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28. Mount the gear S1 on the carrier and fix them with
the snap ring.
than necessary.
C4D590
29. Mount the thrust washer, gear B2, needle and

thrust washer on the carrier 2 and fix them with
the snap ring.
than necessary.
C4D591
30. Install the carrier 2 assembly in the housing.
C4D593
31. Mount the gear S2 on the shaft and fix them with
the snap ring.
than necessary.
C4D594
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32. Fit the O-ring to the housing.
C4D595
33. Supply 330 mL of lubricant and mount the cover.

• Be careful not to damage the O-ring.
• Align the character “DRAIN” on the cover to
the notch on the housing.
34. Fit the snap ring.

• Put the blade of a screwdriver on the snap ring
end and push it into position.
B5D528
35. Wind the seal tape around the plugs and mount it
on the cover.
Plug: 46~51 N·m
B5D529
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Checking the Parts

Parts Area Checked Judgement Criteria Treatment
Floating Seal Sliding Surface There should be no abnormal scratches, Replace
wear or seizing.
Bearing Sliding Surface There should be no abnormal scratches, Replace
wear, flaking, etc. in the ball or race.
Gear Surface of Gear Teeth There should be no abnormal scratches, Replace
wear or flaking of the tooth surfaces (if
there has been pitting which covers 5%
or more of the engagement portion of
the tooth surface).
Front of cage and roller ro- There should be no abnormal scratches,
tating surface. wear or flaking of the rotating surface.
Thrust Washer Front of sliding surface There should be no abnormal scratches, Replace
wear or seizing.
Housing Front of Gear Tooth Sur- There should be no abnormal scratches, Replace
faces wear or flaking in the tooth surfaces (if
there has been pitting which covers 5%
or more of the engagement portion of
the tooth surface).
O-ring ± ± Replace
Shaft Surface of oil seal. There should be no scratches or abnor- Replace
mal wear.
Ball Bearing Front of sliding surface. There should be no abnormal scratches, Replace
wear or flaking in the ball and race.
Oil Seal ± ± Replace
Swash Plate Front of the surface which There should be no abnormal scratches Repair by lapping
slides with the sliding sur- (0.02 mm or greater), wear or seizing. (#1000) or replace.
face of the piston assembly.
Cylinder Block Clearance with the piston 0.04 mm or greater Repair with wrap
assembly. (#1000) or replace
Front of the surface which There should be no abnormal scratches the cylinder block
slides with the valve plate. (0.02 mm or greater), wear or seizing. and piston assem-
bly at the same
Piston Assembly Clearance with cylinder 0.04 mm or greater
time.
block
Front of the surface which There should be no abnormal scratches
slides with the swash plate. (0.02 mm or greater), wear or seizing.
Clearance between piston 0.4 mm or greater Replace
and shoe.
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Parts Area Checked Judgement Criteria Treatment

Valve Plate Front of the surface which There should be no abnormal scratches Repair by lapping
slides with the cylinder (0.02 mm or greater), wear or seizing. (#1000) or replace.
block.
Body Front of the surface which There should be no abnormal scratches, Replace the base
wear or seizing. plate and the spool
Spool slides with the spool. There should be no abnormal scratches, at the same time.
Front of the surface which wear or seizing.
slides with the body. There should be no abnormal scratches, Replace the spool
Front of the surface which wear or seizing. and the check
Check Valve slides with the check valve. There should be no abnormal scratches, valve at the same
Front of the surface which wear or seizing. time.
slides with the spool. There should be contact with the seat
Surface of spool and seat. around the entire circumference.
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TROUBLESHOOTING
Hydraulic Motor
Does not move. • Equipment other than the motor, coun- • Check if the proper pressure is reached
terbalance valve or speed reducer is on the motor inlet port side, then check
malfunctioning. each device and repair if necessary.
• Hydraulic oil is escaping due to ab- • Replace the abnormally worn parts.
normal wear of motor sliding parts.
• Principal motor parts are malfunc- • Replace the damaged parts.
tioning due to damage.
Motor won’t speed up. • The proper volume of hydraulic oil is • Check if the proper pressure is reached
not being supplied to the motor due to on the motor inlet port side, then check
the hydraulic pump, control valve, each device and repair if necessary.
etc.
• The motor’s volumetric efficiency is
• Check if the sliding parts are abnor-
dropping. mally worn, then repair or replace the
worn parts.
Changes in rotational speed • High pressure hydraulic oil is leaking • Replace the abnormally worn parts.
are great. and flowing out of the drain port due
to wear of the motor's sliding parts.
• Bearings are worn. • Replace the bearings if they are abnor-
mally worn.
Oil is leaking. • Oil is leaking due damage to oil seals • Replace the oil seals and O-rings.
or O-rings.
Does not move or rotation is Spool does not switch.
slow. • No hydraulic oil is arriving. • Repair or replace the damaged piping.
• Foreign matter is caught. • Remove the foreign matter and repair
or replace the damaged parts.
• The orifice is clogged up. • Clean it.
Won’t stop or stopping is The spool won’t return.
slow. • Foreign matter gets caught. • Remove the foreign matter and repair
• A spring is missing. • Install the spring.
• A spring is damaged. • Replace the spring.
Shock is great when stopping. Spool return is fast.
• The spring seat is missing. • Install the spring seat.
Valve makes an abnormal The spool does not return.
noise. • Foreign matter gets caught. • Remove the foreign matter and repair
• A spring is damaged. • Replace the spring.
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SLEW MOTOR HYDRAULIC UNITS

SLEW MOTOR
CONSTRUCTION
6 8 23 10
18
13
19
12
21
20
15
7 27
4 5 1 3 2 16 9 22 24 17 14 29 25
11 26 30 28
B5D600
1. X-ring 11. O-ring 21. Pin

2. O-ring 12. Inner Face Seal 22. Drive Gear
3. Berring Housing 13. Outer Face Seal 23. Geroller
4. Shaft 14. O-ring 24. Valve Drive Gear
5. Bearing 15. O-ring 25. Valve Housing
6. Bearing 16. Wear Plate 26. Ball
7. Plug 17. Valve Plate 27. Plug
8. Retaining Ring 18. Valve 28. Spring
9. Shaft Face Seal 19. Balancing Ring 29. Bolt
10. O-ring 20. Spring 30. Plug
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HYDRAULIC UNITS SLEW MOTOR
Brake Valve
8 7
6 5 10
9 11 4 12 2 3 1
B5D601
1. Cap Nut
2. Lock Nut
3. Set Screw
4. Housing
5. Spring Seat
6. Spring
7. Needle Valve
8. Valve Seat
9. Packing
10. Piston
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OPERATION
Hydraulic Motor 1
High pressure hydraulic oil flowing in the main port In this way, orbiting of the rotor (6) of the geroller is
(1) enters the geroller (4) via the valve (2) and valve started by hydraulic pressure, with only the rotations
plate (3). The geroller (4) consists of a stator (5) and which take place in the orbiting action being picked
rotor (6), and the stator (5) contains 7 rollers inside it up by the drive gear (7), causing the shaft (8) to rotate.
and is fixed to the housing. The inner rotor has 6 Also, the rotations of the rotor (6) are transmitted via
external gears. For this reason, 7 chambers are formed the valve drive gear (9) to the valve (2).
inside the geroller. The rotor (6) is constructed so that The rotations of the valve (2) cause the oil holes in the
it orbits around inside the stator. valve which connect with the oil holes in the valve
On the other hand, there are 12 holes in the valve (2) plate (3) to shift in sequence. For this reason, high
for hydraulic oil, with high pressure hydraulic oil or pressure oil flowing in the geroller (4) also flows into
returning oil flowing through half of these holes at a sequentially differing chambers. This causes the motor
time. In the same way, there are oil holes made in the to rotate continuously.
valve plate (3) in 7 places. These oil holes connect
with the 7 chambers in the geroller (4). Thus, since the
7 oil holes in the valve plate (3) connect with some of
the 12 oil holes in the valve (2), a circuit is formed for
oil to flow to the geroller (4).
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Hydraulic Motor 2
B5D602E
In Fig. 1, when high pressure oil is introduced into cycle of shifting the chambers where high pressure oil
chambers B, C and D, the rotor (6) rotates in the arrow is introduced.
direction while making contact with the inside of the At this time, the • mark on the rotor (6) rotates 1/6
stator (5). The valve (2) rotates along with this, so the revolution in the reverse direction.
chambers in which high pressure oil is introduced also From this, we can see that 1 revolution of the output
shift sequentially, but in the direction opposite the shaft is achieved by introduction of high pressure oil
arrow direction. In Fig. 2, the rotor (6) has turned 1/ into 42 chambers, that is, 7 chambers × 6 cycles = 42
14 revolution. This cause the chambers where high chambers.
pressure oil is introduced to shift to A, G and F. At this
time, the center of the rotor Y shifts in a circle about
point X to point Y’. In Fig. 3, Y’ shifts to Y”.
That is, the center of the rotor (6) rotates in a circle
around point X, 6/7 revolution, from Y to Y’ to Y”. In
Fig. 4, point Y” has returned to point Y, making 1
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Brake Valve
Pressure in the circuit is introduced into chamber A.
This pressure is transmitted to chamber E via the
orifice (1) and acts as a force to push the needle valve A E 2 3
(2) to the right. When the pressure acting on the needle
valve (2) is higher than the strength of the spring (3),
the needle valve (2) moves to the right and the
pressure is directed to port M1 and port M2.
1
B5D603
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General Cautions
Disassembly
Hydraulic Motor
1. Remove the installation bolts of the valve hous-
ing.
C4D605
2. Remove the valve housing and then the balancing

ring (5) and valve (6).
• Be careful not to lose the springs (7) and pins
(8) for the balancing ring.
7
8
C4D606
3. Remove the valve plate and valve drive gear.
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4. Remove the geroller and drive gear.
C4D607
5. Remove the wear plate.
C4D608
6. Remove the retaining ring.
C4D609
7. Remove the shaft using a press or plastic hammer.
C4D610
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8. Remove the X-ring from the bearing housing.
C4D611
9. Remove the ball bearing from the bearing hous-

ing.
• Remove the ball bearing by tapping the inner
race of the bearing with a knock pin punch. Do
not remove the ball bearing unless necessary.
C4D612
10. Turn the bearing housing upside down and re-

move the ball bearing. Do not remove the ball
bearing unless necessary.
C4D613
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Valve
1. Remove the plugs, springs and balls from the
valve housing.
C4D614
2. Remove the cap nut (4), lock nut (5) and set screw
(6).
5 4
6
B5D604
3. Remove the housing (7), spring seat (8) and

spring (9).
8
9
7 B5D605
4. Remove the needle valve (10) and valve seat (11),

then remove the packing (12) from the valve seat.
10
11 12
B5D606
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5. Remove the piston (13) from the cartridge (7).
13
7 B5D607
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Assembly
Hydraulic Motor
1. Install the ball bearing in the bearing housing by
using a press or plastic hammer.
C4D615
2. Turn the bearing housing upside down and install

the ball bearing by using a press or plastic ham-
mer.
C4D616
3. Install the X-ring in the bearing housing.
C4D617
4. Insert the shaft into the bearing housing.

• Use a supporting tool and insert the shaft using
a press.
C4D618
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5. Fit the retaining ring to the shaft.

• Fix the flange to the vise.
C4D609
6. Fit the shaft face seal (10) to the wear plate (9).
10
9 C4D620
C4D619
7. Mount the drive gear on the bearing housing.
8. Fit the O-ring to the bearing housing.
9. Mount the wear plate on the bearing housing.
C4D621
10. Fit the large and small O-rings to the wear plate,
and install the geroller.
• Align the drain hole of the wear plate with that
of the geroller.
C4D622
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11. Mount the valve drive gear on the geroller.
C4D623
12. Fit the large and small O-rings to the valve plate,
and then install the valve plate.
• Align the drain hole of the valve plate with that
of the geroller.
C4D624
13. Install the valve.
IMPORTANT: The valve timing determines the

direction of motor rotation. Set the timing care-
fully by referring to the following figure.
B5D608E
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14. Install the springs and pins in the valve housing.
C4D626
15. Mount the inner face seal (11) and outer face seal
(12) on the balancing ring (5).
12 11
5 C4D627
16. Align the notch of the balancing ring (5) with pin 13
and mount on the valve housing (13).
12
11
C4D628
17. Mount the valve housing on the valve. At this

time, insert a small, long tool such as a driver to
hold the balancing ring so that it does not come
off.
• Align the drain hole of the valve housing with
that of the valve plate.
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18. Align the bolt with the bolt hole and tighten the
bolt.
Bolt: 53 N·m
C4D605
Valve
1. Fit the O-rings to the plugs.
2. Install the plugs, springs and balls in the valve

housing.
Plug: 58.8 N·m
B5D610
3. Install the packing (12) and needle valve (10) in

the valve seat (11), then install the valve seat in
the body.
10
11 12
B5D606
4. Install the spring (9) and spring seat (8).
8
9
B5D611
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5. Fit an O-ring in the piston (13), then install it in

the housing.
6. Fit an O-ring on the housing (7).
13
7 B5D607
7. Install the housing (7), then install the set screw

(6), lock nut (5) and cap nut (4) on the housing (7).
Cartridge: 98 N·m
5 4
6
B5D604
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Checking the Parts

Brake Valve
Part Judgment Criteria Treatment
Body • If there are deep scratches in the sliding portions or if they are rough. • Replace
• If there are scratches where leakage of oil occurs. • Replace
Relief Valve • If the set pressure is abnormally low. • Replace
Assembly • If the set pressure is fluctuating without stability. • Replace
• If there is a lot of leakage due to a faulty seal, etc. • Replace
Spring • If it is severely damaged or deformed. • Replace
Ball • If there are scratches where leakage of oil occurs. • Replace
Hydraulic Motor
Part Judgment Criteria Treatment
Shaft • If pitting or peeling off, etc. are occurring on gear tooth surfaces. • Replace
• If flaking or pitting are occurring on rolling surfaces. • Replace
Ball Bearing • If there is an abnormality in turning (abnormal noise, not turning • Replace
smoothly, etc.).
• If flaking, peeling off, etc. are occurring on rolling surfaces. • Replace
Valve Drive Gear, • If pitting or peeling off, etc. are occurring on gear tooth surfaces. • Replace
Drive Gear • If the amount of wear in the spring is great. • Replace
Inner Face Seal, • If there are scratches where leakage of oil occurs. • Replace
Outer Face Seal
Ball • If there are scratches where leakage of oil occurs. • Replace
Geroller • If pitting or peeling off, etc. are occurring on gear tooth surfaces. • Replace
• If there is an abnormality in turning (abnormal noise, not turning • Replace
smoothly, etc.).
Brake Valve
Adjusting the Relief Valve Pressure
“II. Specifications, for Judging Performance”
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TROUBLESHOOTING

The motor dose not turn. • Insufficient oil in the hydraulic oil • Add hydraulic oil to the hydraulic oil tank to
tank. the proper level.
• Hydraulic oil pump is damaged. • Replace the hydraulic pump.
• Relief valve operation is faulty or • Disassemble and clean the relief valve and set
its set pressure is low. it at the proper pressure.
• The hydraulic motor is abnormally • Disassemble and check the hydraulic motor
worn or grinding of parts. and replace the faulty parts.
• There is a short circuit inside the • Check for damage to the face seal or damage
hydraulic motor. to parts.
Replace them if they are abnormal.
Turning is not stable. • The relief valve’s set pressure is • Set the relief valve at the proper pressure.
low.
• Air is being sucked in on the hy- • Check the piping on the hydraulic pump’s
draulic pump’s suction side. suction side and tighten it if necessary.
Direction of rotation is • Reverse the piping. • Repair the pipes.
backwards. • Reverse the timing of the valves in • Switch the valve timing to the correct timing.
the hydraulic motor.
Oil is leaking from joints. • Tightening bolts are loose. • Tighten at the proper tightening torque.
• O-rings are being pinched or are • Replace the O-rings.
damaged.
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SWIVEL JOINT HYDRAULIC UNITS

SWIVEL JOINT
CONSTRUCTION
B5D700E
1. Shaft 9. Spring 17. Backup Ring 25. O-ring

2. Hub 10. O-ring 18. Snap Ring 26. O-ring
3. Flange 11. O-ring 19. Washer 27. Backup Ring
4. Thrust Ring 12. O-ring 20. Housing 28. Ball
5. Housing 13. O-ring 21. Spool 29. Plug
6. Spool 14. O-ring 22. Cover 30. Dust Seal
7. Pin 15. O-ring 23. Cover
8. Cover 16. Backup Ring 24. Spring
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HYDRAULIC UNITS SWIVEL JOINT
OPERATION
The swivel joint is mounted in the center of the

machine’s slew axis. It serves the role of maintaining
continuous connections in the hydraulic circuit re-
gardless of the upper frame’s slew angle.
Above the hub (1) and shaft (2), which are capable of
rotating together, ports (3) are included for oil for the
necessary number of circuits only. The inner circum-
ference surface of the hub and the outer circumfer-
ence surface of the shaft, grooves are cut which serve
as passages for hydraulic oil. Seals (4) are placed
above and below these circumferential grooves.
Oil flowing in from a port flows constantly through
this hydraulic passage (5) between the hub and shaft
and the circuits can be connected without a break
when the upper frame is slewing.
This swivel joint contains two selector valves which

are each capable of switching beetween 2 indepen-
dent circuits.
Selector (1) switches between high speed and low
speed for the travel motors and selector (2) switches
between the dozer blade cylinder and spanner cylin-
der.
Selector (1)
1. When the selector spool is pushed up, hydraulic TRAVEL MOTOR (RIGHT)
oil from pump P1 flows to the right travel motor
SELECTOR(1)
and hydraulic oil from pump P2 flows to the left
travel motor, then returns to the tank. P2
P1
SWIVEL JOINT
TRAVEL MOTOR (LEFT)

B5D701E
2. During travel, when the selector spool is moved SELECTOR(1)

to the down side, hydraulic oil from pump P2 and
hydraulic oil from pump P1 flow together. The TRAVEL MOTOR (RIGHT)
hydraulic oil in this merged flow flows from the

right travel motor, returns temporarily, then flows
to the left travel motor, after which it flows back P2
to the selector and then to the tank.
P1
SWIVEL JOINT
TRAVEL MOTOR (LEFT) B5D702E
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General Cautions
The disassembly procedure for the swivel joint is as

follows. For assembly, follow the same process in
reverse order.
1. Loosen the cap screws and remove the cover (1).

Cap Screw: 12.7 N·m
B5D703
2. Remove the pin (2), then remove the backup ring

(3) and O-ring (4) from the cover.
• Use a miniature screwdriver, etc. to remove the
backup ring and O-ring.
• During assembly, the pins should move
smoothly. 2
DUST SEAL
2
3
4
B5D704E
3. Take the O-ring and cap screws (5) out of the

housing.
B5D705
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4. Turn the housing over, then remove the spring

(6), washer (7) and spool (8).
• During assembly, the washer and spring should
fit the spool easily and the spool should move
smoothly. 6
7
8
B5D706
5. Remove the O-rings (9, 10).

9 10
B5D707
6. Remove the cap screws, selector (2) assembly

and O-ring from the shaft.
Cap Screw: 6.9 N·m
B5D708
7. Take out the cap screws and remove the cover

(11) and O-ring.
Cap Screw: 6.9 N·m
11
B5D709
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8. Remove the plug (12), spring (13) and ball (14)
from the cover.
Plug: 9.8 N·m
13
12
14
B5D710
9. Take out the cap screws (15), then remove the

cover (16) and spool (17). 16
Cap Screw: 6.9 N·m
15
17
B5D711
10. Remove the O-ring (18) and backup ring from the
cover.
• Use a miniature screwdriver, etc. to remove
them.
18
B5D712
11. Take out the cap screws (19) and remove the
flange (20) from the hub.
• During assembly, place a pipe on the shaft lock
pin and check if the shaft rotates.
20
19
B5D713
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12. Remove the O-ring (21), snap ring (22) and thrust
ring (23).
• During assembly, make sure the snap ring fits
23
snugly in the groove.
21
22
B5D714
13. Mount a removing jig on the hub and remove the

shaft.
(FULL THREAD BOLT)
MATERIAL : S35C or
equivalent B5D716E
B5D715
14. Remove the seals from the inner diameter of the

hub, checking the constructional drawing care-
fully.
• Use a long, thin pin with a sharp point to prick
the O-rings and remove them.
B5D717
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Inspection Procedure and Treatment
Inspection Interval Place Inspected Inspection Procedure Treatment

2,000 hrs. Seals which prevent ex- Check if oil is leaking out Replace the O-rings if there
ternal leakage of hy- is leakage
draulic oil
4,000 hrs. All seal parts ± Replace all seal parts
Disassemble and check All sliding parts Check for abnormal wear, Treat in accordance with the
whether there is leak- scratches, corrosion, etc., due use limit
age or not to seizing, biting of foreign mat-
ter, etc.
When disassembling All parts Check for abnormal wear, Treat in accordance with the
due to breakdown scratches, corrosion, etc., due use limit. However, replace
to seizing, biting of foreign mat- the seal kit
ter, etc.
Checking the Parts

Hub, Shaft
Parts Judgment Standard Treatment
Seal parts and sliding • Parts which wear away due to wearing of surfaces Replace with new parts
parts which have undergone ultrasonic tempering, and
parts which come off due to seizing, biting in of
foreign matter, etc.
Hub and shaft sliding • Parts with abnormal wear or with scratches 0.1 mm Replace with new parts
parts other than seals deep or deeper due to seizing or biting in of foreign
matter, etc.
• Parts with scratches less than 0.1 mm deep Repair with an oil stone
Portions which slide • Parts which are worn 0.5 mm or more, or abnormally Replace with new parts
against the thrust ring worn parts
• Parts with less than 0.5 mm of wear Repair so that it is smooth
• Parts with scratches due to seizing, biting in or Repair so that it is smooth
foreign matter, etc., which are within the wear limit
of 0.5 mm and which can be repaired
Flange
Parts Judgment Standard Treatment
Portions which slide • Parts which are worn 0.5 mm or more, or abnormally Replace with new parts
against the shaft end worn parts
• Parts with scratches due to seizing, biting in or Repair so that it is smooth
foreign matter, etc., which are within the wear limit
of 0.5 mm and which can be repaired
IV-83 TB108
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Thrust Ring
Judgment Standard Treatment
• Parts which are worn 0.5 mm or more, or abnormally worn parts Replace with new parts
• Parts with scratches due to seizing, biting in or foreign matter, etc., which are Repair so that it is smooth
within the wear limit of 0.5 mm and which can be repaired
Inspection after Assembly

After assembly is completed, carry out a leak check of
each circuit using the apparatus shown in the figure.
1. Connect a pipe (3) from the hydraulic pump (2) to

the shaft (1) side port.
2. Connect a pressure gauge (5) to the hub (4) side.
3. Increase the pressure gradually to 20.6 MPa while
adjusting the relief valve (6), then perform a 1
minute leak test.
• Release the neighboring ports on both sides
and check visually for leakage from the ports.
• Check for external leakage, etc., by a color
check.
TB108 IV-84
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TROUBLESHOOTING

External Oil Leakage • O-ring is defective •
Replace all the seal parts
Internal Oil Leakage • Thrust ring is defective •
Replace all the seal parts
• Great wear on sliding surfaces •
Replace the assembly
Shaft Sticks • Shaft and hub are stuck together •
Carry out polishing and honing. If looseness
and oil leakage are great, replace the assem-
bly
Flange Looseness • Socket bolt tightening is insuffi- • Retighten to the specified torque
cient
IV-85 TB108
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TB108 IV-86
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V . TROUBLESHOOTING
V-1
IV-87 TB108
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TROUBLESHOOTING
CAUTIONS IN TROUBLESHOOTING AND REPAIRS
(1) Do not begin disassembling the equipment immediately just because it has broken down.
Conduct a thorough preliminary check before attempting disassembly.
a. Ask the user the following questions.
• What were the conditions when the machine broke down?
• Did anything abnormal happen before breakdown occurred?
• Are there any other places which were functioning poorly other than the part that broke
down?
• Are there any parts which have been repaired previous to the breakdown? What were
they?
• Has the same thing happened before?
b. Run the machine yourself and confirm the breakdown conditions.
• Judge whether the machine is really broken down or not following the judgment
standards.
The judgment on whether the machine has broken down may differ between individu-
als.
IMPORTANT: When running the machine, it is possible that moving the machine could
make the breakdown worse than it already is, so do not forget to ask the user if there is
anything to prevent your operating the machine.
c. Based on the information that you have gathered from the user and the information
obtained from running the machine yourself, judge the cause of the trouble. Also keep in
mind that it is difficult to reproduce the conditions of the breakdown again once the
machine has been disassembled, and early disassembly may make it impossible to
determine the true cause of the trouble. Therefore be sure to find the true cause of the
trouble before attempting disassembly.
(2) When it is thought that the trouble has more than one cause, begin investigating from the
simplest cause.
(3) Think over why the trouble could have occurred and try to correct the root cause of that
problem.
TB108 V-2
V-88
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TROUBLESHOOTING
CONTENTS
OVERALL MACHINE
No operations can be done. ................................................................................................................................... 4
All operation can be done, but there is no power. ................................................................................................. 5
MACHINE TRAVEL
Right or left travel is impossible. .......................................................................................................................... 7
Speed drops in the left or right travel, causing the machine to travel in a curve. ................................................. 9
Machine won’t accelerate during travel. ............................................................................................................. 11
SLEWING
No slewing can be done. ...................................................................................................................................... 12
Right or left slewing cannot be done. .................................................................................................................. 14
Slewing speed is low, or there is no power. ........................................................................................................ 15
The machine slews, but overrun when slewing stops is great, or it cannot be stopped. ..................................... 16
When stopped on a slope, the slewing body cannot maintain its posture after stopping. ................................... 17
BOOM
The boom cylinder doesn’t move. ....................................................................................................................... 18
Boom cylinder operation is slow, or there is no power. ...................................................................................... 20
When the boom operation lever is pulled gently, the boom drops temporarily. ................................................. 23
The amount of boom natural drop is great. ......................................................................................................... 24
ARM
The arm cylinder doesn’t move. .......................................................................................................................... 25
Arm cylinder operation is slow, or there is no power. ........................................................................................ 26
The amount of arm natural drop is great. ............................................................................................................ 28
BUCKET
The bucket cylinder doesn’t move, or there is no power. ................................................................................... 29
The amount of bucket natural drop is great. ........................................................................................................ 30
BOOM SWING
The swing cylinder doesn’t move. ....................................................................................................................... 31
DOZER BLADE
The dozer blade cylinder doesn’t move, or there is no power. ............................................................................ 32
The amount of dozer blade natural drop is great or the dozer blade won’t hold the machine up. ...................... 34
SPANNER
The spanner cylinder doesn’t move, or there is no power. .................................................................................. 36
V-3 TB108
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TROUBLESHOOTING OVERALL MACHINE
NO OPERATIONS CAN BE DONE.
Inspect the hydraulic oil Insufficient Replenish the hydraulic

1 2
level. oil.
Proper Amount
• Repair the pump or replace

Pump or coupling is
3 the pump.
faulty.
• Replace the coupling.
1. Inspect the hydraulic oil level.

“III. Machine Configuration, Hydraulic
Tank”
2. Replenish the hydraulic oil.

Take out the plug and replenish the hydraulic oil.
• The hydraulic oil supplied should be the same
brand as the oil currently in the tank.
“II. Specifications, Fluid Capacities”
• After replenishing the hydraulic oil, be sure to
pressurize the Hydraulic Tank.
“III-42”
3. Pump or coupling is faulty.

a. Disconnect the discharge hose (1) from the
pump side.
Also fit a plug in the disconnected hose to keep
the hydraulic oil from pouring out.
b. Disconnect the electrical wiring (2) to the
engine stop solenoid. 1
c. Turn the engine over using the starting motor
and inspect if hydraulic oil is discharged by the
pump.
• The throttle lever should be in the engine
stop position.
If the pump is normal, hydraulic oil will be B5E001
discharged from it. If hydraulic oil is not dis-

charged, the pump or the coupling is faulty.
B5E002
TB108 V-4
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OVERALL MACHINE TROUBLESHOOTING

ALL OPERATIONS CAN BE DONE, BUT THERE IS NO POWER.
Inspect the hydraulic oil Insufficient Replenish the hydraulic

1 2
level. oil.
Proper Amount
Noise generated by the Noise Replace the seal tape, O-rings,

3 Suction line is faulty.
pump. hose.
No Noise
Bubbles from inside Treat beginning at the source

the tank. of the bubbling.
Inspect the main relief Faulty Repair or replace the main

4
valve. relief valve.
Normal
• Repair or replace the pump.

5 Pump is faulty.
• Flush with hydraulic oil.
1. Inspect the hydraulic oil level.

“III. Machine Configuration, Hydraulic
Tank”
2. Replenish the hydraulic oil.

“V-4”
3. Noise generated by the pump.

A faulty suction line can make it easy for cavita-
tion to occur in the pump and for noise to be
generated. Carry out the following inspect.
a. Inspect the piping used for suction of hydraulic
oil.
• Apply grease or oil to the part which appears
to be making the noise and inspect if there is
any change. (Inspect if it is sucking in air or
not.)
b. Inspect for clogging of the suction filter.
c. Pressurize the Hydraulic Tank.
“III-42”
V-5 TB108
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TROUBLESHOOTING OVERALL MACHINE
4. Inspect the main relief valve.

Measure the relief pressure of the main relief
valve.
• The valve is normal if the pressure gauge
reading is the standard value.
“ II. Specifications, Standards for Judging
Performance”
If the main relief valve’s set pressure is too low,

adjust it by tightening the valve set screw gradu-
ally.
• If the pressure doesn’t rise after 1/4 turn of the
screw, the main relief valve is faulty.
Cautions During Disassembly and Assembly

• The dimension A of the set screw (1) should be 1
measured and recorded when the lock nut (2) is
A
2
removed.
• Inspect for biting of foreign matter and for scratches
in the poppet seat surface.
• During assembly, the set screw should be set so that
dimension A, measured before disassembly, is a
little longer than previously. Then the screw should
be tightened gradually to adjust the pressure.
5. Pump is faulty. B5E003
If the pump is abnormally worn internally, or if it

is damaged, it is possible that pieces of metal are
mixed into the hydraulic oil. Therefore, carry out
the following treatment.
• Replace the spin filter cartridge.
• Replace the hydraulic oil or flush out the
hydraulic circuit.
(Up to NAS Class 9)
When replacing the hydraulic oil, be sure to

clean the inside of the Hydraulic Tank and
the suction strainer.
If the pump seal is damaged, replace the seal.

“IV. Hydraulic Units, Hydraulic Pump”
TB108 V-6
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MACHINE TRAVEL TROUBLESHOOTING

RIGHT OR LEFT TRAVEL IS IMPOSSIBLE.
Inspect the operation of

1 actuators other than the
travel motor.
Normal
Faulty Repair or replace the housing

2 Inspect spool operation.
block.
Normal
Faulty Adjust, repair or replace the

3 Inspect the linkage.
parts.
Normal
Faulty Repair or replace the swivel

4 Inspect the swivel joint.
joint.
Normal
Inspect the counterbal- Faulty Repair or replace the counter-

5
ance valve. balance valve.
Normal
Faulty Repair or replace the travel

6 Inspect the travel motor.
motor.
1. Inspect the operation of actuators other than Lever

the travel motor. Place Inspected
Operated
If operation of the right or left travel motor is
If left travel is Main Relief
impossible, operate each respective actuator in Boom Pump P1
impossible valve R1
accordance with the table at right. If operation is
faulty, inspect the main relief valve and pump. If right travel Main Relief
Arm Pump P2
is impossible valve R2
2. Inspect spool operation.

• Spool Stroke : 6.0 mm
• If the spool is sticking, take it out and inspect
it. If it can’t be taken out, or if it is scratched,
replace the housing block.
Another cause of the spool not operating prop-
erly could be that the return spring installation
bolt is loose.
V-7 TB108
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TROUBLESHOOTING MACHINE TRAVEL
3. Inspect the linkage.

To inspect the linkage, remove the yoke connect-
ing the spool and lever, then inspect lever move-
ment.
TRAVEL
B5E008E
4. Inspect the swivel joint.

a. Inspect the operation of the push pin (1).
Inspect if the push pin of the swivel joint’s
selector (2) moves smoothly, making sure that
its stroke is 5 mm.
• If the push pin won’t operate at all, the travel
speed will be low and when it is pushed in,
the travel speed will be high.
2
1
B5E004
b. Inspect the supply pressure from the swivel

joint.
• Disconnect the hose between the swivel
joint and the counterbalance valve from the
counterbalance valve side and set a pressure
gauge in the hose.
• Operate the travel lever and measure the
pressure.
• The swivel joint is normal if the pressure
gauge reading indicates the standard value.
“II. Specifications, Standards for Judg-
ing Performance”
B5E005
5. Inspect the counterbalance valve.

• If neither forward nor reverse travel is pos-
sible, the spool (1) of the counterbalance valve
could be sticking in the neutral position.
• If either forward or reverse travel is possible,
the spool (1) of the counterbalance valve could
be sticking in a position other than the neutral
position.
• Disconnect the counterbalance valve plug (2)
and try pushing the spool (1) with a finger. It is
normal if it moves smoothly about 6 mm.
6. Inspect the travel motor.

“IV. Hydraulic Units, Travel Motor”
TB108 V-8
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SPEED DROPS IN THE LEFT OR RIGHT TRAVEL, CAUSING THE MACHINE TO TRAVEL IN A CURVE.
Within
Is the amount of travel standard Depends on the com-
1 Normal
curve within standard? bination of equipment.
Not within Standard
Inspect the crawler ten- Faulty Adjust to the proper dimen-

2 sion and inspect for for- sions or remove the foreign
eign matter biting in, etc. matter.
Not abnormal
Inspect the operation of Faulty Repair or replace the housing

3
the spool. block.
Normal
The direction of travel curve
• Repair the pump or replace it.
Switch the left and right changes to the opposite side.
4 • Replace the hydraulic oil
pump discharge hoses.
and filter.
No change
The direction of travel
Switch the left and right curve changes to the
opposite side. Inspect the main relief Repair or replace the main
5 main relief valves and
valve. relief valve.
test.
No change

joint.
Normal
Inspect the counterbal- Faulty Repair or replace the counter-

7
ance valve. balance valve.
Normal
Repair or replace the travel

8 Inspect the travel motor.
motor.
V-9 TB108
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TROUBLESHOOTING MACHINE TRAVEL
1. Is the amount of travel curve within stan-

dard?
If the amount of travel curve is within standards,
then operation is normal and the variation de-
pends on the combination of equipment.
Performance”
2. Adjust the tension of the crawler belt.

Performance”
3. Inspect the operation of the spool.

“V-7”
4. Switch the left and right pump discharge

hoses.
Switch the discharge hoses for Pump P1 and
Pump P2. The pump is faulty if the direction in
which the machine curves during travel is in the
opposite direction.
• Disassemble and inspect the pump.
“IV. Hydraulic Units, Hydraulic Pump”
B5E006
5. Switch the left and right main relief valves

and test.
Switch the left and right main relief valves and
test. If the direction in which the machine curves
during travel changes to the opposite direction,
the main relief valve is faulty.
• Inspect the main relief valve
“V-6”
B5E007

“V-8”
7. Inspect the counterbalance valve.

Inspect if the counterbalance valve’s plunger
moves smoothly.
“V-8”
8. Inspect the travel motor.

“IV. Hydraulic Units, Travel Motor”
TB108 V-10
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MACHINE WON’T ACCELERATE DURING TRAVEL.
Inspect if low speed travel

1
is normal.
Normal

2
the spool. block.
Normal
Faulty Adjust, repair or replace the

parts.
Normal
Repair or replace the selector

valve.
1. Inspect if low speed travel is normal.

Inspect if the low speed travel speed is normal.
Performance”

“V-7”

Inspect the operation of the travel block of the
control valve and the yoke connected to the lever
for travel acceleration.
• Remove the pin connecting the yoke and the
spool or the pin connecting the yoke and the
lever, to inspect.

Inspect the operation of the push pin.
“V-8” TRAVEL
B5E008E
V-11 TB108
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TROUBLESHOOTING SLEWING
NO SLEWING CAN BE DONE.

slew motor.
Normal

2
the spool. block.
Normal
Adjust the relief

Inspect the slew hydrau- Pressure is low.
3 valve pressure of the Adjust the set pressure.
lic pressure.
slew brake valve.
Normal
Pressure does not rise. Repair or replace the brake

valve.
Faulty Repair or replace the slew

4 Inspect the slew motor.
motor.
Normal
The slew bearing is faulty. Replace
1. Inspect the operation of actuators other than

the slew motor. Lever Operated Place Inspected
Inspect if the operation of only the slew motor is
Relief Valve
faulty by the following table. If its operation is Arm Pump P2
R2
faulty, inspect the main relief valve and pump.
TB108 V-12
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SLEWING TROUBLESHOOTING
a. Operate the slew lever, inspecting if the spool
stroke is 6 mm.
b. Inspect the linkage. LEVER
• In the linkage inspect, remove the link ball
connecting the spool and lever and inspect LINK BALL
the lever’s movement.
6mm
B5E009E
3. Inspect the slew hydraulic pressure.

Measure the pressure at the left and right slew
relief valves.
• The pressure is normal if it is the standard
value.
Performance”
If adjustment of the pressure is possible, the slew
relief valve’s adjustment is faulty. Also, if the
pressure adjustment is impossible, the slew relief
valve is faulty.
4. Inspect the slew motor.

Separate the slew motor (1) and the turntable (2),
then try turning the turntable (2).
• Turntable doesn’t turn
.............................. Faulty slew bearing (3).
• Turntable turns
.............................. Faulty slew motor (1).
“IV. Hydraulic Units, Slew Motor”
V-13 TB108
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RIGHT OR LEFT SLEWING CANNOT BE DONE.
Operate the slew lever for the

side where slewing is impos-
sible.
Normal

1
the spool. block.
Normal
Adjust the relief

Inspect the slew hydrau- Faulty
lic pressure.
slew relief valve.
Normal

valve.
Repair or replace the slew

3 The slew motor is faulty.
motor.

It could be that the spool will not move only in the
direction in which slewing is impossible.
“V-7”

“V-13”
3. The slew motor is faulty.

TB108 V-14
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SLEWING SPEED IS LOW, OR THERE IS NO POWER.
Is the slewing speed Within the standard.

1 Normal
within the standard?
Slow

2
the spool. block.
Normal
Adjust the relief

lic pressure.
slew brake valve.
Normal
Pressure does not rise. Repair the relief valve or re-

place the brake valve.

motor.
Normal
The slew bearing is faulty. Replace
1. Is the slewing speed within the standard?

Performance”

“V-7”

“V-13”

“V-13”
V-15 TB108
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THE MACHINE SLEWS, BUT OVERRUN WHEN SLEWING STOPS IS GREAT, OR IT CANNOT BE
STOPPED.
Is the amount of overrun Within the standard.

1 when slewing stops Normal
Outside the standard.

2
the spool. block.
Normal
Adjust the relief

lic pressure.
slew brake valve.
Pressure doesn’t rise. Repair or replace the brake

valve.
1. Is the amount of overrun when slewing stops

Performance”

Inspect if the slew lever returns to the neutral
position when it is released after it has been
operated.
“V-7”

“V-13”
TB108 V-16
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WHEN STOPPED ON A SLOPE, THE SLEWING BODY CANNOT MAINTAIN ITS POSTURE AFTER
STOPPING.
Is the amount of natural Within the standard.

1 Normal
drop within the standard?
Not within the standard.
Inspect the relief valve

2 pressure of the slew Adjust the set pressure.
lic pressure.
brake valve.
Normal

valve.

motor.
1. Is the amount of natural drop within the

standard?
Performance”

“V-13”

V-17 TB108
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TROUBLESHOOTING BOOM
THE BOOM CYLINDER DOESN’T MOVE.

1 the actuators other than
the boom cylinder.
Normal

2
the spool. block.
Normal
Operation
Perform a port relief became normal. The port relief valve Repair or replace the port re-
3
valve switching test. is faulty. lief valve.
Does not change.
Inspect the boom cylin- Faulty Repair or replace the boom

4
der. cylinder.

the boom cylinder. Lever Operated Place Inspected
Inspect if the operation of only the boom cylinder
Relief Valve
is faulty by the following table. If its operation is Bucket Pump P1
R1
faulty, inspect the main relief valve and pump.
“V-6”

“V-7”
3. Perform a port relief valve switching test.

Switch the port relief valve for the port relief
valve of the normal arm. If the boom cylinder
operates, the boom side port relief valve is faulty.
B5E012
TB108 V-18
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BOOM TROUBLESHOOTING
4. Inspect the boom cylinder.
a. Disconnect the hose between the control valve
and the boom cylinder at the control valve side.
b. Connect the disconnected hose to the arm
block or the bucket block.
c. Try operating the boom cylinder. If the cylin-
der doesn’t operate, the cylinder is faulty.
When performing the operation in a~c above,

the bucket cylinder should be fully extended,
the arm cylinder should be fully retracted and
the bucket should be lowered to the ground.
V-19 TB108
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BOOM CYLINDER OPERATION IS SLOW, OR THERE IS NO POWER.
Is the boom cylinder’s Within the standard.

1 speed within the stan- Normal
dard?

2
the spool. block.
Normal
Operation
Perform a port relief became normal. The port relief valve Repair or replace the port re-
3
valve switching test. is faulty. lief valve.
Does not change.
Inspect the boom cylin- Faulty Repair or replace the boom

4
der. cylinder.
1. Is the boom cylinder’s speed within the stan-

dard?
Performance”

“V-7”
3. Perform a port relief valves switching test.

“V-18”
4. Inspect the boom cylinder.

Boom Cylinder internal Leakage Inspect (1)
a. With the bucket cylinder fully retracted and
with the rod of the arm cylinder a little ex- SLIGHTLY EXTEND THE ROD
tended from the fully retracted position, lower
the bucket front end to the ground.
B5E010E
TB108 V-20
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b. Disconnect the rod side hose (A) only and let
the oil in the piping run out.
Insert a plug (1) in the disconnected hose.
c. Retract the arm cylinder and lift the bucket so

it is floating above the ground.
At this time, if there is oil leaking from the
piping of the cylinder where the hose was
disconnected, and if the boom cylinder’s rod is
retracted, the cylinder is leaking internally.
Also, if there is no leakage of oil from the
cylinder’s piping, if the boom cylinder’s rod is
retracted, the control valve is leaking inter-
nally.
Boom Cylinder Internal Leakage Inspect (2)

a. Place the machine in the posture shown in the
figure.
b. Disconnect the head side hose (B) and let the

hydraulic oil out of the cylinder’s piping.
V-21 TB108
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c. Operate the bucket and raise the machine’s

body.
At this time, if there is oil leaking from the
piping of the cylinder where the hose was
disconnected, and if the boom cylinder’s rod is
extended, the cylinder is leaking internally.
Also, if there is no leakage of oil from the
cylinder’s piping, if the boom cylinder’s rod is
extended, the control valve is leaking inter-
nally.
If the cylinder is damaged internally, the

system should be flushed out to remove any
broken pieces (NAS Class 9).
TB108 V-22
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WHEN THE BOOM OPERATION LEVER IS PULLED GENTLY, THE BOOM DROPS TEMPORARILY.
Inspect the load check Faulty Repair or replace the housing

1
valve of the control valve. block.
Normal
Inspect for internal leak- Faulty Repair or replace the boom

2
age in the boom cylinder. cylinder.
1. Inspect the load check valve of the control

valve.
and boom cylinder at the control valve side.
b. Connect the disconnected hose to the arm or
bucket section.
c. Try operating the boom cylinder.
If operation is normal, the load check valve is
faulty.
Place the machine in the following posture

when performing the operation in “a~c” above.
• The bucket cylinder should be fully ex-
tended, the arm cylinder should be fully
retracted and the bucket should be low-
ered to the ground.
Reference: When the spool first starts to pull, the

oil’s pressure and flow are small, so if the load
check valve is faulty, it causes a load to bear on the
boom cylinder, which causes the oil to flow
backwards for a time. For this reason, the boom
will drop temporarily.
2. Inspect for internal leakage in the boom

cylinder.
When the boom cylinder’s piston or tube is faulty,
if oil is leaking from the head side (A) to the rod
side (B), since the oil’s pressure and flow are low
when the spool first starts pulling, the boom
cylinder will drop temporarily. Also, the cylinder
will have inadequate driving force. However, in
this case as well, the amount of natural drop will
be great.
• Cylinder Inspect
“V-20~22”
V-23 TB108
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THE AMOUNT OF BOOM NATURAL FALL IS GREAT.

1 Normal
fall within the standard?
Inspect for internal leak- Faulty Repair or replace the boom

2
age in the boom cylinder. cylinder.
Normal
Perform a port relief Faulty The port relief valve is Repair or replace the port re-
3
valve switching test. faulty. lief valve.
Normal
The control valve is leaking

Replace the housing block.
internally.
1. Is the amount of natural fall within the stan-

dard?
Performance”
2. Inspect for internal leakage in the boom

cylinder.
“V-20~22”

“V-18”
TB108 V-24
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ARM TROUBLESHOOTING
THE ARM CYLINDER DOESN’T MOVE.

1 the actuators other than
the arm cylinder.
Normal

2
the spool. block.
Normal
Operation
Perform a port relief became normal. The port relief valve is Repair or replace the port re-
3
Does not change.
Repair or replace the arm cyl-

4 Inspect the arm cylinder.
inder.

the arm cylinder. Lever Operated Place Inspected
Inspect if only the operation of the arm is faulty by
Relief Valve
the table at right. If operation is faulty, inspect the Slew Pump P2
R2
main relief valve and the pump.
“V-6”

“V-7”

Switch the port relief valve with that of the
normal boom. If the arm cylinder then operates,
the port relief valve is faulty.
“V-18”
4. Inspect the arm cylinder.

and the arm cylinder at the control valve side.
b. Connect the disconnected hose to the boom
block or the bucket block.
c. Try operating the arm cylinder. If the cylinder
doesn’t operate, the cylinder is faulty.
When performing the operation in a~c above,

the bucket cylinder should be fully extended,
the arm cylinder should be fully retracted,
and the bucket should be lowered to the
ground.
V-25 TB108
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TROUBLESHOOTING ARM
ARM CYLINDER OPERATION IS SLOW, OR THERE IS NO POWER.
Is the arm cylinder’s Within the standard.

1 speed within the stan- Normal
dard?

2
the spool. block.
Normal
Operation
Perform a port relief became normal. The port relief valve is Repair or replace the port re-
3
Does not change
Faulty Repair or replace the arm cyl-

inder.
1. Is the arm cylinder’s speed within the stan-

dard?
Performance”

“V-7”

“V-18”

a. Fully retract the bucket cylinder, fully retract
the arm cylinder and lower the bucket to the
ground.
TB108 V-26
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ARM TROUBLESHOOTING
b. Disconnect the two hoses connected to the
cylinder. Insert plugs (1) in the disconnected
hoses and the cylinder piping.
c. Raise the boom and raise the hoe attachment so

it floats above the ground. If the arm dorps, the
cylinder is faulty. If the arm does not drop,
there is leakage inside the control valve.
V-27 TB108
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TROUBLESHOOTING ARM
THE AMOUNT OF ARM NATURAL DROP IS GREAT.

1 Normal
Faulty Repair or replace the arm cyl-

inder.
Normal
There is leakage inside

3 Replace the housing block.
the control valve.

standard?
Performance”

“V-26, 27”
TB108 V-28
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BUCKET TROUBLESHOOTING
THE BUCKET CYLINDER DOESN’T MOVE, OR THERE IS NO POWER.

bucket cylinder.
Normal

2
the spool. block.
Normal
Inspect the bucket cylin- Faulty Repair or replace the bucket

3
der. cylinder.

the bucket cylinder.
Inspect if only the operation of the arm is faulty by
the table at right. Lever Operated Place Inspected
If operation is faulty, inspect the main relief valve
Relief Valve
and the pump. Boom Pump P1
R1
“V-6”
2. Inspect the opration of the spool.

“V-7”
3. Inspect the bucket cylinder.

and bucket cylinder at the control valve side.
b. Connect the disconnected hose to the boom
block or the arm block.
c. Try to operate the bucket cylinder. If it does not
operate, the cylinder is faulty.
Place the machine in the following posture

when performing the operation in a~c above.
• The bucket cylinder should be fully extended,
the arm cylinder should be fully retracted and
the bucket should be lowered to the ground.
V-29 TB108
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TROUBLESHOOTING BUCKET
THE AMOUNT OF BUCKET NATURAL DROP IS GREAT.

1 Normal
Inspect the bucket cylin- Faulty Repair or replace the bucket

2
der. cylinder.
Normal
There is leakage inside the

Replace the housing block.
control valve.

standard?
“II, Specifications, Standards for Judging
Performance”
2. Inspect the bucket cylinder.

a. Fully extend the bucket cylinder, fully retract
the arm cylinder and lower the bucket to the
ground,
b. Disconnect the 2 hoses connected to the cylin-
der.
Insert the plugs (1) in the disconnected hoses
and the piping.
c. Raise the boom and raise the hoe attachment so

that it floats above the ground, If the bucket
drops, the cylinder is faulty, If the bucket does
not drop, there is leakage inside the control
valve.
TB108 V-30
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BOOM SWING TROUBLESHOOTING

THE SWING CYLINDER DOESN’T MOVE.

swing cylinder.
Normal

2
the spool. block.
Normal
Inspect the anti-cavita- Faulty Repair or replace the anti-cavi-

3
tion valve. tation valve.
Normal
Inspect the swing cylin- Faulty Repair or replace the swing

4
der. cylinder.

the swing cylinder.
Inspect if the operation of the boom swing only is Lever Operated Place Inspected
faulty by the table at right. If operation is faulty,
inspect the main relief valve and the hydraulic Boom Relief Valve R1 Pump P1
pump.
“V-6”

“V-7”
3. Inspect the anti-cavitation valve.

If right swing cannot be done, then foreign matter
is caught in the anti-cavitation valve or the valve
is sticking.
4. Inspect the swing cylinder.

Disconnect the hose between the swing cylinder
and the control valve at the control valve side,
then measure the pressure supplied from the valve.
If the supply pressure is normal, the cylinder is
faulty.
• Supply Pressure: 15.7 MPa
V-31 TB108
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TROUBLESHOOTING DOZER BLADE
THE DOZER BLADE CYLINDER DOESN’T MOVE, OR THERE IS NO POWER.

dozer blade cylinder.
Normal

2
the spool. block.
Normal
Inspect the control valve Faulty Repair or replace the housing

3
supply pressure. block.
Normal

joint.
Normal
The dozer blade cylinder is Faulty Repair or replace the dozer

faulty. balde cylinder.

the dozer blade cylinder.
Inspect if only the operation of the dozer blade is Lever Operated Place Inspected
faulty by the table at right. If operation is faulty,
inspect the main relief valve and the pump. Arm Relief Valve R2 Pump P2
“V-6”

“V-7”
3. Inspect the control valve supply pressure.

Disconnect one of the hoses connected to the
control valve’s housing block (dozer blade) . Set
a pressure gauge in the disconnected hose, oper-
ate the dozer blade operation lever and inspect the
supply pressure. If the pressure indicated is not
the value below, the housing block is faulty.
Supply Pressure: 15.7 MPa
TB108 V-32
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DOZER BLADE TROUBLESHOOTING

a. Inspect the spool stroke of selector (2) of the
swivel joint and inspect if the spool definitely SPANNER DOZER BLADE
switches to the dozer blade side.
Spool Stroke: 6 mm
b. Disconnect the hose between the swivel joint
and the dozer blade cylinder. Set a pressure
gauge in the disconnected hose and operate the 2
dozer blade operation lever.
If the pressure gauge reading is not the follow-
ing value, the swivel joint is faulty.
Supply Pressure: 15.7 MPa
SPOOL STROKE : 6mm
B5E011E
V-33 TB108
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TROUBLESHOOTING DOZER BLADE
THE AMOUNT OF DOZER BLADE NATURAL DROP IS GREAT OR THE DOZER BLADE WON’T
HOLD THE MACHINE UP.

1 Normal
drop within the standard?
Inspect for internal leak- Faulty Repair or replace the housing

2
age in the blade cylinder. block.
Normal
Repair or replace the swivel

Inspect the swivel joint Faulty
3 joint, or replace the control
and control valve.
valve.
1. Is the dozer blade’s natural drop within the

standard?
Performance”
2. Inspect for internal leakage in the dozer

blade cylinder.
a. Using the hoe attachment, raise the machine’s
body, then lower the dozer blade fully.
b. Disconnect the dozer blade cylinder’s rod side

hose and drain out the oil in the piping.
TB108 V-34
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DOZER BLADE TROUBLESHOOTING

c. Raise the boom and apply a load on the dozer
blade.
• If the machine’s body drops while oil drains
out of the cylinder’s piping, the cylinder is
faulty.
If the body drops even though no oil drains out,
the control valve or the swivel joint is faulty.
3. Inspect the swivel joint and control valve.

Disconnect the hose between the swivel joint and
control valve at the control valve side, then insert
a plug in the disconnected hose.
Apply a load to the dozer blade by the procedure
in the previous item 2, a~c.
If the machine’s body drops, the swivel joint is
faulty.
If the machine’s body does not drop, there is
internal leakage in the control valve.
V-35 TB108
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TROUBLESHOOTING SPANNER
THE SPANNER CYLINDER DOESN’T MOVE, OR THERE IS NO POWER.

spanner cylinder.
Normal

2
the spool. block.
Normal
Faulty Repair or replace the housing

block.
Normal
Inspect the supply pres- Faulty Repair or replace the housing

4
sure to the control valve. block.
Normal

joint.
Normal
The spanner cylinder is Faulty Repair or replace the spanner

6
faulty. cylinder.
The spanner cylinder is used by switching the use of

lever normally used the dozer blade cylinder. For this
reason, the inspect method is the same as that for the
dozer blade cylinder.
“V-32, 33”

the spanner cylinder.

“V-7 ”

“V-8”
4. Inspect the supply pressure to the control

valve.
“V-32”

“V-33”
TB108 V-36
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VI . ENGINE
YANMAR DIESEL ENGINE

Model TNV series
ENGINE MODEL MOUNTING MACHINE

2TNV70 TB108
TB108
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/'
series
(Indirect Injection System)
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Publication No. M9961-02E070

History of Revision
Manual Name Service Manual for Industrial Diesel Engine
Engine Model: 2TNV, 3TNV series (Indirect Injection System)
Number
Date of Reason for Correction item Corrected
of Outline of correction
revision correction No (page) by
revision
New edition September 2003
R.1 June, Revision, 1) Correction of engine output 1) P2,4 Quality
2004 addition & 2) Correction of FO pump drive 2) P69,95,119 Assurance
correction gear nut (Lube oil) Dept.
3) Addition of tip clearance 3) P90,118 Small
(Lube oil pump) Engine
4) Addition of copy right 4) (Preface) Factory
5) Revision of FO,LO & coolant 5) P7,8-1,8-2
6) Other corrections 6) (Precautions),P13,
35,41,59,66,68,71,
72,76,77,78,81,84,
86,88,94,115,116,
117
Printed in Japan
M9961-02E070
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PREFACE
This manual describes the service procedures for the TNV series engines of indirect injection system that
have been certified by the US 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 said engine. Since the explanation in this
manual assumes the standard type engine, the specifications and components may partially be different from
the engine installed on individual work equipment (power generator, pump, compressor, etc.). Please also
refer to the service manual for each work equipment for details.
The specifications and components may be subject to change for improvement of the engine quality without
notice. If any modification of the contents described herein becomes necessary, it will be notified in the form of
correction information each time.
California &DOLIRUQLD
Proposition 65 Warning 3URSRVLWLRQ:DUQLQJ
Diesel engine exhaust and some me off its %DWWHU\ SRVWV
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c 2003 YANMAR CO., LTD

All rights reserved. This manual may not be
reproduced or copied, in whole or in part,
without the written permission of YANMAR
CO., LTD.
(R.1)
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SAFETY LABELS
• Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it
is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully under-
stand safety precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
• It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient consider-
ation for safety is required in addition to the matters marked . Especially for safety precautions
in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable
leader.
• Safety marks used in this manual and their meanings are as follows:
DANGER-indicates an imminently hazardous situation which,

if not avoided, WILL result in death or serious injury.
WARNING-indicates a potentially hazardous situation which, if not

avoided, COULD result in death or serious injury.
CAUTION-indicates a potentially hazardous situation which, if not

avoided, MAY result in minor or moderate injury.
• NOTICE-indicates that if not observed, the product performance or quality may not be guaranteed.
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Safety Precautions
(1) SERVICE AREA
•Sufficient Ventilation
Inhalation of exhaust fumes and dust particles may be hazardous to ones
health. Running engines welding, sanding, painting, and polishing tasks
should be only done in well ventilated areas.
•Safe / Adequate Work Area

The service area should be clean, spacious, level and free from holes in the
floor, to prevent “slip” or “trip and fall” type accidents.
•Bright, Safely Illuminated Area

The work area should be well lit or illuminated in a safe manner. For work in
enclosed or dark areas, a “drop cord” should be utilized. The drop cord must
have a wire cage to prevent bulb breakage and possible ignition of flammable
substances.
•Safety Equipment
Fire extinguisher(s), first aid kit and eye wash / shower station should be
close at hand (or easily accessible) in case of an emergency.
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(2) WORK – WEAR (GARMENTS
•Safe Work Clothing

Appropriate safety wear (gloves, special shoes/boots, eye/ear protection,
head gear, harness’, clothing, etc.) should be used/worn to match the task at
hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes
around moving machinery. A serious accident may occur if caught in moving/
rotating machinery.
(3) TOOLS
•Appropriate Lifting / Holding

When lifting an engine, use only a lifting device (crane, jack, etc.) with
sufficient lifting capacity. Do not overload the device. Use only a chain, cable,
or lifting strap as an attaching device. Do not use rope, serious injury may
result.
To hold or support an engine, secure the engine to a support stand, test bed
or test cart designed to carry the weight of the engine. Do not overload this
device, serious injury may result.
Never run an engine without being properly secured to an engine support
stand, test bed or test cart, serious injury may result.
•Appropriate Tools
Always use tools that are designed for the task at hand. Incorrect usage of
tools may result in damage to the engine and or serious personal injury.
(4) GENUINE PARTS and MATERIALS
•Genuine Parts
Always use genuine YANMAR parts or YANMAR recommended parts and
goods. Damage to the engine, shortened engine life and or personal injury
may result.
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(5) FASTENER TORQUE
•Torquing Fasteners
Always follow the torque values and procedures as designated in the service
manual. Incorrect values, procedures and or tools may cause damage to the
engine and or personal injury.
(6) ELECTRICAL
•Short Circuits
Always disconnect the (-) Negative battery cable before working on the
electrical system. An accidental “short circuit” may cause damage, fire and or
personal injury. Remember to connect the (-) Negative battery cable (back
onto the battery) last.
Fasten the terminals tightly.
•Charging Batteries
Charging wet celled batteries produces hydrogen gas. Hydrogen gas is
extremely explosive. Keep sparks, open flame and any other form of ignition
away. Explosion may occur causing severe personal injury.
•Battery Electrolyte
Batteries contain sulfuric acid. Do NOT allow it to come in contact with
clothing, skin and or eyes, severe burns will result.
(7) WASTE MANAGEMENT
Observe the following instructions with regard to hazardous waste disposal.

Negligence of these will have a serious impact on environmental pollution
concerns.
1)Waste fluids such as lube oil, fuel and coolant shall be carefully put into sep-
arate sealed containers and disposed of properly.
2)Do NOT dispose of waste materials irresponsibly by dumping them into the
sewer, overland or into natural waterways.
3)Waste materials such as oil, fuel, coolant, solvents, filter elements and bat-
teries, must be disposed of properly according to local ordinances. Consult
the local authorities or reclamation facility.
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(8) FURTHER PRECAUTIONS
•Fueling / Refueling
Keep sparks, open flames or any other form of ignition (match, cigarette, etc.)
away when fueling/refueling the unit. Fire and or an explosion may result.
•Hot Surfaces.
Do NOT touch the engine (or any of its components) during running or shortly
after shutting it down. Scalding / serious burns may result. Allow the engine to
cool down before attempting to approach the unit.
•Rotating Parts
Be careful around moving/rotating parts. Loose clothing, jewelry, ties or tools
may become entangled causing damage to the engine and or severe
personal injury.
•Preventing burns from scalding

1)Never open the radiator filler cap shortly after shutting the engine down.
Steam and hot water will spurt out and seriously burn you. Allow the engine
to cool down before attempt to open the filler cap.
2)Securely tighten the filler cap after checking the radiator.
Steam can spurt out during engine running, if tightening loose.
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Precautions for Service Work

(1) Precautions for Safety
Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.
(2) Preparation for Service Work

Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of
the engine.
• Preceding service date
• Period/operation hours after preceding service
• Problems and actions in preceding service
• Replacement parts expected to be required for service
• Recording form/check sheet required for service
(3) Preparation before Disassembly

• Prepare general tools, special service tools, measuring instruments, oil, grease, nonreusable parts, and
parts expected to be required for replacement.
• When disassembling complicated portions, put match-marks and other marks at places not adversely
affecting the function for easy reassembly.
(4) Precautions in Disassembly

• Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface
defect, etc.
• Arrange the removed parts orderly with clear distinction between those to be replaced and those to be
used again.
• Parts to be used again shall be washed and cleaned sufficiently.
• Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel
injection pump.
(5) Precautions for Inspection and Measurement

Inspect and measure parts to be used again as required to determine whether they are reusable or not.
(6) Precautions for Reassembly

• Reassemble correct parts in correct order according to the specified standards (tightening torques, and
adjustment standards). Apply oil important bolts and nuts before tightening when specified.
• Always use genuine parts for replacement.
• Always use new oil seals, O-rings, packing and cotter pins.
• Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact
portions, and apply grease to oil seal lips.
(7) Precautions for Adjustment and Check

Use measuring instruments for adjustment to the specified service standards.
How to Read this Manual

(1) Range of Operation Explanation
This manual explains the troubleshooting, installation/removal, replacement, disassemble/reassembly,
inspection, adjustment and adjusting operation procedures for the TNV series engines with indirect injection
system.
Refer to the manufacturer’s manual for each of the fuel injection pump, governor, starting motor and alternator
except for their installation.
(R.1)
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(2) How to Read the Explanations

• An exploded view, sectional views, a system diagram, etc. are shown at the beginning of each section as
required for easy understanding of the mounted states of the components.
• For the removal/installation of each part, the procedure is shown with the procedural step No. in the illus-
tration.
• Precautions and key points for disassembly and reassembly of parts are described as points. In the expla-
nation for each point, detailed operation method, information, standard and precautions are described.
Description Example
ԠFlywheel
Flywheel hausing
ԢGear case flange

ԟStarter ԝIdle gear
ԡCamshaft
ԙCooling water pump
Camshaft driving gear

ԜFuel injection pump
Crankshaft gear
Pump flange
Don't disassemble! Fuel pump drive gear
Flange bolt
ԛGear case
ԣOil seal
Note) This figure shows the 3TNV76. ԚCrankshaft pulley
The job contents are described in the disassembly procedure for Nos. not shown in the illustration.
• Disassembly procedure
1)Follow steps (1) to (15) of the cylinder head disassembly procedure.
2)Remove the cooling water pump.
3)Remove the crankshaft pulley. (Point 1) I Operation point to be explained on a later page.
• Operation points
Disassemble: Service point for removal
Reassemble: Service point for installation
Disassemble-Reassemble: Service point required in both removal and installation.
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• Contents omitted in this manual

Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual
work:
3)Jacking up and lifting
4)Cleaning and washing of removed parts as required
5)Visual inspection
(3) Definition of Terms

[NOTICE]: Instruction whose negligence is very likely to cause an accident. Always observe it.
Standard: Allowable range for inspection and adjustment.
Limit: The maximum or minimum value that must be satisfied during inspection or adjustment.
(4) Abbreviations
Abbreviation Meaning Abbreviation Meaning

Assy assembly T.D.C. top dead center
Sub-Assy sub-assembly B.D.C. bottom dead center
a.T.D.C after top dead center OS oversize
b.T.D.C before top dead center US undersize
STD Standard Min-1 revolutions per minute
IN Intake PS Output (metric horsepower)
EX Exhaust T Bolt/nut tightening torque
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CONTENTS
1. General ............................................................................................................................ 1
1.1 Engine nomenclature ...............................................................................................................1
1.2 Specifications ...........................................................................................................................1
1.3 Fuel oil, lubricating oil and cooling water .................................................................................7
1.3.1 Fuel oil .............................................................................................................................................. 7
1.3.2 Lubricating oil.................................................................................................................................... 1
1.3.3 Cooling water .................................................................................................................................... 2
1.4 Engine external views ..............................................................................................................9
1.5 Structural description .............................................................................................................10
1.6 Exhaust gas emission regulation ...........................................................................................11
1.6.1 The emission standard in USA ....................................................................................................... 11
1.6.2 Engine identification........................................................................................................................ 12
1.6.3 Guarantee conditions for the EPA emission standard .................................................................... 13
2. Inspection and adjustment ............................................................................................. 15

2.1 Periodic maintenance schedule .............................................................................................15
2.2 Periodic inspection and maintenance procedure ...................................................................16
2.2.1 Check before daily operation .......................................................................................................... 16
2.2.2 Inspection after initial 50 hours operation ....................................................................................... 19
2.2.3 Inspection every 50 hours............................................................................................................... 22
2.2.4 Inspection every 250 hours or 3 months......................................................................................... 26
2.2.5 Inspection every 500 hours or 6 months......................................................................................... 28
2.2.6 Inspection every 1,000 hours or one year....................................................................................... 30
2.2.7 Inspection every 2000 hours or 2 years.......................................................................................... 36
2.3 Adjusting the no-load maximum or minimum speed ..............................................................38
2.4 Sensor inspection ...................................................................................................................39
2.4.1 Oil pressure switch.......................................................................................................................... 39
2.4.2 Thermo switch................................................................................................................................. 39
2.5 Water leak check in cooling water system .............................................................................39
2.6 Radiator cap inspection ..........................................................................................................39
2.7 Thermostat inspection ............................................................................................................40
2.8 Adjusting operation ................................................................................................................40
2.9 Long storage ..........................................................................................................................41
3. Troubleshooting ............................................................................................................. 42
3.1 Preparation before troubleshooting ........................................................................................42
3.2 Quick reference table for troubleshooting ..............................................................................43
3.3 Troubleshooting by measuring compression pressure ..........................................................46
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4. Disassembly, inspection and reassembly of engines .................................................... 48

4.1 Complete disassembly and reassembly .................................................................................48
4.1.1 Introduction ..................................................................................................................................... 48
4.1.2 Special service tools ....................................................................................................................... 49
4.1.3 Complete disassembly.................................................................................................................... 54
4.1.4 Precautions before and during reassembly .................................................................................... 58
4.1.5 Adjusting operation ......................................................................................................................... 58
4.2 Cylinder head: disassembly, inspection and reassembly .......................................................59
4.2.1 Components (2-valve cylinder head) .............................................................................................. 59
4.2.2 Disassembly procedure: ................................................................................................................. 59
4.2.3 Reassembly procedure: .................................................................................................................. 59
4.2.4 Servicing points............................................................................................................................... 60
4.2.5 Parts inspection and measurement ................................................................................................ 63
4.2.6 Valve seat correction ...................................................................................................................... 66
4.2.7 Valve guide replacement ................................................................................................................ 67
4.2.8 Valve stem seal replacement.......................................................................................................... 67
4.3 Gear train and camshaft .........................................................................................................68
4.3.1 Components.................................................................................................................................... 68
4.3.6 Oil seal replacement ....................................................................................................................... 72
4.3.7 Camshaft bushing replacement ...................................................................................................... 72
4.4 Cylinder block .........................................................................................................................73
4.4.1 Components.................................................................................................................................... 73
4.4.6 Cylinder bore correction.................................................................................................................. 87
4.4.7 Piston pin metal replacement.......................................................................................................... 87
4.4.8 Oil seal replacement (Flywheel housing side) ................................................................................ 87
5. Lubrication system ......................................................................................................... 88

5.1 Lubrication system diagram ...................................................................................................88
5.2 Trochoid pump components ...................................................................................................88
5.3 Disassembly (Reverse the below procedure for reassembly) ................................................89
5.4 Servicing Points .....................................................................................................................89
5.5 Parts inspection and measurement ........................................................................................90
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5.5.1 Trochoid pump inspection and measurement................................................................................. 90
6. Cooling system .............................................................................................................. 91

6.1 Cooling water System ............................................................................................................91
6.2 Cooling water pump components ...........................................................................................91
6.3 Disassembly (Reverse the below procedure for reassembly) ................................................92
6.4 Servicing points ......................................................................................................................92
7. Fuel injection pump / Governor ..................................................................................... 93

7.1 Introduction ............................................................................................................................93
7.2 Fuel injection pump ................................................................................................................93
7.2.1 Fuel system diagram....................................................................................................................... 93
7.2.2 External view and components ....................................................................................................... 94
7.2.4 Reassembly procedure ................................................................................................................... 95
7.2.5 Confirmation and adjustment of fuel injection timing ...................................................................... 96
7.2.6 Confirmation and adjustment of no-load maximum and minimum speed ....................................... 96
8. The specifications of a starting motor

and the characteristics ....................................................................................................... 97
8.1 The specifications and the characteristics .............................................................................97
8.1.1 Specifications.................................................................................................................................. 97
8.1.2 Characteristics ................................................................................................................................ 97
8.2 The structure of a starting motor and the wiring diagram .......................................................98
8.2.1 Structure ......................................................................................................................................... 98
8.2.2 Wiring diagram of a starting motor.................................................................................................. 99
8.3 Performance ...........................................................................................................................99
9. Alternator ..................................................................................................................... 100

9.1 20A Alternator ......................................................................................................................100
9.1.1 Specifications................................................................................................................................ 100
9.1.2 Structure ....................................................................................................................................... 101
9.1.3 Wiring diagram.............................................................................................................................. 102
9.1.4 Standard output characteristics .................................................................................................... 102
9.1.5 Inspection...................................................................................................................................... 103
9.2 40A Alternator ......................................................................................................................104
9.2.1 Components.................................................................................................................................. 104
9.2.2 Specifications................................................................................................................................ 105
9.2.3 Wiring diagram.............................................................................................................................. 105
9.2.4 Standard output characteristics .................................................................................................... 106
9.2.5 Inspection...................................................................................................................................... 106
9.3 Troubleshooting ...................................................................................................................107
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10. Electric wiring ............................................................................................................ 108

10.1 Electric wiring diagram .......................................................................................................108
10.1.1 Alternator .................................................................................................................................... 109
10.1.2 Starting motor ............................................................................................................................. 110
10.1.3 Current limiter ............................................................................................................................. 111
10.1.4 Section area and resistance of electric wire ............................................................................... 112
11. Service standards ...................................................................................................... 113

11.1 Engine tuning .....................................................................................................................113
11.2 Engine body .......................................................................................................................114
11.2.1 Cylinder head.............................................................................................................................. 114
11.2.2 Gear train and camshaft ............................................................................................................. 115
11.2.3 Cylinder block ............................................................................................................................. 116
11.3 Lubricating oil system (Trochoid pump) .............................................................................118
12. Tightening torque for bolts and nuts .......................................................................... 119

12.1 Tightening torques for main bolts and nuts ........................................................................119
12.2 Tightening torques for standard bolts and nuts ..................................................................120

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1. General
1. General
1.1 Engine nomenclature
3 TNV ٤٤ - ٤ ٤٤
Destination code
Nominal engine speed or output code
Cylinder bore (in mm)
Model series
Number of Cylinders
The engine specification class

Available engine speed at nominal output
Classification Load Engine speed
(min-1)
CL Constant load Constant speed 1500/1800
CH Constant load Constant speed 3000/3600
VM Variable load Variable speed 2000 to 3000
VH Variable load Variable speed 3000 to 3600
Ú The engine specification class (VM /CH or VH) is described in the specifications table.
1.2 Specifications
NOTE:
1)The information described in the engine specifications tables (the next page and after) is for "standard"
engine. To obtain the information for the engine installed in each machine unit, refer to the manual pro-
vided by the equipment manufacturer.
2)Engine rating conditions are as follows (SAE J1349, ISO 3046/1)
• Atmospheric condition: Room temp. 25 °C, Atmospheric press. 100 kPa (750 mm Hg), Relative humidity
30%
• Fuel temp: 40 °C (Fuel injection pump inlet)
• With cooling fan, air cleaner, exhaust silencer (Yanmar standard parts)
• After running-in hours. Output allowable deviation: ± 3%
1
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1. General
(1) 2TNV70
Engine name Unit 2TNV70
Engine specification class - VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Indirect injection
Number of cylinders - 2
Cylinder bore × stroke mm × mm 70 × 74
Displacement L 0.570
Revolving
speed min-1 -
Continuous
rating kW
Output (NET) -
(ps)
Revolving
speed min-1 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Rated output
kW 6.0 6.3 6.6 7.0 7.3 7.6 7.9 8.2 8.5 8.8 9.1
Output (NET)
(ps) (8.1) (8.6) (9.0) (9.5) (9.9) (10.3) (10.7) (11.1) (11.6) (12.0) (12.4)
Max. no-load speed (± 25) min-1 2160 2250 2355 2460 2570 2675 2780 2890 2995 3100 3210
Ignition order - 1-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 1.7
(oil pan) * Effective L 0.7
Cooling water capacity
L 0.6
(engine only)
Engine Overall length mm 415
Dimensions
Overall width mm 427
(with flywheel
housing) * ** Overall height mm 484
Engine mass (dry) * **
kg 84
(with flywheel housing)
Cooling fan (std.) * mm 260 mm O/D, 5 blades pusher type F
Crankshaft V pulley diameter*
mm ø 110 & ø 110
& Fun V pulley diameter (std.)
* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
(R.1)
2
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1. General
(2) 3TNV70
Engine specification class - CH VH
Revolving
speed min-1 3000 3600 -
Continuous
rating kW 12.1 14.5
Output (NET) -
(ps) (16.5) (19.7)
Revolving
speed min-1 3000 3600 3100 3200 3300 3400 3500 3600
Rated output
kW 13.3 16.0 13.5 14.0 14.3 14.7 15.0 15.4
Output (NET)
(ps) (18.1) (21.7) (18.4) (19.0) (19.4) (20.0) (20.4) (21.0)
Max. no-load speed (± 25) min-1 - 3800 3290 3400 3500 3600 3710 3815
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD
Lubricant capacity Total L 3.8 2.8
(oil pan) * Effective L 1.7 1.3
L 0.9
(engine only)
Dimensions
(with flywheel
housing) * ** Overall height mm 536 506
kg 98
mm ø 110 & ø 100
3
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1. General
3TNV70 (continue)
Revolving
speed min-1 -
Continuous
rating kW
Output (NET) -
(ps)
Revolving
speed min-1 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Rated output
kW 9.0 9.5 9.9 10.5 11.0 11.4 11.8 12.4 12.8 13.2 13.7
Output (NET)
(ps) (12.2) (12.9) (13.5) (14.3) (14.9) (15.5) (16.1) (16.8) (17.4) (18.0) (18.6)
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD
L 0.9
(engine only)
Dimensions
(with flywheel
kg 98
mm ø 110 & ø 100
(R.1)
4
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1. General
(3) 3TNV76
Engine specification class - CH VH
Type - Vertical, in-line, 4-cycle water-cooled diesel engine
Revolving
3000 3600 -
Continuous speed
rating kW 15.1 17.7
Output (NET) -
(ps) (20.5) (24.1)
Revolving
speed min-1 3000 3600 3100 3200 3300 3400 3500 3600
Rated output
kW 16.5 19.5 17.7 18.2 18.7 19.3 19.3 19.5
Output (NET)
(ps) (22.5) (26.5) (24.0) (24.8) (25.4) (26.2) (26.3) (26.5)
Max. no-load speed (± 25) min-1 - 3800 3290 3400 3500 3600 3710 3815
Applicable fuel -
(Cetane No.45 min.)
Lubricant capacity Total L 4.4 3.5
(oil pan) * Effective L 2.1 1.6
L 0.9
(engine only)
Dimensions
(with flywheel
housing) * ** Overall height mm 559 535
kg 112
mm ø 110 & ø 100
5
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1. General
3TNV76 (continue)
Type - Vertical, in-line, 4-cycle water-cooled diesel engine
Revolving
-
Continuous speed
rating kW
Output (NET) -
(ps)
Revolving
speed min-1 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Rated output
kW 11.8 12.5 13.2 13.8 14.3 14.9 15.5 16.1 16.7 17.3 17.9
Output (NET)
(ps) (16.1) (17.0) (17.9) (18.7) (19.5) (20.3) (21.1) (21.9) (22.7) (23.5) (24.3)
Applicable fuel -
(Cetane No.45 min.)
L 0.9
(engine only)
Dimensions
(with flywheel
kg 112
mm ø 110 & ø 100
6
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1. General
1.3 Fuel oil, lubricating oil and cooling water

1.3.1 Fuel oil
IMPORTANT:
Only use the recommended fuel to obtain the best engine performance and to keep the durability of the
engine, also to comply with the emission regulations.
(1) Selection of fuel oil

Diesel fuel oil should comply with the following specifications.
• The fuel specifications need to comply with each national standard or international standards.
• ASTM D975 No.1-D, No.2-D ------------- for USA
• EN590:96-------------------------------------- for EU
• ISO 8217 DMX -------------------------------------- International
• BS 2869-A1 or A2 ---------------------------------- for UK
• JIS K2204 ---------------------------------------- for JAPAN
The following requirements also need to be fulfilled.
• Cetane number should be equal to 45 or higher.
• Sulphur content of the fuel
It should not exceed 0.5%by volume. (Preferably it should be below 0.05 %)
• For alternative fuel (Bio fuel such as FAME, JP-8), please contact YANMAR.
• Water and sediment in the fuel oil should not exceed 0.05% by volume.
• Ash should not exceed 0.01%by mass.
• 10% Carbon residue content of the fuel
It should not exceed 0.35%by volume. (Preferably it should be below 0.1 %)
• Aromatics(total) content of the fuel
It should not exceed 35% by volume. (Preferably it should be below 30%
and aromatics(PAH*) content of the fuel preferably it should be below 10%)
PAH*:polycyclic aromatic hydrocarbons
• DO NOT use Biocide.
• DO NOT use Kerosene, residual fuels.
• DO NOT mix winter fuel and summer fuel.
Note : Engine breakdown can be attributed to insufficient quality of fuel oil.
(2) Fuel handling
• Water and dust in the fuel oil can cause operation
failure. Use containers which are clean inside to store
Pump up only the fuel
fuel oil. Store the containers away from rain water in the upper half to
leave dregs near the bottom
and dust.
• Before supplying fuel, let the fuel container rest for
several hours so that water and dust in the fuel are
deposited on the bottom. Pump up only the clean
fuel.
(3) Fuel tank

Fuel tank inside should be always clean enough and dry Filler port
it inside for the first use. Fuel return
connection
Drain the water according to the maintenance (section 5)
with a drain valve. Primary
strainer
Outlet
(to engine)
Drain cock
(R.1)
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1. General
1.3.2 Lubricating oil

IMPORTANT:
Only use the recommended engine oil to keep the durability of the engine.
(1) Selection of lube oil
Engine oil shoud comply with the following specifications.
1)Classification
• API classification CD, CF, CF-4, CI-4
TBN value : º9(CD), º9(CF), º7(CF-4), º7(CI-4)
• ACEA classification E-3, E-4, E-5
TBN value : º10(E-3), º10(E-4), º10(E-5)
• JASO classification DH-1
TBN value : º10(DH-1)
The oil must be changed when the Total Base Number (TBN) has been reduced to 2.0.
*TBN(mgKOH/g) test method; JIS K-2501-5.2-2(HCI), ASTM D4739(HCI)
DO NOT use The following engine oils.

• API : CG-4 , CH-4
• ACEA : E-1, E-2 , B grade
• JASO : DH-2 , DL-1
Reason
API CG-4, CH-4
In case CG-4, CH-4 is to be used for YANMAR TNV diesel engine series, there is a possibility that
excessive wears occur on the valve train system due to the content of oil.
ACEA E-1,E-2, B
These fuels are developed for the different type of diesel engines.
JASO DH-2, DL-1

These fuels are developed for the different type of diesel engines.
2)Viscosity Selection of viscosity

Selection of viscosity will be determined depending (SAE Service grade)
on the ambient temperature.
9
(Refer to the chart on the right.) 9
9
The following requirements are also need to be 9
fulfilled.
• Standard engine oil service interval is 250 hrs or
every 12 months.
• DO NOT add any additives to the engine oil. ‫ ޓ ޓ ޓ ޓ ޓ ޓ ޓ‬
• DO NOT mix the different types (brand) of engine Atmospheric temperature ( C)
oil.
• DO NOT use synthetic oil.
15W-40/10W-30 can be used
almost throughout the year.
(R.1)
8-1
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1. General
(2) Handling of lube oil

• Keep the engine oil carefully in store in order to prevent any dust or dirt entrance.
• When filling the engine oil to the engine, avoid the spillage and pay attention to be clean around the filler
port.
Contact with engine oil may result in the roughened skin. Care should be taken
so as not to contact with engine oil wearing protective gloves and clothing.
If contact, wash with soap and water thoroughly.
When handling the engine oil, make sure to use the protective gloves at any
time.
In case of contact, wash your hand or body with soap and water thoroughly.
1.3.3 Cooling water

Use clean soft water and always be sure to add LLC (Long Life Coolant) in order to prevent rust built up and
freezing. (Do not use water only.)
The recommended LLC conform to the following specifications.
• JIS K-2234
• SAEbJ814C, J1941, J1034, J2036
• ASTM D4985
IMPORTANT:
• Always be sure to add LLC to soft water. In particular, in cold season, to add LLC is important.
• Without LLC,
• Cooling performance will decrease due to scale and rust in the cooling water system.
• Cooling water may freeze to form ice; it expands approx. 9% in volume.
• This causes serious damage in the cooling system.
• Be sure to use the proper amount of coolant concentrate specified by the LLC manufacturer depending
on the ambient temperature.
• LLC concentration should be 30%as a minimum and 60%as a maximum.
• DO NOT mix the different types of brand of LLC, otherwise harmful sludge may yield.
• DO NOT use hard water.
• Water should be free from sludge and/or particles.
• Replace the coolant every once a year.
When handling LLC, use protective gloves to avoid skin contact.

In case you have a contact with your skin or eyes, wash out it with clean
water.
(R.1)
8-2
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1. General
1.4 Engine external views
Lifting eye
Cooling water pump
Lifting eye
Fuel filter
Air intake port
(from air cleaner)
Intake manifold
Fuel injection pump
Governor lever
Cooling fan
V-belt
Engine oil filter V-pulley
Dipstick (lube oil)
Fuel priming lever Filler port (lube oil)
Mechanical fuel feeding pump Drain plug (lube oil)
Fuel oil inlet
Bonnet (Rocker arm cover)

Filler port (lube oil) Engine name plate
Alternator
Flywheel
Exhaust manifold
Starter motor
9
1. General
Starting performance improvement

㨯Applying super quick glow plug
Noise Reduction
Emission Reduction / Noise Reduction 㨯Molybdenum-coated piston
㨯New combustion chamber

㨯Taper throttle nozzle
࠮࡞
࠯ࠢ 㧭࡯㧼
㧷㧯
㧔㧔
Emission Reduction
㨯New small in-line fuel pump
1.5 Structural description
(Revised ML type)
㨯Precision improvement of fuel injection
quantity in production
㨯Precision improvement of fuel injection
timing in production
10
Noise Reduction
㨯LO pump with more teeth
Quality improvement
㨯Governor performance up
Noise Reduction
㨯Cylinder block of higher stiffness
Noise Reduction Durability improvement Aim
㨯Gear with smaller module (m=1.5) 㨯Applying a V-belt of A type Main change points
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1. General
1.6 Exhaust gas emission regulation

The engines in this manual have been certified by the US EPA and/or California.
California
Proposition 65 Warning
Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts㧘terminals㧘and related accessories contain lead and lead compounds㧘chemicals known to
the State of California to cause cancer and reproductive harm. Wash hands after handling.
1.6.1 The emission standard in USA
(1) EPA nonroad diesel engine emission standards

g/kW•hr (g/bhp•hr)
Engine Power Tier Model Year NOx HC NMHC + NOx CO PM
kW < 8 Tier 1 2000 - - 10.5 (7.8) 8.0 (6.0) 1.0 (0.75)
(hp < 11)
Tier 2 2005 - - 7.5 (5.6) 8.0 (6.0) 0.80 (0.60)
8 <= kW < 19 Tier 1 2000 - - 9.5 (7.1) 6.6 (4.9) 0.80 (0.60)
(11 <= hp < 25)
Tier 2 2005 - - 7.5 (5.6) 6.6 (4.9) 0.80 (0.60)
Note1) The EPA emission regulation under 19 kW is mentioned above.

Note2) As for Model year, the year which a regulation is applicable to is shown.
Transient smoke standards % opacity

Engine classification
(acceleration/lug/peak modes)
Constant speed engine Not regulated
Variable speed engine 20/15/50 or less
(2) California ARB emission regulation

The ARB emission standard is based on that of the EPA.
11
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1. General
1.6.2 Engine identification

To identify the engines, the following emission control labels are affixed on the engines.
(1) Emission control labels of US EPA
# /1&'.;'#475'2#4')7.#6+105 # /1&'.;'#475'2#4')7.#6+105
01041#&%+'0)+0'5%1056#0652''&10.; 01041#&%1/24'55+10+)0+6+10'0)+0'5
"75&"(7'. "75&"(7'.
% & % &
' ( ' (
) * + ) * +
EPA label for constant speed engines EPA label for variable speed engines
(2) Emission control label for both EPA and ARB
$ %
&
' ( )
12
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1. General
1.6.3 Guarantee conditions for the EPA emission standard

The following guarantee conditions are set down in the operation manual. In addition to making sure that
these conditions are met, check for any deterioration that may occur before the required periodic maintenance
times.
(1) Requirement on engine operation condition

(a)Intake air depression
kPa (mmAq)
Initial Permissible
<= 2.94 (300) <= 6.23 (635)
(b)Exhaust gas back pressure

kPa (mmAq)
Initial Permissible
<= 12.75 (1300) <= 15.30 (1560)
(2) Fuel oil

The diesel fuel oil US No.2 diesel fuel oil.
(3) Tamper resistance

Sealing cap
Do not remove the seals restricting injection quantity and Gasket
engine speed. Cap nut
Plate
Copper gasket
Nut Injection quant
limit bc
Tamper Seal washer

resistance Assy
Tamper resistance device
for engines certified by ARB/EPA
(R.1)
13
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1. General
(4) Perform maintenance without fail.

Note: Inspections to be carried out by the user and by the maker are divided and set down in the “List of
Periodic Inspections” and should be checked carefully.
(5) Maintenance period and quality guarantee period for exhaust emission related parts
The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period
as shown in the below table.
A guarantee period is that either the operation hours or years shown in the table come first in the condition
that the maintenance inspection was carried out based on the “List of Periodic Maintenance Schedule”.
Maintenance period Quality guarantee period

Parts Fuel nozzle cleaning Adjustment, cleaning, For nozzle, fuel pump,
repairs for fuel nozzle, turbocharger
fuel pump, turbocharger,
Power Rating electronic control unit etc.
kW < 19 Every 1500 hours Every 3000 hours 1500 hours / 2 years
And constant speed
engines beyond
3000 min-1 under 37 kW
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2. Inspection and adjustment

2.1 Periodic maintenance schedule
The engine periodic inspection timing is hard to determine as it varies with the application, load status,
qualities of the fuel and lube oils used and handling status. General rules are described here.
c: User-maintenance : Parts replacement z: Shop-inspection

Maintenance period
Every Every Every Every
Classification Item Daily Every 250 500 1000 2000
50 hours hours hours hours
hours or 3 or 6 or one or two
months months year years
Whole Visual check around engine c
Fuel tank level check and fuel supply c
Fuel tank draining c
Fuel oil Bleeding the fuel system c
system Water separator draining c
Water separator cleaning c
Fuel filter element replacement
Lube oil level check and replenishment c
Lubricating Lube oil replacement
oil system 2nd time
1st time and
Lube oil filter replacement thereafter
Cooling water level check and
c
replenishment
Radiator fin cleaning c
Cooling c
c 2nd time
water Cooling fan V-belt tension check
1st time and
system thereafter
Cooling water replacement

Cooling water path flushing and
maintenance
Rubber Fuel pipe and cooling water pipe
c z
house inspection and maintenance
Inspection and adjustment of governor
Governor c c z
lever and accelerator
Air cleaner cleaning and element
c
Air intake replacement
system
Diaphragm assy inspection z
(2 years)
Warning lamp & instruments function check c
Electrical
Battery electrolyte level check and battery
system c
recharging
Cylinder Intake/exhaust valve clearance adjustment z
head Intake/exhaust valve seat lapping z
Fuel Fuel injection nozzle pressure inspection z*
injection pump
Fuel injection timing adjustment
and z*
nozzle Fuel pump inspection and adjustment
*) EPA allows to maintain the emission related parts as shown in 1.6.3 of chapter1.
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2.2 Periodic inspection and maintenance procedure

2.2.1 Check before daily operation
Be sure to check the following points before starting an engine every day.
No. Inspection Item
(1) Visual check around engine
(2) Fuel tank level check and fuel supply
(3) Lube oil level check and replenishment
(4) Cooling water level check and replenishment
(5) Fuel pipe and cooling water pipe inspection and maintenance
(6) Inspection and adjustment of governor lever and accelerator
(7) Warning lamp & instruments function check
(1) Visual check around engine.

If any problem is found, do not use before the engine repairs have been completed.
• Oil leak from the lubrication system
• Fuel leak from the fuel system
• Cooling water leak from the cooling water system
• Damaged parts
• Loosened or lost bolts
• Fuel, radiator rubber hoses, V belt cracked, loosened clamp
(2) Fuel tank level check and fuel supply

Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary. (Refer
to 1.3.1
(3) Lube oil level check and replenishment

(a)Checking oil level
Check the lube oil level with the dipstick, after adjusting Filler port
(lube oil)
the posture of the machine unit so that an engine may
become a horizontality. Insert the dipstick fully and
check the oil level. The oil shall not be contaminated Dipstick
heavily and have appropriate viscosity. No cooling water

or diesel fuel shall be mixed.
When lube oil is supplied after the engine running, check
the lube oil level after about 10 minutes pass after the Dipstick
engine shutdown so that the lube oil inside may be
Upper limit φ
returned to the oil pan.
Lower limit φ
Standard
The level shall be between the upper and lower limit
lines on the dipstick.
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(Unit: liter)
Model Class Total volume Effective volume
2TNV70 VM 1.7 0.7
VM/VH 2.8 1.3
3TNV70
CH 3.8 1.7
VM/VH 3.5 1.6
3TNV76
CH 4.4 2.1
Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit.
(b)Replenishing oil pan with lube oil
If the remaining lube oil level is low, fill the oil pan with the specified lube oil to the specified level through the
filler port.
[NOTICE]
The oil should not be overfilled to exceed the upper limit line. Otherwise a naturally-aspirated engine may
intake lube oil in the combustion chamber during the operation, then white smoke, oil hummer or urgent
rotation may occur, because the blowby gas is reduced in the suction air flow.
In case of turbo-charged engine oil may jet out from the breather or the engine may become faulty.
(4) Cooling water level check and replenishment

Daily inspection of cooling water should be done only by coolant recovery tank.
•Never open the radiator filler cap while the engine and radiator are still hot.
Steam and hot water will spurt out and seriously burn you. Wait until the radia-
tor is cooled down after the engine has stopped, wrap the filler cap with a rag
piece and turn the cap slowly to gently release the pressure inside the radia-
tor.
•Securely tighten the filler cap after checking the radiator. Steam can spurt out
during operation, if the cap is tightened loosely.
(a)Checking cooling water volume

Check the cooling water level in the coolant recovery
tank. If the water level is close to the LOW mark, open
the coolant recovery tank cap and replenish the coolant
recovery tank with clean soft water to the FULL mark.
Upper limit
Standard
The water level of the coolant recovery tank shall be Lower limit
between the upper and lower limit lines.
Coolant
(b)Replenishing engine with water recovery tank
If the coolant recovery tank water level is lower than the
LOW mark, open the radiator cap and check the cooling
water level in the radiator. Replenish the radiator with
the cooling water, if the level is low.
• Check the cooling water level while the engine is Tighten Loosen
cool.
Checking when the engine is hot is dangerous. And
the water volume is expanded due to the heat.
Radiator cap
• Daily cooling water level check and replenishing shall
be done only at the coolant recovery tank. Usually do
not open the radiator cap to check or replenish.
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IMPORTANT:
If the cooling water runs short quickly or when the radiator runs short of water with the coolant recovery
tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the coolant
recovery tank water level during operation is not abnormal.
The increased water in the coolant recovery tank returns to the radiator when the engine is cooled down.
If the water level is normal in the coolant recovery tank but low in the radiator, check loosened clamping of
the rubber hose between the radiator and coolant recovery tank or tear in the hose.
Standard
Engine: The radiator shall be filled up.
(Unit: liter)
Model Cooing water volume in an engine
2TNV70 0.6
3TNV70
0.9
3TNV76
Engine cooling water capacity may differ from the above

volume depending on an engine installed on a machine unit.
Check the rubber hoses for fuel and cooling water pipes cracked. If the cracked hose is found, replace it with
new one.
Check the loosened clamp. If found, tighten it.

Make sure the accelerator of the machine unit can be operated smoothly before starting the engine. If it feels
heavy to manipulate, lubricate the accelerator cable joints and pivots. Adjust the accelerator cable if there is a
dislocation or excessive play between the accelerator and the governor lever. Refer to 3.2.3.
(7) Warning lamp & instruments function check

Before and after starting the engine, check to see that the alarm function normally. Failure of alarm cannot
warn the lack of the lube oil or the cooling water. Make it a rule to check the alarm operation before and after
starting engine every day. Refer to each manual for machine units in details.
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2.2.2 Inspection after initial 50 hours operation

Be sure to check the following points after initial 50 hours operation, thereafter every 250 hours or 3 months
operation.
No. Inspection Item
(1) Lube oil and filter replacement
(2) V-belt tension check
When an engine is still hot, be careful with a splash of lube oil which may
cause burns. Replace lube oil after the lube oil becomes warm. It is most
effective to drain the lube oil while the engine is still warm.
In early period of use, the lube oil gets dirty rapidly

because of the initial wear of internal parts. Replace the
lube oil earlier.
Lube oil filter should also be replaced when the lube oil
is replaced.
The procedure of lube oil and lube oil filter replacement
is as follows.
(a)Drain lube oil
• Remove the oil filler cap to drain easily while draining
Oil pan
the lube oil.
• Remove the oil filler cap to drain easily while draining Drain plug
the lube oil.
• Loosen the drain plug using a wrench (customer pro- The location depends on the engine
installed on the machine unit
cured) to drain the lube oil.
• Securely tighten the drain plug after draining the lube
oil.
[NOTICE]
Use a socket wrench or a closed wrench when
removing or tightening a drain plug.
Don’t use a spanner because it has the possibility that
the spanner will slip and it will get hurt.
(b)Replacing oil filter

• Turn the lube oil filter counter-clockwise using a filter
wrench (customer procured) to remove it.
• Clean the mounting face of the oil filter. Loosen
• Moisten the new oil filter gasket with the lube oil and
Tigh
install the new lube oil filter manually turning it clock-

n te
wise until it comes into contact with the mounting sur-

face, and tighten it further to 3/4 of a turn with the
filter wrench.
Tightening torque: 20 to 24 N•m (2.0 to 2.4 kgf•m)
Engine oil filter
Applicable oil filter Part No.
119305-35150
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(c)Filling oil and inspection

• Fill with new lube oil until it reaches the specified
level.
IMPORTANT:
Do not overfill the oil pan with lube oil.
Be sure to keep the specified level between upper
and lower limit on the dipstick.
• Warm up the engine by running for 5 minutes while
checking any oil leakage
• Stop the engine after warming up and leave it stop-
ping for about 10 minute to recheck the lube oil level
with dipstick and replenish the lube oil. If any oil is
spilled, wipe it away with a clean cloth.

When there is not enough tension in the V-belt, the V-
belt will slip making it impossible for the alternator to Radiator
fan
generate power and cooling water pump and cooling fan
$
will not work causing the engine to overheat.
Alternator
Check and adjust the V-belt tension (deflection) in the
following manner.
[NOTICE] Deflection
Be especially careful not to splash lube oil on the V- % #
belt, because it will cause slipping, stretching and
V-belt
aging of the belt.
Crankshaft Press with thumb
1)Press the V-belt with your thumb [approx. V-pulley
98 N (10 kgf)] at the middle of the V-belt span to
check the tension (deflection).
Available positions to check and adjust the V-belt
tension (deflection) are at the A, B or C direction as
shown in the illustration right.
You may choose a position whichever you can easily
carry out the check and adjustment on the machine
unit.
• "New V-belt" refers to a V-belt which has been used
less than 5 minutes on a running engine.
• "Used V-belt" refers to a V-belt, which has been used
on a running engine for 5 minutes or more.
The specified deflection to be measured at each
position should be as follows.
(Unit: mm)
Direction A B C
For used V-belt 10 to 14 7 to 10 9 to 13
For new V-belt 8 to 12 5 to 8 7 to 11
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2)If necessary, adjust the V-belt tension (deflection).

Adjust the V-belt tension
To adjust the V-belt tension, loosen the set bolt and inserting a bar
move the alternator to tighten the V-belt.
3)After replacing with a new V-belt and adjusting it, run
Adjuster
the engine for 5 minutes and readjust the deflection
to the value in the table above.
Alternator
Tension adjustment
4)Visually check the V-belt for cracks, oiliness or wear.

If any, replace the V-belt with new one.
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2.2.3 Inspection every 50 hours

Be sure to check the following points every 50 hours operation.
No. Inspection Item

(1) Fuel tank draining
(2) Water separator draining
(3) Bleeding the fuel system
(4) Battery electrolyte level check and battery recharging
(1) Fuel tank draining

1)Prepare a waste oil container.
2)Remove the drain plug of the fuel tank to drain Fuel tank
(OPTION)
(water, dust, etc.) from the fuel tank bottom.
3)Drain until fuel with no water and dust flow out. Then
tighten the drain plug firmly.
Drain plug
(2) Water separator draining

Drain off the water separator whenever there is a lot of Close
drain collected in the water separator at the bottom of Air bleeding bolts
the cup even if not the time for periodic inspection hour. Outlet
The cup of the water separator is made from semi- Inlet
E
transparency material and in the cup, the red colored Q
float ring which rises on the surface of the drain is

Loosening Tightning
installed to visualize the amount of drain. Fuel cock Retaining ring
Drain off the water separator in the following manner. Open Fuel cock
1)Close the fuel cock. Retaining
spring
2)Loosen the retainer ring, and remove the cup, then Float ring
throw collected water and trash away. Water separator
3)Put a float ring and a spring in the cup, and tighten
the retainer ring.
Tightening torque: 13-16 N•m (1.3-1.6 kgf•m)
4)Be sure to bleed air in the fuel system.
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(3) Bleeding the fuel system

Fuel filter Fuel return hose
Bleed the fuel system according to the following
procedures. When there is air in the fuel system, the fuel
injection pump will not be able to function.
1)Check the fuel oil level in the fuel tank. Refuel if
insufficient.
2)Open the fuel cocks of the water separator and the
fuel filter.
3)Loosen the air bleeding bolt on the water separator
by turning 2 to 3 turns to the counter-clockwise by
using a screw driver.
4)When the fuel coming out is clear and not mixed with Mechanical From oil/water Fuel injection
Fuel feed pump separator pump
any bubble, tighten the air bleeding bolt.
5)Feed the fuel with the fuel priming pump or electro- Priming lever Close
magnetic fuel feed pump. Air bleeding bolts
In case of an engine installed with a fuel priming Outlet
pump.
Inlet
Move the priming lever by hand up and down, and E
Q
feed fuel until the fuel surface inside the fuel filter
cup goes up and the air disappears inside. (Move
the lever until feeling your hand slightly heavy.) Fuel cock
In case of an engine using the electro-magnetic fuel Open
Joint for fuel return Fuel cock
feed pump.
Turn the starter switch to the ON position, and hold it Outlet
in the position and operate the electro-magnetic fuel Close
feed pump for 10 to 15 seconds to bleed the fuel Water separator
system automatically. Inlet (On the piping line)
Loosening Tightning
Note: Retainer ring
Open Fuel cock
Don't do air bleeding by a starting motor.
(4) Battery electrolyte level check and battery

recharging Fuel filter
Fire due to electric short-circuit

•Make sure to turn off the battery switch or disconnect the negative cable (-)
before inspecting the electrical system. Failure to do so could cause short-
circuiting and fires.
•Always disconnect the (-) Negative battery cable first before disconnecting
the battery cables from battery. An accidental "Short circuit" may cause
damage, fire and or personal injury.
And remember to connect the (-) Negative battery cable (back onto the bat-
tery) last.
Proper ventilation of the battery area

Keep the area around the battery well ventilated, paying attention to keep
away any fire source. During operation or charging, hydrogen gas is
generated from the battery and can be easily ignited.
Do not come in contact with battery electrolyte

Pay sufficient attention to avoid your eyes or skin from being in contact with
the fluid. The battery electrolyte is dilute sulfuric acid and causes burns.
Wash it off immediately with a large amount of fresh water if you get any on
you.
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Battery structure
Terminal Cap
Cover
Cathode
plate
Separator
Glass mat
Battery
case
Anode plate
(1) Electrolyte level

• Check the level of fluid in the battery.
GREASE
When the amount of fluid nears the lower limit, fill
with battery fluid (available in the market) to the
upper limit. If operation continues with insufficient
battery fluid, the battery life is shortened, and the bat-
tery may overheat and explode. Upper limit UPPER LEVEL
LOWER LEVEL Lower limit
• Battery fluid tends to evaporate more quickly in the
summer, and the fluid level should be checked earlier
than the specified times. OK Too low Excessive
• If the engine cranking speed is so slow that the
engine does not start up, recharge the battery.
• If the engine still will not start after charging, replace
the battery. Electrolyte level
• Remove the battery from the battery mounting of the
machine unit after daily use if letting the machine unit
leave in the place that the ambient temperature could
drop at -15 °C or less. And store the battery in a
warm place until the next use the unit to start the
engine easily at low ambient temperature.
(2) Battery charge

Use a battery tester or hydrometer and check the battery
condition. If the battery is discharged, recharge it.
(a)Measurement with a battery tester
When checking the battery with the batter tester,
connect the red clip of the tester to the battery positive
(+) terminal and black clip to the battery negative (-)
terminal by pinching them securely, and judge the
battery charge level from the indicator position.
Green zone: Normal

Yellow zone: Slightly discharged
Red zone: Defective or much discharged
Battery tester
Battery charge measurement

with battery tester
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(b)Measurement with hydrometer

When using a hydrometer, the measured specific gravity
must be corrected according to the temperature at the
time of measurement. The specific gravity of battery Float
electrolyte is defined with 20 °C as the standard. Since
the specific gravity increases or decreases by 0.0007
when the temperature varies by 1 °C, correct the value
according to the equation below.
S20 = St + 0.007 ( t - 20 )
Measured electrolyte
temperature
Measured specific gravity
Battery charge measurement
Specific gravity converted with a hydrometer
to 20͠
Specific gravity and remaining battery charge Rubber bulb

Specific Discharged quantity Remaining charge
gravity of electricity
Glass tube
(20 °C) (%) (%)
1.28 0 100
1.26 10 90
Float
1.24 20 80
1.23 25 75
Hydrometer structure
(3) Terminals
Clean if corroded or soiled.
(4) Mounting bracket

Repair or replace it if corroded.
Retighten if loosened.
(5) Battery appearance

Replace the battery if cracked or deformed.
How to read hydrometer
Clean with fresh water if contaminated.
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2.2.4 Inspection every 250 hours or 3 months

Be sure to check the following points every 250 hours or 3 months operation, whichever comes first.
No. Inspection Item
(2) Radiator fin cleaning
(5) Air cleaner cleaning and element replacement
(1) Lube oil and filter replacement (The second replacement and after)
Replace the lube oil every 250 hours operation from 2nd time and on. Replace the lube oil filter at the same
time. Refer to 2.2.2.(1).
(2) Radiator fin cleaning
Beware of dirt from air blowing

Wear protective equipment such as goggles to protect your eyes when
blowing compressed air. Dust or flying debris can hurt eyes.
Dirt and dust adhering on the radiator fins reduce the

cooling performance, causing overheating. Make it a
Dust, dirt
rule to check the radiator fins daily and clean as needed. Radiator fins
• Blow off dirt and dust from fins and periphery with
compressed air [0.19 MPa (2 kgf/cm2) or less] not to Air blow
damage the fins with compressed air.
• If contaminated heavily, apply detergent, thoroughly
clean and rinse with tap water shower.
IMPORTANT:
Never use high pressure water or air from close by
fins or never attempt to clean using a wire brush.
Radiator fins can be damaged.
(3) V-belt tension check (The second time and after)

Check and adjust the V-belt tension. Refer to 2.2.2(2).
(4) Inspection and adjustment of governor

lever and accelerator
The governor lever and accelerating devices
(accelerating lever, pedal, etc.) of the machine unit are High idling speed
limiting bolt
connected by an accelerating wire or rod. If the wire
Governor lever
becomes stretched or the connections loose, the Accelerating wire
deviation in the position may result and make operation Accelerating wire bracket High Low
unsafe. Check the wire periodically and adjust if Low idling speed
limiting bolt
necessary.
Do not strongly move the accelerating wire or
accelerating pedal. It may deform the governor lever or
stretch the wire to cause irregular engine speed control.
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Checking and adjusting procedure are as follows.

1)Check that the governor lever of the engine makes uniform contact with the high idling and low idling lim-
iting bolt when the accelerating devices is in the high idling speed or low idling speed position.
2)If either the high or the low idling speed side does not make contact with the limiting bolt, adjust the accel-
erating wire.
Loosen the accelerating wire fixing nut and adjust the wire to contact with the limiting bolt.
Never release the limiting bolts. It will impair the safety and performance of the product and functions and
result in shorter engine life.
Beware of dirt from air blowing

Wear protective equipment such as goggles to protect your eyes when
blowing compressed air. Dust or flying debris can hurt eyes.
The engine performance is adversely affected when the

air cleaner element is clogged by dust. So periodical Air cleaner case
Arrow mark
cleaning after disassembly is needed. Arrow
Element mark
1)Undo the latches on the dust pan and remove the
dust pan.
2)And pull out the element.
3)Blow air [0.29 to 0.49 MPa (3.0 to 5.0 kgf/cm2)] from
inside the element to blow dust off as shown in the Air blow
illustration right. latch Dust pan
Apply the air blowing pressure as low as possible so OPTION
as not to damage the element.
If having the air cleaner with double elements, never
remove and clean the inner element. Dust indicator (optional)
Air cleaner case
The aim of installing the inner element is for back up Arrow mark
protecting from intaking dust during engine running Inner element
Outer element
when leaving the outer element to reinstall after
Arrow
removing it or when damaging the outer element mark
unexpectedly during engine running. Dust pan
4)Replace the element with new one, if the element is
damaged, excessively dirty or oily.
5)Clean inside of the dust pan. latch
6)Reinstall the element inserting into the air cleaner. Double elements type air cleaner
OPTION with inner and outer element
And install the dust pan to the air cleaner case
matching the arrow marks or the dust pan and air
cleaner case, then fasten the dust pan with the
latches.
IMPORTANT:
• When the engine is operated in dusty conditions,
clean the element more frequently.
• Do not run the engine with removed air cleaner or
element, as this may cause foreign material to enter
and damage the engine.
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2.2.5 Inspection every 500 hours or 6 months

Be sure to check the following points every 500 hours or 6 months operation, whichever comes first.
No. Inspection Item
(1) Water separator cleaning
(2) Fuel filter element replacement
(1) Air cleaner element replacement Close

The cup of an water separator is translucent, and the Air bleeding bolts
inside can be seen. The float ring rises when water Outlet
collects at the bottom of the cup. Inlet
E
Periodically wash the water separator element and Q
inside cup with clean fuel oil.

Loosening Tightning
1)Close the fuel cock. Fuel cock Retaining ring
2)Loosen the retaining ring and remove the cup. Take Open Fuel cock
the water and trash in the cup out. Retaining
spring
3)Wash the element with clean fuel oil. Replace the Float ring
element with new one if any damaged. Water separator
Element Part No.
129335-55700
4)Insert the element to the bracket and put the float

ring and spring in the cup. Tighten the retaining ring.
5)Bleed the fuel system. Refer to 2.2.3(3)
(2) Fuel filter element replacement

Fuel filter Fuel return hose
Replace the fuel filter element at specified intervals
before it is clogged with dust to adversely affect the fuel
flow. Do this work after an engine gets cold fully.
1)Close the fuel filter cock.
2)Loosen the retainer ring and replace the fuel filter
element. Take the water and trash in the cup out.
When removing the fuel filter, hold the bottom of the
fuel filter with a piece of rag to prevent the fuel oil
from dropping. If you spill fuel, wipe such spillage Mechanical From water Fuel injection
carefully. Fuel feeding pump separatr pump
3)Install a new fuel filter element and tighten the Priming lever
retainer ring.
Joint for fuel return
Outlet
Fuel filter element Part No.
Close
119740-55650
Inlet
Loosening Tightning
Retaining ring
Open Fuel cock
Fuel filter
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4)Bleed the fuel system. Refer to 2.2.3.(3)

IMPORTANT:
Be sure to use genuine Yanmar part. Otherwise, it
results in engine damage, uneven engine
performance and decline of engine life.
And, these troubles are outside the guarantee.
Refer to 2.2.4 (5).
Replace the air cleaner element periodically even if it is not damaged or dirty.
When replacing the element, clean inside of the dust pan at the time.
If having the air cleaner with double elements, do not remove the inner element. If the engine output is still not
recover (or the dust indicator still actuates if having the air cleaner with a dust indicator) even though the outer
element has replaced with new one, replace the inner element with new one.
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2.2.6 Inspection every 1,000 hours or one year

Be sure to check the following points every 1,000 hours or one year operation, whichever comes first.
No. Inspection Item
(1) Cooling water replacement
(2) Diaphragm assy inspection
(3) Intake/exhaust valve clearance adjustment
(4) Fuel injection nozzle pressure inspection
(1) Cooling water replacement

Cooling water contaminated with rust or water scale reduces the cooling effect. Even when antifreeze agent
(LLC) is mixed, the cooling water gets contaminated due to deteriorated ingredients. Replace the cooling
water at least once a year. Fill the radiator and coolant recovery tank with the cooling water as following.
1)Remove the radiator cap.
•Never open the radiator filler cap while the engine and radiator are still hot.
Steam and hot water will spurt out and seriously burn you. Wait until the
radiator is cooled down after the engine has stopped, wrap the filler cap with
a rag piece and turn the cap slowly to gently release the pressure inside the
radiator.
•Securely tighten the filler cap after checking the radiator. Steam can spurt
out during operation, if the cap is tightened loosely.
2)Loosen the drain plug at the lower portion of the radi-
ator and drain the cooling water. Radiator cap
3)After draining the cooling water, tighten the drain Radiator
(Option)
plug.
4)Fill radiator and engine with cooling water.
Rubber hose
Refer to 3.4
before filling, check to be sure the drain plug is
closed.
bromide the radiator cap of the radiator by turning FULL
Coolant (Max.limit)
the radiator cap counter-clockwise about 1/3 of a recovery tank
turn.
c)Pour the cooling water slowly into the radiator up
to the lip of the filler port so that air bubbles do not
develop.
d)After supplying the cooling water, surely tighten LOW
the radiator cap. To fasten the radiator cap, align (Min.limit)
Drain plug
the detents on the back face of the radiator cap (Drain plug location depends on the machine unit)
with the slot of the filler port and turn clockwise
pushing it downward approx. 1/3 of a turn until
contact with each other.
e)Remove the cap of the coolant recovery tank,
supply the cooling water to the FULL mark and
fasten the cap.
f)Check the rubber hose connecting the coolant
recovery tank to the radiator. Be sure the rubber is
securely connected and there is no looseness or
damage. When the rubber hose is not water tight,
an excessive amount of cooling water will be
consumed.
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g)When filling with the cooling water for the first time
or replacing, the air contains in the cooling water
system. So as the air in the cooling water system
is made self-bleeding during engine operation, the
cooling water level in the radiator and coolant
recovery tank will be lowered. Replenish the
cooling water into the radiator and coolant
recovery tank until it reaches the FULL mark of the
coolant recovery tank.
Beware of scalding by hot water

Wait until the temperature goes down before draining the cooling water.
Otherwise, hot water may splash to cause scalding.
(2) Diaphragm assy inspection

Inspect the diaphragm assy on the rocker arm cover
every 1000 hours or 2 years, whichever comes first. Diaphragm cover
Rocker arm cover
Refer to 4.2.4 point 6 for the function of the diaphragm. Spring
Center plate
1)Loosen screws, and remove a diaphragm assy, and Diaphragm
check whether oil and so on doesn’t enter between
the diaphragm and the cover. If oil and so on enters
Breather baffle
into the diaphragm assy, the diaphragm doesn’t
work well. Baffle plate
Intake maniforld
2)Check the damages of the diaphragm rubber and
the spring. If necessary, replace with new ones. Breather system componert
[NOTICE]
• When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles
such as combustion defect and so on occur.
• At lube oil replacement or lube oil supply the amount of lube oil isn’t to be beyond the standard upper limit.
If the lube oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum
angle of an engine, the amount of oil mist may be inducted in the combustion chamber and the oil hammer
sometimes may occur.
(3) Intake/exhaust valve clearance adjustment
Make measurement and adjustment while the engine is cold.
(a)Valve clearance measurement
1)Remove the rocker arm cover above cylinder head.
2)Set the No.1 cylinder in the compression TDC
Turn the crankshaft to bring the piston of the No.1 cylinder to its compression top dead center while
watching the rocker arm motion, timing scale and the top mark position of the crankshaft pulley.
(Position where both the intake and exhaust valves are closed.)
Notes:
• The crankshaft shall be turned clockwise as seen from the radiator side.
• The No.1 cylinder position is on the opposite side of the radiator.
• Since there is a clearance between the rocker arm and valve at the compression top dead center, the posi-
tion of TDC can be checked by hand. Also see that the top mark on the crankshaft pulley aligns with the
mark on the gear case. If there is no valve clearance, disassemble and inspect around the valve seat,
since the valve seat may be worn abnormally.
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3)Valve clearance measurement

Insert a thickness gage between the rocker arm and Adjusting screw
valve cap and record the measured valve clearance.
Valve clearance Lock nut
(Use it as data for estimating the wear state.)
4)Adjusting other cylinders
Then in case of 3-cylinder engines turn the crank- Valve cap
shaft clockwise viewed from radiator side at
240 degree, and adjust the valve clearance for the
No.3 cylinder. Then adjust the No.2 cylinders in this
order.
In case of 2-cylinder engines turn the crankshaft
clockwise at 180 degree with 1 turn after the No.1
cylinder’s adjustment.
The cylinder to be adjusted first does not have to be
the No.1 cylinder. Select and adjust the cylinder
where the piston is the nearest to the top dead cen-
ter after turning, and make adjustment for other cyl-
inders in the order of ignition by turning the
crankshaft.
A adjustment method of reducing the flywheel turning numbers for 3 cylinder engines (for reference):
Set No.1 cylinder to the compression T.D.C. and adjust the clearance of the z mark of the bottom table.
Next, turn the flywheel once (the suction / exhaust valve of No.1 cylinder is in the position of the overlap
T.D.C at this time), and adjust the clearance of the c mark.
Ignition order of 3 cylinder engines: 1J3J2
Cylinder No. 1 2 3
Valve Suction Exhaust Suction Exhaust Suction Exhaust
No.1
z z z z The first time
compression T.D.C
No.1
c c The second time
overlap T.D.C
(b)Valve clearance inspection and adjustment

1)Loosen the lock nut and adjusting screw, and check
the valve for any inclination of valve cap, dirt or
wear.
Valve cap
Normal Abnormal
2)Insert a 0.2 mm thickness gage between the rocker

arm and valve cap, and adjust the valve clearance.
Tighten the adjusting screw.
mm
Standard valve clearance
0.15 to 0.25
3)Apply oil to the contact surface between adjusting

screw and push rod.
4)Adjust the other cylinder(s) in the order.
Valve clearance adjustment
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(4) Fuel injection nozzle pressure inspection
Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection
nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or
injury if coming into careless contact with it.
(a)Injection pressure measurement

Standard
Mpa (kgf/cm2)
11.8 to 12.8
(120-130)
[NOTICE] Nozzle tester

As for the opening pressure of the brand-new fuel
nozzle, about 0.5 MPa (5 kgf/cm) declines by the
Injection nozzle
engine operation for about 5 hours because of the
initial wear-out of a spring etc. Therefore, adjust
0.5MPa (5 kgf/cm) higher than the standard value of Injection pressure measurement
with nozzle tester
the above table when adjusting a new fuel nozzle of a
spare part.
Remove carbon deposit at the nozzle hole thoroughly
before measurement.
1)Connect the fuel injection valve to the high pressure
pipe of the nozzle tester.
2)Operate the nozzle tester lever slowly and read the
pressure at the moment when the fuel injection from
the nozzle starts.
3)If the measured injection pressure is lower than the
standard level, replace the pressure adjusting shim
with a thicker one.
Thickness of pressure adjusting shims

Injection pressure adjustment
mm
The injection pressure is increased by approx.
0.1, 0.2, 0.3, 0.4, 0.5 6.9 to 9.8 MPa (7 to 10 kgf/cm2), when the adjusting shim
thickness is increased by 0.l mm.
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[Informative: Fuel injection valve structure]
Nozzle holder
Pressure adjusting shim
Nozzle spring
Nozzle spring seat
Valve stop spacer
Nozzle valve
Nozzle
Nozzle body
Nozzle case nut
(b)Spray pattern inspection

After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and
seat oil-tightness.
Seat oil tightness check
• After injecting a few times, increase the pressure gradually. Hold the pressure for about 5 seconds at a lit-
tle before the valve opening pressure of 1.96 Mpa (20 kgf/cm2), and check to see that oil does not drip
from the tip end of the nozzle.
• If extreme oil leak from the overflow joint exists during injection by the nozzle tester, check after retighten-
ing. If much oil is leaking, replace the nozzle assembly.
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Spray and injection states

• Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection.
• If normal injection as shown below cannot be obtained, replace the fuel injection valve.
• No extreme difference in angle ()
• Finely atomized spray
• Excellent spray departure
ǰ5q
㨪10q
Normal spray pattern Abnormal spray pattern
(c)Nozzle valve sliding test

Wash the nozzle valve in clean fuel oil. Place the nozzle
body vertically and insert the nozzle into the body to
about 1/3 of its length. The valve is normal if it smoothly
falls by its own weight into the body. In case of a new
nozzle, remove the seal peel, and immerse it in clean
diesel oil or the like to clean the inner and outer surfaces
and to thoroughly remove rust-preventive oil before
using the nozzle. Note that a new nozzle is coated with
Nozzle valve sliding check by gravity
rust-preventive oil and is pasted with the seal peel to
shut off outer air.
(d)Nozzle punch mark

NP - DN O P D N159
Design code
Throttle type
Size: size P
Injection angle
Type: pintle type
NP- 9
BOSCH D NOPD N 1 5
Identification
number
(R.1)
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2.2.7 Inspection every 2000 hours or 2 years

Be sure to check the following points every 2,000 hours or two years operation, whichever comes first.
No. Inspection Item
(1) Cooling water path flushing and maintenance
(3) Intake/exhaust valve seat lapping
Fuel injection timing adjustment
(4)
Fuel injection pump inspection and adjustment
(1) Cooling water path flushing and maintenance

Rust and water scale will accumulate in the cooling system through many hours of operation. This lowers the
engine cooling effect. Oil coolers (attached to turbocharged engines and some of naturally aspirated engines)
quickly deteriorate the lube oil. The cleaning and maintenance of the following parts are necessary in
accordance with the cooling water replacement.
Cooling system parts: radiator, cooling water pump, thermostat, cylinder block, cylinder head, oil cooler.
Regularly check the rubber hoses of the fuel system and cooling water system. If cracked or degraded,
replace them with new one. Replace the rubber hoses at least every 2 years even if 2,000 hours doesn’t
come.
(3) Intake/exhaust valve seat lapping

The adjustment is necessary to maintain proper contact of the valves and seats. Refer to 4.2.6 in Chapter 4.
(4) Fuel injection timing adjustment / Fuel injection pump inspection and adjustment
The fuel injection timing and the fuel injection pump are
adjusted so that engine performance may become the Flywheel
housing
best condition. As for the inspection and adjustment of
the fuel pump, it is based on the service manual of the
ML pump of the separate volume. The fuel injection
timing is adjusted by the following procedure.
1)Complete air bleeding from the fuel line and set the
engine ready for starting.
Inspection hole
2)See that the timing marks on fuel pump mounting
flange and gear case are aligned.
3)Set the speed control lever at the operating position.
4)Disconnect the injection pipe on the fuel pump side
for the No.1 cylinder. (Do not remove the delivery
holder.)
5)Check the fuel discharge from the delivery holder Timing marck
while turning the crankshaft clockwise as seen from
the radiator, and stop turning it at the same time
when the fuel comes out. Wipe out the fuel of the Timing scale
delivery holder exit. Next, turn the crankshaft in the
opposite direction (counterclockwise), and return it
to about 20 degrees before top dead center.
6)Check again the fuel discharge from the delivery
holder while turning the crankshaft clockwise, and
stop turning it at the same time when the fuel comes
out.
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7)Read the timing scale on the flywheel from the hole on the flywheel housing. It is standard fuel injection
timing if the timing mark position meets the fuel injection timing of the below table.
Class VM CH VH
Model 2000 2300 2700 3000 3100 3500
name Engine speed min-1 to 2200 to to / to to
2100 2600 3000 3600 3400 3600
2TNV70 15 16 18 - - -
Injection timing
3TNV70 (FID) bTDC Deg. 15 16 18 21 20 21
± 1 deg.
3TNV76 15 16 18 21 20 21
8)Repeat steps 5) to 7) a few times.

Note:
Injection timing check for one cylinder is generally sufficient. If it is to be checked for all cylinders of
3-cylinder engine, check each cylinder in the ignition order of: 1-3-2-1 by turning at each 240 degrees.
The cylinder to be checked is not limited to the No.1 cylinder and any cylinder may be checked.
9)If the injection timing is out of the standard value, loosen the fuel pump mounting nut and incline the fuel
injection pump toward or away from the engine for adjustment. Incline toward the engine to delay the tim-
ing, and away from the engine to advance it.
(One graduation of the timing scale on gear case corresponds to two degrees in injection timing.)
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2.3 Adjusting the no-load maximum or minimum speed

1)After warming the engine up, gradually raise the
speed and set it at the no-load maximum speed.
2)If the no-load maximum revolution is out of the stan-
dard, adjust it by turning the high idle limiting bolt.
3)Then set the no-load minimum speed by adjusting
the low idle limiting bolt. High idling speed
limiting bolt
Governor lever
Accelerating wire
Accelerating wire bracket High Low
Low idling speed

limiting bolt
Standards (Unit: min-1)

No-load maximum No-load minimum
Engine application class Rating speed
(± 25) (± 25)
2000 2160
2100 2250
2200 2355
2300 2460
2400 2570
VM 2500 2675 800
2600 2780
2700 2890
2800 2995
2900 3100
3000 3210
3000 -
CH 1500
3600 3800
3100 3290
3200 3400
3300 3500
VH 800
3400 3600
3500 3710
3600 3815
Note) The engine speed may differ from the above standard depending on an engine installed on a machine unit.
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2.4 Sensor inspection

2.4.1 Oil pressure switch
Disconnect the connector from the oil pressure switch. Oil pressure switch Cylinder block
Keep the voltameter probes in contact with the switch (flywheel side)
terminal and cylinder block while operating the engine. It
is abnormal if circuit is closed.
Tester probes
Continuity test
2.4.2 Thermo switch

Place the thermo switch in a container filled with
Thermometer
antifreeze or oil. Heat it while measuring the fluid
temperature. The switch is normal if the voltameter
Tester probes
shows continuity when the fluid temperature is
107-113 deg C.
Thermo switch
Hot water
2.5 Water leak check in cooling water system

Check cooling water leakage from the cooling water
system visually. If any problem is found, Inspect as
follows.
1)Fill cooling water to the normal level in the radiator,
and install the cap tester on the radiator.
2)Operate the manual pump to set the pressure to
0.09 ± 0.015 MPa (0.9 ± 0.15 kgf/cm2). If the cap
tester pressure gage reading drops then, water is Cap tester
leaking from the cooling water system. Check the
Water leak check in cooling water system
water leaking point.
2.6 Radiator cap inspection

Spread water on the seal surface of the radiator cap
fully, and install the cap to a cap tester. Raise the
pressure of the tester, and check that the valve of the
cap opens by the standard pressure.
0.09 ± 0.015 MPa
Standard pressure
(0.9 ± 0.15 kgf/cm2) Radiator cap
When the cap doesn't open, it is abnormal. Replace the Radiator cap inspection
cap with new one.
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2.7 Thermostat inspection

Place the thermostat in a container filled with water.
Heat it while measuring the water temperature, and see
that the thermostat is actuated at temperature of
following table.
Themostat
Valve opening Full open lift

Temperature (Temperature)
(deg C)* (mm)
69.5 to 72.5 8 or more (85 deg C)
* Valve opening temperature is carved on the flange.
Thermo switch
Thermometer Cooling water pump
Thermostat
2.8 Adjusting operation

Perform the adjusting operation of a engine as follows after the maintenance job:
1)Supply the fuel oil, lube oil and cooling water.
Note:
Check the levels of the lube oil and cooling water again after test running (for about 5 minutes) and add as
required.
2)Start the engine, and carry out idling at the low speed (700 to 900 rpm) for a few minutes.
3)Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak
and existence of abnormal vibration or noise. Also check the oil pressure, cooling water temperature and
exhaust gas color.
4)Adjust the no-load minimum and maximum revolutions. (Refer to 2.3 in chapter 2.)
5)Perform loaded operation as required.
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2.9 Long storage

Observe the following instructions when the engine is to be stored for a long period without operation:
1)Be sure to use clean soft water added Long Life Coolant Antifreeze (LLC) in the cooling water system and
do not drain the coolant before long-term storage.
If drain the cooling water, it will cause to built up rust due to the residual water in the cooling water system.
2)Remove the mud, dust and oil deposit and clean the outside.
3)Perform the nearest periodic inspection before the storage.
4)Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
5)Disconnect the battery cable from the battery negative (-) terminal.
6)Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from deposit-
ing or entrance.
7)Select a well-ventilated location without moisture and dust for storage.
8)Perform recharging once a month during storage to compensate for self-discharge.
9)When storing an engine for long time, run the engine or do motoring periodically according to the following
procedure. Because the rust occurrence inside the engine, the rack agglutination of the fuel pump, and so
on are likely to occur. (In case that the engine is equipped with a machine unit,)
a)Replace the lube oil and the filter before the engine running.
b)Supply fuel if the fuel in the fuel tank was removed, and bleed the fuel system.
c)Confirm that there is the coolant in the engine.
d)Operate the engine at the low idling speed for about five minutes. (If it can be done, one a month)
(R.1)
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3. Troubleshooting
3. Troubleshooting
3.1 Preparation before troubleshooting
If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before
becoming a big accident not to shorten the engine life.
When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the
next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and
prevent the recurrence of the trouble.
1)What’s the occurrence phenomenon or the trouble situation? (e.g. Poor exhaust color)
2)Investigation of the past records of the engine
Check a client control ledger, and examine the history of the engine.
• Investigate the engine model name and the engine number. (Mentioned in the engine label.)
Examine the machine unit name and its number in the same way.
• When was the engine maintained last time?
• How much period and/or time has it been used after it was maintained last time?
• What kind of problem was there on the engine last time, and what kind of maintenance was done?
3)Hear the occurrence phenomenon from the operator of the engine in detail.
5W1H of the occurrence phenomenon : the investigation of when (when), where (where),
who (who), what (what), why (why) and how (how)
• When did the trouble happen at what kind of time
• Was there anything changed before the trouble?
• Did the trouble occur suddenly, or was there what or a sign?
• Was there any related phenomenon
.(e.g. Poor exhaust color and starting failure at the same time)
4)After presuming a probable cause based on the above investigation, investigate a cause systematically by
the next troubleshooting guide, and find out the cause of sincerity.
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3. TROUBLESHOOTING
3.2 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.
High knocking sound during combustion

Insufficient Poor
Cooling Air
Trouble symptom Starting failure engine exhaust Hunting Lube oil
water intake
output color
Difficulty in returning to low speed

Engine
starts Exhaust During
Excessive fuel consumption

Uneven combustion sound
Exhaust temperature rise

but stops color work
Abnormal engine sound
Excessive consumption
Low water temperature

soon.
Large engine vibration

Engine does not start.
Corrective action
Exhaust
Low L.O. pressure

Mixture with water
Much blow-by gas

Dilution by fuel oil
smoke
Pressure drop
Pressure rise
During idling
During work
Overheat
Ordinary
White
White
Black
Black
Much
None
Cause
Little
Improper clearance of intake/exhaust valve c c c c c c Adjust the valve clearance. (See 2.2.6(3) in Chapter2.)
Compression leakage from valve seat c c c c c c c c Lap the valve seat. (See 4.2.6 in Chapter4.)
Seizure of intake/exhaust valve c c c c c c c c c c c Correct or replace.
Blowout from cylinder head gasket c c c Replace the gasket. (See 4.2.2-11) in Chapter4.)
Seized or broken piston ring c c c c c c c c c c c Replace the piston ring. (See 4.4.2-5), 10) in Chapter4.)
Perform honing and use oversize parts.
Worn piston ring, piston or cylinder c c c c c c
(See 4.4.5-(1),(4) and 4.4.6 in Chapter4.)
Seized crankpin metal or bearing c c c c c c c Repair or replace.
Improper arrangement of piston ring joints c c c c Correct the ring joint positions. (See 4.4.4 point 6 in Chapter4.)
Reverse assembly of piston rings c c c Reassemble correctly. (See 4.4.4 point 6 in Chapter4.)
Worn crankpin and journal bearing c c c c c c Measure and replace. (See 4.4.5-(2) in Chapter4.)
Loosened connecting rod bolt c c c Tighten to the specified torque. (See 4.4.4-point 2 in Chapter4.)
Engine system
Foreign matter trapped in combustion chamber c c c c Disassemble and repair.

Excessive gear backlash c Adjust gear meshing. (See 4.3.4-point 2 in Chapter4.)
Worn intake/exhaust valve guide c c c Measure and replace. (See 4.2.5-(2) and 4.2.7 in Chapter4.)
Defective governor c c c c c Make adjustment.
Improper open/close timing of intake/exhaust valves c c c c c c Adjust the valve clearance. (See 2.2.6-(3) in Chapter2.)
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3. TROUBLESHOOTING

Insufficient Poor
Cooling Air
water intake
output color

Engine



soon.

Corrective action
Exhaust
Low L.O. pressure
Much blow-by gas

Mixture with water
smoke
Pressure drop
Pressure rise
During idling
During work
Overheat
Ordinary
Cause
White
White
Much
Black
Black
None
Little
Excessive cooling effect of radiator c c c Defective thermostat (kept closed) (See 2.7 in Chapter2.)
Defective thermostat (kept opened) (See 2.7 in Chapter2.)
Cooling water System
Insufficient cooling effect of radiator c c c

or slipping fan belt (See 2.2.2-(2) in Chapter2.)
Check water leakage from cooling water system.
Insufficient cooling water level c c c
(See 2.2.1-(1)(4)(5) in Chapter2.)
Cracked water jacket c c c Repair or replace.
Slackened fan belt c c c Adjust the belt tension. (See 2.2.2-(2) in Chapter2.)
Defective thermostat c c c c Check or replace. (See 2.7 in Chapter2.)
Improper properties of lube oil c c c c c c Use proper lube oil. (See 1.3.2 in Chapter1.)
Lubricating System
Leakage from lube oil piping system c c Repair.

Insufficient delivery capacity of trochoid pump c Check and repair. (See 5.5 in Chapter5.)
Clogged lube oil filter c c Clean or replace.
Defective pressure regulating valve c Clean, adjust or replace.
Insufficient lube oil level c c Add proper lube oil. (See 2.2.1-(3) in Chapter2.)
Too early timing of fuel injection pump c c c c Check and adjust. (See 2.2.7-(4) in Chapter2.)
Too late timing of fuel injection pump c c c c c c Check and adjust. (See 2.2.7-(4) in Chapter2.)
Improper properties of fuel oil c c c c c c Use proper fuel oil. (See 1.3.1 in Chapter1.)
Water entrance in fuel system c c c c c c c Drain from the fuel system. (See 2.2.3 (1)(2) and 2.2.5(1)(2) in Chapter2.)
Clogged fuel filter c c c Clean or replace. (See 2.2.5(2) in Chapter2.)
Air entrance in fuel system c c c Perform air bleeding. (See 2.2.3(3) in Chapter2.)
Fuel system
Clogged or cracked fuel pipe c c c Clean or replace.

Insufficient fuel supply to fuel injection pump c c c Check the fuel tank cock, fuel filter, fuel pipe, and fuel feed pump.
Uneven injection volume of fuel injection pump c c c c c c c c c Check and adjust.
Excessive fuel injection volume c c c c c c c Check and adjust.
Poor spray pattern from fuel injection nozzle c c c c c c c c c Check and adjust. (See 2.2.6(4) in Chapter2.)
Foreign matter trapped in the valve inside the priming pump.
Priming failure c
(Disassemble and clean.)
Clogged strainer at feed pump inlet c Clean the strainer.
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3. TROUBLESHOOTING

Insufficient Poor
Cooling Air
water intake
output color

Engine



soon.

Corrective action
Exhaust
Low L.O. pressure
Much blow-by gas

Mixture with water
smoke
Pressure drop
Pressure rise
During idling
During work
Overheat
Ordinary
Cause
White
White
Much
Black
Black
None
Little
Clogged air filter c c c c Clean. (See 2.2.4(5) and 2.2.5(3) in Chapter2.)
Air/Exhaust Gas System
Engine used at high temperatures or at high altitude c c c c Study output drop and load matching.
Clogged exhaust pipe c c c c Clean.
Starting motor defect c Repair or replace. (See Chapter8.)

Alternator defect c Repair or replace. (See Chapter9.)
Open-circuit in wiring c Repair. (See Chapter10.)
Electrical System
Battery voltage drop c Inspect and change the battery. (See 2.2.3(4) in Chapter2.)
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3. TROUBLESHOOTING
3.3 Troubleshooting by measuring compression pressure

Compression pressure drop is one of major causes of increasing blowby gas (lube oil contamination or
increased lube oil consumption as a resultant phenomenon) or starting failure. The compression pressure is
affected by the following factors:
1)Degree of clearance between piston and cylinder
2)Degree of clearance at intake/exhaust valve seat
3)Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use
of the engine.
A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air
cleaner element or worn or broken piston ring. Measure the compression pressure to diagnose presence of
any abnormality in the engine.
(1) Compression pressure measurement

method
1)After warming up the engine, remove the fuel injec-
tion pipe and valves from the cylinder to be mea-
Compression
sured. gage
2)Crank the engine before installing the compression
gage adapter.
*1) Perform cranking with the stop handle at the stop
position (no injection state).
*2) See 4.1.2(2)-No.18 in Chapter 4 for the compres-
sion gage and compression gage adapter. Measurement of the compression pressure
3)Install the compression gage and compression gage
adapter at the cylinder to be measured.
*1)Never forget to install a gasket at the tip end of the adapter.
4)With the engine set to the same state as in 2)*1),
crank the engine by the starter motor until the
compression gage reading is stabilized.
(2) Standard compression pressure

Engine compression pressure list (reference value)
Compression pressure Deviation among cylinders
at 250 min-1
Engine mode
MPa (kgf/cm2)
Standard Limit MPa (kgf/cm2)
2/3TNV70 3.24 ± 0.1 (33 ± 1) 2.55 ± 0.1 (26 ± 1) 0.2 to 0.3 (2 to 3)

3TNV76 3.43 ± 0.1 (35 ± 1) 2.75 ± 0.1 (28 ± 1) 0.2 to 0.3 (2 to 3)
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3. TROUBLESHOOTING
(3) Engine speed and compression pressure (for reference)
Compression pressure (kgf/cm2) 3TNV76

40 3.92
35
3.43
30 2.94
2/3TNV70
25 2.45
20 1.96
(MPa)
200 250 300 350 400
Engine speed (min-1)
(4) 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

•Air cleaner element •Clogged element •Clean the element.
1 •Broken element •Replace the element.
•Defect at element seal portion
•Valve clearance •Excessive or no clearance •Adjust the valve clearance.
2
(See 2.2.6(3) in Chapter 2.)
•valve timing •Incorrect valve clearance •Adjust the valve clearance.
3
(See 2.2.6(3) in Chapter 2.)
•Cylinder head gasket •Gas leak from gasket •Replace the gasket.
•Retighten the cylinder head bolts to the
4
specified torque.
(See 4.2.4 point 8 in Chapter 4.)
•Intake/exhaust valve •Gas leak due to worn valve •Lap the valve seat.
5 •Valve seat seat or foreign matter trapping (See 4.2.6 in Chapter 4.)
•Sticking valve •Replace the intake/exhaust valve.
•Piston •Gas leak due to scratching or •Perform honing and use an oversized part.
6 •Piston ring wear (See 4.4.5 and 4.4.6 in Chapter 4.)
•Cylinder
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4. Disassembly, inspection and reassembly of engines
4.1 Complete disassembly and reassembly
4.1.1 Introduction
Make preparation as follows before starting engine inspection and service:
1)Fix the engine on a horizontal base.
Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
2)Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain cooling water, lube oil and fuel.
3)Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as
to prevent any foreign matter from entering the engine.
Always wear glasses or other protectors when using compressed air or steam to prevent any foreign matter
from getting in the eyes.
[NOTICE]
• Any part which is found defective as a result of inspection or any part whose measured value does not sat-
isfy the standard or limit shall be replaced.
• Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of
use should be replaced even when the measured value then satisfies the standard or limit.
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4.1.2 Special service tools

Although main engine parts can be disassembled and reassembled only with standard service toots. It is
recommended to provide the following special service tools and measuring instruments for more efficient and
accurate work. correct measurement, diagnosis, and troubleshooting.
(1) Special tools

No. Tool name Applicable model and tool size Illustration
Valve guide tool
mm
(for extracting valve
guide) L1 L2 d1 d2
20 75 5.5 9.5
1
̪Locally manufactured
Valve guide tool

mm
(for inserting valve
guide) L1 L2 d1 d2
10 60 11 17
2
Tolerance: L10- 0.3
Connecting rod
mm
bushing replacer
(for removal / L1 L2 d1 d2
installation of 25 85 22 25
3 connecting rod
bushing) - -
Tolerance: d1- 00..36 d2 - 00..63
Valve spring
compressor
(for removal /
installation of valve yanmar code No.
4
spring) 129100-92630
Stem seal inserter

(for inserting stem
mm
seal)
d1 d2 㨐3 L1 L2 L3
15.0 21 12 11.0 65 4 or more
Tolerance: d1r0.2 L1r0.1

5
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No. Tool name Applicable model and tool size Illustration

Filter wrench
(for removal /
installation of
6 L.O. filter) Available on the market
Camshaft bushing
tool
(for extracting mm
camshaft bushing) L1 L2 d1 d2
18 70 45 48
7
- -
Tolerance: d1- 00..36 d2 - 00..63
Flex-Hone
mm
(For re-honing of
cylinder liner) Parts No. Cylinder bore
129400-92410 70-76
8
Piston insertion tool

(for inserting piston)
Yanmar code No. 955500-02476

9
̪The above piston insertion tool is applicable
to 60 –125 mm diameter pistons.
Piston ring replacer

(for removal /
installation of piston
ring)
10 Available on the market
Crankshaft pulley
installing tool
Locally manufactured
11 (for 4TNV94L)
(Refer to 4.3.6 in detail)
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(2) Measuring instruments

No. Instrument name Application Illustration
Measurements of shaft bending, and strain
and gap of surfaces
1 Dial gage
Measurements of narrow or deep portions

that cannot be measured by dial gage
2 Test indicator
For holding the dial gage when measuring

using a dial gage, standing angles
adjustable
3 Magnetic stand
For measuring the outside diameters of

crankshaft, pistons, piston pins, etc.
4 Micrometer
For measuring the inside diameters of

cylinder liners, rod metal, etc.
5 Cylinder gage
For measuring outside diameters, depth,

thickness and width
Vernier
6
Calipers
For measuring of valve sink
7 Depth micrometer
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For measuring valve spring inclination
and straightness of parts
8 Square
For measuring shaft bend
9 V-block
For tightening nuts and bolts to the

specified torque
10 Torque wrench
For measuring gaps between ring and

ring groove, and shaft joints during
assembly
11 Thickness gage
For checking water leakage
12 Cap tester
For checking concentration of antifreeze

and the battery electrolyte charge status
13 Battery coolant tester
For measuring injection spray pattern of

fuel injection nozzle and injection
pressure
14 Nozzle tester
For measuring temperatures abcdefghijklmn

abcd efghijk
abcdefghijklmn
abcdefghijklmn
abcdefghijklmnabcdefghijklmn abcdefghijklmn
abcdefghijklmnabcdefghijklmn
15 Digital thermometer
Float
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For measuring revolution by contacting

Contact type
the mortise in the revolving shaft
Revolving shaft
For measuring revolution by sensing the
Photoelectric
reflecting mark on the outer periphery of
type
16 Speedometer the revolving shaft
Reflection mark
Fuel
For measuring the revolution regardless
high-pressure
of the center or periphery of the revolving
pipe clamp
object.
type
For measuring resistance, voltage and

17 Circuit tester
continuity of electrical circuits
For measuring compression pressure

18 Compression gage kit
Yanmar code No. TOL-97190080
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4.1.3 Complete disassembly

Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application.
Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts have
been removed.
Step Removal Parts Remarks

1)Thoroughly remove sand, dust, dirt and soil from
the surface of the engine.
1
2)Drain cooling water and lube oil from the engine.
1)Remove exhaust manifold.

2 2)Remove intake manifold.
1)Close the fuel cock valve of the fuel tank. 1)If nozzle seat is left in the cylinder head, remove
2)Remove high-pressure fuel pipes. the cylinder head before extracting nozzle seat.
3)Remove fuel return pipe. 2)To prevent dust from entering fuel injection noz-
4)Remove fuel injection nozzles zles, fuel injection pump and high-pressure fuel
3
*) Fuel injection nozzle for Indirect injection pipes, seal their respective threads with a tape
system is screwed type. or the like.
3)Whenever extracting fuel injection nozzle,
replace nozzle protector with a new one.
1)Remove rocker arm cover assembly.
4
1)Remove valve rocker arm shaft assembly. 1)Attach a tag to a push rod for each cylinder No.
2)Remove push rods. to put the push rods in order.
2)Remove valve cap from the intake/exhaust valve
head.
5
3)Tappet can be removed at the same time when
push rod is extracted.
4)Attach a tag to a tappet for each cylinder No. to
put the tappets in order.
1)Remove fan mounting bolt, and then remove 1)Never turn down alternator vigorously toward
fan. the cylinder block. Otherwise, your finger may
2)Loosen a adjusting bolt for the V-belt adjuster, be nipped and alternator broken.
6
and then remove V-belt.
3)Remove alternator.
4)Remove the spacer for cooling fan and V-pulley.
1)Remove lube oil filter assembly.
7 2)Extract a dipstick from the oil dip-stick hole.
1)Disconnect fuel return pipes.

8 2)Remove fuel filter.
1)Disconnect cooling water pipe from the cooling

water pump.
9
2)Remove thermostat assembly.
3)Remove cooling water pump.
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1)Remove cylinder head tightening bolts. 1)Lay a cardboard or the like on the floor and
2)Remove a cylinder head assembly. place a cylinder head assembly on it so as not to
3)Remove a cylinder head gasket. damage the combustion surface.
2)The order of loosening the cylinder head tighten-
ing bolts.
Disassembly
Camshaft side
8 14 5
Fan side
2 12 9 3
4 10 11 1
6 13 7
Head bolt disassembly order
3 cylinder head
Disassembly
10 Camshaft side
8 5
Fan side
4 10 1
2 9 3
6 7
Head bolt disassembly order
2 cylinder head
3)To remove the intake/exhaust valves from cylin-

der head assembly, take the following steps.
a)Using a valve spring compressor (see
4.1.2(1) No.4 in Chapter 4), compress a valve
spring and remove a valve cotter.
b)Remove valve retainer and valve spring.
c)Remove intake valve and exhaust valve.
1)Remove crankshaft V-pulley clamping bolt. 1)Extract crankshaft V-pulley by hitting the bolt of
11
2)Using a puller, extract crankshaft V-pulley. the puller using a plastic hammer or the like.
1)Remove oil pan mounting bolts under a gear 1)Never fail to removes stiffner bolt at the center of
case. the gear case
12
2)Remove gear case mounting bolts. 2)When removing the gear case, carefully protect
3)Remove a gear case. oil seal from damage.
1)Remove the nut from fuel injection pump drive 1)Before removing fuel injection pump, make sure
gear. Extract the fuel injection pump drive gear of the position of the arrow on the pump body for
13
using a puller. adjusting fuel injection timing as well as the posi-
tion of the scribed line of the gear case flange.
1)Remove a lube oil pump.
14
1)Remove a starting motor from flywheel housing.

15
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1)Remove flywheel mounting bolts. 1)Carefully protect the ring gear from damage.
16 2)Remove a flywheel.
1)Remove a flywheel housing. 1)Carefully protect the oil seal from damage.
17 2)Remove a oil seal.
1)Put a cylinder block upside down and remove a 1)Carefully protect the combustion surface of the
oil pan and a spacer. cylinder block from damage.
18 2)Be careful not to drop tappets off when the cyl-
inder block is turned upside down, because the
tappet is cylindrical in shape.
1)Remove a idle gear shaft, and then remove a 1)Turn the cylinder block aside and carefully pre-
idle gear. vent tappet from jamming on the cam.
19 2)Remove a mounting bolt of thrust bearing 2)Preheat a camshaft gear and a camshaft
through the hole of the camshaft gear. Remove assembly to 180°-200° before removing them,
camshaft assembly. because they are shrink fitted.
1)Remove a gear case flange.
20
2)Remove a lube oil strainer.

21
1)While turning a crankshaft, place piston at the 1)Remove carbon deposits from the upper wall of
bottom dead center (BDC). the cylinder using fine sandpaper before
2)Remove the crankpin cap of a connecting rod. extracting pistons.
Take care not to damage the inner surface of
the cylinder.
22
2)Make sure that the cap No. of connecting rod
meets the cylinder No.
3)Take care not to drop the crankpin metal when
removing the crankpin cap of the connecting
rod.
1)Remove main bearing cap bolts. While shaking 1)Before extracting a crankshaft, measure the
a main bearing cap, remove it together with the side gap of it.
lower main bearing metal.
2)Extract a crankshaft, taking care not to damage
it.
3)Remove upper main bearing metal.
23
Dial gauge
Crankshaft
Apply a dial gauge to the end of crankshaft.

Force the crankshaft on both sides in the axial
direction to measure the thrust gap.
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Alternatively, insert a thickness gauge directly
between the base thrust metal and the thrust
surface of the crankshaft to measure the gap.
(Refer to 4.4.4 in Chapter 4.)
If the measured gap exceeds the limit, replace
the thrust metal with a new one.
23
2)Notice on the removal of thrust metal
a)When removing thrust metal, ascertain the
position and direction of thrust metal in relation
to the cap.
b)Make sure that the thrust metal groove is
outward to the cap.
1)Remove pistons and connecting rod assem- 1)To selectively remove a desired piston and con-
blies. necting rod assembly without extracting crank-
shaft, take the steps itemized below:
a)Remove carbon deposits from the upper wall of
the cylinder using fine sandpaper, taking care
not to damage the inner surface of the cylinder.
24
b)While turning the crankshaft, with the crankpin
cap removed, raise the piston up to the top dead
center (TDC).
c)Extract the piston/connecting rod assembly
while tapping the connecting rod at the large end
with the handle of a plastic hammer or the like.
1)Remove tappets.
25
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4.1.4 Precautions before and during reassembly

To reassemble engine components, reverse the procedure of disassembly. However, follow the precautions
below and the precautions from chapter 4 to chapter 7 particularly before and during reassembly.
(1) Cleaning the component

Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft. Ensure that they are
free from chips, dust, sand, and other foreign matter.
(2) Parts to be replaced during reassembly

Be sure to replace the following parts with new ones during assembly.
• Valve stem seal
• Head gasket packing
• Various copper packing, O-rings and gasket packing.
4.1.5 Adjusting operation

Make sure to perform adjusting operation after completing reassembly. Refer to section 2.8 in chapter 2 for
the operation procedure.
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4.2 Cylinder head: disassembly, inspection and reassembly

4.2.1 Components (2-valve cylinder head)
4.2.2 Disassembly procedure:

(2-Valve cylinder head)
Disassemble in the order of the numbers shown in the
illustration. Rocker arm cover
1)Remove the alternator assy. (Point1 of 4.2.4)

2)Remove the fan, pulley and V belt. Rocker arm suport
3)Remove the thermostat case. (Point2)
4)Remove the fuel filter and fuel oil piping. (Point3)
Rocker arm
5)Remove the oil level gage.
6)Remove the oil filter. (Point4)
7)Remove the fuel injection pipes. (Point5) Rocker arm
8)Remove the exhaust manifold assy. shaft
9)Remove the rocker arm cover Assy. (Point6)
Valve cap
10)Remove the rocker shaft assy, push rods and valve
Cotter
caps. (Point7) Spring holder
Valve spring
11)Remove the cylinder head assy and head gasket. Stem seal
Valve
(Point8) guide
12)Remove the fuel injection valves and fuel return
pipe. (Point9)
13)Remove the intake/exhaust valves, stem seals and Cylinder head
valve springs. (Point10)
14)Remove the rocker arms from the rocker shaft. Exhaust valve Suction valve
4.2.3 Reassembly procedure:

Reverse order of the disassembly procedure.
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4.2.4 Servicing points

Point 1
Adjust the V-belt tension
[Disassemble] inserting a bar
• Loosen the mounting bolt while supporting the alter-
nator.
Adjuster
Do not tilt the alternator toward the cylinder block in

haste since it may damage the alternator or pinch a
finger.
[Reassemble] Alternator
• The belt deflections A, B & C shall be checked
Tension adjustment
according to 2.2.2(2). in Chapter2.
[Reassemble]
• Replace the belt with a new one if cracked, worn or Radiator
fan
damaged. $
• Carefully prevent the belt from being smeared with oil Alternator
or grease.
Deflection
% #
V-belt
Crankshaft Press with thumb
V-pulley
Point 2
[Reassemble]
• Check the thermostat function. (See 2.7 in Chapter 2
for the check procedure.)
Point 3
[Reassemble]
• Replace the fuel filter element with a new one.
[Disassemble]
• Cover the fuel pipe opening with tape to prevent
intrusion of foreign matters.
Point 4
[Reassemble]
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it
with a filter wrench (see 4.1.2(1) No.6 in Chapter 4)
by 3/4 turn.
Point 5
[Disassemble]
• Cover the fuel injection pipe and pump inlets and out-
lets with tape or the like to prevent intrusion of foreign
matters.
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Point 6
Breather system (A reductor to intake air system of Diaphragm cover
Rocker arm cover
blowby gas) Spring
Center plate
Emitting blowby gas is harmful to natural Diaphragm
environment. Therefore blowby gas reductor is
adopted to TNV series engines as breather system.
Breather baffle
The system of model 3TNV76 is shown as a
representative of that breather system in the right Baffle plate
Intake maniforld
figure. Some of the combustion gas passes through
the clearance between the cylinder and the piston, Breather system componert
piston ring, and flows to the crankcase. This is said as
blowby gas. While it passes into the cylinder head and
the rocker arm cover, the blowby gas mixes with
splash oil, and becomes oil mist-blowby gas. Next, oil
is separated from mist-blowby gas with passing
through the baffle plate inside a rocker arm cover.
And it passes through a diaphragm assy and a intake
Blowby gas
manifold, and is reduced in the combustion chamber. Diaphragm
Pressure inside a crankcase is controlled by the Spring
Diaphragm cover
function of the diaphragm assy, and suitable amount Baffle plate
of blowby gas is reduced in intake air system. Rocker arm
cover
[Disassembly] Cylinder head
When a rocker arm cover is taken off, check whether
oil or the like enter the diaphragm space from a small
hole on the side of a diaphragm cover or not without Blowby gas flow
disassembling the diaphragm.
[NOTICE]
1)When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles
occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring,
much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect
by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.
When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and
so on, it is considered that oil leakage from the joint of a oil pan, a oil seal and so on will occur. When a
diaphragm is damaged, blowby is discharged from the breathing hole on the side of diaphragm cover, and
not reduced in the intake manifold. Therefore, be careful of the diaphragm trouble.
2)At lube oil replacement or lube oil supply
The amount of lube oil isn't to be beyond the standard upper limit (in the engine horizontality, the upper
limit mark of the dip stick). Since the blowby gas reductor is adopted, be careful that the amount of oil mist
may be inducted in the combustion chamber and the oil hammer sometimes may occur, when the lube oil
quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an
engine.
[Reassembly]
Replace the diaphragm with new one, when it is damaged.
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Point 7
[Disassemble] Disassembly
Camshaft side
• Keep the removed push rods by attaching tags show-
8 14 5
ing corresponding cylinder Nos.
Fan side
2 12 9 3
[Reassemble]
• Always apply oil to the contact portions of the push 4 10 11 1
6 13 7
rods and clearance adjusting screws.
Point 8 Head bolt disassembly order
3 cylinder head
[Disassemble] Assembly
• Loosen the cylinder head bolts in two steps in the Camshaft side
illustrated order. 7 1 10
Fan side
13 3 6 12
• Place the cylinder head assy on a paper board to pre-
vent the combustion face from any damage. 11 5 4 14
[Reassemble] 9 2 8
• Remove the head gasket with a new one. Head bolt tightning order
• Uniformly install the head bolts manually after apply- 3 cylinder head
ing oil on the threaded and seat portions Disassembly
Camshaft side
• They shall be tightened in two steps in the reverse of
8 5
Fan side
the order for disassembly. 4 10 1
N•m (kgf•m)
Tightening torque 2 9 3
First step 26.0 to 30.0 (2.7 to 3.1) 6 7
Second step 53.9 to 57.9 (5.5 to 5.9) Head bolt disassembly order
Point 9 2 cylinder head
Assembly
[Disassemble] Camshaft side
• Carefully remove the fuel injection valve so as not to 3 6
Fan side
leave the top end protector from being left inside the 7 1 10
cylinder. 2 8
9
[Reassemble] 5 4
• Replace the fuel injection valve protector with a new Head bolt tightning order
one.
Point 10 2 cylinder head
[Disassemble]
• When removing each intake/exhaust valve from the
cylinder head, use a valve spring compressor
(see 4.1.2.No.4 in Chapter 4) and compress the valve
spring and remove the valve cotter.)
• Keep each removed intake/exhaust valve after attach-
ing a tag showing the corresponding cylinder No.
• If cotter burr is seen at the shaft of each intake/ Valve spring compressor
exhaust valve stem, remove it with an oilstone and
extract the valve from the cylinder head.
[Reassemble]
• Replace the stem seal with a new one when an intake/exhaust valve is disassembled.
• Carefully install each valve after oil application so as not to damage the stem seal.
• Different stem seals are provided for the intake and exhaust valves. Do not confuse them since those for
exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, stem seal, valve spring, seat, and cotter, tap the head of the
valve stem lightly for settling.
• Do not forget to install the valve cap.
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4.2.5 Parts inspection and measurement

Strait-edge
(1) Cylinder head
Clean the cylinder head, mainly the combustion surface,
valve seats and intake/exhaust ports, remove carbon
deposit and bonding agent, and check the surface state.
(a)Appearance check
Check mainly discoloration and crack. If crack is
suspected, perform color check.
(b)Combustion surface distortion Thickness gage
Apply a strait-edge in two diagonal directions and on Distortion at combustion surface
four sides of the cylinder head, and measure distortion
with a thickness gage.
mm Depth micrometer
Standard Limit
Distortion 0.05 or less 0.15
(c)Valve sink
Measure with the valve inserted to the cylinder head.
mm
Standard Limit
Intake 0.4 to 0.6 0.8 Valve sink
Exhaust 0.4 to 0.6 0.8
Valve sinking depth
Valve sink depth
(d)Seat contact
Apply a thin coat of minimum on the valve seat. Insert
the valve in the cylinder and push it against the seat to
check seat contact.
Standard: Continuous contact all around
Seat
Valve seat contact
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(2) Valve guide

Measuring positions
Mainly check damage and wear on the inside wall. Apply
supply part code when replacing the part.
a b c
Service part code A B
119717-11800
Valve guide inside diameter

Valve stem clearance
Part name Place Standard Limit
Guide I.D. 6.000 to 6.012 6.08
Intake valve Stem O.D. 5.960 to 5.975 5.90
Clearance 0.025 to 0.052 0.16
Guide I.D. 6.000 to 6.012 6.08
Exhaust valve Stem O.D. 5.945 to 5.960 5.90
Clearance 0.040 to 0.067 0.17
(3) Intake/exhaust valve

Measuring positions
Mainly clean and check damage and wear at the valve
stem and seat.
(a)Seat contact: See (1) (d) above.
(b)Stem outside diameter: See (2) above.

Valve stem outside diameter
(c)Valve head thickness
mm
Part Standard Limit
Intake 0.9 to 1.1 0.50
Exhaust 1.0 to 1.2 0.50
(d)Valve stem bend

mm
Thickness
Limit 0.01
(e)Overall length Valve head thickness

mm
Standard Limit
Intake/ Exhaust 86.8 to 87.2 86.6 Length
Stool
Valve bend and length
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(4) Valve spring

Mainly inspect damage and corrosion.
mm
Free length standard Inclination limit
37.8 1.3 Free length
Valve spring
Inclination
Valve spring
(5) Valve rocker arm

Mainly inspect valve head cap contact surface, inside
surface defects and wear.
Slight surface defects shall be corrected with an
oilstone.
mm
Items Standard Limit
Arm hole diameter 12.000 to 12.020 12.07
Shaft O.D. 11.966 to 11.984 11.94
Clearance 0.016 to 0.054 0.13
Rocker arm hole diameter
(6) Rocker arm shaft

Mainly inspect seizure and wear at the surface in sliding
contact with the arm. The rocker shaft diameter shall be
as specified in (5) above.
Rocker arm shaft outside diameter
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(7) Push rod

Mainly inspect the surface in contact with the tappet and
adjusting screw. Slight defects shall be corrected with an
oilstone.
Bend limit 0.03 mm
(8) Valve clearance adjusting screw Thickness gage

Mainly inspect the surface in contact with the push rod.
Slight defects shall be corrected with an oilstone.
(9) Rocker arm spring
Mainly inspect surface defects and corrosion.
Push rod bend
4.2.6 Valve seat correction

[NOTICE]
Always check the oil clearance between the valve and
valve guide before correcting the valve seat. If it
exceeds the limit, replace the valve or valve guide first
to make the clearance satisfy the standard. After
correction, wash the valve and the cylinder head
sufficiently with diesel fuel oil to remove all grinding
powder or compound.
1)If the seat surface is slightly roughened: perform
[A] and [B] below.
Seat angle
[A]:Lap the valve and seat with a mixture of valve 150q
40q
compound and lube oil. Seat width
[B]:Lap with lube oil only.

2)If the seat is heavily roughened but the width is
almost normal, correct with a seat grinder or seat
cutter first. Then perform lapping [A] and [B]. Seat cutter
intake Exhaust Cylinder head correction angle

Seat cutter angle 120 90
3)If the seat is heavily roughened and the width is

much enlarged, grind the seat inner surface with a Grinder
seat grinder whose center angle is 40°, then grind
the seat outer surface with a grinder whose center
angle is 150° to make the seat width match the stan-
dard. Then perform seat correction as described in
2), and then carry out lapping [A] and [B].
1 2
Grinding wheel angle Grindstone
40 150
Seat grinder
(R.1)
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4.2.7 Valve guide replacement

1)Use a valve guide extraction tool(4.1.2(1) No.1 in
Valve guide extracting
Chapter 4) and extract the valve guide from the cyl- & inserting tool
inder head.
2)Put liquid nitrogen or ether (or alcohol) with dry ice
added in a container and put the valve guide for Projection
replacement in it for cooling. Then insert it in with a Cylinder head

valve guide inserting tool (Refer to No.2 of 4.1.2(1) in
Chapter 4).
Valve guide
Do not touch the cooled valve guide with bare hands

to avoid skin damage. Valve guide replacement
3)Check the inside diameter and finish to the standard
inside diameter as required with a reamer.
4)Check the projection from the cylinder head.
Projection (mm)
9.8 to 10.0
Valve stem seal inserting tool
4.2.8 Valve stem seal replacement

Always use a new valve stem seal after the intake/
exhaust valve or valve stem seal is disassembled. Since
the one for the exhaust valve is marked with yellow
Stem seal
paint, do not confuse the intake and exhaust valves.
[NOTICE] Valve guide

Painting is applied to the springs of both intake/ Cylinder head
exhaust valve stem seals for the distinction because
both parts are different. Be careful because it causes
oil down when the attachment of intake/ exhaust is Stem seal insertion
mistaken.
Distinction coloration for the intake is “white” and for
the exhaust “black”.
1)Apply lube oil to the lip.

Stem seal
2)Push with the inserting tool (Refer to No.5 of 4.1.2(1)
in Chapter 4) for installation.
3)Measure and check the projection of valve stem seal
Clearance
to keep proper clearance between valve guide and

stem seal.
Projection (mm) Valve guide
10.9 to 11.2
Valve guide projection

Stem seal projection
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4.3 Gear train and camshaft
4.3.1 Components
ԠFlywheel
Flywheel hausing
ԢGear case
ԟStarter ԝIdle gear
ԡCamshaft
ԙCooling water pump

ԜFuel injection pump
Crankshaft gear
Pump flange
Don't disassemble! Fuel pump drive gear
Flange bolt
ԛGear case cover
ԣOil seal
Note) This figure shows the 3TNV76. ԚCrankshaft pulley

Disassemble in the order of the numbers in the illustration.
1)Perform steps 1) to 12) of the cylinder head disassembly procedure.
2)Remove the cooling water pump.
3)Remove the crankshaft pulley. (See Point 1 of 4.3.4)
4)Remove the gear case. (See Point 2 of 4.3.4)
5)Remove the fuel injection pump. (See Point 3 of 4.3.4)
6)Remove the idle gear assy. (See Point 4 of 4.3.4)
7)Remove the PTO drive gear. (See Point 5 of 4.3.4)
8)Remove the starting motor.
9)Remove the flywheel. (See Point 6 of 4.3.4)
10)Remove the camshaft assy. (See Point 7 of 4.3.4)
11)Remove the gear case flange. (See Point 8 of 4.3.4)
12)Remove the oil seal from the gear case. (See 4.3.6)

Reverse of the disassembly procedure.
(R.1)
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Point1
[Disassemble]
• Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley set bolt. When
removing the pulley using the gear puller, use a pad and carefully operate so as not to damage the thread.
Set the gear puller securely to prevent the pulley from being damaged.
[Reassemble]
• When installing the crankshaft pulley, apply lube oil to the set bolt to tighten and carefully assemble so as
not to damage the oil seal.
[NOTICE]
Clean by wiping off any oil on both taper surfaces of crankshaft and pulley using detergent.
N•m (kgf•m)
Material of pulley Tightening torque
FC250 83.3 to 93.3 (8.5 to 9.5)
S48C 113 to 123 (11.5 to 12.5)
Point2
Fuel injection pump drive gear
[Reassemble]
• When installing the gear case, do not forget to install
the two reinforcing bolts at the center.
• Measure the backlash of each gear.
C
B
C
B
mm
Standard Limit A
Crankshaft gear, Camshaft gear
Idle gear A
Camshaft gear,
0.06 to 0.12 0.14
Fuel injection pump gear,
Idle gear, PTO gear, Crankshaft gear
• Apply sealant after checking that oil doesn't stick on either surface of the cylinder block and the gear case
flange and also the gear case flange and the gear case. Install the gear case by correctly positioning the
two dowel pins.
Point3 (Refer to 7.2.5 in chapter 7)
[Disassemble]
• Remove the mounting nut of the fuel injection pump
Fuel injection pump
drive gear, remove the gear using the gear puller, and
Flange
remove the fuel injection pump. When extracting the
Fuel injection
gear using the gear puller, use a pad at the shaft and drive gear
carefully operate so as not to damage the thread. Flange bolt
Spring
[NOTICE] washer
Be sure to remove a flange and a drive gear with a
Don't disassemble
pair without loosening flange installation bolts.
[Reassemble] Pump drive gear nut
• Tightening torque for fuel pump drive gear nut
(without lube. Oil)
N•m (kgf•m)
Tightening torque
58.8 to 68.8 (6 to 7)
(R.1)
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Point4
Fuel injection pump drive gear
[Reassemble]
• Assemble crankshaft gear A, fuel injection pump
drive gear B and camshaft gear C at the same time
by aligning with idle gear A, B and C marks.
B
C
B
• Install the idle gear shaft with the oil hole facing
upward. A
Point5 Camshaft gear
Idle gear A
[Reassemble]
• Install the PTO drive gear with its inner spline side Crankshaft gear
facing the flywheel.
Point6
[Disassemble]
• Install a bolt as a handle in the hole at the end face of the flywheel and remove carefully so as not to dam-
age the ring gear.
[Reassemble]
Flywheel mounting bolt: apply lube oil
N•m (kgf•m)
Tightening torque
80.4 to 86.4 (8.2 to 8.8)
Point7
Camshaft gear
[Disassemble]
• Measure the camshaft side gap. Thrust metal
mm
Item Standard Limit
Side gap 0.05 to 0.15 0.25
• If the measured side gap exceeds the limit, replace

the thrust metal.
[Disassemble]
• Since the camshaft gear is shrink-fit, heat it to
180 °C-200 °C for extraction.
Side gap
• For camshaft removal, raise the engine with its
mounting flange at the bottom. After removing the Camshaft side gap
thrust metal mounting bolt from the camshaft gear
hole, extract the camshaft carefully so as not to dam-
age the bearing bushing.
• Rotate the camshaft a few turns before extracting it to prevent the tappet from being caught by the cam.
• After removing the camshaft, set the engine horizontal and fix it on the base.
Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the
horizontal position. Proceed carefully so as not to lose balance.
Point8
[Reassemble]
• Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case.
• Apply sealant (code No.977770-01212) and install the gear case by matching the two dowel pints.
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Dial gage
(1) Camshaft
Mainly check the contact between the tappet and cam
contact surface, bearing seizure and wear, and gear
damage.
(a)Shaft bend measurement
Support the camshaft with V blocks. Rotate the camshaft
V-block
and measure the distortion at the center of the camshaft
and at each journal with a dial gage. Half of the distortion Camshaft bend
is the bend.
mm
Item Standard Limit
Bend 0 to 0.02 0.05 Micrometer
Cam height
(b)Intake/exhaust cam height measurement
mm
Model Standard Limit
2/3TNV70 34.535 to 34.665 34.29
3TNV76 34.135 to 34.265 33.89 Cam height
(c)Camshaft outside diameter and bearing hole diameter measurement Measure the camshaft
outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the
measured camshaft outside diameter from the camshaft metal inside diameter after insertion to
the cylinder measured with a cylinder gage.
mm
Place Item Standard Limit
Metal I.D. 40.000 to 40.075 40.150
Gear side Camshaft O.D. 39.940 to 39.960 39.905
Oil clearance 0.040 to 0.135 0.245
Metal I.D. 40.000 to 40.025 40.100
Intermediate position Camshaft O.D. 39.910 to 39.935 39.875
Metal I.D. 40.000 to 40.025 40.100
Flywheel side Camshaft O.D. 39.940 to 39.960 39.905
(R.1)
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(2) Idle gear
Shaft outside diameter
Metal inside diameter

Mainly check the metal seizure and wear, and gear Idle gear
Shaft
damage.
Shaft outside diameter and metal inside diameter
measurement
Idle gear
M
mm
Item Standard Limit
Shaft outside diameter 36.950 to 36.975 36.900
Metal inside diameter 37.000 to 37.025 37.075
Clearance 0.025 to 0.075 0.175
(3) PTO drive gear

Mainly check sticking of bearings on both sides, gear
damage and looseness, and gear shaft damage and
wear.
4.3.6 Oil seal replacement

1)Replace the oil seal with a new one when the gear
Gear case
case is disassembled. Crankshaft
pulley
Extract the used oil seal.
2)Insert a new oil seal by using the oil seal insertion
tool on the position of the gear case end face. (Refer
to the right figure.)
3)Apply lithium grease to the oil seal lips.
4)When wear is found on the oil seal contact part of a
crankshaft pulley, replace the pulley with a new one.
Carefully install the pulley so as not to damage the
oil seal.
Oil seal
Replacement of a gear case oil seal
4.3.7 Camshaft bushing replacement

Replace the bushing using the special service tool (Refer to No.7 of 4.1.2(1) in Chapter 4).
(R.1)
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4.4 Cylinder block

4.4.1 Components
ԡPiston ring
Flywheel ԜPiston & Connecting rod
ԝFlywheel hausing
Gear case flange

4KPIIGCT
Oil seal
ԠTappet
Camshaft
Oil filter
ԛOil suction pipe
ԞBearing cap ԟCrankshaft

Crankshaft gear
ԚOil pan spacer
ԚOil pan
Note) This figure shows the 3TNV76
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Disassemble in the order of the numbers in the illustration.
1)Perform steps 1) to 15) in the cylinder head disassembly procedure.
2)Perform steps 1) to 12) in the gear train disassembly procedure.
3)Remove the oil pan and the spacer. (See Point 1 of 4.4.6)
4)Remove the lube oil suction pipe.
5)Remove the piston w/rod. (See Point 2 of 4.4.6)
6)Remove the mounting flange. (See Point 3 of 4.4.6)
7)Remove the bearing metal caps. (See Point 4 of 4.4.6)
8)Remove the crankshaft. (See Point 5 of 4.4.6)
9)Remove the tappets.
10)Remove the rings from the piston. (See Point 6 of 4.4.6)
11)Remove the oil seal from the flywheel housing. (See 4.4.8)

Reverse of the disassembly procedure.
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Point1: Oil pan
[Disassemble]
• Sealant is applied to the oil pan mounting surface on
the block. Carefully operate so as not to damage or
distort the bonding surface.
[Reassemble]
• Apply sealant (code No.977770-01212) before reas-
sembly.
Point2: Piston w/rod Crankshaft
[Disassemble] Thickness gage
• Measure the connecting rod side gap.
mm
Standard Connecting rod side gap
0.20 to 0.40
• Carefully remove the carbon deposit on top of the cyl-

inder so as not to damage the inner side of the cylin-
der.
• Set the piston at the BDC position and remove the
connecting rod cap. Then set the piston at the TDC
position, and push the connecting rod big end with
the wooden shaft of a hammer. Proceed carefully so
as not to cause the cylinder block catch the rod big
end. Set the rod caps and crankpin metals in their
correct combinations.
[Reassemble]
• Apply oil especially carefully to the sliding contact
surfaces of the pistons, rods and rings.
• Use the piston insertion tool (see 4.1.2(1) No.9 in
Chapter 4) to insert each piston w/rod in the cylinder
block and install the bearing metal cap.
Rod bolt tightening torque
N•m (kgf•m)
Standard (apply lube oil)
22.6 to 27.5 (2.3 to 2.8)
Point3: flywheel housing

[Disassemble]
Place the engine on a stable base with the cylinder block upper surface facing down, and remove the
flywheel housing carefully so as not to damage the combustion surface.
[Reassemble]
Apply sealant (code No.977770-01212) and install flywheel housing by matching the two dowel pins. After
assembly, raise the engine with its flywheel housing on the bottom side.
Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully
operate so as not to lose balance.
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Point 4: Journal bearing cap

[Disassemble]
• Before removing the journal bearing, measure the
crankshaft side gap. Measure it in either method
because there are the next two methods.
1)Install a dial gage on the cylinder block, and move a
crankshaft in front and back, and measure the side
gap as shown in the right figure.
Side gap measurement 1

2)Put a thickness gauge in the clearance between
Cylinder block
thrust metal and crankshaft directly, and measure it.
mm Crankshaft
Side gap standard Limit Standard
0.13 to 0.23 0.28 width Thrust metal
Thrust
[Reassemble] face
Bearing cap
• If the side gap exceeds the standard, replace the
thrust metal with an oversized one.
• 0.25 mm Oversized thrust metal (0.25 DS) Thickness gauge
mm
Thrust metal assy code Standard thickness
119810-02940 2.055 to 2.105 Side gap measurement2
[Disassemble]
• Remove the bearing caps, cap bearings, and thrust Main bearing cap
Flywheel side
Block side main

metals. Place each thrust metal with identification of bearing metals
the position and direction. Cap side main
bearing metals
• Carefully install each thrust metal so that the grooved
one is positioned away from the cap.
[Reassemble]
Gear side
• Do not confuse the upper and lower main bearing

metals. The upper main bearing metal (block side) Thrust metals
has an oil hole, and the lower one does not. The Main bearing cap bolt
“wheel and arrow” marks on the cap shall face the fly-
Main bearing
wheel.
Main bearing cap bolt tightening torque (apply lube oil)
N•m (kgf•m)
Standard
75.5 to 81.5 (7.7 to 8.3)
Flywheel side Gearcase side
(9
(R.1)
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Point5: Crankshaft
[Disassemble]
• Remove the crankshaft. Remove each main bearing metal upper (block side) and pair it with the metal cap
side lower metal.
Carefully prevent the bearing from being damaged or finger injury when removing the crankshaft because it
is heavy.
Point 6: Piston pin and rings
[Disassemble]
• Using the piston ring replacer (see 4.1.2(1) No.10 in Make the punched manufacturer's
mark face upward.
Chapter 4), remove the piston rings.
• Remove the circlip and remove the piston pin by
Piston ring
pushing it out.
[Reassemble] Oil ring joint
• Install each piston ring on the piston, with the
punched manufacturer’s mark facing upward. 120q
Second 120q
[Reassemble] ring joint
120q
• The piston ring joints shall be staggered at by 120 °C Top ring joint
intervals. Do not position the top ring joint vertical to
the piston pin. The coil expander joint shall be oppo-
site to the oil ring joint.
Expander joint
Ring joints
[Reassemble]
Piston ID mark
• When installing the piston pin to the rod and piston,
Camshaft side
the punched match mark on the big end of the con-

Nozzle side
necting rod shall be opposite to the size mark on the

piston top.
[Reassemble]
• Install the piston in the cylinder block. The embossed (Flywheel side)
mark on the connecting rod shall be on the flywheel Cylinder size mark
side.
Piston ID mark
Embossed mark
(Flywheel side)
Match mark
( Assembly direction of connecting

rod and piston )
(R.1)
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(1) Cylinder block

Especially clean head surface, cylinder bores and oil
holes, and check the below items after removing any
carbon deposit and bonding agent.
(a)Appearance inspection
Check if there is any discoloration or crack. If crack is
suspected, perform color check. Sufficiently clean the oil
holes and check they are not clogged.
(b)Cylinder bore and distortion
Measure at 20 mm below the crest of the liner, at 20 mm
from the bottom end and at the center in two directions A
Cylinder bore
and B as shown in the below figure.
Roundness:
Roundness is found as follows though it is the simple a 20mm
method. Measure cylinder diameters of the A direction A
and the B direction on each section of a, b and c.

b
Roundness is the maximum value among those
B
difference values.
Measure in two directions
Cylindricity: c A and B at points a,b and c.
20mm
Cylindricity is found as follows though it is the simple
method. Cylinder bore measurement positions
Measure cylinder diameters of a, b and c sections in
the A direction, and calculate the difference in
maximum value and minimum value of the measured
diameters.
In the same way measure and calculate the difference
in the B direction.
Cylindricity is the maximum value between those
difference values.
mm
Item Model Standard Limit
2/3TNV70 70.000 to 70.030 70.200
Cylinder inside diameter
3TNV76 76.000 to 76.030 76.200
Roundness
Cylinder bore all TNV 0.01 or less 0.03
Cylindricity
(R.1)
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(c)If the limit is exceeded or any surface defect is

found, repair by boring and honing. Use an
oversized piston (and new piston rings) as
required.
Oversized piston (0.25 mm) mm

Model Code No. Standard
2/3TNV70 ø 70.250
3TNV76 119717-22090 ø 76.250
Piston ring for oversized (0.25 mm)

Model Piston ring code No. (Assy)
2/3TNV70
3TNV76 119717-22550
Cylinder boring dimension mm

Model Boring dimension
2/3TNV70 ø 70.250-70.280
3TNV76 ø 76.250-76.280
(2) Crankshaft
Mainly check seizure and wear of the crankpins and
journals. Since the crankshaft gear is shrink-fitted, heat
to 180 to 200 °C when extraction is necessary.
(a)Shaft portion color check
After washing the crankshaft, inspect it by means of
color check or a magnaflux inspector. Replace it if
cracked or heavily damaged. Slight defects shall be
corrected by grinding.
Inspection by color check
(b)Crankshaft bend
Support the crankshaft journals at both ends with V-
blocks. Use a dial gage and measure the run-out at the Bend
center journal while rotating the shaft to inspect the
bend. The bend is half of the run-out value.
Limit 0.01 mm or less
Deflection
Dial gage
V-block V-block
(R.1) Crankshaft bend measurement

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(c)Crankpin and journal measurement

Measure the outside diameter, roundness and taper at
each crankpin and journal.
Correct by grinding if unevenly wear, roundness
exceeding the limit or insufficient outside diameter is
found. Replace if the defect is excessive.
Crankpin
If a clearance is necessary, measure the inside
diameter by following (5) d) " Rod big end
measurement ", and calculate it.
mm
Item Standard Limit
Pin outside diameter 41.952 to 41.962 41.902
R
Roundness 0.01 or less 0.02 R
If the oil clearance exceeds the limit, use an

undersized bearing.
Crankshaft
Undersized bearing (0.25 mm) journal
Code No.(assy) Crankpin
119717-23610 Measuring position of the crankpin

and crank journal
Pin machining dimension mm
Pin machining dimension
ø 41.702 to 41.712
Crank journal
mm
Item Standard Limit
Journal O.D. 46.952 to 46.962 46.902
Roundness 0.01 or less 0.02
If the clearance limit is exceeded, use an undersized

bearing and machine the crank journal into the value
of the below table.
Undersized bearing (0.25 mm)

Code No. (assy)
119717-02870
Crankshaft Journal machining dimension

mm
Journal machining dimension
ø 46.702 to 46.712
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Dimension R and finishing precision of crankshaft

journal and pin
As for grinding processing of journal and pin, machine Super
polishing
it by using the grinding wheel of the dimension R of Ry=0.8S
Super
below table. polishing
Thrust
face
Ry=0.8S
mm
R
R
R
Finishing precision standard of dimension R
R
0 .3
R
0
3.5
Crank Pin Crank Journal
Surface finishing precision standard on journal and
Crankshaft R machining
pin:
Ry=0.8S super polishing
Surface finishing precision standard on the thrust side
1.6
of crankshaft arm:
[NOTICE]
1)lf the oil clearance is excessive though the thickness
of the journal and crankpin metals are normal or if
partial uneven wear is observed, re-grind the crank-
shaft and use an undersized metals.
2)lf rust or surface roughening exists on the rear side
of the metals, coat it with blue or minimum.
Then assemble the crankpin metal to the connecting
rod, and tighten the rod bolt to the specified torque to
check the metal for contact. If the contact surface
occupies 75 % or more, the metal is normal. If the
contact surface is insufficient, the metal interference
is insufficient. Replace the metal with a new stan-
dard one.
(3) Thrust metal inspection

(a)Inspect any damage or wear.
(b)Measure side gap and thrust metal thickness
Side gap and thrust metal thickness mm
Side gap Thrust metal thickness
Standard Limit Standard Limit
0.111 to 0.250 0.30 1.930 to 1.980 1.850
If the side gap is exceeded, use an oversized thrust

metal.
Oversized metal (0.25 mm) mm
Code No. (assy) Standard thickness
119810-02940 2.055 to 2.105
(R.1)
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(4) Piston
Especially clean the combustion surface, circumference,
ring grooves and piston pin bosses, and check after
removing any carbon deposit. Any burr at a ring groove
or snap ring groove shall be removed. If crack is
suspected, inspect by color check.
(a)Piston outside diameter measurement
Measure the long diameter at H mm from the bottom end
of the piston of the oval hole in the vertical direction to Measurement
position
the piston pin hole.
H mm
The clearance between a piston and a cylinder is
calculated by using a measured piston outside diameter Piston outside diameter
and a cylinder inside diameter measured according to
4.4.5(1) (b).
mm
Clearance between Measurement position
Model Piston outside diameter Limit
piston and cylinder (H)
2/3TNV70 69.960 to 69.990 69.915 0.030 to 0.050 22 to 25
3TNV76 75.955 to 75.985 75.910 0.035 to 0.055 22 to 25
If the piston outside diameter exceeds the limit, replace the piston with new one.
If necessary, use an oversized piston. (Refer to the tables of oversized pistons, oversized piston rings and
cylinder boring dimension in 4.4.5(1)(c).)
Selective pairing of cylinder and piston

Piston must be paired with cylinder according to the below table. The size mark of a piston is shown on
the top surface of the piston and the size mark of a cylinder block is shown on the non-operating side of
the cylinder block. The service parts of pistons are provided.
(mm)
Piston outside diameter. D2
+0.015 max. below+0.005 below 0 below -0.005
Tolerance
+0.005 min. 0 min. -0.005 min. -0.015 min.
Size mark L ML MS S
+0.030 max.
L c c ° °
Cylinder +0.020 min.
inside below +0.020
M ° c c °
diameter +0.010 min.
D1 below +0.010
S ° ° c c
0 min.
(mm)
Model Cylinder inside diameter Piston outside diameter.
D1 D2
2/3TNV70 70 69.975
3TNV76 76 75.970
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(b)Piston pin and piston pin hole measurement

Measure the outside diameter of piston pin and the Measure at positions a,b and c
in directions A and B.
inside diameter of piston pin hole. Calculate the
a b c
clearance between piston pin and piston pin hole. If any A
data exceeds the limit, replace the part with a new one.
mm B
Item Standard Limit
Piston pin outside diameter
Pin I.D. 22.000 to 22.009 22.039
Pin O.D. 21.995 to 22.000 21.965 Measure at positions a and b
in directions A and B.
Clearance 0.000 to 0.014 0.074
a b A
Piston pin hole
(c)Piston ring, ring groove and end clearance

measurement
• Except for the top ring, to measure the piston ring Top ring
groove width, first measure the width of the piston
ring. Then insert the piston ring into the ring. Then
Second ring
insert the piston ring into the ring groove. Insert a
thickness gage in between the piston ring and groove
to measure the gap between them. Obtain the ring Oil ring
groove width by adding ring width to the measured
side clearance.
• To measure the end clearance, push the piston ring
into the sleeve using the piston head, insert a thick- Ring components
ness gage in end clearance to measure. The ring
shall be pushed in to approx. 30 mm above the bot-
tom end of the cylinder. For the top ring, measure
only the piston ring joint end clearance in normal Head surface
state.
Cylinder block
Pistonring
Approx.
30mm
Width
Joint end clearance

Thickness
Measuring side clearance Ring joint end clearance measurement
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Piston ring dimension mm

Model Part Item Standard Limit
Ring groove width 1.550 to 1.570 -
Ring width 1.470 to 1.490 1.450
Top ring
Side clearance 0.060 to 0.100 -
End clearance 0.15 to 0.30 0.39
Ring groove width 1.540 to 1.560 1.660
Ring width 1.470 to 1.490 1.450
2/3TNV70 Second ring
Side clearance 0.050 to 0.090 0.210
Ring width 2.970 to 2.990 2.950
Oil ring
Ring width 1.470 to 1.490 1.450
Top ring
Ring width 1.470 to 1.490 1.450
3TNV76 Second ring
Ring width 2.970 to 2.990 2.950
Oil ring
End clearance 0.20 to -0.45 0.540
(R.1)
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(5) Connecting rod

(a)Appearance inspection
Inspect the portion near the boundary of the chamfered
m
portion and I-beam section of the big and small ends of 0m
10
the connecting rod as well as the portion near the oil m
0m Parallelism
hole of the bushing at the small end for cracks, 10
deformation, and discoloration.
(b)Twist and parallelism measurement Use a
connecting rod aligner and measure the twist
and bend. Twist
mm
Standard Limit Mandrel
Item
dimension dimension
Twist and 0.03 or less
0.08
parallelism per 100 mm Twist and parallelism measurement
Connecting rod
aligner
Twist measurement using

a connecting rod aligner
(c)Rod small end measurement

Measure the pin outside diameter according to
4.4.5.(4)(b) described above.
mm
Item Standard Limit
Piston pin metal I.D. 22.025 to 22.038 22.068
Pin O.D. 21.991 to 22.000 21.963
Clearance 0.025 to 0.047 0.105
Cylinder gage
If the metal is to be replaced because the oil clearance
exceeds the limit, use spare part.
Service part code
119717-23910
Connecting rod small end
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(d)Rod big end measurement

Measure the crankpin outside diameter.
The oil clearance is calculated as the difference in the
crankpin outside diameter and the crank pin metal inside
diameter (refer to 4.4.5.(2)(c) ).
Replace the crankpin metal if a clearance becomes
close to the limit value in the table below.
If wear and unevenly wear on the crankpin is found,
correct by grinding the crankpin and apply the
undersized bushing (refer to 4.4.5.(2)(c) ) Cylinder gage
[NOTICE]
When measuring the inside diameter of the rod big
end, install the bushing in the rod big end not to
mistake top and bottom of the crankpin metal and
fasten the rod bolts by the standard torque shown in
the table.
Tightening torque of rod bolt N•m (kgf•m) Crankpin metal I.D. measurement
Lube oil application
Tightening torque (threaded portion,
and bearing seat surface)
22.6 to 27.5 (2.3 to 2.8) Lube. oil applied
Standard of rod big end mm
Item Standard Limit
Crankpin O.D. 41.952 to 41.962 41.900
Metal I.D. 41.982 to 42.002 -
Metal thickness 1.503 to 1.509 -
Clearance 0.020 to 0.058 0.120
(6) Tappet
Mainly check the tappet contact surface with the cam
and push rod. Slight surface defects shall be corrected
with an oilstone.
Tappet stem outside diameter measurement
The outside diameter of the tappet stem is measured by
a micrometer.
The clearance is calculated from the measured tappet Abnormal contact Normal contact
surface surface
hole and the measured stem diameter.
Tappet
mm
Item Standard Limit
Tappet hole I.D. 21.000 to 21.021 21.041
Stem O.D. 20.927 to 20.960 20.907
Clearance 0.040 to 0.094 0.134
(Tappet stem outside diameter measurement)
(R.1)
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4.4.6 Cylinder bore correction

(a)Slight uneven worn, flawed, etc. shall be
corrected by honing only. If the cylinder is Flex-Hone
unevenly worn partially, flawed or otherwise
damaged and cannot be repaired simply by
honing, rebore the cylinder first and then hone.
Electric drill
See 4.4.5.(1)(c) for the boring dimension.
(b)Items to be prepared for honing Lube oil Diesel oil
• Flex-Hone (see No.8 of 4.1.2 in Chapter 4) 50% 50%
• Electric drill
• Honing fluid (50:50 mixture of lube oil and diesel oil) Flex-Hone Honing fluid
(c)Apply the honing fluid to the Flex-Hone and turn Items to be prepared for honing
the electric drill at 300 to 1200 min-1. Then insert
the Flex-Hone into the cylinder bore while turning
it, and move it up and down for about 30 sec. to
obtain a honing mark with a cross hatch angle of
30 to 40°.
[NOTICE]
1)Avoid faster revolution than 1200 min-1 since it may 㨪40q
30q
cause breakdown.
2)Do not insert or extract the Flex-Hone in stopped
state because the cylinder will be damaged.
Honing cross hatch
4.4.7 Piston pin metal replacement

Replace metal by using the special service tool (see No.3 of 4.1.2 in Chapter 4).
4.4.8 Oil seal replacement (Flywheel housing side)

1)Replace an oil seal with new one when a flywheel
housing is removed. Extract the used oil seal. Cylinder block
Flywheel
2)Insert a new oil seal by using the oil seal insertion housing
tool on the position of the flywheel housing end face.
Oil seal
(Refer to the right figure.)
3)Apply lithium grease on the lip. Crank shaft
4)Install the flywheel housing on the cylinder block with
being careful not to damage the oil seal.
Replacement of a flywheel housing oil seal
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5. Lubrication system
5.1 Lubrication system diagram
Lube oil filter
Bypass valve Fuel injection

pump
Oil pressure
swich
Cylinder block Main gallery

Regulator
valve
Intermediate Camshaft Crank
Lube oil pump gear shaft metal journal metal
Rocker arm Crank

Oil suction pipe metal pin metal
(strainer)
Rocker arm
Tappet
Cam face
Oil pan
5.2 Trochoid pump components

Trochoid pump
Cover
Outer rotor
Control
valve Inner rotor
Gear case cover
(R.1)
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5.3 Disassembly (Reverse the below procedure for reassembly)

1)Loosen the belt, and remove the radiator pulley, fan and V-belt. (See 4.2.2. 2) in Chapter 4.)
2)Remove the crankshaft pulley. (See 4.3.2. 3) in Chapter 4.)
3)Remove the gear case cover. (See 4.3.2. 4) in Chapter 4.)
4)Remove the lube oil pump cover from the gear case cover. (Point 1 in 5.4)
5)Remove the pressure regulating valve from the lube oil pump cover. (Point 2 in 5.4)
5.4 Servicing Points

Point 1
[Disassemble]
• Check if the pump rotates smoothly and see that there is no play between the shaft and gear, and inner
rotor.
[Reassemble]
• Rotor (outer/inner) insertion part is to apply lube oil.
• For installation on the gear case cover, tighten the lube oil pump cover by the standard torque.
N•m (kgf•m)
Lube oil application
Tightening torque (threaded portion,
and bearing seat surface)
5.9 to 7.9 (0.6 to 0.8) Lube. oil applied
• When replacing the lube oil pump, replace the whole assy including the outer/inner rotor.
[NOTICE]
Always check if the pump rotates smoothly after installation on the gear case cover.
Running the engine when the pump rotation is heavy may cause the pump to be burnt.
Point 2
[Disassemble-Reassemble]
• Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation
is detected.
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5.5 Parts inspection and measurement
5.5.1 Trochoid pump inspection and measurement
(1) Outside diameter clearance and side clear-

Gear case
ance of outer rotor Outer rotor
Insert a gap gauge between the outer rotor and the gear
case cover, and measure outside diameter gap.
Put a ruler on the end face of the gear case cover, and
insert a gap gauge between rotor, and measure a side
gap.
Outside clearance mm Inner rotor
Standard Limit Outer diameter clearance

0.12 to 0.21 0.30
Side clearance mm
Standard Limit
0.02 to 0.07 0.12
Outer rotor
Side clearance
(2) Tip clearance between outer rotor and inner rotor

Insert a gap gage between an outer rotor and an inner rotor, and measure the tip clearance.
Tip clearance mm
Standard Limit
- 0.16
(3) Outside diameter clearance of inner rotor centering location part

Measure the outside diameter of inner rotor centering location part and the hole diameter of gear case cover.
Calculate the clearance from that difference.
Inspection item Standard Limit

Gear case cover I.D. 46.13 to 46.18 -
Inner rotor O.D. 45.98 to 46.00 -
Rotor clearance 0.13 to 0.20 0.25
(R.1)
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6. Cooling system
6. Cooling system
6.1 Cooling water System
Thermostat
Cylinder head
Bypass
Radiator
Sub-tank
Cylinder block
Cooling water pump
6.2 Cooling water pump components
Cylinder head Thermostat cover

Thermostat
Cooling water pump
Thermo switch
V-pulley
Spacer
Note) This figure shows the 3TNV76 Fan
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6. Cooling system
6.3 Disassembly (Reverse the below procedure for reassembly)

1)Remove the alternator. (See 4.2.2. 1) in Chapter 4.)
2)Remove the fan, V-belt and pulley. (See 4.2.2. 2) in Chapter 4.)
3)Remove the thermostat case. (See 4.2.2. 3) in Chapter 4.)
4)Remove the cooling water pump. (Point 1, in 6.4)
5)Remove the thermostat. (Point 2 in 6.4)
6.4 Servicing points

Point1
[Disassemble-Reassemble]
• Check to see that the cooling water pump bearing is free from abnormal noise, sticking or play and water
leakage from the bearing. If replacement is necessary, replace the whole cooling water pump assy.
[NOTICE]
Replace the O-ring of the installation part to the Cooling water pump
cylinder block of the cooling water pump with new one
when disassembling. And, be sure to use the special
O-ring for each engine model, because the material is
different, although the dimension is the same as a
commercial part. (Refer to the right figure.)
Point2
O-Ring
[Disassemble]
• Check the thermostat function. See 2.7 in Chapter 2
for the inspection method.
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7. Fuel injection pump / Governor

7.1 Introduction
A fuel injection pump is the most important device which
adjusts an injection quantity precisely corresponding to Fuel
the change of engine load. injection pump
Therefore, not only a very precise machining should be
necessary all parts but also the assembling, adjustment
which top-level is excellent in should be necessary. Governor
The careful consideration to avoid dust and rust at the

time of disassembly, adjustment, reassembly of the fuel
injection pump in the market is necessary.
Fuel injection pumps manufactured by Yanmar, YPES-
ML type series are inline type.
A cam shaft is driven through the timing gear, and
mechanical type fuel feed pump driven by a cam shaft
sends fuel to the fuel filter from the fuel tank.
The fuel which passed through the fuel filter is supplied
to the storeroom of the pump housing, and the pressure
of the fuel rises by the plunger The fuel passes through
the fuel high pressure pipe and the fuel is injected to
each cylinder from the fuel injection nozzle.
The manual of the separate volume is referred to for the
disassembly and assembly, adjustment procedure of
only the YPES-ML type fuel pump.
7.2 Fuel injection pump

7.2.1 Fuel system diagram
Fuel injection valve

Fuel injection pipe
Fuel return pipe
To fuel tank
Fuel injection pump
Fuel filter OIl / water separator

(Option)
From fuel tank

Feed pump
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7.2.2 External view and components
Exhaust manifold
Rocker arm cover
Fuel injection pipe
Fuel injection
valve
Cylinder head
Gear case flange

Idle gear
Camshaft
Cooling water pump
Crankshaft gear
Fuel filter
Crankshaft
Pump flange Gear case cover

Don't disassemble!
Fuel pump drive gear
Drive gear nut
Oil seal
Crankshaft pulley
Note) This figure shows the 3TNV76.
(R.1)
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The procedure to remove a fuel injection pump from the
gear case is shown.
[NOTICE]
Be sure to remove a flange and a fuel injection pump
drive gear with a pair without loosening the flange
Fuel injection pump
installation bolts.
Flange
1)Remove fuel injection pipes, fuel pipes and a remote Fuel injection
drive gear
control wire. Block the entrance with tape so that
Flange bolt
trash may not enter the fuel injection pipes and the Spring
fuel injection pump. washer
2)Mark the position of the timing marks of a fuel pump Don't disassemble
and a gear case. Or, put a mark on the gear case at
the position to agree the timing mark of a fuel pump. Pump drive gear nut
3)Remove a pump cover from the gear case.
4)Give the marks on a fuel injection pump drive gear
and a idle gear with paint or the like.
5)Loosen fuel injection pump installation nuts (three
nuts).
6)Loosen a installation nut of a fuel injection pump
drive gear.
7)Move a pump drive gear and a flange with a pair to
your side by gear puller.
8)Remove an installation nut and a washer.
9)Remove a fuel injection pump. Leave the pump drive
gear in the gear case.
7.2.4 Reassembly procedure

[NOTICE]
• Use a new O-ring on the fuel pump flange and apply grease.
• Confirm whether the marks (7.2.3-4) of the pump drive gear and the idle gear is correct.
1)Turn a cam shaft so that the key of the pump cam shaft may almost agree in a position of the key groove
of a pump drive gear.
2)Insert a fuel injection pump into the installation hole of the gear case straight to prevent the damage of the
O-ring. Insert a fuel pump with confirming whether the key of a camshaft and the key groove of a drive
gear agree.
3)Assemble a pump drive gear installation nut and a washer together temporarily.
4)Turn a fuel injection pump to the position where the marks (7.2.3-2) of the fuel injection pump and the gear
case agrees.
5)Fasten pump installation nuts (three nuts).
6)Tighten the pump installation nut which was assembled temporarily by the specified standard torque.
Tightening torque of the gear installation nut (without lube oil)
N•m (kgf•m)
Tightening torque
58.8 to -68.8 (6 to 7)
(R.1)
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7.2.5 Confirmation and adjustment of fuel injection timing

Refer to 2.2.7 in Chapter 2.
7.2.6 Confirmation and adjustment of no-load maximum and minimum speed

Refer to 2.3 in Chapter 2. And, fuel injection pipes, fuel pipes and a remote control wire are installed in the
former condition.
[NOTICE]
Monitor the oil and fuel leakage from the fuel pump system or the oil leakage from the fuel pump flange
during the engine running.
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8. The specifications of a starting motor and the characteristics
8. The specifications of a starting motor

and the characteristics
8.1 The specifications and the characteristics
A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance
such as the compression pressure and the friction loss of the engine and makes the engine start.
8.1.1 Specifications
Manufacturer’s model (Denso) - P1.1
Yanmar code - 119717-77010
Nominal output kW 1.1
Weight kg 3.0
Revolution direction (as viewed from pinion) - Clockwise
Engagement system - Magnetic shift
Terminal voltage/current V/A 11.5/90 or less
No-load
Revolution min-1 3000 or above
Terminal voltage/current V/A 2.5/325 or less
Loaded
Torque N•m (kgf•m) 8.24 (0.84)
Clutch system - Overrunning
Pinion projection voltage (at 100 °C) V 8.0 or less
Pinion DP or module/number of teeth - M2.54/9
Application - Standard
8.1.2 Characteristics
TOROUE (N࡮m)
SPEED (min-1)
STARTER
OUTPUT (kW)
VOLTAGE (V)
STANDARD PERFORMANCE 12V 1.1kW
6000 24 1.2 12
V kW
5000 20 1.0 10
N࡮m
4000 16 0.8 8
3000 12 0.6 6
2000 8 0.4 4
min-1
1000 4 0.2 2
0 0 0 0
0 100 200 300 400 500
CURRENT (A)
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8.2 The structure of a starting motor and the wiring diagram

8.2.1 Structure
(1) Disassembly drawing
Switch Assy Turminal cover
Lever
Gear
Bearing
Clutch Assy
Housing Flame
Needle bearing
Gear
Yoke Assy
Armature Assy
Bearing
Plate
Shaft
(2) Structure
When the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. The pinion
engages with the ring gear of a engine, and the engine is started.
Magnetic switch
Shift lever
Pinion clutch Assy
Pinion case Brush
Armature Assy
Yoke Assy End flame cover
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8.2.2 Wiring diagram of a starting motor

1)When a starting switch is turned on, a magnet switch
is charged, and a moving core is absorbed, and a Starting switch
pinion clutch is moved forward through a lever, and 50

the pinion engages with a ring gear. 30
2)When the pinion engages the ring gear, because a
main contact point is closed and the main electric Battry
current flows and a pull coil is short-circuited by the
Magnetic switch
main contact point and it stops being charged with
electricity, the pinion is kept at the position by a hold-
ing coil during the start,
3)When the starting switch is turned off, the main con-
tact point becomes open, and the pinion clutch is Starter
returned to the stop position by a return spring.
8.3 Performance
The specified characteristics of a starting motor (at 20 deg. C)
1)No load: Less than electric current 90 A, more than rotation speed 3000 min-1 at voltage 11.5 V.
2)Load: More than rotation speed 1130 min-1, torque 6.86 N•m (0.70 kg•fm) at voltage 8.7 V and electric
current 230 A.
3)Restraint: Less than electric current 325 A, torque 8.2 N•m (0.84 kgf•m) at voltage 2.5 V.
4)Operation voltage: In the position of a ring gear, less than 8 V.
Since the characteristics of a starting motor can be confirmed easily in the no-load test comparatively, perform
the test by the next point.
No-load test
Fix the starting motor on a test bench and connect wiring. When the switch is closed, a current flows in the
starting motor, which is rotated at no-load. Measure the current, voltage and number of revolutions then
and check if they satisfy the specified characteristics.
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9. Alternator
9. Alternator
As a representative example of alternator, the alternators of 20A and 40A are shown in this chapter.
9.1 20A Alternator

Manufacturer’s model (Kokusan) - GP9191

Yanmar code - 119910-77200
Rating - Continuous
Battery voltage V 12
Nominal output A 20
Rated revolution min-1 3,500
Operating revolution min-1 1,400-6,600
Grounding characteristics - Minus side grounding
Direction of revolution (viewed from pulley) - Clockwise
Integrated regulator IC regulator
Weight kg 1.8
Pulley (outside diameter) mm 65 for A-belt or 58 for special M-belt
Belt shape - Type A or type special M
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9. Alternator
9.1.2 Structure
Coil Plate
FW Assy
Stator
22.5 22.5
)0
(1
Collar
Clamp
Washer (3)
0)
3
(R
Spring washer
Nut
Bolt for washer R4
(15q
)
Bearing
Tube (red)
Coupler
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9. Alternator
9.1.3 Wiring diagram
Standard circuit composition for output confirmation
KEY SW
Load
IC Regurator
12V
Charge lamp Battery
Generator
[NOTICE]
1)Don't do mis-connecting and short-circuit of each terminal.
2)Don't remove a battery terminal and a B terminal when rotating.
3)Shut out a battery switch during the alternator stop.
9.1.4 Standard output characteristics

The standard output characteristics of this alternator are shown as the below figure.
STANDARD CHARACTERISTICS (12V)
25
20
OUTPUT CURRENT (A)
15
10
0
1 2 3 4 5 6 7103
ALTERNATOR SPEED (min-1)
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9. Alternator
9.1.5 Inspection
(1) V belt inspection

Normal Defect
4)Inspect the matter whether there are not crack, stick-
iness and wear on the belt visually.
Check that a belt doesn't touch the bottom part of the
pulley groove. If necessary, replace the V belt set.
5)V belt tension: Clearance
(Refer to 2.2.2.(2) in Chapter 2.)
(2) Visual check of wiring and check of

Inspection of V pulley
unusual sound
1)Confirm whether wiring is right or there is no loose-
ness of the terminal part.
2)Confirm that there is no unusual sound from the
alternator during the engine operation.
(3) Inspection of charge lamp circuit

1)Move a start switch to the position of on. Confirm
lighting of the charge lamp.
2)Start an engine, and confirm the lights-out of the
lamp. Repair a charge lamp circuit when a lamp
doesn't work.
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9. Alternator
9.2 40A Alternator
9.2.1 Components
(1) Parts related to the alternator
V-belt adjuster
Alternator
(2) Alternator components of disassembly and assembly
Rotor Assy
Flame Assy
Washer
Bearing cover
Bearing
Retainer plate
Collar Bearing
Pulley
Nut
Brush holder
Insulation bushing
Rear end cover

Brush Assy
Regulator Assy
Holder
Rear flame Assy
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9. Alternator
Manufacturer’s model (Denso) - ACFA68

Yanmar code - 129423-77200
Rating - Continuous
Battery voltage V 12
Nominal output (13.5 V heat) A 40
Rated revolution min-1 5,000
Operating revolution min-1 1,350 to 18,000
Grounding characteristics - Minus side grounding
Direction of revolution (viewed from pulley) - Clockwise
Integrated regulator IC regulator
Weight kg 2.8
Pulley (outside diameter) mm 69.2
Belt shape - Type A
9.2.3 Wiring diagram
WIRING DIAGRAM
IG Key switch
IG P
B
PI P L
Charge lamp
F (Max. 3.4W)
IC
L
L L
O O
0.5ǴF
A B A
D Battery A D
E T
ALTERNATOR ASSY IC REGURATOR
[NOTICE]
1)Don't do mis-wiring and short-circuit of each terminal.
2)Don't remove a battery terminal and a B terminal when rotating.
3)Shut out a battery switch during the alternator stop.
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9. Alternator
9.2.4 Standard output characteristics

The standard output characteristics of this alternator are
shown as the right figure.
STANDARD CHARACTERISTICS
13.5V CONSTANT
AMBIENT TEMP:25͠
60
Cold
50
Hot
OUTPUT CURRENT
40
30
20
(A)
10
0 1 2 3 4 5 6 7 8
ALTERNATOR SPEED (X103 min-1)
9.2.5 Inspection
Perform the same procedure as that of 9.1.5 in Chapter 9.
106
Ground L-terminal of the
Turn key switch to ON. OFF Disconnect GN coupler driven machine side coupler OFF
Does the charge lamp (L, IG). Replace the charge lamp
(L, IG)
9. Alternator
come ON? Does the charge lamp

come ON? The charge lamp is available from
the driven machine manufacturer.
ON ON Inspect the rotor coil and

brush IC-RG
Turn the key switch to START.
(The engine starts.)
Inspect or replace the fan belt,
At idling ON and inspect the alternator
9.3 Troubleshooting
Does the charge lamp The lamp flashes

goes OFF? Inspect the diode ( + side)
The lamp is lit

OFF dimly
Increase the engine speed to
1500 rpm and turn the light
switch to ON.
107
Excessive voltage drop between
VB - VL > 0.5V BAT and batt ( + side) terminal
Does the charge lamp The lamp is lit Measure VB and VL at
come ON? dimly BAT L-terminal during
idling
VB - VL < 0.5V L-terminal defective conduction
Inspect the diode ( - side)
OFF
Measure VB at BAT terminal

with the engine running at VB > 15.5 Replace IC-RG
1500 rpm
VB = 13㨪15 Turn the light switch Does the charge lamp ON Inspect the auxiliary diode
to ON during idling come ON?
OFF
̪ Remarks Explanation on abbreviations: Not abnormal
1) Use a fully charged battery GN : Alternator
2) DC voltmeter: 0 to 30 V, 0.5 class IC-RG : IC regulator
3) The check method is also applicable to VB : BAT terminal voltage
the bench test VL :L-terminal voltage
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10. Electric wiring
10. Electric wiring

10.1 Electric wiring diagram
This is a typical example.
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10. ELCTRIC WIRING
10.1.1 Alternator
In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions
carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage
to the user.
(1) When the battery cable can be connected backwards

The alternator diode will be damaged and recharging made impossible if the plus and minus ends of the
battery cable are confused. The stator coil will also be burned as a result. To prevent this, supply the user with
a cable of such a length or structure that the plus and minus ends cannot be confused. Also warn the user not
to connect the cable backwards.
(2) When charging output voltage is used for control purposes

The engine speed at starting is not proportional to the output voltage of the alternator, so this output voltage
must not be used for any control systems. It is especially wrong to use it for the control signal of the safety
relay for cutting the starting motor because this will damage the starting motor and cause engine starting
failure.
(3) When the L line is used for control purposes

Consult with Yanmar first before connecting any load other than the charge lamp to the L line. Damage to the
alternator and related equipment will not be warranted without such prior consultation.
(4) Non-use of the Yanmar wiring diagram

Use without prior consultation of any wiring diagram other than that provided by Yanmar removes any
breakdown of any electrical equipment from the warranty.
(5) Regarding lamp control

Once the charge lamp goes out after the start of charging, it does not come on again even if the engine speed
falls and charging is insufficient. The lamp will not light again if the charging circuit is normal. The lamp only
comes on during operation if the alternator itself is broken or the drive V-belt breaks. However, when an LED
is used for the charge lamp, the LED will shine faintly even during normal operation. This is due to the control
system for the alternator lamp and is not an abnormality.
(6) Use of a non-specified V-belt

Use of a non-specified V-belt will cause inadequate charging and shorten the life of the belt. Use a belt of the
specified type.
(7) Direct high pressure washing is prohibited

Water will enter the brush if the alternator is washed directly at high pressure, causing inadequate charging.
Warn users not to use direct, high-pressure washing.
(8) Adhesion of agricultural and other chemicals (direct contact or airborne)

Adhesion of agricultural and other chemicals, especially those with high sulfur content, to the IC regulator
corrodes the conductor on the substrate, leading to over-charging (battery boiling) and charging malfunctions.
Consult with Yanmar prior to using the engine in such an environment. Use without prior consultation removes
any breakdown from the warranty.
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10. ELECTRIC WIRING
10.1.2 Starting motor

to the user.
(1) Starting performance in the case of using an untested battery

The starting performance of the engine is closely dependent on the battery capacity. This battery capacity is
itself affected by the climate and the type of equipment installation. The details regarding ambient
temperature and equipment installation vary depending on the OEM, so Yanmar cannot decide the battery
capacity on its own. Confer with Yanmar in advance after checking these conditions and fix the battery
capacity on the basis of confirmatory tests.
(2) When the resistance of the battery cable exceeds the specified value
The combined total resistance of the battery cable in both directions between the starting motor and battery
should be within the value indicated on the wiring diagram. The starting motor will malfunction or break down
if the resistance is higher than the specified value.
(3) When the resistance of the starting motor circuit exceeds the specified value
The combined total resistance of the wiring between the starting motor and key switch (or power relay or
safety relay, depending on the application) should be within the value indicated on the wiring diagram. Engine
starting will be difficult if the resistance is higher than the specified value. This can also cause welding of the
magnet switch at the point of contact and resultant burning of the armature coil.
(4) When there is no safety relay

Over-running (when the electric current flows for too long) is a major cause of starting failure. This burns the
armature coil and causes clutch failure. Excessive work and failure of the key switch to return properly are the
main causes of over-running. The user must be given sufficient warning about this.
Be sure to use the safety relay to prevent over-running. This safety relay is supplied as an option. Consult
Yanmar first when planning to install a safety relay at your own company. In the case of failure to consult with
Yanmar, our warranty will not be applied to all the electrical equipment.
(5) When there is too much rust due to the entry of water
The water-proofing of the starting motor is equivalent to R2 of JIS D 0203. This guarantees that there will be
no damage from the sort of exposure encountered in rain or when water is poured on from a bucket. You
should, however, avoid the use of high-pressure washing and steeping in water.
(6) Regarding the heat resistance of the starter motor

The starting motor has heat resistance for an ambient temperature of 80 °C and surface temperature of
100 °C. Insulators must be installed to prevent overheating when used near high temperature parts such as
the exhaust system.
(7) Corrosion of magnet switch contact point by corrosive gas.

When using equipment with a dry clutch, ammonium gas generated by friction is liable to corrode the contact
of the magnet switch. Be sure to install a vent in the clutch case.
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10. ELCTRIC WIRING
10.1.3 Current limiter

to the user.
(1) When an over-discharged battery is used

Use of booster starting with an over-discharged battery (when the voltage has dropped to 8 V or less) will
destroy other electrical equipment by generating an abnormally high voltage. A specialized battery charger
should be used to recharge such an over-discharged battery (when the voltage has dropped to 8 V or less).
(2) When checks for malfunctioning are not performed

When high voltage noise from other electrical equipment is impressed on the current limiter upon turning off
the key switch, the current limiter can be damaged and cause loss of control over the output voltage. Other
electrical equipment may also be damaged if this happens, so surge killers should be fitted to the electrical
equipment whenever necessary. Be sure to check prior to mass production whether electrical noise might
damage the current limiter by turning the key switch and other electrical equipment on and off while the
engine is running, using both the vehicle and the wire harness that will be used in mass production.
(3) Removal of the battery cable during operation

The current limiter may malfunction if the battery cable and/or battery are removed during operation,
depending on the kind of electrical equipment being used, causing loss of control over the output voltage. In
such cases, the current limiter and other electrical equipment will be damaged by the generation of a
continuous high voltage of 24-43 V (for 5,000 rpm dynamo). All electrical equipment falls outside the scope of
the warranty under these circumstances. Be sure to warn the user not to remove the battery cable and/or
battery during operation.
(4) If the battery cable can be attached in reverse

The current limiter’s SCR diode will be destroyed if the plus and minus ends of the battery cable are
connected the wrong way around. This causes charging malfunctioning and burns the harness. Give the user
a cable of such a length that it cannot be connected the wrong way and warn the user against connecting the
cable backwards.
(5) Non-use of the Yanmar wiring diagram

Use without prior consultation of any wiring diagram other than that provided by Yammer removes any
breakdown of any electrical equipment from the warranty.
(6) Installation environment

Observe the following when installing the current limiter:
1)Do not install it on the engine.
2)Place it in a well-ventilated place with an ambient temperature of 65 °C or less.
3)Ensure that the cooling air flows in the right direction for the current limiter’s cooling fins.
4)Do not use the earth wire of the current limiter to earth any other electrical equipment.
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10. ELECTRIC WIRING
10.1.4 Section area and resistance of electric wire
(1) Allowable maximum cable length (Terminal resistance is not included.)
Cable size Cable construction Resistance 2 m Note1 20 m Ref. 50 m Note2

2 (/m)
mm Element No. Cable dia. (m) (m) (m)
3 41 ø 0.32 0.005590 0.36 3.58 8.94
5 65 ø 0.32 0.003520 0.57 5.68 14.20
8 50 ø 0.45 0.002320 0.86 8.62 21.55
15 84 ø 0.45 0.001380 1.45 14.49 36.23
20 41 ø 0.80 0.000887 2.25 22.55 56.37
30 70 ø 0.80 0.000520 3.85 38.46 96.15
40 85 ø 0.80 0.000428 4.67 46.73 116.82
50 108 ø 0.80 0.000337 5.93 59.35 148.37
60 127 ø 0.80 0.000287 6.97 69.69 174.22
85 169 ø 0.80 0.000215 9.30 93.02 232.56
100 217 ø 0.80 0.000168 11.90 119.05 297.62
Note1) Allowable maximum resistance of Battery cable

Note2) Allowable maximum resistance of Starting motor circuit
(2) Terminal resistance

Generally, a terminal resistance is 15 m per coupler and 0 per screw setting. This resistance should be
included in allowable maximum resistance when the cable length is planned.
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11. Service standards

11.1 Engine tuning
Reference
No. Inspection item Standard Limit
page
Gap at intake/exhaust valve heads
1 0.15 to 0.25 - 2.2.6(3)
mm
Between alternator Used part 10 to 14 -
and crank pulley
(Direction A) New part 8 to 12 -
V-belt tension Between alternator Used part 7 to 10 -
2 mm and radiator fan 2.2.2.(2)
at 98 N (10 kgf) (Direction S) New part 5 to 8 -
Between radiator Used part 9 to 13 -
fan and crank pulley
(Direction C) New part 7 to 11 -
Fuel injection pressure 11.8 to 12.8
3 2 - 2.2.6.(4)
MPa (kgf/cm ) (120 to 130)
Fuel injection timing FID Refer to 2.2.7(4)
4 - 2.2.7.(4)
degrees (bTDC) in chapter 2.
Compression pressure 2/3TNV70 3.24 (33) ± 0.1 (1) 2.55 (26) ± 0.1 (1)
5 (at 250 min-1) 3.3
MPa (kgf/cm2) 3TNV76 3.43 (35) ± 0.1 (1) 2.75 (28) ± 0.1 (1)
Cooling water Capacity 2TNV70 0.6 -

6 (Only engine body) 2.2.1.(4)
(Liter) 3TNV70/76 0.9 -
Model Total Effective
2TNV70 (VM) 1.7 0.7 -
Lube oil capacity 3TNV70 (VH/VM) 2.8 1.3 -
7 (oil pan) 2.2.1.(3)
(Liter) 3TNV70 (CH) 3.8 1.7 -
3TNV76 (VM/VH) 3.5 1.6 -
3TNV76 (CH) 4.4 2.1 -
at rated speed at low idle speed -
Lube oil pressure
8 0.06 (0.6) or
MPa (kgf/cm2) 0.29 (3.0) to 0.44 (4.5) -
above
Oil pressure switch operating pressure 0.05 ± 0.01
9 - -
MPa (kgf/cm2) (0.5 ± 0.1)
valve opening Full opening lift
temperature (mm)
10 Thermostat deg. C (temperature) 2.7
8 or above
69.5 to 72.5
(85 deg.C)
Thermo switch actuating temperature
11 107 to 113 - 2.4 (2)
(deg.C)
*Lube oil capacity may differ from the above depending on an engine installed on a machine unit.
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11.2 Engine body

11.2.1 Cylinder head
(3) Cylinder head
Inspection item Standard Limit Reference page
Combustion surface distortion
0.05 or less 0.15
mm
4.2.5.(1)
Valve sink Intake 0.4 to 0.6 0.9
mm Exhaust 0.4 to 0.6 0.8
Intake 120 -
Seat angle Deg.
Valve seat Exhaust 90 - 4.2.6.
Seat correction angle deg. 40, 150 -
(4) Intake/exhaust valve and guide

mm
Guide inside diameter 6.000 to 6.012 6.08
Intake Valve stem outside diameter 5.960 to 5.975 5.90
Clearance 0.025 to 0.052 0.16
4.2.5.(2)
Guide inside diameter 6.000 to 6.012 6.08
Exhaust Valve stem outside diameter 5.945 to 5.960 5.90
Clearance 0.040 to 0.067 0.17
Valve guide projection from cylinder head 9.8 to 10.0 -
4.2.7.
Valve guide driving-in method Cold-fitted -
(5) Valve spring

mm
Free length 37.8 -
4.2.5.(4)
Inclination - 1.3
(6) Rocker arm and shaft

mm
Arm shaft hole diameter 12.000 to 12.020 12.07
Shaft outside diameter 11.966 to 11.984 11.94 4.2.5.(5)
Clearance 0.016 to 0.054 0.13
(7) Push rod

mm
Bend - 0.03 4.2.5.(7)
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11.2.2 Gear train and camshaft
(1) Camshaft
mm
Side gap 0.05 to 0.15 0.25 4.3.4
Bending (1/2 the dial gage reading) 0 to 0.02 0.05
4.3.5 (1)
Cam height 34.135 to 34.265 33.89
Shaft outside diameter / Metal inside diameter
Bushing inside diameter 40.000 to 40.075 40.150
Gear side Camshaft outside diameter 39.940 to 39.960 39.905
Clearance 0.040 to 0.135 0.245
Intermediate
Camshaft outside diameter 39.910 to 39.935 39.875 4.3.5 (1)
(No bushing)
Clearance 0.065 to 0.115 0.225
Wheel side
Camshaft outside diameter 39.940 to 39.960 39.905
(No bushing)
Clearance 0.04 to 0.085 0.195
(2) Idle gear shaft and bushing

mm
Shaft outside diameter 36.950 to 36.975 36.900
Bushing inside diameter 37.000 to 37.025 37.075 4.3.5(2)
Clearance 0.025 to 0.075 0.175
(3) Backlash of each gear

mm
Crank gear, cam gear, idle gear,
0.06 to 0.12 0.14 4.3.4.
fuel injection pump gear and PTO gear
(R.1)
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11.2.3 Cylinder block
(1) Cylinder block

mm
2/3TNV70 70.010 to 70.020 70.200
Cylinder inside diameter
3TNV76 76.010 to 76.020 76.200
4.4.5.(1)
Roundness
Cylinder bore 0.01 or less 0.03
Cylindricity
(2) Crankshaft
mm
Bending (1/2 the dial gauge reading) - 0.02
Roundness 0.01 or less 0.02
Pin outside diameter 41.952 to 41.962 42.902
Metal inside diameter 41.982 to 42.002 -
Crank pin
4.4.5.(2)
Clearance 0.020 to 0.050 0.110
Journal outside diameter 46.952 to 46.962 46.902
Metal inside diameter 46.982 to 47.002 -
Crank journal
Clearance 0.020 to 0.050 0.120
(3) Thrust bearing

mm
Crankshaft side gap 0.111 to 0.250 0.28
4.4.5 (3)
Metal thickness 1.930 to 1.980 1.850
(R.1)
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(4) Piston and ring

Piston
mm
Piston outside diameter 2/3TNV70 69.960 to 69.990 69.915
(Measure in the direction
vertical to the piston pin.) 3TNV76 75.955 to 75.985 75.910
Piston diameter
measure position 2/3TNV70
22 to 25 -
(Upward from the bottom 3TNV76 4.4.5.(4)
end of the piston)
Hole inside diameter 22.000 to 22.009 22.039
Piston pin Pin outside diameter 21.995 to 22.000 21.965
Clearance 0.000 to 0.014 0.074
Piston ring
mm
Model Inspection item Standard limit Reference page
Ring width 1.470 to 1.490 1.450
Top ring
Ring width 1.470 to 1.490 1.450
2/3TNV70 Second ring
Ring width 2.970 to 2.990 2.950
Oil ring
4.4.5.(4)
Ring width 1.470 to 1.490 1.450
Top ring
Ring width 1.430 to 1.450 1.410
3TNV76 Second ring
Ring width 2.970 to 2.990 2.950
Oil ring
(R.1)
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(5) Connecting rod

mm
Thrust clearance 0.2 to 0.4 - 4.4.4
Rod small end

mm
Item Standard Limit Reference page
Pin outside diameter 21.991 to 22.000 21.963 4.4.5.(5)
Clearance 0.025 to 0.047 0.105
(6) Tappet
mm
Tappet hole (block) inside diameter 21.000 to 21.021 21.041
Tappet stem outside diameter 20.927 to 20.960 20.907 4.4.5.(6)
Clearance 0.040 to 0.094 0.134
11.3 Lubricating oil system (Trochoid pump)
(1) Outside clearance of outer rotor

mm
Standard Limit Reference page
0.12 to 0.21 0.30 5.5.1
(2) Tip clearance between outer rotor and inner rotor

Insert a gap gage between an outer rotor and an inner rotor, and measure the tip clearance.
mm
- 0.16 5.5.1
(3) Side clearance of outer rotor

mm
0.02 to 0.07 0.12 5.5.1
(4) Outside clearance of inner rotor centering location part

mm
0.13 to 0.20 0.25 5.5.1
(R.1)
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12. Tightening torque for bolts and nuts

12.1 Tightening torques for main bolts and nuts
Lube oil
Thread diameter Tightening torque application Reference
Part and engine model
× pitch (thread portion, and page
mm N•m (kgf•m) seat surface)
53.9 to 57.9
Cylinder head bolt M9 × 1.25 Applied 4.2.4
(5.5 to 5.9)
22.6 to 27.5
Connecting rod bolt M7 × 1.0 Applied 4.4.4
(2.3 to 2.8)
80.4 to 86.4
Flywheel set bolt M10 × 1.25 Applied 4.3.4
(8.2 to 8.8)
75.5 to 81.5
Bearing cap set bolt M10 × 1.25 Applied 4.4.4
(7.7-8.3)
83.3 to 93.3
FC250
Crankshaft (8.5 to 9.5)
M12 × 1.25 Applied 4.3.4
pulley set bolt 113 to 123
S48C
(11.5 to 12.5)
58.8 to 68.8
Fuel pump drive gear nut M12 × 1.75 Not applied 4.3.4
(6.0 to 7.0)
32.3 to 36.3
Fuel pump gear bolt M8 × 1.0 Not applied -
(3.3 to 3.7)
29.4 to 34.4
Fuel injection pipe sleeve nut M12 × 1.25 Not applied -
(3.0 to 3.5)
49.0 to 53.0
Fuel injection nozzle nut M20 × 1.5 Not applied -
(5.0 to 5.4)
68.7 to 73.7
Governor weight support nut M12 × 1.25 Applied -
(7.0 to 7.5)
14.7 to 19.6
Glow plug M10 × 1.25 Not applied -
(1.5 to 2.0)
(R.1)
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12.2 Tightening torques for standard bolts and nuts
Nominal thread diameter Tightening torque

Item Remarks
× pitch mm N•m (kgf•m)
9.8 to 11.8 Use 80 % of the value at left when
M6 × 1
(1.0 to 1.2) the tightening part is aluminum.
Use 60 % of the value at left for
22.5 to 28.4
M8 × 1.25 4T bolts and lock nuts.
Hexagon bolt (7T) (2.3 to 2.9)
and nut 44.1 to 54.1
M10 × 1.5
(4.5 to 5.5)
78.3 to 98.3
M12 × 1.75
(8.0 to 10)
9.8
1/8
(1.0)
19.6
1/4
(2.0)
PT plug -
29.4
3/8
(3.0)
58.8
1/2
(6.0)
12.7 to 16.7
M8
(1.3 to 1.7)
24.5 to 34.4
M12
(2.5 to 3.5)
Pipe joint bolt -
39.1 to 49.1
M14
(4.0 to 5.0)
48.9 to 58.9
M16
(5.0 to 6.0)
Note) Lube oil is not applied to threaded portion and seat surface.
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YANMAR AMERICA CORP.

951 CORPORATE GROVE DRIVE, BUFFALO GROVE, IL 60089-4508, U.S.A.
TEL : 1-847-541-1900
FAX : 1-847-541-2161
YANMAR EUROPR B.V.

P.O. BOX 30112,1303 AC ALMERE NL
BRUGPLEIN 11, 1332 BS ALMERE-DE VAART, THE NETHERLANDS
TEL : 31-36-5493200
FAX : 31-36-5493209
YANMAR ASIA (SINGAPORE) CORPORATION PTE LTD.

4 TUAS LANE, SINGAPORE 638613
TEL : 65-6861-3855
FAX : 65-6862-5195
YANMAR CO,. LTD.

SMALL ENGINES FACTORY
ENGINE PRODUCT OPERATIONS DIVISION
1009-2, KAWAMICHI, BIWA-CHO, HIGASHIAZAI-GUN, SHIGA 526-0111, JAPAN
TEL : 81-749-72-5195
FAX : 81-749-72-5214 / 5158
Printed in Japan

Takeuchi Tb108 Service Sec Wat

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MACHINE FRONT AND REAR, LEFT AND RIGHT

MACHINE SERIAL NUMBER

FOOT OF THE PAGE

6. Bleed the air from the cylinders.

Indicates the mass of a part or device.

Safety Precautions ................................................................................................................................................. 3

SAFETY ALERT SYMBOL

DANGER WARNING CAUTION

Observe all safety rules

• Operation, inspection and maintenance of this ma-

• Wear a hard hat, safety shoes, safety glasses, filter

Use anti-explosive electrical fixtures and lights when

Attach a “DO NOT OPERATE” tag Do not allow unauthorized personnel in

Use the correct tools

Prepare the work area

• Select a firm, level work area. Make sure there is

Replace important safety parts

• Replace fuel hoses periodically. Fuel hoses be-

• Clean the machine before performing maintenance.

Stay clear of moving parts

Secure the engine hood or cover when

Be sure to secure the engine hood or cover when

• Stay clear of all rotating and moving parts. Wrap-

Fuel, oil or hydraulic fluid leaks can cause a fire.

Be careful with hot and pressurized

Use caution when fueling

Stop the engine and allow the machine to cool down

The track adjuster contains highly pressurized grease.

Release all pressure before working on

Oil may spurt out if caps or filters are removed or

Have a Takeuchi service agent repair

Ask a Takeuchi service agent to repair any welding

• Keep all safety signs clean and legible.

4. Clean all disassembled parts and new parts, then

5. Be sure to replace all seals and cotter pins, etc.,

7. When installing bearings, bushings and oil seals,

8. After installation of the hydraulic unit, be sure to

2. Use 2 spanners, each on an opposite side, to DIRT

2. Be careful not to twist O-rings. If an O-ring is

3. During insertion, be careful not to damage the

4. Handling of Floating Seals

5. Apply grease to the lip of the oil seal.

Bite Type Pipe Fitting for Steel Pipe

Pipe Outer Diameter Torque

Joints for Piping (O-ring Seal Type)

1 107.9 ±9.8 79.5 ±7.2

Nominal Thread Torque

3. Points where thread-locking compound is used

Names of Components .......................................................................................................................................... 3

In regard to Standard Values and Allowable Values

NAMES OF COMPONENTS SPECIFICATIONS

1. Canopy 11. Engine 21. Bucket

LIFTING CAPACITIES SPECIFICATIONS

Load Hooking System

SPECIFICATIONS LIFTING CAPACITIES

Equipped with Standard Arm Unit: daN (lbs.)

Over Front; Dozer Blade Up

Over Rear Over Side Upper Crawler width 900 mm

LIFTING CAPACITIES SPECIFICATIONS

Over Front; Dozer Blade Up

Over Rear Over Side Upper Crawler width 900 mm

SPECIFICATIONS SPECIFICATION TABLES

Serial Number 10820001~