CX36B Mini Excavator

CX31B
CX36B
Compact Hydraulic Excavator
CX31B - PIN PW14-46519 - and higher
CX36B - PIN PX15-21105 - and higher
SERVICE MANUAL
Printed in U.S.A. Part number S5PW0032E02

English
Copyright © 2010 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. August 2010
Racine Wisconsin 53404 U.S.A.
COMPACT HYDRAULIC EXCAVATOR
MAINTENANCE SPECIFICATIONS
SHOP CX31B
MANUAL model CX36B
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
Book Code No.S5PW0032E02

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

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

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
CASE-NA INDEX CX31B
CX36B
Book Code No. Index
Distribution Year–Month
Title
No. 33 1
MAINTENANCE SPECIFICATIONS
S5PA0105E01
2010-03
OUTLINE 1
S5PW0232E02
2010-06
SPECIFICATIONS 2
S5PW0332E02
ATTACHMENT DIMENSIONS 3 2
2010-06 42 34
S5PW1131E02
TOOLS 11
2010-06
S5PW1231E02 STANDARD MAINTENANCE
2010-06 TIME TABLE
12
S5PW1332E02 MAINTENANCE STANDARD
13
2010-06 AND TEST PROCEDURE
43 11 3
_ 51
S5PW2232E02
2010-06
HYDRAULIC SYSTEM 22
S5PW2332E02
SYSTEM
2010-06
ELECTRIC SYSTEM 23
44 12
S5PW2432E02
2010-06
COMPONENTS SYSTEM 24
_
13
S5PA3105E01 GENERAL DISASSEMBLY
DISASSEMBLING
2010-03 & ASSEMBLY

31
S5PW3232E02
ATTACHMENT 32
2010-06
S5PW3332E02 UPPER SLEWING
2010-06
33
STRUCTURE
S5PW3432E02 22
2010-06
TRAVEL SYSTEM 34
E / G TROUBLESHOOTING
S5PW4231E02
2010-06
HYDRAULIC SYSTEM 42
S5PW4331E02
2010-06
ELECTRICAL SYSTEM 43 31 23
S5PW4431E02
ENGINE 44
2010-06
S5PW5131E02
ENGINE 51
2010-06
_
32 24
_
PW14-46519~
PX15-21105~ APPLICABLE MACHINES
0-5
NOTE: This Manual may be revised due to the improvement of
products, modification of specifications, etc. There may
This manual contains information necessary for the
be cases where the system on the actual machine may
maintenance and repair of hydraulic excavators. It is
differ with the manual - this may be due to variation of
categorized into seven chapters: Specification, Mainte-
specifications by countries. Contact your local distribu-
nance, System, Disassembly, Troubleshooting, Engine
tor if you need clarification.
and Installation Procedures for Optional Attachment.
When ordering replacement or service parts, refer to

• The Chapter "Specification" describes the specifi- the most recent Parts Catalog for the machine to get
cations for the entire machine and replacement and the correct replacement/service part number.
repairing of attachments.
• The Chapter "Maintenance" contains material for
service and adjustment of the entire machine.
• The Chapter "System" describes the operating sys-
tem, including the hydraulic system, electric sys-
tem, components, etc.
• The Chapter "Disassembly" describes the removal
and installation of assemblies mounted on the up-
per structure and undercarriage, and the assem-
bling and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the faults in equipment.
• The Chapter "Engine" contains the complete "Main-
tenance Manual" provided by the engine supplier.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
1. OUTLINE
1. OUTLINE
TABLE OF CONTENTS
1.1 GENERAL PRECAUTIONS FOR REPAIRS ........................................................1-3

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

S5PA0105E01
First Edition June, 2009 E10SR : PA03-05001~
(NHK-EUR)
↑
↑ ↑ E10SR : PA03-05001~
(NHK-AUS)
↑
↑ ↑ SK10SR-2 : PA03-05001~
(AUS)
↑
↑ July, 2009 SK10SR-2 : PA03-05001~
(KOR)
↑
↑ December, 2009 E18SR : PU09-08001~
(NHK-EUR)
↑
↑ ↑ SK17SR-3K : PU09-08001~
(KOR)
↑
↑ January, 2010 SK17SR-3 : PU09-08001~
(Oceania)
SK30SR-5 : PW14-45964~ ↑
↑ ↑
SK35SR-5 : PX15-20658~ (KCM North America)
↑
↑ ↑ CX17B : PU09-08001~
(CASE AUS)
↑
↑ ↑ E18SR : PU09-08001~
(NH AUS)
CX31B : PW14-45964~ ↑
↑ ↑
CX36B : PX15-20658~ (CASE-NA)
E30B : PW14-45964~ ↑
↑ ↑
E35B : PX15-20658~ (NH-NA)
↑
↑ ↑ SK17SR-3 : PU09-08001~
(NA)
↑
↑ ↑ SK50SR-5 : PJ06-08890~
(NA)
SK30SR-5 : PW14-45001~ ↑
↑ February, 2010
SK35SR-5 : PX15-20001~ (KCM S.E.ASIA&OCE)
CX31B : PW14-45001~ ↑
↑ ↑
CX36B : PX15-20001~ (CASE-AUS)
↑
↑ ↑ CX50B : PJ06-08890~
(CASE-NA)
↑
↑ ↑ E50B : PJ06-08890~
(NH-NA)
E30B : PW14-45001~ ↑
↑ ↑
E35B : PX15-20001~ (NH-AUS)
↑
↑ ↑ SK27SR-5 : PV13-33292~
(NA)
SK30SR-5 : PW14-46519~ ↑
↑ March, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR REPAIRS
1.1.1 PREPARATION BEFORE DISASSEMBLING 1
Read Operator's Manual

before disassembling
(1) Understanding operating procedure

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

STANDARD HANDBOOK FOR MECHANICAL ENGINEERS)
Introduction Base units

Table 1-1
Although this manual includes International System of Unit
Derived units
and Foot-Pound System of Units, if you need SI unit, refer Supplemen of base units
to the following international system of units. SI units tary units Table 1-3
Given hereinafter is an excerpt of the units that are related SI unit Table 1-2
system Derived units
to this manual.
Derived bearing peculiar
1. Etymology of SI Unites designations
units
French: Le Systeme International d' Unites Table 1-4
English: International System of Units
2. Construction of SI Unit System Prefixes of SI
(n-th power of 10, where n is an integer)
Table 1- 5
(1) Base units (4) Derived Units bearing Peculiar Designations

Table 1-1 Table 1-4
QUANTITY UNIT SYMBOL QUANTITY UNIT SYMBOL FORMULA
Length meter m Frequency hertz Hz 1/s
Mass kilogram kg Force newton N kg • m/s 2
Time second s Pressure and
pascal Pa N/m2
Electric current ampere A Stress
Thermodynamic Energy, Work
kelvin K
temperature and Quantity of joule J N•m
Amount of heat
mol mol
substance Power watt W J/s
Luminous Quantity of
candela cd coulomb C A•s
intensity electricity
Electric
(2) Supplementary units potential
Table 1-2 difference,
volt V W/A
Voltage, and
QUANTITY UNIT SYMBOL
Electromotive
Plane angle radian rad
force
Solid angle steradian sr
Quantity of
static electricity
(3) Derived Units farad F C/V
and Electric
Table 1-3 capacitance
QUANTITY UNIT SYMBOL Electric
ohm V/A
Area square meter m2 resistance
Volume cubic meter m3 celcius
Celcius
Velocity meter per second m/s degree or C (t+273.15)K
temperature
Acceleration meter per second squared m/s2 degree
Density kilogram per cubic meter kg/m3 Illuminance lux lx l m/m2
1-8
1. OUTLINE
(5) Prefixes of SI (6) Unit Conversion

Table 1-5 Table 1-6 1
PREFIX SYMBOL MULTIPLICATION FACTORS QUANTITY Gravitational SI CONVERSION FACTOR
giga G 10 9
Mass kg kg
mega M 106 Force kgf N 1 kgf=9.807 N
kilo k 10 3
Torque kgf•m N•m kgf•m=9.807 N•m
hecto h 10 2
Pressure kgf/cm 2
MPa 1 kgf/cm2=0.09807 MPa
deca da 10 Motive
PS kW 1 PS=0.7355 kW
deci d 10 –1 Power
centi c 10–2 Revolution rpm min–1 r/min *1
milli m 10–3
*1 Units that are allowed to use.
micro μ 10–6
nano n 10–9
pico p 10–12
1-9
1. OUTLINE
1-10
2. SPECIFICATIONS
2. SPECIFICATIONS
TABLE OF CONTENTS
2.1 COMPONENTS NAME ........................................................................................2-3

2.2 MACHINE DIMENSIONS .....................................................................................2-4
2.3 SPECIFICATIONS AND PERFORMANCE ..........................................................2-6
2.4 MACHINE & COMPONENTS WEIGHT (DRY) ....................................................2-8
2.5 TRANSPORTATION .............................................................................................2-10
2.6 TYPE OF CRAWLER SHOES .............................................................................2-13
2.7 TYPE OF BUCKET ..............................................................................................2-14
2.8 ENGINE SPECIFICATIONS .................................................................................2-15
2.8.1 SPECIFICATIONS .......................................................................................2-15
2.8.2 ENGINE PERFORMANCE CURVE .............................................................2-16
Book Code No. S5PW0232E02
2-1
2. SPECIFICATIONS

CX31B : PW14- S5PW0232E01
First Edition March, 2010
CX36B : PX15- (CASE-NA)
CX31B : PW14-46519~ S5PW0232E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
2-2
2. SPECIFICATIONS
2.1 COMPONENTS NAME
ARM CYLINDER
LIGHT
BOOM
BOOM CYLINDER 2
BUCKET
CYLINDER CANOPY
OPERATING LEVER
ARM
DOZER OPERATING LEVER
HYDRAULIC TANK
LINK
CONTROL VALVE
BUCKET
TRAVEL LEVER MONITOR PANEL
(GAUGE CLUSTER)
RADIATOR
AIR CLEANER
SWING CYLINDER
RESERVOIR TANK
DOZER CYLINDER
MUFFLER
BATTERY ENGINE
FUEL TANK
DOZER
RUBBER CRAWLER SHOE

IDLER ASSY
LOWER ROLLER OIL FILTER
UPPER ROLLER SLEWING MOTOR
SLEWING BEARING SWIVEL JOINT
TRAVEL MOTOR
HYDRAULIC PUMP
2-3
2. SPECIFICATIONS
2.2 MACHINE DIMENSIONS
(1) CX31B (CANOPY) Unit: mm (ft-in)
{7.28"}
185
660 {2'2.0"} 660 {2'2.0"}
1550 {5'1.0"}
R775
{2'6.5"}
{2.0"}
50
{3.3"}
85
4470 {14'8.0"}
1840 {6'0.44"}
1380 {4'6.3"}
1550 {5'1.0"}
775 {2'6.5"}
2570 {8'5.2"}
{1'10.4"}
570
345 {13.6"}
300 1550 {5'1.0"}

{11.8"} 1250 {4'1.2"} 1700 {5'6.9"}
1550 {5'1.0"} 2150 {7'0.6"}
2630 {8'7.5"}
(2) CX31B (CAB)

{7.28"}
185
660 {2'2.0"} 660 {2'2.0"}
1550 {5'1.0"}
R775
{2'6.5"}
{2.0"}
50
{3.3"}
85
4470 {14'8.0"}
1840 {6'0.44"}
1380 {4'6.3"}
1550 {5'1.0"}
775 {2'6.5"}
{1'10.4"} 2570 {8'5.2"}
570
345 {13.6"}
300 1550 {5'1.0"}

{11.8"} 1250 {4'1.2"} 1700 {5'6.9"}
1550 {5'1.0"} 2150 {7'0.6"}
2630 {8'7.5"}
2-4
2. SPECIFICATIONS
(3) CX36B (CANOPY) Unit:mm(ft-in)
160{6.3"}
660 {2'2.0"} 660 {2'2.0"}
1700 {5'6.9"}
R850
{2'9.5"}
{2.0"}
50
2
{2.4"}
60
4710 {15'5.4"}
1910 {6'3.2"}
1550 {5'1.0"} 1460 {4'9.5"}
850 {2'9.5"}
2570 {8'5.2"}
{13.6"}
330 {13.0"}
345
{1'10.4"}
570
1600 {5'3.0"}
300 1700 {5'6.9"}
{11.8"} 1400 {4'7.1"} 2150 {7'0.6"}
1700 {5'6.9"} 2680 {8'9.5"}
(4) CX36B (CAB)

160{6.3"}
660 {2'2.0"} 660 {2'2.0"}
1700 {5'6.9"}
R850
{2'9.5"}
{2.0"}
50
{2.4"}
60
4710 {15'5.4"}
1910 {6'3.2"}
1460 {4'9.5"}
1550 {5'1.0"} 850 {2'9.5"}
2610 {8'6.8"}
330 {13.0"}
{13.6"}
345
{1'10.4"}
570
1600 {5'3.0"}
300 1700 {5'6.9"}
{11.8"} 1400 {4'7.1"} 2150 {7'0.6"}
1700 {5'6.9"} 2680 {8'9.5"}
2-5
2. SPECIFICATIONS
2.3 SPECIFICATIONS AND PERFORMANCE
SPEED AND GRADEABILITY
Model CX31B CX36B

Applicable Machines PW14-46519~ PX15-21105~
Iron shoe Iron shoe
Shoe Type Rubber shoe Rubber shoe
(OPT) (OPT)
Slewing Speed min -1 {rpm} 8.9 (8.9) 8.9 (8.9)
Low High Low High Low High Low High
Travel Speed km/h (mph) (1st) (2nd) (1st) (2nd) (1st) (2nd) (1st) (2nd)
2.5 4.5 2.5 4.5 2.5 4.5 2.5 4.5
Gradeability % (degree) 58(30)
ENGINE
Model (YANMAR) 3TNV88-BPYB

Type Water-cooled, 4-cycle type Swirl chamber type diesel engine
Number of cylinders-Bore X Stroke 3 - 88 dia. mm X 90 mm (3.46 in X 3.54 in)
Total Displacement L 1.642 (100.2 cu-in)
Output Rating kW/min-1 {PS/rpm} 21.2/2,400 (29/2,400)
-1
Maximum Torque N-m/min (lbf-ft/rpm) 98.0/1,440 (72.3/1,440)
Starting Motor V X kW 12 X 1.7
Generator VXA 12 X 55
HYDRAULIC COMPONENTS
Hydraulic Pump Variable displacement axial piston + gear pump

Hydraulic Motor Axial piston
Hydraulic Motor w/Reducer (Travel) 2-Axial piston, 2-Speed motor
Control Valve 10-spool multiple control valve
Cylinder (Boom, Arm, Swing, Bucket, Dozer) Double action cylinder
Return Filter Safety valve containing/Filter Type (30μ)
SIDE DIGGING & DOZER
Type Boom swing by hydraulic cylinder

Boom Swing Angle Right 60 degrees
Left 70 degrees
Stroke of Dozer (above/below) mm (in) 560 / 410 (22.0/16.1) 540 / 440 (21.3/17.3)
2-6
2. SPECIFICATIONS
WEIGHT
Rubber shoe Iron shoe Rubber shoe Iron shoe

Machine Weight kg (lb)
3,200 (7050) 3,340 (7360) 3,580 (7900) 3,700 (8160)
Upper slewing body kg (lb) 1,600 (3530) <-- 1,900 (4190) <--
1,140 (2520)
Travel system kg (lb) 1,120 (2470) 1,230 (2710) 1,260 (2780)
Attachment
(Boom+STD Arm+STD Bucket)
kg (lb) 400 (880) 460 (1020) 2
Oil & Water kg (lb) 80 (175) <--
This figure is calculated with Japanese standard bucket.
2-7
2. SPECIFICATIONS
2.4 MACHINE & COMPONENTS WEIGHT (DRY)

Unit ; kg (lb)
CX31B
MODEL RUBBER SHOE IRON SHOE
CANOPY CAB CANOPY CAB
COMPLETE MACHINE 3,200 (7050) 3,340 (7360) 3,310 (7300) 3,450 (7600)
UPPER FRAME ASSEMBLY 1,600 (3530) 1,740 (3840) 1,600 (3530) 1,740 (3840)
(ASSY OF FOLLOWINGS)
UPPER FRAME 348 (767) <-- <-- <--
CANOPY / CAB 85 (187) 220 (485) 85 (187) 220 (485)
ENGINE 155 (340) <-- <-- <--
HYDRAULIC PUMP 28 (60) <-- <-- <--
RADIATOR 3 (7) <-- <-- <--
HYDRAULIC TANK 42 (93) <-- <-- <--
FUEL TANK 4 (9) <-- <-- <--
SWING BRACKET 82 (181) <-- <-- <--
SWING CYLINDER 37 (82) <-- <-- <--
SLEWING MOTOR 38 (84) <-- <-- <--
CONTROL VALVE 25 (55) <-- <-- <--
COUNTERWEIGHT 370 (815) <-- <-- <--
GUARD - BONNET 92 (203) <-- <-- <--
BOOM CYLINDER 35 (77) <-- <-- <--
LOWER FRAME ASSEMBLY 1,120 (2470) <-- 1,230 (2710) <--
LOWER FRAME 350 (771) <-- <-- <--
SLEWING BEARING 42 (93) <-- <-- <--
TRAVEL MOTOR 42X2 (93X2) <-- <-- <--
LOWER ROLLER 6X 8 (13X 8) <-- <-- <--
FRONT IDLER 22X2 (49X2) <-- <-- <--
IDLER ADJUSTER 16X2 (35X2) <-- <-- <--
SPROCKET 9X2 (20X2) <-- <-- <--
RUBBER CRAWLER SHOE 141X2 (311X2) <-- - -
300mm (11.8") IRON SHOE - - 190X2 (420X2) <--
SWIVEL JOINT 22 (49) <-- <-- <--
DOZER 140 (310) <-- <-- <--
DOZER CYLINDER 27 (60) <-- <-- <--
ATTACHMENT ASSEMBLY 400 (880) <-- <-- <--
BOOM ASSEMBLY 220 (485) <-- <-- <--
BOOM 130 (286) <-- <-- <--
ARM CYLINDER 30 (66) <-- <-- <--
ARM ASSEMBLY 120 (265) <-- <-- <--
ARM 70 (155) <-- <-- <--
BUCKET CYLINDER 20 (44) <-- <-- <--
BUCKET LINK 10 (22) <-- <-- <--
IDLER LINK 4X2 (9X2) <-- <-- <--
BUCKET ASSEMBLY (STD) 81 (180) <-- <-- <--
FLUIDS 80 (176) <-- <-- <--
HYDRAULIC OIL 42 (93) <-- <-- <--
FUEL 32 (70) <-- <-- <--
COOLANT 4 (9) <-- <-- <--
Bucket weight is shown with Japanese standard bucket weight.
2-8
2. SPECIFICATIONS
Unit ; kg (lb)
CX36B
MODEL RUBBER SHOE IRON SHOE
CANOPY CAB CANOPY CAB
COMPLETE MACHINE 3,580 (7890) 3,720 (8200) 3,700 (8160) 3,840 (8470)
UPPER FRAME ASSEMBLY 1,900 (4190) 2,040 (4500) 1,900 (4190) 2,040 (4500)
UPPER FRAME 348 (767) <-- <-- <-- 2
CANOPY / CAB 85 (187) 220 (485) 85 (187) 220 (485)
ENGINE 155 (340) <-- <-- <--
HYDRAULIC PUMP 28 (60) <-- <-- <--
RADIATOR 3 (7) <-- <-- <--
HYDRAULIC TANK 42 (93) <-- <-- <--
FUEL TANK 4 (9) <-- <-- <--
SWING BRACKET 82 (181) <-- <-- <--
SWING CYLINDER 37 (82) <-- <-- <--
SLEWING MOTOR 38 (84) <-- <-- <--
CONTROL VALVE 25 (55) <-- <-- <--
COUNTERWEIGHT 665 (1470) <-- <-- <--
GUARD - BONNET 92 (203) <-- <-- <--
BOOM CYLINDER 35 (77) <-- <-- <--
LOWER FRAME ASSEMBLY 1,140 (2520) <-- 1,260 (2780) <--
LOWER FRAME 370 (815) <-- <-- <--
SLEWING BEARING 42 (93) <-- <-- <--
TRAVEL MOTOR 42X2 (93X2) <-- <-- <--
LOWER ROLLER 6X8 (13X8) <-- <-- <--
FRONT IDLER 22X2 (49X2) <-- <-- <--
IDLER ADJUSTER 16X2 (35X2) <-- <-- <--
SPROCKET 9X2 (20X2) <-- <-- <--
RUBBER CRAWLER SHOE 141X2 (311X2) <-- - -
300mm (11.8") IRON SHOE - - 190X2 (420X2) <--
SWIVEL JOINT 22 (49) <-- <-- <--
DOZER 150 (330) <-- <-- <--
DOZER CYLINDER 27 (60) <-- <-- <--
ATTACHMENT ASSEMBLY 460 (1020) <-- <-- <--

BOOM ASSEMBLY 190 (420) <-- <-- <--
BOOM 140 (310) <-- <-- <--
ARM CYLINDER 34 (75) <-- <-- <--
ARM ASSEMBLY 140 (310) <-- <-- <--
ARM 80 (175) <-- <-- <--
BUCKET CYLINDER 20 (44) <-- <-- <--
BUCKET LINK 10 (22) <-- <-- <--
IDLER LINK 4X2 (9X2) <-- <-- <--
BUCKET ASSEMBLY (STD) 89 (196) <-- <-- <--
FLUIDS 80 (176) <-- <-- <--
HYDRAULIC OIL 42 (93) <-- <-- <--
FUEL 32 (70) <-- <-- <--
COOLANT 4 (9) <-- <-- <--
Bucket weight is shown with Japanese standard bucket weight.
2-9
2. SPECIFICATIONS
2.5 TRANSPORTATION
(1) LOADING MACHINE ON A TRAILER

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

During transportation, the bucket or attachments may hit the canopy or the cab. Therefore, set the machine in
the transporting position by observing following points:
a. Extend the bucket cylinder fully.
b. Extend the arm cylinder fully.
c. Lower the boom.
d. If machine cannot be transported with arm cylinder fully extended, remove bucket or attachment and extend
arm cylinder.
(2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT

1. BOOM WITH ARM CYLINDER
Model CX31B CX36B

LXHXW 2,390 X 870 X 320 2,590 X 810 X 320
mm(ft-in) (7'10.1") (2'10.2") (12.6") (8'6.0") (2'7.9") (12.6")
Weight w/Arm cyl. kg (lb) 163 (360) 184 (405)
2-10
2. SPECIFICATIONS
2. ARM & BUCKET (Japanese standard bucket)
Model CX31B CX36B

LXHXW 2,190 X 450 X 500 2,360 X 450 X 600
mm (ft-in) (7'2.2") (17.7") (19.7") (7'8.9") (17.7") (1'11.6")
Weight kg (lb) 198 (435) 219 (485)
2
H
3. ARM
Model CX31B CX36B

LXHXW 1,520 X 430 X 280 1,690 X 430 X 280
mm (ft-in) (4'11.8") (16.9") (11.0") (5'6.5") (16.9") (11.0")
Weight kg (lb) 112 (245) 123 (270)
4. BUCKET (Japanese standard bucket)
Model CX31B CX36B

Heaped capacity
0.09 (0.118) 0.11 (0.144)
m3(cu-yd)
LXHXW 670 X 620 X 500 670 X 620 X 600
mm (ft-in) (2'2.4") (2'0.4") (19.7") (2'2.4") (2'0.4") (1'11.6")
Weight kg (lb) 81 (180) 89 (196)
2-11
2. SPECIFICATIONS
5. DOZER w/o cylinder weight
Model CX31B CX36B

LXHXW 1,230 X 330 X 1,550 1,280 X 330 X 1,700
mm (ft-in) (4'0.4") (13.0") (5'1.0") (4'2.4") (13.0") (5'6.9")
Weight kg (lb) 142 (315) 150 (330)
2-12
2. SPECIFICATIONS
2.6 TYPE OF CRAWLER SHOES
Total Crawler Ground pressure

Shoe width Number of
Type Model width kPa (psi)
mm (in) Link
mm (ft•in) CANOPY CAB
Rubber shoe
CX31B 300 (11.8") 1,550 (5’1.0") 88 27 (3.9) 28 (4.1)
2
CX36B 300 (11.8") 1,700 (5’6.9") 88 31 (4.5) 32 (4.6)
Iron shoe (option)

CX31B 300 (11.8") 1,550 (5’1.0") 45 28 (4.1) 29 (4.2)
CX36B 300 (11.8") 1,700 (5’6.9") 45 32 (4.6) 33 (4.8)
2-13
2. SPECIFICATIONS
2.7 TYPE OF BUCKET
Heaped Outer width mm (in)

Number of Weight
Type Model capacity with side without Remarks
tooth kg (lb)
m3 (cu.yd) cutter side cutter
Back hoe bucket
500 430
CX31B 0.09 (0.118) 4 81 (179)
(1’7.7") (1’4.9")
Standard
size
600 530
CX36B 0.11 (0.144) 4 89 (196)
(1’11.6") (1’8.9")
This table shows Japanese standard bucket.
2-14
2. SPECIFICATIONS
2.8 ENGINE SPECIFICATIONS
2.8.1 SPECIFICATIONS
Model CX31B, CX36B

Engine Model 3TNV88-BPYB
Type Vertical, 4-cycle water-cooled diesel engine
No. of cylinders - Bore × Stroke 3 - 88 mm (3.46 in) × 90 mm (3.54 in) 2
Total displacement 1.642 liter (100 cu•in)
Compression ratio 19.1
Rated output 21.2 kW (28.8 PS) at 2400 rpm
Maximum torque 98 ~ 106.8 N•m (72.3 ~ 78.8 lbf•ft) at 1440 rpm
Low idling 1250±25 rpm
High idling 2590±25 rpm
Fuel consumption rate 245 g / kW•h (180 g / PS•h) LESS THAN
Allowable tilting angles Continuous ; 30° for all direction
Rotating direction Counterclockwise as seen from flywheel side
Firing order 1-3-2-1
Fuel injection timing (b.T.D.C.) (FIT) 15.0±1 / (FIR) 5.0±1
+10 +140
Fuel injection pressure 200 0 kg / cm2 (2840 0 psi)
Open Close
Valve action Intake valve b.T.D.C. 15±5 a.B.D.C. 45±5
Exhaust valve b.B.D.C. 56±5 a.T.D.C. 18±5
Intake valve 0.2 mm (0.008 in) in cold condition
Valve clearance
Exhaust valve 0.2 mm (0.008 in) in cold condition
Thermostat action Start 71 ± 1.5 C (160 ± 3 F) / Full open 85 C (185 F)
Compression pressure 3.43 ± 0.1 MPa (500 ± 14 psi) at 250 rpm
Lubrication oil pressure 0.392 MPa (57 psi) at 2400 rpm
Dimensions L × W × H 585 × 539 × 648 mm (23.0 × 21.2 × 25.5 in)
Dry weight 155 kg (342 lb)
Governor Mechanical centrifugal governor (All speed type)
Fuel filtration cartridge type paper filter
Lubrication system Forced lubrication with trochoid pump
Cooling system Liquid cooling / Radiator
Starter capacity 12 V × 1.7 kW
Generator capacity 12 V × 55 A
Starting aid Glow plug (12 V - 300 W)
Cooling water capacity : Max / Engine 4.0 / 2.0 liter (1.06 / 0.53 gal)
Engine oil volume : High / Low 6.7 / 3.9 liter (1.77 / 1.03 gal)
2-15
2. SPECIFICATIONS
2.8.2 ENGINE PERFORMANCE CURVE

CX31B, CX36B
Model : 3TNV88-BPYB
Rated Output : 21.2 kW / 2400 min-1 (28.8 PS / 2,400 rpm)
N.m (lbf.ft)
120 (89)
[T]
100 (74)
SHAFT TORQUE
(PS) kW
T
80 (59)
(34) 25 60 (44)
40 (30)
(27) 20
POWER OUTPUT
kW
(20) 15
g/kWh (g/psh)
[F]
FUEL CONSUMPTION RATE

(14) 10 280 (206)
260 (191)
(7) 5 240 (176)

F
220 (162)
200 (147)
1000 1500 2000 2500
Engine speed min 1{rpm}
F kWh
Fuel consumption volume = XPX
X 1000 kW
245
= X 21.2 X
0.835 X 1000
3.73 ~ 4.35 L / h (load factor : (0.60 ~ 0.70))
= 6.22
2-16
3. ATTACHMENT DIMENSIONS
3
TABLE OF CONTENTS
3.1 BOOM .................................................................................................................. 3-3

3.1.1 BOOM DIMENSIONAL DRAWINGS ........................................................... 3-3
3.1.2 BOOM MAINTENANCE STANDARDS ........................................................ 3-4
3.2 ARM ..................................................................................................................... 3-8
3.2.1 ARM DIMENSIONAL DRAWINGS .............................................................. 3-8
3.2.2 ARM MAINTENANCE STANDARDS ........................................................... 3-10
3.3 BUCKET .............................................................................................................. 3-15
3.3.1 BUCKET DIMENSIONAL DRAWINGS ........................................................ 3-15
3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION .......................... 3-16
3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION ........................ 3-16
3.4 DOZER ................................................................................................................ 3-17
3.4.1 DOZER DIMENSIONAL DRAWINGS .......................................................... 3-17
3.4.2 DOZER MAINTENANCE STANDARDS ...................................................... 3-18
3.5 SWING ................................................................................................................. 3-20
3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ........................................ 3-20
3.5.2 SWING PORTION MAINTENANCE STANDARDS ..................................... 3-21
3-1

CX31B : PW14- S5PW0332E01
CX31B : PW14-46519~ S5PW0332E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
3-2
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWINGS
Boom Dimensional Drawings
DIMENSIONS [mm(ft-in)]
No. NAME
CX31B CX36B
A Boom length 2300 (7'6.55") 2500 (8'2.43")
B Distance between pins of boss R1217.5 (3'11.93") R1210 (3'11.64")
C Distance between pins of bracket R1130.5 (3'8.51") R1157 (3'9.55")
D Height of boom cylinder rod pin 420.5 (1'4.56") 385.5 (1'3.18")
E Height of arm cylinder (head side) pin 764 (2'6.08") 708 (2'3.87")
F Boom foot width 178 (7.01") <--
G Inner width of bracket for boom cylinder (rod side) mounting 61 (2.40") <--
H Boom end inner width 150 (5.91") <--
J Boom end outer width 235 (9.25") <--
K Inner width of bracket for arm cylinder (head side) 61 (2.40") <--
d1 Boom foot pin dia. 45 dia. (1.77") <--
[Bushing outer dia.] [55 dia. (2.17")]
d2 Boom cylinder (rod side) pin dia. 45 dia. (1.77") <--
d3 Pin dia. of arm end 45 dia. (1.77") <--
d4 Arm cylinder (head side) pin dia. 45 dia. (1.77") <--
3-3
3.1.2 BOOM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing on boom section
Clearance of pin and bushing on boom section
Unit : mm (in)
Standard dimensions Clearance
Tolerance Standard
Pos. Item Pin part No. Tolerance Standard Serviceabi Remedy
Pin dia. on bushing value for
on pin dia. value lity limit
bore dia. repair
–0.02 +0.10 0.07-
–0.05 +0.05 0.15
A Boom foot PX02B01299P1
(-0.0008) (+0.0039) (0.0028-
(-0.0020) (+0.0020) 0.0059)
–0.02 +0.12 0.08-
Boom
–0.08 +0.06 0.20
B cylinder PX02B01263P1 Replace
(-0.0008) (+0.0047) (0.0031- 0.7 1.0
(Head side) bushing
(1.7717) (-0.0031) (+0.0024) 0.0079) (0.028) (0.039)
or pin
Boom
C cylinder –0.02 +0.13 0.09-
(Rod side) –0.05 +0.07 0.23
PW02B01306P1
Arm (-0.0008) (+0.0051) (0.0035-
D cylinder (-0.0020) (+0.0028) 0.0091)
(Head side)
-The tolerance for bushing inside diameter means the dimension after fitting of it into place.
-The part number for pins may be changed owing to improvement, use them only for reference.
3-4
This page is blank for editing convenience.
3-5
(2) Clearance in thrust direction on boom and cylinder installation section
PL2
L2 X
Clearance in thrust direction on boom section
3-6
Unit : mm (in)
Standard Clearance X adjusted with shim
Pin length
dimensions (total of both sides)
Sec. Item Standard Remedy
Standard Serviceabili
No. Dimensions value for No. Dimensions
value ty limit
repair
178
Boom
0.2-0.6
(7.008 ) 297
A-A Boom foot L1 (0.008- PL1
(11.69)
Swing 178 0.024)
bracket
(7.008 )
Boom 60
cylinder 0.1-0.5 3
Boom cylinder (2.362 ) 178
B-B L2 (0.004- PL2
(Head side) (7.01)
Swing 61 0.020)
bracket Adjusted
(2.402 ) 1.0 1.5
with
(0.039) (0.059)
Boom 60 shim
cylinder 0.5-0.9
Boom cylinder (2.362 ) 151
C-C L3 (0.020- PL3
(Rod side) (5.94)
61 0.035)
Boom
(2.402 )
Arm 60
cylinder 0.1-0.5
Arm cylinder (2.165 ) 151
D-D L4 (0.004- PL4
(Head side) (5.94)
61 0.020)
Boom
(2.205 )
3-7
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWINGS
Arm dimensional drawings
3-8
Dimensions [mm(ft-in)]
No. Name
CX31B CX36B
A Arm length 1180(3'10.46") 1320(4'3.97")
B Distance between pins of boss and bracket R304.5(11.99") R314(1'0.36")
C Distance between pins of boss and bracket R1036(3'4.79") R1036(3'4.79")
D Distance between pins of boss and boss R190(7.48") R190(7.48")
E Height between pins of boss and bracket 332(1'1.07") 332(1'1.07")
F Height between pins of boss and bracket 180(7.09") 149.5(5.89")
G Height between pins of boss and center 8(0.31") 8(0.31")
H Boss width 140(5.51") 140(5.51")
J Boss width 150(5.91") 150(5.91") 3
K Bracket inner width 56(2.20") 56(2.20")
L Bracket inner width 61(2.40") 61(2.40")
M Idler link dimension 310(1'0.20") 310(1'0.20")
N Bucket link dimension 285(11.22") 285(11.22")
D1 I.D. of boss 50 dia.(1.97") 50 dia.(1.97")
d1 Pin dia. 40 dia.(1.57") 40 dia.(1.57")
d2 Pin dia. 40 dia.(1.57") 40 dia.(1.57")
d3 Pin dia. 45 dia.(1.77") 45 dia.(1.77")
d4 Pin dia. 40 dia.(1.57") 40 dia.(1.57")
d5 Pin dia. 45 dia.(1.77") 45 dia.(1.77")
3-9
3.2.2 ARM MAINTENANCE STANDARDS
(1) Clearance of pin and bushing
Clearance of pin and bushing on arm section
• CX31B Unit : mm (in)

Tolerance Standard
Pos. Item Pin part No. Tolerance Standard Serviceabili Remedy
on pin dia. value ty limit
bore dia. repair
Arm point +0.11 0.08-
(Connected +0.06 0.16
A
part of (+0.0043) (0.0031-
bucket) (+0.0024) 0.0063)
PW12B01351P1
+0.11 0.07-
Bucket link +0.05 0.16
B
(Bucket side) (+0.0043) (0.0028-
(+0.0020) 0.0063)
+0.08 0.05-
Idler link
+0.03 0.13
C (Connected PW12B01311P1
(+0.0031) (0.0020-
part of arm)
ø40 (+0.0012) 0.0051)
(1.575) +0.09
Bucket link 0.05-0.14
+0.03
D (Idler link (0.0020-
–0.02 (+0.0035)
side) 0.0055) Replace
–0.05 (+0.0012) 0.7 1.0
PX12B01319P1 bushing
(-0.0008) +0.25 0.07- (0.028) (0.039)
Bucket or pin
(-0.0020) +0.05 0.30
D’ cylinder
(+0.0098) (0.0028-
(Rod side)
(+0.0020) 0.0118)
+0.13 0.09-
Bucket
+0.07 0.18
E cylinder PW12B01220P1
(+0.0051) (0.0035-
(Head side)
(+0.0028) 0.0071)
+0.10 0.07-
Arm foot
+0.05 0.15
F (Connected PX12B01370P1
(+0.0039) (0.0028-
part of boom)
ø45 (+0.0020) 0.0059)
(1.772) +0.13 0.09-
Arm cylinder +0.07 0.18
G PW02B01306P1
(Rod side) (+0.0051) (0.0035-
(+0.0028) 0.0071)
3-10

Tolerance Standard
Pos. Item Pin part No. Tolerance Standard Serviceabili Remedy
on pin dia. value ty limit
bore dia. repair
Arm point +0.11 0.08-
(Connected +0.06 0.16
A
part of (+0.0043) (0.0031-
bucket) (+0.0024) 0.0063)
PW12B01351P1
+0.11 0.07-
Bucket link +0.05 0.16
B
(Bucket side) (+0.0043) (0.0028-
(+0.0020) 0.0063)
+0.08 0.05-
Idler link
+0.03 0.13 3
C (Connected PW12B01311P1
(+0.0031) (0.0020-
part of arm)
ø40 (+0.0012) 0.0051)
(1.575) +0.09
Bucket link 0.05-0.14
+0.03
D (Idler link (0.0020-
–0.02 (+0.0035)
side) 0.0055) Replace
–0.05 (+0.0012) 0.7 1.0
PX12B01319P1 bushing
(-0.0008) +0.25 0.07- (0.028) (0.039)
Bucket or pin
(-0.0020) +0.05 0.30
D’ cylinder
(+0.0098) (0.0028-
(Rod side)
(+0.0020) 0.0118)
+0.13 0.09-
Bucket
+0.07 0.18
E cylinder PX12B01206P1
(+0.0051) (0.0035-
(Head side)
(+0.0028) 0.0071)
+0.10 0.07-
Arm foot
+0.05 0.15
F (Connected PX12B01370P1
(+0.0039) (0.0028-
part of boom)
ø45 (+0.0020) 0.0059)
(1.772) +0.13 0.09-
Arm cylinder +0.07 0.18
G PX12B01320P1
(Rod side) (+0.0051) (0.0035-
(+0.0028) 0.0071)
3-11
(2) Clearance in thrust direction on arm and cylinder installation section
3-12
Clearance in thrust direction on arm section

Standard Clearance X adjusted with
Pin length
dimensions shim (total of both sides)
Sec. Item Standard Servicea Remedy
Standard
No. Dimensions value for bility No. Dimensions
value
repair limit
140
Arm
(5.512) 268
A-A Arm point L1 PL1
141±0.7 (10.55)
Bucket
(5.551±0.028) 0.5-2.1
(0.020- See "NOTE"
140
Link side 0.083)
268
B-B Bucket link L2 (5.512 ) PL2
141±0.7
(10.55)
3
Bucket
(5.551±0.028)
140
Idler link Arm 0.1-0.5
(5.551) 204.5
C-C (Connected L3 (0.004- — PL3
— (8.05)
part of arm) Link side 0.020)
(—)
55
Rod side
Less
Bucket link (2.165 ) 1.0 1.5
L4 than 0.5
(Rod side) (0.039) (0.059)
56 (0.020)
Link side
204.5
D-D (2.205 ) PL5
(8.05)
140 Adjusted
Bucket link 0.1-0.5 with
Bucket link
L5 (5.512 ) (0.004- — shim
(Idler link side)
— 0.020)
Idler link
(—)
55
Head side
0.5-0.9
Bucket cylinder (2.165 ) 153
E-E L6 (0.020- PL6
(Head side) (6.02)
56 0.035)
Arm
(2.205 )
150
Arm
Less
(5.906 ) 1.0 1.5 234.5
F-F Arm foot L7 than 0.5 PL7
(0.039) (0.059) (9.23)
150 (0.020)
Boom
(5.906)
60
Rod side
0.5-0.9
G-G L8 (0.020- PL8
(Rod side) (5.94)
61 0.035)
Arm
(2.402 )
Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.
3-13

Standard Clearance X adjusted with
Pin length
dimensions shim (total of both sides)
Sec. Item Standard Servicea Remedy
Standard
No. Dimensions value for bility No. Dimensions
value
repair limit
140
Arm
(5.512) 268
A-A Arm point L1 PL1
141±0.7 (10.55)
Bucket
(5.551±0.028) 0.5-2.1
(0.020- See "NOTE"
140
Link side 0.083)
268
B-B Bucket link L2 (5.512 ) PL2
(10.55)
141±0.7
Bucket
(5.551±0.028)
140
Idler link Arm 0.1-0.5
(5.551) 204.5
C-C (Connected L3 (0.004- — PL3
— (8.05)
part of arm) Link side 0.020)
(—)
55
Rod side
Less
Bucket link (2.165 ) 1.0 1.5
L4 than 0.5
(Rod side) (0.039) (0.059)
56 (0.020)
Link side
204.5
D-D (2.205 ) PL5
(8.05)
140 Adjusted
Bucket link 0.1-0.5 with
Bucket link
L5 (5.512 ) (0.004- — shim
(Idler link side)
— 0.020)
Idler link
(—)
55
Head side
0.5-0.9
Bucket cylinder (2.165 ) 157
E-E L6 (0.020- PL6
(Head side) (6.18)
56 0.035)
Arm
(2.205 )
150
Arm
Less
(5.906 ) 1.0 1.5 234.5
F-F Arm foot L7 than 0.5 PL7
(0.039) (0.059) (9.23)
150 (0.020)
Boom
(5.906)
60
Rod side
0.5-0.9
G-G L8 (0.020- PL8
(Rod side) (6.30)
61 0.035)
Arm
(2.402 )
Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.
3-14
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWINGS
Bucket dimensional drawings
No. Model CX31B CX36B

Heaped Capacity m3 0.09 0.11
(cu.yd) (0.118) (0.144)
A Distance between pin and bracket 200 (7.87") <--
B Distance between bucket pin and tooth end R712 (2'4.03") <--
C Inner width of bucket top end 430 (1'4.93") 530 (1'8.87")
D Inner width of lug 193 (7.60") <--
E Inner width of bracket 141 (5.55") <--
F Outer width of side cutter 500 (1'7.69") 600 (1'11.62")
G Outer width of bucket bottom plate 405 (1'3.94") 505 (1'7.88")
H Outer tooth distance 367 (1'2.45") 468 (1'6.43")
J Pitch between teeth 122 (4.80") 156 (6.14")
J0 Pitch between teeth 123 (4.83") 156 (6.14")
d1 Pin dia. 40 dia.(1.57") <--
d2 Pin dia. 40 dia.(1.57") <--
1. Japanese standard bucket.
3-15
3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION
Dimension of lug section
Unit : mm (in)
Plate outer dia. Boss thickness Pin bore dia. Lug plate thickness
Portion
øA B øC D
ø85 26 ø40 14
Dimensions
(3.35) (1.02) (0.551)
(1.578 )
3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION
Dimension of boss section
Unit : mm (in)
Portion øA øB øC øD E F øG
65 43 60 63 12 24 11
Dimensions
(2.56) (1.69) (2.36) (2.48) (0.472) (0.945) (0.433)
3-16
3.4 DOZER
3.4.1 DOZER DIMENSIONAL DRAWINGS
Dozer dimensional drawings
Dimensions [mm(ft-in)]
No. NAME
CX31B CX36B
A Blade width 1550 (5'1.02") 1700 (5'6.93")
B Blade height 346 (1'1.62") 345 (1'1.58")
C Distance from dozer attaching pin center to cutting edge end R1187 (3'10.73") R1232 (4'0.50")
D Inner width of dozer attaching bracket 500 (1'7.69") <--
E Width of dozer attaching bracket 60 (2.36") <--
F Distance from dozer attaching pin center to attaching pin on R608 (1'11.94") R626 (2'0.65")
dozer cylinder head side
G Attaching bracket inner width on dozer cylinder head side 62 (2.44") <--
H Horizontal distance from dozer attaching pin center to edge end 1144 (3'9.04") 1192 (3'10.93")
J Vertical distance from dozer attaching pin center to edge end 315 (1'0.40") 310 (1'0.20")
d1 Dozer attaching pin dia. 40 dia.(1.57") <--
d2 Attaching pin dia. on dozer cylinder head side 45 dia.(1.77") <--
3-17
3.4.2 DOZER MAINTENANCE STANDARDS
Dozer maintenance standards

Unit : mm (in)
Standard dimension Clearance
Tolerance Tolerance Standard
Pos. Item Pin part No. Standard Serviceabi Remedy
Pin dia. on pin dia. on bushing value for
value lity limit
bore dia. repair
Dozer blade
A cylinder –0.06 +0.20 0.11-
(Head side) ø45 –0.11 +0.05 0.31
PH12B01009P1
Dozer blade (1.772) (-0.0024) (+0.0079) (0.0043-
Replace
B cylinder (-0.0043) (+0.0020) 0.0122) 0.7 1.0
bushing
(Rod side) (0.028) (0.039)
or pin
–0.06 +0.22 0.18-
Dozer blade ø40 –0.09 +0.12 0.31
C PW51B01028P1
foot (1.575) (-0.0024) (+0.0087) (0.0071-
(-0.0035) (+0.0047) 0.0122)
3-18
(2) Clearance in thrust direction on the dozer and cylinder installation section
Unit : mm (in)
Standard dimensions Pin length
Pos. Item Clearance X Remedy
No. Dimensions No. Dimensions
(total of both sides)
Head side
60 3
Dozer blade
(2.362 ) 137
A cylinder L1 PL1
(5.39)
(Head side) 62
Dozer blade
(2.441 )
When
60 0.6-2.0
Rod side clearance X
Dozer blade (0.023-0.079)
(2.362 ) exceeds 3.5 137
B cylinder L2 After shim PL2
mm, adjust it (5.39)
(Rod side) Lower 62 adjustment
with shim.
frame
(2.441 )
60±0.3
Dozer blade
(2.362±0.012)
Dozer blade 127
C L3 PL3
foot Lower 62 (5.00)
frame
(2.441 )
3-19
3.5 SWING
3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS
E
H
d3
B A G
d2
C
F1
d4
F
F2 J
d1
Swing bracket dimensional drawings
No. NAME DIMENSION [mm(in)]

A Distance between swing center pin and boom foot pin 96 (3.78)
B Distance between boom foot pin and boom cylinder pin 176.8 (6.96)
C - ditto - 266.9 (10.51)
D Distance between swing center pin and swing cylinder pin R264 (10.39)
E - ditto - 257 (10.12)
F Inside width of swing center 303.7 (11.96)
F1 - ditto - 75.7 (2.98)
F2 - ditto - 73.5 (2.89)
G Inside width of boom foot 178 (7.01)
H Inside width for installing boom cylinder 61 (2.40)
J Inside width for installing swing cylinder 67 (2.64)
d1 Pin dia. of swing center 65 dia.(2.56)
d2 Pin dia. of boom foot 45 dia.(1.77")
d3 Pin dia. of boom cylinder 45 dia.(1.77")
d4 Pin dia. of swing cylinder 45 dia.(1.77")
3-20
3.5.2 SWING PORTION MAINTENANCE STANDARDS
Clearance of pin and bushing on swing portion
Unit : mm (in)
Standard dimension Clearance
Tolerance Standard
Pos. Item Pin part No. Tolerance Standard Serviceabi Remedy
on pin dia. value lity limit
bore dia. repair
Swing
A cylinder PX02B01241P1 +0.20 0.07-
(Rod side) ø45 +0.05 0.25
Swing (1.772) (+0.0079) (0.0028-
–0.02
B cylinder PW02B01271P1 (+0.0020) 0.0098) Replace
–0.05 0.7 1.0
(Head side) bushing
(-0.0008) (0.028) (0.039)
Swing or pin
(-0.0020) +0.07 0.04-
C center PX02B01239P1
ø65 +0.02 0.12
(Upper side)
(2.559) (+0.0028) (0.0016-
Swing center
D PX02B01275P1 (+0.0008) 0.0047)
(Lower side)
3-21
(2) Clearance in thrust direction on swing bracket and cylinder installation section

Clearance in thrust direction on swing portion
3-22
Unit : mm (in)
Standard Clearance X adjusted with shim
Pin length
Dimension (total of both sides)
Sec. Item Standard Remedy
Standard Serviceability
No. Dimensions value for No. Dimensions
value limit
repair
65
Cylinder
Swing 0.5-0.9
(2.559 ) 1.5 123
A-A cylinder L1 (0.020- — PL1
(0.059) (4.84)
(Rod side) 67 0.035)
Bracket
Adjusted
(2.638 )
with
65 shim
Swing
Cylinder
0.1-0.5 3
(2.559 ) 1.0 128
B-B cylinder L2 (0.004- — PL2
(0.039) (5.04)
(Head side) Upper 67 0.020)
frame
(2.638 )
71±0.5
Upper
Swing (2.795
frame
center ±0.020) Replace 153.5
C-C L3 — PL3
(Upper 75.7±1 washer (6.04)
side) Bracket (2.98
±0.039)
71.5±0.5
Upper
Swing (2.815
frame 0.5-0.9 Adjusted
center ±0.020) 1.5 134
D-D L4 (0.020- — with PL4
(Lower 73.5±1 (0.059) (5.28)
0.035) shim
side) Bracket (2.894
±0.039)
3-23
3-24
11. TOOLS
11. TOOLS
11
TABLE OF CONTENTS
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS .............................. 11-3

11.1.1 Metric Coarse Thread Standard Tightening Torque Values ....................... 11-3
11.1.2 Metric Fine Thread Standard Tightening Torque values ............................. 11-4
11.2 SCREW AND TOOL SIZES ............................................................................... 11-5
11.2.1 CAPSCREW .............................................................................................. 11-5
11.2.2 CAPSCREW (SOCKET BOLT) .................................................................. 11-5
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ................................ 11-6
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) ..................................... 11-6
11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ........................................... 11-6
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS ............... 11-7
11.4.1 SLEEVE TYPE TUBE FITTINGS .............................................................. 11-7
11.4.2 PART NO. .................................................................................................. 11-7
11.5 PLUGS ............................................................................................................... 11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................... 11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................... 11-9
11.6 SPECIAL SPANNERS FOR TUBES .................................................................. 11-10
11.7 SPECIAL TOOLS ............................................................................................... 11-11
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ............ 11-12
11.9 COUNTERWEIGHT LIFTING JIG ..................................................................... 11-13
11.10 UPPER FRAME LIFTING JIG ............................................................................ 11-14
11-1
11. TOOLS

SK30SR-5 : PW14- S5PW1131E01
SK35SR-5 : PX15- (KCM North America)
CX31B : PW14- ↑
↑ ↑
E30B : PW14- ↑
↑ ↑
E35B : PX15- (NH-NA)
SK30SR-5 : PW14-46519~ S5PW1131E02
Revision June, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~ ↑
↑ ↑
E35B : PX15-21105~ (NH-NA)
11-2
11. TOOLS
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS
The following Torque Specifications are provided for use when actual torque value of a fastener is not known.
Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the
periodical maintenance. Retighten the loosened ones, and install new ones for the dropped off. For the new
machine, the check and retightening of them must be carried out at first 50 hours operation. For the replacement of
them, make sure to use the same size of manufacturer's genuine parts.
Refer to the table below for the tightening and retightening of capscrews.
• The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening
torque for such capscrews, consult with an authorized our distributor. Over-tightening may cause damages on
the parts to be fixed.
• In case that the tightening torque is specified in the manual, use such torque values regardless to the table
below.
• Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is
provided for smaller size of capscrews, M 5 or less.
11
Make certain to tighten all capscrews and nuts to proper torque values.
11.1.1 Metric Coarse Thread Standard Tightening Torque Values
Torque value Unit : N•m (lbf•ft)

Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9
M8 P=1.25
(7.9±0.8) (6.6±0.7) (17.3±1.5) (14.5±1.5) (31.1±2.9) (26.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9
M10 P=1.5
(15.9±1.4) (13.2±1.3) (34.0±3.6) (28.9±2.9) (61.5±6.5) (52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12
M12 P=1.75
(26.8±2.9) (23.2±2.1) (58.6±5.8) (49.2±5.1) (105±11) (89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19
M14 P=2
(42.7±4.4) (36.1±3.6) (92.9±9.6) (78.2±7.4) (167±15) (141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29
M16 P=2
(65.1±6.5) (55.0±5.1) (141±15) (119±12) (253±29) (209±21)
122±12 103±10 265±29 226±20 481±49 402±39
M18 P=2.5
(90.0±8.9) (75.8±7.2) (195±21) (167±15) (355±36) (297±29)
172±17 144±14 373±39 314±29 667±69 559±59
M20 P=2.5
(127±13) (106±10) (275±29) (232±21) (492±51) (412±44)
11-3
11. TOOLS

226±20 192±20 500±49 422±39 902±88 755±78
M22 P=2.5
(167±15) (142±15) (369±36) (311±29) (665±65) (557±58)
294±29 235±29 637±69 520±49 1160±118 941±98
M24 P=3
(217±21) (173±21) (470±51) (383±36) (856±87) (694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137
M27 P=3
(318±29) (260±29) (694±72) (564±58) (1250±123) (1010±101)
588±59 490±49 1285±127 1079±108 2300±235 1940±196
M30 P=3.5
(434±44) (361±36) (948±94) (796±80) (1700±173) (1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265
M33 P=3.5
(586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333
M36 P=4
(760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246)
11.1.2 Metric Fine Thread Standard Tightening Torque values

11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1.0
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9
M10 P=1.25
(16.7±1.5) (13.8±1.4) (35.5±3.6) (30.3±2.9) (64.4±6.5) (54.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13
M12 P=1.25
(28.9±2.9) (24.6±2.1) (62.9±6.5) (52.8±5.1) (114±12) (95.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29
M16 P=1.5
(68.0±6.5) (57.2±5.8) (145±15) (125±13) (268±29) (224±21)
186±19 155±16 402±39 333±29 726±69 608±59
M20 P=1.5
(137±14) (114±12) (297±29) (246±21) (535±51) (448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98
M24 P=2
(232±21) (195±21) (506±51) (420±44) (915±87) (760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206
M30 P=2
(470±44) (391±36) (1030±101) (853±87) (1840±188) (1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275
M33 P=2
(629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203)
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
(789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260)
11-4
11. TOOLS
11.2 SCREW AND TOOL SIZES
11.2.1 CAPSCREW
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M6 10 M24 36
M8 13 M30 46
M10 17 M36 55 B
M12 19 M42 65
M16 24 M48 75
M20 30
11
11.2.2 CAPSCREW (SOCKET BOLT)
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M6 5 M20 17
M8 6 M24 19
M10 8 M30 22 B
M12 10 M36 27
M14 12 M42 32
M16 14 M48 36
(M18) 14
11-5
11. TOOLS
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE)
Nominal screw size Spanner size Tightening torque

(PF) (mm) N•m (lbf•ft)
1/8 14 17±2 (12±1)
1/4 19 36±2 (27±1)
3/8 22 74±5 (54±4)
1/2 27 108±9.8 (80±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)
11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE)
Nominal screw size Spanner size Tightening torque

(PF) (mm) N•m (lbf•ft)
1/8 17 15±2.0 (11±1)
1/4 19 29±4.9 (22±4)
3/8 22 49±4.9 (36±4)
1/2 27 78±4.9 (58±4)
3/4 36 118±9.8 (87±7)
1 41 137±15 (101±11)
NOTE : The application of the tightening torque is subject to a dry condition.
11-6
11. TOOLS
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS
11.4.1 SLEEVE TYPE TUBE FITTINGS
Tube size Spanner size Tightening Torque

OD × Thickness (mm) (mm) N•m (lbf•ft)
10 × 1.5 19 44±4.9 (33±4)
15 × 2.0 27 147±20 (110±14)
18 × 2.5 32 177±20 (130±14)
22 × 3.0 36 216±20 (160±14)
28 × 4.0 41 275±29 (200±22)
35 × 5.0 55 441±44 (330±33)
11
11.4.2 PART NO.
SLEEVE NUT
B
d
d
Part NO. Opposing Part NO.

Tube size Tube size
flats(HEX)
ød Ihara Koatu Nippon A.M.C ød Ihara Koatu Nippon A.M.C
B
6 ZF93S06000 — 6 14 ZF93N06000 —
8 ZF93S08000 — 8 17 ZF93N08000 —
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 — 12 22 ZF93N12000 —
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 — 32 50 ZF93N32000 —
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 — 38 60 ZF93N38000 —
11-7
11. TOOLS
11.5 PLUGS
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT

(1) Cap nut (Joint plug)
Applicable Cap nut parts Opposing flats

tube T screw
A
No.
O. D : A H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41
(2) Plug (Tube plug)
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
D Screw tube Nut parts No. D screw Opposing flats
A
O. D : A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
11-8
11. TOOLS
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
11
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
(3) Plug for(F)flare hose
PF screw
PF screw Plug parts No. B mm

PF1/4 2444Z2728D1 14
60
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
PF screw Plug parts No. E mm F mm

PF PF1/4 2444Z2729D1 14 19
60
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
11.6 SPECIAL SPANNERS FOR TUBES
Applicable tube diameter HEX Dimensions of a special spanner

Part No.
mm (in) mm mm (in)
70(2.76)
(0.630) (0.866)
15 (0.591) 2421T160 27 (0.315)
40(1.57) 12.7 (0.500 )
70(2.76)
42(1.65)
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
28 (1.102) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )
11-10
11. TOOLS
11.7 SPECIAL TOOLS
No. Tools name Tools No. Shape Use.
Torx driver 4.4 (0.17")

(with tamper
For instrument
1 proof) — Nose shape
R.H cover
T25
(for M5)
11
11-11
11. TOOLS
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS
Manufacturer
Service Features
Loctite Three-Bond
#242 1360K Low strength
Screw locking
#262 1374 Middle strength
compound
#271 1305 High strength
Sealing compound #515 1215 Sealing
11-12
11. TOOLS
11.9 COUNTERWEIGHT LIFTING JIG
11
Counterweight lifting jig
11-13
11. TOOLS
11.10 UPPER FRAME LIFTING JIG
5 40(2)-100
Q'ty : 2 sets (0.20") (1.58"(0.079")-3.94")
2-
Material : Mild steel
5")
20
0.9
Unit : mm (in)
(0
.7
24(
9"
)
(1.97")
50
244 (9.61") 16 (0.63")
300 (11.8")
100
(3.94") ") 15
R 1. 58
40( (0.59")
5 40(4)-120
(0.20") {1.58"(0.16")-4.72"}
470 (18.5")
536 (21.1")
12 (0.47") 12 167
420 (16.5")
(0.47") (6.58")
50
(1.97")
5
(0.20")
R3 8")
(1
0
.1
C2 .98"
(1.97")
(0
5 )
50
R2 9")
(0
0
.3 0
.7
(0.63")
)
C1
9"
16
(0
Upper frame lifting jig
11-14
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME

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

SK30SR-5 : PW14- S5PW1231E01
CX31B : PW14- ↑
↑ ↑
E30B : PW14- ↑
↑ ↑
SK30SR-5 : PW14-46519~ S5PW1231E02
Revision June, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~ ↑
↑ ↑
E35B : PX15-21105~ (NH-NA)
12-2
PREFACE
(1) Working Conditions
1. Technicians : One more technicians who are qualified by Manufacturer are needed. The technicians need five of
more years of experience, and they have to complete the training in the operation of this machine.
2. Facilities : General jigs, tools, apparatus, testers to be provided.
The maintenance workshop to be equipped with a good enough capacity of building with crane and inspection
instruments necessary for specific self inspection activities.
3. Place : The workshop should have a level surface where work can be performed with access to a lift crane.
(2) Applicable Range of Standard Maintenance Time

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

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

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

EXCAVATOR
(1) Standard maintenance time table

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

ATT ; Attachment SW ; Switch Inst. ; Installation
BRG ; Bearing V ; Valve O/H ; Overhaul
C/V ; Control valve F hose ; Flexible hose
Cyl ; Cylinder E/G ; Engine
(2) Classification of work code
No. GROUP REMARKS

01 Attachment To indicate removing, installing, replacement
02 Canopy and Guard and overhaul.
03 Upper Structure
04 Under carriage
01 Attachment(1/2)
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
00 Bucket portion Refer to 32.1.2
01 Bucket ASSY Rem./Inst. 1 pc. Include adjustment 0.4
02 -Bucket removing / installing position Preparation 1 pc. 0.1
03 -Bucket installing pin Rem./Inst. 1 pc. Include stopper pin. 0.1
04 -Bucket drive pin - ditto - 1 pc. 0.1
05 -Bucket sling and transfer Preparation 1 pc. 0.1
06 Bucket (Single) O/H 1 pc. Not include removal / inst. 0.6
07 -Bushing Replace 1 pc. 0.5
10 Arm portion Refer to 32.1.3
11 Arm ASSY Rem./Inst. 1 pc. 0.8
12 -Bucket cylinder removing / installing Preparation 1 pc. 0.2
position and piping
13 -Bucket cylinder rod pin Rem./Inst. 1 pc. Include stopper pin. 0.1
14 -Bucket cylinder head pin - ditto - 1 pc. Include stopper pin. 0.1
15 -Bucket cylinder assy - ditto - 1 pc. 0.1
16 -Arm cylinder rod pin - ditto - 1 pc. Include stopper pin. 0.1
17 -Boom top pin - ditto - 1 pc. 0.1
18 -Arm sling and transfer - ditto - 1 pc. 0.1
12-4
01 Attachment(2/2)
WORK TO UNIT:
BE DONE HOUR
20 Boom portion Refer to 32.1.4
21 Boom ASSY Rem./Inst. 1 pc. 1.0
22 -Boom removing / installing position Preparation 1 pc. 0.1
23 -Boom cylinder temporary slinging - ditto - 1 pc. Include stopper pin. 0.1
24 -Boom cylinder rod pin Rem./Inst. 1 pc. 0.1
25 -Boom cylinder piping - ditto - 1 pc. 0.1
26 -Arm & Bucket piping - ditto - 1 pc. 0.2
27 -Boom assy temporary slinging Rem./Inst. 1 pc. Include stopper pin. 0.1
28 -Boom foot pin - ditto - 1 pc. 0.1
29 -Boom assy slinging - ditto - 1 pc. 0.1
30 Arm cylinder removing / installing - ditto - 1 pc. 0.3
31 -Arm cylinder piping - ditto - 1 pc. 0.1
32 -Arm cylinder head pin - ditto - 1 pc. Include stopper pin. 0.1
33 -Arm cylinder slinging - ditto - 1 pc. 0.1
40 Boom cylinder removing / installing - ditto - 1 pc. 0.3
41 -Boom cylinder piping - ditto - 1 pc. 0.1
42 -Boom cylinder head pin - ditto - 1 pc. 0.1
43 -Boom cylinder slinging - ditto - 1 pc. 0.1
50 Bucket cylinder O/H 1 pc. 2.5 12
51 -Pin bushing Replace 1 set Include seal. 1.0
60 Arm cylinder O/H 1 pc. 2.5
70 Boom cylinder O/H 1 pc. 2.5
80 Swing portion Refer to 32.1.5
81 Swing bracket assy Rem./Inst. 1 pc. After removing boom. 0.4
82 -Swing cylinder rod pin - ditto - 1 pc. 0.1
83 -Swing bracket slinging - ditto - 1 pc. 0.1
84 -Swing center pin - ditto - 1 pc. 0.1
85 Swing cylinder removing / installing - ditto - 1 pc. After removing swing 0.3
86 -Swing cylinder hose Rem./Inst. 2 pcs. bracket. 0.2
87 -Swing cylinder head pin - ditto - 1 pc. 0.1
88 Swing cylinder O/H 1 pc. 2.5
89 -Pin bushing Replace 1 pc. 1.0
Other necessary works Rem./Inst. 1 set Include seal. 0.1
Panel assy (3)
90 Dozer portion Refer to 32.1.6
91 Dozer ASSY Rem./Inst. 1 pc. 0.6
92 -Dozer cylinder hose - ditto - 2 pcs. 0.2
93 -Dozer cylinder rod pin - ditto - 1 pc. 0.1
94 -Dozer installing pin - ditto - 2 pcs. 0.2
95 Dozer cylinder O/H 1 pc. 2.5
12-5
02 Canopy & Guard (1/1)
WORK TO UNIT:
BE DONE HOUR
00 Canopy portion Refer to 33.1.1
01 Canopy assy Rem./Inst. 1 pc. 0.2
02 -Hand rail - ditto - 1 pc. 0.1
10 Cab portion Refer to 33.1.1
11 Cab assy Rem./Inst. 1 pc. 0.4
12 -Harness - ditto - 1 pc. 0.1
20 Bonnet & Guard Refer to 33.1.2
21 Cover assy (1) Rem./Inst. 1pc. 0.1
22 Bonnet assy (2) - ditto - 1pc. 0.1
23 Cover assy (3) - ditto - 1pc. 0.1
24 Cover assy (4) - ditto - 1pc. 0.1
25 Cover assy (5) Rem./Inst. 1pc. 0.1
30 Control stand portion Refer to 33.1.15
31 Control stand ASSY Rem./Inst. 1 pc. 1.0
32 -Air cleaner - ditto - 1 pc. 0.1
33 -E / G control cable - ditto - 1 pc. 0.2
34 -Deceleration motor (OPT) - ditto - 1 pc. 0.1
35 -Filler neck - ditto - 1 pc. 0.1
36 -Fuel air bleed hose - ditto - 1 pc. 0.1
37 -Harness - ditto - 1 set 0.3
Other necessary works Rem./Inst. 1 set Canopy 0.2

- ditto - 1 set Floor cover 0.1
- ditto - 1 set Guard (Cover, support) 0.4
- ditto - 1 pc. Counterweight 0.4
- ditto - 1 pc. Negative terminal of 0.1
battery
40 Floor plate portion Refer to 33.1.3
41 Floor plate assy Rem./Inst. 1 set 0.5
Other necessary works - ditto - 1 pc. Canopy removal / inst 0.2
50 Counterweight portion Refer to 33.1.5
51 Counterweight ASSY Rem./Inst. 1 pc. 0.4
52 -Lifting tools Preparation 1 set 0.1
53 -Slinging Rem./Inst. 1 pc. 0.1
54 -Counterweight fixing bolt - ditto - 1 set 0.1
Other necessary works - ditto - 3 pcs. Guards 0.3
12-6
03 Upper structure (1/4)
WORK TO UNIT:
BE DONE HOUR
00 Control portion
01 E / G control cable Rem./Inst. 1 pc. 0.2
04 Other necessary works - ditto - 1 set Cover and Hose 0.4

10 Intake portion Refer to 33.1.12
11 Air cleaner ASSY Rem./Inst. 1 pc. 0.3
12 -Hose (1) - ditto - 1 pc. 0.1
13 -Hose (2) - ditto - 1 pc. 0.1
14 -Element Replace 1 pc. 0.1
20 Exhaust portion Refer to 33.1.14
21 Muffler ASSY Rem./Inst. 1 pc. 0.4
22 -Clamp - ditto - 1 pc. 0.1
23 -Exhaust manifold attaching nuts - ditto - 4 pcs. 0.1
24 -Muffler fixing bolt - ditto - 4 pcs. 0.1
Other necessary works - ditto - 1 set Heat insulation cover 0.1
30 E / G Accessory portion Refer to 33.1.13 & 33.1.16
12
31 Generator Rem./Inst. 1 pc. 0.6
32 -Connector - ditto - 1 pc. 0.1
33 -Generator fixing bolt - ditto - 2 pcs. 0.1
34 -V-belt - ditto - 1 pc. Include tension adjusting 0.3
Other necessary works - ditto - 1 set Covers 0.1
battery
36 Starter Rem./Inst. 1 pc. 0.5
37 -B-terminal - ditto - 1 pc. 0.1
38 -S-terminal connector - ditto - 1 pc. 0.1
39 -Starter fixing bolt - ditto - 2 pcs. 0.2
Other necessary works - ditto - 1 set Cover and Floor plate 0.1
- ditto - 1 set Seat and Stand cover 0.3
battery
40 Fuel portion Refer to 33.1.10
41 Fuel tank ASSY Rem./Inst. 1 pc. 0.6
42 -Fuel Replace 1 pc. 0.2
43 -Hose (Supply ; water separator side) Rem./Inst. 1 pc. 0.1
44 -Hose (Return ; filter side) - ditto - 1 pc. 0.1
45 -Level sensor connector - ditto - 1 pc. 0.1
46 -Fuel tank fixing bolt - ditto - 4 pcs. 0.1
Other necessary works - ditto - 1 pc. Covers 0.2
12-7
WORK TO UNIT:
BE DONE HOUR
50 Hydraulic oil tank portion Refer to 33.1.11
51 Hydraulic oil tank ASSY Rem./Inst. 1 pc. After removing fuel tank ; 1.6
52 -Return filter Replace 1 pc. Include pressure releasing 0.2
& replacing O-ring
53 -Hydraulic oil - ditto - 1 pc. 0.2
54 -Suction hose Rem./Inst. 1 pc. 0.2
55 -Strainer Replace 1 pc. Include replacing O-ring 0.1
56 -Pilot return hose Rem./Inst. 1 pc. 0.1
57 -Swivel drain hose - ditto - 1 pc. 0.1
58 -SOL. valve return hose - ditto - 1 pc. 0.1
59 -Slewing, C / V return hose - ditto - 2 pcs. 0.2
60 -Tank fixing bolt - ditto - 4 pcs. 0.2
Other necessary works - ditto - 1 pc. Covers 0.2
- ditto - 1 pc. Control valve 1.6
- ditto - 1 pc. Solenoid valve 0.1
Preparation 1 pc. Hyd. oil tank pressurizing 0.1
70 Pump portion Refer to 33.1.6
71 Pump ASSY Rem./Inst. 1 pc. After removing 1.2
counterweight
72 -Hydraulic oil Replace 1 pc. Include pressure releasing 0.2
73 -Pilot delivery oil hose Rem./Inst. 1 pc. 0.1
74 -Suction hose - ditto - 1 pc. 0.2
75 -Suction tube (pump side) - ditto - 1 pc. 0.2
76 -Main pump delivery hose - ditto - 3 pcs. 0.2
77 -Pump fixing bolt - ditto - 2 pcs. 0.2
78 Pump ASSY O/H 1 pc. 3.0
Other necessary works Feed 1 pc. Hyd. oil in pump 0.1
Preparation 1 pc. Hyd. oil tank pressurizing 0.1
80 Radiator portion Refer to 33.1.17
81 Radiator ASSY Rem./Inst. 1 pc. 1.2
82 -Coolant (LLC) Replace 1 pc. 0.2
83 --Coolant density Measuring 1 pc. (0.2)
84 -Reserve tank hose Rem./Inst. 1 pc. 0.1
85 -Radiator hose - ditto - 2 pcs. 0.2
86 -Cooler hose - ditto - 2 pcs. 0.2
87 -Radiator fixing bolt - ditto - 3 pcs. 0.1
88 -Radiator lifting or slinging - ditto - 1 pc. 0.1
Other necessary works - ditto - 1 pc. Counterweight 0.4
- ditto - 1 set Covers 0.2
- ditto - 1 pc. Duct 0.1
12-8
WORK TO UNIT:
BE DONE HOUR
90 Engine (E / G) Installing portion Refer to 33.1.18
91 Engine ASSY Rem./Inst. 1 pc. 1.0
92 -Fuel hose - ditto - 4 pcs. For injection pump - 2 pcs. 0.2
& For feed pump - 2 pcs.
93 -Harness, connector and cable Rem./Inst. 1 set 0.3
94 -Engine fixing nut - ditto - 1 pc. 0.2
95 -Engine slinging - ditto - 1 set 0.2
Other necessary works - ditto - 1 set Covers 0.2
- ditto - 1 pc. Canopy 0.2
- ditto - 1 set Control stand 1.0
- ditto - 1 pc. Air cleaner 0.2
11 Air cleaner ASSY - ditto - 1 pc. Muffler 0.4
12 •Hose (1) - ditto - 1 pc. Pump 1.2
13 •Hose (2) - ditto - 1 pc. Radiator 1.0
14 •Element - ditto - 1 pc. Battery negative terminal 0.1
100 Control valve portion Refer to 33.1.7
101 Control valve ASSY Rem./Inst. 1 pc. 1.6 12
102 -Piping connector, hose - ditto - 1 set Include attaching hose's 1.0
tag and plug
104 -Fixing bolt - ditto - 1 set 0.1
105 Control valve ASSY O/H 1 pc. 3.0
Other necessary works Rem./Inst. 1 set Covers 0.1
- ditto - 1 set Hoses 0.2
110 Slewing motor portion Refer to 33.1.20
111 Slewing motor ASSY Rem./Inst. 1 pc. 1.0
112 -Piping connector, hose - ditto - 7 pcs. Include attaching hose's 0.5
tag and plug
113 -Fixing bolt - ditto - 1 pc. 0.3
114 Slewing motor ASSY O/H 1 pc. 3.0
Other necessary works Rem./Inst. 1 set Floor plate, Covers 0.2
Feed 1 pc. Hyd. oil in motor 0.1
120 Swivel joint portion Refer to 33.1.21
121 Swivel joint ASSY Rem./Inst. 1 pc. After removing slewing 2.5
motor
122 -Under cover - ditto - 1 pc. 0.1
123 -Piping connector, hose - ditto - 1 set Include attaching hose's 1.5
tag and plug
124 -Stopper - ditto - 1 pc. 0.1
125 -Fixing bolt - ditto - 1 set 0.2
126 Swivel joint ASSY O/H 1 pc. 2.0
Other necessary works Preparation 1 pc. Removal / Inst. position. 0.1
(Secure working space.)
1 pc. Canopy removal / inst. 0.2
(for easy working)
1 pc. Floor plate cover (2) 0.1
removal / inst.
12-9
03 Upper structure(4/4)
WORK TO UNIT:
BE DONE HOUR
130 Upper frame portion Refer to 33.1.22
131 Upper frame ASSY Rem./Inst. 1 pc. 1.0
132 -Fixing bolt - ditto - 1 set Apply sealant 0.3
133 -Upper frame slinging - ditto - 1 pc. 0.3
134 -Cleaning Cleaning 1 pc. 0.2
Other necessary works Rem./Inst. 1 pc. Canopy 0.2
- ditto - 1 pc. Guard (Cover, support) 1.5
Drain / Feed 1 pc. Hydraulic oil 0.2
Rem./Inst. 1 set Swivel joint hose 0.5
- ditto - 1 set Boom, Swing bracket 1.5
12-10
04 Under carriage
WORK TO UNIT:
BE DONE HOUR
00 Travel portion Refer to 34.1.2
01 Rubber crawler Rem./Inst. One side 0.6
02 -Rubber shoe removing / inst. position. Preparation One side 0.1
03 -Tension adjusting Adjusting One side 0.2
04 -Crawler shoe Rem./Inst. One side 0.2
10 Upper roller portion Refer to 34.1.3
11 Upper roller ASSY Rem./Inst. 1 pc. After removing crawler 0.2
12 Upper roller O/H 1 pc. shoe 1.0
20 Lower roller portion Refer to 34.1.4
21 Lower roller ASSY Rem./Inst. 1 pc. 0.2
22 Lower roller O/H 1 pc. 1.0
30 Front idler & Idler adjuster portion Refer to 34.1.5 & 34.1.6
31 Idler & Idler adjuster ASSY Rem./Inst. One side After removing crawler 0.5
32 Idler & Idler adjuster ASSY O/H One side shoe 0.1
33 Idler ASSY O/H One side 1.0
34 Idler adjuster ASSY - ditto - One side 0.5
12
40 Sprocket portion Refer to 34.1.7
41 Sprocket Replace One side After removing crawler 0.5
shoe
50 Travel motor portion Refer to 34.1.8
51 Travel motor ASSY Rem./Inst. One side After removing crawler 1.0
52 -Motor cover - ditto - One side shoe 0.1
53 -Hydraulic connector, hose - ditto - One side 0.6
Include attaching hose's
54 -Motor fixing bolt - ditto - One side tag and plug 0.3
55 -Motor slinging - ditto - One side 0.1
56 Travel motor O/H One side 3.0
57 Travel reduction unit - ditto - One side 3.0
Other necessary works Feed One side Hyd. oil in motor 0.1
60 Slewing bearing portion Refer to 34.1.9
61 Slewing bearing ASSY Rem./Inst. 1 pc. After removing upper 0.6
62 -Slewing bearing fixing bolt - ditto - 1 pc. frame 0.3
63 -Slewing bearing Cleaning 1 pc. 0.1
64 -Slewing bearing slinging Rem./Inst. 1 pc. Decreasing / 0.2
Replenishment
12-11
12-12
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND

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

13.2 PERFORMANCE INSPECTION STANDARD TABLE ........................................13-5
13.2.1 STANDARD VALUE TABLE .......................................................................13-5
13.3 MEASURING ENGINE SPEED ..........................................................................13-7
13.3.1 ENGINE SPEED MEASUREMENT ...........................................................13-7
13.4 MEASURING HYDRAULIC OIL PRESSURE ....................................................13-9
13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT ........13-9
13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT ................................13-9 13
13.5 MEASURING TRAVEL PERFORMANCES .......................................................13-13
13.5.1 TRAVEL .....................................................................................................13-13
13.5.2 TRAVEL DEVIATION .................................................................................13-13
13.5.3 MOVEMENT DRIFT DUE TO GRAVITY ....................................................13-14
13.5.4 DRAIN RATE OF TRAVEL MOTOR ..........................................................13-14
13.6 MEASURING SLEW PERFORMANCES ...........................................................13-16
13.6.1 SLEW TIME ...............................................................................................13-16
13.6.2 OVERRUN WHEN SLEWING STOPS ......................................................13-16
13.6.3 SLEW DRIFT DUE TO GRAVITY ..............................................................13-16
13.6.4 DRAIN RATE OF TRAVEL MOTOR ..........................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES .......................13-18
13.7.1 CYLINDER SPEED ....................................................................................13-18
13.7.2 GRAVITY DRIFT OF CYLINDERS ............................................................13-19
13.8 MEASURING SLEW BEARING PERFORMANCES ..........................................13-20
13.8.1 SLEW BEARING-BUCKET TIP PLAY .......................................................13-20
13.8.2 SLEW BEARING PLAY ..............................................................................13-20
13.9 MEASURING CRAWLER TENSION ..................................................................13-22
13.9.1 CRAWLER TENSION ................................................................................13-22
13-1

CX31B : PW14- S5PW1332E01
CX31B : PW14-46519~ S5PW1332E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
13-2
13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS
(1) Application
1. For New Machine;
This manual is to be used to compare actual performance and functions of the machine with performance
standards.
2. At Specific Self-Inspection (as per LOCAL RULES);
The maintenance standards are criteria to determine time needed for reconditioning, adjustment and
replacement.
3. At Deterioration of Performance;
This manual provides the criteria for safe and economical judgment on whether the deterioriation of
performance on the machine is caused by a fault or normal
4. For Replacement of Major Components;
This manual is the standard to determine the time for replacement to maintain the performance of major
components such as pump, etc
(2) Terminology
1. Standard Values :
These are the standard values to assemble and regulate a new machine. Where special notes are not given,
these values are based on the machine with standard structure (machine with standard attachments and
shoes).
2. Standard Values for Repair :
These are of the values at which the reconditioning is required.
In order to ensure the performance and safety, it is strictly prohibited to use the machine with the parts and
components over the standard values.
3. Serviceability Limit :
This is of the service limit for each part and component at which reconditioning is impossible and the part must 13
be replaced with a new one.
All the parts and components which are estimated to exceed the serviceability limit up to the next periodic
inspection and maintenance, should be also be replaced.
Operating the machine with parts and components that have exceeded the serviceability limit is unsafe and
could result in equipment failuer and down time.
(3) Precautions for Judgment :

1. Evaluation for Measured Data :
Some variation on the measured data is inevitable, due to differences between old and new versions of the
machine and measurement conditions.
Measured data should be judged comprehensively, taking into consideration the level and extent of
measurement, rather than merely compared with standard values.
2. Determination for Reconditioning, Adjustment or Replacement :
There are two kinds of deterioration of machine performance; one is due to normal wear over time, and the
other is recoverable to the standard values with the adjustment for presssure, etc.
Therefore, the determination for reconditioning, adjustment or replacement should be conducted taking various
factors into consideration such as operating hours, working conditions and maintenance conditions of the
machine, so that the machine is able to be operated at the optimum performance level.
13-3
(4) Other Precautions

1. Parts with Aging Effect :
The rubber products such as hydraulic hoses, O-rings, oil seals, etc. will deteriorate with age. It is necessary to
replace them to new ones at periodic intervals or at every overhaul.
2. Parts required Periodical Replacement :
It is recommended to designate the important hoses critical for safety as Very Important Parts (V.I.P.), and
periodically replace them with new ones.
3. Inspection & Replacement of Lubricants :
The machine operator should become familiar with the procedures and precautions for safe handling and
maintenance of the machine, including procedures for inspection and lubrication. Refer to the OPERATOR'S
MANUAL.
13-4
13.2 PERFORMANCE INSPECTION STANDARD TABLE
13.2.1 STANDARD VALUE TABLE
Model CX31B CX36B

Applicable machines PW14-46519~ PX15-21105~
Repairable Repairable
Div. Item Unit Standard value Standard value
value value
Hyd. oil cleanliness Class 8±1 — 8±1 —
Measuring
condition
Hyd. oil temperature

50~60 (122~140) — 50~60 (122~140) —
(Tank surface) C
Coolant temperature ( F)
60~90 (140~194) — 60~90 (140~194) —
(Radiator surface)
Low idle 1200±25 — 1200±25 —
Engine
speed
High idle rpm 2550±25 — 2550±25 —

Deceleration 1200±25 — 1200±25 —
Boom • Bucket •
Main relief valve
P1 23.0 (3340 ) — 23.0 (3340 ) —

Travel (LH)
pressure
Arm • Swing •
Travel (RH) • P2 MPa 23.0 (3340 ) — 23.0 (3340 ) —
Service (psi)
Dozer • *1 Slew P3 20.0 (2900 ) — 20.0 (2900 ) —
Pilot relief valve
Pilot Line — 3.5 (508 ) — 3.5 (508 ) —
pressure
Head 13
*2 Port (Over load) relief
Boom 27.5 (3990 ) — 27.5 (3990 ) —

Rod
valve pressure
Head
Arm 25.5 (3700 ) — 25.5 (3700 ) —
Rod MPa
Bucket Head (psi) 25.5 (3700 ) — 25.5 (3700 ) —
Dozer Head 27.5 (3990 ) — 27.5 (3990 ) —
*1 Slew LH/RH 20.0 (2900 ) — 20.0 (2900 ) —

Rubber Low 33.2±1.6 43 33.2±1.6 43
Crawler
crawler high 18.9±0.9 24 18.9±0.9 24
Speed sec.
Iron Low 34.0±1.7 44 34.0±1.7 44
(5 rev.)
crawler High 19.3±0.9 25 19.3±0.9 25
Travel Rubber Low 14.5±0.7 19 14.5±0.7 19
Travel
Speed crawler High 8.3±0.4 11 8.3±0.4 11

sec.
10 m Iron Low 14.9±0.7 19 14.9±0.7 19
(32.8 ft) crawler High 8.5±0.4 11 8.5±0.4 11
Travel deviation 140 (5.5 ) 280 (11.0) 140 (5.5 ) 280 (11.0)
w / P.B. mm (in)
Drift due to gravity 0 (0) 1 (0.04) 0 (0) 1 (0.04)
(5 min)
*1. The pressure for slew is controlled by the relief valve attached to the slew motor.
*2. Reference value for checking of pressure
(tighten up the adjusting nut of main relief valve. Refer to item 13.4.2.1)
13-5
Model CX31B CX36B

Applicable machines PW14-46519~ PX15-21105~
Repairable Repairable
Div. Item Unit Standard value Standard value
value value
Slew time per 2–revolution sec. 13.8±0.7 18 13.8±0.7 18
Slew
Overrun when slewing stops mm 85 95 85 95

Drift due to gravity (in) 0 — 0 —
Ext. 2.4±0.4 3.1 2.3±0.4 2.9
Canopy
Ret. 2.4±0.4 3.1 2.3±0.4 2.9
Boom
Ext. 2.0±0.4 2.6 2.0±0.4 2.6
Cab
Ret. 2.1±0.4 2.7 2.0±0.4 2.6
Cylinder speed
Ext. 2.6±0.4 3.3 3.1±0.3 4.0

Arm
Ret. 1.6±0.3 2.1 2.0±0.3 2.6
sec.
Ext. 2.8±0.4 3.6 2.8±0.4 3.6
Bucket
Ret. 1.8±0.3 2.3 1.8±0.3 2.3
Ext. 5.4±0.9 6.9 5.4±0.9 6.9
Swing
Cylinders
Ret. 4.0±0.7 5.1 4.0±0.7 5.1

Ext. 3.9±0.5 5.0 3.9±0.5 5.0
Dozer
Ret. 3.0±0.4 3.8 3.0±0.4 3.8
Boom 12 (0.47 ) 24 (0.94) 12 (0.47 ) 24 (0.94)
C yl i n d e r G r a v i t y m o v e
Arm 5 (0.20 ) 10 (0.39) 5 (0.20 ) 10 (0.39)
(10 min) Bucket mm 3 (0.12 ) 6 (0.24) 3 (0.12 ) 6 (0.24)
Dozer (in) 6 (0.24) 6 (0.24)

3 (0.12 ) 3 (0.12 )
Bucket tip 150 (5.9 ) 300 (12) 150 (5.9 ) 300 (12)
(5 min) Swing 6 (0.24 ) 12 (0.47) 6 (0.24 ) 12 (0.47)

Crawler Slew bearing
Bucket tip play 60 (2.4 ) 120 (4.7) 60 (2.4 ) 120 (4.7)

mm
(in) 0.6~1.8 0.6~1.8
Slew bearing play 2.6 (0.10) 2.6 (0.10)
(0.024~0.071) (0.024~0.071)
Rubber 70~80 (2.76~3.15) — 70~80 (2.76~3.15) —

mm
Crawler tension 115~130 115~130
Iron (in) — —
(4.53~5.12) (4.53~5.12)
13-6
13.3 MEASURING ENGINE SPEED
13.3.1 ENGINE SPEED MEASUREMENT

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

shows concept)
(2) Engine Warming up Operation

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

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

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

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

(1) Measuring Conditions
Engine speed : High idling
Hydraulic oil temperature : 50 to 60°C
(122 to 140°F) 13
Coolant temperature (on radiator surface) :
60 to 90°C (140 to 194°F)
13-9
(2) Pressure Measuring Procedures

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

Operating Circuit
Port Location Size Valve
Boom, Bucket
& Travel (left) G1 MR1
Arm, Travel (right)

G2 PF1/4 MR2
Swing & Service
Dozer & Slew G3 MR3
Attaching position of overload relief valve

OR1 BUCKET DIGGING OR6 DOZER DOWN Main hydraulic oil pressure measurement (2/2)
OR2 BOOM UP OR7 SLEW RIGHT
OR3 BOOM DOWN OR8 SLEW LEFT
OR4 ARM IN
OR5 ARM OUT
(3) Pressure Adjustment

1. Control Valve : Main Relief Valve and Overload Relief Valve
a. Loosen the lock nut (2), and adjust the setting
pressure turning the setscrew (1). 2
Roughly with one full turn :
Main relief valve & Overload relief valve :
Approximately 12.2 MPa (1770 psi) 1
CW turning : Increasing setting pressure
CCW turning : Decreasing setting pressure
b. After the adjustment, tighten up the lock nut holding MAIN RELIEF VALVE
the setscrew not to turn around. OVERLOAD RELIEF VALVE
c. Again activate the relief valve to check the stable Relief valve
setting pressure.
Tightening torque for nut (2) : 19.6 N-m (14.5 lbf-ft)
13-10
2. Slewing Motor : Relief Valve

a. Loosen the lock nut (2). Then adjust the
setting pressure turning the setscrew (1).
OR8
Roughly with one full turn :
Approx. 9.8 MPa (1420 psi) 1
CW turning : Increasing setting pressure
CCW turning : Decreasing setting pressure OR7
b. After the adjustment, tighten up the lock 2
nut holding the setscrew not to turn around.
Tightening torque for nut (2) :
34.3 N-m (25.3 lbf-ft) Relief valve (Slewing motor)
13.4.2.2 PILOT CIRCUIT PRESSURE

(1) Measuring Conditions
Engine : High idling G4
PF1/4 PLUG
Hydraulic oil temp. : 50 to 60°C (122 to 140°F)
SOLENOID VALVE
Coolant temp. : 60 to 90°C
(140 to 194°F)
at radiator surface
(2) Measurement
Releasing pressure in the hydraulic oil tank of
hydraulic system, and setting a 6.86 MPa (1000 FROM
PUMP
psi) pressure gauge to the pressure detecting port
(G4, PF 1/4 with plug), measure the pilot relief
pressure.
13
Unplug PF1/4, and set a 6.86MPa (1000psi) pressure gauge

Pilot oil pressure measurement
Pressure Detecting Port

Relief Valve
Port Location Size
G4 PF1/4 PR1
13-11
(3) Pressure Adjustment

Adjust it with the relief valve attached to the solenoid valve.
1. Loosen the lock nut (2), then turn the setscrew (1)
to adjust the set pressure.
CW screwing : Set pressure is increased. 1
CCW screwing : Set pressure is decreased.
2. After the adjustment, lock the setscrew with the
2
lock nut holding the setscrew not to allow its
turning.
3 RELIEF VALVE
3. Again actuate the relief valve, and verify that the PR1
set pressure is being stable.
Tightening Torque :
Lock Nut (2) : 7.8 N-m (5.8 lbf-ft)
Relief valve (PR1) : 44 N-m (32 lbf-ft)
Capscrew (3) : 7.8N-m (5.8 lbf-ft)
Relief valve
13-12
13.5 MEASURING TRAVEL PERFORMANCES
TEST PROCEDURES
Measure 3-time each.
Apply average data of the above for judgement.
13.5.1 TRAVEL
(1) Travel Speed (5 Revolutions)
• Engine : High Idle

• Hydraulic Oil Temp. : 50 to 60°C (122 to 140°F)
• Measurement Posture : Machine Body is raised using
both hoe attachment and dozer blade.
• Set crawler shoes in motion. Starting after one full
revolution, measure the time required for 5 revolutions.
(To measure speed after it has stabilized.)
(2) Travel Speed (10 m)
• Engine : Rated r.p.m.

• Measurement Posture : Travel Posture
• Set machine in motion. Starting after a running of 5 5m(16.4ft) 10m(32.8ft) 13
meters, measure the time required to travel 10 meters. Do PRELIMINARY MEASUREMENT
this on level and hard ground. RUNNING DISTANCE
START
• Travel Posture :
Fully extend the arm and bucket cylinders and place the
hoe attachment so that its lowest part is even with the
machine's minimum ground clearance level. The hoe
attachment must be in a no-load and the dozer blade
must not touch the ground.
GROUND
CLEARANCE
13.5.2 TRAVEL DEVIATION
• Engine : Rated r.p.m.

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

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

(1) Preparation
FORWARD
1. Apply stopper pins for both travel sprockets of left and
right.
2. Stop the engine, and release air in the hydraulic oil
tank. RIB "A"
3. Connect a hose to the drain port of travel motor, and
receive the drained oil in a container.
4. Apply a plug to the drain piping at tank side. ROTATING
DIRECTION
STOPPER PIN
(2.36")
(0.47") 60
12 12 (0.47")
70 (2.76")
øD L
L 40 80
(1.57) (3.15)
D Stopper pin size
Make sure of the rotating direction of travel motor referring to the figure. Otherwise, the rib "A" may be broken by
the stopper pin.
13-14
(2) Measurement :
• Engine : At rated speed

• Hydraulic oil temp. : 50 to 60°C (122 to 140°F)
• Machine posture : Locking the traveling, and allowing
relief on the travel motor
• Measure the drained volume of oil for 30 seconds of
relief.
Unit : liter (gal.) /30sec

DRAIN RATE OF TRAVEL MOTOR
SPEED
Standard Standard value Serviceability
SHIFT
value for repair limit
1 st 1.5 (0.40) or less - 3 (0.79) or more
13
13-15
13.6 MEASURING SLEW PERFORMANCES
TEST PROCEDURES
13.6.1 SLEW TIME

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

Same as that for measuring slew time.
• Prior to measuring, draw matching marks on the outer
race of the slew bearing and lower frame at exactly 180
degrees slew from the starting point. Then with the hoe
attachment in a no-load, slew 180 degrees from
starting point. At which point return the operating lever
to neutral. Measure the distance between the position
marks and the point the hoe attachment stops.
13.6.3 SLEW DRIFT DUE TO GRAVITY
• Slew the upper slewing structure and stop at right
angle to the slope, then draw matching marks on the
slew bearing's outer race and the lower frame. Then
measure the distance that develops between the marks
after 5 minutes. Measure for both RH and LH
directions.
13-16
13.6.4 DRAIN RATE OF TRAVEL MOTOR

(1) Preparation
1. Stop the engine, and release air inside the
hydraulic oil tank.
2. Disconnect the slew motor drain hose at the return
side to the hydraulic oil tank. Then receive the drain
oil to a container.
Install plug on bore of tank after removing drain
hose.
(2) Measurement :
• Engine : At rated speed
• Hydraulic oil temp. : 50 to 60°C (122 to 140°F) Unit : liter (gal.) /30sec
• Machine posture : DRAIN RATE OF SLEW MOTOR
Pushing a fixture with the side of bucket, operating Standard value Serviceability
Standard value
the engine. for repair limit
• Measure the drained volume of oil for 30 seconds 4.2 (1.1) or less 9 (2.4) or more
relieving at full stroke of the slewing operation.
13
13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES
TEST PROCEDURES
13.7.1 CYLINDER SPEED

(1) Boom Cylinder Speed

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

cylinder, fully extend the bucket cylinder, position the
arm horizontally and place 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).
(3) Bucket Cylinder Speed

cylinder, position the arm horizontally and place 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).
13-18
(4) Swing Cylinder Speed

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

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

(1) Boom, Arm, Bucket, Dozer, Bucket Tip
• Engine : Stopped 13
• Hydraulic Oil Temp. : 50 to 60°C (122 to 140°F
degrees)
• Measurement Posture : Completely retract the dozer
and arm cylinders, fully extend the bucket cylinder and
position the bucket pin to the same height as the boom
foot pin.
• Maintain the position for 10 minutes then measure the
change of rod length and distance of the bucket tip.
(2) Swing Cylinder
• Slew the upper slewing structure and stop at right
angle to the slope, then measure the change in rod
length after 5 minutes.
13-19
13.8 MEASURING SLEW BEARING PERFORMANCES
TEST PROCEDURES
Measure 3-times each.
13.8.1 SLEW BEARING-BUCKET TIP PLAY

cylinder and fully extend the bucket cylinder.
• Move the tips of the bucket teeth from side to side (left
and right) and measure the play.
13.8.2 SLEW BEARING PLAY
(1)
Attach a dial gauge to the bottom face of the slew
bearing's outer-race located in front of the upper slewing
structure.
(2)
Raise the crawler on one side off the ground and set the
dial gauge to zero.
13-20
(3)
Then raise the opposite crawler and read the dial gauge.
13
13-21
13.9 MEASURING CRAWLER TENSION
13.9.1 CRAWLER TENSION
• Raise the machine completely off the ground using the

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

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

22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT ........................ 22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS ................................... 22-4
22.2.1 STANDARD SPECIFICATION ................................................................... 22-7
22.2.2 ANGLE DOZER SPECIFICATION ............................................................. 22-8
22.3 HYDRAULIC CIRCUIT OPERATION ................................................................ 22-10
22.3.1 COLOR CODING STANDARD FOR HYDRAULIC .................................... 22-10
22.3.2 NEUTRAL CIRCUIT .................................................................................. 22-10
22.3.3 TRAVEL CIRCUIT .................................................................................... 22-12
22.3.4 SLEW OPERATING CIRCUIT ................................................................... 22-14
22.3.5 BUCKET OPERATING CIRCUIT ............................................................... 22-16
22.3.6 BOOM OPERATING CIRCUIT .................................................................. 22-18
22.3.7 ARM OPERATING CIRCUIT ..................................................................... 22-20
22.3.8 SWING OPERATING CIRCUIT ................................................................. 22-22
22
22.3.9 DOZER OPERATING CIRCUIT ................................................................. 22-24
22.3.10 NIBBLER & BREAKER OPERATING CIRCUIT ........................................ 22-26
22.3.11 TRAVEL / DOZER COMBINED OPERATING CIRCUIT ........................... 22-28
22.3.12 TRAVEL / BOOM COMBINED OPERATING CIRCUIT ............................. 22-30
22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM ........................................... 22-32
22-1

CX31B : PW14- S5PW2232E01
CX31B : PW14-46519~ S5PW2232E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
22-2
22.1 SUMMARY
22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT

The hydraulic circuits have the following functions and features for easy operation, safety and high efficiency.
Perfor
Device Function Features
mance
• Straight traveling • Straight traveling secured by independent
Travel
travel function in combined operations

• Preventing overrunning of travel motor • Preventing overrunning on a slope
• Parking brake • Automatic braking at parking
• Slewing (with dozer) independent circuit • Constant slewing speed when operating in
simultaneous operation condition
Easy Operation and Safety
Slew
• Auto slewing parking brake • Protecting against slewing drift on a slope

• Slewing shockless function • Smooth feeling when starting and stopping
slewing operation
• Hydraulic pilot control system • Responsive operability
Attachment
• Dozer (with slewing) independent circuit. • Secure the travel straight when travelling and
working with dozer.
• Multi-control valve • Capable of selecting operation pattern from two
types using one lever
• Closed pressurized hydraulic oil tank • Preventing contamination of hydraulic oil and
improving self sucking up efficiency
Others
• Suction strainer • Removing dirt of suction side

• Line filter in pilot circuit • Preventing malfunction in pilot operating circuit
• Return filter • Preventing contamination of hydraulic oil
Low fuel Consumption High Working Performance
Attachment Travel Pump
• Effective use of engine power with variable

• Total power control (Pumps : P1 + P2 + P3)
pump (Power shifting by P3 pump)
• Improving working efficiency with 2 travel
• 2 speeds traveling
speeds shifting 22
• P3 pump oil flow conflux in arm or N & B • Speed increased by conflux P3 pump oil piping
operation (when no dozer or slewing used)
Electricity
• When waiting for dump truck, the engine speed

• Push button deceleration is repeatedly changed and the fuel
consumption and noise are reduced
22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS
STANDARD SPECIFICATION PX01Z00035P1E CX31B

No. NAME PART No. MODEL No.
1 PUMP ASSY PX10V00013F1 AP2D18LV3RS7
2 CONTROL VALVE PX30V00041F4 BCV35-JAA10
3 SLEWING MOTOR PX15V00024F1 MSG-27P-16E-17
4 TRAVEL MOTOR PX15V00025F1 GM04VA
CANOPY PW01V00068F1 Ø80-Ø45-585
5 BOOM CYLINDER
CAB PW01V00071F1 Ø80-Ø45-559
6 ARM CYLINDER PW01V00070F2 Ø75-Ø45-541
7 BUCKET CYLINDER PX01V00064F1 Ø65-Ø40-497
8 SWING CYLINDER PX01V00042F2 Ø80-Ø45-488
9 DOZER CYLINDER PX01V00043F2 Ø100-Ø50-160
10 SWIVEL JOINT PW55V00015F2 YV-7200
11 PILOT VALVE (ATT) PX30V00043F1 PV48M2042
12 PILOT VALVE (TRAVEL) PM30V00019F6 PVD6P4042
13 SOLENOID VALVE PX35V00003F1 2KWE5G-30/G12WS-249A
14 PILOT VALVE (DOZER) PB30V00002F2 PV6P1075
15 SHUTTLE VALVE PH26V00001F1
16 MULTI CONTROL VALVE PX30V00060F1
17 RETURN FILTER (ELEMENT) PW52V01001F2
18 SUCTION STRAINER PW50V00015F1
19 INLINE FILTER YN50V00020F1 Y-457400
20 CHECK VALVE PW21V00003F1 Y-2389
23 STOP VALVE PF25V00001F2
24 SELECTOR VALVE PA30V00005F1
25 BREATHER ASSY YN57V00002F4 AB0210GA0018
26 HYDRAULIC OIL TANK -
52 RELIEF VALVE PM22V00005F3
53 SOLENOID VALVE PW35V00002F1
This is for reference only, because the model number might be changed due to improvement.
22-4
STANDARD SPECIFICATION PX01Z00035P1E CX36B

1 PUMP ASSY PX10V00013F1 AP2D18LV3RS7
2 CONTROL VALVE PX30V00041F4 BCV35-JAA10
3 SLEWING MOTOR PX15V00024F1 MSG-27P-16E-17
4 TRAVEL MOTOR PX15V00025F1 GM04VA
CANOPY PX01V00062F1 Ø80-Ø45-578
5 BOOM CYLINDER
CAB PX01V00066F1 Ø80-Ø45-555
6 ARM CYLINDER PX01V00063F2 Ø80-Ø45-560
7 BUCKET CYLINDER PX01V00064F1 Ø65-Ø40-497
8 SWING CYLINDER PX01V00042F2 Ø80-Ø45-488
9 DOZER CYLINDER PX01V00043F2 Ø100-Ø50-160
10 SWIVEL JOINT PW55V00015F2 YV-7200
11 PILOT VALVE (ATT) PX30V00043F1 PV48M2042
12 PILOT VALVE (TRAVEL) PM30V00019F6 PVD6P4042
13 SOLENOID VALVE PX35V00003F1 2KWE5G-30/G12WS-249A
14 PILOT VALVE (DOZER) PB30V00002F2 PV6P1075
15 SHUTTLE VALVE PH26V00001F1
16 MULTI CONTROL VALVE PX30V00060F1
17 RETURN FILTER (ELEMENT) PW52V01001F2
18 SUCTION STRAINER PW50V00015F1
19 INLINE FILTER YN50V00020F1 Y-457400
20 CHECK VALVE PW21V00003F1 Y-2389
23 STOP VALVE PF25V00001F2
24 SELECTOR VALVE PA30V00005F1 22
25 BREATHER ASSY YN57V00002F4 AB0210GA0018
26 HYDRAULIC OIL TANK -
52 RELIEF VALVE PM22V00005F3
53 SOLENOID VALVE PW35V00002F1
This is for reference only, because the model number might be changed due to improvement.
22-5
22-6
22.2.1 STANDARD SPECIFICATION
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12
No. NAME PRESSURE:MPa{psi} 53

13 201 MAIN RELIEF VALVE P1,P2 23.0{3340}
202 MAIN RELIEF VALVE P3 20.0{2900}
19 203 OVER LOAD RELIEF VALVE 27.5{4000}
204 OVER LOAD RELIEF VALVE 25.5{3700}
304 SLEW RELIEF VALVE 20.0{2900} 14
13-1 PILOT RELIEF VALVE 3.5{508}
22-7
22.2.2 ANGLE DOZER SPECIFICATION
ANGLE DOZER SPECIFICATION PW01Z00023P1

50 CONTROL VALVE PX30V00072F3 BCV35-JAH11-12
51 SWIVEL JOINT PW55V00014F2 YV-7203-OB
52 ANGLE CYLINDER PW01V00052F2 80-45-300
52 53 SOLENOID VALVE PE35V00001F2 16351-00000
NOTE :
1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
51
53
50
PW01Z00023P1 (02)
22-8
22
22-9
22.3 HYDRAULIC CIRCUIT with its motion and led to the control valve (2) from
the pilot valve to shift each spool of shifting valve.
OPERATION
(2) Main Circuit
1. Variable Pump Circuit
22.3.1 COLOR CODING STANDARD FOR The delivered oil from A1 and A2 ports on variable
HYDRAULIC pump enters into P1 and P2 ports on control valve
Blue : Feed, drain circuit,less than 0.34 MPa (50 psi) (2) respectively.
Green : Return, make-up circuit,0.34 to 0.59 MPa (50 All the discharged oil from these two ports finally
to 86 psi) returns to the hydraulic oil tank (26), through each
Purple : Secondary pilot pressure,0.59 to 3.5 MPa (85 valve of travel left, boom and bucket for the P1 oil,
to 508 psi) and through each valve of travel right, swing,
Red : Primary pilot pressure,3.5 to 3.9 MPa (508 to
service and arm for the P2 oil.
566 psi)
Orange : Main pump drive pressure,4.9 to 23 MPa 2. Third Pump Circuit
(711 to 3340 psi) The oil delivered from A3 port on 3rd pump enters
into P3 port on control valve (2).
Blue tone : At valve selection The whole amount of oil discharged through the
Red valve : When proportional valve (reducing) is port P3 returns to the hydraulic oil tank (26) through
operating
the selector valves for the dozer and slewing and
Red solenoid : In active and exciting
the independent travel and flow conflux valves.
Displaying the flow circuit and standby circuit when
operating.
Regarding the electrical symbols in this manual, refer
to the electric circuit diagram.
22.3.2 NEUTRAL CIRCUIT

(1) Pilot Circuit
1. Pilot Primary Pressure Circuit
The oil delivered from the A4 port on pump assy (1)
enters into the solenoid valve (13) through the line
filter (19).
The pressurized oil from the port A2 of the solenoid
valve (13) with the safety lock lever released (in the
operating condition) is supplied to the P ports of the
pilot valves for attachment (11), travel (12), dozer
(14) and nibbler & breaker (53).
Since the operating circuit is fully closed in the
neutral position, the oil delivered by the pump other
than the oil supplied to the Pp1 port of the control
valve loses its flowing passage, and returns to the
hydraulic tank (26) through the relief valve (set
pressure : 3.5MPa [508 psi]) built in the solenoid
valve (13).
The oil supplied to the Pp1 port is led to the tank
passage through the pilot passages provided to the
service spool and through the pilot passages
provided to the right and left travel spools.
2. Pilot Secondary Pressure Circuit
While the pilot valves (11),(12), (14) and solenoid
valve for nibbler & breaker are being in neutral, the
pilot secondary pressure is not generated.
By means of operating the operating lever, the
secondary pressure is generated in accordance
22-10
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17
26
11 11
22
52
12

Neutral circuit
22-11
22.3.3 TRAVEL CIRCUIT speed corresponding to the supplied oil volume of

the pump.
Pilot oil hydraulic system with operating lever
c. The counterbalance valve spool is so designed that
it is gradually shifted by a throttle effect to stop or
22.3.3.1 2nd Speed Operating Circuit
(Independent-forward travel) start the motor absorbing shock at the start and
stop of the machine.
(1) Pilot Circuit
d. When load increases during high speed travel, the
1. Shifting signal for 2nd speed travel
When the "Rabbit and Turtle" mark (at the power speed automatically shifts to the 1st speed,
resulting in low speed and high torque.
cut-off, it automatically takes back for 1st speed) on
the nob of travel right lever is pushed down, it
actuates the 1st and 2nd speed travel shifting valve
of solenoid valve (13).
The pressurized oil signal for 2nd speed is
generated from the A1 port of solenoid valve(13),
and led to the P port on travel motor (4) through
swivel joint (10), and shifts the 2-speed shifting
valve (404).
2. Changing travel valve spool
The pilot secondary pressure is generated from
pilot valve (12) by the operation for travel forward.
The pressurized oil is led to the Pb7 and Pb6 ports
on control valve (2) to shift the travel valve spool.
(2) Main Circuit
1. Circuit up to Travel Motor (4)
The delivered oil from A1 and A2 ports on variable
pump enters into the P1 and P2 ports of control
valve (2), and led to the B7 and B6 ports through
the travel valve.
Then it is led to the A and B ports on left and right
travel motors respectively through the swivel joint
(10).
2. Travel Motor
a. The pressurized oil supplied to the travel motor
shifts the spool of the counterbalance valve (brake
valve) (408), releases the parking brake (403),
opens the hydraulic circuit having closed by the
check valve (407) and rotates the travel motor.
It actuates the speed shifting valve (404) when the
2nd speed signal is sent. The high pressure oil
pumped through the shuttle valve (406) passes the
speed change valve (404), actuates the 2-speed
shifting piston (401) and provides the motor with
high speed and low torque.
b. When the motor reaches near to a self-running
condition (over-running) at going down a slope and
so on, the oil pressure of supply side gets down to
lower pressure, and the counter balance valve
[brake valve] (408) spool moves to the neutral
position with the spring force.
As the results, the passage in return oil side is
throttled, and the motor speed is suppressed by a
back-pressure, then the motor is controlled to the
22-12
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Travel circuit : Travel foward operation at travel 2nd speed
22-13
22.3.4 SLEW OPERATING CIRCUIT

22.3.4.1 Slew (left) Operating Circuit

(1) Pilot Circuit
1. Slew Valve Spool Shifting
With operation for slew (left), the pilot secondary
pressure oil is generated from the pilot valve (11),
and led to the Pb2 port of control valve (2) to shift
the slew valve spool.
2. Releasing Parking Brake
The pilot primary pressure is always led to PG port
on the timer valve (303).
With the slew operation, the operating pilot
secondary pressure is led to SH port on the timer
valve (303) through the shuttle valve (15) to shift
the spool.
It leads the pilot primary pressure 3.5 MPa (508 psi)
to the parking brake to release it. (Similarly, the arm
in operation releases the slew brake.)
3. Activating Parking Brake
When the slew operating lever is returned to neutral
position to stop slewing, the pilot secondary
pressure disappears causing to shift the timer valve
(303), then the pressurized oil is shut down.
The oil in the brake cylinder is discharged due to
spring force, and drained through the throttle in the
timer valve (303).
Thus the braking is activated with some time lag for
2.5 to 5.0 seconds to smoothly absorb the slewing
inertia at its stop of motion.
(2) Main Circuit
1. Supply Circuit for Slewing Motor (3)
The oil delivered from the A3 port on hydraulic oil
pump (1) is supplied to the B port on slewing motor
(3) through the P3 port on control valve (2) and
slew valve to drive the slewing motor.
2. Slewing Motor (3)
a. The relief valve (304) relieves rapidly increased
pressure at start and stop of the machine to ease
shock.
b. The make-up valve (check valve) (305) has a
function to replenish oil from the return oil circuit
that is led to the tank [T2 port on control valve (2)]
to the slewing motor, to prevent the slewing motor
from the cavitation due to negative pressure
generated in it because of inertia on the slewing
mass.
22-14
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Slewing circuit : Slewing left operation
22-15
22.3.5 BUCKET OPERATING CIRCUIT

22.3.5.1 Bucket Digging Operation Circuit

(1) Pilot Circuit
1. Bucket Spool Shifting
When the operating lever is put at bucket digging
position, the pilot secondary pressure oil is
generated from the pilot valve (11). The pressurized
oil entered into the Pb10 port on control valve (2)
shifts the bucket valve spool.
(2) Main Circuit
1. Supply Circuit for Cylinder (7)
The oil delivered from A1 port on variable pump of
pump assembly (1) enters into P1 port on control
valve (2). The pressurized oil from B10 port through
bucket valve is supplied to the head side of bucket
cylinder (7) to activate the digging work.
The return oil from the rod side of cylinder (7)
enters into A10 port on control valve (2) and returns
into the tank through bucket valve.
22.3.5.2 Bucket Dumping Operating Circuit

(1) Pilot Circuit
1. Bucket Spool Shifting
When the operating lever is moved to bucket
dumping position, the pilot secondary pressure oil
is supplied from pilot valve (11), and enters into
Pa10 port on control valve (2) to shift the bucket
valve spool.
(2) Main Circuit
Similar to the case for bucket digging, the
pressurized oil delivered from A1 port on variable
pump enters into P1 port on control valve (2).
The oil supplied from A10 port through bucket valve
is entered into the rod side of bucket cylinder (7) to
activate the bucket dumping.
22-16
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Bucket circuit : Bucket digging operation
22-17
22.3.6 BOOM OPERATING CIRCUIT

22.3.6.1 Boom UP Operating Circuit

(1) Pilot Circuit
1. Boom Spool Shifting
When the operating lever is put at boom up
generated from pilot valve (11). The pressurized oil
entered into Pa8 port on control valve (2) shifts the
boom valve spool.
(2) Main Circuit
The oil delivered from A1 port on variable pump of
pump assy (1) enters into P1 port on control valve
(2). The oil supplied from B9 port through boom
valve and lock valve is entered into the head side of
boom cylinder (5) to up the boom.
22.3.6.2 Boom Down Operating Circuit

(1) Pilot Circuit
1. Boom Spool Shifting
When the operating lever is put at boom down
generated from pilot valve (11), and enters into Pb8
port on control valve (2) to shift the boom valve
spool.
At the same time, the pilot secondary pressure is
led to the boom lock valve (206) to push up the
check valve and open the oil path from closed
condition.
(2) Main Circuit
1. Supply Circuit for Cylinder (5) and Return Oil Circuit
The pressurized oil delivered from A1 port on
variable pump is led to boom valve provided on
control valve (2), and supplied to the rod side of
boom cylinder (5) to down the boom.
The oil returned from the head side of cylinder (5)
enters into B9 port on control valve (2), and returns
to the tank through the boom lock valve (206) and
boom valve.
Its flow rate is restricted by the throttle effect in
boom valve, accordingly the boom is lowered at a
stable speed.
a. Boom lock valve (206)
This is of a check valve mechanism to prevent the
boom from lowering due to its own weight while the
boom valve is being at neutral position.
22-18
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Boom circuit : Boom up operation
22-19
22.3.7 ARM OPERATING CIRCUIT

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

(1) Pilot Circuit
1. Shift for Arm Spool
At the arm in operation, the pilot secondary
pressure generated from the pilot valve (11) is led
to the Pa3 port on control valve (2) to shift the arm
valve spool.
Furthermore, the pilot secondary pressure acts to
the SH port on timer valve (303) through the shuttle
valve (15) to release the parking brake.
Since the spool of the arm valve shifts to close the
pilot passage, the pressure of pilot oil thru the Pp1
port equals to the supply pressure.
Thus the pressure overcomes the spring forces of
the independent travel and flow conflux valves to
shift the valve spool.
(2) Main Circuit
The oil delivered from the A2 port on variable pump
enters into P2 port on control valve (2).
The pressurized oil from the P3 port joins with the
oil from the P2 port through the independent travel
and flow conflux valves. The joined oil flows out
from the A3 port through the arm valve and is
supplied to the head side of the arm cylinder (6) to
perform arm in work.
2. Return Line from Cylinder (6)
The return oil from the rod side of arm cylinder
enters into the B3 port on control valve(2), and is
led to the return line from the T1 port through arm
valve, then return to the tank.
22.3.7.2 Operating Circuit for Arm Out

(1) Pilot Circuit
At the operation for arm out, the pilot secondary
pressure is generated from the pilot valve (11), and
led to the Pb3 port on control valve (2) to shift the
arm valve spool.
The independent travel and flow conflux valves are
actuated as in the excavating operation.
(2) Main Circuit
As in the case of excavating operation, the oil
having flown into the control valve (2) joins with the
pressurized oil from P2 and P3, flows out from the
B3 port and is supplied to the rod side of the arm
cylinder to perform arm out work.
22-20
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Arm circuit : Arm in operation
22-21
22.3.8 SWING OPERATING CIRCUIT

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

(1) Swing Operation
When depress the left side of swing pedal, the swing
valve spool in control valve (2) is shifted by the cabling
mechanism. Since the pilot oil pressure is not utilized
for it is activated regardless to the safety lock lever.
(2) Main Circuit
The delivered oil from A2 port on variable pump
enters into P2 port on control valve (2), and comes
out from A5 port through swing valve, and is
supplied to the head side of cylinder (8) to activate
the swing (left).
a. At activation of the swing valve spool for both left
and right swing motions, a part of appropriate
volume of oil is returned to the tank through the P2
bypass circuit due to the throttle effect on the spool.
Then supplying volume of oil to the cylinder is
restricted to ensure the slow and stable swing
motions for both leftward and rightward.
22-22
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Swing circuit : Boom swing left operation
22-23
22.3.9 DOZER OPERATING CIRCUIT

Pilot oil system with operating lever
22.3.9.1 Dozer Down Operating Circuit

(1) Dozer Operation
When the operating lever is pushed forward, the pilot
secondary pressure is generated from the pilot valve
(14) to shift the dozer valve spool through the Pb1 port
of the control valve (2).
(2) Main Circuit
The oil delivered from A3 port of the hydraulic
pump (1) enters into P3 port on control valve (2),
and is led to B1 port through dozer valve. The
pressurized oil passed through swivel joint (10) is
supplied to the head side of dozer cylinder (9) to
activate dozer down motion.
22-24
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Dozer circuit : Dozer down operation
22-25
22.3.10 NIBBLER & BREAKER (2) Main Circuit

OPERATING CIRCUIT The pressurized oil is flowed in the control valve (2)
together, and it is same operation as closing circuit.
Pilot oil hydraulic system with operating pedal, and The confluent oil flows from A4 port, enters into R side
with 3rd. pump conflux function of Nibbler cylinder, and opens the Nibbler.
22.3.10.1 Nibbler Close Operating Circuit

(1) Pilot Circuit 22.3.10.3 Breaker Blow Operating Circuit
1. Service Spool Shifting Change the valve position of selector valve (24) to the
Slide the slide switch on the grip of right control position for Breaker.
lever to the left, and secondary pilot pressure flows (1) Pilot Circuit
out from A2 port of solenoid valve (53). 1. Service spool shifting
The secondary pressure of pilot valve is varied Press the button on the grip of right control lever,
according to the sliding distance. and secondary pilot pressure flows out from A1 port
The pressurized oil which entered into Pb4 port of of solenoid valve (53).
control valve (2) switches the spool for Nibbler/ The pressurized oil which entered into Pa4 port of
Breaker. control valve (2) switches the spool for Nibbler/
Consequently the service spool shifts to close the Breaker.
pilot passage, the pressure of pilot oil thru Pp1 port By this shift of service spool, the independent and
equals to the supply pressure. flow conflux valves are actuated like the Nibbler-
Thus the pressure overcomes the spring forces of close operation.
the travel independent and flow conflux valves to (2) Main Circuit
shift the valve spool. 1. Supply Circuit for Breaker
(2) Main Circuit Both P2 and P3 pump oil flow together in the
1. Supply Circuit for Nibbler Cylinder control valve, and this is same operation as closing
Delivery oil from A2 port on the variable Nibbler.
displacement pump enters into P2 port on control The conflux oil is delivered from A4 port through the
valve (2). And the pressurized oil from P3 port flows service valve, and is supplied into Breaker, and
together the oil from P2 port thru travel makes the blow work of Breaker.
independent/conflux valve. 2. Return Line from Breaker
The confluent oil flows from B4 port thru service The return oil of Breaker flows through the selector
valve, enters into H side of Nibbler cylinder, and valve (24), and the oil returns directly to hydraulic
closes the Nibbler. tank.
2. Return Line from Nibbler Cylinder
The return oil from Nibbler cylinder enters into A4
Slide
port on control valve (2), and flows into return path Button switch
switch
thru the service valve, and then returns from T1
port to the hydraulic tank.
22.3.10.2 Nibbler Open Operating Circuit

(1) Pilot Circuit
Slide the slide switch on the grip of right control lever
to the right, and secondary pilot pressure flows out
from A1 port of solenoid valve (53).
The secondary pressure of pilot valve is varied
according to the sliding distance.
The pressurized oil which entered into Pa4 port of
control valve (2) switches the spool for Nibbler/
Breaker.
By this shift of service spool, the independent and flow
conflux valves are actuated like the Nibbler-close
operation.
22-26
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Nibbler & breaker circuit : Nibbler close operation
22-27
22.3.11 TRAVEL / DOZER COMBINED

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

Down Operating Circuit
(1) Pilot Circuit
Both the travel and dozer are operated by the lever
using the pilot oil system.
The operation of each lever directly shifts the travel
valve spool and dozer valve spool in the control valve
(2) respectively.
(2) Main Circuit
The oil delivered from A1 and A2 ports on the variable
pump (1) enters into P1 and P2 ports on control valve
(2), and each flow of left and right is led to swivel joint
(10) and travel motor (4) respectively through each
travel valve of left and right.
The oil delivered from A3 port on the third pump enters
into P3 port on control valve (2), then it is led to the
dozer cylinder (9) through dozer valve and swivel joint
(10).
1. The dozer is operated by the pressurized oil
supplied by the third pump which has no relation
with travel circuit. Then there is no variation on the
supply volume of pressurized oil for both travel
motors of left and right even though the dozer is
operated during traveling.
Thus the straight traveling is secured.
(The slewing is operated in the same way as the
dozer.)
2. As the above mentioned, the traveling speed is not
changed from the single operation for traveling
securing the straight traveling.
22-28
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Combined operation circuit : Travel (forward) 1st speed / Dozer down operation
22-29
22.3.12 TRAVEL / BOOM COMBINED

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

Operating Circuit
(1) Pilot Circuit
The traveling/boom up is of the pilot oil hydraulic
system with lever operation.
By means of pushing forward of travel operating lever
and pulling this side of boom up operating lever, the
pilot secondary pressure shifts the travel valve spool
and/or boom spool in the control valve (2).
Thus the pilot passage of the boom valve is closed to
make the pressure of the oil from the Pp1 port equal to
the supply pressure. Therefore the hydraulic pressure
overcomes the spring force of the independent travel
and flow conflux valves to shift the valve spool.
(2) Main Circuit
The oil delivered from A1 and A2 ports on the variable
pump enters into P1 and P2 ports on the control valve
(2).
The whole amount of oil from the P1 and P2 ports is
supplied to the travel motor in the same way as
operating the independent travel. The oil flows from
the travel valve through the B7 and B6 ports and the
swivel joint (10) to the right and left travel motor (4).
The oil delivered from the port A3 of the hydraulic
pump (1) is supplied to the boom cylinder. The oil
through the P3 port of the control valve (2) flows
through the dozer and slewing valves and through the
shifted independent travel and flow conflux valves to
the boom valve.
The oil from the B9 port through the boom and block
valves is supplied to the head side of the boom
cylinder (5).
1. When the travel and other attachments (boom, arm,
bucket, swing, and service (for N & B) are operated
in combination, the independent travel and flow
conflux valves are actuated. Thus the attachments
are actuated only by oil supplied from the P3 port.
Therefore the oil of the P1 and P2 ports is utilized
only by the travel to secure stable travel in the
combined operation.
22-30
9
4
5 (CX31B)
21 (CX36B)
3
6 (CX31B)
22 (CX36B)
23
7
24 15
8
1 10
25
20
2 16
18 17 26
11 11
22
52
12

Combined operation circuit : Travel (forward) 1st speed / Boom up operation
22-31
22.4 SCHEMATIC PIPING FOR

HYDRAULIC SYSTEM
NIBBLER & BREAKER
SOLENOID VALVE (LEFT) (RIGHT)
TRAVEL PILOT VALVE
3 1
H R
4 2
BUCKET CYLINDER
P T
C H R
SHUTTLE
D VALVE B10 A10
Pb10 BUCKET Pa10
Pb8' BOOM CYLINDER
A B BOOM B9
Dr1
H R
Pb8 BOOM B8 T2 Pa8
TRAVEL
LEFT B7 A7 SWING CYLINDER
Pb7 Pa7
ATT PILOT VALVE (L.H.) ATT PILOT VALVE (R.H.) P1

P2
H R
(4) A6
Pb6 TRAVEL Pa6
B6
RIGHT ARM CYLINDER
4 4 (2) B5 SELECTOR
P 1 P 1 SWING
BREAKER
(1) MULTI A5 VALVE
3 3 CONTROL STOP VALVE
2 T 2 T B4
VALVE Pb4 SERVICE Pa4
(N&B) A4
B3 H R
(3) Pb3 Pa3
ARM A3
BOOM UP
NIBBLER CYLINDER
BOOM DOWN T1 P3
ARM IN Pp1
ARM OUT
SLEWING MOTOR BUCKET DUMP RETURN FILTER
A2 HYDRAULIC
BUCKET DIG. Pb2 SLEW B2 Pa2
CHECK OIL TANK
A1 VALVE
PG Pb1 DOZER B1 Pa1
SH SLEW LEFT CONTROL VALVE

SLEW RIGHT
B M DB A
SLEW RIGHT
SUCTION
SLEW LEFT STRAINER
IN OUT
A4 DOZER PILOT
A3 A1
ENGINE FILTER VALVE
A2
HYDRAULIC PUMP P1 T
RELIEF
S OIL COOLER VALVE
E F C A G P B D
SWIVEL JOINT P
DOZER CYLINDER P2 2 1
A1
R H
A2 TRAVEL 2-SPEED
SOLENOID VALVE LEVER LOCK

D1 D2 T1
PILOT CIRCUIT
FORWARD FORWARD
A B
P BACKWARD BACKWARD MAIN CIRCUIT
B A
SUPPLY / RETURN (DRAIN) CIRCUIT
TRAVEL MOTOR (LEFT) TRAVEL MOTOR (RIGHT)
22-32
23. ELECTRICAL SYSTEM

TABLE OF CONTENTS
23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION ............ 23-3
23.1.1 ELECTRIC CIRCUIT DIAGRAM ............................................................... 23-3
23.1.2 HARNESS CONNECTION ........................................................................ 23-3
23.2 ELECTRICAL EQUIPMENT & HARNESS ......................................................... 23-4
23.2.1 ELECTRICAL EQUIPMENT LIST ............................................................. 23-4
23.2.2 HARNESS & CABLE LIST ........................................................................ 23-6
23.2.3 ELECTRIC CIRCUIT DIAGRAM ............................................................... 23-7
23.2.4 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS ........... 23-11
23.2.5 DETAIL OF HARNESS & CABLE .............................................................. 23-23
23
23-1

CX31B : PW14- S5PW2332E01
CX31B : PW14-46519~ S5PW2332E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
23-2
23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION
23.1.1 ELECTRIC CIRCUIT DIAGRAM

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

Example : 6 2 R Symbol Color Symbol Color Symbol Color
B BLACK Y YELLOW Gr GRAY
Wire Color : Red
G GREEN P PINK Sb SKY BLUE
Wire Size : 2 sq (mm2) L BLUE O ORANGE V VIOLET
Wire No. : 6 R RED Br BROWN
W WHITE Lg LIGHT GREEN
23.1.2 HARNESS CONNECTION

(1) Indication for Connector
Lock Wire No. Connector No.
Connector Name
Wire color
1. The figure for the connector pin arrangement is shown by putting the lock (nail) to upper portion, and looking
from the fitting face.
2. The numbers in the connector show the wire No., and alphabetical letters show the wire color.
3. On the side face of connector, the connector name and serial number of the connector No. are indicated.
4. At the place indicated as "DOUBLE SPLICE", Two wires are connected to one place.
(2) The connector is to be connected with engaging the male (M) and female (F) connectors of the same number.
Example : CN-101M and CN-101F
Where : M means for Male, and F for Female.
(3) +<-- mark means the connector with diode. The direction for diode is shown by the arrow.
(4) The AVSS wires are to be used for the size between 0.75 sq and 2 sq. AVS wires between 3 sq and 5 sq and 23
others are AV wires, unless otherwise specified.
(5) The wire size is 0.75 sq, unless otherwise specified.
(6) The treatment for the harness end is to be as follows :
1) : After roughly applying harness taping, wires are installed in a corrugated tube.
2) : Harness taping by two plies.
3) : No harness treatment for connection.
(7) The length for the above (6)-3) is to be 20 to 40 mm. (0.8 to 1.6 in), and the length includes in the total length of
wire shown in the diagram.
23-3
23.2 ELECTRICAL EQUIPMENT & HARNESS
23.2.1 ELECTRICAL EQUIPMENT LIST
Group Code Part Name Part No.

D-1 DIODE YN02D01001P1
D-2 DIODE ↑
D-3 DIODE ↑
D-4 DIODE ↑
Diode
D-12 DIODE ↑
D-14 DIODE ↑
D-18 DIODE ↑
D-20 DIODE ↑
E-1 FUSE BOX PW73E00003F1
E-2 GENERATOR (ALTERNATOR) E/G accessory (119626-77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E-8 GLOW PLUG E/G accessory (129008-77800)
Electical
E-10 RADIO (OPT) Cab accessory (PY54S00001P1)
Fittings
E-12 HEATER (OPT) PM21M00005F1
E-13 BATTERY PW72S00004P1
E-14 SEQUENCE BOX PA24S00002P3
E-20 TRAVEL ALARM (OPT) PW53S00002F1
E-26 HOUR METER YT58S00006P1
E-32 FUSE 2479R655S10
L-1 ROOM LAMP PM80S00006P1
Light L-2 BOOM WORKING LIGHT PM80S00008F1
L-5 CANOPY WORKING LIGHT PW80S00003F1
M-1 STARTER MOTOR E/G accessory (129242-77010)
M-2 WIPER MOTOR (CAB) Cab accessory (PM76S00001F1)
Motor M-3 WASHER MOTOR (CAB) Cab accessory (PE54C00002S002)
M-4 DECELERATION MOTOR PW20S00012F1
M-6 FUEL PUMP PW22P00001P1
R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
R-3 DECELERATION RELAY PA24E01001P1
R-6 TIMER UNIT PH25S00002P1
Relay
R-7 E/G STOP RELAY PX24S00003P1
R-8 CHARGE INDICATOR RELAY PA24E01001P1
R-9 CAB / CANOPY WORKING LIGHT RELAY PA24E01001P1
R-31 HORN RELAY ↑
23-4

SE-1 FUEL SENSOR PX52S00006F1
Sensor
SE-2 ENGINE THERMO SENSOR PA24S00003P1
SV-1 LEVER LOCK SOL.
PX35V00003F1
SV-2 2-SPEED SELECT SOL.
Solenoid SV-3 E/G STOP SOL. E/G accessory (119233-77932)
SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
SV-8 TILT ANGLE SELECT SOL. ↑
PSV-D NIBBLER OPEN PROPORTIONAL SOL.
PW35V00002F1
Proportional PSV-E NIBBLER CLOSE PROPORTIONAL SOL.
Solenoid
Valve PSV-F REVOLUTION LEFT(A1) PROPORTIONAL SOL. Pending
PSV-G REVOLUTION RIGHT(A2) PROPORTIONAL SOL. ↑
SW-1 KEY SWITCH PW50S00005S001
SW-2 WORKING LIGHT SW. PV24E01001P2
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
SW-6 E/G OIL PRESSURE SW. E/G accessory (114250-39450)
SW-7 HORN SW. YN50E01001P2
SW-9 LEVER LOCK SW. PA50S00001P1
SW-10 HEATER SW. (OPT) PY50S00003P2
SW-11 DECELERATION SW. PM50S00005P1
SW-14 AIR FILTER RESTRICTION SW. PW11P00010S004
Switch
SW-17 TILT ANGLE SELECT SW. PW03M01350F1
TRAVEL RIGHT(FORWARD) PRESSURE SW.
SW-24 GB50S00049F2
(OPT)
TRAVEL RIGHT(REVERSE) PRESSURE SW.
SW-25 ↑
(OPT)
TRAVEL LEFT(FORWARD) PRESSURE SW.
SW-26 ↑
(OPT)
SW-27 TRAVEL LEFT(REVERSE) PRESSURE SW. (OPT) ↑ 23
SW-30 SLEWING LEVER PRESSURE SW. (LEFT) ↑
SW-31 SLEWING LEVER PRESSURE SW. (RIGHT) ↑
SW-35 NIBBLER OPEN-CLOSE SW. PW03M01958F1
SW-37 (A1, A2) REVOLUTION SW. PW03M01959F1
The part numbers may be changed due to modification, use them only for reference.
23-5
23.2.2 HARNESS & CABLE LIST
Code Name Part No. Remarks

H-1 Inst - Main Harness PW14E01064P1
H-2 Proportional N&B Harness PH14E01041P2
H-3 Engine Harness PW16E01024P1
H-4 Starter Cable (+) PW13E01090P1
H-5 Battery Ground Cable (-) PW13E01091P1
H-6 Engine Ground Cable PH13E01047D1
H-7 Boom Harness PW15E01007P1
H-8 Key Switch Harness PW50E01002P1
H-9 Canopy Work Light Harness PW11E01026D4
H-10 Boom Work Light Extension Harness PW14E01038D1
H-11 Connection Harness with Cab PW14E01041P1 (OPT.)
H-12 Air Filter Harness PW11E01044D1
H-13 Travel Alarm Harness PW13E01069P1 (OPT.)
H-14 Alarm Extension Harness PH13E01078P1 (OPT.)
H-15 Heater Harness PW13E01068P1 (OPT.)
H-16 Cooler Harness PH11E01031P2 (OPT.)
H-17 Horn Switch Harness PH14E01013D1
The part numbers may be changed due to modification, use them only for reference.
23-6
23.2.3 ELECTRIC CIRCUIT DIAGRAM
INST-PANEL AND RELAY ASSY (PART IN RELAY CONSOLE) ENGINE
1 RADIO,HEATER,WIPER
2RG HORN,ROOM LAMP
6 GAUGE CLUSTER
5 ENG.STOP SOL.
E-13:
3 WORK LIGHT
BATTERY 40R (CX50B)
2 RELAY,SOL
20B (CX31B/CX36B) 30R (CX31B/CX36B) B
M-1:
WG 2 YB 40B (CX50B) S STARTER MOTOR
6 2 R M
M-6:FEED PUMP
B B
4
2YG
1.25
1.25
WG
WY
5W
YB
9 5R
E-1:
FUSE BOX
30A
30A
30A
10A
30A
10A
R-1:
8 2R BATTERY RELAY
71 3Y 8 3R 14 3WR 14 3WR
8 5R B
E-4:FUSIBLE LINK(45A)
8 5R 9 5R
(D-12)
POSITION PREHEATING
B S
S C P 11 WY 11 WY BAT P L IG
E-2:
O 81 O
O T AC R-8:CHARGE INDICATOR RELAY 1 GENERATOR
F A E
TERMINAL N IC
F R
T R-2: REG
B 8 5R SAFETY RELAY 6 WG 6 WG
47 3LY 47 3LY
R1
E-8:
47 3LY AIR HEATER
R2
ACC
72 1.25L CX31B/CX36B 3PCS
BR
13 1.25GB CX50B 4PCS
C
SW-1:
KEY SW. 6 1.25WG 6 1.25WG HOLD
6
5 5 5W 70 3BR 70 3BR
6 WG 15 YG R-7: 6 70 PULL SV-3:
16 RW ENG.STOP RELAY WG BR ENG.STOP SOL.
D-2 D-14
D-3
B R-6:
TIMER UNIT E 3B
B
4 RG 4 RG B
R-31: E-3:HORN
10 HORN RELAY L-1:
(NORTH AMERICA STD) 17 PB B
ROOM LAMP(FOR CAB)
SW-7: TO (2/3)
HORN SW. D-1
1 WY 1 WY
POSITION
B
E-10:
O L H RADIO (FOR CAB OPT.)
F
POSITION F O I
SW-10: B
HEATER SW. E
(OPT.) 18 LY
M
L
19 LB 23
1 WY
POSITION
W O O W
A F A
S S M-2:
POSITION H F N H M
E E WIPER MOTOR(FOR CAB)
SW-4: R R
20 G R +1 - B
WIPER WASHER SW. L M
E-12:
(FOR CAB) 22 Br Y S L
E +B HEATER(OPT.)
H 21 WB
M 1 WY
SW-35, 37: B
11 M
NIBBLER OPEN-CLOSE . REVOLUTION SW. (NORTH AMERICA STD) M-3:
WASHER MOTOR(FOR CAB)
TO (2/3) (1/3)
PW03Z00015P1 05
23-7
INST-PANEL AND RELAY ASSY

FROM (1/3)
E-6:GAUGE CLUSTER FROM (1/3)
ENGINE
6 WG TWO-SPEED LB
6 5 7 57 2 D-4:DIODE
EMPTY 58 GB
6
ENG.WATER TEMP. YG 51 YG SW-5:
4 51
ENG.WATER TEMP SW.
ENG.OIL PRESS 50 GW 50 GW SW-6:

8 2
B ENG.OIL PRESS SW.
CHARGE 48 LgB
3
6 114 P 81 O
1 E-2:GENERATOR
FUEL METER (D-18)
10 11 56 YB
R-8:CHARGE INDICATOR RELAY SE-2:
TERMO METER 13 52 YR 52 YR
COOLANT THERMO SENSOR
86 LgR ILLUMINATION B
4 1 12
SW-2: SE-1:
WORLING LIGHT SW. B FUEL SENSOR
AIR FILTER RESTRICTION 92 L B SW-14:

9 AIR FILTER RESTRICTION SW.
NORTH AMERICA:STD
H M 49 P
E-26:HOUR METER
POSITION
C-8:
O 5 INDICATOR(OPT)
O
F
TERMINAL N E-6:
F
SW-2: 4 CLUSTER GAUGE
WORKING LIGHT SW.
E L-2:
R-9: E-32:
3 BOOM WORKING
L WORK LIGHT RELAY FUSE
LIGHT LEFT(55W)
YG YG 86 LgR WY 5A WY
3 3 B +V
B 1 FUSE
2 YB 2 YB P PSV-D:
BP NIBBLER OPEN
GND PROPORTIONAL SOL.
39 GW B PW
BREAKER SW. (RIGHT SLIDE)
SW-9: G
LEVER LOCK SW. SV-1: SW3 PSV-E:
OPERATING LEVER YB NIBBLER CLOSE
GND
LOCK SOL PROPORTIONAL SOL.
SW-35:
(LEFT SLIDE)
63 BY NIBBLER OPEN-CLOSE SW.
64 LW
R-3:DECEL RELAY M-4: WY

DECEL MOTOR +V
60 GY 60 GY A B
M P
64 LW P1 PSV-G:
61 LB OW
8 R-20: 2 YB B B GND REVOLUTION RIGHT
CRANE TIMER RELAY(OPT.) LY (A2) PROPORTIONAL SOL. (RIGHT SLIDE)
63 BY P2 RG PSV-F:
BW REVOLUTION LEFT
(A1) PROPORTIONAL SOL. (REFT SLIDE)
E-14: SW-11: HORN SW.
SEQUENCE BOX DECEL SW. WR E-3:HORN
RG PB B
B 4 FUSE
2 61 LB RG
SW-37: D-1
6 WG 1 B
HOLD 4 45 BW (A1, A2) REVOLUTION SW.
R-31:
B HORN RELAY
6 3 43 Lg SV-2:
TWO-SPEED SELECT SOL.
HOLD 5 46 WB NORTH AMERICA : STD
2 YB
PROPORTIONAL HAND CONTROL
43 Lg
D-4
E-6: SW-3:
2
GAUGE CLUSTER TWO-SPEED SELECT SW.
46 WB B
(2/3)
PW03Z00015P1 05
23-8
COOLER (FOR CAB)
CONTROL PANEL
VOLUME
A/C SW
AIR COMPRESSOR SW.

ON DISTINCTION COMPRESSOR RELAY FAN MOTOR RELAY
OFF L M H
C
GW
YW
GB
YB
B
THERMO
BLOWER SW.
0.85RW
0.85YG
1.25LW
0.85LR
1.25LB
0.5WG
1.25LY
0.5YW
0.5YG
0.5GB
0.5BP
0.5YB
0.5LR
0.85R
0.85R
0.5LR
0.85Y
1.25B
0.85L
0.5Br
0.5G
0.5G
0.5B
SW-17: SV-8:
FUSE TILT ANGLE TILT ANGLE
(15A) SELECT SW. SELECT SOL.
YB RW B
E-18:
COMPRESSOR B 93 LW 0.85L
SV-5: B 90 RW 0.85RW
CX31B/CX36B OPT.
POWER SHIFT SOL.
(PTPA DOZZER)
(NORTH AMERICA ANGLE DOZZER)
E-17: B 96 1.25RL 0.85YG 0.5YB
CONDENSER MOTOR
(CET-1A22100A)
1.25B 1.25B 0.5GB
FUSE (15A)
1 1.25WY 1.25WG 0.5WG
AMP
1.25WY 1 1.25WY 0.85R 0.85Br
0.5BW
0.5BR
1.25WG
1.25LW
1.25LB
1.25LB
1.25LY
0.5BW
0.5BR
0.5BP
0.5BP
PRESS SW. BLOWER MOTOR THERMISTOR
YB
2
RESISTOR SOCKET
B
COOLING UNIT
E-7:
POWER SOCKET
EU:STD
SW-23: SW-24: SW-24: R-9:

TRAVEL ALARM SELECT SW. TRAVEL RIGHT(FORWARD)PRESS.SW. TRAVEL RIGHT(FORWARD)PRESS.SW. WORK LIGHT RELAY.
1 WY 54 PL 55 YL E-20: 1 WY 54 PL 55 YL E-20: 1.25YG 87 1.25BrR B L-5:
B TRAVEL ALARM B TRAVEL ALARM 3
86 LgR B CAB/CANOPY WORKING
3
SW-25: SW-25: SW-2:
LIGHT
23
TRAVEL RIGHT(REVERSE)PRESS.SW. TRAVEL RIGHT(REVERSE)PRESS.SW. WORK LIGHT SW.
SW-26: SW-26:
TRAVEL LEFT(FORWARD)PRESS.SW. TRAVEL LEFT(FORWARD)PRESS.SW. R-26:
ROTARY LIGHT L-9:
RELAY SWING ROTARY LIGHT
SW-27: SW-27:
TRAVEL LEFT(REVERSE)PRESS.SW. TRAVEL LEFT(REVERSE)PRESS.SW. YB 250 R B
2
SW-31: 96 LW B
SLEWING LEVER
OCEANIA:STD NORTH AMERICA:OPT PRESS. SW. RIGHT
EU:OPT
SW-30:
SLEWING LEVER PRESS. SW. LEFT
NORTH AMERICA : OPT (3/3)

INCREASE IN QUANTITY
WEIGHT PW03Z00015P1 05
23-9
23-10
23.2.4 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS

23.2.4.1 Upper Frame Portion: PW03E00010F1, PH11E00021F1 (1/4)
23
23-11
23-12
23
23-13
DETAIL OF BATTERY GROUND

CABLE INSTAL
DETAIL E
10.7 7.9
23-14
23.2.4.2 Engine Portion: PW16E00008F1
23
23-15
23.2.4.3 Relay Unit Portion: PX24E00007F2
23-16
23.2.4.4 Fuel Tank Portion: PW20P00022F1, PW21P00009F1
23
23-17
23.2.4.5 Work Light Portion
(1) Boom Work Light : PW15E00008F1 (2) Canopy / Cab Work Light
: PW80E00006F1
H-9 : CANOPY WORKING

LIGHT HARNESS
IT IS THE INSIDE OF
THE PILLAR OF A CANOPY
FIX TO THE
WELDING CLIP.
TO CONNECT HARNESS OF
UPP FRAME SIDE.
: PW80E00007F1
CONNECTS WITH CABLE TERMINAL OF

THE HARNESS OF HARNESS ASSY, CAB.
L-5 :
CAB WORKING LIGHT
TUBE
A TUBE IS ROLLED
FOCUSING ON A
CONNECTION PART
AFTER CABLE
TERMINALS
CONNECTION.
H-9 : CAB WORKING
CLIP LIGHT HARNESS
FIX TO THE BRACKET (CAB ACCESSORY)
OF A LIGHT.
23-18
23.2.4.6 Cab Portion (OPT): PW14E00002F1
23
23-19
23.2.4.7 Travel Alarm Portion (OPT): PW53E00006F1

23.2.4.8 Air Filter Portion (Restriction Switch): PW11E00013F1
Travel Alarm Portion(OPT) : PW53E00006F1 Air Filter Portion (Restriction Switch) : PW11E00013F1
23-20
23.2.4.9 Heater Portion (OPT): PW21M00013F1
17.3
17.3
17.3
17.3
18
SW-10 :
HEATER
SWITCH
23
E-12 :
HEATER
E-12 :
HEATER
23-21
23.2.4.10 Cooler Portion (OPT): PH11E01031P2
23-22
23.2.5 DETAIL OF HARNESS & CABLE

23.2.5.1 Inst - Main Harness (No. H-1: PW14E01064P1) (1/4)
23
23-23
23-24
23
23-25
HARNESS CONNECTION TABLE (1/3) HARNESS CONNECTION TABLE (2/3) HARNESS CONNECTION TABLE (3/3) CONNECTORS SELECTION TABLE
TWIST PAIR
NOTE 7
(TIN PLATING)
(TIN PLATING)
23-26
23.2.5.2 Proportional N&B Harness (No. H-2: PH14E01041P2)
CONNECTORS SELECTION TABLE
23
23-27
23.2.5.3 Engine Harness (No. H-3: PW16E01024P1)
23-28
23.2.5.4 Starter Cable (+) (No. H-4: PW13E01090P1)

23.2.5.5 Battery Ground Cable (-) (No. H-5: PW13E01091P1)
23.2.5.6 Engine Ground Cable (No. H-6: PH13E01047D1)
23.2.5.7 Boom Harness (No. H-7: PW15E01007P1)
Starter Cable (+) (No. H-4: PW13E01090P1) Engine Ground Cable (No. H-6: PH13E01047D1)
Battery Ground Cable (-) (No. H-5: PW13E01091P1) Boom Harness (No. H-7: PW15E01007P1)
23
23-29
23.2.5.8 Key Switch Harness (No. H-8: PW50E01002P1)

23.2.5.9 Canopy Working Light Harness (No. H-9: PW11E01026D4)
23.2.5.10 Boom Work Light Extension Harness (No. H-10: PW14E01038D1)
Key Switch Harness (No. H-8: PW50E01002P1) Canopy Working Light Harness (No. H-9: PW11E01026D4)
Boom Work Light Extension Harness (No. H-10: PW14E01038D1)
23-30
23.2.5.11 Connection Harness with Cab (No. H-11: PW14E01041P1) (OPT)

23.2.5.12 Air Filter Harness (No. H-12: PW11E01044D1)
23.2.5.13 Travel Alarm Harness (No. H-13: PW13E01069P1) (OPT)
Connection Harness with Cab (No. H-11: PW14E01041P1) (OPT) Air Filter Harness (No. H-12: PW11E01044D1)
E-10 : RADIO TO COOLER

CN-3F CN-8F
3FA-CNA 4FA-CNA
E3 - E4E5 DOUBLE
SPLICE
B - 1.25
B
DOUBLE 1B
4B 1A1C SPLICE 1C 90
1.25
RG WY DOUBLE
WY RW
0.75
SPLICE
TO INST MAIN HARNESS RADIO COOLER

CN-2M
14MA-070ML EARTH
TAPING P-1
21 20 - 4B 4A 1B
1.25
LA108
WB G - RG RG WY E1
1.25
90 E1 E2 E3 E4 - 87 22 B
1.25 1.25 1.25
RW B B B B - BrR Br
E6 87
1.25
1.25
B
BrR
CA104 CB104 Travel Alarm Harness (No. H-13: PW13E01069P1) (OPT)

M-1 F-1
TO CAB WORKING LIGHT

1 2
AMP
E5
E6 DOUBLE
1.25
B SPLICE 4A 1A
22 RG WY
Br - 21 20 E2
- WB G B
2FA-CNA AMP
CN-4F 6 5 4 3
M-3 : WASHER MOTOR TO CAB HARNESS
CN-1M
6MA-070ML
HARNESS CONNECTION TABLE
23
23-31
23.2.5.14 Alarm Extension Harness(No. H-14: PH13E01078P1) (OPT) 23.2.5.16 Cooler Harness (No. H-16: PH11E01031P2) (OPT)
23.2.5.15 Heater Harness (No. H-15: PW13E01068P1) (OPT)
Unit : mm (in)
23.2.5.17 Horn Switch Harness (No. H-17: PH14E01013D1)
23-32
24. COMPONENTS SYSTEM

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

24.1.1 HYDRAULIC PUMP ...................................................................................24-3
24.1.2 PILOT VALVE (ATT) ...................................................................................24-15
24.1.3 PILOT VALVE (TRAVEL) ...........................................................................24-19
24.1.4 CONTROL VALVE .....................................................................................24-25
24.1.5 SLEWING MOTOR ....................................................................................24-41
24.1.6 TRAVEL MOTOR .......................................................................................24-52
24.1.7 SWIVEL JOINT ..........................................................................................24-63
24.1.8 CYLINDER .................................................................................................24-66
24.2 ELECTRICAL EQUIPMENT ...............................................................................24-75
24.2.1 ELECTRICAL EQUIPMENT LIST ..............................................................24-75
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ........................................24-78
24
24-1

CX31B : PW14- S5PW2432E01
CX31B : PW14-46519~ S5PW2432E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
24-2
24.1 HYDRAULIC COMPONENTS
24.1.1 HYDRAULIC PUMP
24.1.1.1 SUMMARY
(1) GENERAL VIEW
Hydraulic ports
No. Ports name Size
S1 Suction port SAE 11/2
A1, A2 Delivery port PF 1/2
A3 Delivery port PF 1/2
A4 Pilot delivery port PF 3/8
R1 Air bleeder port (with breather valve) M10
General view of hydraulic pump
(2) SPECIFICATIONS
Model (Type) AP2D18LV3RS7–898–0

Piston pump Gear pump Trochoid pump
Item
P1 + P2 P3 P4
Working pressure MPa (psi) 23.0 (3340) 20.0 (2900) 3.5 (508)
Displacement cc/rev (cu•in/rev) 16.0 (0.98) 2 8.6 (0.52) 5.1 (0.31)
Delivery flow L/min (gal/min) 38.4 (10.1) 2 20.6 (5.44) 12.2 (3.22) 24
Control system Total power shift control by tilting angle (power shift)
Rated revolution min-1(rpm) 2400
Weight kg (lb) 27.5(60.6)
24-3
24.1.1.2 CONSTRUCTION - FUNCTION
No. NAME No. NAME

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

• This pump is a variable displacement double piston pump which delivers two equal flows with one cylinder block
and has only one inlet port, but the flow is separated into two flows by the control plate on the cover and is led to
two delivery ports provided on the cover.
• The hydraulic pressure produced by the delivery oil acts on the hanger, resists the spring force, and tilts the
hanger. As the piston stroke is changed by the tilting of the hanger, the flow rate varies.
• The 3rd pump or pilot pump is installed on the same shaft with a coupling.
24-4
(2) Operation
1. Pump operation
a. The cylinder block is fitted on the spline and rotates with the drive shaft.
b. The piston fitted on the cylinder block follows the sliding surface of the hanger and moves back and forth.
c. The piston moves to increase the capacity from the bottom dead point to the top dead point, the pressure oil
flows from the inlet port into cylinder block through the control plate. (Suction stroke)
d. But as the piston moves to decrease the capacity from the top dead point to the bottom dead point, the pressure
oil is sent out to the delivery port. (Delivery stroke)
e. By changing the tilting angle of the hanger (sliding surface), the displacement varies.
f. The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside of the control
valve.
g. The oil sucked from the outside port of the cylinder block is delivered from the delivery port outside of the control
plate.
24
24-5
2. Control
a. The piston sliding on the surface of the hanger acts on the hanger through the hydraulic pressure due to the
delivery oil pressure P1 and P2.
b. The spring is located in the position which is in opposition to the delivery oil pressure.
c. When the hydraulic pressure acting on the hanger through the piston goes below the setting load of the spring,
the hanger is fixed at the maximum tilt angle.
d. When the hydraulic pressure acting on the hanger through the position exceeds the setting load of the spring,
the hanger is tilted and held tilting at the position where the hydraulic pressure balances the spring pressure.
(Control line, Area A)
e. The control line is shifted after the hydraulic pressure P3 acts on the shift piston.
24-6
3. Adjusting procedure of set torque
a. Adjusting procedure
1. Loosen the hexagon nut.
2. Set the power line by tightening or loosening the adjusting screw.
24
24-7
24.1.1.3 INNER CONSTRUCTION

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

1 Shaft 1 6 Key 1
4 Ring 1 7 Shim 1
5 Snap ring (for Shaft) 1 8 Shim 1
(2) Swash plate (Hanger)

1 Hanger 1 4 Guide (Delivery) 1
2 Guide (Suction) 1 5 Bushing (Delivery) 1
3 Bushing (Suction) 1
24-8
(3) Rotary group

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

1 Spring seat 1 8 Capscrew (M8X30) 2
2 Spring seat 1 9 Nut 1
24
3 Cover 1 10 Spring 1
4 Setscrew 1 34 Shim 2
5 Spring 1 44 Shim 2
6 Spring 1 54 Shim 2
7 O-ring 1
24-9
(5) Cover

1 Cover 1 7 Bearing 1
2 Control plate 1 8 Plug 2
3 Parallel pin 1 9 Capscrew (M12X55) 1
4 Capscrew (M12X40) 3 10 Plug 3
5 Packing 1 12 Orifice 1
6 Plug 3
24-10
(6) Gear pump
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

3 Housing 1 10 Plate 2 16 Square ring 1
4 Cover 1 11 Guide 2 17 Square ring 2
5 Gear 1 12 Coupling 1 18 O-ring (1B P6) 1
6 Gear 1 14 O-ring 2 19 Capscrew (M12X25) 2
7 Side plate assembly 2 15 O-ring 1 21 Capscrew (M10X20) 4
24
24-11
(7) Housing

1 Housing 1 8 O-ring (1B P9) 1 22 Distance piece 1
2 Oil seal 1 9 Distance piece 1 23 Snap ring 1
3 Bearing 1 12 Guide 1 30 Shim 1
4 Piston 1 16 Sleeve 1 31 Shim 1
5 Parallel pin 1 18 Shim 1 32 Shim 1
6 Disk spring 5 19 Shim 1
7 O-ring (1B P15) 1 20 Shim 1
24-12
(8) Trochoid pump

1 Gear 1 6 Capscrew 3
2 Casing 1 7 Side plate (B) 1
3 Side plate (A) 1 8 Spring pin 1
4 O-ring 1 9 Plate 1
5 Spring pin 1
24
24-13
24-14
24.1.2 PILOT VALVE (ATT)
24.1.2.1 SUMMARY
(1) General view
PORT 2
SINGLE SINGLE
OPERATION OPERATION PORT 3
ANGLE ANGLE
(PORT 2,4) (PORT 1,3)
T PORT
P PORT
PORT 1
PORT 4
VIEW A
Parts number PX30V00043F1

Max. primary pressure 6.9MPa (1,000 psi)
Rated flow 15 L/min (4.0 gal / min)
Weight 1.6 kg (3.5 lb)
PORT 1,3 SINGLE OPERATION TORQUE
580 2.95
Secondary pressure (MPa)
Secondary pressure psi
497
435 2.2
Operation torque
Operation torque
SECONDARY
300 22 PRESSURE
290 1.48
1.35
145 0.74
78 0.69
0 0
Push rod stroke mm
0 5 10 15 19
PORT 2,4 Operation angle (deg.)
580 2.95
Secondary pressure (MPa)
497
SINGLE-OPERATING
435 TORQUE 2.2
Operation torque
Operation torque
300 22 1.75
290 1.48
1.39
145 0.74 24
78 SECONDARY 0.69
PRESSURE
0 0
Push rod stroke mm
0 5 10 15 20 25
Operation angle (deg.)
24-15
24.1.2.2 CONSTRUCTION
APPLY LOCTITE #277

(PART OF SLANT LINE)
APPLY
GREASE
ON TOP
APPLY GREASE 1 3 2 4
ON TOP
HYDRAULIC SYMBOLS
RIGHT PILOT VALVE

PORT
OPERATION
NO.
1 BUCKET DIGGING
2 BOOM DOWN
3 BUCKET DUMP
4 BOOM UP
LEFT PILOT VALVE

SECONDARY PORT
OPERATION
PRESSURE NO.
ADJUSTING SHIMS
1 SLEWING LEFT
2 ARM OUT
3 SLEWING RIGHT
4 ARM IN
PORT 2,4 PORT 1,3
Pilot valve-Sectional view

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

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

When the lever is tilted till the pressure of the port 2, 4
rises to an oil pressure corresponding to the set spring
force, the hydraulic pressure is balanced with the
spring (241) force. And when the pressure of the port
2, 4 rises above a set pressure, the port P are closed
and the port T are opened. When the pressure of the
port 2, 4 falls below a set pressure, the port P are
caused to open and the port T are caused to close,
thus holding the second pressure constant.
24
Lever being held
24-17
24-18
24.1.3 PILOT VALVE (TRAVEL)
24.1.3.1 SUMMARY
(1) General view
(2) Specifications
ITEM SPECIFICATIONS
Model (Type) PVD6P4042
Max. primary pressure 6.9MPa (1000 psi)
Rated flow 10 L/min (2.6 gal/min)
Weight 3.9 kg (8.6 lb)
(3) Performance Characteristics
580 MPa 8.85

Operation torque
7.69
435 6.64
24
319 21
290 4.43
4.27
145 2.21
Secondary
78 pressure
(The actual required torque is found by

Push rod stroke (mm) adding the operating torque of the damper
in the valve operating torque in the left
Operation angle (deg.) operating lines.)
24-19
472
501 Apply grease to bearing
471 413
414
Apply grease on top 214 420

210 203
Apply grease on top 202
271
201
212
11
213
336
102
218
225
311
211
16 252
217 15
313
251
261
301
101
Pilot valve-Sectional view
Torque Torque
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 261 O-ring 3
102 Casing (Damper) 1 8.8(6.5) 271 Capscrew 4
201 Cover 2 301 Spool 4
202 Plug 4 311 Spring seat 4
203 Grease cup 4 313 Washer 4
210 Packing 4 336 Spring 4
211 O-ring 4 413 Cam shaft 2
212 O-ring 4 414 Bushing 4
213 O-ring 2 420 Cam 2
214 Push rod 4 471 Stee lball 4
217 Shim 4 6.9(5.1) 472 Set screw 2
218 Spring seat 4 501 Boots (Bellows) 2
225 Steel ball 12 11 Piston 4
29.4(21.7) 251 Ro plug 3 15 Spring 4
252 Plug 2 16 Spring 4
24-20
24.1.3.3 OPERATION
1. Reducing valve
(1) When the lever is at neutral position

The spool is pushed up by the return spring (15) through
spring seat (311), and is positioned at the neutral position
in the right figure. Therefore, the pressure at delivery ports
1 and 2 is equivalent to that of port T because the delivery
port is connected to only port T following the switched
spool condition.
311
15
301
PORT 2 (4) PORT 1 (3)
Neutral position
(2) In case where the lever is tilted
Full stroke
By rotating cam (420) in clockwise, push rod (214) on the
port 1 side is pushed down, and the spool moves down by
way of spring seat (311), spring (16) for setting the 420
secondary pressure, shim (217) and washer (313) and
consequently the port P is connected to the port 1 and the
214
supplied oil from the pilot pump flows into port 1 and
generates pressure.
When the pressure at port 1 rises to the pressure
equivalent to the spring pressure for the secondary
pressure setting set by tilting the control section, the
hydraulic pressure applied to the spool balances the
spring force, and maintains port 1 at a constant delivery
pressure. 311
The spool on the port 2 side is held at neutral position, and 16
the return oil from the control valve is discharged through
port T. 217
313
24
PORT 2 (4) PORT 1 (3)
24-21
2. Damping mechanism
(1) In case of neutral position,
Push rod (214) is pushed up by damping spring (336) through piston (11), and holds at the position shown in
Fig. "Pilot valve-Sectional view".
(2) Where the control section is inclined from the neutral position,
By rotating the cam clockwise, the push rod on the port 1 side is pushed down, and the piston also moves down.
Then, the oil in the damping piston chamber is discharged through the orifice, and the simultaneously generated
pressure produces damping force.
On the other hand, the push rod on the port 2 side moves up by the damping spring through the piston.
Then, oil is sucked from the tank into the damping piston chamber through three ball check valves. The oil
outside of the piston chamber flows out through the passage leading to port T on the casing top end.
Cam
Push rod
Orifice
Piston
Piston
When stroking from the

neutral position towards
the mark , the oil in
the piston chamber on
the right(left) side is
discharged through the
orifice, and the
simultaneously
generated pressure
produces damping
force.
Steel ball
PORT 2 (4) PORT 1 (3)

Operation when the lever is stroked from the neutral position
24-22
(3) Where the control section is inclined in the opposite direction from the full tilting
After tilting the cam clockwise fully, if it is rotated counterclockwise, the push rod on the port 2 side is pushed down
and the piston moves down.
Then, the same as above, the oil in the damping piston chamber is discharged through restriction of piston, and the
simultaneously generated pressure produces damping force.
On the other hand, the push rod on the port 1 side is moved up by the force of the return spring and damping
spring.
Similarly oil is sucked from the tank into the damping piston chamber through three ball check valves.
And the oil in the piston chamber flows out through the passage leading from the casing top end to the tank port.
That is, either tilting operation from the neutral position to the full tilting position or the full tilting position to the
neutral position is designed to produce the damping force.
Neutral position
Full stroke
Cam
Push rod The oil outside of the piston

is ows out through the
passage leading to port T
on the casing top end. ( In
operation in direction)
Piston
When tilting in reverse

direction from the neutral Damping spring
position, the push rod is
pushed up by the force of
the damping spring. ( In
operation in direction) The oil in the piston
chamber is discharged
Oil in T line is sucked in through the restriction,
the damper chamber and the simultaneously
through three ball check generated pressure
valves. ( In operation in produces the damping
direction) force. (IN operation in
direction)
When shifting the lever in Return spring

reverse from direction
to condition, the
piston on the left side
immediately performs the
roles of the damper
piston.
The damping force is

produced on both 24
sides constantly.
PORT 2 (4) PORT 1 (3)
Operation when the lever is stroked or operated in reverse
24-23
24-24
24.1.4 CONTROL VALVE
24.1.4.1 GENERAL VIEW AND HYDRAULIC PORTS NO.
24.1.4.2 SPECIFICATIONS
Model (Type) BCV35–JAA10

Manual Swing
Valve operation Travel left, Travel right, Boom, Arm, Bucket, Slewing,
Pilot
Dozer, Service, Independent travel and conflux
Flow rate P1, P2 – 38.4 L/min(10.1gal/min), P3 → 20.6 L/min(5.4gal/min)
P1, P2: 23.0 MPa (3340 psi) at 38.4 L/min (10.1 gal/min)
Setting pressure at main relief valve
(RV1, RV2)
P1, P2, P3 24
P3:20.0 MPa (2900 psi) at 20.6 L/min (5.4 gal/min) (RV3)
B1, A3, B3, A4, B4, B10 port (OR6, OR4, OR5, OR10, OR11, OR1)
Setting pressure at over load relief
25.5 MPa (3700 psi) at 5 L/min (1.3 gal/min)
valve
B8, B9 port (OR3, OR2) 27.5 MPa (4000 psi) at 5 L/min (1.3 gal/min)
24-25
(1) Control Valve: Overall composition

1 Dozer section 1 7 Travel (right) section 1 14 P3 Main relief valve 1
2 Slewing section 1 8 P1, P2 inlet straight 1 15 Over load relief valve 6
P3 inlet, independent 9 Travel (left) section 1 16 Over load relief valve 2
3 travel & conflux 1
section 10 Boom section 1 17 Anti cavitation valve 1
4 Arm section 1 11 Boom lock section 1 18 Tie bolt 4

5 Service section 1 12 Bucket section 1 19 Nut 4
6 Swing section 1 13 P1, P2 Main relief valve 2
24-26
(2) Component Parts

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

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

1. Manual operation: Swing (No.6)
No. NAME Q’TY

1 Body 1
2a Spool 1
2b O-ring 1A P12 1
2c Dust wiper 1
2d Oil seat retainer 1
2e Spring seat 2
2f Spring 1
2g Spool end 1
3 O-ring 1A P12 1
4 Dust wiper 1
5 Oil seal retainer 1
6 Load check valve 1
7 Spring (for check valve) 1
8 O-ring 1B P11 2
9 Plug (for check valve) 1
10 Socket bolt M5X10 2
11 Cover 1
13 Anti cavitation valve 1
2. Pilot operation: Slewing (No.2)
No. NAME Q'TY

1 Body 1
2a Spool 1
2b Spring seat 1
2c Spring 1
2d Spring seat 1
2e Spool end 1
5 O-ring 1B P11 1
7 O-ring 1B S22 2
8 Pilot cover 1 24
9 Pilot cover 1
24-27
3. Main relief valve (P1, P2, P3) and overload relief valve
15 14 13 5 11 4 8 7 No. NAME Q’TY

1 Socket 1
2 Pressure regulating 1
3 Piston 1
4 Plug 1
5 Body 1
6 Adjust valve 1
7 Adjust screw 1
8 Lock nut M14 1
9 Spring (Adjust valve) 1
10 Spring (Pressure regulating) 1
1 2 10 3 6 16 12 9 11 O-ring 1B P15 1
12 O-ring 1B S10 1
(Only for Over load relief valve & Main relief valve for P3) 13 O-ring 1A P7 2
14 Back up ring 2
15 O-ring 1B P14 1
16 Spring guide 1
4. Anti cavitation valve
24-28
24.1.4.4 HYDRAULIC CIRCUIT
No. NAME
Dozer 1 Dozer spool
2 Slewing spool
3 Travel Independent & conflux spool
4 Arm spool
Slewing 5 Service spool
6 Boom swing spool
7 Travel right spool
8 Travel left spool
Supply & 9
Independent travel Boom spool
10 Bucket spool
11 P1 RV1 relief valve
14 B1 Over load relief valve
Arm
15 A3 Over load relief valve
Service 18 B9 Over load relief valve
20 Boom lock valve
21 Anti cavitation valve
22 Over load relief plug
Boom swing 23 P1 by-pass passage
24 P2 by-pass passage
25 P3 by-pass passage
Travel right 26 P1 parallel passage
27 P2 parallel passage
28 P3 parallel passage
Supply
29 PP1 Pilot passage
30 Tank passage
Travel left
Boom
Bucket
24
24-29
24.1.4.5 EXPLANATION OF OPERATION

(1) Neutral position
P1:
The oil delivered from the hydraulic pump flows from the P1 port of the control valve (hereafter called a C/V) into
the left travel spool section through the passage of the supply section.
At the spool neutral position, the entered oil passes through the by-pass of the spool leading from the left travel to
the boom because the spool does not cut off the by-pass and flows out to the tank circuit through the by-pass of the
spool for the bucket and the by-pass leading to the tank.
P2:
The oil delivered from the hydraulic pump flows from the P2 port of C/V into the right travel spool section through
the passage of the supply section.
At the spool neutral position, the entered oil passes through the by-pass of the spools for the right travel, boom
swing and service, and flows out to the tank circuit through the by-pass circuit leading from the by-pass of the spool
for service.
P3:
The delivery from the hydraulic pump flows from the (C/V) P3 port into the parallel circuit of swing and dozer
operation.
Since the spool does not shut off the by-pass passage in the neutral spool condition, the oil having flown into the
parallel passage flows out to the tank passage through the by-pass passages of the spools for the dozer and
slewing and through the by-pass passage of the P3 supply section.
As the flow from the pump is fed into each line (P1, P2, P3), the switching sections of respective line shown below
are in operable condition. Therefore, don't operate them except when working.
- P1 line: Left travel, Boom, Bucket
- P2 line: Right travel, Boom Swing, Service and Arm
- P3 line: Dozer, slewing [Service and Arm]
Pp1:
The delivery oil from the gear pump flows from the (C/V) Pp1 port into the pilot circuit through the orifice provided
on P3 supply section. (Two systems for shifting independent travel and for shifting arm and service flow conflux)
In the neutral spool condition, the oil of the independent travel shifting side flows out to the tank passage through
the passages provided to the right and left travel spool and the swing spool.
Therefore the pilot circuit pressure becomes equal to the tank pressure, the received pressure of the independent
travel valve is equal to the tank pressure, and consequently the independent travel spool does not switch.
Moreover, the oil of the flow conflux shifting side flows out to the tank passage through the passage provided to the
service spool. Since the pilot passage pressure equals to the tank pressure and the receiving pressure of the flow
conflux piston equals to the tank pressure, the flow conflux spool is not shifted.
When the engine is stopped (when each hydraulic pump is stopped), the actuator does not function even when
being loaded by the self weight, because the pilot pressure does not act on the pilot control spool (except for the
condition where the accumulator, etc. is attached and the pressure remains due to the pipe volume). On the spool
of boom swing which directly actuates the spool, the port on the loaded side is led to the tank circuit with the
operating direction making it unable to hold the load, consequently the actuator may be actuated causing danger.
Therefore, even if the engine is stopped, when there are people around the machine or it may be in contact with
implements, don't use the control lever.
24-30
Operation at neutral position
24
24-31
(2) Pilot operating section

1. Operating boom raise
With the boom raise operation, the pilot secondary pressure enters into the Pa8 port, and moves the spool for the
boom operation. And with the movement of the spool, as the by-pass circuit is cut at the boom switching section,
the oil received through the P1 port flows from the parallel circuit through the check valve installed on the upper
part of the spool by-pass circuit for the travel operation into the parallel circuit on the boom switching section.
With the movement of the spool, as the circuit from the passage leading to the boom lock section to the bridge
passage is opened, the oil entered in the parallel circuit passes through the load check valve on the boom
switching section and flows into the boom lock section through the bridge passage. The oil entered in boom section
opens the lock valve and is fed into the boom cylinder head side.
On the other hand, the return oil from the boom cylinder rod side flows into the B8 port, and with the movement of
the spool the oil flows out into the tank circuit that is connected by the notch of the spool. Consequently, the boom
cylinder extends and raises the boom.
The oil from the Pp1 port passes through the orifice provided on the P3 supply section and flows into the pilot
circuit.
The oil entered into the pilot circuit flows from the travel switching section to the tank circuit, and the pilot circuit
pressure becomes equal to the tank pressure, consequently the independent travel spool is not switched.
Operation at boom raising
24-32
(3) Manual operation section

1. Left swing operation
With the left swing operation, the swing spool moves to the push-in direction.
With the movement of the spool, as the by-pass circuit is cut off at the swing switching section, (a portion of the oil
flows out to the by-pass (tank) circuit through the notch provided on the swing spool.), the oil entered through the
P2 port flows into the parallel circuit through the check valve provided on the upper part of the travel spool by-pass
circuit.
With the movement of the spool, as the circuit from the A5 port to the bridge passage is open, the oil entered in the
parallel circuit passes though the load check valve, flows into the A5 port through the bridge passage, and is fed
into the swing cylinder head side.
On the other hand, the return oil from the swing cylinder rod side flows into through the B5 port, and with the
movement of the spool the return oil flows out to the tank circuit that is connected by the notch of the spool.
Consequently, the swing cylinder extends, and the boom swings leftward.
The oil entered through Pp1 port passes through the orifice provided on the P3 supply section, and flows into the
pilot circuit.
As the oil entered in the pilot circuit flows out from the travel switching section into the tank circuit, the pilot circuit
pressure becomes equal to the tank pressure, and consequently the independent travel spool is not switched.
Operation of swing
24
24-33
(4) Flow conflux function

This valve actuates the arm and service using joined flow amount of P2 and P3.
The flow conflux circuit is used only for actuating the arm and service as explained below. (The explanation shown
below for the service shifting is also applicable to the arm.)
The operation for the service shifts the spool for the service by the secondary pressure from the remote control
valve.
Since the spool shifting results in shutoff of the pilot and tank passages for flow conflux, the pressure in the flow
conflux pilot passage equals to the Pp1 port supply pressure, which acts on the flow conflux piston to move it to the
position where the piston collar contacts with the inner shoulder the valve.
At the same time, the flow conflux piston moves the flow conflux and independent travel spools.
Once the spool is shifted, the pressurized oil supplied from P3 flows into the second by-pass passage of P2 side
through the parallel and by-pass passages of the slewing and dozer shifting and through the check valve provided
to the P3 supply section, which is connected to the by-pass passage of the P2 side at the upstream (between boom
swing and service) of the service shifting section, and also connected to the by-pass passage of the P2 side
through the check valve at the P3 supply section. Therefore the flow of oil supplied from P3 joins in the parallel
passage of the P2 side in proportion to an operating amount of the arm or the service.
(The drawing below shows service operation.)
Actuation of flow conflux circuit in service operation
24-34
(5) Independent travel function

When both right and left travels is shifted, and one of boom, bucket and boom swing is shifted, the oil flows from the
Pp1 port through the throttle into the pilot passage, in which pressure equals to the Pp1 port supply pressure
because the pilot passage is shut off from the tank passage.
Then the Pp1 port supply pressure acts on the independent travel spool, and the spool moves until it contacts with
the pilot cap overcoming the spring force.
Once the spool is shifted, the pressurized oil supplied from P3 passes through the parallel and by-pass passages
of the slewing and dozer shifting sections, and passes through the spool of the P3 supply section and the land of
main unit to flow into the second parallel passage of the P1 side and the parallel passage of the P2 side.
After these shifting, the pressurized oil supplied to P1 and P2 actuates the right and left travel, and the pressurized
oil supplied to P3 actuates the other attachments.
Therefore even if the travel and other attachment are simultaneously operated, the travel is correctly performed
without deviating.
The arm or service operated in the flow conflux position without relating to the independent travel function can be
simultaneously performed with the travel in the same operability as the independent travel function.
Independent travel actuation
24
24-35
(6) Function of Lock Valve

1. Piston Holding
When the boom spool is at neutral position, the pilot piston chamber (a) is connected to the drain passage through
the pilot port (Pb8') for releasing lock valve. And the piston chamber (b) is also connected to the drain passage
through the drain port (Dr1).
Therefore the piston (A) is held at the position shown in the figure.
And the hydraulic pressure to hold the boom cylinder is applied to the lock valve chamber as shown in the figure,
pressing the needle valve and lock valve to their seats respectively. Then it prevents leakage on the head side of
boom cylinder, and also prevents the arm cylinder from its movement due to leakage.
Function of Lock Valve (piston holding)
24-36
2. Release
When the pilot pressure is applied to the pilot port (Pb8') for releasing lock valve, the piston (A) is moved to the
right side opening the needle valve through piston (B).
At that time, the return oil from boom cylinder passes through the throttle on lock valve, then lock valve chamber --
> pilot piston chamber --> drilled hole in turn, and flows into the tank path through the throttle hole (drilled hole) on
boom spool pushing up the steel ball.
The opening of the needle valve results in the pressure drop in the lock valve chamber. The return oil from the
boom cylinder opens the lock valve, and flows into the tank passage through the notch (groove) of the boom spool
and the throttle (drilled hole).
Function of Lock Valve (release)
24
24-37
(7) Operation of relief valve

1. Operation at relief condition
a.
The pressure oil passes through the inside of the piston placed in the pressure regulating valve (main valve) and
fills in "A" chamber inside of the piston through the orifice "B" to securely seat the pressure regulating valve and the
socket, and the socket and the body seat.
Orifice "B" Piston Adjust valve spring

Tank Passage
Body seat
"A"chamber
Socket Adjust valve
Pressure regulating valve
b.
When the pressure of the oil in the P port reaches to the set pressure of the spring, the pressure oil acts on the
adjust valve through the piston and opens the adjust valve.
Then, the pressure oil passes through the inside of the piston, orifice B, A chamber, ring orifice, and drilled hole D
in order, and flows out to the tank circuit around the socket.
Ring orifice "C" Drilled hole"D"
c.
The pressure in "A" chamber drops because the adjust valve is open, consequently the pressure oil in the P port
flows out to the tank circuit through the drilled hole "E".
Drilled hole "E"
d.
When the pressure on the P port drops lower than the spring set pressure of the adjust valve, the adjust valve is
pushed against the seat by the adjust valve spring force of the adjust valve and the pressure in "A" chamber is
equal to the pressure in the P port, consequently the adjust valve is also pushed against the seat and returns to the
former condition(Fig. 24.1.4.5-(7)-1-a).
24-38
2. Suction operation
When the negative pressure is generated in the P port, the oil is supplied through the tank circuit.
When the pressure of the tank circuit from the P port rises, the socket is pushed up.
Consequently, the space between the body seat and the socket opens, and the oil flows from the tank passage into
the P port and the space fills with the oil.
Tank Passage
(8) Operation of anti-cavitation valve

When the negative pressure is generated in the P port, the oil is supplied through the tank circuit. When the
pressure from the P port rises, the valve is pushed up.
Consequently, the space between the body seat and the socket opens, and the oil flows from the tank circuit into
the P port and the space fills with the oil.
Tank Passage
Body seat
Socket
24
24-39
24-40
24.1.5 SLEWING MOTOR
24.1.5.1 GENERAL VIEW
PG
SH
PT1/8 port for grease

piping
G5 A
M
G6 B M DB A G5
G6 DB
24.1.5.2 HYDRAULIC CIRCUIT
Port NAME Size

A Main port
B Main port
M Make up port PF3/8
DB
SH DB Drain port
PG PG Slewing parking brake release port
PF1/4
SH Slewing parking brake pilot port
G5 Gauge port PF1/8
G6 G5 G6
Rotational direction : Inlet A port : CW
Inlet B port : CCW
(View from shaft end)
B M A
Model (Type) MSG-27P-16E-17

cm3/rev
Hydraulic motor Displacement 20.7 (1.26)
(cu-in/rev)
Rated flow L/min (gal/min) 20.6 (5.44)
Parking brake torque N-m (lbf-ft) 1022 (754) or more
24
Parking brake releasing pressure MPa (psi) Min 2.0 (290), Max 6.4 (928)
Parking brake timing sec 2.5 to 4.9
Relief valve Set pressure MPa (psi) 20.0 (2900) at 20.5 L (5.4 gal)/min
Reduction Reducting ratio 1/15.5
Weight kg (lb) 38 (84)
24-41

1 Housing 1 21 Ball bearing 1 46 Socket bolt (M12X30) 5
2 Pinion shaft 1 22 Shaft 1 47 Orifice 1
3 Collar 1 23 Thrust plate 1 48 Timer valve assembly 1
4 Plate 1 24 Cylinder block 1 48-1 Sleeve 1
5 Taper roller bearing 1 25 Collar 1 48-2 O-ring (1B P10A) 1
6 Oil seal 1 26 Spring 1 48-3 O-ring (1B P12) 1
7 Taper roller bearing 1 27 Washer 1 48-4 O-ring (1B P14) 1
8 Shim t2 (Shim select) 2 28 Snap ring 1 48-5 Spool 1
Shim t3 (Shim select) 2 29 Pin 3 49 Washer 1
Shim t4 (Shim select) 2 30 Retainer holder 1 50 Spring 1
Shim t5 (Shim select) 2 31 Retainer plate 1 51 O-ring (1B P18) 1
Shim t13 (Shim select) 2 32 Piston assembly 9 52 Plug 1
Shim t14 (Shim select) 2 33 Disk 1 53 Relief valve assembly 2
9 Collar 1 34 Brake piston 1 54 Check valve 2
10 Holder 1 35 O-ring (1B G110) 1 55 Spring 2
11 Thrust washer 3 36 O-ring (1B G135) 1 56 Plug 2
12 Inner race 3 37 Spring seat 2 57 O-ring (1B P14) 2
13 Needle bearing 3 38 Spring 1 58 Plug 2
14 Planetary gear 3 39 O-ring 1 59 O-ring (1B P8) 2
15 Thrust plate 1 40 Cover 1 60 Plug 1
16 Drive gear 1 41 Ball bearing 1 61 O-ring (1B P11) 1
17 Plug 1 42 Pin 1 62 Socket bolt (M12X30) 2
18 O-ring (1B P8) 1 43 Valve plate 1 63 Name plate 1
19 O-ring 1 44 Pin 2 64 Rivet 2
20 Casing 1 45 O-ring (1B P21) 2 65 Thrust plate 1
24-42

66 Sun gear 1 69 Needle bearing 4 72 Holder 1
67 Screw 4 70 Inner race 4
68 Planetary gear 4 71 Thrust washer 4
6 10 12 14 1 3
No. NAME Q'ty
53-1 Body 1
53-2 Poppet 1
53-3 Seat 1
53-4 Spring seat 1
15 53-5 Spring 1
53-6 Plug 1
53-7 Set screw 1
7 53-8 O-ring 1B P24 1
53-9 O-ring 1B P10 1
9 8 5 4 2 11 13 53-10 O-ring 1A P15 1
53-11 O-ring 1B P12 1
53-12 Back up ring 2
53-13 Back up ring 2
53-14 Piston 1
53-15 Lock nut 1
Relief valve assembly (No.53)
24.1.5.5 FUNCTION AND OPERATION

(1) Swash plate motor
The cylinder block (24) is equipped with 9 pistons (32). And the end face of cylinder block (24) is in contact with
valve plate (43) having two crescent ports C and D (high and low pressure switching distributor).
(Principles of torque generation)
On leading the high pressure oil (pressure P) to the A port, the swash plate is pushed by the force of each piston (F
= PXA, A : Piston cross sectional area) and the piston receives the reaction force from the swash plate for the
piston and the directional torque of the reaction rotation is generated. And the sum total of the rotation directional
torque produces a turning force in cylinder block (24) and the torque is conducted to shaft (22) through the spline
resulting in the piston rotation.
And, the output torque and the rotation number are found from the following equation.
Where,
•Output torque (T):(N•m)

D : Displacement volume (cm3/rev)
T=
100 P D i m G P : Effective driving pressure (MPa)
2 100
Q : Flow rate (L/min)
•Rotation number (N):(min-1) m : Mechanical efficiency (motor) (% 10-2)
v : Volumetric efficiency (motor) (% 10-2)
N= i : Speed ratio of reduction unit 24
G : Reduction unit efficiency (% 10-2)
24-43
Construction of slewing motor
32
24
43
22
C D
Valve plate, Viewed from X-X (Outline)
24-44
(2) Parking brake

The parking brake is of hydraulic release and chamber type multi-disk construction.
1. When parking brake is ON, (Refer to Fig. "Parking brake is ON condition")
When the pressure oil for releasing the brake is cut off, regarding the disk (33) joined to the exterior of the cylinder
block with a spline, brake piston (34) which is secured with pin on the case is pushed by spring (38), and cylinder
block (24) and casing (20) are fixed by the frictional force. Consequently the shaft is locked.
2. When parking brake is OFF, (Refer to Fig. "Parking brake is OFF condition")
When the brake releasing pressure is led to brake cylinder chamber "C" through PG port, brake piston (34)
operates resisting the force of spring (38), removing the friction with disk (33), and the shaft rotates freely.
(3) Hydraulic timer (Specification with hydraulic timer only)
The hydraulic timer is provided to protect the parking brake from dragging and plays to secure delay time so that
the parking brake does not actuate when the hydraulic dynamic brake is absorbing swing inertia energy, and the
delay time is set by restricting the delivery oil from the cylinder chamber with orifice and by controlling the flow rate.
By returning the control valve from motor rotating condition to the neutral position, the valve switching pressure
"SH" interlocking with switching signal for the control valve lowers, and for the valve, the brake cylinder chamber is
interlocked with the drain port through the valve as shown in the figure. (In this condition, the energy of the upper
structure is transformed into heat energy and absorbed by the relief valve and the hydraulic dynamic braking
action.).
On the other hand, the oil led to the brake cylinder chamber "C" tries to move in the direction to push the disk by the
spring force acting on the brake piston, but as the flow rate of the delivery oil from the brake cylinder chamber is
controlled by the orifice of the valve, the brake piston is not in contact with the disk before an elapse of the specified
time and the brake does not work.
PG (Brake releasing pressure) OFF
24
33
34
38
20
Parking brake is ON condition
24
24-45
PG (Brake releasing pressure) ON
24
33
34
C (Brake cylinder chamber)

38
20
Parking brake is OFF condition
24-46
Spring
Drain
To brake cylinder
chamber C
PG
Valve
SH
Drain Orifice Drain

Brake cylinder Brake cylinder
chamber chamber
PG PG
ON SH SH OFF
In P/B releasing In P/B operation

The above function is explained in the diagram shown below.
Diagram
MAX
Shuttle valve switching outer In this interval, main control
signal pressure SH valve is switched.
0
Time zone the flow is

MAX controlled by orifice.
Pressure of parking brake C2
cylinder chamber C1
0 In this interval, “PG” supply
pressure is acting on.
t2 Timer set time
MAX Releasing
Parking brake torque parking brake
0
In this interval, parking brake
does not act on and does not draggs
Upperstructure
Set slewing speed
24
slewing speed
0
Acceleration Uniform Deceleration area
speed area Hydraulic pressure dynamic brake
Time (t)
24-47
(4) Operating principle of relief valve

The relief valve is used to decide the driving power and brake force when slewing the hydraulic excavator and each
is equipped with main port A and B. And it is constructed so that the relief valve return oil returns in a circuit to the
main low pressure line on the other side.
And, it is provided with a shockless function to reduce the shock produced when speeding up or down.
The relief valve is made up of the
a. Area difference & direct operated type relief valve
b. Shockless piston.
The installation of shockless type relief valve is effective for the reduction of the shock, reduction of the stress
generated on the structure of the machine.
Area difference & direct operated relief valve
Shockless piston
Construction of relief valve
24-48
The relief valve is operated by the following two steps.
1st step:
When starting operation, the interior of the spring (5) is held in low pressure because shockless piston (14) moves.
Consequently the pressure receiving area (S2) of poppet (2) becomes equal to the area (S1) of seat (3) and has a
large pressure receiving area when compared with the area (S1-S2) for the regular relief set pressure.
Therefore the low pressure holding time is decided by the diameter of the poppet orifice, the pressure receiving
area of the free piston and the free piston stroke.
3 2 14 5
S1 S2
1st step: Operation of relief valve

2nd step:
After the movement of shockless piston (14), the pressure inside of spring chamber (5) rises and becomes equal to
the pressure the front and behind of poppet (2). And the relief valve is operated by the regular set pressure.
2 14 5
2nd step: Operation of relief valve
The pressure wave forms in the conventional type and the shockless type are shown below.
Conventional type Shockless type

Pressure
Pressure
24
Time Time
Comparison of pressure wave forms
24-49
(5) Make-up valve (check valve, No.54)

The make-up valve performs the following two functions.
The 1st function is to prevent the cavitation produced when overrunning to avoid the overrun of the upper structure.
The motor revolved by the inertia force of the upper structure causing the pumping action, and when the motor
speed is over the speed equivalent to the oil quantity fed into the motor, the shortage of oil is made up from the
outside to the motor main circuit through the make-up valve to protect the circuit from the generation of vacuum.
The 2nd function is, when the closed circuit is formed between the control valve and the motor as when braking, to
protect the circuit from the generation of the vacuum by making up the shortage due to the motor drain and valve
leak from the make up valve to maintain the braking function in the regular circuit condition.
Make-up valve
24-50
(6) Reduction Unit (2-stage planetary)

Refer to the cross sectional view.
The motor shaft (22) is connected to the drive gear (16) with the spline on it. The driving power on the hydraulic
motor is transmitted from the drive gear (16) to the planetary gear (14) which is engaged to the drive gear (16). The
planetary gear (14) is engaged to the ring gear on the reduction unit housing (1). Then it revolves around the ring
gear with its rotation. The planetary gear (14) is held on the holder (10) with the bearing, and the holder (10)
transmits the revolving motion of planetary gear (14) to the sun gear (66) which is engaged to the holder (10) with
the spline on it. The sun gear (66) is engaged to the planetary gear (68), and transmits the revolving motion to the
planetary gear (68) as the same routing as the first stage. Since the planetary gear (68) is held on the holder (72)
with the bearing, the holder (72) transmits the revolving motion of the planetary gear (68) to the pinion shaft (2)
which is engaged to the pinion shaft (2) with the spline on it.
24
24-51
24.1.6 TRAVEL MOTOR
(1) General View
OIL FILLING PORT

OIL LEVEL CHECK PORT
P2, P3 DRAIN PORT
No. NAME SIZE

A,B Hydraulic oil fill / drain port PF1/2
D1,D2 Drain port PF1/4
P 1st/2nd speed select port PF1/8
P2,P3 Pressure gauge port PT1/8
The relation between rotating direction of reduction unit
and oil inlet and outlet port (View from X side)
Rotating direction Oil inlet port Oil outlet port
Clockwise A B
Counterclockwise B A
VIEW X
(2) Specifications
Model (Type) GM04VA

Rated output revolution (1st / 2nd) rpm 36.7 / 64.0
Reduction unit Output torque (1st / 2nd) N-m (lbf-ft) 3470 / 1900 (2560 / 1400)
Reduction ratio 1 / 53.7
Displacement (1st / 2nd) cm3/rev (cu-in/rev) 20.5 / 11.5 (1.25 / 0.70)
Rated operating pressure MPa (psi) 23.0 (3340)
Rated output revolution (1st / 2nd) min-1(rpm) 1970 / 3439
Hydraulic motor
Rated flow L/min (gal/min) 41.2 / 10.9
2-Speed shifting pressure MPa (psi) 3.5 (507)
Automatic 2-speed shifting pressure MPa (psi) 18.5 (2680)
Static friction torque N-m (lbf-ft) 32.4 (23.9)
Parking brake
Releasing pressure MPa (psi) 0.89 (129)
Weight kg (lb) 43 (95)
24-52
(1) Construction (Outline)
24
24-53
(2) Sectional view
24-54

1 Hub 1 Cylinder and piston kit 1
2 Spindle 1 104 -Cylinder block 1
3 Carrier 1 -Piston kit 1
4 Sun gear (1) 1 --Piston assembly 7
5 Planetary gear (1) 3 105 ---Piston 1
6 Sun gear (2) 1 106 ---Shoe 1
7 Planetary gear (2) 4
9 Thrust washer (1) 2 Piston kit 1
11 Thrust collar (4) 4 -Piston assembly 1
12 Thrust washer (3) 7 161 --Piston 1
13 Cover 1 162 --Shoe 1
14 Coupling 1 163 -Seal ring 1
22 Ring nut 1 102 Shaft 1
24 Ball bearing 2 103 Swash plate 1
27 Needle roller bearing with retainer 3 107 Retainer plate 1
28 Needle roller bearing with retainer 4 108 Thrust ball 1
29 Inner race 3 109 Timing plate 1
30 Inner race 4 110 Washer 2
112 Piston 1
Floating seal kit 1 113 Spring 8
31 Floating seal 2 114 Spring 1
115 Friction plate 1
33 Plug with flange 1 116 Separator plate 2
35 O-ring 1 132 Oil seal 1
37 O-ring 1 135 O-ring 1
39 Plug 2 139 O-ring 1
40 Hexagon head screw 7 145 Snap ring 1
41 Steel ball 1 149 Ball bearing 1
42 Parallel pin 2 150 Ball bearing 1
43 O-ring 2 151 Roller 3
44 O-ring 1 167 Pivot 2
45 Ring 1 177 Parallel pin 2
47 Hexagon socket set screw 2 190 Spring 1
54 Hexagon socket plug 1
24
24-55

Rear flange assembly 1 236 -O-ring 2
-Rear flange kit 1 237 -O-ring 2
201 --Rear flange 1 252 -Hexagon socket plug 4
223 --Spool 1 254 -Hexagon socket plug 4
-Spool kit 1 266 -Spring 1
263 --Spool 1 268 -Steel ball 1
264 --Oil stopper 1 273 -O-ring 2
221 -Plug 2 275 -Orifice 1
224 -Plug 2 279 -Filter 1
225 -Stopper 2 280 -Plug with flange 1
226 -Plug 2 299 -Name plate 1
227 -Valve 2
228 -Spring 2 241 Parallel pin 2
230 -Spring 2 243 Capscrew 6
24-56
24.1.6.3 FUNCTION
24.1.6.3.1Reduction Unit
(1) Function
This reduction gear unit is composed of two stage planetary gear mechanism.
The reduction gear reduces the high speed of hydraulic motor and converts it low-speed, high- torque rotation.
(2) Operating Description

The rotation of hydraulic motor shaft is transmitted to sun gear (4) of the first stage which is linked with shaft (102)
in spline.
Sun gear (4) is meshed with three planetary gears (5), and three planetary gears (5) mesh with hub (1) while
rotating on their axis.
At that time, the hub is rotated by the rotation of the planetary gears (5).
The hub rotation is transmitted to carrier (3) which connected to planetary gears (5), and that causes sun gear (6)
rotation of the second stage.
The rotation of sun gear (6) is transmitted to the hub via four planetary gears (7) of the second stage.
The generated rotation of reduction gear is output rotation.
24.1.6.3.2 Hydraulic Motor Section (Brake valve, parking brake, high and low speed change mechanism)
(1) Function
1. Hydraulic motor: Hydraulic motor is referred to as a swash plate type axial piston motor which converts the
pressure oil power fed by pump into rotary motion.
2. Brake valve
a. Travel motor controls the force of rotational inertia of the body to brake and stop the rotation smoothly.
b. Check valve function to prevent hydraulic motor from cavitation.
c. Open the port to release the parking brake force at travel motor operation, and close the port at a standstill.
3. Parking brake:
The parking brake is used to the prevent machine from running away or slipping while parking on a slope using
the friction plate type brake mechanism, and is installed on the hydraulic motor.
4. High / Low 2-speed shifting mechanism: By means of changing the tilt angle of the swash plate to change the
stroke volume of piston with help of the function on the shifting valve and control piston, the speed is shifted to
high speed with low torque or low speed with high torque.
24
24-57
(2) Operation
1. Hydraulic motor
Hydraulic oil fed by pump enters rear flange (201) of travel
motor, and is led from timing plate (109) to cylinder block
(104) through brake valve mechanism. This pressure oil is
led to only the one side of Y1-Y2 tied between top dead
point and bottom dead point of piston (105) stroke. And
the pressure led to one side of cylinder block pushes 4 or
5 pistons (105), generating the power {F (N) = 100 X P
(MPa) X A (cm2)}. This power enters on swash plate (103),
but swash plate (103) is fixed having an angle (Alfa)
against axis of drive shaft (102), and divided into
component of force (F2, F3). And the radial component of
force (F3) generated various torque (T = F3 X ri) against
line Y1-Y2. The total torque [T = (F3 X ri)] is connected to
turning effort, and rotates cylinder block (104) through
piston (105).
This cylinder block (104) is connected with drive shaft
(102) with spline, and rotates drive shaft (102) to transmit
torque.
2. Brake valve
a. Operation (Brake released)
The pressure oil is led to through port (A), opens valve
(227), and led to port (C) on the section side of hydraulic
motor to rotate hydraulic motor. At the same time, the
pressure oil enters chamber (b) through passage (a) from
the small hole of spool (223), and exerts on the end of
spool to generate the force.
Then the force of spring (228) slides the spool placed on
the neutral position leftward.
The sliding of spool forms the space (passage) between
spool and rear flange with spool groove. This passage is
connected to port (D) and port (B) of the return circuit of
the hydraulic motor, and the return oil returns to tank side,
enabling hydraulic motor to rotate.
Then, the sliding of spool (223) leads pressure oil to port
(P). The pressure oil led to port (P) moves piston (112) of
parking brake, and releases parking braking force. (For
details, refer to item "Parking brake".) If pressurized oil is
supplied from port (B) the movements of spool (223) and
valve (227) are reversed so that the hydraulic motor is
rotated reversely.
24-58
b. Stop / Stall (braking action)

If pressurized oil supply through the port (A) is suspended
while travelling, the hydraulic force to push up the spool is
lost, and the spool (223) which is slided to left side, tries to
return to the neutral position through the stopper (225) due
to the spring (228) force. At that time, through the oil in the
chamber (b) tries to flow out to the port (A) side through
the passage (a) in the spool, its flow is restricted and some
back pressure is generated by the throttle effect in the
passage (a) controlling the return speed of the spool. At
the same time, the hydraulic motor tries to rotate with its
inertia force even though the pressurized oil is suspended,
and the return oil from the hydraulic motor tries to return to
the port (B) side from the port (D) through the passages on
spool groove and rear flange.
When the spool entirely return to the neutral position, the
passage on the hydraulic motor of the oil return side is
completely closed by the spool, and the hydraulic motor
ceases its rotation. While machine working, the brake
valve smoothly stops rotation of the hydraulic motor which
tries to rotate with its inertia force, by means of throttling
the return side passage of the hydraulic motor, generating
back pressure due to shape of the spool groove and
controlling the return speed of the spool.
On the other hand, when braking is operated, the hydraulic
motor tries to rotate with its inertia force and to intake oil
with its pumping function. However, because the intake
side is closed its passage with the spool, the oil supply is
suspended. This causes cavitation in the hydraulic motor.
To prevent the cavitation, the valve (227) is operated by
very slight negative pressure to open the passages of port
(A) side and intake port (C) of the hydraulic motor.
And when pressurized oil is supplied through the port (B),
each motion of the above mentioned parts becomes
symmetrical right and left to stop the hydraulic motor.
c. Self-traveling
While machine is being operated, as the travel speed is
increased due to steep slope, the oil flow rate of the
hydraulic motor is higher than the supply flow rate of the
hydraulic oil pump. The rotation of the hydraulic motor in
this case is called a self-traveling (Overrun).
While self-traveling, the oil pressure is lowered similar to
the stopping condition. Then brake valve is moved similar
to the stopping condition, throttles passage in the return
side of hydraulic motor, and generate backing pressure.
In addition, the force of inertia decreases the revolution of
hydraulic motor to revolution having a balance with the
supply flow rate of pump.
24
24-59
3. Parking brake
a. Traveling
The pressure oil led trough brake valve actuates on spool
(223) of brake valve on the hydraulic motor section, opens
passage to parking brake, and is led to cylinder chamber
(a) compressed of spindle (2) and piston (112) on the
reduction gear section.
If the pressure of oil which is 0.89MPa(129 psi) or higher it
exceeds the force of spring moving piston (112) toward
rear flange (201) side. This movement of piston (112)
reduces the push power to separator plate (116) and
friction plate (115), and makes the movement of friction
plate (115) which is installed to cylinder block (104) on
hydraulic motor section free releasing the brake power to
cylinder block (104).
b. Stopping
If pressure oil from brake valve is cut, and the pressure in
cylinder chamber (a) lowers 0.89MPa(129 psi) or less, the
piston (112) goes to rightward by the force of spring (113).
Also, the force of the spring pushes mating plate (116) and
friction plate (115), which is in a free state because piston
(112) is pushed, against spindle (2) on the reduction gear
section. The frictional force produced by the push power
stops the rotation of cylinder block (104), and transmits
braking torque 32.4N-m (23.9 lbf-ft) to hydraulic motor
shaft. And since oil is controlled through the proper oil
passage, it results in smooth operation.
24-60
4. High / Low 2-speed shifting mechanism

a. Low speed
When the pilot pressure is not supplied through the port (D), the valve (263) is pushed up to the upper position due
to the spring (266) force and pressurized oil through the port (A) or (B), the pressurized oil is cut off at port (C), and
oil in the chamber (P) is released into the drain (motor case) through the valve (263). Accordingly, the tilt angle of
the swash plate (103) becomes the maximum 1 resulting the maximum stroke volume and low speed rotation of
the hydraulic motor.
b. High speed
When 3.5 MPa (507 psi) of the pilot pressure is supplied through the port (D), it defeats the spring (263) force and
pressurized oil through the port (A) or (B) to push down the valve (263) to lower position, the pressurized oil at the
port (C) is led to the chamber (P) through the valve (263), and the piston (161) pushes the swash plate (103) up to
the plane X and maintain it at its position. At that time, the tilt angle of the swash plate becomes the minimum 2
resulting the minimum stroke volume and high speed rotation of the hydraulic motor.
24
24-61
c. Automatic shifting to low speed during high speed operation

If the load is increased while high speed operation, the oil pressure at the port (A) or (B) is also increased. And
when the oil pressure reaches to 18.5MPa (2680 psi), it excesses the pilot pressure of 3.5MPa(507 psi), and the
valve (263) is pushed up to upper position, and oil in the chamber (P) is released into the drain (motor case)
through the valve (263). At that time, the swash plate (103) gets touch with the plane Y of spindle, and the tilt angle
of swash plate becomes the maximum 1 and is maintained at its position resulting low speed rotation.
24-62
24.1.7 SWIVEL JOINT
24.1.7.1 GENERAL VIEW
General view
Model (Type) YV-7200

Port No. A, B, C, D E, F P G (Drain)
Max. working pressure MPa (psi) 24.5 (3550) <-- 20.6 (2990) 0.5 (73)
Pressure test MPa (psi) 36.8 (5340) <-- 30.9 (4480) 1.0 (145)
Flow L/min (gal/min) 60 (15.8) 30 (7.9) 5 (1.3) <--
Revolution rpm Less than 15
Weight kg (lb) Approx 22 (49)
24
24-63
Construction

1 SHAFT 1 9 DUST SEAL 1
2 BODY 1 10 DUST SEAL 1
3 FLANGE 1 11 SNAP RING 1
4 THRUST RING 1 12 BOLT 4
5 PIN 1 13 PLUG 3
6 SLIPPER SEAL 4 14 SPRING WASHER 4
7 O-RING 1 15 BACK-UP RING 1
8 O-RING 1 16 SLIPPER SEAL 3
24-64
24.1.7.4 FUNCTION
The swivel joint is installed at the slewing center of 3

1
machine, and is to maintain the connection of hydraulic oil
circuits regardless to the slewing angle on the upper
2
frame. On the body (2) and shaft (1) which are able to
independently rotate with each other, the necessary
number of ports (3) are provided corresponding to the 4
number of circuits. The necessary number of grooves is
5
machined on both of the body (2) at its inner periphery and
the shaft (1) at its outer periphery, and these grooves are 4
sealed at upper and lower portions with the seal (4) The
hydraulic oil flowing into the shaft from the port (3) is able
to keep its flowing along through the hydraulic circuit (5)
which is provided between the body (2) and shaft (1), and
the circuits maintained without any hindrance due to the
independent rotation of the body (2) and shaft (1).
24
24-65
24.1.8 CYLINDER
(1) General View
General view of cylinder
24-66
CX31B
Cylinder Bore / Center distance of mounting pins

Stroke Dry weight
Cylinder Rod Dia. Full extend B / Full retract A Cushion
mm (ft-in) kg (lb)
mm (ft-in) mm (ft-in)
Boom 80 dia. / 45 dia.
585 (1'11") 1500 / 915 (4'11.1" / 3'0.0") 35 (77)
(Canopy) (3.15" / 1.77")
Rod side
80 dia. / 45 dia.
Boom (Cab) 559 (1'10.0") 1474 / 915 (4'10.0" / 3'0.0") 35 (77)
(3.15" / 1.77")
75 dia / 45 dia.
Arm 541 (1'9.3") 1398 / 857 (4'7.0" / 2'9.7") Head side 31 (68)
(2.95" / 1.77")
65 dia / 40 dia.
Bucket 497 (1'7.6") 1272 / 775 (4'2.1" / 2'6.5") None 20 (44)
(2.56" / 1.57")
80 dia. / 45 dia.
Swing 488 (1'7.2") 1286 / 798 (4'2.6" / 2'7.4") None 37 (82)
(3.15" / 1.77")
100 dia / 50 dia.
Dozer 160 (6.3") 633 / 473 (2'09" /1'6.6") None 27 (60)
(3.94" / 1.97")
CX36B
Cylinder Bore / Center distance of mounting pins

Stroke Dry weight
Cylinder Rod Dia. Full extend B / Full retract A Cushion
mm (ft-in) kg (lb)
mm (ft-in) mm (ft-in)
Boom 80 dia. / 45 dia.
578 (1'10.8") 1486 / 908 (4'10.5" / 2'11.7") 35 (77)
(Canopy) (3.15" / 1.77")
Rod side
80 dia. / 45 dia.
Boom (Cab) 555 (1'9.8") 1463 / 908 (4'9.6" / 2'11.7") 35 (77)
(3.15" / 1.77")
80 dia. / 45 dia.
Arm 560 (1'10") 1432 / 872 (4'8.4" / 2'10.3") Head side 32 (71)
(3.15" / 1.77")
65 dia / 40 dia.
Bucket 497 (1'7.6") 1272 / 775 (4'2.1" / 2'6.5") None 20 (44)
(2.56" / 1.57")
80 dia. / 45 dia.
Swing 488 (1'7.2") 1286 / 798 (4'2.6" / 2'7.4") None 37 (82)
(3.15" / 1.77")
100 dia / 50 dia.
Dozer 160 (6.3") 633 / 473 (2'09" /1'6.6") None 27 (60)
(3.94" / 1.97")
24
24-67
24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1Construction
(1) Boom cylinder
Construction of boom cylinder

1 CYLINDER TUBE ASSY 1 10 O-RING 1 19 SETSCREW 1
2 PIN BUSHING 2 11 HOLDER 1 20 STEEL BALL 1
3 PISTON ROD ASSY 1 12 SPACER 1 21 CUSHION BEARING 1
4 CYLINDER HEAD 1 13 CUSHION SEAL 1 22 TUBE ASSY 1
5 BUSHING 1 14 COLLAR 1 23 CAPSCREW 1
6 U-RING 1 15 BACK-UP RING 1 24 LOCK WASHER 1
7 WIPER RING 1 16 PISTON 1 25 WASHER 1
8 O-RING 2 17 SEAL RING ASSY 1 26 DUST SEAL 4
9 BACK-UP RING 1 18 SLIDE RING 1 27 GREASE NIPPLE 2
24-68
(2) Arm cylinder
Construction of arm cylinder

1 CYLINDER TUBE ASSY 1 8 O-RING 1 15 STEEL BALL 1
2 PIN BUSHING 2 9 BACK-UP RING 1 16 CUSHION BEARING 1
3 PISTON ROD ASSY 1 10 O-RING 1 17 CUSHION SEAL 1
4 CYLINDER HEAD 1 11 PISTON 1 18 STOPPER 2
5 BUSHING 1 12 SEAL RING ASSY 1 19 SNAP RING 1
6 U-RING 1 13 SLIDE RING 2 20 DUST SEAL 4
7 WIPER RING 1 14 SETSCREW 1 21 GREASE NIPPLE 2
24
24-69
(3) Bucket cylinder
Construction of bucket cylinder

1 CYLINDER TUBE ASSY 1 7 U-RING 1 13 DUST SEAL 1
2 PIN BUSHING 1 8 WIPER RING 1 14 SLIDE RING 2
3 PISTON ROD ASSY 1 9 O-RING 1 15 SETSCREW 1
4 PIN BUSHING 1 10 BACK-UP RING 1 16 STEEL BALL 1
5 CYLINDER HEAD 1 11 O-RING 1 17 DUST SEAL 4
6 BUSHING 1 12 PISTON 1 18 GREASE NIPPLE 2
24-70
(4) Swing cylinder
Construction of swing cylinder

1 CYLINDER TUBE ASSY 1 7 WIPER RING 1 13 SLIDE RING 2
2 PIN BUSHING 2 8 O-RING 1 14 SETSCREW 1
3 PISTON ROD ASSY 1 9 BACK-UP RING 1 15 STEEL BALL 1
6 U-RING 1 12 SEAL RING ASSY 1
24
24-71
(5) Dozer cylinder
Construction of dozer cylinder

1 CYLINDER TUBE ASSY 1 7 WIPER RING 1 13 SLIDE RING 2
2 PIN BUSHING 2 8 O-RING 1 14 SETSCREW 1
3 PISTON ROD ASSY 1 9 BACK-UP RING 1 15 STEEL BALL 1
6 U-RING 1 12 SEAL RING ASSY 1 18 GREASE NIPPLE 1
24-72
24.1.8.2.2 Function (Example for boom cylinder)

(1) Fundamental Function
This is hydraulic cylinder is a linear actuator that converts the energy in pressurized oil supplied by the hydraulic
pump from rotary force to linear force conveyed by the piston of the cylinder. It also changes the operating direction
for extension or retraction by actuating the valve lever to change over the direction of pressurized oil flow.
(2) Function of each Part

The following description is based on a cylinder with a typical structure (Boom cylinder).
1. Cylinder Head Assembly
The cylinder head assembly also works as a bearing by means of pressing the bushing (5) into the cylinder head
(4). The oil leakage is prevented by insersion of the U-ring (6) into the bore of cylinder head. The dust invasion is
protected by pressing the wiper ring (7) into the bore of cylinder head. By means of fitting with the cushion bearing
(22) at adjacent to the fully extended position of the cylinder, a high oil pressure is generated to absorb the cylinder
shock at the fully extended position. And the cylinder head has another function of charging and discharging highly
pressurized oil from the inside of cylinder tube to the port.
Cylinder head assembly

a. Bushing (5)
The bushing (5) is pressed into the bore on cylinder head to support the piston rod. Along with the slide ring
installed outer periphery of the piston, the bushing (5) bears radial load imposed on the cylinder, and performs
linear movement against the piston rod at high facial pressure, and minimized the eccentricity of piston rod that
badly affects to the sealing effect by supporting its one end.
b. Wiper Ring (7)
The wiper ring (7) is located at the entrance where the piston rod comes in and out. Its function is to protect
invasion of dust and water into the cylinder to secure good sealing effect of the U-ring (6), as well as to remove
dust and mud adhered on the piston rod.
24
24-73
2. Piston Assembly
The piston assembly has the seal ring (18) which is inserted at the center portion of the piston (17), to prevent
leakage of pressurized oil from either chamber of left or right to the other chamber. The slide rings (19) are inserted
in both sides of the seal ring (18) to bear radial load imposed on the cylinder, and also to catch contamination.
SET SCREW 20 SEAL RING 18 CUSHION BERING 22

STEEL BALL 21 SLIDE RING 19 PISTON 17
CUSHION STROKE
Piston assembly
a. Seal Ring (18)
The location of seal ring (18) is the center of piston. The seal ring (18) is to seal the circular gap between the
piston and the cylinder tube utilizing a tension of the O-ring, to form both chambers of high pressure side and
low pressure side isolating from each other making the piston as the border.
b. Slide Ring (19)
Two slide rings are provided at both sides of the seal ring (18) directly getting in touch with the cylinder tube.
Along with the bushing (5), the slide rings (19) bear radial load imposed on the cylinder, perform linear
movement against inside face of cylinder at high facial pressure, and minimize the eccentricity of piston rod that
badly affects to the sealing effect by supporting it at one end. And the slide ring has another function of burying
and catching contaminations between the cylinder tube and the slide rings.
c. Cushion Bearing (22)
The cushion bearing (22) is located between the piston and the stepped portion of piston rod. Along with the
cylinder head, it has the functions to form a circular gap adjacent to the fully extended position, and to throttle
the oil to absorb the collision speed of cylinder at the fully extended position to soften the shock.
24-74
24.2 ELECTRICAL EQUIPMENT
24.2.1 ELECTRICAL EQUIPMENT LIST

D-1 DIODE YN02D01001P1
D-2 DIODE ↑
D-3 DIODE ↑
Diode D-4 DIODE ↑
D-12 DIODE ↑
D-14 DIODE ↑
D-18 DIODE ↑
E-1 FUSE BOX PW73E00003F1
E/G accessory
E-2 GENERATOR (ALTERNATOR)
(119626-77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E/G accessory
E-8 GLOW PLUG
(129008-77800)
Electical
Fittings Cab accessory
E-10 RADIO (OPT)
(PY54S00001P1)
E-12 HEATER (OPT) PM21M00005F1
E-13 BATTERY PW72S00004P1
E-14 SEQUENCE BOX PA24S00002P3
E-20 TRAVEL ALARM (OPT) PW53S00002F1
E-26 HOUR METER YT58S00006P1
E-32 FUSE 2479R655S10
Cab accessory
L-1 ROOM LAMP
(PM80S00006P1)
Light
L-2 BOOM WORKING LIGHT PM80S00008F1
L-5 CAB / CANOPY WORKING LIGHT PW80S00003F1
E/G accessory
M-1 STARTER MOTOR
(129242-77010)
Cab accessory
M-2 WIPER MOTOR (CAB)
(PM76S00001F1)
Motor
Cab accessory
M-3 WASHER MOTOR (CAB)
(PE54C00002S002) 24
M-4 DECELERATION MOTOR PW20S00012F1
M-6 FUEL PUMP PW22P00001P1
24-75

R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
R-3 DECELERATION RELAY (EU - NA - Aust) PA24E01001P1
R-6 TIMER UNIT PH25S00002P1
Relay
R-7 E/G STOP RELAY PX24S00003P1
R-8 CHARGE INDICATOR RELAY PA24E01001P1
R-9 CAB / CANOPY WORKING LIGHT ↑
R-31 HORN RELAY ↑
SE-1 FUEL SENSOR PX52S00006F1
Sensor
SE-2 ENGINE THERMO SENSOR PA24S00003P1
SV-1 LEVER LOCK SOL.
PX35V00003F1
SV-2 2-SPEED SELECT SOL.
E/G accessory
Solenoid SV-3 E/G STOP SOL.
(119233-77932)
SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
SV-8 TILT ANGLE SELECT SOL. ↑
PSV-D NIBBLER OPEN PROPORTIONAL SOL.
PW35V00002F1
Proportional PSV-E NIBBLER CLOSE PROPORTIONAL SOL.
Solenoid
Valve PSV-F REVOLUTION LEFT (A1) PROPORTIONAL SOL. Pending
PSV-G REVOLUTION RIGHT (A2) PROPORTIONAL SOL. ↑
24-76

SW-1 KEY SWITCH PW50S00005S001
SW-2 WORKING LIGHT SW. PV24E01001P2
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
E/G accessory
SW-6 E/G OIL PRESSURE SW.
(114250-39450)
SW-7 HORN SW. YN50E01001P2
SW-9 LEVER LOCK SW. PA50S00001P1
SW-10 HEATER SW. (OPT) PY50S00003P2
SW-11 DECELERATION SW. (OPT) PM50S00005P1
SW-14 AIR FILTER RESTRICTION SW. (NA) PW11P00010S004
Switch
SW-17 TILT ANGLE SELECT SW. PW03M01350F1
TRAVEL RIGHT (FORWARD) PRESSURE SW. (OPT)
SW-24 GB50S00049F2
(NA)
TRAVEL RIGHT (REVERSE) PRESSURE SW. (OPT)
SW-25 ↑
(NA)
TRAVEL LEFT (FORWARD) PRESSURE SW. (OPT)
SW-26 ↑
(NA)
TRAVEL LEFT (REVERSE) PRESSURE SW. (OPT)
SW-27 ↑
(NA)
SW-30 SLEW/SWING LEVER PRESS. SW.(LEFT) ↑
SW-31 SLEW/SWING LEVER PRESS. SW.(RIGHT) ↑
SW-35 NIBBLER OPEN-CLOSE SW. (NA) PW03M01958F1
SW-37 (A1, A2) REVOLUTION SW. (NA) PW03M01959F1
- The part numbers may be changed due to modification, use them only for reference.
- NA : North America, Aust : Australia
24
24-77
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
D-1, 2, 3, 4, 12, 13, 14,

18 Type 7321-9822-30
Max Current 3A
Diode rated Breakdown 400V
YN02D01001P1
Horn
E/G stop solenoid
Mating connector
E/G stop relay
Maker Housing Terminal
Travel 1, 2 speed sol.
2poles
Battery relay
Swing select sol. 4poles
E/G stop solenoid
Generator
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
E-1 Spare fuse 10A one‚ 30A two
Wiper
Fuse box 30A Heater
30A
10A
Relay
30A 30A Solenoid
PW73E00003F1
30A Working light
30A
30A
Circuit protection Horn

10A 10A 10A Room lamp
30A Engine stop
PW14-45001~
30A
30A Solenoid
PX15-20001~ 10A Battery relay
10A Gauge cluster
PW14-46519~
PX15-21105~
Connection
24-78
Code No.
Parts Name
Use
Applicable Machine
E-2 YANMAR Part No. 119626-77210 on

cti
Voltage 12V dire
ing
Generator tat
Rated revolution 5,000r.p.m Ro
Current 55A (13.5V)

(Alternator)
Weight 3.5kg (7.7 lb)
119626-77210
PW14-45001~
PX15-20001~
PW14-46519~ CONNECTOR
PX15-21105~
KEW SWITCH
Mating connector
SUMITOMO 6189-0442.0443
DETAIL OF CONNECTOR
ALTERNATOR ASSY IC REGULATOR

CONNECTION
E-3 Maker Part No. ND-012

Rated Voltage
Horn T2
Rated current
T1
Basic frequency
PY53S00002P1
Sound level
Warning sound Insulation resistance
PW14-45001~
PX15-20001~
PW14-46519~ COIL
PX15-21105~ AIR SHAFT
ELECTRIC CIRCUIT
E-4 Allowable current 45A
Fusible link
PH73S00001P1
45A 24
Fuse
PW14-45001~ 45A
PX15-20001~
PW14-46519~
PX15-21105~
24-79
Code No.
Parts Name
Use
Applicable Machine
E-6 Operating voltage 12V CONNECTOR TABLE

No. Connection
1 Illumination (+)
Gauge Cluster 2 E/G oil press (-)
3 Charge (-)
4 E/G coolant temp (-)
PH59S00005F1 Front side
Lamp power source-1 (+) [E/G coolant,
5
Fuel, Travel 2 speed]
Monitor Panel 6 Fuel (-)
7 Travel 2 speed (-)
PW14-45001~ Lamp power source-2 (+) [E/G oil
8
press., Charge, Air cleaner clogging]
PX15-20001~ 9 Air cleaner clogging (-)
PW14-46519~ 10 F/T IGN (+)
PX15-21105~ Reverse side 11 FUEL UNIT
12 F/T illumination GND (-)
13 TEMP UNIT
14 NOT USE
Connector :
AMP 917532-1 (White)
E-8 YANMAR Part No. 129008-77800

Rated voltage DC11V
Glow plug
Rated current 7A (Reference)
Temperature 800
129008-77800
Standard preheating time 15 seconds
E/G starter
PW14-45001~
PX15-20001~
PW14-46519~ M10 1.25 M4 0.7
PX15-21105~
Hex opposite 12
E-10 Maker CLARION

Voltage 12V
Tuner Display button Display
PY54S00001P1
Radio (OPT)
PW14-45001~
PX15-20001~ Speaker Preset Tune /time Power
PW14-46519~ button adjust / volume
PX15-21105~
24-80
Code No.
Parts Name
Use
Applicable Machine
E-12
Heater
ELECTRIC CIRCUIT
Vinyl tube
PM21M00005F1
Heating (OPT)
PW14-45001~ Machine side

PX15-20001~
PW14-46519~
PX15-21105~
E-13 Type 95D31L

Rated voltage DC12V
Battery
Capacity 74.3Ah/5HR
Amount of electrolyte 5.3L
PW72S00004P1
Power source
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
E-14 Rated voltage DC12V
Relay
PA24S00002P3
Sequence
(Holding circuit) Input/output operation
GND
PW14-45001~
PX15-20001~ Decel.relay Decel.SW AMP : 0-175783-1
solenoid
PW14-46519~ Mating connector : 0-174923-1
Terminal : 175027-1
PX15-21105~ Travel1,2speed solenoid Travel1,2
speed SW Pin arrangement
Electric circuit
E-20 Maker's Part No. MAZIMA BA-102-12V PROTECTIVE TUBING
Travel alarm Rated voltage DC12V

(Australia, China)
I
(Usage range)
Max 0.3A
PW53S00002F1 Rated current
at rated voltage 24
Sound pressure
Warning sound
at rated voltage CONNECTOR SPECIFICATION :
PW14-45001~ AMP ECONO SEAL MARK II
WATER PROOF POWER SOURCE (+) (RED)
PX15-20001~ HOUSING : 174354-2
PW14-46519~ POWER SOURCE (-) (BLACK)
TERMINAL : 171661-1
PX15-21105~ HARNESS SEAL : 176886-2
RETAINER : 1-174355-1 VIEW I
24-81
Code No.
Parts Name
Use
Applicable Machine
E-26 Movement Quartz

Rated voltage
Hour meter TERMINAL PARTS No : 2962447
CONNECTOR PARTS No : 2962448
YT58S00006P1
Service meter
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
E-32 Type Slow blow fuse

Allowable current 5A
Fuse
2479R655S10
Fuse
PW14-46519~
PX15-21105~
L-1 Rated voltage 12V

Bulb 12V-10W
Light
PM80S00006P1
Room light (Cab Spec.)
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
L-2 Maker’s P/No. BL84-150

Effective area of lens 82cm2
Light Halogen12V-55W
Bulb
PM80S00008F1
Boom working light

(L.H.)
PW14-45001~
PX15-20001~ CA104
M12 Bolt
PW14-46519~
PX15-21105~
24-82
Code No.
Parts Name
Use
Applicable Machine
L-5 Maker’s P/No. BL84-290

Effective area of lens 54cm2
Light Halogen12V-55W
Bulb
PW80S00003F1
Canopy / Cab working

light
WATER DRAIN HOLE (POWER)
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
(GROUND)
M-1
Motor
129242-77010
E/G starter
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
YANMAR Part No. 129242-77010

M-2 Maker’s 849100-5120
Rated P/No.
voltage DC12 V
Rated voltage 12V
Motor Output 1.7 kW
Wiping angle
Rated time 30 Sec
PM76S00001F1
Rotating direction Clockwise as seen from pinion
R(+1) Y(S)
Wiper (Cab Spec.) Weight 3.4 kg (7.5 lb)
PW14-45001~
PX15-20001~ B(-)
L(+)
PW14-46519~
YAZAKI
PX15-21105~
7322-2045
24
24-83
Code No.
Parts Name
Use
Applicable Machine
WINDOW WASHER TANK ASSY

M-3 Maker's P / NO. 060210-1480 P/No.PE54C00002F1
Rated voltage DC 12V (+) (-)
Motor
PE54C00002S002
Window washer
(Cab Spec.)
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
MOTOR
M-4
(0.236")
Motor
(0.394")
PW20S00012F1
(1.65")
(1.46") (1.42")
Deceleration
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
Switch OFF : P2
ON : P1
Rated voltage 12V common
Stroke 36 2 mm (1.42" 0.08") ( Ð)
Working force 109N {11Kgf} or more

Working time 1 sec. or less
Working current 8.5A or less (Ð) Relay
PTC Thermistor
Circuit diagram
24-84
Code No.
Parts Name
Use
Applicable Machine
M-6 YANMAR Part No. 129612-52100

Rated voltage DC12V
Fuel pump Max.working current 1.5 A or less
At open condition
PW22P00001P1 Delivery rate 400cc/min {24.4 cuin/min}
or more
Auto air bleed
PW14-45001~ YAZAKI
PX15-20001~
PW14-46519~
PX15-21105~ AV 0.5R (Red)
AV 0.5B(Black)
Vinyl tube (Blue)
R-1 Maker's P/No. VF7-41F11

Rated voltage DC12V
Relay Coil resistance
Insulation resistance
PH24S00001P1
Applicable connector VCF7-1000(P&B)
Battery relay Applicable terminal AMP280756-4
E/G stop relay AMP280755-4
PW14-45001~ AMP42281-1
PX15-20001~
PW14-46519~
PX15-21105~
Connection diagram
R-2 YANMAR Part No. 119802-77200

Rated voltage DC12V
Safety relay Rated Continuous
Temperature range
PX24S00001P1 Rated load B terminal starter (Max 40A)
24
Key switch
Protection of starter CONNECTOR A : 6195-0057 (SUMITOMO) CONNECTOR
MATING : 6195-0060 (SUMITOMO) A CONNECTOR
B
PW14-45001~ Controller
Battery
PX15-20001~
Starter
PW14-46519~
CONNECTOR
PX15-21105~ CONNECTOR B : 6195-0024 (SUMITOMO) TERMINAL
Connection diagram MATING : 6195-0021 (SUMITOMO) ARRANGEMENT
24-85
Code No.
Parts Name
Use
Applicable Machine
R3, 8, 9, 31 Maker's P/No. RC-5103

Rated voltage DC12V
Relay Insulation resistance
PA24E01001P1
Deceleration relay
4
Charge indicator relay 3
Working light relay etc. 5 1 5
PW14-45001~ 4 3
PX15-20001~
PW14-46519~
1 2
PX15-21105~ Circuit diagram
2
R-6 YANMAR Part No. 129211-77920

Rated voltage 12V z
Relay Exciting current 1A
Timer 1sec Connector
PH25S00002P1 YAZAKI 7122-2446
Timer Unit Red (Acc) Red / White

(Relay)
PW14-45001~
PX15-20001~ Black (GND) Yellow
PW14-46519~ (Relay)
PX15-21105~ View Z
R-7 YANMAR Part No. 119650-77910 LABEL

Rated voltage DC12V RED
Relay Constant rating 10MIN
Coil resistance 37
PX24S00003P1
Inductance 66mH (at 1kHz) 1 TERMINAL MATERIAL INNER WIRE
: C2680 (BRASS)
E/G stop relay CONNECTION
3
PW14-45001~
PX15-20001~
4
PW14-46519~ OTHER CONNECTOR
PX15-21105~ 2 : 7323-2228 (YAZAKI)
OTHER CONNECTOR : 7323-3010 (YAZAKI)
24-86
Code No.
Parts Name
Use
Applicable Machine
SE-1 Rated voltage 12V
Sensor Float position

Resistance
PX52S00006F1
Allowable
Fuel sensor TYCO ELECTRONICS AMP (174359-2)
121 (4.76") (1.74")

PW14-45001~
44.3
PX15-20001~ GND (Black)
117.5 (4.63")
PW14-46519~
PX15-21105~ UNIT(Yellow)
Thermistor (Red)
Connector
)}
(3.92"
{R99.6
201 (7.91")
Circuit diagram
SE-2 Rated voltage DC 12V

Type Thermistor type
Sensor 17 (0.67")
M16 X 1.5
PA24S00003P1
E/G thermo sensor
PW14-45001~
PX15-20001~ (50) 80 100 (120) CA 104
PW14-46519~ (153.9) 51.9 27.4 (16.1)
PX15-21105~
The figures in parentheses are reference values
24
24-87
Code No.
Parts Name
Use
Applicable Machine
SV-1,2 Rated voltage DC12V

Relief valve set pressure 3.5MPa (507psi)
Solenoid 15L/min (3.96 gal/min)
Flow rate
(P port)
PX35V00003F1
Safety lever lock

Travel 2-speed select
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~ Hydraulic symbols
Connector shape :
Equivalent cap housing

Equivalent cap housing : 1743854-2
Equivalent terminal : 173706-1
SV-3 YANMAR P/No. 119233-77932 Stroke7.4mm

(0.291")
Rated voltage DC 12V
Solenoid
Pull coil : 36.5Amps GND(Black)
Rated current
Hold coil : 0.49Amps
119233-77932
E/G stop
Connector
PW14-45001~
YAZAKI 7222-6234-40
PX15-20001~
PW14-46519~ Pull coil (White)
PX15-21105~ Hold coil (Red)
P
SV-5,8 Type AGCD
Rated voltage DC12V
Solenoid Capacity 12W EARTH POWER SOURCE
CORD COLOR : BLACK CORD COLOR : RED
Operating pressure 4.9MPa (710psi) T
YJ35V00004F2 AMP MARK II 2P
Max. flow 160 L/min (42gal/min) HOUSING : 174354-2
PLATE : 174355-7
Power shift A TERMINAL : 173706-1
VIEW A
(Air-con spec.) GUM PLUG : 172888-2
Tilt angle select 3-PF1/4 A
PW14-45001~ A
PX15-20001~
PW14-46519~
PX15-21105~
T P Circuit diagram
24-88
Code No.
Parts Name
Use
Applicable Machine
PSV-D, E A2 A1
Rated voltage 12V
Retad current 1600mA T
Solenoid
Coil resistance 3.2 0.5
PW35V00002F1 Max. working press. 7MPa (1,015psi) P
Flow rate 10L/min (2.72gal/min)
Nibbler open/close per 1 spool HYDRAULIC SYMBOL
PSV-E PSV-D
PW14-45001~ Nibbler close and Nibbler open
PX15-20001~ Breaker ON proportional sol. Cnnector shape
proportional sol.
PW14-46519~ Equivalent to AMP eco seal
PX15-21105~ J mark (+) cap hausing
Cap hausing : 174354-2
Terminal : 173706-1
A2 A1
P
SW-1 CONNECTION TABLE
Switch TO
AU RN OFF
TU ACC
RE
AU TUR
PW50S00005S001 BR ACC R1 RE
R2 TO N
Key switch ST
PW14-45001~
PX15-20001~ C
PW14-46519~ (DRAIN HOLE)
PX15-21105~ R1 B
OFF
SW-2 Connection table ON
M L (E)
Switch OFF
PV24E01001P2 24
ON L:70WX2 lamps
L
Working light
( Unconnected )
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
M E
24-89
Code No.
Parts Name
Use
Applicable Machine
Switch & Marks

SW-3 Type Buried in right travel lever
Switch
YN03M01286S002
(Right travel lever)
Trvel 1, 2 speed
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~ CA103
SW-4 Type 0850-00596

Auto return
Insulation resistance 1M or more (DC500V Megger) H
OFF ON
Switch WAS Auto
Connection table return
Load
2A WASH
PY50S00004P2
3A (Peak10A)
Wiper washer
(Cab only) 3A (Peak10A)
5A (Peak10A)
PW14-45001~
Wiper motor
PX15-20001~
Connector
PW14-46519~ Cam switch, Wiper YAZAKI 7323-2446
PX15-21105~ Washer, Motor
SW-5 YANMAR Part No. 121250-44901

21 (0.83")
Operating temperature M16 X 1.5
Switch
Electric capacity DC12V 1A

PM50S00006P1
E/G water temperature
Tightening torque 27N m (19.9 )
PW14-45001~
PX15-20001~ Identification : Gray Paint
PW14-46519~
PX15-21105~
SW-6 YANMAR Part No. 114250-39450

Rated voltage DC6V, 12V, 24V
Switch Rated load 5W (Lamp load) PT1/8 24 (0.95")
Operating
114250-39450 pressure
E/G oil pressure
PW14-45001~
PX15-20001~ CA104
PW14-46519~
PX15-21105~
24-90
Code No.
Parts Name
Use
Applicable Machine
SW-7 MIYAMA DS-257

Type
OFF-(ON) momentary
Switch Rated 125V 3A (AC)
Insulation
YN50E01001P2
resistance
Horn switch
SUMITOMO
PW14-45001~ Housing 6090-1031
PX15-20001~ Terminal 8230-4282
PW14-46519~
PX15-21105~
SW-9 Rated voltage DC12V

Rated current 15A
Switch CA104 (With sleeve) M20 X 1.5
Switch ON :
PA50S00001P1 Stroke
2 1mm, (0.08" 0.04")
Lever lock SW.
PW14-45001~
PX15-20001~ CB104 (With sleeve)
PW14-46519~
PX15-21105~
SW-10 Maker's part No. 0850-00595
Switch Load
PY50S00003P2
OFF
Heater switch
(OPT)
M PLUG
PW14-45001~
PX15-20001~ Connector
PW14-46519~ YAZAKI 7323-2446
PX15-21105~ E L
Connection table
SW-11 DC12V
Rated voltage
(MAX:DC16V)
Switch Insulation resistance
24
PM50S00005P1
a b
Deceleration switch d
(OPT)
PW14-45001~
PX15-20001~
PW14-46519~ c e 6242-1061(SUMITOMO)
PX15-21105~ Mating connector
6242-5061(SUMITOMO)
24-91
Code No.
Parts Name
Use
Applicable Machine
SW-14 Maker s part No. 11304-6000

Voltage : DC5V 30V
Switch Contact rating
Current : 3A or less
PW11P00010S004 Operating negative

Pressure 6.22 kPa (0.90 PSi)
Air filter
restriction switch PT 1/8
HEX 12
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
SW-24, 25, 26, 27, 30, 31 Maker's Part No. 53900-KW2300
Contact rating
Travel alarm
(Australia) AMP MARK II 2P
Slew/Swing lever HOUSING : 174354-2
(North America) PLATE : 174355-7
PW14-45001~
PX15-20001~
PW14-46519~
PX15-21105~
2 1 SW-35
SW-35 Right CONNECTOR
LEAD WIRE COLOR
PIN ARRANGEMENT
RED
Grip & Switch +V 1
POWER SOURCE
BLACK
P 2
GND
GND
PW03M01958F1 WHITE
3 SOLENOID 1
SWITCH 3 BROWN
4 SOLENOID 2
Nibbler open-close SW. SW3
GREEN
5 SOLENOID RETURN 1
SW3
(North America) GND
GREEN
6 SOLENOID RETURN 2
PW14-46519~
PX15-21105~ ELECTRIC CIRCUIT
TYCO ELCTRONICS AMP

ECONOSEAL J SERIES MARK II (+)
3 2 1 CAP HOUSINGCAP HOUSING: 174264-2
TERMINAL: 171631-1
6 5 4
24-92
Code No.
Parts Name
Use
Applicable Machine
SW-37
2 1 SW-37
Left CONNECTOR
LEAD WIRE COLOR
PIN ARRANGEMENT
Grip & Switch +V
RED
1
POWER SOURCE
BLACK
P 2
GND
GND
PW03M01959F1 WHITE
3 SOLENOID 1
SWITCH 1 BROWN
4 SOLENOID 2
(A1,A2) Revolution SW. GREEN
5 SOLENOID RETURN 1
(North America) GREEN
6 SOLENOID RETURN 2
PW14-46519~ ORANGE
1
SW1 SWITCH 1
PX15-21105~ GRAY
2
CONNECTOR
ELECTRIC CIRCUIT
TYCO ELCTRONICS AMP

ECONOSEAL J SERIES MARK II (+)
CAP HOUSING: 174264-2
1 TERMINAL: 171631-1
3 2
SUMITOMO WIRING SYSTEMS Ltd.

6 5 4 HM SERIES 090 (2PIN)
HOUSING: M(6090-1031)
TERMINAL: M(8230-4282)
2 1
24
24-93
24-94
31. GENERAL DISASSEMBLY AND ASSEMBLY
31. GENERAL DISASSEMBLY AND

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

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

S5PA3105E01
First Edition June, 2009 E10SR : PA03-05001~
(NHK-EUR)
↑
↑ ↑ E10SR : PA03-05001~
(NHK-AUS)
↑
↑ ↑ SK10SR-2 : PA03-05001~
(AUS)
↑
↑ July, 2009 SK10SR-2 : PA03-05001~
(KOR)
↑
↑ December, 2009 E18SR : PU09-08001~
(NHK-EUR)
↑
↑ ↑ SK17SR-3K : PU09-08001~
(KOR)
↑
↑ January, 2010 SK17SR-3 : PU09-08001~
(Oceania)
SK30SR-5 : PW14-45964~ ↑
↑ ↑
↑
↑ ↑ CX17B : PU09-08001~
(CASE AUS)
↑
↑ ↑ E18SR : PU09-08001~
(NH AUS)
CX31B : PW14-45964~ ↑
↑ ↑
CX36B : PX15-20658~ (CASE-NA)
E30B : PW14-45964~ ↑
↑ ↑
E35B : PX15-20658~ (NH-NA)
↑
↑ ↑ SK17SR-3 : PU09-08001~
(NA)
↑
↑ ↑ SK50SR-5 : PJ06-08890~
(NA)
SK30SR-5 : PW14-45001~ ↑
↑ February, 2010
SK35SR-5 : PX15-20001~ (KCM S.E.ASIA&OCE)
CX31B : PW14-45001~ ↑
↑ ↑
CX36B : PX15-20001~ (CASE-AUS)
↑
↑ ↑ CX50B : PJ06-08890~
(CASE-NA)
↑
↑ ↑ E50B : PJ06-08890~
(NH-NA)
E30B : PW14-45001~ ↑
↑ ↑
E35B : PX15-20001~ (NH-AUS)
↑
↑ ↑ SK27SR-5 : PV13-33292~
(NA)
SK30SR-5 : PW14-46519~ ↑
↑ March, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
31-2
31.1 GENERAL DISASSEMBLY AND ASSEMBLY
31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY

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

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

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

32.1.1 ATTACHMENT ASSEMBLY AND NAME ...................................................32-3
32.1.2 BUCKET ....................................................................................................32-4
32.1.3 ARM ...........................................................................................................32-6
32.1.4 BOOM ........................................................................................................32-8
32.1.5 SWING .......................................................................................................32-12
32.1.6 DOZER ......................................................................................................32-14
32.2 DISASSEMBLING AND ASSEMBLING .............................................................32-15
32.2.1 CYLINDER .................................................................................................32-15
32
32-1
32. ATTACHMENTS

CX31B : PW14- S5PW3232E01
CX31B : PW14-46519~ S5PW3232E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
32-2
32. ATTACHMENTS
32.1 REMOVING AND INSTALLING
32.1.1 ATTACHMENT ASSEMBLY AND NAME
(N) SWING CYLINDER HEAD PIN
(M) SWING CYLNDER ROD PIN
(L1) (UPPER)
(L2) (LOWER)
SWING CENTER PIN
(C) BOOM CYLINDER ROD PIN (A) BOOM FOOT PIN
(D) ARM CYLINDER HEAD PIN (B)

BOOM CYLINDER
HEAD PIN
(F) BOOM TOP PIN
(E)
ARM CYLINDER
ROD PIN
(I) (K)
IDLER LINK PIN BUCKET (Q) (P)DOZER PIN
ATTACHING PIN DOZER CYLINDER
HEAD PIN
(G) (H) (J)
BUCKET
(R)
DOZER CYLINDER
32
BUCKET CYLINDER BUCKET CYLINDER
HEAD PIN ROD PIN DRIVE PIN ROD PIN
Attachment name and position
32-3
32. ATTACHMENTS
32.1.2 BUCKET
32.1.2.1 REMOVAL OF BUCKET

(1) Operate the operating lever and place the bucket
on the ground, so the bucket and arm connecting
pins are not loaded.
(2) Move the O-rings (3) toward the bucket bosses
using a spatula.
(3) In order to remove pin (K) which links arm and
bucket, remove the ring (2) and the pin (3) by
means of straight driver, and draw out pin (K).
To place bucket on ground
• If the pin does not come off easily, the pin is loaded. Take off the load by manipulating the operating lever.
• Take care so the dust seal between the arm and the bucket bosses is not damaged.
(4) Adjust the bucket by manipulating the operating

3
lever so the pin (J) between the bucket link and the
bucket is not loaded.
J B
(5) Remove the ring (2) and pin (1) then pull out the pin
(J).
(6) Remove bucket assembly. 2
Weight : B
81kg (179 lbs) - CX31B
PIN FOR BUCKET
89kg (196 lbs) - CX36B LINK
DUST SEAL DUST SEAL
1 SECTION BB 3
K
B
PIN FOR ARM
Assembly of pin (SECTION A-A)
32-4
32. ATTACHMENTS
32.1.2.2 INSTALLATION OF BUCKET

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

that there are no cracks on the parts.
(2) Check that the dust seal is not damaged, and
replace a faulty one if necessary.
(3) Replace the worn pins and bushings according to
the Section "ATTACHMENT DIMENSIONS" of
"SPECIFICATIONS".
(4) When inserting the pin, coat the shaft with grease.
-The bucket can be mounted easily if the bucket
link is installed in the beginning.
Installation of bucket
32
32-5
32. ATTACHMENTS
32.1.3 ARM
32.1.3.1 REMOVAL OF ARM

(1) Making the arm cylinder and bucket cylinder to the
most retracting conditions, get touch the arm tip
with the ground.
(2) Shut off the engine and operate the arm control
lever several times at the same moment, and the
pressure in circuit is released.
Then put the safety lock lever in the "Locked"
position, and depress the air breather on the
hydraulic oil tank, release the pressure in the tank.
(3) Disconnect the 2 hoses connected to the bucket Arm removal
cylinder. Then apply plugs to the openings.
Tools : Spanner : 22mm
(4) Lift up the arm cylinder body with a nylon sling in

order not to exert any load to the pin (E).
E
(5) Remove the capscrew and nuts that are preventing
the pin (E) from coming out. Then remove the pin
(E) and shims.
(6) Placing a square timber under the arm cylinder, get
down the cylinder. F
(7) Install the pin (E) to the original position, and install
the capscrew and nuts that prevents the pin (E)
from coming out. Applying a rope to the pin (E) and
the arm tip, slightly lift it up in order not to exert any
load to the pin (F).
PIN (F) PORTION PIN (E) PORTION

Sectional view of installing pin
(8) Remove the capscrew that is preventing the pin (F)

connecting the arm and boom, from coming out.
Then pull off the pin (F). BUCKET CYLINDER
(9) Remove the arm assembly paying attention to the G
stability of arm. H
E
Weight of arm assembly : approximately
120kg (265 lbs) - CX31B
140kg (309 lbs) - CX36B
Removal of arm assembly
(10)Removal of Bucket Cylinder

1. Remove the capscrew that is preventing the rod pin SHIM SHIM
(H) from coming out, then pull off the pin (H).
Tools : Spanner : 24 mm
2. Remove the capscrew and nuts that are preventing
the head pin (G) from coming out, then pull off the
pin (G).
PIN (H) PORTION PIN (G) PORTION
3. Apply a nylon sling to the tube of bucket cylinder,
and remove the cylinder.
Weight ; approximately 20 kg (44 lbs)
32-6
32. ATTACHMENTS
32.1.3.2 INSTALLATION OF ARM

Installation is performed in the reverse order of removal, including the following workings.
-At the alignment of pin positions, never insert your finger into the pin holes.
-Make sure to align them with visual confirmation.
G
(1) Make the welded area clean to inspect H any cracks
there. BOSS E
(2) Check the dust seal for damages, and replace the
faulty dust seal to new one (referring to Fig. "Dust
seal installation" for the installing procedures).
(3) Referring to the Section "ATTACHMENT
DIMENSIONS" of Specifications, replace the worn- DUST SEAL
out pin and bushing to new ones. F
The sum of both cleamnces to be within
(4) Before installing the pin, apply grease to the shaft 0.1mm(0.004in) to 0.5mm(0.02in)
area. The sum of both clearances: SHIM The sum of both clearances:
The sum of both clearances : To be from 0.5mm(0.020in)to BUSHING
The sum of both clearances :
(5) Referring to Fig. "Sectional
less than 0.5mm(0.020in) view of Installing Pin", To be from 0.5mm(0.020in)to
0.9mm(0.035in) less than0.5mm(0.020in) 0.9mm(0.035in)
install
after the
shim capscrew
adjustment and nuts to afterprevent the pin
shim adjustment after shim adjustment after shim adjustment
SHIM SHIM Dust seal installation
SHIM SHIM
from coming out.
A
(6) Make sure to provide an appropriate clearance for
thrust direction at the installation of pin referring to
Fig. "Sectional view of Installing Pin".
(7) For the adjustment for clearance, insert resin
(plastic)
Clearance shim first,
of portion on "A" then
to be adjust the clearance with Apply Loctite #262
Apply Loctite #262
0.1~0.5mm (0.004~0.02in).
steel shims. equivalent equivalent
PIN (H) PORTION PIN (G) PORTION PIN (F) PORTION PIN (E) PORTION
32
32-7
32. ATTACHMENTS
32.1.4 BOOM
32.1.4.1 REMOVAL OF BOOM

(1) Get down the boom from which the arm was
D
removed, and support the boom end with a stable
stand.
(2) Disconnect all hoses from the bucket cylinder, arm
cylinder and boom cylinder, and apply plugs to all
the openings. A
C
(3) Disconnect the wiring for working light at the
B
connector.
Removal of boom cylinder
(4) Removal of Boom Cylinder

1. Temporarily lift up the boom cylinder with a nylon
sling to prevent the boom cylinder from falling
down.
2. Removing the capscrew and nuts that are
preventing the rod pin (C) from coming out, remove
the pin (C). PIN (C) PORTION PIN (B) PORTION
3. Retract the rod, then put the cylinder on a stable
stand.
4. Removing the capscrew that is preventing the head
pin (B) from coming out, remove the pin (B).
5. Remove the boom cylinder.
Weight :
35 kg (77 lbs) - CX31B
35 kg (77 lbs) - CX36B
(5) Removal of Boom assembly

1. Temporarily lift up the boom assembly in order not
to exert any load to the boom foot pin (A).
Weight of boom assembly : approximately
D
220 kg (375 lbs) - CX31B
190 kg (419 lbs) - CX36B
2. Removing the capscrew that is preventing the
boom foot pin (A) from coming out, pull off the pin A
(A).
3. Applying a sling to the boom assembly, remove the
boom assembly.
Removal of boom assembly
32-8
32. ATTACHMENTS
(6) Removal of Arm Cylinder

1. Removing the capscrew and nuts that are
preventing the head pin (D) from coming out,
remove the pin (D).
2. Applying a nylon sling to the tube of arm cylinder,
remove the arm cylinder. PIN (D) PORTION PIN (A) PORTION
Weight :
30 kg (66 lbs) - CX31B
34 kg (75 lbs) - CX36B
32
32-9
32. ATTACHMENTS
32.1.4.2 INSTALLATION OF BOOM

Installation is performed in the reverse order of removal, including the following.
-At the alignment of pin positions, never insert your finger into the bores.
-Make sure to align them with visual confirmation.
(1) Make clean the welded area on each of structure to

inspect any cracks there. BOSS
(2) Check the dust seal for damages, and replace the
faulty dust seal to new one (referring to Fig. "Dust
seal installation" for the installing procedures).
DUST SEAL
DIMENSIONS" of Specifications, replace the worn-
out pin and bush to new ones.
(4) Before inserting the pin, apply grease to the shaft
area.
BUSHING
(5) Referring to Fig. "Sectional view of Installing Pin",
install the capscrew and nuts to prevent the pin
Dust seal installation
from coming out.
(6) Make sure to provide an appropriate clearance for
thrust direction at the installation of pin referring to
Fig. "Sectional view of Installing Pin".
(7) For the adjustment for clearance, insert resin
(plastic) shim first, then adjust the clearance with
steel shims.
32-10
32. ATTACHMENTS
C
A
Apply grease when install
Apply Loctite
#262 equivalent
B
PIN (A) PORTION
The sum of both clearances:
To be from 0.5mm (0.020in) The sum of both clearances to be
from 0.1mm(0.004in) to 0.5 (0.02in) The sum of both clearances to be
to 0.9mm (0.035in) from 0.1mm (0.004in) to 0.5 (0.02in)
after shim adjustment after shim adjustment
after shim adjustment
SHIM SHIM SHIM
1.0~1.5 1.0~1.5
(0.04"~0.06") (0.04"~0.06")
Apply Loctite Apply Loctite Apply Loctite

#262 equivalent #262 equivalent #262 equivalent
PIN (C) PORTION PIN (B) PORTION PIN (D) PORTION
32
32-11
32. ATTACHMENTS
32.1.5 SWING
32.1.5.1 PREPARATION FOR REMOVAL

(1) To make the removing work easy, swing by around 30 degrees for leftward.
(2) Disconnect the hoses of bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all the openings.
32.1.5.2 Removal of Swing Bracket and Cylinder

(1) Removal of swing bracket (A9)
1. Removing the capscrew (C4) that is preventing the
rod side pin (M) of swing cylinder (C11) from C5
C11
coming out, remove the pin (M). N
Tools : Socket : 17mm
2. Install the boom foot pin (A) to the original position
M
on swing bracket (A9), then temporarily lift it up.
3. Removing two capscrews (B8) (B9) those are
preventing the pins (L1) (L2) from coming out,
C4
remove the pins (L1) (L2).
4. Remove the swing bracket (A9).
Weight of Swing Bracket : 93kg (205 lbs).
I
B8 Apply loctite #262 equivalent
(2) Removal of Swing Cylinder (C11)

1. Disconnect 2 connecting hoses for the
swing cylinder.
A
2. Removing the capscrew (C5) that is A9
preventing the head side pin (N) of swing
cylinder from coming out, remove the pin B9
(N).
3. Take out the swing cylinder (C11) from the front

A
side.
Weight of Swing Cylinder : 37kg (82 lbs)
A9
L1
B9
L2
VIEW I
Swing portion
32-12
32. ATTACHMENTS
32.1.5.3 INSTALLATION OF SWING BRACKET AND CYLINDER

Installation is performed in the reverse order of removal, including the following workings.
(1) Check the dust seal for damages, and replace the faulty dust seal to new one.
(2) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the worn-out pin and bushing
to new ones.
(3) Before inserting the pin, apply grease to the shaft area.
(4) Refer to Fig. "Sectional view of Pin Installing" for the shim adjustment at pin installing portion.
WASHER
(Thickness 2.3)
SHIM
To be from 0.5mm(0.020in)to SECTION C-C To be from 0.5mm(0.020in)to
The sum of both clearance : To be within 0.9mm(0.035in)
0.9mm(0.035in) after shim adjustment
after shim adjustment 0.1mm(0.004in) to 0.5mm(0.02in) after
shim adjustment
SHIM SHIM
Apply Loctite
Apply Loctite #262 equivalent
Apply Loctite
#262 equivalent #262 equivalent
SECTION A-A SECTION B-B VIEW I
Sectional view of pin installation
32
32-13
32. ATTACHMENTS
32.1.6 DOZER
32.1.6.1 REMOVAL
(1) Put a support of appropriate height under the
mounting side of dozer body, and make the dozer B2, B3 Q
at a stable condition not to exert any load to the pin C3, C4
C1
(P).
R
(2) Disconnect the hydraulic hoses and apply a plug to
the connecting portions.
(3) Apply a nylon sling to the dozer cylinder (C1), and
lift it up slightly not to exert any load to the pin (Q)
of rod side.
(4) Remove the capscrew (C3) and nuts (C4) that are P SUPPORT
preventing the pin (Q) from coming out, of rod side.
Removing/installing dozer
Remove the pin (Q), and support the cylinder (C1)
with a wood block, etc.
(5) Remove the capscrew (B2) and nuts (B3) that are
preventing the dozer body fixing pin (P) from
coming out, and remove the two pins (P).
(6) Gradually move the machine backward to remove
the dozer.
Weight of dozer assembly :
170 kg (375 lbs) - CX31B
180 kg (397 lbs) - CX36B
(7) If necessary, remove the dozer cylinder by means
of removing the pin (R) of head side.
Weight of dozer cylinder :
27 kg (60 lbs) - CX31B
27 kg (60 lbs) - CX36B
32.1.6.2 INSTALLATION
The installation is carried out with the reverse order of the removal paying attention for the following.

DIMENSIONS" of Specifications, replace the worn-
out bushings and dust seals to new ones.
(2) Before installing pin (P), (Q) and (R), apply grease
to their shaft area.
(3) Referring to Fig. "Tightening Procedures for Nuts",
install the nuts for capscrew to prevent the pin from
coming out.
Tightening procedures for nuts
32-14
32. ATTACHMENTS
32.2 DISASSEMBLING AND ASSEMBLING
32.2.1 CYLINDER
32.2.1.1 NECESSARY TOOLS

Though the required tools and jigs differ in types of cylinders, as a guide line, tools and jigs to be prepared are
shown in Table "List of Tools and Jigs".
List of Tools and Jigs
Tool/Jig Remarks Tool/Jig Remarks

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

• Carry out the disassembly and assembly works in a clean work shop, and always keep disassembled parts at
clean conditions.
• Prior to disassembly, thoroughly clean the cylinder externally.
• Use caution not to give any damages to the parts while carrying out the disassembly / assembly works.
• Thinly apply grease or hydraulic oil to seals prior to installation.
• After the installation of O-ring, confirm there is no twist on it.
• Apply clean hydraulic oil to each sliding portion before the installation.
• Ensure each sliding portion for no burr and defect, and its smooth sliding operation.
• This manual describes mainly for the boom cylinder as an typical example.
Refer to 24.1.8 of COMPONENT SYSTEM for the construction of hydraulic cylinders when disassembling and
reassembling the cylinders.
32
32-15
32. ATTACHMENTS
32.2.1.3 CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER)

• See 24.1.8 CYLINDER for the others.
Construction of boom cylinder

1 CYLINDER TUBE ASSY 1 10 O-RING 1 19 SETSCREW 1
2 PIN BUSHING 2 11 HOLDER 1 20 STEEL BALL 1
3 PISTON ROD ASSY 1 12 SPACER 1 21 CUSHION BEARING 1
4 CYLINDER HEAD 1 13 CUSHION SEAL 1 22 TUBE ASSY 1
5 BUSHING 1 14 COLLAR 1 23 CAPSCREW 1
6 U-RING 1 15 BACK-UP RING 1 24 LOCK WASHER 1
7 WIPER RING 1 16 PISTON 1 25 WASHER 1
8 O-RING 2 17 SEAL RING ASSY 1 26 DUST SEAL 4
9 BACK-UP RING 1 18 SLIDE RING 1 27 GREASE NIPPLE 2
32.2.1.4 DISASSEMBLY
• The numbers in ( ) following to each part name are the Items corresponding to those in Fig. "Construction of
boom cylinder" unless otherwise noted.
(1) Disassembly of cylinder assembly
1. Fix the clevis portion of tube with a vice, and hold
the other end with a wooden stand to hold the
cylinder in level.
2. Drain hydraulic oil remained in the cylinder.
-Slowly move the piston rod so that the hydraulic oil
does not spout out.
Disassembling cylinder assembly
32-16
32. ATTACHMENTS
3. Make straight the locking fin for the cylinder head

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

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

1. Fix the piston rod assembly in level.
2. Disassembly of the piston
a. Remove the setscrew (19), then remove the steel
ball (20).
-Since the setscrew (19) is caulked at two positions
with a punch, take off the caulked portion with a
hand drill.
b. Remove the piston (18) assembly.
c. Remove the cushion bearing (21)
(for boom cylinder only).
Disassembling piston rod
3. Disassembling of cushion bearing of retraction side (head side) (Only for arm cylinder)
32
21
16
19
20
Removing piston assembly
32-17
32. ATTACHMENTS
4. Remove cylinder head (4) and holder (11).

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

1. Remove the slide ring (18) from the piston (16). 18
-Expand the split on the slide ring (18) as minimum
as required to pull it off for axial direction. (2 Points)
2. Remove the seal ring assembly (17).
-Cut off the seal ring (17) or remove it using a
minus screw driver.
17
Disassembling piston assembly
(4) Disassembly of cylinder head assembly :

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

a. Remove collar (14).
b. Remove cushion seal (13).
c. Remove spacer (12).
d. Remove O-ring (8) and back-up ring (15)
of outer diameter.
Disassembling holder
32-18
32. ATTACHMENTS
3. Removal of U-ring
Remove the U-ring (6).
Disassembling cylinder head
4. Remove the wiper ring (7).

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

1. Remove the dust seal (26) from the clevis portion of
tube (1) and piston rod (3). 3
32
26
Removing dust seal
32-19
32. ATTACHMENTS
2. Remove the pin bushing (2).

-Using a metal block, push it out with a press
machine.
Removing pin bushing
32.2.1.5 ASSEMBLY
(1) Assembling Clevis Portion
1. With the installing jig (B) shown Item 32.2.1.7,
press the bushings (2) into the piston rod (3) and
tube (1).
-Prior to the work, apply hydraulic oil on the surface
B
of parts.
2
Installing pin bushing (2)
2. With the setting tool, install the dust seal (26).
Installing dust seal
32-20
32. ATTACHMENTS
(2) Assembling Cylinder Head

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

a. Install spacer (12).
b. Install cushion seal (13).
c. Install collar (14).
d. Install back-up ring (16) and O-ring (8).
Installing holder
32
32-21
32. ATTACHMENTS
4. Using the setting tool, install the wiper ring (7).
Installing wiper ring
5. Install the back-up ring (9) and O-rings (8) and (10).
Installing back-up ring and O-ring
(3) Assembly of piston portion :

1. Install the O-ring for the seal ring assembly (17). O-RING
Assembling piston assembly
2. Set the sliding jig (C) on the piston (16), then 17

quickly push the seal ring (17) with the pushing jig 16
(D).
D C
Assembling piston assembly
32-22
32. ATTACHMENTS
3. Since the seal ring (17) is extremely stretched at O-RING

the installation, reform it with the reforming jig (E) 17
shown Item 1-7.
Reforming seal ring
4. Install the slide ring (18). 18

-Expand the split on the slide ring (18) as minimum
as required to install it toward the axial direction. (2
points)
17
Installing slide ring
(4) Installation of piston rod assembly :

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

a. Install the cushion bearing (21) (for boom cylinder
only) and piston (16) on the piston rod (3), and
tighten them up.
-Tightening torque for piston : See Section 21
32.2.1.6(1).
b. Put the steel ball (20) into the threaded bore, and
32
16
securely tighten it with the setscrew (19). And caulk 19
the setscrew with a punch at two points. 20
-Tightening torque for setscrew :
See Section 32.2.1.6(1).
Installing piston assembly
32-23
32. ATTACHMENTS
(5) Assembly of cylinder :

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

-Apply hydraulic oil on the packings (seals) prior to
install.
-Tightening torque for cylinder head :
See Section 32.2.1.6(1).
Installing cylinder head
3. Bend the locking fin on the tube to lock the cylinder

head.
Assembling cylinder assembly
32-24
32. ATTACHMENTS
32.2.1.6 MAINTENANCE STANDARDS

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

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

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

2 Seals and slide rings Replace them when cylinder is disassembled.
3 Pin bushing Where severe scuffing is appeared.
4 Piston rod Where the bent 0.5 mm/m (0.02 in/3.3 ft) or more is appeared.
32
32-25
32. ATTACHMENTS
(3) Service limits

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

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

V-blocks of the dial gauge Remedy
m (ft) mm (in)
1 (3.3) 1 (0.04) Replace

2 (6.6) 2 (0.08) Replace
V-BLOCK 0 1/2 0
Measuring method
(4) Tightening torque
A : CYLINDER HEAD
B : PISTON ASSY
C : SETSCREW
Unit : N-m (lbf-ft)
Model Cylinder Cylinder head A Piston B Setscrew C

Boom 450 (332) 1150 (848)
Arm 422 (311) 1090 (804)
16.2 (12)
CX31B Bucket 343 (253) 550 (406)
Swing 450 (332) 1240 (915)
Dozer 647 (477) 1590 (1173) 31.4 (23)
Boom 450 (332) 1150 (848)
Arm 450 (332) 1350 (996)
16.2 (12)
CX36B Bucket 343 (253) 550 (406)
Swing 450 (332) 1240 (915)
Dozer 647 (477) 1590 (1173) 31.4 (23)
32-26
32. ATTACHMENTS
(5) Inspection after installation

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

2. Repeat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine.
-Move the piston rod 100 mm (4 in) short of its stroke end.
Do not extend or retract the rod until the end to prevent the relief condition.
3. Perform the above 2) procedures at high idling speed, then move the piston rod to its stroke end at low idling
speed to reach the relief condition.
32
32-27
32. ATTACHMENTS
32.2.1.7 JIG LIST

(1) Installing Jig (A) for Press Fitting of Head Bushing.
Unit : mm (in)
C D E Applicable Cylinder
Dimension
CX31B CX36B
(Rod dia ; 40 (1.58)) A 43.0 (1.69)
B 39.5 (1.56)
0.008)
0.008)
)
-0.1 -0.004
Bucket C 25.0 (0.98)

A
D 40.0 (1.57)
(
0.2 (
0.2 (
E 30.0 (1.18)
0
F 50.0 (1.97)
(Rod dia ; 45 (1.77)) A 49.0 (1.93)
Material : SS410 or mild steel

B 44.5 (1.75)
Boom
C 25.0 (0.98)
Arm
D 40.0 (1.57)
Swing
E 30.0 (1.18)
F 50.0 (1.97)
A 53.0 (2.09)
(Rod dia ; 50 (1.97))
B 49.5 (1.95)
C 25.0 (0.98)
Dozer
D 50.0 (1.97)
E 30.0 (1.18)
F 60.0 (2.36)
(2) Installing Jig (B) for Press Fitting of Pin Bushing.
Unit : mm (in)
0 0
(
-0.25 -0.01 ) Applicable Cylinder
Dimension
C D E CX31B CX36B
(Pin dia ; 40 (1.58)) A 49.0 (1.93)
B 39.5 (1.56)
Bucket C 10.0 (0.39)
D 5.0 (0.20)
A
E 30.0 (1.18)
F 60.0 (2.36)
(Pin dia ; 45 (1.77)) A 54.0 (2.13)
B 44.5 (1.75)
Boom
C 10.0 (0.39)
Arm
Material : SS410 or mild steel D 5.0 (0.20)
Swing
E 30.0 (0.18)
Dozer
F 65.0 (2.56)
32-28
32. ATTACHMENTS
(3) Sliding Jig (C) for Seal Ring
Unit : mm (in)
30 (1.18) A+0.5(+0.02) Applicable Cylinder
Dimension
CX31B CX36B
(Tube dia ; 65 (2.56)) A 9.5 (0.37)
8
+0.1 (+0.004 )
0.05 ( 0.002)
+0.008
B 65.5 (2.59)
Bucket C 63.3 (2.49)
C +0.2
D
E
D 45.0 (1.77)
E 25.0 (0.98)
R (Tube dia ; 75 (2.95)) A 9.5 (0.37)
15˚
)
.2
(0 B 75.5 (2.97)
5
R
50 (1.97)
2 (0.08) Arm C 73.3 (2.89)
80 (3.15) D 55.0 (21.7)
E 35.0 (1.38)
(Tube dia ; 80 (3.15)) A 9.5 (0.37)
B 80.5 (3.17)
Material : SS410 or mild steel Boom Boom
C 78.3 (3.08)
Swing Arm
D 60.0 (2.36)
Swing
E 40.0 (1.57)
(Tube dia ; 100 (3.94)) A 12.0 (0.47)
B 100.5 (3.97)
Dozer C 98.3 (3.87)
D 80.0 (3.15)
E 50.0 (1.97)
(4) Pushing Jig (D) for Seal Ring (18)
Unit : mm (in)
2 (0.08)
Applicable Cylinder
Dimension
CX31B CX36B
C (Tube dia ; 65 (2.56)) A 70.0 (2.76)
B
Bucket B 68.0 (2.68)

C 60.0 (2.36)
5 (0.20) (Tube dia ; 75 (2.95)) A 80.0 (3.15)
45 (1.77) B 78.0 (3.07)
Arm
C 70.0 (2.76)
83 (3.27) A 85.0 (3.35)
(Tube dia ; 80 (3.15))
Boom Boom B 83.0 (3.27)
Arm
Swing Swing C 75.0 (2.95)
Material : Nylon
(Tube dia ; 100 (3.94)) A 75.0 (2.95)
B 73.0 (2.87)
Dozer
C 65.0 (2.56)
32
32-29
32. ATTACHMENTS
(5) Reforming Jig (E) for Seal Ring (18)
Unit : mm (in)
20 (0.79) Applicable Cylinder
Dimension
CX31B CX36B
(Tube dia ; 65 (2.56)) A 80.0 (3.15)
R3
R3 2)
)
(R 0.12) Bucket
+0.004
0.1 B 65.0 (2.56)
(R
15
0 ( 0
A
(Tube dia ; 75 (2.95))
B +0.1
A 90.0 (3.54)
Arm B 75.0 (2.95)
(Tube dia ; 80 (3.15)) A 95.0 (3.74)

C Boom Boom
50 (1.97) Arm B 80.0 (3.15)
Swing Swing
Material : STKM13C or carbon steel tube
(Tube dia ; 100 (3.94)) A 115 (4.53)
Dozer B 100 (3.94)
32.2.1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY
Trouble Conditions Major Possible Causes Remedy

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

periphery of cylinder head. Damages on back-up ring. Replace.
Oil leakage from welded
Damages on welded portion on tube. Replace.
portion.
Piston movement due to Foreign matter is caught by sliding face
Remove foreign matter.
leakage. of slide ring.
(For the case when static load
Scuffing or faulty condition on sliding
that is equivalent to product of Replace.
face of slide ring.
multiplication of max. working
pressure and cylinder area, is Scuffing on sliding face of seal ring
Replace.
applied to rod, max. movement assembly.
of piston is larger than 0.5mm
(0.02 in)) per 10 minutes. Damages on O-ring. Replace.
32-30
33. UPPER SLEWING STRUCTURE
33

TABLE OF CONTENTS

33.1.1 CANOPY / CAB .........................................................................................33-3
33.1.2 GUARD (COVER) ......................................................................................33-6
33.1.3 FLOOR PLATE ASSEMBLY ......................................................................33-8
33.1.4 BATTERY ...................................................................................................33-11
33.1.5 COUNTERWEIGHT ...................................................................................33-12
33.1.6 PUMP .........................................................................................................33-13
33.1.7 CONTROL VALVE .....................................................................................33-15
33.1.8 SOLENOID VALVE ....................................................................................33-19
33.1.9 MULTI-CONTROL VALVE ..........................................................................33-20
33.1.10 FUEL TANK ...............................................................................................33-21
33.1.11 HYDRAULIC OIL TANK .............................................................................33-23
33.1.12 AIR CLEANER ...........................................................................................33-27
33.1.13 GENERATOR ............................................................................................33-28
33.1.14 MUFFLER ..................................................................................................33-29
33.1.15 CONTROL STAND ....................................................................................33-30
33.1.16 STARTER ..................................................................................................33-35
33.1.17 RADIATOR .................................................................................................33-36
33.1.18 ENGINE .....................................................................................................33-38
33.1.19 PILOT VALVE ............................................................................................33-40
33.1.20 SLEWING MOTOR ....................................................................................33-42
33.1.21 SWIVEL JOINT ..........................................................................................33-44
33.1.22 UPPER FRAME .........................................................................................33-47
33.2.1 HYDRAULIC PUMP ...................................................................................33-49
33.2.2 CONTROL VALVE .....................................................................................33-74
33.2.3 PILOT VALVE (Attachment) .......................................................................33-93
33.2.4 PILOT VALVE (TRAVEL) ...........................................................................33-105
33.2.5 SLEWING MOTOR ....................................................................................33-110
33.2.6 SWIVEL JOINT ..........................................................................................33-132
33-1

CX31B : PW14- S5PW3332E01
CX31B : PW14-46519~ S5PW3332E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
33-2
33.1.1 CANOPY / CAB 33
33.1.1.1 CANOPY REMOVAL

(1) Remove the floor mats (5) and (8).
(2) Removing handrail (A3) 8 5
Loosen the sems-bolt M10X40 (A8) and M16X100
(A5) to remove the handrail (A3).
Tools: Socket: 17 mm and 24 mm
Floor mat removal
(3) Removing canopy assembly

1. Disconnect the light harness (B1) that runs inside
the support (A1) and is connected to the main
harness with a connector.
2. Loosen one capscrew M16X65 (A4) and eight
capscrews M12X55 (A7) to remove the canopy.
B1
Canopy weight: 85 kg (187 lbs) B2
(4) Install the canopy in reverse order of the removal.
A1
Tighten the capscrews at the torque specified
below: HARNESS
M10: T=46N-m (34 lbf-ft) A3 A2 OUTLET
M12: T=79 N-m (59 lbf-ft) A8 A7
A4
M16: T=191 N-m (141 lbf-ft)
A5
Removal of canopy assembly and handrail
33.1.1.2 CAB REMOVAL (Option)

33.1.1.2.1 Cab removal preparation
(2) Removing cab harness connector
1. Respectively disconnect 6P connectors of cab
harness and cab connecting harness, 2P connector
of washer motor, 3P connector of radio (optional)
and so on. (See ELECTRICAL SYSTEM)
Floor mat removal
33-3
33.1.1.2.2 Cab r
(1) Remove the fuel filler cap (A2) and rubber cover
(20).
(2) Removing cover installed on rear of cab
Loosen three sems-bolt M6X25 (12) for installing
the cover (13).
Tools: Plus screwdriver
(3) Removing cab mounting screws
Loosen six capscrews for mounting the cab.
Two capscrews (1) M16X100
One capscrew (2) M16X50 B
Two capscrews (3) M12X50
One capscrew (24) M12X40
- An extension tool about 1 m (3'3.4") long is
required for removing the capscrew item 1 (with
mark *).
13 12
A2
20
3
12
VIEW B
Outside of cab
(4) Lifting cab

1. Loosen the sems-bolt M10X20 (C6) to remove the
seat belt assembly (C2) in advance to prevent it from
interfering with the cab during lifting.
Tools: Spanner: 17 mm
2. Put slings through the lifting eyes on the cab top and
lift up.
Cab weight: 220 kg (485 lbs)
Cab assembly fastening positions
(5) Installing cab

Install the cab in reverse order of the removal.
-In the fastening position of the capscrew (24), it is
necessary to adjust the clearance with shims as
shown in Fig. "Cab assembly fastening positions".
Tighten screws to the torque specified below.
A
M6: T=4.4 N-m (3.3 lbf-ft)
M10: T=46 N-m (34 lbf-ft)
M12: T=79 N-m (59 lbf-ft)
M16: T=191 N-m (141 lbf-ft)
C2
C6
Seat belt assembly removal
33-4
33.1.1.2.3 CAB DOOR ADJUSTMENT

(1) When the door is opened and the door is fixed in the place, proper rebound of the rubber stopper in three places
shown in right figure is needed. 33
For this rebound adjust the pushing depth of rubber from 0.6 to 1 mm (0.02 to 0.04 in) (In terms of screw
rotation, the depth is equivalent from half turn to three-fourths turn).
-After this adjustment, the force for door release becomes about 98 to 118 N (22 to 27 lb).
-Tightening torque of rubber stopper lock nut: 35 to 42 N-m (26 to 31 lbf-ft).
RUBBER STOPPER 3 PLACES
pushing
depth
SECTION C-C
33-5
33.1.2 GUARD (COVER)
33.1.2.1 REMOVAL
• The right figure shows the method for removing the 1
cover of the canopy.
5
C
D
E
A
G B
3
2
Cover removal
(1) Removing bonnet assembly (2)

Unlock and open the bonnet assembly (2). Loosen
two capscrews M12X30 (37) of the hinge section 37
(2-8) to remove the bonnet (2). 2-8

Tools: Socket: 19 mm
Bonnet assembly (2) removal
(2) Removing cover assembly (3) 21

Loosen two M8X20 sems-bolts (21) and one 45
M8X25 sems-bolt to remove the cover assembly
(3).
3
21
Cover assembly (3) removal
33-6
(3) Removing cover assembly (4) 4 19

Loosen three M10X30 sems-bolts (19) to remove 19
19
the cover assembly (4). 33
Tools: Socket: 17mm 19
(4) Removing cover assembly (5) 5
19
Loosen four M10X30 sems-bolts (19) to remove the
cover assembly (5).
Tools: Socket: 17mm
19
19
Cover assemblies (4) and (5) removal
(5) Removing cover assembly (1) 1-8

1. Unlock the cover (1-8) to open the cover 1
assembly (1).
2. Loosen two M12 nuts (31) to remove the cover
assembly (1).
31
33.1.2.2 Installation
Install the above assemblies in reverse order of the removal.
Tighten the capscrews to the torque specified below:
M8: T=24 N-m (18 lbf-ft)
M10: T=46 N-m (34 lbf-ft) (Exclude item 19 with * mark)
M12: T=79 N-m (59 lbf-ft)
M16: T=191 N-m (141 lbf-ft)
ltem 19 with * mark: T = 19.6 to 24.5 N-m (15 to 18 lbf-ft)
33-7
33.1.3 FLOOR PLATE ASSEMBLY

Remove floor plate together with the travel pilot valve assembly and the swing pedal in one piece.
33.1.3.1 FLOOR PLATE REMOVAL PREPARATION

(1) Remove the floor mats (5) and (8). (See Section
33.1.1.) 8 5
(2) Remove the canopy or cab. (See Section 33.1.1.)
(3) Remove the covers (2) and (4) as well as the plates 4
(3).
2
(4) Remove the cover assembly (5) of the deck under
the floor [See Section 33.1.2.1-(4)].
(5) Disconnect electrical wiring for travel 2-speed
1
selector switch from the connector portion.
If this machine was equipped with the travel alarm, 3
The figure is for the standard canopy.
disconnect the connectors of electric wirings of four
pressure switches on travel pilot valve.
In advance, disconnect the negative terminal of the battery to prevent danger of short circuit, etc.
(6) Removing travel pilot piping (prior to this work, release the pressure in the piping)
Disconnect hoses of the travel pilot valve (A10) at the valve side position marked with * and then plug their
openings.
-Attach a tag recording the valve connecting port to each of the disconnected hoses. For installation, tighten the
hose fittings at the following torque:
Tightening torque N m (lbf ft)

Thread Spanner O-ring type flare type T
size used
(PF) (mm) fitting fitting
1/4 19 26.5 (20) 29.4 (22) TANK
A10
P
1
A2 2
S/V
3
4 Pb6
Pa6
C/V
C/V
Pb7
C/V Pa7
C/V
Pilot piping disconnection
Be careful not to over-tighten as the pilot valve is made of aluminum.
33-8
(7) Removing cable of swing pedal

1. Loosen four M8X20 sems-bolts (B11) to pull out B11
the support (B1) upward. B4
33
Tools: Spanner: 13 mm B1
2. Pull out the pin (B6) and loosen the adjusting nut
to disconnect the control cable (B4). NUT
123
B6
Swing cable disconnection
(3) Removing N&B solenoid piping (prior to this work, release the pressure in the piping)
Disconnect hoses of the N&B solenoid valve (B5) at the valve side position marked with * and then plug their
openings.
-Attach a tag recording the valve connecting port to each of the disconnected hoses. For installation, tighten the
hose fittings to the following torque:
B5
Thread Spanner P
O-ring type flare type
size used
1/4 19 36.3 (26.8) 29.4 (22)
S/V T
T S/V
P A
B
C/V
Pa4
Pb4 C/V
Pilot piping removal
Be careful not to over-tighten as the pilot valve is made of aluminum.
33-9
33.1.3.2 FLOOR PLATE REMOVAL

(1) Remove the M8X20 sems-bolt (6).
6
(2) Remove the floor plate assembly (1).
The figure is for the standard.

Floor plate (1) removal
33.1.3.3 ASSEMBLING FLOOR PLATE

(1) Assemble the floor plate in reverse order of the disassembly.
Sems-bolt (6) M8:
Tightening torque: 23.5 N-m (17 lbf-ft)
33-10
33.1.4 BATTERY
33.1.4.1 REMOVAL PREPARATION 33

(2) Remove the cover (4).
8 5
(3) Remove the cover assembly (5) of the lower left
side [See Section 33.1.2.1-(4)].
4
Floor section removal preparation
33.1.4.2 REMOVAL
(1) Disconnect the negative side terminal of the cable. 7
7 2 6
(2) Then, disconnect the positive side terminal of the
4
cable.
5
Battery removal
Follow the removal procedure of battery cable. Firstly disconnect the grounding side cable. Connect the grounding
side last. Failure to do so may result in dangerous situation due to spark.
(3) Loosen the M8 nut (7) to remove the plate (5) and the rod (4).
(4) Take out the battery (1) holding the straps attached to it.
Install the battery in reverse order of the removal.
Nut (7) M8:
Tightening torque: 3.5 N-m (2.6 lbf-ft)
33-11
33.1.5 COUNTERWEIGHT
33.1.5.1 REMOVAL PREPARATION

(1) Remove the cover assemblies (1), (3), (4) and (5) SCREW(A)
as well as the bonnet assembly (2) (See Section
33.1.2). SLING A
(2) Lifting tools preparation
-Lifting jigs for counterweight (see Tool list)
-Two M20X35 screws (A) Lifting jig
-Wire rope (Nylon sling) for counterweight
33.1.5.2 REMOVAL
(1) Remove the plate (9) and attach the lifting jigs for
counterweight. 9
(2) Put a rope through the lifting lugs and temporarily
9
lift up the counterweight so that the rope is not
slack. 1
Counterweight weight:
370 kg (820 lbs) for CX31B
665 kg (1,470 lbs) for CX36B
(3) Loosen one M20X90 capscrew (2) and two
M20X65 capscrews (3). 5
6 5 5
Tools: Socket: 30 mm 7 6 6
(4) Remove the shims (5), (6) and (7). 7 7
(5) Remove counterweight (1).
4
3
4
3 2
Counterweight removal
(1) Install the counterweight in reverse order of the
removal.
(2) Reinstall the shims (5), (6), and (7).
(3) Lifting counterweight
Make sure that all the three fixing bolts can be
manually screwed.
(4) Apply Loctite #262 on the capscrews (2) and (3)
and tighten them together with the washer (4).
Tightening torque : 373 N-m (275 lbf-ft)
(5) Remove lifting jigs.
Counterweight installation
33-12
33.1.6 PUMP

(1) Remove the cover assembly (3) and (5) (See
Section 33.1.2).
*
(2) Remove the counterweight (See Section 33.1.5).
*!&
(3) Depressurize the hydraulic oil tank and drain the
hydraulic oil (See Section 33.1.12). *!'
-Spread a vinyl sheet under the pump to prevent
contamination due to oil leakage.
(4) Loosen clip (B38) to remove the filler neck (B1) of
the fuel supply port to improve workability.
Two sems-bolts M8X20 (B39)
Tightening torque : 23.5 N-m (17 lbf-ft) Filler neck removal
33.1.6.2 REMOVAL
(1) Disconnecting hoses and fittings connected to the
S/V
pump P1
-Attach a tag to each hose for identification. Z

B23 A4
1. Loosen four M12X35 capscrews (19) to remove 10 C/V
8 C/V P2
the tube (14). P1
Tools: Allen wrench: 10 mm

2. Remove the pilot delivery hose (B23). 9 C/V
P3
3. Remove the main pump delivery hoses (8), (9) A1
and (10). A3
A2
25
Tools: Spanner: 27 mm 12
(2) Loosen two M12X30 capscrews (C4) to remove the
pump (C8).
Tools: Allen wrench: Ball joint type 10 mm
Pump weight: 28 kg (62 lbs) C8 C4
25 14
19
Pump removal
33-13
Install the pump in reverse order of the removal according to the tightening torque and sealant instructions.
(1) Apply grease to the spline part of the pump input shaft.
Grease : Shell Retinax AM Grease or equivalent (Molybdenum disulfide extreme pressure multipurpose grease)
(2) Insert the pump spline part to the coupling.
(3) Fix the pump by the capscrew (C4).
Tools: Allen wrench: Ball joint type 10 mm
(4) Install the main pump delivery hoses (8), (9), and (10), and the pilot delivery hose (B23) (See Fig. "Pump
rermoval").

Thread Spanner O-ring type flare type
size used
3/8 22 73.5 (54) 49.0 (36)
1/2 27 108 (80) 78.5 (58)
Pump installation
(5) Tighten the capscrew (19) to install the suction tube (14).
(6) When the suction hose (12) is removed, apply sealant on the inserted portion of the hose and fix the tube with
the clip (25).
Tools: slotted screwdriver
T=5.4 N-m (4.0 lbf-ft)
(7) Supply the tank with hydraulic oil [approximately 38 liters (10 gal)].
(8) Loosen the air bleed valve of the pump to release air from the casing, and fill it with hydraulic oil (See Fig.
"Pump installation").
(9) Reinstall each component removed in the above removal preparation.
(10)After starting the engine, release air (See Section 33.1.11.3).
33-14

(1) Unlock and open the right upper cover (1).
(2) Remove the right lower cover (4) [See Section 33.1.2.1-(3)].
-Spread a vinyl sheet under the control valve to prevent contamination due to oil leakage.
(3) Release the residual pressure in the circuit and the pressure in the hydraulic oil tank.
33.1.7.2 REMOVAL
(1) Disconnecting hoses
Disconnect all the hoses connecting to the control valve, and attach blind plugs and tags recording the
installation place.
-Remove the return hose to the hydraulic oil tank to improve workability.
A8 A5 A15
H/P : Hydraulic pump
A12
S/J : Swivel joint B10 B7 C
BUCKET S/J
S/M : Slewing motor B9
(H) BOOM
A14
(R)
BOOM
(H) SEL/V
B8
A6 B8
B6 B5 D
S/J
SW/CYL A17
(R)
A10 BUCKET A7
(R) B4 B3
ARM
A10 (R)
B2 B1 A7
B A10
S/M A2
E A
S/J A1
S/M
F
S/J
A18
A7 A3
A10 ARM
A15 (H)
8
A4
A B7
A9
A1 S/J A6 A5 N&B 23
B (R)
H/P T2
S/J
SW/CYL COOLER OIL
(H) (UPPER)
24 M
HYDRAULIC TANK
10 S/M
P1 21
P2 Dr1
A2
T1
P3 H/P
9
A3
H/P
Main hydraulic hose disconnection
33-15
S/V E6
P/V D4 C9 B2
F11
4 2
1 P/V(N&B) S/V
A1
P/V P/V D5
D1 8
Pb8 Pb7 Pb5 D8
Pb10 Pb6
Pb4
Pb3 Pb2
Pp1
C5
P/V D2 Pa10
2 Pb1
Pb8'
C9
Pa8
P/V
3
Pa7
D3 Pa6
Pa5 Pa4
P/V S/V
Pa3 Pa1
P/V : Pilot valve 7 Pa2 A2
C/B : Control block B1 D7
S/V D6
SHUT/V : Shuttle valve
S/V : Solenoid valve F10
E7 1
P/V(N&B)
P/V P/V
3 1
A7 A14
SHUT/V
SLEW/SWING B
S/V B28
Pb7 Pb6 A1 S/M B27
PG
B27
F12 Pb2
Pp1
Pb1
P/V
4
2 9
A8 Pa7 P/V
Pa6
P/V
2 Pa1
Pa2
A15 Pa3
SHUT/V
SHUT/V A 1
C P/V 8
B26 B39
A2
SLEW/SWING
S/V
F13
Pilot hydraulic hose disconnection
33-16
(2) Disconnecting cable CONTROL VALVE

Turn the rod end (B14) to disconnect the control
valve from the swing cable (B4). 33
B14
B4
Cable disconnection
(3) Removing control valve

1. Loosen four M10X50 capscrews (2) to remove the 10 A
control valve (10) with the bracket (1).
1
4
Weight of removed parts : Approximately 33 kg (73
lbs)
2. Loosen three M10X25 capscrews (4) to remove the
control valve (10).
2
Tools: Socket: 17 mm 6 35
Weight: Approximately 25 kg (55 lbs) 8 97
Control valve removal
(1) Install the control valve in reverse order of the removal.
(2) Attach the capscrews (4).
Tightening torque : 65.7 N-m (48 lbf-ft)
Clean the mounting surface and take care to prevent deformation of the valve.
33-17
(3) Attach the capscrew (2).

(4) Tighten the hose fittings to the following torque :

2
size used
1/4 19 36.3 (26) 29.4 (22)
1
3/8 22 73.5 (54) 49 (36)
1/2 27 108 (80) 78.5 (58)
3/4 36 162 (119) 118 (87)
1 41 255 (188)
10
Dozer
Slewing
Supply and
Travel straight Bucket
Arm Boom lock
Service (N&B) Boom
Travel (left) VIEW A
Swing Supply
Travel (right)
Control valve
(5) Operate the attachment to check the performance.

(6) Check the tank and piping for oil leakage and oil level.
33-18
33.1.8 SOLENOID VALVE

(2) Remove the right lower cover (4) [See Section 33.1.2.1-(3)].
33.1.8.2 REMOVAL
Disconnect all the hoses connected to the solenoid
valve (B1). Then attach a plug and a tag recording
the connecting port to each of their openings.
-Item (B32) is a drain hose for the hydraulic oil tank.
When disconnecting this hose, take care of oil
leakage.
(2) Disconnecting connector
Disconnect two connectors connected to the main
harness.
(3) Removing solenoid valve
Loosen two M8X20 capscrews (B5) to remove the
solenoid valve (B1).
Solenoid valve removal
(1) Install the solenoid valve in reverse order of the removal.
Tighten the fittings at the following torque:
Tool Torque Tightening torque N m (lbf ft)

Item Name
(mm) N m (lbf ft) Thread Spanner O-ring type flare type
size used
B5 Capscrew (M8) 13 33.3 (25) (PF) (mm) fitting fitting
B33 Clip 2.94 (2.2) 1/4 19 36.3 (27) 29.4 (22)
B34 Capscrew (M10) 17 65.7 (48) 3/8 22 73.5 (54) 49 (36)
33-19
33.1.9 MULTI-CONTROL VALVE

(2) Remove the right lower cover (4). [See Section 33.1.2.1-(3)]
(3) Release the residual pressure in the piping and hydraulic oil tank.
33.1.9.2 REMOVAL
Disconnect all the hoses connected to the multi-control valve. Then attach plugs and tags recording the
connecting ports to each of their openings.
Hose removal
(2) Removing multi-control valve

Loosen four M8X16 capscrews (2) to remove multi-
control valve (1).
1
Hydraulic
tank
Multi-control valve removal
(1) Install the multi-control valve in reverse order of the removal.
Tighten the fittings at the following torque :

Item Name
size used
2 Capscrew (M8) 13 33.3 (3.4) (PF) (mm) fitting fitting
1/8 14/19 16.7 (1.7) 29.4 (3.0)
33-20
33.1.10 FUEL TANK
33.1.10.1 DISASSEMBLY PREPARATION 33

(1) Remove the floor mats (5) and (8), the floor covers
(2) and (4), and the floor plate (1)
(See Section 33.1.3.1).
(2) Remove the cover assembly (5) on the left lower
side
[See Section 33.1.2.1-(4)].
(3) Remove the battery
(4) Remove the stopper plate (6) of the battery (1)
(See Fig. "Battery removal").
Two M10X20 capscrews (2)
Tightening torque : 52 N-m (38lbf-ft)
Fuel drain
33-21
(1) Open the fuel filler cap (B2) and loosen the drain plug (B11) to drain fuel.
Tank capacity : 38 liters (10 gal)
(2) Disconnect the hoses (2) and (3) for the fuel inlet and outlet, the hose (B4) for the fuel supply port, and two air
bleed hoses.
(3) Loosen the M10X20 sems-bolt (B10) to remove the boss (B12) together with the drain hose (B13).
(4) Disconnect connector (A13) for the level sensor.
(5) Remove two M10X20 sems-bolts (B8).
(6) Remove the fuel tank (A1) together with the bracket assembly (B15).
AIR BLEED HOSE Disconnect A13 A1

air bleed hose at this point
A1
3
B11
B10
B15
B12
B2
B13
B38
B8
B4
Fuel tank removal
Assemble the fuel tank in reverse order of the removal
and tighten the screws to the specified torque shown in Tool Torque
Item Name
the following table: (mm) N m (lbf ft)
B8 Capscrew (M10) 17 46.1 (34)
B10 Sems-bolt (M10) 17 34 (25)
0.49 0.78
B38 Clip
(0.36 0.58)
33-22
33.1.11 HYDRAULIC OIL TANK

(1) Swing approximately 90 degrees to the right to
facilitate to remove the tank.
(3) Remove the right lower cover (4) [See Section
33.1.2.1-(3)].
(4) Remove the floor cover (2) (See Section 33.1.3.1).
(5) Remove the inspection cover (1-5) of the control
stand.
Six M8X20 sems-bolts (1-8)
Cover removal
(6) After releasing internal pressure of the hydraulic oil

tank, remove the plug (B14) below the solenoid
valve to drain hydraulic oil.
Tank capacity : 38 liters (10 gal)
-Spread a vinyl sheet under the solenoid valve to
prevent contamination around the valve due to oil
leakage.
-Releasing tank pressure
Press the cap boot of breather assembly (A15) with
a finger to release the internal pressure (See Fig.
"Suction hose removal").
Draining hydraulic oil
Press and hold the boot until air-relieving sound stops.
(7) Remove the control valve (See Section 33.1.7.2).

(8) Remove the solenoid valve (See Section 33.1.8.2).
(9) In addition, remove the harness and hose clamped on the tank.
-Remove the multi-control valve (option) if it is equipped.
33-23
(1) Disconnecting suction hose
1. Remove the guide (30). CAP BOOT
2. Remove the clip (25).
3. Remove the hose (11).
25 30
11
Suction hose removal
(4) Removing return oil hose and drain oil hose

Disconnect each hose from the position marked
D13 D13
with *.
Tools: Spanner: 19, 22, and 36 mm
Tools: slotted screwdriver T T M
P/V P/V S/M
17
17
16
Dr1 S/M
C/V DB
P/V
S/V T
T
A13
B33
A13
T
P/V
SELECTOR
VALVE
(N&B Spec.)
Return oil hose removal
33-24
(5) Removing hydraulic oil tank

Loosen four M12X30 sems-bolts (B1) to remove
the hydraulic oil tank (A1). 33
Tools: Socket: 19 mm A11
Weight : about 42 kg (93 lbs) A1
B1
B1
Hydraulic oil tank removal
33.1.11.3 ASSEMBLY
(1) Clean hydraulic oil tank, hose, and components.
(2) Install the tank in reverse order of the disassembly.
The specified tightening torque is shown in the following table:
-Apply Loctite #262 to B1.

Item Name
size used
B1 Capscrew (M12) 19 79.4 (59) (PF) (mm) fitting fitting
B14 Plug (PF 3/8) 22 73.5 (54) 1/4 19 36.3 (27) 29.4 (22)
Minus 3/8 22 73.5 (54) 49 (36)
D13 Clip 2.94 (2.2)
screwdriver 1/2 27 108 (80) 78.5 (58)
3/4 36 162 (119) 118 (87)
16,17 Clip Minus 5.39 (4.0)
A13,B33 screwdriver
(3) After assembling, fill the tank with the specified hydraulic oil and check the oil level with the level gauge (A1-11)
(See Fig. "Hydraulic oil tank removal").
Oil quantity : about 38 liters (10 gal)
(4) Air bleeding

1. Start the engine.
2. Run the engine in low idle condition for two or three minutes. Then extend and retract each cylinder several
times to bleed air in the circuit.
33-25
(3) Rechecking oil level

Stop the engine in the posture shown in the right
figure to recheck oil level. In addition, ensure no oil
leakage is found on each part.
Posture for stopping engine
33-26
33.1.12 AIR CLEANER

Open the rear bonnet assembly.
(1) Pull out two connectors of the harness from the
HARNESS INDICATOR
indicator on the air-cleaner (1).
WITH SWITCH
-If the indicator is not equipped with a switch, this
CONNECTOR
work is not required.
(2) Loosen the clip (5) to remove the air hoses (2) and
(3).
(3) Loosen two M8X16 (14) and two M8X25 (8) sems- CONTROL STAND 14 8
bolts to remove the air cleaner assembly (1). INDICATOR
Tools: Spanner: 13 mm WITHOUT SWITCH
5
3
Air cleaner removal
33.1.12.3 ASSEMBLY
Assemble the air cleaner in reverse order of the disassembly.
-Tightening torque
Sems-bolts (8) and (14): 17.7 N-m (13 lbf-ft)
33-27
33.1.13 GENERATOR
33.1.13.1 DISASSEMBLY PREPARATION

(1) Remove the cover at the lower right of the seat [See Section 33.1.11.1-(5)].
(2) Disconnect the negative side terminal of the battery.
(1) Disconnect the connector and remove the nut (M6)
for the terminal B.
(2) Remove the capscrews (1), (2), and (3).
Tools: Spanner: 13mm
(3) Remove the V-belt and the generator.
Generator removal
33.1.13.3 ASSEMBLY
(1) Assemble the generator in reverse order of the
disassembly.
(2) V-belt tension
Press the middle of the V-belt with a thumb to
adjust the deflection within the following range:
Deflection: 10 to 14 mm (0.39 to 0.55 inch) ; For
used V-belt
Deflection: 8 to 12 mm (0.31 to 0.47 inch) ; For new
V-belt
Generator terminal
33-28
33.1.14 MUFFLER

(1) Remove the bonnet assembly (2) [See Section 33.1.2.1-(1)].
(2) Remove the cover assembly (3) [See Section 33.1.2.1-(2)].
(1) Loosen three M8X20 sems-bolts (8) to remove the
cover (16). 8
14 29
Tools: Spanner: 13 mm 9-2
(2) Remove capscrew (7) and M10 nut (19) to loosen
A
the clamp (4), and loosen four M8 nuts (9-1) to
remove U bolt (27) then disconnect the exhaust 19
16
tube (3). 1 4 B
8
(3) Loosen four M8 nuts (9-2) fastening the exhaust 9-1
manifold for the engine to remove the muffler.

3
(4) Loosen four M8X20 sems-bolts (14) to remove the A
muffler (1).
Muffler removal
33.1.14.3 ASSEMBLY
Install the muffler in reverse order of the removal and tighten the screws and nuts to the specified torque shown in
the following table :
Tool Torque
Item Name
(mm) N m (lbf ft)
7 Capscrew (M10) 17 23.5 (17)
8 Sems-belt (M8) 13 23.5 (17)
9-1 Nut (M8) for U-bolt 13 10.8 (8.0)
9-2 Nut (M8) for Manifold 13 23.5 (17)
14 Capscrew (M8) 13 23.5 (17)
33-29
33.1.15 CONTROL STAND

(1) Remove the canopy and the handrail (See Section 33.1.1).
(2) Remove the floor covers (2) and (4), and the plates (3) (See Section 33.1.3.1).
(3) Remove the covers (1), (3), (4) and (5) for the guards, and the bonnet (2) (See Section 33.1.2).
(5) Remove the negative terminal of the battery.
(1) Remove the air cleaner (See Section 33.1.12).
(2) Removing throttle cable (15)
1. Pull out the pin (10) and remove the pin (8). 15
2. Loosen the adjusting nut (M8) to remove the 10
cable.
8
(3) Removing deceleration motor (option)
1. Disconnect the connector.
2. Loosen the adjusting nut (M8) to remove the
cable.
3. Loosen three M8X20 sems-bolts (13) to remove
the deceleration motor (16).
Control cable removal
(4) Removing filler neck (fuel supply port)

1. Pull out the hose (B4) connected to the fuel tank.
*
2. Loosen clip (B38) and remove two M8X25 sems-
*!&
bolts (B39) to remove the filler neck (B1).
Tools: Socket: 13 mm *!'
Filler neck removal
(5) Disconnect the air bleed hose for the fuel tank. Disconnect
AIR BLEED HOSE
air bleed hose at this point
A1
Air bleed hose disconnection
33-30
(6) Pilot valve removal for dozer

1. Disconnecting hoses
Disconnect all the hoses connected to the Pilot 33
valve (10). Then attach a plug and a tag recording
the connecting port to each of their openings.
2. Removing pilot valve
Loosen two M8X20 capscrews (11) to remove the
pilot valve.
Pilot valve removal for dozer
(7) Removing seat and front stand cover

Loosen four M8X20 sems-bolts (15) to remove the
seat assembly (7) and the front stand cover (14) in
one piece.
Seat and cover removal
(8) Removing heat insulation cover

Loosen two M8X20 sems-bolts (24) to remove the
cover (5). 5
24
24
Cover removal
33-31
(9) Disconnecting pilot hose

1. Disconnect the hose of the right pilot valve (R)
under the pilot valve
2. Disconnect the hose of the left pilot valve (L)
from the control valve and solenoid valve sections
(See Sections 33.1.7.2 and 33.1.8.2).
-When a multi-control valve (option) is equipped,
disconnect hose at the multi-control valve section.
Pilot hose disconnection
(10)Removing heater hose (option) 12

Remove the engine side clip (5) to disconnect the
heater hoses (1) and (6).
1
-Four M8X16 sems-bolts (12) for fastening heater
(2)
2 5
Tools: Socket: 13 mm 6
5
Heater hose disconnection
33-32
(11)Disconnecting harness
See below drawing to disconnect the harness connected to the instrument harness and main harness.
33
(12)Removing control stand

Remove M8 (A1), M10 (19) and M12 (20) sems-
bolts for fastening the stand in addition to the sems-
bolts already removed to disassemble the canopy
and floor covers.
Tools: Socket: 13 mm, 17 mm and 19 mm
Weight of removed stand: approximately 55 kg (120
lbs)
-Before lifting the control stand, ensure that
harnesses and hoses are already disconnected.
Control stand removal
33-33
(13)Removing support 26
1. Loosen two M6X20 sems-bolts (A9) to remove
the reserve tank (A5).
2. Remove the M8X16 capscrew (A10) for the 7
clamp (A6) of the oil cooler hose (A2).
3. Loosen two M12X50 (26) and two M16X50 (23) B
capscrews to remove the support (7).

B A5
A
Weight : approximately 39 kg (86 lbs) A
A9
23
A6 A10
A2
Support (7) removal
(1) Install the control stand in reverse order of the removal.
Tighten the capscrews and sems-bolts at the torque specified below:

Thread size
size used
M6 10 4.4 (3.3) (PF) (mm) fitting fitting
M8 13 23.5 (17) 1/4 19 36.3 (27) 29.4 (22)
M10 17 46.1 (34) 3/8 22 49 (36)
M12 19 79.4 (59)

M16 24 191 (141)
33-34
33.1.16 STARTER

(1) Remove the floor cover (See Section 33.1.3.1).
(2) Remove the seat and the front stand cover, loosen
four M8X20 sems-bolts (15), and remove the seat
assembly (7) and the front stand cover (14) in one
piece.
Tightening torque: 23.5 N-m (17 lbf-ft)
(3) Disconnect the negative side terminal of the
battery.
Seat and cover removal
33.1.16.2 REMOVAL
(1) Remove the M8 nut for the terminal B of the starter.
(2) Disconnect connector on the terminal S of the starter.
(3) Loosen two fastening bolts (1) to remove the starter.
Starter removal
Install starter in reverse order of the removal.
33-35
33.1.17 RADIATOR

(1) Remove the right side cover assemblies (1) and 6
(4), and the bonnet assembly (2) (See Section
33.1.2). 21
(3) Remove the duct (6) for the radiator.
Two M8X20 sems-bolts (21)
Tools: Socket: 13 mm, T=23.5 N-m (17 lbf-ft)
-In order to facilitate the work, remove the related
covers and components if necessary.
Duct removal
(1) Draining water form radiator
B6
1. Remove the radiator cap.
2. Loosen the clip (A8), then remove the plug (A14) A7
to drain water.
Volume: approximately 1.6 litters (0.42 gal)
A3 A4
(2) Draining hydraulic oil in oil cooler
1. Release the pressure in the hydraulic circuit. B B3
2. Remove the oil cooler hoses (21) and (22), and
then plug the inlet/outlet ports of the oil cooler and B
A
the openings of the hoses. A A8
(3) Disconnect the hose (A4) of reservoir (A5) by
removing the clip (A8).
(4) Remove the M8X16 capscrews (A10) for the horse A5
clamp (A6). A6 A10
Tools: Spanner: 13 mm A2 A7
(5) Remove the radiator hoses (A2) and (A3) fixed by
A8
clip (A7). A14
Tools: Cutting pliers and slotted screwdriver
Radiator disassembly
33-36
(6) Removing radiator 22

Loosen two M8X20 (B6) and two M10X25 (B3)
capscrews to remove the radiator assembly.
C/V
33
Tools: Socket: 13 mm and 17 mm T1
Weight: 10 kg (22 lbs)

21
16
COOLER OIL IN
(UPPER) 16
COOLER OIL
OUT
(LOWER)
COOLER OIL
Draining hydraulic oil in oil cooler
33.1.17.3 ASSEMBLY
(1) Assembly the radiator in reverse order of the Position the fan at a distance of
disassembly. 27.5 mm (1.1") from radiator shroud.
(2) Apply Loctite #262 on the capscrews (B3) to fix the SHROUD
radiator by them.
(3) Apply Loctite Hi-Tack gasket sealant to the fittings 27.5 (1.1")
of radiator hoses (A2) and (A3) prior to the
15 (0.59")
connection.
(4) Install the fan and shroud, adjusting their positions
according to the right figure.
Tightening torque for related parts Adjust the clearance between
the fan and radiator shroud so
that it is set to 15 mm (0.59")
around the circumference.
FAN
Radiator installation
Tool Torque
Item Name
(mm) N-m (lbf-ft)
A10, B6 Capscrew (M8) 13 23.5 (17)
B3 Capscrew (M10) 17 46.1 (34)
(5) Feed cooling water (LLC : Long Life Coolant)

See Maintenance section of the OPERATION & MAINTENANCE MANUAL for the mixing ratio of LLC.
33-37
33.1.18 ENGINE

(1) Remove the side cover and the bonnet (See Section 33.1.2).
(2) Remove the canopy (See Section 33.1.1).
(3) Remove the negative side terminal of the battery.
(5) Remove the control stand (See Section 33.1.15).
(6) Remove the air cleaner (See Section 33.1.12).
-Remove the air cleaner together with the bracket (28) for installing the water separator (1) (See Fig. "Fuel hose
removal").
(7) Remove the muffler (See Section 33.1.14).
(8) Remove the radiator (See Section 33.1.17).
(9) Remove the pump or disconnect the hose connected to the pump (See Section 33.1.6).
33.1.18.2 REMOVAL
(1) Disconnecting fuel hose
Disconnect each hose from the position marked
with *.
(2) Disconnecting cable connector
(for details, see ELECTRICAL SYSTEM) 28
1. Disconnect the terminal B of the starter motor
(M-1) on the positive cable of the battery (See
Section 33.1.16.2). 1
2. Disconnect the grounding cable of the engine.
(3) Removing engine
FUEL FILTER
A
FUEL FEED PUMP
Fuel hose removal
Prepare a worktable capable of enduring the weight of the engine and stably receiving the removed engine.
1. Loosen four M12X120 capscrews (12) fixing the engine on the rubber mount (6) to remove the engine.
2. Lifting engine
Pass a wire rope through the two lifting eyes at the top of the engine and lift the engine.
Weight : approximately 155 kg (340 lbs)
3. Place the engine stably on the worktable.
33-38
(1) Install the engine in reverse order of the removal.
See the following table for the tightening torque and the sealant: 33
Tightening torque for related parts

Tool Torque
Item Name N m (lbf ft) (0.24" 0.04")
(mm)
46.1 (34)
10 and 11 Sems-bolt (M10) 19
Apply Loctite #262.
79.4 (59)
12 Capscrew (M12) 22 Apply Loctite #262.
Mount rubber setting
• Use the mount rubber (6) with identification color of "blue" (three Places).
• Use the mount rubber (7) with identification color of "red" (one Place).
12
10
7
12
12 7
12
6
6
11
6
6
6
Engine removal
33-39
33.1.19 PILOT VALVE
33.1.19.1 PREPARATION FOR REMOVAL

Since the same method applies to the right-hand and the left-hand pilot valve, only the method for the right-hand is
described.
(1) Disconnect the negative side terminal of the
battery.
(2) Release the residual pressure in the circuit and the
pressure in the hydraulic tank.
10
(3) Remove the right and left control boxes and the
monitor panel. 10
(4) Loosen sems-bolts (10) to remove the cover 10
assembly (18) and (19) [See Fig. "Cover removal
(Right control box)"]. 19
Tools: Torx driver
10
18
Cover removal (Right control box)
33.1.19.2 REMOVAL
(1) Disconnect each hose at the position marked with *
A2 C/V
and attach a plug and tag to facilitate installation. Pb10
1
(2) Shift the boot and remove four capscrews (A2).
A1 TANK
4
(3) Remove the pilot valve (A1). C/V
T
Pb8
P 2
3
C/V S/V C/V
A2 Pa10
Pa8
Hose removal
33-40
(1) Install the pilot valve in reverse order of the removal to the following tightening torque:
1. Attaching sems-bolts (10). 33
Tools: Torx driver
T=0.27 N-m (0.2 lbf-ft)
2. Installing hoses, etc.
P 4 Boom (R)
Thread Spanner O-ring type flare type 2 Bucket (R)
size used
1/4 19 36.3 (27) 29.4 (22) 1 Bucket (H)
3/8 22 49 (36)
3 Boom (H) T
Right side
8 Arm (R)
P
6 Slewing (R)
5 Slewing (L)
T
7 Arm (H)
Left side
Pilot valve port location
Take care of the tightening torque as the pilot valve is made of aluminum.
(2) Pressurize the hydraulic tank (See Section 33.1.11.3).

(3) Operate the attachment to check the performance.
(4) Check the tank and piping for oil leakage and oil level.
33-41

(1) Remove the floor mat, the floor plate and the cover (See Section 33.1.3.1).
(2) Release the residual pressure in the circuit and the pressure in the hydraulic tank.
33.1.20.2 REMOVAL
(1) Disconnect six hoses (A7), (A10), (19), (20), (23) and (25) connected to the slewing motor (See Fig. "Main hose
disconnection").
Tools: Spanner: 22 and 27 mm
A10
C/V 23
A A2 M
T2
B C/V DB C/V
B2
19
A7 TANK, HYD
S/J
G
Main hose disconnection 20
25
TANK, HYD
Main hose disconnection
(2) Remove three pilot hoses (B25), (B26) and (B27) C/V B27
connected to the slewing motor. Pp1
PG
S/V
P2
SH
B26
B25
D
SHUT/V
Pilot hose removal
33-42
(3) Loosen five M12X40 capscrews (3) to remove the

slewing motor.
1
Tools: Allen wrench: 10 mm [a long type approxi- 33
mately 300 mm (11.8") in length required]. 3
Weight: about 38 kg (84 lbs)
Slewing motor removal
(1) Install the motor in reverse order of the removal according to the tightening torque shown below.
1. Apply Loctite #515 on the entire circumferential surface for mounting the slewing motor (1).
2. Install the capscrews (3) for fixing the motor.
T=115 N-m (85 lbf-ft)
Apply Loctite #262 to the capscrew.
3. Connect the hoses
-Fill the casing with hydraulic oil through the motor drain port prior to connecting drain piping.
Tightening torque N-m (lbf-ft)

Thread Spanner
O-ring type 30°flare type
size used
fitting fitting
(PF) (mm)
1/4 19 36.3 (27) 29.4 (22)
3/8 22 73.5 (54) 49 (36)
1/2 27 108 (80) 78.5 (58)
(4) Check the hydraulic oil tank for the oil level. Supply oil if necessary.
(5) At the start, run the motor in the low idling condition of the engine for a few minutes to check for oil leakage and
abnormal noise.
33-43
33.1.21 SWIVEL JOINT

(1) Lift the machine by approximately 30 cm (1 foot)
and insert support blocks at four places of the
crawler shoes, namely, front, rear, right and left, to
secure working space under the machine.
(2) Remove the cover (2) of the floor plate (See
Section 33.1.3.1).
Lifting machine
(3) Loosen four M10X16 capscrews (A5) to remove the

under cover (A4).
(4) Release the residual pressure in the circuit and the
hydraulic tank.
(5) Disconnect the hose of the slewing motor (See
Section 33.1.20).
- Remove the canopy to facilitate to remove the
swivel joints.
A4 A5
Undercover removal
33-44
33.1.21.2 REMOVAL
(1) Remove the upper-side drain hoses (25) and the HYDRAULIC OIL TANK
connector (1) (4).
25 33
G
1
4
Drain hose disconnection
(2) Disconnect all other hoses connected to the swivel joint.

-Attach a plug and tag to each of the openings.
C/V
A7 A7
C/V A1
B6 C/V
A14 B7 F
A20 DOZER CYLINDER
C/V B
B1 P
A15 C/V A6 A
A6 D
A1
P B
A19 E
A5
A10 P
C/V DOZER CYLINDER C G
A A1 D2
D C A1 A
A10 A4
E B A
G
S/V B30 A5
A1 A1
F
B D1
P
P
A4
Upper side hose disconnection Lower side hose disconnection
(3) Removing stopper

Loosen two M12X40 capscrews (A6) to remove the
stopper (A3).
Tools: Socket: 19 mm [a long type approximately
300 mm (11.8") in length required].
Stopper removal
(4) Removing swivel joint

Loosen four M12X40 capscrews (C2) to remove the C2
swivel joint (C1) downward.

Weight: 22 kg (49 lbs)
Swivel joint removal
33-45
(1) Install the swivel joint in reverse order of the removal to the tightening torque shown below.
1. Install the capscrews (C2).
T=102 N-m (75 lbf-ft)
Apply Loctite #262 on the capscrews.
2. Install the capscrews (A6).
T=115 N-m (85 lbf-ft)
3. Connect the hoses.

size used
1/4 19 36.3 (27) 29.4 (22)
3/8 22 73.5 (54) 49 (36)
Connecting port relation
(2) Reinstall all the removed parts.

(3) Pressurize the hydraulic tank.
(4) Check the performance.
33-46
33.1.22 UPPER FRAME

(1) Remove the floor plate and the floor cover (See Section 33.1.3).
(2) Remove the canopy (See Section 33.1.1).
(3) Remove the guards (See Section 33.1.2).
(5) Drain hydraulic oil from the hydraulic tank (See Section 33.1.11.2).
(6) Disconnect the upper-side hoses for the swivel joint (See Section 33.1.21.2).
(7) Remove the stopper for the swivel joint (See Fig.
"Stopper removal").
(8) Remove the attachment (See the "BOOM" section
of the Chapter of ATTACHMENT).
(9) Needed Tools
-Lifting device for upper frame. See section "Tools".
-Two bolts M20X110
-Two nuts M20
-Two washers M20
Slewing bearing and upper frame
33.1.22.2 REMOVAL
(1) Providing match marks to slewing bearing
Provide match marks between the upper frame and
the outer race of slewing bearing.
(2) Lifting upper frame temporarily
1. Attach the upper frame lifting jigs to the rear end
of upper frame using the counterweight mounting
holes.
2. Temporarily lift the upper frame at three points
applying wire ropes on a position of the swing-
bracket mounting hole for the front side and on two
places of the rear end of the upper frame.
(3) Removing bolt for mounting upper frame WIRE ROPE
Loosen one reamer bolt (5) and fifteen capscrews
(4) fixing the outer race of the slew bearing to the
upper frame.
(4) Removing upper frame
Lift the upper frame a little to ensure safety. Then
remove it and place on a worktable capable of UPPER FRAME
enduring the weight. LIFTING JIG
Weight: Approximately
1,100 kg (2,430 lbs) for CX31B
Weight: approximately
1,300 kg (2,870 lbs) for CX36B
Lifting upper frame
33-47
(1) Install the upper frame in reverse order of the
removal.
(2) Cleaning contact surface
Clean the bottom surface of the upper frame and
the top surface of the slewing bearing.
Fig. "Slewing bearing installation"
-Apply Loctite #515 over the entire circumference
of the outer race inside of the capscrew.
Slewing bearing installation
(3) Lifting method

1. Apply wire ropes to the upper frame and lift up
horizontally.
2. Check the match marks provided at the
disassembly.
3. Slowly lower the upper frame while aligning the
match marks and watching the engaging condition
between the slewing pinion gear and the internal
gear of the inner race of slewing bearing.
(4) Installing slewing bearing and upper frame
1. Apply Loctite #262 on a reamer bolt (5) and
fifteen capscrews (4) and temporarily tighten them.
2. Tighten the reamer bolt and capscrews to the
specified torque at the front, rear, right and left
positions facing each other in order alternately.
Tools: Socket: 19 mm, T=115 N-m (85 lbf-ft)
Apply Loctite #262 to the bolt and capscrews.
Reamer bolt position
3. Fill the grease bath portion surrounding the gear
teeth of the slewing bearing with about 2.5 kg (5.5
lbs) of "Lithium grease."
(5) Install the components removed to the original
position and check the performance.
33-48
33.2.1 HYDRAULIC PUMP 33
No. NAME
1 Shaft assembly
2 Swash plate assembly (Hanger assembly)
3 Rotary group
4 Cover assembly
5 Spring assembly
7 Gear pump assembly
8 Housing assembly
9 Trochoid pump assembly
Refer to section 33.2.1 HYDRAULIC PUMP in COMPONENTS SYSTEM PW24 for detail.
33-49
33.2.1.2 DISASSEMBLY AND ASSEMBLY

33.2.1.2.1 Tools and Jig
(1) Tools
Name Q'ty Size(Nominal) Name Q'ty Size(Nominal)

One Possible to tighten to the
Allen wrench 4, 6. 8 and 10 Torque wrench 1
each specified torque
Plastic hammer 1 Medium type Grease Little
For hole
Snap ring plier 1 Adhesive agent Little Loctite high tack sealant #98
(for snap ring 22)
For shaft
Snap ring plier 1
(for snap ring 20)
(2) Jig
1. Place the pump, facing downward, on the work
bench.
2. If the shaft end does not make contact with the
bench, support it with a timber block or other
appropriate support.
3. To preserve the shaft, use a jig to remove and install
the cover.
4. When removing the 4-socket bolt (M12), take care
to prevent the control spring from raising the cover
diagonally.
5. During assembly, install the cover on the housing,
keeping it horizontal.
6. The right Figure shows the construction of the jig.
The jig is constructed to push the cover and apply the
machined end of the hexagon socket set screw
(M16x150) to the adjusting screw.
(Note 1)
When the socket bolt is used, machine 15 mm (0.59")
from the top end in Ø8 (Ø0.315").
33.2.1.2.2 Cautions during Assembling and Dissembling

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

1. Wash each part thoroughly.
2. During assembling, take utmost care not to damage the part or allow foreign materials to enter.
3. As a rule, the O-ring and oil seal should not be reused.
4. In our assembly work, the torque wrench is used to control the torque. Be sure to use the torque wrench.
33-50
33.2.1.2.3 Disassembly
(1) Removing gear pump
1. Remove two capscrews (M10X25).

33
-Pay attention not to miss O-ring (two places) fitted on
the hosing.
2. Remove the coupling.
(2) Removing trochoid pump
1. Remove three M5X12 capscrews.

2. Remove the case, side plate (A) and gear.

-Use two M5X90 screws.
33-51
3. Take the gear out of the casing.
4. Remove the side plate (A) from the casing.
5. Remove the side plate (B) from the cover.
6. Remove the key of the shaft
33-52
(3) Disassembling main pump

1. Removing cover
Since the control spring is strong, remove three (M12X40) and one (M12X55) capscrews while pressing the 33
cover with jig.
2. Removing cover
Loosen hexagon socket set screw of jig slowly keeping the cover horizontal with jig and remove the cover.
-Pay attention not to drop the control plate attached on the back side.
3. Remove the packing.
33-53
4. Removing control spring section
a. Remove two springs (inside and outside) and the

guide.
b. Remove the spring seat.
5. Removing rotary group

a. Remove the shim and then remove the C-snap ring (20 for shaft).
Snap ring plier (for snap ring 20 for shaft)
33-54
b. Place the pump laterally and remove the rotary group

from the shaft.
33
6. Removing shaft
Wind protective tape on the spline section, and draw
the shaft out straight taking care not to damage the oil
seal.
7. Removing swash plate section
a. Remove the swash plate.
33-55
b. Remove the guide.

-Orientation: Put marks to avoid directional errors, like right and left, etc.
8. Disassembling cover section
a. Remove the control plate.
b. Remove two socket bolts (M8X30) to remove the cover

of control spring.
33-56
c. Remove the spring seat.

33
9. Disassembling housing section

a. Remove the piston, coned disk spring, distance piece and shim of P3 shift side.
b. Remove the parallel pin and sleeve (6 dia.) of P3 shift

side.
33-57
c. Remove piston of Pz shift side.
d. Remove parallel pin and sleeve (8.5 dia.) of Pz shift

side.
e. Removing minimum flow stopper

Remove the snap ring (22 for hole).
Snap ring plier (for snap ring 22 for hole)
f. Remove the guide, disk spring, distance piece and

shim.
33-58
10.Disassembling gear pump (GSP2)
a. Loosen four socket bolts (M10X20).

33
b. Remove the cover.
c. Remove the square ring.
d. Remove two plates, guide and O-ring.
33-59
e. Remove the drive gear, idle gear and side plate.
33-60
33.2.1.2.4 Assembly
Assemble the main pump in reverse order of the disassembly.
(1) Assembly of main pump

33
1. Assembling housing section
a. Install the parallel pin and sleeve (6 dia.) of the P3 shift

side into the housing.
b. Install the piston, coned disk spring, distance piece and shim of P3 shift side into housing.
-Be careful to the orientation of the disk spring.
c. Install the parallel pin and sleeve (10 dia.) of Pz shift side.
33-61
d. Install the piston of Pz shift side.
e. Installing minimum flow stopper

Install the guide, disk spring, distance piece and shim in the housing.
-Be careful of direction of a disk spring.
f. Place snap ring (22 for hole) in.

Snap ring plier (for snap ring 22 for hole)
33-62
2. Installing swash plate

a. Place the guide in the housing.
-Place in paying attention to the matchmark put on at disassembling. 33
b. Build the swash plate into the housing.
3. Installing shaft
Wind protective tape on the spline section taking care not to flaw on the oil seal and insert the shaft straight.
-Ensure that the shim is placed on the bearing.
33-63
4. Installing rotary group
a. Insert 10 pistons in the retainer.
b. Apply grease on the spherical section of the guide.
c. Placing guide between the retainer and cylinder block,

and insert the pistons into bores on the cylinder block.
-Apply grease on the shoe end.
5. Installing rotary group
a. Install the rotary group aligning it to the spline of the

shaft.
33-64
b. Fit the snap ring (20 for shaft) and insert the shim.
Snap ring plier (For snap ring 20 for shaft)
33
6. Installing control spring section
a. Apply grease on the spherical section of the spring seat

and install the control spring section.
b. Insert two springs (inside and outside) and the guide.
33-65
7. Assembling cover
a. Insert the spring seat in the cover.
b. Install the cover for the control spring section and

tighten screws (two M8X30).
Tightening torque : 28 to 35 N-m (21 to 26 lbf-ft)
c. Apply grease on the rear surface of the control plate to

prevent it from dropping and place it in the cover
aligning the hole for positioning pin.
8. Installing cover
a. Fit the packing.
33-66
b. Tighten the hexagonal socket set screw of the jig slowly keeping the cover horizontal and install the cover.
33
c. Fasten the cover with three M12X40 and one M12X55

capscrews.
9. Trochoid pump
a. Insert the key in the shaft.
-Insert the key directing the round side to the trochoid pump side.
33-67
b. Install the side plate (B) on the cover.
c. Place the gear (inner rotor) through the shaft.

-Install aligning the matchmark to the side plate (B) side.
d. Install the side plate (A) into the casing.
e. Install the gear (outer rotor) into the casing.

-Direct the matchmark side to the side plate (B) side.
33-68
f. Install the casing to the cover.

33
g. Tighten three M5X12 capscrews.

Tightening torque : 6.9 to 8.3 N-m (5.1 to 6.1 lbf-ft)
10.Installing gear pump
a. Fit the coupling to the shaft end on the main pump side.
b. Connect the gear pump to the main pump.
33-69
c. Fix the gear pump with two (M10X25) capscrews.

11.Assembling gear pump
a. Fit the square ring to the plate on the assembling side of gear pump (GSP2).
Then pay attention to the suction and delivery.
b. Install the drive gear and idle gear in the side plate.
33-70
c. Install the drive gear, idle gear and side plate into the
housing.
33
d. Insert O-ring into the guide, and install it to the plate.
e. Install the plate, guide and O-ring into the housing.

Then pay attention to the suction and delivery direction.
33-71
f. Fit the square ring.
g. Install the cover to the housing.
h. Fix the housing and the cover with four M10X20

capscrews.
33-72
33.2.1.3 MAINTENANCE STANDARD

(1) Parts replacement standard
33
Item Replacement criterion Remedy
Piston assembly • Visual inspection • Replace.
and cylinder block To be free from flaw, galling and
PISTON ASSY CYLINDER BLOCK wear.
(Especially the sliding section)
• Check clearance between the
piston outer diameter and inner
diameter of the cylinder block.
D-d 0.06 mm (0.0024 in)
Piston shoe and • Piston shoe and piston • Replace.

piston • Check the play in the axial
SHOE PISTON direction of the piston and shoe
shaft.
0.2 mm (0.0079 in)
Shaft • Shaft • Replace.

• Check the wear of the oil seal.
OIL SEAL INSTALLING RANGE
Wear amount 0.025 mm
(0.0010 in)
Control plate • Check the sliding surface for • Replace it when

flaw. the flaw is
severe.
Guide and retainer • Check ifit is free from galling • Replace it in a

and step wear. set if it is
GUIDE impossible to
repair.
• Check if it is free from slight • After repairing
galling and flaw. with lapping,
clean it to
RETAINER remove the
lapping
compound.
33-73
33.2.2.1 ASSEMBLY DRAWING

1. Outside view

1 Dozer section 1 11 Boom lock section 1
2 Slewing section 1 12 Bucket section 1
3 P3 inlet and travel straight conflux section 1 13 P1, P2 Main relief valve 2
4 Arm section 1 14 P3 Main relief valve 1
5 Service section 1 15 Over load relief valve 6
6 Swing section 1 16 Over load relief valve 2
7 Travel (right) section 1 17 Anti cavitation valve 1
8 P1 and P2 inlet section 1 18 Tie bolt 4
9 Travel (left) section 1 19 Nut 4
10 Boom section 1
33-74
2. Cross section
The control valve is roughly classified into the following four sections.
33
-Manual operation section : Swing
-Pilot operation section : Travel right and left, boom, arm, bucket, slewing, travel straight conflux,
dozer and service (Nibbler & breaker)
-Accessory section : P1 and P2 inlets, and P3 inlet (common with travel straight and conflux)
-Accessory section (valve) : P1, P2, P3 main relief, overload relief, anti cavitation, boom lock
* For respective operation section, only typical example is described.

(1) Manual operation : Swing (Item 6)
Item NAME Q TY
1 Body 1
2a Spool 1
13 7 9 6 8 2b O-ring 1A P12 1
2c Dust wiper 1
2d Oil seat retainer 1
12 2e Spring seat 2
2f Spring 1
2g Spool end 1
3 O-ring 1A P12 1
4 Dust wiper 1
5 Oil seal retainer 1
8 O-ring 1B P11 2
10 5 4 3 1 2a 2b 2c 2d 2e 2f 11 2g 9 Plug (for check valve) 1
11 Cover 1
(2) Pilot operation : Slewing (Item 2)
Item NAME Q’TY

1 Body 1
2a Spool 1
2b Spring seat 1
2c Spring 1
2d Spring seat 1
2e Spool end 1
5 O-ring 1B P11 1
7 O-ring 1B S22 2
8 Pilot cover 1
9 Pilot cover 1
11 Overload relief valve 1
33-75
(3) Main relief valve (P1, P2, P3) and overload relief valve
15 14 13 5 11 4 8 7
Item NAME Q'ty
1 Socket 1
2 Pressure regulating valve 1
3 Piston 1
4 Plug (adjust section body) 1
5 Body 1
6 Poppet 1
7 Adjust screw 1
8 Lock nut M14 1
9 Spring (Adjust valve) 1
10 Spring (Pressure regulating) 1
11 O-ring 1B P15 1
1 2 10 3 6 16 12 9 12 O-ring 1B S10 1
13 O-ring 1A P7 2
14 Back up ring 2
(Only for Overload relief valve & P3 main relief valve) 15 O-ring 1B P14 1
16 Spring guide 1
(4) Anti cavitation valve
1 7 5 6 2 4 3 8
Item NAME Q'ty
2 Body 1
3 Plug 1
4 Spring 1
5 Back up ring 1
6 O-ring 1A P10A 1
7 O-ring 1B P14 1
8 O-ring 1B P15 1
33-76
33.2.2.2 PRECAUTIONS FOR DISASSEMBLY
33
Precautions (These precautions must be observed for safety.)
The disassembly and assembly is fundamentally to be carried out at the manufacturer's plant, but when they are
unavoidably necessary, observe the following precautions.
(1) All hydraulic equipment is machined in precision and consequently the clearance of each part is very small.
Therefore when disassembling and assembling, place the machine in the clean area to prevent it from the entry
of dust, earth and sand.
(2) Before disassembly, prepare the valve construction drawing to understand the construction clearly.
(3) When removing the control valve from the machine, never forget to cap every port to prevent dust, etc. from
entering. And before disassembly, recheck that every post is capped and clean the outer surface of the
assembly. The work should be carried out on the appropriate work bench which is covered by clean paper or
rubber mat.
(4) When it is required to leave it in the removed condition, apply rust preventives or seal them to protect them from
rusting.
(5) The control valve should be transported or moved holding the main body. Especially, after removing the pilot
cover, carefully handle it paying attention not to touch the exposed surfaces.
(6) Even when the movement is not smooth, never strike it.
(7) In addition, after assembly of equipment, various tests {relief setting, leak test, flow resistance (pressure loss)
test} are required, but these tests require hydraulic test equipment. Therefore, do not remove the equipment
which is impossible to adjust through respective test, even if the disassembly is possible technically.
33.2.2.3 REQUIRED TOOLS AND OTHERS

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

Allen wrench One each 4, 5, 6, 8 mm
Spanner One each 13, 19, 21, 22, 26 mm
Socket wrench One each 13, 19, 21, 22, 26 mm
Torque wrench 1 1.96 to 19.6 N-m (1.4 to 14 lbf-ft)
Torque wrench 1 19.6 to 98.1 N-m (14 to 72 lbf-ft)
Magnet 1
Pliers 1
Screw driver (-) 1
Tweezer 1
Prepare wash oil, hydraulic oil, grease, Loctite #242, tag and marker (felt-tip pen) beforehand.
33-77
33.2.2.4 DISASSEMBLING
(1) Drawing the spool out
Place the control valve on work bench directing the actuator port upward.
1. In case of hydraulic pilot switching type,

How to take out the spool for slewing is as follows. [See Fig. "(2) Pilot operation: Swing Item 2)" and Fig.
"Hydraulic pilot switching type"]
First, loosen and remove 2 washer socket bolts (10) with Allen wrench of 4 mm. Then, remove pilot cover (9).
The spring section of the slewing spool is disposed, so draw out and take out spool assembly (2a-2e) slightly
and horizontally (parallel to the spool hole) from the body holding the spring section. Other pilot spools can be
taken out from the same face by the same procedure. Then, check that the O-ring (7) on the flange bottom
installing the pilot cover on the body side is not separated.
Hydraulic pilot switching type

2. In case of manual switching type,
How to remove this type as an example of the swing spool is as follows. [See Fig. "(1) Manual operation:Swing
(Item 6)" and Fig. "Manual switching type"]
First, loosen and remove 2 socket bolts (12) with Allen wrench of 4 mm.
Then, remove end cover (11).
The spring section of the swing spool is disposed, so draw out and take out spool assembly (2a-2g) slightly and
horizontally (parallel to the spool hole) from body (1) holding the spring section.
Then, pull the spool assembly carefully, or the spool seal [dust wiper (2c) and O-ring (2b)] moves to the edge
section of the spool and the lip section may be damaged.
Replace the removed O-ring with new one.
If it absolutely has to be used, check that it is free from flaw, deformation and foreign matter adhered.
13 7 9 6 8
12
10 5 4 3 1 2a 2b 2d 2f 2g 11
2c 2e
Manual switching type
3. Precautions when replacing spool
When replacing the spool, in no case should the spool be disassembled, but replace it with the new spool
assembly.
33-78
4. In case of independent travel spool (See Fig. "P3 supply and travel straight sections")
Firstly loosen and remove two sems-bolts (11) with an Allen wrench of 4 mm. Then remove the pilot cover (10).
Remove the disposed spring (4) and spring seat (3). Pull out the spool assembly (2) slowly and horizontally (in 33
parallel to the spool hole axis) from the valve by holding the end of the independent travel spool.
At this time, ensure that the O-ring (9) in the bottom of the flange installing the pilot cover on the main body side
is in place without coming off.
Further loosen three socket bolts (20) with an Allen wrench to remove the body assemblies (16-19) and the
piston (14).
At this time, ensure that O-rings (9)(10) in the installing surface of the body assembly on the main body side is
in place without coming off.
P3 supply and travel straight sections

(2) Relief valve (Code : RV)
How to remove overload relief valve (Code : ORV)
First, fix the valve on the work bench or ask people to hold down the valve. Then, loosen the hexagonal section
(opposing flat, 22) of RV and ORV with spanner of 22 mm. At that time, do not remove the valves applying spanner
to the opposing flat, 19.
The set pressure of the RV and ORV differs at the position, so tag every valve with respective attaching position.
And handle the removed RV and ORV paying attention not to damage the seat section.
The RV and ORV are essential for the performance and safety, but do not disassemble the RV and ORV because
it is very difficult to reset the pressure. When there is a failure, replace the assembly.
33-79
(3) How to disassemble load check valve

First, fix the valve on the work bench, or ask people to hold down the valve in order to keep it from moving. Loosen
plug (9) at the center of the valve upper surface with spanner of 19 mm (or socket wrench).
It may be difficult to loosen the plug because O-ring gets caught in the thread. Then, do not force it to loosen, but
tighten the plug once again and loosen it again. Take out spring (7), load check valve (6) through the hole used to
remove the plug with tweezers or magnet.
The item numbers in Fig. "Load check valve" correspond to that of the swing section in Fig. "(1) Manual
operation:Swing Item 6)". The travel switching, boom lock valve and service switching sections having different
forms can be disassembled in the same manner.
9
8
A : Load check valve

Dozer, Slewing, Arm, Swing,
Boom, Bucket B : Load check valve C : Load check valve
Travel right and left switching, (Service switching section)
P3 supply and boom lock
valve sections
Load check valve
(4) Disassembling lock valve
If the lock valve became abnormal, replace it with new one as assembly.
The disassembling procedures described below are for reference only to check the cause for abnormality.
At first, loosen two socket bolts (20) with a 5 mm Allen wrench. Then remove the lock valve cover (1).
-Pay attention not to drop off and lose two positioning pins (9) and give any damages to them.
Remove the exposed lock valve (2) and needle valve (10).
-Remove and store the needle valve firstly because it easily comes off.
-Do not disassemble the lock valve, store it as assembly (2~8, 11).
33-80
Fix the lock valve cover with a vise, loosen and remove the bush (17) with a 26 mm spanner (or socket wrench).
33
-Fix the lock valve cover with a vise at the side faces other than the port face.
Remove the pistons B (15) and A1 (14) with a pair of tweezers or a magnet through the bore for bushing.
-Mark on the pistons (B) and (A1) to identify the assembled direction.
-Do not disassemble the piston guide (13), and store it at assembly with the lock valve cover.
Loosen the ball retainer (19) with a 4 mm Allen wrench.
Remove the É”7steel ball (18) with a magnet through the bore for ball retainer.
(5) Disassembling other parts

Remove the other parts, not described in par. (1) through (4), in the following procedures :
1. Service section
Plug for actuator part (See Fig. "Service section")
Fix the valve directing the actuator port upward.
Loosen and remove plug (11) on both right and left sides of the upper surface of the service change section with
spanner of 21 mm (or socket wrench).
Service section
33-81
2. Pilot cover of hydraulic pilot switching section (See Fig. "Hydraulic pilot switching type")
Loosen and remove two socket bolts (10) with an Allen wrench of 4 mm.
Remove the pilot cover (8) horizontally. At the same time, ensure that the O-ring (7) in the bottom of the flange
for securing the pilot cover on the main frame side is in place without coming off.
3. Spool seal of manual switching section (See Fig. "Manual switching type")
Loosen and remove two socket bolts (10) with an Allen wrench of 4 mm.
The oil seal retainer (5) is also removed simultaneously. Remove the spool seal [O-ring (3) and dust wiper (4)]
through the spool hole on the side of the main frame, paying attention not to damage the spool seal and
switching main frame. Don't reuse the O-ring.
When it is required to be used again, check that it is free from flaw, deformation, foreign matter adhered, and so
on before installation.
4. Plug in the bottom of boom lock valve section (See Fig. "Plug in the bottom of boom lock valve section")
Put the valve on work bench directing the actuator port downward.
Remove the plug (8) in the middle of the bottom of the boom lock valve section with an Allen wrench of 6 mm,
and also remove the O-ring (7).
Plug in the bottom of boom lock valve section
(6) Disassembling main frame of switching section

The figures in parentheses following the part names in the description are the item numbers used in the outline
view. (See Fig. 33.2.2.1 "Outside view")
Loosen and remove four M8 nuts (19) for fastening the main frame of the switching section on the valve side with a
wrench (socket wrench) of 13 mm.
Pull four tie-bolts (18) from the side and remove each main frame of the switching section. Then, care should be
taken not to miss various O-rings fitted on the mating face of respective main frames.
Do not remove a number of plugs screwed in the unnecessary holes for valve manufacturing of the main frame of
the switching section unless required.
(7) Precautions for disassembly
The removed parts should be carried and stored carefully to prevent damage and contamination. And when the
removed parts are applied, stored, or carried in the removed condition, fill up the holes after the removal of parts
with cap, tape, etc. to protect it from entry of dust, dirt, etc.
33-82
(8) Disassembling anticavitation valve
33
Since the anticavitation valve is essential for the performance, replace it with the new assembly if necessary.
Procedures for disassembling the valve to check for abnormality is shown below for reference. The figures in
parentheses following the part names in the description are the item numbers in the cross-sectional drawing ( Fig.
"(4) Anticavitation valve").
Firstly, hold the hexagonal section having width across flats of 22 mm with a vise lightly.
Loosen and remove the plug (3) with an Allen wrench of 8 mm.
Remove the spring (4). Then push in the anti-cavitation valve (1) from the seat side while taking care not to
damage the seat section. Pull out the O-ring (6) and back-up ring (5) from the side from which the plug (3) was
removed while taking care so that the rings are not damaged by the internal thread of the body (2).
(9) Relief valve (Code : RV)

Disassembling overload relief valve (Code : ORV)
Since the overload relief valve is essential for the performance and safety and the resetting of the pressure is very
difficult, replace it with the new assembly when an abnormality is detected. For reference, how to disassemble for
checking the abnormality is shown below.
The figures in parentheses following the part names in the description are the item numbers in the cross-sectional
drawing [Fig. "(3) Main relief valve (P1,P2,P3) and overload relief valve"].
First, hold the body (5) with vise at the hexagonal section of the opposing flat, 22. Loosen and remove adjusting
screw (7) with Allen wrench of 4 mm. Take out spring (9), poppet (6) and spring guide (16) with tweezers, etc.
Then, loosen and remove plug (4) with spanner of 19 mm, and the remaining parts can be taken out at the same
time. And take out socket (1), piston (3), spring (10) and pressure regulating valve (2) in order.)
33-83
33.2.2.5 PRECAUTIONS WHEN ASSEMBLING
Precautions (Observe the following for safety.)
(1) The unevenness of tightening torque and the contamination by dust during assembly may cause a failure. And
observe the tightening torque specified in the description.
(2) When assembling, check up on the valve construction drawing, identify the number of parts, and ensure that
there is no installation error and omission of parts, etc.
(3) After cleaning the parts required to use with cleaning solvent, immerse them in hydraulic oil as required and
reassemble them.
(4) Before applying Loctite, clean and decrease the surface sufficiently, and apply it to two threads.
(Over application may cause a malfunction due to the squeezing out.)
33.2.2.6 PRECAUTIONS WHEN FITTING SEALS
Precautions (Observe the following for safety.)
(1) Replace seals with new ones when assembling.

(2) Ensure that seals are free from deformation and flaw coming about when handling them.
(3) Apply grease or hydraulic oil to the seals and seal fitting section to make the sliding smooth, unless otherwise
specified.
(4) Do not stretch the seals too much. Otherwise they may be permanently deformed.
(5) Pay attention not to roll the O-ring when fitting. Because it is difficult for the twisted O-ring to be restored
naturally after fitting, and it may cause oil leakage.
33-84
33.2.2.7 ASSEMBLY WORK

(1) Perform assembling work referring to the drawings in "Disassembly" Section.
(2) Assembling procedure 33
1. Assembling the main frame of the switching section (See Fig. 33.2.2.1 "Outside view")
Put all sections of main frame in order as shown in the below table directing the actuator port downward.
SECTION MARK
(Block) JAA10
Dozer SR
Slewing GE
P3 inlet-Travel straight UO
Arm TP
Service FY
B/Swing FZ
Travel RH CX
P1, P2 inlet XD
Travel LH BR
Boom EL
Boom lock KE
Bucket VF
The symbols are engraved on the upper surface of the main frame of the switching section (Actuator port face)
-Then, check that the mating surface of the main frame of each switching section is free from dust, etc. and the O-
ring is securely fitted in the groove.
And, insert four tie bolts (18) through the main frame of the switching section from the side, and tighten four M8 lock
nuts (19) to the specified torque with socket wrench of 13 mm.
T=16.7 to 17.7 N-m (12 to 13 lbf-ft)
-Observe the specified torque. When the lock nut is not tightened to the torque other than specified, it may cause a
distortion and oil leakage of the main frame.
At this time, do not tighten the lock nuts at a time, but tighten four lock nuts to make uniform in several times.
Tighten the lock nuts making the upper and lower, and right and left sides uniform with a plastic hammer, etc.
following the sketch drawing, or make them uniform with press, etc. after tightening.
33-85
2. Installing plug in the bottom of boom lock valve (See Fig. "Plug in the bottom of boom lock valve section")
Put it on work bench directing the actuator port of the valve downward. Fit the O-ring (7) securely to the
counterbore in the middle of the boom lock valve section. Tighten plug (8) to the specified torque with Allen
wrench of 6 mm.
T=9.8 N-m (7 lbf-ft)
3. Assembling load check valve
Put the load check valve of the valve on the work bench directing the actuator port upward.
a. Sections other than travel, P3 supply, boom lock valve and service (See Fig. "Load check valve")
Place load check valve (6) in the hole at the center of the valve in normal condition (direct the cap section
downward.), and check that it is placed in at the center. Fit spring (7) on the guide of the load check valve.
Tighten the plug by hand so that the guide of the load check valve can be fitted on the guide of plug (9), and the
spring can be in place.
Then, check that O-ring (8) is fitted on the plug.

Screw in with a certain amount, and tighten it to the specified torque with spanner of 19 mm (or socket wrench).
T=39.2 N-m (29 lbf-ft)
b. Travel, P3 supply, boom lock sections (See B of Fig. "Load check valve")
Service section (See C of Fig. "Load check valve")
Place the load check valve in the hole at the center of the valve in the normal direction (direct the cap section
downward.), and check that it is placed in at the center.
Apply grease to the spring (4) and fit the plug in the guide.
-Then, ensure that the O-ring (5) is fitted on the plug (6).
Tighten the plug by hand so that the guide of the load check valve installed on the main frame of the switching
section can be fitted on the guide of the plug after checking that the check valve spring does not drop even when
the plug is reversed up and down in this condition.
Screw in with a certain amount, and tighten it to the specified torque with a wrench (socket wrench) of 19 mm.
T=39.2 N-m (29 lbf-ft)
-Assemble it paying attention to the correct position where two types of the load check valve are installed.
4. Assembling RV and ORV
-Tighten the RV and ORV to respective port for installation to the specified torque.
T=39.2 N-m (29 lbf-ft)
-Observe the specified torque. When the respective valve is not tightened to the torque other than the specified, it
may cause a distortion and oil leakage of the connection. Since the pressure settings of RV and ORV on each
places differ, install them on the position as they were in order not to make a mistake referring to the tags attached
when disassembling.
33-86
5. Assembling spool assembly

a. In case of hydraulic pilot switching type, (See Fig. "Hydraulic pilot switching type")
Insert respective spool assembly in the spool holes of the main frame of the switching section paying attention 33
to the positions and directions so as not to make a mistake, after checking that respective spool assembly and
the spool holes of the main frame of the switching section are free from dust, etc. and also O-ring (7) is securely
fitted on the bottom of the flange of the main frame of the switching section (2 places before and after the main
frame of the switching section.)
Then, apply a slight hydraulic oil to the spool before insertion. And, do not force the insertion of the spool due to
the difficulty to getting in, or it may cause malfunction, etc.
Next, check that the spool moves smoothly by getting it in and out several times by hand, and be sure that there
are no unsmooth movements or catching.
Where there is no above feeling of the physical disorder, replace the set of the spool assembly and the main
frame of the switching section.
And, install pilot cover (9) on the flange section of the main frame of the switching section from the spring side of
the spool assembly securely, and install it on the main frame of the switching section by tightening washer
socket bolt (10) with Allen wrench of 4mm.
T=5.9 to 6.9 N-m (4.3 to 5.1 lbf-ft)
Fit the flange section on the opposite end of the main frame of the switching section so that pilot cover (8) snaps
into the flange section of the main frame of the switching section after checking that O-ring (7) is placed in, and
then install it on the main torque of the switching section with flange socket bolt (10) tightening with Allen
wrench of 4 mm to the specified torque.
T=5.9 to 6.9 N-m (4.3 to 5.1 lbf-ft)
b. In case of manual switching type (See Fig. "Manual switching type")
Insert respective spool in the spool holes of the main frame of the switching section paying attention to the
position and direction after checking that respective spool assembly and the spool holes of the main frame of
the switching section are free from dust, etc.
-Then, do not force the insertion of the spool due to the difficulty to getting in, or it may cause malfunction, etc.
Next, check that the spool moves smoothly by getting it in and out several times by hand, and be sure that there
are no unsmooth movements or catching.
And, install end cover (11) on the main frame of the switching section from the spring side of the spool assembly
with socket bolt (12) tightening with Allen wrench of 4 mm.
T=5.9 to 6.9 N-m (4.3 to 5.1 lbf-ft)
-At the time, do not tighten 2 socket bolts at a time, but tighten them slightly and alternately several times to make
uniform.
And, fit O-ring (3), dust wiper (4) and oil seal retainer (5) in order on the spool prevented from the opposite end of
the main frame of the switching section, and tighten socket bolt (10) with Allen wrench of 4 mm.
T=5.9 to 6.9 N-m (4.3 to 5.1 lbf-ft)
At this time, pay attention to the direction of the dust wiper (direct the lip outward.)
And, do not tighten socket bolts at one time, but tighten 2 socket bolts slightly so that oil seal presser is inserted in
parallel.
33-87
c. In case of P3 supply and independent travel spools (See Fig. "P3 supply and travel straight sections")
Ensure that the independent travel spool, piston and spool hole for the main frame of switching section are free
from dust, and that the O-rings (9) and (15) are securely fitted in the flange bottom of the main frame of the P3
supply section (three places in front and back of the main frame of supply section). Then install the piston (14) in
the flange section (the side of two O-ring grooves) of the main frame.
Insert the socket bolts (20) to the pilot body assembly (16 - 19) to fix it temporarily to the main frame.
-At this time, roughly adjust the vertical and horizontal orientations of the pilot body against the main frame.
Tighten three socket bolts with an Allen wrench of 4 mm to the specified torque equally.
T=5.9 to 6.9 N-m (4.3 to 5.1 lbf-ft)
Apply a small amount of hydraulic oil to the independent travel spool (2) and insert it through the spool hole
opposite to the side where the pilot body assembly was installed, without mistaking front and rear orientation.
-Do not use excessive force to push in the spool if it is sticking.
Then install the spring seat (3) and spring (4).
Further fit the pilot cover (10) in the flange section of the main frame securely, and tighten the sems-bolt (11) with
an Allen wrench of 4 mm at the specified torque to fix the install the cover to the main frame.
T=5.9 to 6.9 N-m (4.3 to 5.1 lbf-ft)
6. Assembling lock valve

If the lock valve became abnormal, replace it with new assembly.
The assembling procedures described below are only for reference after disassembling to investigate the cause
for abnormality. (See Fig. "(4) Disassembling lock valve")
At first, fix the lock valve cover (1) with a vise at the side faces other than the port face.
After fixing, insert the piston A1 (14) into the bore on piston guide (13) paying attention to its direction. Then
insert the piston B (15) into the bore on the lock valve cover paying attention for its direction. After that, tighten
the bush (17) with 26 mm wrench (or socket wrench) to the specified torque.
T=58.8 to 68.6 N-m (43 to 51 lbf-ft)
-At that time, confirm the fact that the O-ring (16) has been surely installed to the bush.
-If the pistons (A1 and B) are difficult to insert, do not try to insert them by force. It may lead to malfunction.
After the insertion of pistons (A1 and B), confirm smooth movement of them by taking them in and out with hand for
several times.
If the movement is not so smooth, replace the pistons (A1 and B) to new ones together with the lock valve cover as
assembly.
After setting the Ø7 steel ball to the place, tighten up the ball retainer (19) at the specified torque.
T=7.8 to 9.8 N-m (5.8 to 7.0 lbf-ft)
-At that time, confirm the fact that the O-ring (12) has been surely installed to the ball retainer.
After confirmation for the fact that the flat O-ring has been surely installed to the inserting side of lock valve of lock
valve body, set the lock valve assembly (2 to 8, 11) and needle valve (10), and insert it into the bore for lock valve.
Then aligning two positioning pins (9) on the lock valve cover with the bores on the lock valve body, slowly press
the lock valve cover until getting touch with the lock valve body.
T=9.8 to 10.8 N-m (7.2 to 8.0 lbf-ft)
At that time, confirm that the needle valve (10) is surely placed on the seat inside the lock valve cover.
Then tighten the socket bolts (20) with the 5 mm Allen wrench to the specified torque.
-At the tightening, make sure to tighten up two socket bolts alternatively so that the lock valve cover does not
incline.
33-88
7. Assembling relief valve and overload relief valve

The relief valve is essential for the performance and safety, and it is very difficult to reset the pressure.
Therefore, in case of the abnormality, replace it with a new assembly. 33
The assembling procedures described below are only for reference after disassembling to investigate the cause
for abnormality.
The figures in parentheses following the part names in the description are the item numbers in the cross-
sectional drawing [Fig. "(3) Main relief valve (P1,P2,P3) and overload relief valve"].
First, place spring guide (16) in adjusting screw (7) and then place spring (9) in.
Then, shake the adjusting screw lightly and be sure that the interference of spring guide (16) and spring (9) is
sufficiently ensured. If the interference is insufficient, spring (9) pops out or the protrusion from adjusting screw
(7) becomes larger. Thereafter fit poppet (6) in plug (4) and tighten adjusting screw (7) {spring guide (16), spring
(9) are already fitted.} lightly.
At that time, tighten lock nut M14 (8) lightly. And place spring (10) and piston (3) in poppet (2), and place it in
socket (1). And tighten body (5) and plug (4) to the specified torque after checking that piston (3) is inserted in
the hole of the top end of plug (4).
T=58.8 N-m (43 lbf-ft)
And adjust the pressure by adjusting screw (7) with Allen wrench of 4 mm, and tighten lock nut M14 (8) to the
specified torque.
T=19.6N-m (14 lbf-ft)
Assemble the relief valves in the reverse procedure of the disassembly paying attention to the direction and
order and observing the specified torque. Failure to do so may result in oil leakage or breakage.
8. Assembling anticavitation valve

The anticavitation valve is essential for the performance and safety, so in case of abnormality replace it with a
assembly.
For reference, the procedure for disassembly and assembly is shown below.
The figures in parentheses following the part names in the description are the item numbers in the cross-
sectional drawing [Fig. "(4) Anti cavitation valve"].
( Fig. 33-85).
First, place anti cavitation valve (1) in body (2), and place spring (4) in it. Then tighten the plug to the specified
torque.
T=58.8 N-m (43 lbf-ft)
Assemble the anti cavitation valve by the reverse procedure of the disassembly paying attention to the direction
and order and observing the specified torque.
Failure to do so may result in oil leakage or breakage.
33-89
33.2.2.8 Maintenance standard

Parts inspection
Parts name Inspection item Criterion and corrective action

Main frame of 1. 1.
switching section Existence of scratch, rust and corrosion Replace it when there is flaw on the
following section.
-Sliding section against the spool, especially
land section where the hold pressure is
applied.
-Seal pocket section where the spool is
placed in or flange section
-Seal section of the port in contact with O-
ring
-Seat section of relief valve and overload
relief valve failure it may cause malfunction,
etc.
Spool 1. 1.
Existence of scratch, rust and corrosion Replace it when there is scratch on the
peripheral sliding surface
2. 2.
Insert spool in the hole of the main frame of In case the spool is not smooth, repair or
the switching section, stroke it while rotating. replace it.
Load check valve 1. 1.
Damage of load check valve and spring In case there are flaws and scratches on the
seat section, repair or replace it.
2. 2.
Insert load check valve in plug and When it moves smoothly, normal, but if it
experimentally operate it. moves unsmoothly, replace it.
Around spring 1. 1.
Rust, corrosion, deformation and breakage Replace it when the movement is unsmooth
of spring, spring seat, plug, and cover or there is damage causing poor durability.
Around of seal of 1. 1.
spool Hardening, deformation and flaw of O-ring Replace
2. 2.
Deformation and flaw of dust wiper Replace
3. 3.
Rust, corrosion and deformation of oil seal Repair or replace
retainer
Relief valve 1. 1.
Overload relief valve Rust on outer surface Replace
2. 2.
Contact surface of valve seat In case there are flaw and dent, replace it.
3. 3.
Spring in abnormal condition Replace
4. 4.
O-ring, back-up ring Replace all parts, as a general rule.
33-90
33.2.2.9 Cause of failure and corrective action

(1) When abnormal condition is detected, check on the control valve, pump, cylinder, and motor for abnormality or
failure on the circuit. 33
For that, measure the pilot pressure, delivery pressure of the pump, load pressure, etc. And when a part of them
is required to disassemble for checking, follow the procedure of the disassembly and assembly in the above
description.
(2) Since dust is very harmful for hydraulic equipment, pay attention to the dust proof.
When a part of them is required to disassemble, before starting the work take a measure for dust protection.
(3) Handle the movable section carefully. Even if there is a slight flaw, repair it with oil stone or replace it. When
replaced, clean them.
(4) Handle O-ring, etc. carefully in order not to damage the gasket surface. These flaws will cause oil leakage.
1. Control valve
Phenomenon Cause Corrective action

1. 1. 1.
Each attachment Malfunction of relief valve Measure the pressure of relief valve
does not function, or -Dust caught between pressure regulating -Replace the assembly. *
the actuation is slow. valve and seat. *
(Poor power) -Dust caught between poppet and seat. * -Replace the assembly. *
Or there is no -Pressure regulating valve is stuck. * -Replace the assembly. *
response.section -Breakage or permanent set in fatigue of -Replace the assembly. *
spring. * -Readjust it, and tighten the lock nut to the
-Loose of adjusting screw specified torque.
2. 2.
Dust caught between the main frame and Disassemble and clean it.
spool, or stuck In case of severe flaw, replace the main
frame and spool.
2. 1. 1.
When spool is The space between the main frame of the Replace spool.
placed on the neutral switching section and the spool is too large.
position, the natural 2. 2.
drop of the cylinder is The spool is not returned to the neutral Measure pilot secondary pressure.
large. position completely.
-Dust caught between the main frame and -Disassemble and clean, or when stuck,
spool, or stuck replace the main frame and spool together.
-Breakage or permanent set in fatigue of -Replace spring.
spring
3. 3.
Malfunction of ORV Measure the pressure of ORV.
Refer to the description marked with *. Refer to the description marked with *.
4. 4.
Malfunction of lock valve Replace with a new lock valve section
-Dust caught in the seat section of the lock assembly (including the lock valve main
valve or needle valve body).
-Stick of the lock valve or needle valve
-Dust caught in the throttle of the lock valve
* In case of abnormality marked with *, do not fail to replace with the new relief valve assembly.
33-91

3. 1. 1.
When the cylinder is Malfunction of load check valve
set to the raise -Dust caught between load check valve and -Disassembly and cleaning.
position, the cylinder main frame. In case of the severe damage, replace the
moves downward main frame and load check valve together.
reversely when -Ditto
starting the -Load check valve is stuck. -Replace spring.
operation. -Breakage and permanent set in fatigue of
spring
* In case of abnormality marked with *, do not fail to replace with the new relief valve assembly.
2. Relief valve
The relief valve is essential for the performance and the safety, and it is difficult to reset the pressure other if
there is no facility in service shop, so when abnormality occurs, do not fail to replace the assembly. The
handling method is for reference, replace the assembly as a rule.

1. The pressure adjusting valve of each relief -Check that the engagement valve of
Pressure does not valve, poppet and piston are stuck, kept respective valve doesn't get matters caught
rise. open, or got caught dust in the seat section in it.
of the valve. -Each part slides freely.
-Clean all parts completely.
2. The adjusting valve of respective valve is -Replace the damaged part.
Relief pressure is damaged, or the piston is stuck to the -Clean all parts completely.
unstable. poppet. -Remove flaw on the surface.
3. 1. 1.
The relief pressure is Wear due to dust Disassemble and clean
not within the limit of 2. 2.
set values. Lock nut and adjusting screw are loose. Adjusting pressure
-Breakage and permanent set in fatigue of -Replace spring.
spring
3. 3.
Malfunction of RV and ORV Measure the pressure of RV and ORV.
4. 1. 1.
Oil leakage Damage on each seat section Replace the worn or damaged part.
Wear of O-ring Check that respective part move smoothly
before installing.
2. 2.
Respective part is stuck due to dust entered. Check that it is free from scratch, score and
foreign matter before installing.
33-92
33.2.3 PILOT VALVE (Attachment)
33.2.3.1 CONSTRUCTION 33
Pilot valve (Attachment)
Tightening Torque Table

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

101 CASING 1 213 SEAL 4 241-1 SPRING 2
151 PLATE 1 214 O-RING; 1B P20 4 241-2 SPRING 2
201 SPOOL 4 216-1 SPRING SEAT 2 301 JOINT; M14 1
211 PLUG 4 216-2 SPRING SEAT 2 302 DISK 1
212-1 PUSH ROD 2 217 WASHER 2 4 312 ADJUSTING NUT; M14 1
212-2 PUSH ROD 2 221 SPRING 4 501 BELLOWS 1
33-93
33.2.3.2 DISASSEMBLY & ASSEMBLY
No. Tool Name Remarks

(1) Tools 15~100N m class
a Torque wrench
(10~75 )
b Screw driver ( ) W= 2 ~ 3, 4 ~ 5
c Screw driver ( )
d Spanner 22mm and 32mm
(2) Jig
Special jig : for disassembling and assembling the joint
(301).
33.2.3.3 Disassembling procedure

33.2.3.3.1 General cautions for disassembly
(1) Since all the parts are very precisely manufactured, carefully handle them without causing collision with each
other or dropping.
(2) Perform the wark carefully without hammering or using excessive force even if the part is sticking. Otherwise
burrs may be produced or the part is damaged, leading to oil leakage or performance deterioration.
(3) When leaving the parts in the disassembled condition, always take rust preventive and dust protective
measures. Otherwise rust may be produced on the parts due to humidity or dust.
33-94
(1)
Remove the handle lever assembly and boot from the
casing (101). 33
(2)
Clean the pilot valve with white kerosene.
-Screw a blind plug in each port in advance.
(3)
Hold the pilot valve with a vise by applying a copper or
lead sheet.
Handle lever disassembly
(4)
Apply wrenches to the adjusting nut (312) and the disk
(302) across the flats to loosen and remove them.
Adjusting nut (312) removal
(5)
Turn the joint (301) counterclockwise with a jig to
loosen.
Joint (301) removal
When pulling off the joint, be careful that the joint is no sooner loosened than the plate (151), plug (211) and push
rod (212) may pop up if the return spring (221) is too strong.
33-95
(6)
Remove the plate (151).
Plate (151) removal
(7)
If the return spring (221) is not strong, use a slotted
screwdriver to pull out the plug (221) which remains
inside the casing (101) due to sliding resistance of the
O-ring.
-Apply the tip of the slotted screwdriver to the external
groove of the plug (211) while preventing damage to
the plug due to eccentric load.
Spring (221) removal
Be careful that the plug (211) may pop up due to the return spring (221) force when removing the plug.
(8)
Remove the push rod (212), plug (211), pressure
reducing valve section assembly, and return spring
(221) from the casing (101).
-Record the relation between the casing hole positions
and these parts.
Push rod (212) removal
33-96
(9)
In order to disassemble the pressure reducing valve,
shift the spring seat (216) laterally while pushing in the
spring seat (216) to make the secondary pressure 33
spring (241) deflect, and remove the valve from the
spool (201) through the larger hole.
-Be careful not to damage the surface of the spool
(201).
-Do not push down the spring seat (216) by more than
6 mm (0.24").
Pressure reducing valve disassembly
(10)
Separate the spool (201), spring seat (216), secondary
pressure spring (241), and washer 2 (217).
-Handle these parts as an assembly until assembling.
Pressure reducing valve disassembly
(11)
Pull out the push rod (212) from the plug (211).
Pulling out plug (211)
(12)
Remove the O-ring (214) and seal (213) from the plug
(211). Remove the seal (213) using a small slotted
screwdriver and so on.
Seal (213) removal
33-97
(13)
Cleaning parts
1.
Clean the parts in a rough cleaning container containing white kerosene (rough cleaning).
-Immerse the parts in the kerosene to facilitate the removal of dust and oil. Otherwise the parts may be damaged
due to using excessive force.
-Check the white kerosene for contamination and use clean one. Otherwise the parts may be damaged, leading to
performance deterioration after reassembling.
-Do not dry the parts with compressed air. Otherwise the parts may be damaged by dust or moisture in air or rust
may be produced.
2.
Put a part in a finish cleaning container containing white kerosene and turn the part slowly to sufficiently clean the
part including its interior (finish cleaning).
Dry parts by wiping off kerosene with clean rag.
3.
Rust prevention of parts
Apply rust preventive agent to the parts.
-Do not leave the parts without applying rust preventive agent. Otherwise rust may be produced, leading to
malfunction after assembly.
33-98
33.2.3.4 Assembling procedures

33.2.3.4.1 General cautions for assembling work
(1) General cautions for assembling work are almost similar to that for disassembling work. 33
(2) Remove metal chips or foreign substances from all the parts and ensure that the parts have no burrs or flaw
prior to assembly. Remove burrs or flaw if any, using oil stone.
(3) Replace the O-rings and back-up rings with new ones in principle.
(4) Be careful not to damage the O-rings and back-up rings when fitting them. (Apply a small amount of grease to fit
them smoothly.)
(5) Apply grease to the parts to be installed in order to prevent them from dropping.
(6) Tighten screws at the torque specified in tightening torque tabe. Watch the torque using a torque wrench.
(7) After finishing the assembly, screw blind plugs in all the ports to prevent dust intrusion.
33.2.3.4.2 Assembly
(1)
Insert the washer (217), secondary pressure spring
(241), and spring seat (216) to the spool (201) in this
order.
Assembling spool (201)
(2)
Shift the spring seat (216) laterally while pushing in the
spring seat (216) to make the secondary pressure
spring (241) deflect, and install the valve to the spool
(201) through the larger hole.
-Do not push down the spring seat by more than 6 mm
(0.24").
Assembling spool (201)
(3)
Install the return spring (211) into the casing (101).
Install the pressure reducing valve assembly into the
casing (101).
-Install these parts into the position before
disassembling.
Installing spool (221)
33-99
(4)
Insert the O-ring (214) and seal (213) into the plug (221).
-Direct the lip of the seal (213) as shown below :
Installing seal (213)
(5)
Install the push rod (212) into the plug (221).
-Apply hydraulic oil to the surface of push rod.
Installing push rod (212)
(6)
Install the plug assembly into the casing (101).
If the return spring (221) is not strong, the assembly
may stop due to sliding resistance of the O-ring (214).
-Do not use excessive force with the spool (201)
inclined. Otherwise the casing hole may be damaged.
Installing plug assembly
33-100
(7)
If the return spring (221) is too strong, install four
assemblies at the same time using the plate (151) and
temporarily fasten with the joint (301). 33
Installing plug assembly
Be careful to popping up of the plug assembly and plate (151).
(8)
Install the plate (151).
Install the joint (301) to the casing (101) and tighten
the joint to the specified torque using a jig.
Installing joint (301)
(9)
Install the disk (302) into the joint (301). Then install
and tighten the adjusting nut (312) to the specified
torque while holding the disk (302) across the flats with
a wrench.
-Do not change the position of the disk (302) during
tightening.
Installing joint (301)
Screw in until the disk contacts with four push rods (212) equally.
Carefully adjust the screwing position of the disk (302) because excessive screwing may result in secondary
pressure generation at the neutral position of the lever, leading to malfunction of the actual machine.
33-101
(10)
Apply grease to the rotating section of the joint (301)
and the push rod (212).
(11)
Install the handle lever assembly and boot to the
casing (101).
Applying grease
33-102
33.2.3.5 Maintenance standard
Maintenance item Standard Remarks 33

Amount of leakage Replace with a complete set of pilot valve when Condition :
the amount of leakage reaches more than 1000 Primary pressure : 2.94MPa (427 psi)
cc/min (61 cu•in/min) or 2000 cc/min (122 cu•in/ Oil viscosity : 23 mm2/s
min) at the neutral position of the handle or
during operation, respectively.
Spool Replace with a complete set of pilot valve when The wear condition to the left is
an amount of wear at the sliding section is more considered to correspond to the
than 10 µm (0.0004") in comparison with the above amount of leakage.
non-sliding section.
Push rod Replace when a wear amount of the tip is more than 1 mm (0.04").
Unnecessary play in Replace when a play more than 2 mm(0.079") A play generated by loosening of
operation section due to wear and so on is found on the disk (302) tightening portion should be adjusted.
or joint section (301) of the operation section.
Action stability Replace with a complete set of pilot valve when
abnormal noise, hunting or primary pressure
drop is generated during operation and the
trouble cannot be remedied according to
Section 33.2.3.6 TROUBLESHOOTING.
Replace seal such as O-ring with new ones after every disassembly.
33-103
33.2.3.6 TROUBLESHOOTING
Phenomenon Possible Cause Corrective action

Secondary pressure 1. 1.
does not rise. Primary pressure is insufficient. Secure primary pressure.
2. 2.
Springs (241-1, 241-2) are broken or Replace with new ones.
fatigued.
3. 3.
Clearance between spool (201-1, 201-2) Replace assembly.
and valve body (101) is abnormally large.
4. 4.
Play of handle portion is too much. Disassembly and reassembly or replace
handle portion.
is unstable. Sliding parts are caught. Correct.
2. 2.
Tank line pressure varies. Return directly to oil tank.
3. 3.
Air has contained into pipeline. Release air.
is high. Tank line pressure is high. Return directly to oil tank.
2. 2.
Sliding parts are caught. Correct.
33-104
33.2.4 PILOT VALVE (TRAVEL)
33.2.4.1 CONSTRUCTION 33
472
APPLY GREASE
501 TO BEARING
471 413
414
APPLY GREASE
TO TOP 420
214
210 203
APPLY GREASE
TO TOP 202
271
201
212
11
213
336
102
218
225
311
211
16 252
217 15
313
251
261
301
101
Pilot valve (Travel)
Torque Torque
N-m (lbf-ft) N-m (lbf-ft)
101 CASING 1 261 O-RING 3
102 CASING (DAMPER) 1 8.8(6.5) 271 SOCKET BOLT 4
201 COVER 2 301 SPOOL 4
202 PLUG 4 311 SPRING SEAT 4
203 GREASE CUP 4 313 WASHER 4
210 PACKING 4 336 SPRING 4
211 O-RING 4 413 CAM SHAFT 2
212 O-RING 4 414 BUSHING 4
213 O-RING 2 420 CAM 2
214 PUSH ROD 4 471 STEE LBALL 4
217 SHIM 4 6.9(5.1) 472 SET SCREW 2
218 SPRING SEAT 4 501 BELLOWS (BOOTS) 2
225 STEEL BALL 12 11 PISTON 4
29.4(21.7) 251 RO PLUG 3 15 SPRING 4
252 PLUG 2 16 SPRING 4
33-105

(1) Special jig for disassembly and assembly
Special jig 1 (for removal of bushing)
Special jig 1
(2) Precautions for disassembly and assembly

1. Disassemble and assemble the pilot valve paying attention to the rust protection for dust, dirt, etc. in order not to
allow them to enter in.
2. Handle parts carefully not to damage.
3. Write down the installing positions of respective part during disassembly, and assemble respective part to the
position as they were before.
(4) Disassembly
1. Stop respective port (P, T, 1, 2, 3, and 4) of the valve with plugs and clean the outer surface.
2. Fix the cleaned valve with vise.
3. Remove bellows (501) from cover (201).
4. Remove set screw (472).
5. Contact pry bar (Ø7 or less) to one end of cam shaft (413), and strike it lightly with a hammer.
6. Remove cam (420).
7. Remove socket bolt (271).
8. Remove cover (201).
9. Remove the casing upper assembly and fix the assembly with vise, again.
10.Draw push rod (214) out of plug (202).
11.Remove plug (202) with grease cup (203), packing (210) and O-ring (212).
12.Remove piston (11).
13.Remove damping spring (336) from the casing.
14.Take out spring seat (218) from casing (102) with tweezers.
15.Take out steel ball (225) using magnet.
16.Fix the lower casing assembly with vise, and take out O-rings (211 and 213) from casing (101).
17.Remove reduction unit valve assembly and return spring (15) from casing (101).
18.Place cover (201) on the flat bench transverse, apply bushing (414) to special jig 1, strike it lightly with hammer,
and pull the bushing out.
19.For disassembly of the reduction unit valve assembly first push spring seat (311) in and shift the spring seat
crosswise making secondary pressure spring (16), remove it from spool (301) passing through the large hole.
33-106
-Handle the assembled unit as an assembly.
33
20.Separate spool (301), spring (16) for secondary pressure setting, shim (217) and washer.
-Handle the assembled unit as an assembly. And there may be unit on which washer is not installed.
21.Remove grease cup (203) from plug (202).
22.Remove O-ring (212) from plug (202).
33.2.4.3 ASSEMBLY
(1) Clean all parts before assembly, and dry them by means of compressed air. Don't use rag.
-Repair the parts damaged when being disassembled, clean them, apply oil to the moving section, and install
the same parts on the positions where they are before.
-Replace every O-ring and packing with new ones.
(2) Install washer (313), shim (217), spring (16) for resetting the secondary pressure, and spring seat on spool
(301) in order.
(3) Pass spool (301) through the larger hole of spring seat (311), push the spring seat in, and install it making the
spring for the secondary pressure deflect and shifting the spring seat laterally.
(4) Fix casing (101) with vise, and place spring (15) for return in casing (101).
(5) Place the reduction unit subassembly described above par. 2) and 3) in casing (101).
-Install them on the positions as they were before.
-When placing the reduction unit subassembly in, pay attention to the spool lower end so as not to bring into
contact with the corner of the casing.
33-107
(6) Place O-rings (211, 213) in casing (101).

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

(14)Install push rod (214) on plug (202).
(15)Place the push rod subassembly which is assembled by the procedures in par. 11) to 14) in casing (102).
(16)Put cover (201) on the flat work bench, press bushing (414) with special jig 1, and press fit the bushing striking
lightly.
(17)Fix the lower cover assembly which is assembled by the procedures in paragraph 2) to 6) with vise, and install
the upper cover assembly which is assembled by the procedures in paragraph 7 to 15) on it.
(18)Install cover (201) on casing (102).
(19)Tighten socket bolt (271) to the specified torque.
(20)Install cam (420) on cover (201).
(21)Insert cam shaft (413) from the outside pressing cam (420).
(22)Apply Loctite #241 or equivalent to the thread of socket bolt.
(23)Tighten socket set bolt (472) to the specified torque.
(24)Incline cam (420), apply grease to the top end of push rod (214), and fill grease cup (203) of plug (202) with
grease.
(25)After fitting the top end of bellows (501) in cam (402), fit the lower side in the groove of cover (201).
33-108

33
does not rise. Insufficient primary pressure Secure primary pressure.
2. 2.
Permanent set in fatigue of spring (324) for Replace it with new one.
setting of secondary pressure.
3. 3.
The gap between spool and casing is too Replace it with complete remote control
large. valve.
4. 4.
The control section is loosened. Replace parts of control section.
is unstable. Sliding part is not smooth. Repair unsmooth section.
2. 2.
Variation of pressure of tank line Return oil to oil tank directly.
3. 3.
Air contamination in piping Bleed air by operating several times.
is high. Pressure of tank line is high. Return oil to oil tank directly.
2. 2.
Sliding part is not smooth. Repair unsmooth section.
Damping does not 1. 1.
work. Air is accumulated in piston chamber. Bleed air by operating several times.
2. 2.
Sliding part is not smooth. Repair unsmooth section.
3. 3.
Permanent set in fatigue of damping spring Replace it with new one.
(336)
4. 4.
Gap between damping piston (224) and Replace it with complete remote control
casing (damper) (102) is too large. valve.
5. 5.
Malfunction of check valve Disassemble and check on check valve
section.
6. 6.
Orifice of damping piston (224) is too large. Replace damping piston.
Damping torque is 1. 1.
heavy. Sliding part is not smooth. Repair unsmooth section.
2. 2.
Orifice of damping piston (224) is clogged. Repair or replace damping piston.
33-109

1 Housing 1 18 O-ring (1B P8) 1 40 Cover 1
2 Pinion shaft 1 19 O-ring 1 41 Ball bearing 1
3 Collar 1 20 Casing 1 42 Pin 1
4 Plate 1 21 Ball bearing 1 43 Valve plate 1
5 Taper roller bearing 1 22 Shaft 1 44 Pin 2
6 Oil seal 1 23 Thrust plate 1 45 O-ring (1B P21) 2
7 Taper roller bearing 1 24 Cylinder block 1 46 Socket bolt (M12X30) 5
8 Shim t2 (Shim select) 2 25 Collar 1 47 Orifice 1
Shim t3 (Shim select) 2 26 Spring 1 48 Timer valve assy 1
Shim t4 (Shim select) 2 27 Washer 1 48-1 Sleeve 1
Shim t5 (Shim select) 2 28 Snapring 1 48-2 O-ring (1B P10A) 1
Shim t13 (Shim select) 2 29 Pin 3 48-3 O-ring (1B P12) 1
Shim t14 (Shim select) 2 30 Retainer holder 1 48-4 O-ring (1B P14) 1
9 Collar 1 31 Retainer plate 1 48-5 Spool 1
10 Holder 1 32 Piston assy 9 49 Washer 1
11 Thrust washer 3 33 Disk 1 50 Spring 1
12 Inner race 3 34 Brake piston 1 51 O-ring (1B P18) 1
13 Needle bearing 3 35 O-ring (1B G110) 1 52 Plug 1
14 Planetary gear 3 36 O-ring (1B G135) 1 53 Relief valve assy 2
15 Thrust plate 1 37 Spring seat 2 54 Check valve 2
16 Drive gear 1 38 Spring 1 55 Spring 2
17 Plug 1 39 O-ring 1 56 Plug 2
33-110

57 O-ring (1B P14) 2 63 Name plate 1 69 Needle bearing 4
33
58 Plug 2 64 Rivet 2 70 Inner race 4
59 O-ring (1B P8) 2 65 Thrust plate 1 71 Thrust washer 4
60 Plug 1 66 Sun gear 1 72 Holder 1
61 O-ring (1B P11) 1 67 Screw 4
62 Socket bolt (M12X30) 2 68 Planetary gear 4
33.2.5.2 DISASSEMBLING PROCEDURE

(1) Precautions before disassembling
1. Remove mud, dust, etc. on the outer surface.
2. Drain the hydraulic oil in piston motor case and the port circuit.
3. Select clean work area, and pay attention to the parts in order not to adhere mud, dust, etc.
4. Don't disassemble the motor frequently more than necessary.
Disassemble the slewing motor by the following procedure.
(1) Separate the motor and the reduction unit. 62
Fix the motor assembly with vise, and remove socket
bolt (62).
(2) Disassembling motor 46 46

1.
Fix the motor assembly with vise.
Loosen socket bolt (46) and remove cover (40).
46 46
46
33-111
Be careful not to drop valve plate (43) when removing cover (40).
2.
Remove valve plate (43) and pin (42).
Valve plate (43) may be left on the motor side.
3.
Take out ball bearing (41).
Take out O-ring (45).
4.
Disassemble check valve
a.
Loosen and remove plug (56).
33-112
b.
Remove check valve (54) and spring (55).
33
5.
Removing relief valve (53)
a. 53
Loosen plug (53-6) and remove relief valve assembly
(53).
53-7
53-6
-Don't turn set bolt (53-7) to maintain the set pressure.

-Don't disassemble relief valve assembly because it has an important function.
6.
Remove valve plate (43), pin (44) and O-ring (39).
Valve plate (43) may be left on the cover side.
33-113
7.
Take out spring (38) and spring seat (37), and remove parking brake piston (34) by use of the gauge port of casing
(20).
The piston may pop out due to the air pressure, so be careful not to be injured. So, set the air pressure to low
position, and adjust the pressure checking the removing condition of the piston. And, the parking brake timer
should be removed after removing the brake piston.
(Otherwise the parking brake timer may not be removed.)
8.
Remove cylinder block, etc.
Cylinder block (24)
Collar (25)
Spring (26)
Washer (27)
Snap ring (28)
Pin (29)
Retainer holder (30)
Retainer plate (31)
Piston Assembly (32)
Disk (33)
33-114
9.
Remove retainer plate (31) and piston assembly (32).
33
10.
Remove pin (29) and retainer holder (30).
11.
Remove snap ring (28) keeping washer (27) pressed. 27 28
12.
27 25 26
Remove collar (25), spring (26) and washer (27).
33-115
13.
Remove thrust plate (23).
14.
Remove the shaft tapping the top end of shaft (22) with
a hammer.
15.
Remove ball bearing (21) and shaft (22).
Don't reuse the removed ball bearing.
16. 52
Disassembling timer valve (48)
a.
Remove plug (52).
33-116
b. 50
Remove spring (50), washer (49) and spool (48-5).
c.
Remove sleeve (48-1). 49
33
48-1
48-4
48-3
48-5
48-2
(3) Disassembling reduction unit

1.
Remove O-ring (19),
thrust plate (15),
drive gear (16),
planetary gear (14),
needle bearing (13),
inner race (12),
thrust washer (11),
and holder (10).
33-117
2.
Remove sun gear (66).
3.
Remove holder (72) and other related parts.
4.
Fix holder (72) to a vise, and loosen screw (67) to
remove thrust plate (65).
5.
Remove planetary gear (68),
needle bearing (69) and inner race (70).
Screw is difficult to remove because Loctite was applied to it at assembling. Warming up screw with a drier is
effective for easy removal.
For taper roller bearings (5 and 7) and collar (3), replace the body assembly.
6.
Remove collar (9) and shim (8).
7.
Remove pinion shaft (2).
Be careful not to drop the shaft when removing. When it is difficult to pull it out, tap it by a hammer.
33-118
8. 7
Separate the inner race from taper roller bearing (7).
33
9. 6
Break oil seal (6) and take it out.
Don't reuse the removed oil seal. When removing, be careful not to damage the outer race of taper roller bearing
(5) (7).
10.
7 17
Remove taper roller bearing (7), outer race and plug
(17). The disassembly is now completed.
33-119
33.2.5.4 ASSEMBLING PROCEDURE

(1) Precautions for assembly
1. Clean all parts with cleaning solvent, and blow air.
2. Handle the clean parts carefully without allowing dust to adhere and without producing dent, flaw, etc.
3. Replace seals, bearing and pin with new ones.
4. Tighten the respective fastener to the specified torque.
5. Apply grease to the oil seal and O-ring before fitting.
(Especially oil seal lip section)
6. There are many kinds of small item, so be careful not to miss them. (Especially drop in the hole.)
33.2.5.5 ASSEMBLY
Assemble the slewing motor by the following procedure.
(1) Assembling motor
1. Install relief valve assembly (53).
T=147 to 167 N-m (109 to 123 lbf-ft) 53
2. Install check valve (54) and spring (55).
55 54
3. Install plug (56).

T=37.2 to 41.2 N-m (27.5 to 30.5 lbf-ft)
56
33-120
4. Fit O-rings (48-2, 48-3 and 48-4) on sleeve (48-1).
48-1
33
48-4
48-3
48-2
5. Install sleeve (48-1) on case (20), and

51 50 52
place spool (48-5), washer (49) and
spring (50) in the hole of the sleeve.
6. Install plug (52) with O-ring (51). 49
T=79 to 89 N-m (58 to 66 lbf-ft)
48-1
20
48-5
Fit O-ring (51) carefully without damaging.
33-121
7. Install collar (25), spring (26) and washer (27) on 27 25 26 24

cylinder block.
TAPER SURFACE
CYLINDER BLOCK
Do not mistake the direction of installation.
8. Fit the snap ring (28) while keeping the washer (27) 27 28
pressed.
9. Apply grease to pin (29) and insert it to cylinder 30 29

block (24).
10.Install retainer holder (30).
11.Set piston assembly (32) on retainer plate (31), and 31 32

install it in the cylinder block (24).
33-122
Apply enough hydraulic oil on the sliding section before installation. 33

12.Press fit ball bearing (21) on shaft (22).
Install ball bearing (21) directing the snap ring as shown in the figure.
13.Press fit shaft (22) and ball bearing (21) on casing

(20).
14.Apply grease on the back side of thrust plate (23)

23
before installation.
Direct the taper side toward

the motor case side.
Do not mistake the direction of the thrust plate.
33-123
15.Install cylinder block (24), etc.
Be careful not to drop pin (29) when installing. Install disk (33).
16.Apply grease to O-rings (35) (36) and install it on 34

brake piston (34).
35 36
17.Place brake piston (34) in casing (20) paying 38 37 34

attention to the hole position of pin (44).
18.Fit spring seat (37) and spring (38) without
mistaking the direction.
37
38
37
Pay attention to the direction.
19.Apply grease to O-ring (39) and place it in casing 44 39

(20).
Check if pin (44) can be built in the hole of casing
(20) and brake piston (34).
If not remove brake piston (34) and align the
position again.
33-124
20.Apply grease to O-ring (45) and pin (44) and install 45 41 44

them on cover (40). Press fit ball bearing (41).
33
40
21.Install pin (42), and then install valve plate (43).

43 42
Apply grease to the back face to prevent dropping.
22.Install cover (40), etc. on casing (20) without 44 40 43

mistaking the position of pin (44).
20
Be careful not to drop pin (44) and valve plate (43).
23.Tighten socket bolt (46) temporarily, and then 46 46

tighten it to the specified torque with a torque
wrench.
T=121 to 235 N-m (89 to 99 lbf-ft)
46 46 46
33-125
(2) Assembling reduction unit

1. Press fit oil seal (6). 6
4mm(0.16in)
Dimension after oil seal is press-fitted
Apply grease to the oil seal fitting section of housing (1) and around the oil seal before press fitting.
2. Press fit taper roller bearing (7) and install plug

(17). 7 17
3. Seal grease in taper roller bearing inner race (5) 2 5

installed on pinion shaft (2).
Brand name of grease : SHELL Albania EP2
Sealing q'ty : 17 to 20 cm3
(approximately 1.04 to 1.22 cu-in)
4. Install pinion shaft (2) and so on.

Install inner race of taper roller bearing (7).
33-126
Apply grease to the lip section of oil seal (6) before installing pinion shaft (2). 33
5. Install thrust washer (71), inner race (70),

72 65 67 70 69
needle bearing (69), planetary gear (68),
thrust plate (65) and screw (67) on 68
holder (72).
71
Tighten up screw (67) after applying Loctite #242.

6. Install collar (9) and shim (8). 9 8 72

7. Install holder (72), etc.
8. Install sun gear (66). 66

Install holder (10).
10
33-127
9. Install thrust washer (11), inner race (12), needle

19 15 16 14 13 12 11 10
bearing (13), planetary gear (14), thrust plate (15)
and drive gear (16) on holder (10).
10.Apply grease to O-ring (19), and fit it in the housing

(1).
Selection for thrust plate (15)

When any components of the reduction unit were changed, select and install thrust plate corresponding to the
measured value "E" referring to the table below.
Dimension E (measured value) less than 6.6 (0.26") 6.6 - 7.2 (0.26"~0.28") more than 7.2 (0.28")
Part No. of Thrust plate (15) 80841-23020 80841-23019 80841-23018
Plate thickness : mm (in) 3.2 (0.13) 2.8 (0.11) 2.3 (0.09)
33-128
(3) Assembling motor assembly

62
1. Install the reduction unit on the motor assembly, tighten
socket bolt (62) temporarily, and tighten it to the
33
specified torque.
T=121 to 135 N-m (90 to 100 lbf-ft)
Align the protruded

section with port.
33-129
33.2.5.6 MAINTENANCE STANDARD

Replace each part referring to the list shown below.
(1) Motor
Part name Maintenance standard

Piston assembly (32) 1. Severe flaw and roughness of each sliding surface
2. Too large gap from the assembly to cylinder block bore
Upper limit of diameter clearance : 0.04 mm (0.0016")
3. Large play of shoe ball
Max. play (moving amount) : 0.4 mm (0.016")
Thrust plate (23) 1. Severe flaw and roughness of each sliding surface
Retainer holder (30)
Retainer plate (31)
Valve plate (43)
Brake piston (32)
Cylinder block (24) 1. Severe flaw and roughness of each sliding surface
2. Severe wear or breakage of the mating surface
Disk (33) 1. Severe flaw or peeling of each sliding surface (Friction plate)
2. Severe wear and peeling of mating surface
Ball bearing 1. Flaking and peeling of rolling contact surface
(21, 41) 2. Indentation of rolling contact surface
3. Abnormality of bearing rotation (Noise, unsmooth rotation)
Spring (26) 1. Sever breakage and deformation
O-ring 1. Flaw causing oil leakage, flaw causing insufficient sealing, and permanent set
(35, 36, 39, 45, 57, 59 and
61)
(2) Reduction unit

Pinion shaft (2) 1. Severe flaw, wear and flaking of gear tooth surface
Plate (4) 1. Severe flaw and wear
Taper roller bearing (5, 7) 1. Severe flaw, indentation and flaking of roller and race section
2. Unsmooth rotation with noise
* Replace the body assembly when required to replace the taper roller bearing.
Oil seal (6) 1. Severe flaw, deformation and wear of lip section
2. Hardening of lip section
Housing (1) 1. Severe flaw, wear and flaking of gear tooth surface
Holder (10) * Replace the body assembly when it is necessary to replace the housing.
Drive gear (16)
Planetary gear (14)
Inner race (12, 70) 1.Severe flaw, wear and flaking of needle bearing rolling surface
Needle bearing (13, 69) 1. Severe flaw, wear and flaking of needle bearing surface
Planetary gear (14, 68) 1. Severe flaw, wear and flaking of gear tooth surface
2. Severe flaw, wear and flaking of rolling surface in contact with needle bearing
Thrust plate (15, 23 and 1. Severe flaw, wear and seizure of sliding surface
65)
33-130
(3) Valve

33
Piston (53-14) 1. Severe flaw of sliding section and roughness of sliding surface
Casing (20) 2. Too large gap between piston and case hole
Upper limit of diameter clearance : 0.04 mm (0.0016")
Spring (50) 1. Severe breakage and deformation
Spring (55)
Plug (56, 53-6) 1. Flaw causing oil leakage, flaw causing insufficient sealing and permanent
Check valve (54) deformation.
O-ring
(53-8 to 53-11) (57)
Back up ring
(53-12, 53-13)
O-ring
(48-2 to 48-4) (51)
(4) Others

Other plug and O-ring 1. Flaw causing oil leakage, flaw causing insufficient sealing and permanent
deformation.
33-131
33.2.6 SWIVEL JOINT
13
10
5
9
15 7
16
8
4
3
11
14
12
TIGHTENING TORQUE :
52 57 N m
Construction

1 SHAFT 1 9 DUST SEAL 1
2 BODY 1 10 DUST SEAL 1
3 FLANGE 1 11 SNAP RING 1
4 THRUST RING 1 12 BOLT 4
5 PIN 1 13 PLUG 3
6 SLIPPER SEAL 4 14 SPRING WASHER 4
7 O-RING 1 15 BACK-UP RING 1
8 O-RING 1 16 SLIPPER SEAL 3
33-132

33.2.6.2.1 General precautions
• For disassembly and assembly, select the clean area and prepare clean containers to put the removed parts. 33
• Clean around the port and remove the paints of the joint with wire brush.
• Clean the removed parts with cleaning solvent, like light oil, etc.
• Replace seals with new ones every disassembly, and apply grease lightly.
• Check every part for severe wear and seizure, and remove burr, etc. with emery paper.
• Check that seal groove is free from foreign substances, dust, etc.
(1) Loosen bolt and remove flange (3).
Fix the body (2) with vise.
or
(2) Take out O-ring (8), snap ring (11) and thrust ring
(4). 4
8
11
(3) Remove shaft (1) from the body (2).

-Apply the knock pin to the end face of the shaft,
and strike it with hammer.
-Choose the knock pin made of copper, plastic, etc.
KNOCK PIN
2
33-133
(4) Remove dust seal (10) from the shaft.
10
(5) Remove seal, etc. from the inside of the body.

-Be sure of the position of seal, etc. referring to the
construction drawing.
-Take out O-ring with the pointed tool like a gimlet.
33.2.6.2.3 Assembling
(1) Insert seals in the body.
-Check the seal position referring to the
construction drawing.
-Ensure that O-rings are free from twisting.
-Don't deform or bend the slipper seal extremely.
(2) Install dust seal (10) to shaft (1).

-Apply enough grease to the lip section of the dust
seal.
10
33-134
(3) Install shaft (1) to body (2).

-Apply hydraulic oil or grease around the shaft
lightly. 33
-Strike the shaft with a plastic hammer carefully not
to damage seal.
1
(4) Fit thrust ring (4) and snap ring (11).

-Fit the snap ring in the groove correctly.
11
(5) Fit O-ring (8) and install flange (3).

(6) Install spring washer (14) and bolt (12).
or
-Tightening torque : 52 to 57 N-m (38 to 42 lbf-ft)
-Put pipe through the locking pin of the shaft, and
check that the shaft rotates smoothly at a torque of
approximately 78 to 108 N-m (58 to 80 lbf-ft)
33-135

33.2.6.3.1 Check Procedures and Remedy
Check Interval Place Checked Check Procedure Remedy

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

(1) Body and Shaft
Portion Judgment Criteria Remedy

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

-Portions of flange which -Wearing by 0.5 mm (0.020 in) or more, or abnormal Replace
slide against the shaft end. wear.
-Thrust ring
Body and shaft sliding -Wear less than 0.5 mm (0.020 in). Repair so that is smooth.
portion other than seals.
-Defects due to seizing or Repair so that is smooth.
foreign material catching,
etc., which are within the
wear limit of 0.5 mm (0.020
in) and to within repairable
level.
33-136
(3) Slipper Seal
Portion Judgment Criteria Remedy 33

• Seal is excessively extruded from groove. Replace
LOOSEN
SEAL
1.5mm (0.059") or more

• Slipper seal width is 1.5 mm (0.059 in) or more Replace
smaller than the width of the seal groove.
• Unequal wear of 0.5 mm (0.020 in) or more. Replace

0.5mm (0.02")
or more
(4) O-ring

• O-ring is excessively extruded from groove. Replace
LOOSEN
O-RING
• Unequal wear of 0.5 mm (0.020 in) or more. Replace
0.5mm (0.02")
or more
(5) Backup Ring

Width 4mm (0.16") or less • Thickness of 1.5 mm (0.059 in) or less Width of Replace
4 mm (0.16 in) or less.
Thickness
1.5mm (0.059")
or more
33-137
33.2.6.3.3 Inspection After Assembly

After assembly is completed, check for leakage of oil in each circuit using the equipment shown below.
(1) Connect a pipe (3) between the hydraulic pump (2) and the shaft (1) side port.
(2) Connect a pressure gauge to the body (4) side.
(3) Increase the pressure gradually to 22.6 MPa (3270 psi) adjusting the relief valve (6), then perform 1 minute leak
test.
-Open the neighboring ports on both sides and check visually for leakage from the ports.
-Check the body for crack, which may cause oil leakage, by a dye check.

External Oil Leakage -O-ring is defective. -Replace all the seal parts.
Internal Oil Leakage -Thrust ring is defective. -Replace all the seal parts.
-Excessive wear on sliding surfaces. -Replace the assembly.
Shaft Sticks -Shaft and body are stuck together. -Carry out grinding and honing. If excessive
looseness cause oil leakage, replace the
assembly.
Flange Looseness -Capscrew tightening is insufficient. -Retighten to the specified torque.
33-138
34. TRAVEL SYSTEM
34
34. TRAVEL SYSTEM

TABLE OF CONTENTS

34.1.1 NAME OF TRAVEL SYSTEM PARTS .......................................................34-3
34.1.2 CRAWLER .................................................................................................34-3
34.1.3 UPPER ROLLER .......................................................................................34-11
34.1.4 LOWER ROLLER ......................................................................................34-15
34.1.5 FRONT IDLER ...........................................................................................34-22
34.1.6 IDLER ADJUSTER ....................................................................................34-26
34.1.7 SPROCKET ...............................................................................................34-30
34.1.8 TRAVEL MOTOR .......................................................................................34-32
34.1.9 SLEWING BEARING .................................................................................34-35
34.2.1 TRAVEL MOTOR .......................................................................................34-38
34-1
34. TRAVEL SYSTEM

CX31B : PW14- S5PW3432E01
CX31B : PW14-46519~ S5PW3432E02
Revision June, 2010
CX36B : PX15-21105~ (CASE-NA)
PREFACE
(1) This manual covers all the procedures required for the dis / re-assembling of the machine.
(2) This manual consists of 34.1 ; REMOVING AND INSTALLING, and 34.2 ; DISASSEMBLING AND
ASSEMBLING.
(3) Although general disassembly and assembly procedures can be done in the order of the Table of Contents,
some items may be omitted because of circumstances or to save time.
(4) Please understand that it is impossible to describe all cases of the actual process for the removal / installation of
the assembled components, because of difference in the field conditions.
(5) Please be aware of the importance to establish the working order. Prior to starting the work, read and
understand the pertinent sections of this manual.
34-2
34. TRAVEL SYSTEM
34.1.1 NAME OF TRAVEL SYSTEM PARTS
34
Name and location of parts
34.1.2 CRAWLER
34.1.2.1 REMOVAL AND INSTALLATION PROCEDURES
34.1.2.1.1Removing Rubber Crawler

(1) Lift the one side of machine with attachment, as
shown in Fig. "Crawler removing posture", and
place support under lower frame to support
machine.
SUPPORT
Crawler removing posture
(2) Loosen grease nipple for crawler adjuster, discharging grease in cylinder, and release tension of crawler.
• When loosening the grease nipple of the adjuster,

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

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

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

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

securely with the sprocket, idler and lower roller.
(5) Tighten the grease nipple for the crawler adjuster,
and adjust tension by feeding grease.
Tools : Socket : 17mm, T=74 N-m (54.6 lbf-ft)
GREASE GUN
Rubber shoe
Appropriate tension A :
CX31B : 70 to 80mm(2.8 to 3.1 in)
CX36B : 70 to 80mm(2.8 to 3.1 in)
Steel shoe
Appropriate tension A :
CX31B : 115 to 130mm(4.5 to 5.1 in)
CX36B : 115 to 130mm(4.5 to 5.1 in)
Feeding grease
34-4
34. TRAVEL SYSTEM
34.1.2.2 REMOVAL AND INSTALLATION PROCEDURES (STEEL : OPT)

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

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

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

striking by hammer. B
-Remove lock pin (8) with shoe plate.
5. Apply master pin drawing out jig (a) to the small
diameter section of master pin (6), and draw it out
striking by hammer.
6
A
8
Removing lock pin
Removing master pin
-Especially Pay attention to the front idler which may spring out due to the force of spring when drawing out master
pin (6) to repair broken parts relating to the front idler.
-Be careful not to be injured by scattering materials, when large hammer is used.
6. Move the machine back slowly, and remove the

crawler extending it to the ground.
Weight of steel crawler (One side) :
CX31B, CX36B : 190kg (420 lb)
WOODEN BLOCK
Removing crawler
Don't approach the machine because the end of the crawler may drop just before extending the track link assembly
to the ground while rotating the sprocket. Put wooden block just in case.
34-6
34. TRAVEL SYSTEM
(2) Installation
1. Install the crawler to the position where the end of
the track link engages with the sprocket placing the
track link narrowing toward the end toward the front To front idler
idler side as shown in the figure.
34
Direction of crawler
2. Move the machine forward slowly by inserting the

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

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

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

-Apply molybdenum grease to the master pin before press fitting.
34-7
34. TRAVEL SYSTEM
5. After press fitting master pin (6), insert lock pin (8)
and bend the top end in advance.
6. After completion of installation, adjust the tension of
crawler by the same procedure of the rubber
crawler.
Extension of track link (Example for rubber

crawler)
(1) Construction of rubber crawler
No. NAME Q’TY per machine 1
1 RUBBER CRAWLER ASSY 2
Parts No. of Rubber Crawler Assy

CX31B, CX36B PX61D00026P1
Rubber crawler assy
• This standard machine provides rubber crawler.
(2) Construction of steel crawler
(Q’TY for one side)

No. NAME CX31B, CX36B
Shoe assy PX60D00012F1 2
4
1 • Shoe (Master) 1 2
1-2 • • Bushing 1 1
3
5
2 • Shoe (Track) 44 1-2 2
2
2-2 • • Bushing 44 4
3 • • Pin (Master) 1 2-2
4 • • Pin (Track) 44
1
5 • • Pin 1
Construction of steel crawler
34-8
34. TRAVEL SYSTEM

(1) Rubber crawler
Place M mark or mark CORE RUBBER COVER

at machine center
34
L : Distance between the bottom of
CENTER LINE OF STEEL CORD
frame and top of rubber crawler
SECTION B-B
Rubber crawler shoe
REPAIRABLE SERVICEABILITY
ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
Sag of rubber crawler L 70~80 (2.8~3.1) - - Adjustment
Where the depth of Where the depth of
Cracks and notch on
None them does not reach them reaches to the Replace
rubber crawler
to the steel cords. steel cords.
Breakage of steel cords None None Exist Replace
Where 10 percent of Where half of cores
Contact surface of rubber
None cores are visible are visible from Replace
crawler and lower roller
from outside. outside.
Height (H) 76.5 (3.0) - 51.5 (2.0) Replace
Lug projection (h) 25 (0.98) - 0 (0) Replace
34-9
34. TRAVEL SYSTEM
(2) Steel crawler (Track link)

Master pin
Track pin
Master link
G F
E H
Bushing
4 or more 40
6 or more TYP-2
60
C
A A
L : Distance between the bottom of

L frame and top of rubber crawler
Unit : mm (in)
Symbol ITEM Reference value Repairable level Service limit Remedy
A Link pitch 101.6 (4.0) 105 (4.14) 107 (4.24)
B Link height 60 (2.4) 57 (2.24) 56 (2.20) Parts over the critical
C Height of shoe lug 16.5 (0.65) 10 (0.39) 8 (0.32) value in use should
be replaced with link
ø32.2 ø30 ø28
D Bushing O.D. assembly.
(ø1.18) (ø1.10)
(ø1.27 )
Basic dimension Fit Fit
ø32.2
Shaft Interference
Interference of bushing
E (ø1.27 ) 0.11~0.20 Interference
and link
(0.0043~ 0
ø32
Hole 0.0079)
(ø1.26 ) Replace
ø19.2
Shaft
Interference
Interference of track pin (ø0.76 ) Interference
F 0.15~0.26
and link 0
ø19 (0.006~0.010)
Hole
(ø0.75 )
ø18.93
Shaft Clearance
Fitting of master pin and (ø0.745 ) 0.02~0.12
G — Replace link.
link (0.0008~
ø19
Hole 0.0047)
(ø0.75 )
4 6
0.9 (One side)
H Clearance gap of link (both side) (both side) Replace
(0.035)
(0.157) (0.236)
— Welding of link and shoe To be free from weld crack, blow hole, etc. Repair weld.
L Slack of iron crawler 115~130mm (4.5~5.1) — Adjust the tension.
34-10
34. TRAVEL SYSTEM
34.1.3 UPPER ROLLER
34.1.3.1.1 Removal
(1) Loosen the grease nipple for crawler adjusting
within one turn to discharge grease and release
tension on the crawler.
Tools : Socket : 17mm 34
Releasing crawler tension
Turn the grease nipple slowly paying attention not to turn more than one turn, and be careful for the spouting out
grease.
(2) Push up the crawler with a hydraulic jack, and

place suitable wooden block to keep a clearance
between the crawler and lower frame.
(3) Remove the fixing capscrews and nuts, and
remove the upper roller from the lower frame.
Weight of upper roller assembly : 3kg (6.6 lbs)
Supporting with wooden blocks
34-11
34. TRAVEL SYSTEM
34.1.3.1.2Installation
Before installing the upper roller, make sure that sufficient oil is filled in and that the upper roller rotates smoothly by
hand. If the oil volume is insufficient, refill oil, or if the upper roller does not rotate smoothly or oil is leaking, check
the bearing and the seals and replace them where necessary.
Oil : Gear oil SAE#90, API GL-4grade
Volume : 45cc (2.7cu-in)
(1) Insert the shaft of the upper roller assembly into the
lower frame.
(2) Coat mounting capscrews with Loctite #262 and
tighten it to the torque.
Tightening torque : 66 N-m (48.7 lbf-ft)
-Install it so the nut is located on the idler side.
-At installation, support the crawler with wooden
blocks the same way as it was dismantled so it
does not disturb the work.
(3) After installing upper roller, tighten grease nipple for
crawler adjuster, grease it, and adjust crawler Removing/Installing upper roller
tension.
No. NAME Q'TY No. NAME Q'TY 7 6 1 8 5 3 2

1 ROLLER 1 6 BEARING 2
2 SHAFT 1 7 O-RING 1
3 SEAL COVER 1 8 SNAP RING 1
4 COVER 1 9 PLUG 1
5 SEAL 1
4 9
Construction of upper roller
34-12
34. TRAVEL SYSTEM

The seal cover (3) and cover (4) of both sides of upper roller are press-fitted into the roller (1).
Therefore, this portion is usually not disassembled and assembled. If it is necessary, do as follows :
34.1.3.3.1 Disassembling
(1) Remove plug (9), and drain out oil.
Tools : Allen wrench : 5mm
(2) Remove seal cover (3) by means of drilling holes
on or cutting it, then remove seal (5). 34
(3) Remove snap ring (8).
(4) Remove cover (4) utilizing threaded hole (PT 1/8)
on it or other means.
(5) Place roller (1) with its end face on to the support
base, and set the press-in jig. Pull out shaft (2)
together with bearings (6) by means of a press
machine or hammering.
(6) If removing bearings (6) from shaft (2) is required,
remove them by means of using a gear puller or
other means.
Pressing out shaft
(1) Apply molybdenum grease to shaft (2), then install
two bearings (6) on it.
(2) Place roller (1) on to a plane base, applying a pad
to shaft (2) end, press it together with bearings (6)
into roller (1) with a press machine or hammering.
(3) Attach snap ring(8).
(4) Applying grease to new O-ring (7), attach it to cover
(4), then press it in roller (1).
(5) Install new seal (5).
(6) Install new seal cover (3).
(7) Fill 45 cc (2.7 cu in) of gear oil SAE #90, API GL- 4
in the roller (1) through plug bore on cover (4).
(8) Tighten plug (9).
Installing shaft
34-13
34. TRAVEL SYSTEM
Upper roller
Unit : mm (in)
REPAIRABLE SERVICE
CODE ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
ø75 ø71 ø69
A Tread dia.
(2.95) (2.80) (2.72) Replace
B Tread width 98 (3.86) — —
Basic
dimensi Tolerance Fit Fit Fit
on
Interference Replace
+0.015 (+0.0006) 0.002
C between shaft and Shaft shaft or
+0.002 (+0.0001) ~ Interference
bearing ø25 bearing
0.025 0.002 —
(0.984) 0
Hole (0.0001~ (0.0001)
-0.010 (-0.0004)
0.0010)
0 Clearance
Shaft
-0.013 (-0.0005) 0.004
~ Clearance Replace
Fitting between ø52
D Interference 0.004 — roller or
roller and bearing (2.05) -0.009 (-0.0004)
Hole 0.039 (0.0002) bearing
-0.039 (-0.0015)
(0.0002~
0.0015)
+0.050 (+0.0020) 0.009
Shaft
Interference +0.034 (+0.0018) ~
ø45 Interference
E between roller and 0.050 —
(1.77) +0.025 (+0.0010) 0.009 (0.0004)
cover Hole (0.0004~
0
0.0020) Replace
+0.14 (+0.0055) 0.074 cover
Shaft
Interference +0.12 (+0.0047) ~ Interference
ø63
F between roller and 0.140 0.074 —
(2.48) +0.046 (+0.0018)
cover Hole (0.0029~ (0.0029)
0
0.0055)
— Oil Gear oil SAE #90 API GL — 4 Grade, about 45cc (2.7 cu•in) Replenish
— Roller rotation Roller rotates smoothly by hand Reassembly
34-14
34. TRAVEL SYSTEM
34.1.4 LOWER ROLLER

Q'ty on one side : 4 pcs.
34.1.4.1.1 Removing
(1) Slightly loosen capscrews (M14X50) (2) fastening
lower roller assembly (1) to the lower frame.
Tools : Socket : 22mm 34
(2) As same as the case for removal of the crawler,
loosen the grease nipple for crawler adjusting
within one turn to discharge the grease, and
release the tension on the crawler.
Tools : Socket : 17 mm
Lower roller assembly
(3) Lift the lower frame high enough to remove the

lower roller, using the attachment.
(4) After lifting the lower frame to a proper height, place
square lumber under the lower frame to stabilize
the machine.
(5) Remove the capscrews (2) fastening the lower
roller, and remove the lower roller assembly.
Weight of lower roller assembly : 6 kg (13 lbs)
Crawler removing posture
34-15
34. TRAVEL SYSTEM
34.1.4.1.2Installing
(1) Installing position of lower roller
Install the lower roller assembly so that the plug
directs outward from the machine.
(2) Coat the mounting capscrews (2) with Loctite #262
in advance.
Place the roller assembly (4) between the crawler
and lower frame.
Fasten the capscrews (2) temporarily.
(3) Lower the machine in full contact with the ground
and tighten the capscrews (2) as specified.
Tools : Socket : 22mm, T=208 N-m (153 lbf-ft)
Installing lower roller
(4) Tighten the grease nipple of the crawler adjuster.
Lift the machine, and adjust the crawler tension by
feeding grease.
Tools : Socket : 17mm, T=74 N-m (54.6 lbf-ft)
No. NAME Q'TY 6

1 Roller 1
2 Collar 1
3 Collar 1
4 Shaft 1
5 Bushing 2
6 Stopper ring 1
7 Seal 2
8 O-ring 1
9 Plug : PT 1/8 1
Lower roller construction
34-16
34. TRAVEL SYSTEM
(1) Loosen the plug (9) to drain oil.
(2) Remove the stopper ring (6).
(3) Removing collar (2) and O-ring (8)
Place the lower roller on the jig (A) so that the shaft
(4) stands vertically. Apply the extruding jig (C) to 34
the upper shaft end. Push the shaft (4) with a press
or a hammer until the O-ring comes out from the
collar (2) to remove the upper collar (with seal) and
O-ring (8).
(4) Removing shaft
Push the shaft further to remove the shaft (4) and
the lower collar (with seal) (3) in one piece.
Removing shaft(4), collar(2) and O-ring(8)
Prior to extruding the shaft, prepare a drain oil container to receive lubricating oil remaining in the lower roller.
Otherwise the lubricating oil flows out to contaminate the work floor.
(5) Removing collar (3)

Place the shaft (4) with the collar (3) pulled out
according to the above procedure on the jig (B).
Apply the extruding jig (C) to the shaft to push it out
using a press.
(Note) The collar (3) is press fitted to the shaft (4).
-Interference for reference : 0.030 to 0.083 mm
(0.0012 to 0.0033 in)
Removing collar (3)

(6) Removing the seal (7)
Remove the seal (7) from the collars (2) and (3).
Removing the seal(7)
34-17
34. TRAVEL SYSTEM
(7) Removing the seal (7)

Take out the seal (7) from the roller (1).
Removing the seal(7)
(8) Removing bushing (5)

Cut off the bushing (5) having very small thickness
with a lathe or tear it off without damaging the bore.
When an amount of wear of the bushing is small,
place the roller (1) on the jig (A) and apply the tip of
the extruding jig (D) to the end surface of the
bushing (5) to hammer out the bushing.
Removing bushing(5)
In order to avoid damage to the bore of the roller (1), hammer the bushing (5) lightly and change the jig applying
position circumferentially little by little to push out the bushing slowly.
34.1.4.3.2 Assembly
(1) Press fitting bushing (5)
Align the center of the bushing (5) with that of the
bore of the roller (1) with the bushing press fit jig (E)
inserted to the bushing (5) to push the bushing in
with a press vertically.
Press fit the opposite side bushing (5) too.
-Apply molybdenum disulfide grease to the press fit
section of the bushing to press fit the bushing at a
normal temperature.
-If the press fit failed due to eccentric pushing and
so on, always replace the bushing with new one.
Press fitting bushing(5)
34-18
34. TRAVEL SYSTEM
(2) Press fitting collar (3)

Press fit the collar (3), into which the seal (7) is built
in advance, into the shaft (4) with a press.
-Press fit according to the arrow and dimensions
shown in Fig. "Press fitting collar (3)".
34
Press fitting collar (3)
(3) Installing roller side seal (7)

Install the seals (7) into both ends of the roller (1).
(See Fig. "Removing the seal(7)")
-Reuse the seals after ensuring that their surfaces
are free from damage or rust.
(4) Inserting roller (1)
Insert the roller to the shaft (4).
Installing roller(1)
(5) Installing O-ring (8)

Install the O-ring (8) to the shaft groove.
-Apply grease to the O-ring.
-Always replace the O-ring with new one prior to
reassembling.
(6) Installing collar (2)
Insert the collar (2), into which the seal (7) is built in
advance, into the shaft (4).
-Insert it until the stopper ring groove of the shaft
(4) is in alignment with the end surface of the collar
(2).
(7) Installing stopper ring (6)
Fit the stopper ring (6) in the stopper ring groove of
the shaft (4).
Installing the collar (2)
34-19
34. TRAVEL SYSTEM
(8) Oil supply

Supply 35 cc (2.1 cu in) of SAE #30 CD class
engine oil through the plug (9) hole.
(9) Leakage test
Perform leakage test at an air pressure of 2.0 kgf/
cm2 (14 psi) prior to tightening the plug (9).
(10)Installing plug (9)
Apply oil resistant sealing agent to the plug (4), and
screw it in the plug hole in the end surface of the
collar (2).
Tightening torque : 9.8 N-m (7.2 lbf-ft)
Installing oil supply plug (9)
After assembling the lower roller as a single unit, ensure that it shows no oil leakage and can be manually rotated.
34-20
34. TRAVEL SYSTEM
34
Lower roller
Unit : mm (in)
REPAIRABLE SERVICE
Code ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Flange O.D. ø107 (4.21) — —
Welding repair or
B Tread O.D. ø85 (3.35) ø77 (3.03) ø74 (2.91)
replacement
C Flange width 31 (1.22) 26 (1.02) 24 (0.94)
Basic
dimensi Tolerance Fit Fit Fit
on
–0.040
Clearance (–0.0016)
Shaft Clearance
D between shaft –0.073
0.1 (0.0039)
and bushing ø30 (–0.0029)
~ — —
(1.18) +0.185
0.258
(+0.073)
Bushing (0.0102) Replace bushing
+0.060
(+0.0014)
+0.15
Interference
(+0.0059)
Bushing 0.075
Interference +0.10
ø34 (0.0030) Interference
E between roller (+0.0039) —
(1.34) ~ 0
and bushing +0.025
0.15
Roller (+0.0010)
(0.0059)
0 (0)
— Oil Engine oil SAE #30 CD class 35cc (2.1cu•in) Replenish
— Roller rotation Rollers rotate smoothly by hand Reassembly
34-21
34. TRAVEL SYSTEM
34.1.5 FRONT IDLER
34.1.5.1.1 Removing
(1) Remove the crawler assembly.
(2) Remove idler together with idler adjuster assembly,
rolling it, using a pry-bar or equivalent.
(3) Loosen capscrews (M10×45) (c), and separate idler
assembly (a) from idler adjuster assembly (b).
Weight of idler assembly : 24 kg (53 lbs)
Weight of idler adjuster assembly : 14 kg (31 lbs)
Removing idler assembly

a c b
Disassembling idler assembly
The separated idler assembly (a) is easy to fall down.

Lay it down so it does not fall down on your feet, utilizing wooden blocks.
34.1.5.1.2 Installing
(1) Install idler assembly (a) to the idler adjuster 1 2
assembly (b) by means of capscrews (c) in the
reverse order of removing the idler assembly. Coat
the threaded part of capscrews (c) with Loctite
#262 beforehand.
Tools : Spanner : 17mm, T=66 N-m (48.7 lbf-ft)
(2) The assembly of the idler and idler adjuster is to be
installed to the lower frame so that the grease
feeding plug (1) is positioned to upside, and the
grease nipple (2) is facing to outside.
Installing idler assembly
(3) Following procedures of section 2, install the
crawler assembly, and adjust the crawler tension.
-On that occasion, confirm the lubrication through
the grease nipple is proper and that grease is not
leaking from the grease cylinder.
34-22
34. TRAVEL SYSTEM
10
1 9
8 7
5
2 6
3
4 34
Idler assembly construction

1 Idler 1 6 Seal 2
2 Collar 1 7 Snap ring 1
3 Collar 1 8 Capscrew 2
4 Shaft 1 9 Plug : PT 1/8 1
5 Bearing 2 10 Washer 2
(1) Remove the plug (9) and drain the oil. [Approx. Push with a press
80cc (4.9 cu in)] 4
SHAFT EXTRUDING JIG
(2) Remove the capscrew (8) for preventing coming 5
off, and pull of the collars (2) and (3) from the shaft. 1
(3) Remove the seals (6) and snap ring (7).
(4) Supporting the idler (1) with the supporting stand,
apply the shaft extruding jig to the shaft (4), and
push it out together with the bearing (5) using a
pressing machine.
-Except the case that replacement of the bearing
(5) is necessary, do not remove the bearing from STAND
the shaft (4).
Inserting shaft and bearing
34-23
34. TRAVEL SYSTEM
34.1.5.3.2 Assembly
(1) Apply molybdenum grease to the shaft (4), and Push with a press
install the bearings (5). 4
SHAFT EXTRUDING JIG
-In case of re-use of the bearing, confirm its smooth
rotation, and no defect and rust on them. 5
(2) Applying molybdenum grease to the idler (1), press 1
the shaft (4) together with the bearings into the
idler.
(3) Install the snap ring (7) and oil seal (6).
STAND
Inserting shaft and bearing
(4) For the oil seal (6), first apply grease into the
7 SEAL PUSHING JIG
groove on lip portion of the seal body (6a). Then 6b
push the seal body (6a) and sleeve (6b) into the 6
6a
place evenly with the special pushing jig carefully
not to give any distortion on the lip.
-Replace the seal to new one at reassembly.
-When the seal is not installed properly due to one-
sided pressing etc, replace it with new one.
(5) Install the opposite seal (6) by the same procedure.
Installing seal
(6) Insert the collar (2) to the shaft (4) and install the
capscrew (8).
Install the collar (3) and the capscrew (8) of the
opposite side in a similar way.
(7) Fill in 80 cc (4.9 cu-in) of the gear oil SAE #90 GL-4
through the plug hole in the idler (1).
(8) Tighten the plug (9).
Assembling idler
34-24
34. TRAVEL SYSTEM
D
C
34
G
A B E F
Idler assembly
Unit : mm (in)
REPAIRABLE
Code ITEM STANDARD VALUE SERVICE LIMIT REMEDY
LEVEL
Dia. of idler ø337
A ø343 (13.66 ) ø339 (13.2)
projection (13.3)
ø299
B Tread dia. ø305 ±0.5 (12 ±0.02) ø297 (11.7) Replace
(11.8)
C Flange width 27 (1.06) 22 (0.87) 20 (0.79)
D Tread width 71 (2.80) — —
Basic dimension Fit Fit Fit
Interference
0.002
Fitting shaft / Interference Replace of shaft or
E (0.00008)
bearing ø35 (1.38) 0.002 — bearing
~
(0.00008)
0.028
(0.00110)
Clearance
0.004
(0.00016) Clearance
Fitting idler / Replacement of
F ø80 (3.15) ~ 0.004 —
bearing idler or bearing
Interference (0.00016)
0.039
(0.00154)
— Oil Gear oil SAE #90 GL-4, 80cc (4.9 cu•in) Replenish
— Idler rotation Idler rotates smoothly by hand Reassembly
T=66 N•m (48.7 lbf•ft) :

G Tightening Torque 17mm — Retightening
Apply Loctite #262
34-25
34. TRAVEL SYSTEM
34.1.6 IDLER ADJUSTER
34.1.6.1.1 Removing
(1) Idler adjuster assembly assembled with idler
a c b
assembly (a) is removed from the lower frame.
Do this work by referring to 34.1.5.1.1 Removing
front idler.
(2) Loosen capscrews (c) and separate idler assembly
(a) from idler adjuster (b).
Disassembling idler assembly
Weight of idler assembly : 24 kg (53 lbs)
Weight of idler adjuster assembly : 14 kg (31 lbs)
The separated idler assembly is easy to fall down. Lay it down so it does not fall down on your feet, utilizing
wooden blocks.
(1) Installation is done in the reverse order of removal :
First of all, assemble idler assembly (a) to idler adjuster assembly (b), and tighten them together with capscrews
(c).
In that case, coat the threaded part of capscrews (c) with Loctite #262 beforehand.
Tools : Spanner : 17mm, T=66 N-m (48.7 lbf-ft)
(2) Before installing the idler adjuster to the crawler frame, assemble it with the idler assembly. For the procedure,
refer to 34.1.5.1.2 Installing front idler.
No. NAME Q'TY 9

1 Piston 1
2 Grease cylinder 1
3 Spring 1
4 Plate 1
VIEW A
5 Nut 1
6 Pin 2
7 Oil seal 1
8 O-ring 1
9 Split pin 1 9 5 4 3 2 7 8 1 6
10 Grease nipple 1
10
Idler adjuster assembly
34-26
34. TRAVEL SYSTEM

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

stand.
3. Loosen the holding-down nuts of the jig and draw
out the retainer upward.
4. Draw out piston (1) from grease cylinder (2) of the
idler adjuster assembly.
5. Taken out oil seal (7) and O-ring (8) from grease
cylinder (2).
Slinging work of idler adjuster
6. Set the idler adjuster assembly on the stand of the

jig (V), with its plate (4) side facing up.
7. Fit retainer plate to plate (4) tighten holding-down
nuts alternately, and secure idler adjuster
assembly.
Fixing Holding-down nut
34-27
34. TRAVEL SYSTEM
8. Remove split pin (9), press spring (3) lifting it with

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

spring is extended to its free length.
Remove the retainer plate and take off plate(4).
The free length of the spring : Approx. 247.3 mm RETAINER PLATE
(9.74 in)
10.Hook lifting eye nut (W) to screw M24×P3 on
grease cylinder (2) top end and hoist it.
Lifting nut : M24×P3
11.Remove the grease cylinder (2) and from the spring
4
(3).
Removing retainer plate
(2) Assembly
Perform assembly in the reverse order of disassembly.
1. Insert grease cylinder (2) into spring (3) and erect it

in the center of the jig stand upright.
2. Install the plate (4) on top of spring (3).
Center the rod of grease cylinder (2) and the holes
in bracket (4). Attach the retainer plate and four
holding-down nuts. Fasten the nuts evenly all round
fix the idler adjuster assembly to the jig body.
3. Extend the hydraulic jack, compress spring (3) to a
set length and screw in nut (5) to the screwed part
at the tip of grease cylinder (2).
Set length of the spring : 196 mm (7.72 in)
Removing and installing of idler adjuster assembly
34-28
34. TRAVEL SYSTEM
4. Tighten nut (5) till the holes for locking split pins (9)
are aligned, then fit split pin (9).
5. Remove the idler adjuster assembly from the jig.
6. Fit oil seal (7) and O-ring (8) to grease cylinder (2).
-Apply grease on oil seal (7) and O-ring (8).
7. Fill up grease in grease cylinder (2), remove the
grease nipple from piston (1) and press the piston
by hand to discharge the inside air. 34
-Push the piston in while directing the grease nipple
hole downward to make it easier to release air.
8. Tighten grease nipple to piston (1). Attach idler adjuster assembly to the jig

Unit: mm (in)
Code ITEM Rubber crawler Steel shoe

A Installed length of spring 196 (7.72) <--
B Free length of spring 247.3 (9.74) <--
C Stroke 20 (0.79) <--
D Set length 352 (13.9) 354 (13.9)
E Outside view of piston No scoring and rusting <--
F Tightening torque of grease nipple 74 N-m (54.6 lbf-ft) <--
D (STEEL SHOE)
D (RUBBER CRAWLER)
A,B
E
F
Idler adjuster assembly
34-29
34. TRAVEL SYSTEM
34.1.7 SPROCKET
34.1.7.1.1 Removing
(2) Place wooden block under the lower frame so the
sprocket is off the ground.
(3) Loosen capscrew (M12) for the mounting of the
sprocket by means of an Allen wrench and remove
the sprocket.
Tools : Allen wrench : 10 mm
Single weight of sprocket : 9 kg (20 lbs)
Making sprocket free
(1) Check the fixing parts of the travel motor and the
sprocket, eliminate burrs and dirt thoroughly, and
install the sprocket.
(2) Apply Loctite #262 to the threaded portion of
capscrew to mount the capscrew and fasten the
temporarily.
Removing sprocket
(3) Remove the wooden block under the lower frame

and tighten capscrew to specified torque to fix
sprocket and travel motor.
Tools : Allen wrech : 10 mm
T=107 N-m (78.9 lbf-ft)
(4) Install crawler.
Tightening capscrew
34-30
34. TRAVEL SYSTEM
6.6
34
(14.83")
P, C, D37
Sprocket
STANDARD REPAIRABLE SERVICE

Code ITEM REMEDY
VALUE LEVEL LIMIT
A Width of sprocket teeth 24 (0.94) 21 (0.83) 20 (0.79) Replace
B O.D. of sprocket ø385.6 (15.18) ø380 (14.96) ø378 (14.88) Welded repair, or replace
34-31
34. TRAVEL SYSTEM
34.1.8 TRAVEL MOTOR
34.1.8.1.1 Removing
(2) Place wooden block under the lower frame so the
sprocket is off the ground.
(3) Remove the capscrews (A5) located inside the
lower frame and remove the covers (A2).
(4) Push the air bleeding cap with boots on hydraulic
oil tank to release air in the tank.
Making sprocket free
(5) Disconnect the joint of hydraulic piping connected A2

with the travel motor, and plug the joints in order to
prevent outflow of oil and entering of dust.
Tools : Spanner : 19 mm and 22 mm A5
(6) Loosen the capscrew M12×25 (B3) that fasten the

travel motor to the lower frame. On that occasion,
put a matching mark between the lower frame and
the travel motor.
B3
Tools : Allen wrench : 10 mm
Removing cover and travel motor
(7) Apply a wire rope to a part near the sprocket of the

travel motor for balancing, and remove the unit out
of the lower frame.
Weight of travel motor (with sprocket) :
52 kg (115 lbs)
WOODEN
BLOCK
Removing and installing travel motor
34-32
34. TRAVEL SYSTEM
(1) If there are burrs and dirt on fitting part with which
CAPSCREW for SPROCKET
the travel motor are fastened, eliminate it Loctite #262 TRAVEL MOTOR
beforehand. Place a wire sling in the travel unit with 107 N m (78.9 lbf ft)
the same way as in the removing, and install it to

the lower frame.
(2) Coat the threaded part of the mounting capscrew
(B3) with Loctite #262 and tighten them.
Tools : Allen wrench : 10 mm 34
T=107N-m (78.9 lbf-ft)
CAPSCREW for TRAVEL MOTOR

Loctite #262
107 N m (78.9 lbf ft)
Installing travel motor
(3) Reconnect the hydraulic pipings as before, and tighten the joints to the specified torque.
-Fill the casing with hydraulic oil prior to perform drain piping.

size (PF) used (mm) fitting fitting
1/8 17 16.7 (12)
1/4 17,19 36.3 (27) 29.4 (22)
3/8 22 73.5 (54) 49.0 (36)
1/2 27 108 (80)
Installing hydraulic pipings (LH-travel motor)
(4) Install the covers (A2) located inside the lower FILL PLUG
frame, and tighten capscrews (A5).
(See Fig. Removing cover and travel motor)
LEVEL PLUG
T = 65.7 N-m (48.5 lbf-ft)
(5) Remove the wooden block supporting the lower
frame and install the crawler.
(6) Check the oil level in the reduction unit of travel
motor [See Item (7) below] and replace or replenish GL
oil as required. DRAIN PLUG

Oil : GEAR OIL SAE#90 GL-4
Volume of oil : 700 cc (43 cu-in)
Checking oil level
(7) Checking oil level in reduction unit

a. Stop the machine so that the drain plug of the reduction unit is located in the lowest position.
b. Remove the level plug and check the oil level and contamination. The oil level is proper if it is close to the plug
bore. Replenish oil if necessary.
-When starting operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leakage and noise.
34-33
34. TRAVEL SYSTEM
ITEM SPEC.
OIL TIGHTENING TORQUE
Sprocket fixing
Capscrew M12
Apply Loctite #262

Travel motor fixing 107 N•m (78.9 lbf•ft)
Capscrew M12
Spec. and grade Gear oil SAE#90 GL-4

Volume 700cc (43 cu•in)
34-34
34. TRAVEL SYSTEM
34.1.9 SLEWING BEARING
34.1.9.1.1 Removing
(1) Remove the upper slewing structure. (See detail of A B
"Upper Slewing Structure")
(2) Remove capscrews (B) that fix the inner race of
slewing bearing (A). 34
Tools: Socket: 19mm
(3) Remove the grease in the inner race of slewing
bearing.
(4) Screw lifting-bolts in the slewing bearing (A), and lift
it by crane.
Weight of slewing bearing assembly : 42kg (95 lbs)
Slewing bearing
Lifting slewing bearing
(1) Before installing the slewing bearing, clean A B LOCTITE #262
thoroughly the bearing and the mating surface of T=115 N m (84.8 lbf ft)
the lower frame to be free from dirt, oil and other GREASE BATH
foreign materials.
LOWER FRAME T=33.3 N m (24.6 lbf ft)
(2) Lift up the bearing and place it on the lower frame,
aligning the "S" mark engraved on the inner race as
shown in Fig. "Location of "S" mark to install
slewing bearing". Section A-A
(3) Coat the threads of the capscrews (B) with Loctite
#262 and tighten all capscrews temporarily.
(4) Tighten the capscrews at 180intervals alternately,
and tighten them up to the specified torque.
T=115 N-m (84.8 lbf-ft)
(5) Replenish 2.5 kg (5.5 lbs) of "Lithium grease" to the
grease bath.
(6) After installing the slewing bearing on the lower
frame, install upper slewing structure.
SLEWING BEARING
INNER "S" ZONE
(S-MARK)
Location of "S" mark to install slewing bearing
34-35
34. TRAVEL SYSTEM
No. NAME Q'TY No. NAME Q'TY 3, 4, 5 1

1 INNER RACE 1 6 PLUG 1
2 OUTER RACE 1 7 TAPER PIN 1 2
3 BALL 70 9 SEAL B 1 6
4 SPACER 65 10 GREASE NIPPLE 1 10
5 SPACER (ADJUSTING) 5 7
9
Cross-section of slewing bearing
(1) Take off seal B (9) fitted in the groove on lower
1
circumference of inner race (1), and place the
7
bearing in level on a wooden block.
(2) Remove taper pin (7), using a hammer and a push 2
rod. WOODEN
(3) Remove plug (6) with an puller bolt making use of BLOCK
the threaded bore in the center of the plug (6).
(4) After removing plug (6), take out balls (3) and 6
spacers (4) (5) from the bore in order, while rotating 9
outer race (2) slightly.
Disassembling slewing bearing
1
4 5
3
Removing balls / spacers
Installing balls
(1) Degrease thoroughly the groove for seal B (9) located in the outer circumference of inner race (1). Coat the
grooves with adhesive Cyano Bond PO-1, fit seal B (9), and place inner race (1) on a surface table.
(2) Lift and lower outer race (2) slowly till the top surface of inner race (1) matches the bottom of the sealing groove
of outer race (2). Place an adjusting washer under outer race (2) in order to support the outer race so the track
surface of ball (3) is aligned.
(3) Insert balls (3) and spacers (4) (5) coating with grease (NLGI No.2 Lithium bace with MoS2) alternately through
the hole for plug (6) on outer race (2).
34-36
34. TRAVEL SYSTEM
When inserting balls (3) and spacers (4) (5), the ball tracks must be aligned completely.
To achieve it, outer race (2) should be adjusted. It is very dangerous to put your finger into the plug bore directly ;
always use a push rod or a hooked rod.
(4) Install plug (6) to outer race (2), confirming the

direction and the position of the bore for taper pin
(7). 34
(5) Push taper pin (7) into bore, and caulk the head of
the taper pin with a punch.
(6) Confirm that grease nipple (10) is useful. Apply
grease (NLGI-2 EP type) and confirm that the outer
race rotates smoothly and that the lip of the seal is
not scored.
Grease amount : Approx. 90g (3.2oz)
Installing spacer

Regarding the maintenance standards for the wear of the slewing bearing, refer to the Article Measuring Slewing
Performances in PW13 Maintenance Standards and Test Procedures.
34-37
34. TRAVEL SYSTEM

34.2.1 TRAVEL MOTOR
34.2.1.1 SUMMARY
(1) General View
P2 P3
(2) Hydraulic circuit diagram
34-38
34. TRAVEL SYSTEM
(3) EXPLODED VIEW OF TRAVEL MOTOR AND REDUCTION UNIT
34
34-39
34. TRAVEL SYSTEM

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

Rear flange assembly 1 236 -O-ring 2
-Rear flange kit 1 237 -O-ring 2
201 --Rear flange 1 252 -Hexagon socket plug 4
223 --Spool 1 254 -Hexagon socket plug 4
-Spool kit 1 266 -Spring 1
34
263 --Spool 1 268 -Steel ball 1
264 --Oil stopper 1 273 -O-ring 2
221 -Plug 2 275 -O-ring 1
224 -Plug 2 279 -Filter 1
225 -Stopper 2 280 -Plug with flange 1
226 -Plug 2 299 -Name plate 1
227 -Valve 2
228 -Spring 2 241 Parallel pin 2
230 -Spring 2 243 Capscrew 6
34-41
34. TRAVEL SYSTEM
34.2.1.2 TOOLS AND JIGS

(1) Standard tools
No. NAME SIZE Q'TY

1 Allen wrench 8 (For M10&PF3/4), 10 (For M17), 14 (For M16) 1 each
2 Socket wrench Barrel type 1
(Ratchet handle)
3 Torque wrench Dial type, about 12 N-m (8.7 lbf-ft) 1 each
Dial type, about 90 N-m (65 lbf-ft)
Dial type, about 280 N-m (203 lbf-ft)
4 Torque wrench adaptor Nominal socket size 13 1 each
Nominal rod size 8 and 10
5 Hexagon socket For width across flats of 3 mm 1
6 Extension bar 150 mm (6") 1
7 Hammer Nominal size 12 1
8 Plastic hammer L= about 300 mm (12") 1
9 Flat screwdriver about 150 mm (6"), 50 mm (2") 1
10 Snap ring pliers For shaft 1
For hole
11 Cutting pliers (JIS B 4623) 200 mm (8") 2
12 Lifting tool Lifting capacity : 300 kg (660 lbs) or over 1 set
Lifting eye (for M16) (2)
Lifting eye (for PF 3/8) (2)
Wire with hooks (1)
13 Container Vat for general use : 2
W450 X D300 X H120 (W17.7" X D11.8" X H4.7")
14 Leather gloves 1 pair
(2) Tools
APPLICATION ITEM
NAME SIZE REMARKS Q'TY
(Item in cross-sectional or exploded view)
General
Disassembly and assembly 1 set
workbench
Parts cleaning Cleaning bath For rough and finish cleaning 1 set
Workbench for Pressing capacity : 1.96 kN
104 and 149 1 set
press [440 lbs] or over
Heating capacity : 100C
degrees or over (212F
149 Heating bath degrees) 1 set
Volume 500 X 500 X 500 mm
(20" X 20" X 20")
Pressure
Disassembly 161, 162, 163, and 112 Compressed
(294~490 kPa)
Drying after cleaning air
(43~71 psi)
34-42
34. TRAVEL SYSTEM
(3) Jigs
No. NAME No. NAME

1 Working bench for travel motor 2 Fixing metal
34
This is used to carry out the work for assembly and This is used to connect the spindle (2) and hub (1).
disassembly of travel motor easy and safe.
3 Retainer metal (I) 4 Retainer metal (II)
This is used to insert spring (114), washer (110), This is used to pull out bearing (149) from drive
snap ring (145) into cylinder block (104), and also shaft (102).
used to remove spring (114) from cylinder block
(104).
5 Oil seal press fit tool 6 Bearing press fit tool
For press fitting the oil seal (132) in the oil seal hole For press fitting the ball bearing (24) in the hub (1).
of the spindle (2).
7 Jig for adjusting the preload to the bearing 8 Steel rod (1)
For installing the ring nut (22) to the spindle (2). This is used to remove the ring (45) from the hub
(1).
34-43
34. TRAVEL SYSTEM
No. NAME No. NAME

9 Long lifting eye 10 Spatula
Application "A"
Hub M12
Spindle M12
Travel motor M12
"A"
This lifting eye is used to sling up travel motor, the This is used to remove the timing plate (109) from
spindle (2) and the hub (1). rear flange (201).
11 Pin punch 12 Jig for cover removal
This is used to remove the outer race of floating This is used to remove the cover (13) from the hub
seal (31). (1).
13 Floating seal (F/S) inserting jig (I) 14 Floating seal (F/S) inserting jig (II)
For building the floating seal (31) into the hub (1). For building the floating seal (31) into the hub (1)
and spindle (2).
15 Floating seal (F/S) inserting jig (III)
For building the floating seal (31) into the spindle

(2).
34-44
34. TRAVEL SYSTEM
34.2.1.3.1 PREPARATIONS FOR DISASSEMBLY

(1) Workbench preparation
-Prepare workbench for travel motor.
-Prepare workbench which is rigid enough to disassemble or assemble internal parts of travel motor and has a
wide area for placing them to prevent them from moving or dropping during the work.
-Cover workbench with rubber, vinyl, etc.
(2) Preparations of tools and materials 34
Prepare materials shown in 34.2.1.2 TOOLS AND JIGS.
34.2.1.3.2 GENERAL PRECAUTIONS FOR WORKING
-Internal parts during disassembly are slippery as they are smeared by hydraulic oil. Handle them with extreme
care not to drop them.
Otherwise, you may be injured or they may be damaged.
-Combustible material such as kerosene is used to clean the parts.

Handle it with extreme care not to cause fire or burns, as it catch fire easily.
(1) Prior to disassembly, make a good judgment on the features etc. of the generated abnormalities to work
according to the disassembling procedure.
(2) All parts are manufactured in high precision. Therefore handle them with care not to bump them each other or
drop them.
(3) Work patiently not to forcibly strike or pry the sticking parts during disassembly. Otherwise it may result in
generating burrs, damages, and performance deterioration.
(4) Be careful not to leave the disassembled parts without appropriate protection. Otherwise they may be rusted by
moisture and or contaminated by dust.
(5) Put a match mark on each mating surface of part during disassembly.
(6) Carry out the work putting every removed part in order, and taking care not to cause damage or loss.
(7) Sealing parts shall be replaced in principle, even though no damage is found on them. Keep them on hand prior
to disassembly.
(8) Photos and figures of typical models are shown. Any partial difference between them and the product in use
does not affect the disassembling procedure.
34-45
34. TRAVEL SYSTEM
34.2.1.3.3 DISASSEMBLING
(1) Cleaning travel motor
1. Tighten the lifting eyes into the tapped holes of the
spindle (2).
Mounting lifting eye
Screw two lifting eyes into the tapped holes of the spindle diagonally located with each other.
2. Pass a wire sling through the lifting eyes, lift up the

travel motor by hoist, and carry into the cleaning
bath.
3. Clean the travel motor with a car brush.
Cleaning travel motor
Since soil and sand are accumulated in the clearance (where the floating seal is fixed) between the hub (1) and the
spindle (2), clean it with particular care.
34-46
34. TRAVEL SYSTEM
(2) Installing travel motor

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

workbench.
Fixing travel motor on workbench
(3) Draining lubricating oil

1. Turn over the travel motor.
2. Loosen a plug (33) and two socket plugs (39).
-If the plug (33) and the socket plugs (39) are
removed and the travel motor is reversed, oil spills.
Loosen them to such an extent that they can be
turned by hand.
Removing plug (33)
34-47
34. TRAVEL SYSTEM
4. Remove the plug (33) and two socket plugs (39)

from the cover (13) and drain out the lubricating oil.
-When draining out the lubricating oil, place a
container under the workbench.
(Oil quantity 0.6 liter (0.16 gal)
5. Remove the O-rings (37) from the plug (33) and
two socket plugs (39).
Draining oil
(4) Removing cover (13)

2. Remove the ring (45).
3. Loosen two capscrews in the middle of the cover
removal jig in the thread holes from which the plugs
(33) and (39). (Two places)
4. Apply a block to two capscrews in the middle of the
cover removal jig and tighten the screws to remove
the cover (13).
-If it is difficult to remove the cover (13) due to
resistance of the O-ring (35), lift the cover while
lightly tapping the external periphery of the cover
with a plastic hammer.
Removing ring (45)
5. Remove the O-ring (35) from the hub (1)

-Do not reuse the removed O-ring (35).
Removing cover (13)
34-48
34. TRAVEL SYSTEM
(5) Removing sun gear 1 (4)

1. Pull out the sun gear 1 (4) by hand.
2. Remove the steel balls (41) from the shaft (102).
-The coupling (14) may come off at the same time.
34
Removing sun gear 1 (4)
(6) Removing carrier assembly

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

a. Loosen the hexagonal head screws (40) to remove
three thrust washers 3 (12).
b. Remove three thrust washers (12), three planetary
gears 1 (5), three needle roller bearings with
retainers (27) and three bearing inner races (29)
from the carrier (3).
Disassembling carrier assembly
34-49
34. TRAVEL SYSTEM
5. Remove the thrust washer 1 (9) from the carrier (3).
Removing thrust washer (9)
(7) Removing planetary gear 2 (7)

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

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

-Follow the procedures below to make it easy to
remove the plug when disassembling the interior of
the rear flange (201).
-Do not loosen the plugs unless disassembling the
interior of the rear flange.
2. Loosen two plugs (224).
Unscrewing plug (224)
34-50
34. TRAVEL SYSTEM
3. Loosen two plugs (226).
34
Unscrewing plug (226)
4. Loosen six socket bolts (243) and remove them

from the rear flange (201).
Removing socket bolt (243)
5. Remove the rear flange (201) from the spindle (2).

-Hold the rear flange by both hands, hold it up
gently upright to remove it. Perform the work with
care not to forcibly pry or strike the flange.
Otherwise it may cause the timing plate (109) to
drop and be damaged.
Removing rear flange (201)
6. Remove the parallel pins (42) from the spindle (2).
Removing parallel pin (42)
34-51
34. TRAVEL SYSTEM
7. Remove the O-rings (43) and (44) from the spindle

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

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

(201).
Removing parallel pin (241)
4. Remove bearing (150) from the rear flange (201).
Removing bearing (150)
34-52
34. TRAVEL SYSTEM
(10)Removing brake valve parts from rear flange

1. Remove two plugs (224) from the rear flange (201).
34
Removing plug (224)
2. Remove two stoppers (225) and two springs (228)

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

(223)
4. Remove two plugs (226) from the rear flange (201).
Remove the plug (226)
34-53
34. TRAVEL SYSTEM
5. Remove two springs (230) and two valves (227)

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

Removing O-ring (236)
7. Remove the O-ring (237) from the plug (226).

Removing O-ring (237)
34-54
34. TRAVEL SYSTEM
(11) Removing two-speed switching spool

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

rear flange (201).
Removing spool (263)
34-55
34. TRAVEL SYSTEM
(12)Removing the parking brake section
Install a protection cover on the piston (112). Otherwise the piston may fly out suddenly from the spindle (2) due to
compressed air to cause injury.
1. Blow compressed air into the passage hole for the

parking brake of the spindle (2) and take out the
piston (112) from the spindle (2).
Removing piston (112)

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

-When placing the travel motor on its side, place an oil pan under the travel motor to receive oil flowing out from the
travel motor.
1. Incline travel motor 90 degrees.
2. Drain oil out of the travel motor.
3. Remove two separator plates (116) and, one
friction plate (115).
Lifting cylinder block (104)
34-56
34. TRAVEL SYSTEM
4. Hold the cylinder block (104) by hand and turn it 2

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

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

assembly (105) and (106) [seven sets].
Removing piston assembly (105) and (106)
34-57
34. TRAVEL SYSTEM
8. Remove the thrust ball (108) from the cylinder block

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

(104).
Removing roller (104)
(14)Removing spring inside cylinder block

1. Place the cylinder block (104) on the press bench.
-Remove the spring, only when its replacement is
necessary.
-When removing the spring, align the center of the
retainer metal ( I ) with the washer center in order to
prevent the cylinder block from being damaged by
contact.
-Put a vinyl sheet over the cylinder block so as not
to damage the surface of the cylinder block.
Removing spring (114)
34-58
34. TRAVEL SYSTEM
2. Place the retainer metal ( I ) against the washer

(110), remove the snap ring (145) from the snap
ring groove of the cylinder block (104) with a snap
ring plier.
34
Removing spring (114)
Release pressing force slowly. Otherwise the spring may fly out to cause injury.
3. Remove the snap ring (145), washer (110), spring

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

1. Remove the swash plate (103) from the drive shaft
(102).
-When removing the swash plate (103), ensure that
pivot (167) is not adhered on the swash plate (103).
Removing swash plate (103)
34-59
34. TRAVEL SYSTEM
2. Pull the drive shaft (102) out of the spindle (2).

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

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

and put the drive shaft (102) into it.
2. Hold down the tip of the drive shaft (102) by a press
and remove the bearing (149) from the shaft.
-Do not reuse the ball bearing.
Removing 2-speed switching piston kit
Removing ball bearing (149)
34-60
34. TRAVEL SYSTEM
(17)Removing spindle
1. Apply the clamp plates to the spindle (2) in the
equally spaced positions, and fasten three
M16×2.0×150 (approx.) to the workbench.
Tightening torque : 39 to 79 N-m (29 to 57 lbt-ft)
2. Turn over the travel motor. (Direct the reduction unit
side upward.)
34
Fixing spindle (2)
3. Remove two hexagon set screws (47).
Removing hexagon set screw (47)
4. Loosen the ring nut (22) using a tightening jig.

-Do not reuse the removed ring nut (22) of which
tooth flank may be damaged.
Loosen ring nut (22)
Installing jig
34-61
34. TRAVEL SYSTEM
5. Remove the ring nut (22) from the spindle (2).
Removing ring nut (22)
(18)Removal of the ring nut

1. Turn over the travel motor. (Direct the motor side
upward.)
2. Remove the clamp plates from the workbench.
3. Tighten two M16 eyebolts in the mounting thread
holes of the spindle (2) in the diagonal position.
4. Hook a wire rope with hook to M16 eyebolts, and lift
by a crane to remove the spindle (2) from the hub
(1). At this time, the floating seal (31) and oil seal
(132) will be removed together with the spindle (2).
Removing spindle (2)
(19)Removing main bearing

1. Remove the floating seal (31) from the hub (1).
-Do not reuse the removed floating seal (31).
2. Apply a punch between the inside periphery of the
hub (1) and the main bearing (24) to remove the
main bearing using a hammer.
-When the fit section of the outer race of ball
bearing (24) comes out of hub (1), the ball bearing
drop from the hub.
Therefore place a receptacle under the workbench
and spread a rubber mat on the receptacle so as
not to damage the parts.
Removing floating seal (31)
34-62
34. TRAVEL SYSTEM

4. Tapping the end face of outer race of ball bearing
(24) with aluminum rod (pin punch) and hammer,
remove the ball bearing from hub (1).
-Remove ball bearing (24) little by little, tapping
evenly the end face of outer race of the ball bearing
at 3 or 4 points of the from the hub so that the ball
bearing is not suck.
34
Removing ball bearing (24)
(20)Removing spindle fittings

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

-Never reuse the removed oil seal (132).
Removing oil seal (132)
34-63
34. TRAVEL SYSTEM
(21)Rough washing of parts
Cleaning each part
1. Separate the four parts, namely the hub (1), spindle (2), cover (13), and rear flange (201), from the other parts
(hereafter referred to as built-in parts).
2. Put the hub, spindle, cover, and rear flange in a cleaning bath and clean them.
-Carefully remove dust accumulated on the surfaces of parts to make them completely clean.
Kerosene is combustible. Be careful not to cause fire, burns, and injury.
-Before cleaning stained parts, immerse them in kerosene until dust and stain become soft and are floated so as to
prevent damage when cleaning.
3. Put the built-in parts in a rough cleaning bath

containing kerosene and clean them.
Cleaning each section
(22)Finish cleaning
1. Put parts in a finish cleaning bath containing
kerosene and clean them well, turning them slowly.
2. Wipe off kerosene adhered to the parts using a
clean waste cloth.
-Dry the inner surfaces of the hub (1) and the
spindle (2) in the dust-free and dry conditions by
blowing compressed air on them. After drying,
apply hydraulic oil to every part.
Finish cleaning
34-64
34. TRAVEL SYSTEM
-Dry the inner surface of the rear flange (201) and the
hydraulic motor components in the dust-free and dry
conditions by blowing compressed air on them. After
drying, apply hydraulic oil to every part.
34
Finish cleaning
34-65
34. TRAVEL SYSTEM
34.2.1.4 ASSEMBLY
Perform assembly basically in reverse order of disassembly.
34.2.1.4.1 PREPARATION
Prepare a workbench, tools and jigs as in the case of Section 34.2.1.3; DISASSEMBLY.
34.2.1.4.2 GENERAL PRECAUTIONS FOR ASSEMBLY

(1) For assembly also, take the general precautions described in Section 34.2.1.3; DISASSEMBLY.
(2) For assembly, remove any metallic dust or foreign material from all parts and make sure that the parts are free
of burrs and dents which should be ground off using an oilstone.
(3) Replace the O-rings, oil seals, and floating seals with new ones.
(4) Bonding adhesive is applied to the threaded portions and tapped holes of spindle (2) and carrier (3) when
assembling.
Remove their grease by using the tap (M8xp1.25), and wash with solvent. After that, degrease solvent of the
holes by spraying with compressed air.
Replace hexagon head bolt (40) with new ones.
(5) Be careful not to damage the O-rings, oil seals, and floating seals at installation (Lightly apply grease to them for
smooth installation).
(6) Prior to assembly, apply clean hydraulic oil (NAS standards class 9 or higher) to movable and sliding portions of
hydraulic motor components and valves.
(7) Use no cloth gloves during assembly to prevent malfunctions due to textile lint.
(8) On completion of assembly, plug every opening to prevent the entry of dirt.
(9) Photos and figures of typical models are shown. Any partial difference between them and the product in use
does not affect the assembling procedure.
34.2.1.4.3 ASSEMBLING PROCEDURE
After replacing any of the following parts with new ones, adjust the preload of the ball bearing and thickness of the
snap ring without fail :
(1) Parts requiring preload adjustment of the ball bearing after their replacement : hub (1), the spindle (2) and ball
bearing (21)
When replacing any of the above parts, use the parts previously adjusted.
Otherwise, the travel motor may malfunction resulting in premature breakage.
34-66
34. TRAVEL SYSTEM
(1) Assembling hub section

1. Place the hub (1) on the press workbench.
2. Insert the main bearing (24) in the hub (1). Place
the main bearing press fit jig on the outer race of
the main bearing (24). Push down the jig by a press
to press fit the bearing into the hub (1).
3. Turn over the hub (1).
4. Press fit the main bearing (24) into the hub (1) in
the same way as the above item 2).
-Be careful not to mistake orientation of the main
34
bearing (24) when press fitting.
Inserting bearing (24)
5. Apply grease to the O-ring of the floating seal (31).

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

hub (1) in diagonal position.
7. Attach a wire with hooks to the lifting eyes, lift the
hub (1) by a crane and then install the hub (1) on
the workbench.
-While aligning the tapped hole in the hub (1) with
the fixing hole in the workbench, carefully insert the
hub (1) into the fixing hole in the workbench.
Lifting hub (1)
34-67
34. TRAVEL SYSTEM
8. Attach the hub (1) to the workbench by tightening

the socket bolts in diagonal position.
Installing hub (1) to the workbench
Fully tighten the socket bolts. Otherwise, the travel motor may fall down to cause injury when it is turned over.
(2) Assembling spindle section

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

position.
3. Attach a wire with hooks to lifting eyes, lift the
spindle (2) by crane and then insert the spindle (2)
in the hub (1) slowly.
4. Fix the hub (1) and the spindle (2) with fixing plate
in diagonal position.
Tightning torque : 39 to 79 N-m (29 to 57 lbf-ft)
(Direct the reduction unit side upward.)
Inserting spindle (2)
34-68
34. TRAVEL SYSTEM
6. Tighten the ring nut (22) into the spindle using a

tightening jig.
Tightening torque : 295 to 353 N-m (217 to 261 lbf-
ft)
34
Installing ring nut (22)
7. Tighten two hexagon socket set screws (47).

Attaching hexagon set screw (47)

upward.)
9. Remove the clamp plates from the workbench.
Removing fixing plate
(3) Assembling motor parts inside spindle

1. Press fit the oil seal (132) into the spindle (2) using
the oil seal press fit tool and a hammer.
-Apply lithium grease to the lip of the oil seal before
installing.
-Be careful not to mistake the orientation of the oil
seal.
2. Insert two parallel pins (177) into the pin holes of
the spindle (2).
3. Apply lithium grease to the semi-spherical surface
of two pivots (167) and fit them to the parallel pins
(177) installed to the spindle (2).
Installing Oil seal (132)
34-69
34. TRAVEL SYSTEM
4. Apply grease to the spring pin (190) to install to the

piston kit consisting of piston (161), shoe (162) and
seal ring (163).
5. Apply grease to the sliding surface of the piston
assembly to install to the piston hole of the spindle
(2).
Installing piston kit
(4) Inserting shaft
-Carefully carry out the insertion work using leather gloves to prevent possible burns.
-Insert bearing (149) until it closely contacts the flange of the drive shaft (102).
1. Put the ball bearing (149) in a heating bath to heat

it at 90 to 110C degrees (149 to 230F degrees) for
10 minutes and then insert it onto the drive shaft
(102).
Inserting bearing (149)
2. Incline the travel motor by 90 degrees.

3. Insert the shaft (102) into the spindle (2).
-Insert the shaft (102) into the spindle (2) slowly
and carefully. Otherwise the lip of the oil seal (132)
fitted inside the spindle (2) may be damaged.
Damage to the lip may cause oil leakage, leading to
premature failure of the travel motor.
Inserting shaft
34-70
34. TRAVEL SYSTEM
4. Install the swash plate (103) into the spindle (2).

-Apply grease to an interface between the swash
plate (103) and the spindle (2).
-Align two pivots (167) installed in the spindle (2)
with the pivot mounting holes of the swash plate to
fit the swash plate (103) into the spindle (2).
34
Installing swash plate (103)
(5) Installing cylinder block

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

(110). While holding down the retainer metal ( I ) by
press, fit the snap ring (145) into the snap ring
groove of the cylinder block (104) with a snap ring
plier.
-Pressing force of the spring (114) is more than
1180 N-m (265 lbf).
-Cover the cylinder block (104) with a vinyl sheet to
prevent damage to the contact plane between the
cylinder block (104) and the timing plate (109).
Installing snap ring (145)
34-71
34. TRAVEL SYSTEM
(6) Assembling hydraulic motor section

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

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

(107)
5. Insert the cylinder block (104) onto the drive shaft

(102).
-For installation, align the spline hole in the cylinder
block (104) with the spline shaft of the drive shaft
(102).
-After installing the cylinder block, turn it by hand to
make sure that it fits properly. If not, inspect it.
-Do not take up the cylinder block (104). Otherwise
the thrust balls (108) may come off, leading to
abnormality in rotation.
Inserting cylinder block (104)
34-72
34. TRAVEL SYSTEM
(7) Installing parking brake

-Prior to installing, immerse the friction plate (115) in hydraulic oil.
1. Incline the workbench by 90 degrees.
2. Assemble one friction plate (115) and two separator
plates (116) into the cylinder block (104) alternately
one by one.
3. Lightly coat the O-rings (135) and (139) with grease
and install them into the O-ring grooves of the
piston (112).
34
Installing friction plates (115) and separator plates

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

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

1. Fit two O-rings (237) to two plugs (226).
-Coat the O-rings (237) with grease.
2. Install the valve (227) and spring (230) onto the
plug (226), applying grease to them so as to
connect all of them by adhesion of grease.
3. Insert the plug (226) with the valve (227) and spring
(230) assembled in one piece, into the rear flange
(201).
-For insertion of the plug (226), place the rear
flange (201) on the workbench, facing the tapped
hole for plug mounting of the rear flange (201)
upward and align the center of tapped hole with the
plug center. This is intended to prevent the O-ring
from being damaged and spring (230) from coming Inserting plug (226)
out of valve (227) due to contact between the bore
of the rear flange and the valve.
34-73
34. TRAVEL SYSTEM
4. After installing two plugs (226) to the rear flange

(201), temporarily tighten them using an Allen
wrench.
Temporarily tightening plug (226)
5. Insert the spool (223) into the rear flange (201).

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

7. Install the spring retainer (225) and spring (228)
into the plug (224).
8. Tighten two plugs (224) into the rear flange (201).
9. Temporarily tighten two plugs (224) to the rear
flange (201) with a wrench.
Installing O-ring (236)
(9) Assembling rear flange fittings

1. Installing two-speed switching spool inside rear
flange
a.
Insert the spring (266) and the spool (263) into the
rear flange (201).
b.
Fix the O-ring (273) to the plug (221).
-Apply grease to the O-ring (273).
c.
Tighten the plug (221) into the rear flange (201).
Temporarily tightening plug (224)
34-74
34. TRAVEL SYSTEM
d.
Tighten the plug (221) in the rear flange (201) at the
specified torque with a hexagonal wrench key.
Tightening torque : 49.2 to 68.8 N-m (36 to 50 lbf-ft)
34
Inserting spool (263)
2. Coat the ball bearing (150) with hydraulic oil and fit
it to the rear flange (201).
3. Put two the parallel pins (241) into the pin holes in
the rear flange (201).
4. Apply grease to the mating face of the timing plate
(109) in contact with the rear flange (201).
Installing bearing (150)
5. Install the timing plate (109) into the rear flange

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

1. Insert the O-rings (43) and (44) into the O-ring
groove of the spindle (2).
-Fit the O-rings (43) without applying grease.
Otherwise grease may ooze out of the contact face
between the rear flange (201) and the spindle (2)
as if oil leakage occurred.
Installing O-rings (43) and (44)
34-75
34. TRAVEL SYSTEM
2. Fix two the parallel pins (42) to the spindle (2).

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

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

and tighten them at the specified torque.
Tightening socket bolts (243)
6. Tighten the plug (226) at the specified torque.

Tightening torque: 68.7 to 88.3 N-m (51 to 65 lbf-ft)
Tightening plug (226)
34-76
34. TRAVEL SYSTEM
7. Tighten the plug (224) at the specified torque.

Tightening torque : 181.3 to 210.7 N-m (134 to 156
lbf-ft)
34
Tightening plug (224)
(11) Installing carrier assembly

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

thrust washers 3 (12) to fasten the carrier assembly
to the column section of the carrier to the specified
torque.
[Carrier assembly finished]
Tightening hexagon head screw (40)
34-77
34. TRAVEL SYSTEM
(12)Tightening planetary gear 2

1. Turn over the travel motor. (Direct the reduction unit
side upward.)
2. Install the thrust washer 1 (9) to the spindle (2).
3. Insert four thrust collars 4 (11) and four inner races
(30) into the column section of the spindle (2).
4. Insert four needle roller bearings with retainer (28)
into the column section of the spindle (2).
5. Make four planetary gears 2 (7) intermesh with the
internal teeth of the hub (1) to insert them into the
column section of the spindle (2).
-Clean the thread hole at the tip of the column
section of the spindle (2) by removing oil and
Installing planetary gear 2
grease using degreasing agent if necessary.
-Remove oil and grease from four hexagon head
screws (40).
6. Tighten four thrust washers 3 (12) into the column

sections of the spindle (2) with four hexagon
screws (40) at the specified torque.
Tightening hexagon head screw (40)
(13)Installing sun gear 2

1. Install the coupling (14) to the shaft (102).
2. Make the sun gear 2 (6) mesh with the planetary
gear 2 (7) to install.
Installing sun gear 2 (6)
34-78
34. TRAVEL SYSTEM
(14)Installing carrier assembly

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

1. Insert the sun gear 1 (4) into the coupling (14).
Assemble the steel balls (41) into the sun gear 1 (4)
in advance.
-Apply grease to the steel balls (41) to prevent
them from dropping before assembling them into
the sun gear 1 (4).
2. Install the sun gear 1 (4) while making it mesh with
three planetary gears 1 (5).
Installing sun gear 1 (4)
(16)Installing cover
1. Supply 0.6 liters of lubricating oil to the hub (1).
-Apply grease to the O-ring (35)
2. Fit the O-ring (35) into the O-ring groove of the hub
(1).
3. Install the cover (13) to the hub (1).
-When it is difficult to fit the cover (139) into the hub
(1), tap the periphery of the cover (13) lightly and
uniformly with a plastic hammer. Otherwise the O-
ring (35) may be damaged to cause oil leakage.
Lubricating oil may also gush out through the
thread hole.
Supplying lubricating oil
34-79
34. TRAVEL SYSTEM
4. Fit the ring (45) into the ring groove of the hub (1).
-Avoid the position in which the mating port of the
ring (45) faces the notch of the hub (1).
5. Install the O-rings (37) to two plugs (33) and (39).
-Apply grease to the O-ring (37) lightly.
6. Tighten the plugs (33) and (39) into the cover (13)
to the specified torque.
Installing cover (13)
(17)Removing travel motor

upward.)
2. Remove the travel motor mounting screws from the
workbench.
3. Screw two eyebolts into the thread holes of the
spindle (2).
-Arrange the two eyebolts in the diagonal position.
4. Hook the wire rope with hook to the eyebolts to
remove the travel motor from the workbench using
a crane.
Removing travel motor
34-80
34. TRAVEL SYSTEM

After disassembling GM motor, follow these standards to perform maintenance. Handle every part with care and, in
particular, avoid damaging the moving and sliding portions.
(1) Replace any seal (O-ring, oil seal, and floating seal) once used even if no damage is found.
(2) Wear parts maintenance standard
1. Replace any part heavily damaged visually.
2. Replace a part that shows the following abnormalities.
Item
Standard
Allowable
34
Part name Phenomenon value(Standar
No. value(Criteria)
d dimension)
-Severe visual damage
(1) Hub -Pitting recognized on ring gear tooth flank - -
-Abnormal wear such as galling
-Severe visual damage
(2) Spindle - -
-Abnormal wear such as galling.
(3)
Carrier assembly -Abnormal wear such as galling - -
etc.
(4) Sun gear 1
(6) Sun gear 2 -Pitting recognized on tooth flank
- -
(5) Planetary gear 1 -Flaking recognized on bearing rolling surface
(7) Planetary gear 2
(9) Thrust washer 1
-Sliding surface discolored and/or abnormally
(11) Thrust collar 4 - -
worn
(12) Thrust washer 3
-Dent recognized
(24) Main bearing -Flaking recognized - -
-Uneven wear recognized
(27) Needle roller -Pitting recognized on roller
- -
(28) bearing -Abnormal wear on cage end surface
(29)
Bearing inner race -Flaking recognized on bearing rolling surface - -
(30)
-Scratch recognized on valve (263) sliding
(201) Rear flange - -
surface
-Oil seal (132) contacting surface worn
(102) Shaft - -
-Spline worn
(103) Swash plate -Seizure is recognized - -
-Spline worn
-Bore severely worn
(104) Cylinder block - -
-Scratch and uneven wear recognized on timing
plate (109) sliding surface
-Clearance exists between piston (105) and
Piston assembly Clearance Clearance
shoe (106)
(105) Piston 0.05 mm 0.15 mm
-Abnormal and uneven wear recognized on
(106) Shoe (0.002") (0.006")
shoe surface
-Uneven wear recognized on shoe (106) sliding
surface
(107) Retainer plate - -
-Scratch and uneven wear recognized on thrust
ball (108) sliding surface
34-81
34. TRAVEL SYSTEM
Standard
Item Allowable
Part name Phenomenon value(Standard
No. value(Criteria)
dimension)
-Uneven wear recognized on retainer plate
(108) Thrust ball - -
(107) sliding spherical surface
-Seizure and uneven wear recognized on
(109) Timing plate
sliding surface
Braking
-Uneven wear recognized on both end surfaces Braking torque
(115) Friction plate torque
-Specified torque nor attained 32.4 N-m
(116) Mating plate 32.4 N-m
-Seizure recognized (23.9 lbf-ft)
(23.9 lbf-ft)
(105) Piston -Scratch recognized on periphery - -
-Dent recognized
(149)
Ball bearing -Flaking recognized - -
(150)
-Wear recognized
Two-speed piston kit -Abnormal wear recognized on periphery
(161) Piston -Abnormal and/or uneven wear recognized on
- -
(162) Shoe shoe surface
(163) Seal ring -Abnormal wear recognized on Seal ring
(223) -Uneven wear recognized on periphery
Spool - -
(263) -Scratch recognized on periphery
34-82
34. TRAVEL SYSTEM
34.2.1.6 Performance verification test

• After finishing maintenance of the GM motor, carry out performance verification tests according to the
procedures below :
(1) Measuring instruments to be used
1 Pressure gauge for 35 kgf/cm2 (500 psi) 2

2 Measuring cylinder (for 5 liters) (1.32 gal) 1
3 Stopwatch 1 34
(2) Test procedure
Mounting and Mount the GM motor on the body (frame section) and connect piping.
1 piping of However, do not install the crawlers.
GM motor (Because the performance test (no-load run) of the GM motor is
carried out.)
Note) 1. Connect piping so that a pressure gauge can be installed

(in the main circuit) and an amount of drain of the hydraulic
motor can be measured.
2. Mount the GM motor carefully using bolt holes without
hammering.
GM motor speed Pressure Rotating Operating time

Running-in of direction
2 GM motor 1 10 rpm Right One minute
No load and or more each
2 20 rpm left
Performance
3 verification test
of GM motor
Preparation operation before testing Run the machine for preparation until the following
1 temperatures are approximately achieved:
Hydraulic oil temperature 45-55 (113-131 )
External temperature of reduction unit hub 40-80 (104-176 )
Verification test Measure the following values to decide acceptance or rejection.
2 Acceptance criteria - GM motor drive pressure 1.57 MPa (228 psi) or lower at 10 rpm
Drain amount of hydraulic motor 0.5 L/min (0.13 gal) or less at
10 rpm
Accept Reject
Install crawlers Disassemble and adjust again
34-83
34. TRAVEL SYSTEM
34-84
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)
42
42. TROUBLESHOOTING
(HYDRAULIC SYSTEM)
TABLE OF CONTENTS
42.1 GENERAL PRECAUTIONS ...............................................................................42-3

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

SK30SR-5 : PW14- S5PW4231E01
CX31B : PW14- ↑
↑ ↑
E30B : PW14- ↑
↑ ↑
SK30SR-5 : PW14-46519~ S5PW4231E02
Revision June, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~ ↑
↑ ↑
E35B : PX15-21105~ (NH-NA)
42-2
42.1 GENERAL PRECAUTIONS
Troubleshooting provides the process to investigate the cause of trouble. This manual describes how to solve the
problems systematically and quickly. To troubleshoot the engine, refer to the engine operator's manual.
42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE

(1) Get to the site as quickly as possible.
42
Verify the machine model, serial number, situation of
trouble and field, and notify possible arrival time to the
user.
Make field investigation
(2) Verify background
1. Model name and serial number.

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

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

1. Explain the cause of trouble to the user.
For example, explain the oil leakage through the piston is caused by a defect on the piston rod. Explain proper
operating procedures to the user to prevent reoccurrence of the same kind of trouble.
2. Handling of damaged parts
The damaged parts are the evidence, so they should be handled with care as they are claimed and returned.
Cap all ports on hydraulic components to protect them from invasion of water, soil, etc. Pack carefully to avoid
damage and breakage during transport.
42-4
42.2 TROUBLE DIAGNOSIS : HYDRAULIC
Causes Pump Valve Actuator
Main pump
Gear pump
Main gear pump R/V

Each overload R/V
Trochoid pump
Check valve
Travel motor unit

Travel & ATT main R/V
Travel straight valve

Travel spool
Shuttle valve
H y d r a u l i c c yl i n d e r
Attachment spool
Slewing motor unit

Reference No.
Classification
42
Phenomenon
(1) Attachment operational failure
Attachment
(2) Travel speed is slow.

1
(3) Attachment operating power is low.
(4) Malfunction of attachment
Pump Slewing operation Travel operation
(1) Travel operational failure

(2) Travel speed is slow.
2
(3) Travel operating power is low.
(4) It deviates in travel independent operation.
(1) Slewing operational failure
(2) Slewing speed is slow.
3
(3) Slewing operating power is low.
(4) Malfunction of slewing operation
(1) Engine speed is reduced due to pump load.

4
(2) Malfunction of pump
Abbreviation
E/G : Engine
SOL : Solenoid
SW : Switch
ATT : Attachment
C/V : Control valve
R/V : Relief valve
V : Valve
42-5
42.3 TROUBLESHOOTING
42.3.1 ATTACHMENT
42.3.1.1 ATTACHMENT OPERATIONAL FAILURE (Excluding swing operations)
Boom, arm, bucket, YES One or more of them YES Spool stick of C/V
Check C/V spool
dozer and travel can not be operated? exists?
can be operated?
NO Secondary pressure
normally generated Check pilot valve
by pilot valve?
Check lever lock SOL
Lever lock SOL or
Primary pilot pressure YES lever lock S/W is
or lever lock SW.
normal? (To Troubleshooting
failed.
for Electric system)
NO
YES Failure of pilot relief

Pump delivers oil?
valve
NO
Failure of pilot pump
42.3.1.2 ATTACHMENT SPEED IS SLOW
(1) Attachment operating speed is slow.
Is each operating Is the speed of

NO YES
speed of boom, arm travel sprocket Failure of cylinder
and bucket within the within the reference
reference value? value?
YES NO
Failure of pump
Does C/V spool out of NO
Failure of C/V spool
reference function?
YES
Set cylinder to stroke end,
disconnect hose on the return NO
side, apply pressure, and check Failure of cylinder
that leaking inside of piston is
within the reference value.
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42-6
42.3.1.3 ATTACHMENT OPERATING POWER IS LOW
Is main relief pressure

NO
within reference value Failure of main relief V
?
YES
Is overload relief pressure NO Failure of overload

within reference value? relief V
42
YES
Set cylinder to stroke end,

disconnect hose on the return NO Failure of cylinder or
side, apply pressure, and failure of cylinder side V
check that leaking inside of
piston is within reference value.
42.3.1.4 MALFUNCTION OF ATTACHMENT
Natural drop of YES Is oil tightness of YES Is leaking inside of NO

Failure of cylinder
attachment is large. each cylinder is within cylinder within
reference value? reference value?
YES
Port relief pressure YES
Failure of C/V spool or
normal? failure of lock valve
(only for boom)
NO Failure of port relief

valve
Travel normal, but boom, arm,

YES Flow conflux valve
bucket or swing impossible to
actuate together with travel does not switch.
Failure of swing cylinder
Operational YES Does swing spool NO Check on P/V or

failure in C/V move? replace it.
YES
Swing cylinder NO Failure of C/V
pressurised? swing spool.
YES Failure of swing

cylinder
Impossible to Leakage in pressurised YES

YES Check the check valve
hold cylinder section within
in C//V for dust, etc.
reference value?
NO Failure of swing
cylinder
42-7
42.3.2 TRAVEL OPERATION
42.3.2.1 TRAVEL OPERATIONAL FAILURE
NO Is pilot pump delivery NO

Is travel pilot pressure normal? pressure is approx. Failure of pilot pump
3.5MPa(508psi) or over.
YES YES
Failure of travel pilot V
NO
Does travel spool move? Failure of C/V travel spool
YES
Is much wear metal powder
YES
accumulated on hydraulic oil Failure of travel motor
return filter?
NO
Is much wear metal powder YES
mixed in lubricating oil for Failure of travel reduction unit
travel reduction unit?
42.3.2.2 TRAVEL SPEED IS SLOW
Is travel sprocket speed YES Travel sprocket speed YES Is much wear metal YES Failure of travel motor
within reference value? changes between 1st powder accumulated on
and 2nd speed. hydraulic oil return filter?
NO NO
NO
Does 2-speed change Is much wear metal
spool of travel motor powder mixed in hy- YES Failure of travel
move? draulic oil for travel reduction unit
reduction unit?
NO YES
NO
Failure of travel motor Is amount of travel
NO
spool motor drain within Failure of travel motor
reference value?
Check on travel 2nd speed SOL.V. (To troubleshooting for Electric System)
Is ATT operating speed YES Is travel pilot YES

Does C/V spool move?
NO Failure of C/V
other than travel speed pressure normal? travel spool
within reference value? YES
NO
Failure of pilot pump
NO
Primary pressure of NO Failure of pilot relief
travel pilot normal? valve
Failure of pump
YES
Failure of travel pilot
valve
Is E/G speed within YES
reference value? Failure of pump
NO
YES NO
E/G speed error Adjust accel wire. Adjust E/G speed.
42-8
42.3.2.3 TRAVEL POWER IS LOW
Is the power of boom, arm NO NO

Is main relief pressure normal? Failure of main relief V
and bucket normal?
YES
YES
C/V travel spool shows YES
abnormality such as stick? Failure of C/V travel spool
NO
Abnormal wear metal powder 42
YES
accumulated on hydraulic oil Failure of travel motor
return filter?
NO
Abnormal wear metal powder YES Failure of travel reduc-
mixed in lubricating oil for tion unit
travel reduction unit?
42.3.2.4 IT DEVIATES IN TRAVEL INDEPENDENT OPERATION
There is a big difference NO Is tension of shoe within NO

Adjust shoe tension.
between right and left spro- reference value?
cket speeds at travel idling.
YES It may be caused by
deflection of construction
YES
like lower frame, etc.
Is it free from bent of hose of YES Replace hose.
travel line and oil leakage?
NO
NO Check or replace travel
Travel pilot normal?
pilot valve.
YES
Does the flow change in YES
Check on pump or replace it.
reverse by changing the conne-
ction of pump delivery hose?
NO
Does the deviation change in YES There is flaw on the outer YES Replace travel spool
reverse by changing the surface of the travel spool. assembly.
connection of right and left
NO
hoses between C/V and Replace C/V.
travel motor?
NO
Is much wear metal powder YES Check travel motor
accumulated on hydraulic or travel reduction unit,
oil return filter? or replace it.
NO
Replace travel spool
Is amount of travel motor YES
assembly.
drain within reference value?
NO Check travel motor
or travel reduction unit,
or replace it.
42-9
42.3.3 SLEWING OPERATION
42.3.3.1 SLEWING OPERATIONAL FAILURE
NO
Dozer operable? Failure of P3 pump
YES Failure of P3 relief valve

NO
Slewing relief valve normal? Replace slewing relief valve
YES
Is slewing speed within YES Is slewing relief pressure NO
NOwithin reference value? Failure of slewing relief V
reference
Does slewingvalue at
spool no
for load?
C/V
It is difficult to perform slewing move? Failure of C/V slewing spool
motion and boomYES load opera- NO Is gear pump main YES relief pre- NO Improper gear pump
tion. It is impossible to carry ssure within reference value? main relief pressure
Is
outmuch wear metal
diagonal powder accumulated YESIs amount of slewing motor
pulling NO
NO operation Failure
Failureofofslewing
slewingmotor
motor
on hydraulic
of swing oil return filter?
and arm. YES
drain within reference value? when it is gun metal
It is impossible to
Is dozer operating speedslewing YES
because of poor slewing Failure of C/V slewing spool
within reference value?
power at slope.
Failure of slewing reduction
NO
YES unit when it is steel powder
Is engine speed within NO
YES
Is slewing relief pressure Failure
Failure of
of slewing relief V
gear pump
reference value?
within reference value?
42.3.3.2 SLEWING SPEED NO IS SLOW
YES Improper E/G speed
Is much wear metal powder YES Failure of slewing motor
accumulated on hydraulic when it is gun metal
oil return filter?
42.3.3.3 SLEWING POWER IS LOW Failure of slewing reduction
unit when it is steel powder
42-10
42.3.3.4 MALFUNCTION OF SLEWING OPERATION
(1) It is impossible to stop slewing YES Is slewing parking brake NO Parking brake spring
operation at slope. power within reference value? failure in slewing motor,
or friction plate failure
for parking brake
(2) Slewing drift after slewing YES Is slewing brake power

inertia exerted on it is large. within reference value?
42
NO
NO
Is swing relief pressure within Failure of slewing relief V
reference value?
42.3.4 PUMP
42.3.4.1 ENGINE SPEED IS REDUCED DUE TO PUMP LOAD
E/G speed lowers by performing

slewing, boom and arm YES Is E/G speed lowered and YES Malfunction of control
operations simultaneously, finally is it stopped? unit of pump
or dozer, travel and boom
operations simultaneously. NO
OK
42.3.4.2 MALFUNCTION OF PUMP
(1) Oil leaks between Is coupling worn Replace coupling and

YES YES
E/G and pump severely? seal for pump shaft
installing flange.
NO
Is pump internal pressure NO NO
within reference value? Is return filter normal? Replace return filter
YES
Replace seal for Does hydraulic oil in tank NO Flush hydraulic oil, or
pump shaft. satisfy NAS 9 class? replace return filter.
(2) Noise from pump YES

Is the hydraulic oil YES YES
in hydraulic tank Shortage of hydraulic oil Replenish hydraulic oil.
cloudy white?
NO
Check for air intake
NO through piping on the
suction side.
Is much wear metal YES Replace parts inside

powder on return filter
of pump.
in hydraulic tank?
NO Check coupling for

severe wear. (Refer to
Article before mentioned.)
42-11
42-12
43. TROUBLESHOOTING (ELECTRICAL SYSTEM)
43. TROUBLESHOOTING
(ELECTRICAL SYSTEM) 43
TABLE OF CONTENTS
43.1 TROUBLE DIAGNOSIS : ELECTRIC SYSTEM ................................................ 43-3

43.2 TROUBLESHOOTING ....................................................................................... 43-4
43.2.1 GENERAL ................................................................................................. 43-4
43.2.2 ATTACHMENT OPERATION ..................................................................... 43-8
43.2.3 TRAVEL OPERATION ............................................................................... 43-11
43.2.4 DECELERATION ....................................................................................... 43-12
43-1

SK30SR-5 : PW14- S5PW4331E01
CX31B : PW14- ↑
↑ ↑
E30B : PW14- ↑
↑ ↑
SK30SR-5 : PW14-46519~ S5PW4331E02
Revision June, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~ ↑
↑ ↑
E35B : PX15-21105~ (NH-NA)
43-2
Travel Travel Attachment
Deceleration General Classification
alarm operation operation
43.1
2
1
Reference No.
3 (1)
(1)
(6)
(5)
(3)
light up.
actuate.
actuate.
function.
carried out.
Abbreviation
SW : Switch
SOL : Solenoid
5 (1) does not sound
not be changed.
Phenomenon
does not actuate.
not be carried out.
Decel : Deceleration
Water temperature
Travel alarm (OPT)

(4) Hourmeter does not
All controls does not

Fuel gauge does not
(2) operation can not be

(2) Horn does not sound.
(1) Engine does not start.
Working light does not
Deceleration switching
4 (1) operation in option can
Travel 1 & 2 speed can
Causes
Slewing/Swing switching
Gauge cluster
Current limiter
Working light
Decel motor
Electrical
Horn
equipment
Travel alarm
Coolant temp.sensor
43-3
Fuell level sensor
Travel 1,2 speed SOL
Lever lock SOL
Engine stop SOL
Sensor Solenoid
Slewing/Swing switching SOL

Horn switch
Working light switch
TROUBLE DIAGNOSIS : ELECTRIC SYSTEM
Travel 1,2 speed switch

Lever lock limit switch
Deceleration switch
Switch
Slewing/Swing switching SW
Slewing lever pressure SW
Travel pressure SW
Engine stop SOL relay
Charging indicator relay
Safety relay
Timer unit
Holding ciruit unit
Relay
Switching relay
Slewing/Swing holding relay
Slewing/Swing switching relay
Fuse,Disconnection,Short circuit,Looseness Others
43
43.2.1 GENERAL
43.2.1.1 ENGINE DOES NOT START.
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43-4
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43-5
43.2.1.2 HORN DOES NOT SOUND.
When horn switch is pressed,
Voltage between pink-black YES

Failure of horn Replace horn.
and black harness is 12V.
NO
Voltage of red-green harness YES Breakage of harness

Check harness.
of horn switch (SW-7) is 12V. between horn (E-3) and horn
switch (SW-7)
NO
Failure of horn switch (SW-7) Replace horn switch.
Voltage between red-green YES Breakage of harness

Check harness.
harness of fuse box is 12V. between horn switch (SW-7)
and fuse box
NO
YES Harness is short-circuited Check harness of short-

No.4 fuse is blown.
to frame. circuited section.
Check that line in fuse box

is free from breakage.
Check diode (D-1) for short

circuiting.
43.2.1.3 WORKING LIGHT DOES NOT LIGHT UP.
When key is switched ON,
Voltage between light green YES

Working light error Replace working light.
-red and black harness of
working light (L-2) is 12V.
NO
Voltage between yellow and YES Breakage of harness between

working light switch (SW-2) Check harness.
green harness of working
light switch (SW-2) is 12V. and working light (L-2)
Failure of working light Replace working light switch.

NO
switch (SW-2)
Voltage of yellow-green YES Breakage of harness

between working light switch Check harness.
harness of fuse box is 12V.
(SW-2) and fuse box
NO
YES Harness is short-circuited Check harness of the short-

No.3 fuse is blown.
to frame. circuited section.
Check that line in the fuse box

is free from disconnection.
43-6
43.2.1.4 HOURMETER DOES NOT ACTUATE.
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43.2.1.5 FUEL GAUGE DOES NOT ACTUATE.
When key is switched ON,

When sensor moved,
resistance between yellow
Voltage between white- and black harness of YES
green and black harness YES connector (CN-27F) of gauge Check and replace
of connector (CN-27F) cluster (E-6) changes gauge cluster
of gauge cluster (E-6) Breakage of harness
(approx. 10 at full and NO between gauge
is 12V. approx. 90 at empty) Check harness.
cluster (E-6) and fuel
NO sensor (SE-1)
Voltage of white-green YES Breakage of harness
line of fuse box is 12V. between gauge cluster
(E-6) and fuse box Check harness
placed on short-
NO circuited section.
No.6 fuse of fuse box YES Harness is short-
Check that harness
is blown. circuited to frame.
in fuse box is free
from breakage.
43.2.1.6 WATER TEMPERATURE METER DOES NOT ACTUATE.
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43-7
43.2.2 ATTACHMENT OPERATION
43.2.2.1 ALL CONTROLS DO NOT FUNCTION
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! "&'
+

$

./" )

(

( # ! "&'
+

#

(
./"

(

43-8
(2) When key is switched ON.

Slewing / swing switching operation can not be carried out
• Swithching operation dose not change from slewing to swing.
When slewing / swing select switch is depressed.
Voltage between light

green and black harness Check on slewing/
of connector (CN-120F) YES swing select solenoid.
of slewing/swing select (To troubleshooting
solenoid (SV-12) is 12V. for hydraulic system).
NO
Voltage between green Voltage between ground
white and black harness and green / white har-
YES
of connector (CN-65F) ness of connector (CN- Check and replace.
of slewing / swing select 65F) of slewing/swing
relay is 12V. select relay. 43
NO
NO Disconnection of har-
Voltage between ground NO ness between relay
and white harness of No.3 fuse is blown. Check on harness.
connector (CN-64F) of and fuse.
slewing / s wing select
switch (SW-28) is 12V. YES Harness is short- Check harness on
circuited to frame. the short-circuited
Disconnection of har-
section.
ness between slew-
ing / s wing select
Check on harness. Check that line in
switch (SW-28) and
slewing / s wing se- the fuse box is free
NO lect relay (R-14). from disconnection.
Failure of slewing /
swing select switch Replace slewing/
(SW-28). swing select switch.
Voltage between blue Check on slewing lev-

green and black harness er pressure switch RH
YES
of connector (CN-67F) (SW-31) slewing lever
of switch change relay pressure switch LH
(R-22) is 12V. (SW-30) and harness.
NO
Voltage between ground
and yellow / g reen har-
ness of connector (CN- YES Failure of switch Replace switch
67F) of switch change re- change relay (R-22). change relay.
lay (R-22) is 12V.
Disconnection of har-
NO NO ness between relay
No.3 fuse is blown. Check on harness.
and fuse.
YES
Check harness on
Harness is short- the short-circuited
circuited to frame. section.
Check that line in

the fuse box is free
from disconnection.
43-9
(3) • Swithching operation dose not change from swing to slewing.
When slewing / swing select switch is not pressed.
Voltage between light green

and black harness of con- Check on slewing / swing
nector (CN-120F) of slew- NO select solenoid. (To trouble-
ing / s wing select solenoid shooting for hydraulic sys-
(SV-12) is 12V. tem).
YES
Voltage between green/
white and black harness of NO Failure of slewing/swing
connector (CN-68F) of slew - Check and replace.
select relay (R-14).
ing/swing select relay (R-
14) is 12V.
YES
Voltage between ground
and green/white harness of
NO Failure of slewing/swing
connector (CN-64F) of slew - Check and replace.
ing / s wing select switch select switch (SW-28).
(SW-28) is 12V.
YES
Voltage between ground and Check on harness between
white / r ed harness of con- NO slewing/swing select switch
nector (CN-68F) of diode (D- and slewing / s wing select
13) is 12V. relay.
YES
Failure of slewing lever

pressure switch RH (SW-
Check and replace.
31) or slewing lever pres-
sure switch LH (SW-30).
Check on following harness.

Fuse box No, slewing lever
pressure switch and slew-
ing/swing holding relay.
43-10
43.2.3 TRAVEL OPERATION
43.2.3.1 TRAVEL 1 & 2 SPEED CHANGE CAN NOT BE CARRIED OUT.
(1) When key is switched ON, (regardless of 1,2 speed mode)
Voltage of yellow-black harness NO Breakage of harness between

of connector (CN-109F) of travel fuse box and travel 1&2- Check harness.
2-speed solenoid valve (SV-2) speed solenoid valve (SV-2)
is 12V.
YES
Voltage of white-green harness NO Breakage of harness between

of connector (CN-1F) of holding fuse box and holding Check harness.
circuit unit (E-14) is 12V. circuit unit(E-14)
YES 43
No.6 fuse of fuse box is blown.
YES
Check harness of the short-
Harness is short-circuited to frame.
circuited section.
To "after selector switch was switched ON." Check that line in fuse box is
free from disconnection.
(2) After selector switch was switched ON,
Voltage of light green harness YES Check travel 1&2-speed

of connector (CN-109F) of solenoid valve. (To Trouble-
travel 1&2-speed solenoid shooting for Hydraulic System)
valve (SV-2) is 0V.
NO
Voltage of light green line of YES Breakage of harness between

connector (CN-1F) of holding travel 1&2-speed solenoid Check harness.
circuit unit (E-14) is 0V. valve and holding circuit unit
NO
Voltage of white-black harness Check harness of travel
of connector (CN-1F) of holding NO
1&2-speed switch, and bet-
circuit unit (E-14) when travel ween travel 1&2-speed switch
1&2-speed selector switch is and holding circuit unit.
pressed.
YES
Check holding circuit unit
43-11
43.2.4 DECELERATION
43.2.4.1 DECEL CHANGE OPERATION IN OPTION CAN NOT BE CARRIED OUT.
+
/0

/ &
$ ' ( !
!
! $ $ ' !

$ !
1(*
$ '

/ &
" $ ' ( $ !

# !
#
1(* $ '
!
+ . 0
$

% ! 1(*
$ ,-$ !
+ . 0

& ,-$ !

% ! )
#
/
+ . 0
1(*
$ $
# #.
!
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# % !
/
+ *+ .0
1(* $ $ $ #. $ $!

$ $ ( % !
/
$ *+ !
&

*+ !
$ $ (
43-12
44. TROUBLESHOOTING (ENGINE)

TABLE OF CONTENTS
44.1 TROUBLE DIAGNOSIS : ENGINE .................................................................... 44-3

44.2 TROUBLESHOOTING ....................................................................................... 44-6
44.2.1 STARTING TROUBLE ............................................................................... 44-6
44.2.2 E/G ROTATION TROUBLE ....................................................................... 44-8 44
44.2.3 OUTPUT DROPS DOWN .......................................................................... 44-9
44.2.4 OTHER TROUBLE .................................................................................... 44-10
44-1

SK30SR-5 : PW14- S5PW4431E01
CX31B : PW14- ↑
↑ ↑
E30B : PW14- ↑
↑ ↑
SK30SR-5 : PW14-46519~ S5PW4431E02
Revision June, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~ ↑
↑ ↑
E35B : PX15-21105~ (NH-NA)
44-2
44.1 TROUBLE DIAGNOSIS : ENGINE
Cause Serviceman
Inspection Visual check
Filters Fluid Gas/fluid
Improper viscosity or level of engine oil, or leakage

Improper specific gravity of battery electrolyte
Classification
Group No.
Breather hose clogged or depressed
Gas leakage through valve gasket

Poor quality fuel or heavy oil used
Improper battery electrolyte level

Air or water entered fuel system
Excessive amount of engine oil

Large amount of blowby gas
Poor quality fuel or leakage
Primary fuel filter clogged
Air cleaner clogged
No fuel or leakage
Fuel filter clogged

Oil filter clogged 44
Coolant level
Trouble Fan belt slip
Starting (1) Starter not rotate

1
trouble (2) Starter rotates but hard to start
(1) Idling not smooth
Rotation (2) Medium speed hunting

2
trouble High speed not smooth
(3)
Not reach max. speed
Engine output not enough
Output drops (1)
3 Overheat
down
(2) Knocking at high temperature
Large amount of black exhaust
(1) gas
White exhaust gas
(2) Excessive oil consumption
Other trouble 4 (3) Excessive fuel consumption

Engine not stop when key
(4)
turned OFF
When key is turned OFF, power
(5) supply disconnected but engine
not stop
44-3
Cause Serviceman Engine dealer

Mechanism Engine Suction/
Fuel system exhaust
Electric Electric
system
Classification
Group No.
Generator current limiter
Air cleaner and muffler

Check injection timing
Connector and wiring
Feed pump function
Valve spring fatigue

Stop solenoid valve
Valve clearance
Injection pump
Check nozzle
Starter motor
Safety relay
Starter key
Glow relay
Glow plug
Fuse
Trouble

1

2
(3)
Output drops (1)
3 Overheat
down
(1) gas
White exhaust gas

(4)
turned OFF
not stop
44-4
Cause Engine dealer

Lubricati
Cooli
on Mechanical
ng
system
Oil gets into comb. chamber through piston / valve guide

Classification
Group No.
Control rack movement not smooth
Crank shaft oil seal defective

Oil cooler element damaged
Compression pressure low
Flywheel gear damaged

Governor spring fatigue
Defective head gasket

Internal part seizure
Check relief valve
Check thermostat
Piston liner worn

Piston ring worn
Check fuel feed

Fuel mixed 44
Trouble
1

2
(3)
Output drops (1)
3 Overheat
down
(1) gas
White exhaust gas

(4)
turned OFF
not stop
44-5
44.2.1 STARTING TROUBLE
44.2.1.1 STARTER DOES NOT ROTATE
NO
Check voltage of battery. Check battery fluid and Charge battery, or
specific gravity. replace it.
OK
Check on starter motor Voltage of B terminal of NO Replace starter cable.

IN side. starter motor(M-1) is 12V.
OK
Voltage of B terminal of NO Replace fusible link
key switch is 12V. 45A.
OK
Voltage of C terminal of NO
key switch is 12V. Replace key switch.
OK (Hereafter when key is in start position.)
Check safety relay of Voltage of black-white NO

IN side. harness(C terminal) at Check harness.
connector(CN-7F) of
OK
safety relay(R-2) is 12V.
Check safety relay of Voltage of white-red NO Malfunction of safety OK

harness(S terminal) at Replace safety relay.
OUT side. relay
connector(CN-7F) of
safety relay(R-2) is 12 V. NO
OK Check generator.
Check starter motor of Voltage of S terminal NO Breakage of Check harness.
IN side. of starter motor(M-1) harness between
is 12V. safety relay(R-2)
and starter motor
OK
Replace starter motor.
44-6
44.2.1.2 STARTER ROTATES BUT HARD TO START
Check starter power Less Check battery electrolyte Charge or replace battery
level and specific gravity
OK
Check compression pressure
Valve clearance
Check engine itself Piston liner worn
Piston ring worn
Defective head gasket
Flywheel gear damaged
Check air suction Air cleaner clogged Check radiator and thermostat
system Check indicator
OK
Check fuel meter Feed pump performance

Check fuel feed Check water separator OK Check injection pump
system Check fuel filter Check injection nozzle
Check fuel quality Check injection timing
Check electrical YES

12 V detected for glow plug Defective glow plug
system
NO 44
NO Defective harness between
Improper ground connection
key switch and glow
Check if engine oil viscosity NO

Check engine oil
suitable for ambient Change engine oil
viscosity
temperature
Note: Check with the engine start key being in ON position.
44-7
44.2.2 E/G ROTATION TROUBLE
Check injection pipe

Check injection nozzle
Idling not smooth Cylinder compression
pressure not even
Check injection pump
(1) Idling Check thermostat
Idling speed too high Adjust engine speed
Check control rack

(2) Medium speed Medium speed hunting
Check governor spring
YES
Check if air mixed in fuel Release air
OK
(3) High speed
Check air suction system Check if air cleaner clogged
OK
Check fuel meter

Check water separator
Check fuel feed system
Check fuel filter
OK Check fuel quality

Check injection pump
Not reach max. speed Adjust engine speed
Note: Check the above items in the condition of coolant temperature at more than 50 . (122 )
44-8
44.2.3 OUTPUT DROPS DOWN
44.2.3.1 ENGINE OUTPUT NOT ENOUGH
Engine coolant temperature OK

(1) Overheat Check shovel work condition
lamp lighted
NO
Check engine coolant
Check electrical system temperature switch
Check gauge cluster
OK Check wiring and connector
Check coolant level

Check fan belt slip
Check cooling system
Check radiator clogging
OK Check thermostat
Check fuel quality

Check fuel system Check injection timing
OK Check fuel injection valve
Check engine oil system Check engine oil filter

44
Check air suction Air filter clogging OK
(2) Check air cleaner filter
system Check indicator
OK
Check fuel feed

Check if air mixed in fuel Release air
system
OK
OK
Check feed pump performance
Check water separator Check injection pump
Check fuel filter Check injection nozzle
Check fuel quality Check injection timing
Check if engine oil viscosity

Check engine oil suitable for ambient Change engine oil
OK
temperature
Large amount of blowby gas Check compression pressure

Gas leakage through gasket Check valve clearance
Check engine Check if engine oil gets into Valve spring fatigue
mechanical comb. chamber through Control rack not smooth
piston / valve guide Piston ring worn
Note: Check in the condition of operating at high speed. Failure of head gasket
44.2.3.2 KNOCKING AT HIGH TEMPERATURE
Check fuel system Check fuel quality Change fuel
Check engine Check if engine oil gets into Check oil adhering
mechanical comb. chamber condition at exhaust port
OK
Check compression pressure
Gas leakage through gasket
Note: Check in the condition at engine coolant temperature of more than 50 . (122 )
44-9
44.2.4 OTHER TROUBLE
44.2.4.1 EXHAUST TROUBLE
Large amount of
Check air cleaner Replace air element
black exhaust gas
OK
Check engine oil viscosity
Check if engine oil too
much
OK Check injection pump
Check valve clearance
Check gas leakage Valve spring fatigue
through head gasket Check piston ring defect
Large amount of
Check if water mixed in fuel Check water separator
white exhaust gas
OK
Check if engine oil gets into
comb. chamber through
piston / valve guide Check compression pressure
Large amount of blowby gas Check injection timing
Gas leakage through gasket
Note: Check in the condition at engine coolant temperature of more than 50 . (122 )
A breather mechanism of blow-by gas reduction system is applied to the engine as shown in the drawing. Remove
and plug the suction manifold to check blow-by gas.
SPRING
CENTER PLATE
DIAPHRAGM DIAPHRAGM
COVER
Remove this side BONNET
BREATHER PIPE
BREATHER
PLUG BAFFLE
SUCTION
MANIFOLD BAFFLE PLATE
(CONSTRUCTION OF BREATHER MECHANISM)
44-10
44.2.4.2 EXCESSIVE OIL CONSUMPTION
Check engine oil Check ground under Tighten packing and seal or
leakage engine and oil pan replace if necessary
(Check if engine oil too much)
OK
Check if breather hose

Replace breather hose
depressed or clogged
OK
Check fuel quality Instruct to feed proper fuel
OK
Check engine oil viscosity Instruct to feed proper
engine oil
OK
Check if engine oil gets into Defective crank shaft oil seal
comb. chamber through Piston liner worn
piston / valve guide Piston ring worn
Note: Check in the condition of no engine oil leakage.
44.2.4.3 EXCESSIVE FUEL CONSUMPTION 44
Check fuel leakage Check fuel quality Instruct to feed proper fuel
OK

Check gas leakage through Check nozzle function
gasket OK
Check compression
Note: Check in the condition the proper fuel is used. pressure
44.2.4.4 ENGINE NOT STOP WHEN KEY TURNED OFF
Engine stop
Engine stop solenoid NO Correct engine
solenoid valve
valve (SV-3) normally stop solenoid valve
incorrectly installed
energised installation
YES
YES
Check resistance of Resistance 0 Replace key switch
starter key terminal detected between
(between terminals terminals B and ACC
B and ACC)
NO
Check harness
Note: Check with the engine start key being in OFF position.
44-11
44-12
51. ENGINE
51. ENGINE
51
PREFACE
This manual explains the engine and is a direct reprint of YANMAR DIESEL ENGINE'S service manual.
51-1
51. ENGINE

SK30SR-5 : PW14- S5PW5131E01
CX31B : PW14- ↑
↑ ↑
E30B : PW14- ↑
↑ ↑
SK30SR-5 : PW14-46519~ S5PW5131E02
Revision June, 2010
CX31B : PW14-46519~ ↑
↑ ↑
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~ ↑
↑ ↑
E35B : PX15-21105~ (NH-NA)
51-2
TNV DI Service Manual
TNV series
SERVICE MANUAL
3TNV82A(-B) • 3TNV84 • 3TNV84T(-B) •
3TNV88(-B)(-U)
4TNV84 • 4TNV84T(-Z) •
4TNV88(-B)(-U)
4TNV94L
4TNV98(-Z)(-E) • 4TNV98T(-Z)
4TNV106 • 4TNV106T
P/N: 0BTNV-G00101
INDUSTRIAL
ENGINES
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in
mind and may not contain the necessary detail or safety statements that may be required for a non-
professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar
repair or service professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and /
or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems -
without the written permission of Yanmar Co., Ltd.
© 2005 Yanmar Co. Ltd.
ii TNV DI Service Manual

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

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

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

INTRODUCTION
1-2 TNV DI Service Manual

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

YANMAR WARRANTIES

Yanmar Limited Warranty YANMAR WARRANTIES
YANMAR LIMITED WARRANTY

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SAFETY

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

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

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

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

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

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

A DANGER A DANGER

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

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

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

A DANGER A DANGER

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

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

A WARNING A WARNING
SEVER HAZARD! EXHAUST HAZARD!

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

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

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

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

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

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

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

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

wear SAFETY GLASSES while servicing
the engine.
0000013en

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

A CAUTION A CAUTION
COOLANT HAZARD! PINCH HAZARD!

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

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

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

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

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

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

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

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

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

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

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

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

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

indicated in the Battery Cable
CAUTION
Resistance chart in the Electric Wiring
Section of this manual. The starter Do not allow any material to fall into the
motor will malfunction and fail if the oil lines or the oil inlet and outlet ports
resistance is higher than the specified of the turbocharger.
value. 0000064en
0000057en

CAUTION CAUTION
If the waste valve does not meet Do not rotate the crankshaft with the
specifications, replace the turbocharger injection pump removed.
or have it repaired by a qualified repair 0000083en
facility.
0000078en
CAUTION
Keep the piston pin parts, piston
CAUTION assemblies, and connecting rod
• NEVER attempt to modify the engine’s assemblies together to be returned to
design or safety features such as the same position during the
defeating the engine speed limit reassembly process. Label the parts
control or the diesel fuel injection using an appropriate method.
quantity control. 0000088en
• Modifications may impair the engine’s

safety and performance CAUTION
characteristics and shorten the
Do not allow the honing tool to operate
engine’s life. Any alterations to this
in one position for any length of time.
engine may void its warranty. Be sure
Damage to the cylinder wall will occur.
to use Yanmar genuine replacement
Keep the tool in constant up-and-down
parts.
motion.
0000079en
0000090en
CAUTION CAUTION
Identify all parts and their location using
Any part which is found defective as a
an appropriate method. It is important
result of inspection or any part whose
that all parts are returned to the same
measured value does not satisfy the
position during the reassembly process.
standard or limit must be replaced.
0000080en
0000119en
CAUTION CAUTION
Each pressure adjusting shim removed
Any part determined to not meet the
or added changes the pressure
service standard or limit before the next
threshold by approximately 275 psi
service, as determined from the state of
(1.9 MPa, 19 kgf/cm2). Adding adjusting
current rate of wear, should be replaced
shims increases the threshold pressure.
even though the part currently meets the
Removing adjusting shims reduces the
service standard limit.
pressure threshold.
0000120en
0000081en

CAUTION CAUTION
• NEVER remove or attempt to remove Shut down the engine if the fault
the tamper-proof devices from the indicator comes on.
full-load fuel adjusting screw or the Continuing running the engine with the
high-speed throttle limit screw on the fault indicator being on may result in a
fuel injection pump and governor serious malfunction of or damage to the
assembly. These adjustments have engine, and will void the engine
been made at the factory to meet all warranty.
applicable emissions regulations and
9999999en
then sealed.
• NEVER attempt to make any
adjustments to these sealed
CAUTION
adjustment screws. If adjustments are Do not energize the starter for a period
required, they can be made only by a of longer than 15 seconds.
qualified fuel injection shop that will Take a pause of at least 30 seconds
ensure the injection pump continues between energization of the starter.
to meet all applicable emissions
regulations and then replace the Otherwise the starter could suffer
tamper-proof seals. damage.
9999998en
• Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.” CAUTION
0000146en • High-pressure washing not
recommended.
CAUTION • Avoid using high-pressure washing for
Never use a steel wire brush to clean electronic or electric devices installed
fuel injectors. Damage to the nozzle and in, on or around the engine, including
other components is likely to result. the E-ECU, relays and harness
couplers.
0000172en
Otherwise such devices may suffer
malfunction due to water ingress into
CAUTION them.
Allow the engine to warm-up for at least 9999997en
five minutes and the idle speed of the
engine to return to normal before
engaging the transmission or any PTOs.
Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the
equipment.
0000159en

CAUTION
• Do not plug or unplug the E-ECU for a
period of at least 6 seconds after
power to the unit has been turned on
or off.
• Do not touch connector pins of the E-
ECU with bare hands.
Doing so may result in corrosion of the
connector pins and/or damage to the
internal circuits of the E-ECU due to
static electricity.
• Do not force a measuring probe into
the female coupler.
Doing so may cause contact failure of
the connector pins, resulting in
malfunction of the E-ECU.
• Take care to prevent water from
entering the couplers when plugging
or unplugging the connector.
Water inside the couplers may cause
corrosion, resulting in malfunction of
the E-ECU.
• Avoid plugging/unplugging the
connector more than approx. 10 times.
Frequent plugging/unplugging of the
connector may cause contact failure of
• Do not use the E-ECU that has ever
suffered drop impact.
9999996en
CAUTION
Always check the battery for proper
charge.
Otherwise the electronically controlled
engines may fail to start.
9999995en


Section 4
GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-5
Engine Nameplate (Typical) ...................................................... 4-6
Emission Control Regulations ......................................................... 4-6
EPA / ARB Regulations - USA Only .......................................... 4-6
Emission Control Labels.................................................................. 4-6
The 97/68/EC Directive Certified Engines....................................... 4-7
Engine Family.................................................................................. 4-7
Function of Major Engine Components ........................................... 4-8
MAIN ELECTRONIC CONTROL COMPONENTS AND
FEATURES ..................................................................................... 4-9
Function of Cooling System Components ..................................... 4-11
Diesel Fuel .................................................................................... 4-12
Diesel Fuel Specifications ....................................................... 4-12
Filling The Fuel Tank ............................................................... 4-13
Priming the Fuel System ......................................................... 4-15
Engine Oil...................................................................................... 4-15
Engine Oil Specifications ........................................................ 4-15
Engine Oil Viscosity................................................................. 4-16
Checking Engine Oil ................................................................ 4-16
Adding Engine Oil.................................................................... 4-17
Engine Oil Capacity (Typical) .................................................. 4-17
Engine Coolant.............................................................................. 4-18
Engine Coolant Specifications................................................. 4-19
Filling Radiator with Engine Coolant........................................ 4-19
Engine Coolant Capacity (Typical) .......................................... 4-20
Specifications ................................................................................ 4-21

GENERAL SERVICE INFORMATION
Description of Model Number................................................... 4-21
Engine Speed Specifications.................................................... 4-21
Engine General Specifications ................................................. 4-22
Principal Engine Specifications ...................................................... 4-23
3TNV82A (~ EPA Tier2) ........................................................... 4-23
3TNV84 (~ EPA Tier2) ............................................................. 4-24
3TNV84T (~ EPA Tier2) ........................................................... 4-25
3TNV88 (~ EPA Tier2) ............................................................. 4-26
4TNV84 (~ EPA Tier2) ............................................................. 4-27
4TNV84T (~ EPA Tier2) ........................................................... 4-28
4TNV88 (~ EPA Tier2) ............................................................. 4-29
4TNV94L (~ EPA Tier2) ........................................................... 4-30
4TNV98 (~ EPA Tier2) ............................................................. 4-31
4TNV98T (~ EPA Tier2) ........................................................... 4-32
4TNV106 (~ EPA Tier2) ........................................................... 4-33
4TNV106T (~ EPA Tier2) ......................................................... 4-34
3TNV82A-B (complies with EPA Interim Tier4)........................ 4-35
3TNV84T-B (complies with EPA Interim Tier4) ........................ 4-36
3TNV88-U (complies with EPA Interim Tier4) .......................... 4-37
3TNV88-B (complies with EPA Interim Tier4) .......................... 4-38
4TNV84T-Z (complies with EPA Interim Tier4) ........................ 4-39
4TNV88-U (complies with EPA Interim Tier4) .......................... 4-40
4TNV88-B (complies with EPA Interim Tier4) .......................... 4-41
4TNV98-E (complies with EPA Interim Tier4) .......................... 4-42
4TNV98-Z (complies with EPA Interim Tier4) .......................... 4-43
4TNV98T-Z (complies with EPA Interim Tier4) ........................ 4-44
Engine Service Standards.............................................................. 4-45
Tightening Torques for Standard Bolts and Nuts ........................... 4-46
Abbreviations and Symbols............................................................ 4-48
Abbreviations............................................................................ 4-48
Symbols.................................................................................... 4-48
Unit Conversions ............................................................................ 4-49
Unit Prefixes ............................................................................. 4-49
Units of Length ......................................................................... 4-49
Units of Volume ........................................................................ 4-49
Units of Mass............................................................................ 4-49
Units of Force ........................................................................... 4-49
Units of Torque......................................................................... 4-49
Units of Pressure...................................................................... 4-49
Units of Power .......................................................................... 4-49
Units of Temperature................................................................ 4-49

Component Identification GENERAL SERVICE INFORMATION
COMPONENT IDENTIFICATION
Figure 4-1 shows where the major engine components are located.
3TNV82A(-B),3TNV84,3TNV84T(-B),3TNV88(-B)(-U),4TNV84,4TNV88(-B)(-U),
4TNV94L,4TNV984TNV106,4TNV106T
(1) (2) (20)

(19)
(3)
(18)
(4)
(17)
(16)
(15)
(5) (21)
(14)
(25)
(6)
(13)
(24)
(22)
(23)
0000015B
(12) (11) (10) (9) (8) (7)
1 – Lifting Eye (Flywheel End) 14 – Governor Lever
2 – Turbocharger* 15 – Intake Manifold
3 – Lifting Eye (Engine Cooling Fan End) 16 – Fuel Filter
4 – Engine Coolant Pump 17 – Fuel Inlet
5 – Engine Cooling Fan 18 – Fuel Return to Fuel Tank
6 – Crankshaft V-Pulley 19 – Top Filler Port (Engine Oil)
7 – V-Belt 20 – Rocker Arm Cover
8 – Side Filler Port (Engine Oil) 21 – Air Intake Port (From Air Cleaner)
9 – Drain Plug (Engine Oil)** 22 – Flywheel
10 – Fuel Injection Pump 23 – Starter Motor
11 – Engine Oil Cooler*** 24 – Exhaust Manifold
12 – Engine Oil Filter 25 – Alternator
13 – Dipstick (Engine Oil)
Figure 4-1
* Only applies to 3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T

** The engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models

GENERAL SERVICE INFORMATION Component Identification
Figure 4-2 shows where the major engine components are located.
4TNV84T-Z, 4TNV98-E, 4TNV98-Z, 4TNV98T-Z
(2) (19) (4) (3) (20) (26)
(18)
(17) (28)
(1)
(16) (27)
(15)
(21)
(14)
(25)
(13) (5)
(22)
(6)
(24)
(23)
(12) (11) (9) (10) (8) (7)
1 – Lifting Eye (Flywheel End) 15 – Intake Manifold

2 – Turbocharger* 16 – Fuel Filter
3 – Lifting Eye (Engine Cooling Fan End) 17 – Fuel Inlet
4 – Engine Coolant Pump 18 – Fuel Return to Fuel Tank
5 – Engine Cooling Fan 19 – Top Filler Port (Engine Oil)
6 – Crankshaft V-Pulley 20 – Rocker Arm Cover
7 – V-Belt 21 – Air Intake Port (From Air Cleaner)
8 – Side Filler Port (Engine Oil) 22 – Flywheel
9 – Drain Plug (Engine Oil)** 23 – Starter Motor
10 – Fuel Injection Pump 24 – Exhaust Manifold
11 – Engine Oil Cooler*** 25 – Alternator
12 – Engine Oil Filter 26 – EGR valve
13 – Dipstick (Engine Oil) 27 – EGR cooler****
14 – Eco-governor 28 – EGR pipe
Figure 4-2
* Only applies to 4TNV84T-Z, 4TNV98T-Z.

** Engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models.
**** Only applies to 4TNV84T-Z, 4TNV98T-Z.

Location of Labels GENERAL SERVICE INFORMATION
LOCATION OF LABELS
Figure 4-3 shows the location of regulatory and safety labels on Yanmar TNV series engines.
(1) (4) (1) (3)

(4) (2)
0000019A-01
Figure 4-3
Location of labels/nameplates on direct injection model engines

EPA/ARB Certification 97/68/EC Emission Control
Model Engine Nameplate
Label Label
3TNV82A,3TNV84,3TNV84T,3TNV88 On the top of the locker On the top of the locker On the exhaust side of the locker
3TNV82A-B,3TNV88-B,3TNV88-U arm cover(cooling fan end) arm cover (flywheel end) arm cover(near the flywheel)
3TNV84T-B Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (2)
On the top of the locker On the top of the locker On the exhaust side of the locker
4TNV84,4TNV88,4TNV84T
arm cover(cooling fan end) arm cover(flywheel end) arm cover(near the flywheel)
4TNV88-B,4TNV88-U,4TNV84T-Z
Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (1)
4TNV94L,4TNV98,4TNV98T On the top of the locker On the top of the locker On the top of the locker arm
4TNV106,4TNV106T arm cover(flywheel end) arm cover(center) cover(fan end)
4TNV98-Z,4TNV98-E,4TNV98T-Z Figure 4-3 right, (4) Figure 4-3 right, (1) Figure 4-3 right, (3)

GENERAL SERVICE INFORMATION Emission Control Regulations
Engine Nameplate (Typical) EMISSION CONTROL LABELS

Since emission control regulations are being issued
on a global basis, it is necessary to identify which
regulations a particular engine complies with. We
have listed several different types of labels you
might find on your engine.
EPA / ARB Labels
" "
0003852
EMISSION CONTROL (EPA) Less than 50 HP SAE (37kW)

REGULATIONS
EPA / ARB Regulations - USA Only
Yanmar TNV engines meet Environmental " US-2D " FUEL
Protection Agency (EPA) (U. S. Federal) emission
control standards as well as the California Air
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA / ARB installation
(page 5-16) and maintenance (page 5-16) in the (EPA) Greater than or Equal to 50 HP SAE (37kW)
Periodic Maintenance Schedule section of this
manual. Also refer to the Emission System
Warranty on page 2-6.
(EPA and ARB) 0000086-01

The 97/68/EC Directive Certified Engines GENERAL SERVICE INFORMATION
THE 97/68/EC DIRECTIVE

CERTIFIED ENGINES 97/68/EC DIRECTIVE
The engines described in this manual have been

certified by the 97/68/EC Directive.
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
(97/68/EC)
the engines.
ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all have an Engine Family field. The following is an
explanation of the Engine Family designation:
5 YDX L 1.33 M 3 N
Method of air aspiration
Number of cylinders
Engine speed specifications
Displacement (liter)
Non-road / Off-road engine
Yanmar Diesel
*2005 Model Year
5*: 2005
6 : 2006
7: 2007
8: 2008
9: 2009

GENERAL SERVICE INFORMATION Function of Major Engine Components
FUNCTION OF MAJOR ENGINE COMPONENTS

Components Functions
The air cleaner prevents airborne contaminants from entering the engine. Since
the air cleaner is application specific, it must be carefully selected by an application
Air Cleaner engineer. It is not part of the basic engine package as shipped from the Yanmar
factory. Periodic replacement of the air cleaner filter element is necessary. See the
Periodic Maintenance Schedule on page 5-17 for the replacement frequency.
The alternator is driven by a V-belt which is powered by the crankshaft V-pulley.
Alternator The alternator supplies electricity to the engine systems and charges the battery
while the engine is running.
The engine oil dipstick is used to determine the amount of engine oil in the
Dipstick (Engine Oil)
crankcase.
The electric fuel pump makes sure there is a constant supply of diesel fuel to the
fuel injection pump. The electric fuel pump is electro-magnetic and runs on
Electric Fuel Pump
12 VDC. It must be installed on every application. This is standard equipment with
every engine.
The engine oil filter removes contaminants and sediments from the engine oil.
Engine Oil Filter Periodic replacement of the engine oil filter is necessary. See the Periodic
Maintenance Schedule on page 5-17 for the replacement frequency.
The engine oil cooler helps to keep the engine oil cool. Engine coolant from the
Engine Oil Cooler
cooling system is circulated through an adapter at the base of the engine oil filter
(If Equipped)
assembly and then returned to the coolant pump inlet.
The fuel filter removes contaminants and sediments from the diesel fuel. Periodic
replacement of the fuel filter is necessary. See the Periodic Maintenance Schedule
Fuel Filter
on page 5-17 for the replacement frequency. Please note that the word “diesel”
is implied throughout this manual when the word “fuel” is used.
The fuel filter / water separator removes contaminants, sediments and water from
the diesel fuel going to the fuel filter. This is a required component of the fuel
Fuel Filter / Water Separator system. This is standard equipment with every engine. The separator is installed
between the fuel tank and the electric fuel pump. Periodically drain the water from
the fuel filter / water separator.
The fuel tank is a reservoir that holds diesel fuel. When the fuel leaves the fuel tank
it goes to the fuel filter / water separator. Next the fuel is pumped to the fuel filter
by the electric fuel pump. Then the fuel goes to the fuel injection pump. Since the
Fuel Tank fuel is used to keep the fuel injection pump cool and lubricated, more fuel than
necessary enters the injection pump. When the injection pump pressure reaches
a preset value, a relief valve allows the excess fuel to be returned back to the fuel
tank. The fuel tank is a required engine component.
You can fill the crankcase with engine oil from either the side or the top filler port
Side and Top Filler Port (Engine Oil)
depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key switch in the
Starter Motor operator’s console to the START position, the starter motor engages with the ring
gear installed on the flywheel and starts the flywheel in motion.
Turbocharger
The turbocharger pressurizes the air coming into the engine. It is driven by a
(Only applies to 3TNV84T, 4TNV84T,
turbine that is energized by exhaust gases.
4TNV98T, 4TNV106T)

MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES GENERAL SERVICE INFORMATION
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES

4TNV84T-Z, 4TNV98-E, 4TNV98-Z,
4TNV98T-Z
Component/Feature Description
Engine controller (E-ECU) Adjusts the rack position of the fuel injection pump
depending on the speed command signal from the
accelerator sensor, thus regulating the engine speed and
power. The engine controller also regulates the opening of
the EGR valve depending on the engine speed and
power. It serves as the master station for the following
components/control features.
Electronic governor (Eco-governor) Consists of the engine speed sensor, rack actuator, etc.,
and is directly connected to the fuel injection pump in
order to regulate the rack position of the fuel injection
pump depending on the signals communicated with the E-
ECU.
Fuel injection pump (for Eco-governor) Is of single plunger type and equipped with a CSD
solenoid valve that allows the fuel injection timing to
advance and the injection quantity to increase, thereby
improving the cold start performance of the engine.
EGR valve Controls the exhaust gas recirculation flow rate
depending on the engine speed/load signals from the E-
ECU. It is installed on the top of the exhaust manifold.
Accelerator sensor Unlike mechanical governors, the Eco-governor has no
governor lever. The accelerator sensor serves as the
governor lever to provide the speed command signal
(voltage signal) to the E-ECU for engine speed control. It
is installed in the operator cabin of the driven machine.
Constant speed engines for e.g. generator use do not
require accelerator sensors because the engine speed
can be shifted via a switch on the operator's console.
Optional CAN communication capability is available as an option.
Fault indicator Is installed on the operator's console. If a fault occurs in
the E-ECU or Eco-governor, the fault indicator flashes
alerting the operator to a fault. The number of flashes
and/or the flashing pattern vary depending on the type or
Optional source of the fault, enabling quick-fix.

GENERAL SERVICE INFORMATION MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
Component/Feature Description
Engine diagnosis tool Allows the operator to troubleshoot the cause of a
problem based on detailed information regarding the
problem occurring in the E-ECU or Eco-governor. This
tool can also be used for data maintenance tasks
including programming and mapping. See
Option for service Troubleshooting Chart on page 7-113.
Engine coolant temperature sensor Allows the CSD and ERG to be controlled in engine cold-
start conditions.
Glow plugs Optional When the key switch is turned to the ON position, the glow
Air heater plugs/air heater are/is energized for up to 15 seconds
(glow plugs) or up to 23 seconds (air heater). The duration
of energization depends on the engine coolant
temperature. The HEAT indicator is on during
energization. When the indicator goes out, turn the key
switch to the START position to start the engine.
After heater Optional In extreme cold start conditions, the after heater is
energized for up to 80 seconds or until the coolant
temperature reaches 10°C after the engine has started, in
order to help ensure the engine continues to run without
stall.This option is not available for glow plug engines.
Droop control Standard with VM series Reduces the engine speed by a certain percentage from
no load to full (rated) load in steady state operation. The
same percentage droop is maintained even when the load
increases at any no-load speed.
Isochronous control Standard with CL series Offers a constant engine speed from no load to full load.
Optional with VM series The engine speed does not decrease even when the load
increases at any no-load speed.
Low-idling speed up Increases the low-idling speed to up to 1000 rpm
depending on the engine coolant temperature. When the
coolant temperature reaches a predetermined value, this
feature returns the engine speed to the normal low idle
setting, thus reducing the warm-up time.
High-idling speed Optional Decreases the high-idling speed depending on the engine
down coolant temperature. When the coolant temperature falls
to a predetermined value, this feature returns the engine
speed to the normal high idle setting, thus minimizing the
emission of white smoke at low temperatures.
Auto deceleration Optional Brings the running engine in low idle mode automatically
when the accelerator pedal is not operated for a
predetermined period of time. When the pedal is
operated, i.e., the accelerator sensor is activated, the low
idle mode is cancelled.

Function of Cooling System Components GENERAL SERVICE INFORMATION
FUNCTION OF COOLING SYSTEM COMPONENTS

Components Functions
The TNV engine is liquid-cooled by means of a cooling system. The cooling system
consists of a radiator, radiator cap, engine cooling fan, engine coolant pump,
thermostat, and reserve tank. Note that all cooling system components are
Cooling System required for proper engine operation. Since some of the components are
application specific, they must be carefully selected by an application
engineer. The application specific items are not part of the basic engine
package as shipped from the Yanmar factory.
The engine cooling fan is driven by a V-belt which is powered by the crankshaft
Engine Cooling Fan V-pulley. The purpose of the engine cooling fan is to circulate air through the
radiator.
The engine coolant pump circulates the engine coolant through the cylinder block
Engine Coolant Pump
and the cylinder head and returns the engine coolant to the radiator.
The radiator acts as a heat exchanger. As the engine coolant circulates through
the cylinder block it absorbs heat. The heat in the engine coolant is dissipated in
Radiator
the radiator. As the engine cooling fan circulates air through the radiator, the heat
is transferred to the air.
The radiator cap controls the cooling system pressure. The cooling system is
pressurized to raise the boiling point of the engine coolant. As the engine coolant
temperature rises, the system pressure and the coolant volume increases. When
the pressure reaches a preset value, the release valve in the radiator cap opens
Radiator Cap
and the excess engine coolant flows into the reserve tank. As the engine coolant
temperature is reduced, the system pressure and volume is reduced and the
vacuum valve in the radiator cap opens allowing the engine coolant to flow from
the reserve tank back into the radiator.
The reserve tank contains the overflow of engine coolant from the radiator. If you
Reserve Tank need to add engine coolant to the system, add it to the reserve tank; not the
radiator.
A thermostat is placed in the cooling system to prevent the engine coolant from
circulating into the radiator until the engine coolant temperature reaches a preset
temperature. When the engine is cold, no engine coolant flows through the
Thermostat radiator. Once the engine reaches its operating temperature, the thermostat opens
and allows the engine coolant to flow through the radiator. By letting the engine
warm up as quickly as possible, the thermostat reduces engine wear, deposits and
emissions.

GENERAL SERVICE INFORMATION Diesel Fuel
DIESEL FUEL • Fuel additives are not recommended. Some fuel

additives may cause poor engine performance.
Diesel Fuel Specifications Consult your Yanmar representative for more
information.
Diesel fuel should comply with the following
specifications. The table lists several worldwide • The ash content must not exceed 0.01% by
specifications for diesel fuels. volume.
• The carbon residue content must not exceed
Diesel Fuel Specification Location 0.35% by volume. Less than 0.1% is preferred.
No. 2-D, No. 1-D, • The total aromatics content should not exceed
USA
ASTM D975-94 35% by volume. Less than 30% is preferred.
European • The PAH (polycyclic aromatic hydrocarbons)
EN590:96
Union content should be below 10% by volume.
ISO 8217 DMX International • The metal content of Na, Mg, Si, and Al should be
United equal to or lower than 1 mass ppm. (Test analysis
BS 2869-A1 or A2 method JPI-5S-44-95)
Kingdom
JIS K2204 Grade No. 2 Japan • Lubricity: The wear mark of WS1.4 should be
KSM-2610 Korea Max. 0.018 in (460 µm) at HFRR test.
GB252 China Bio-Diesel Fuels

In Europe and in the United States, as well as some
Additional Technical Fuel Requirements other countries, non-mineral oil based fuel
• The fuel cetane number should be equal to 45 or resources such as RME (Rapeseed Methyl Ester)
higher. and SOME (Soybean Methyl Ester), collectively
known as FAME (Fatty Acid Methyl Esters), are
• The sulfur content must not exceed 0.5% by
being used as extenders for mineral oil derived
volume. Less than 0.05% is preferred.
diesel fuels.
For electronically controlled engines 4TNV84T-Z,
4TNV98-Z, 4TNV98-E, and 4TNV98T-Z, it is Yanmar approves the use of bio-diesel fuels that do
mandatory to use fuel that does not contain not exceed a blend of 5% (by volume) of FAME with
0.05% or more sulfur content. 95% (by volume) of approved mineral oil derived
In general, using a high sulfur fuel may possible diesel fuel. Such bio-diesel fuels are known in the
result in corrosion inside the cylinder. marketplace as B5 diesel fuels.
• Bio-Diesel fuels. See Bio-Diesel Fuels on These B5 diesel fuels must meet certain
page 4-12. requirements.
• NEVER mix kerosene, used engine oil, or 1. The bio-fuels must meet the minimum
residual fuels with the diesel fuel. specifications for the country in which they are
used.
• The water and sediment in the fuel should not • In Europe, bio-diesel fuels must comply with
exceed 0.05% by volume. the European Standard EN14214.
• Keep the fuel tank and fuel-handling equipment • In the United States, bio-diesel fuels must
clean at all times. comply with the American Standard
ASTM D-6751.
• Poor quality fuel can reduce engine performance
and / or cause engine damage. 2. Bio-fuels should be purchased only from
recognized and authorized diesel fuel suppliers.

Diesel Fuel GENERAL SERVICE INFORMATION
Precautions and concerns regarding the use of Filling The Fuel Tank
bio-fuels:
1. Free methanol in FAME may result in corrosion A DANGER
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures, FIRE AND EXPLOSION HAZARD!
and poor injection nozzle spray atomization.
4. FAME may have adverse effects on some under certain conditions.
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine • Only fill the fuel tank with diesel fuel.
lubricating oil. Filling the fuel tank with gasoline may
result in a fire and will damage the
5. Even bio-diesel fuels that comply with a suitable
engine.
standard as delivered, will require additional
care and attention to maintain the quality of the • NEVER refuel with the engine running.
fuel in the equipment or other fuel tanks. It is • Wipe up all spills immediately.
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system, • Keep sparks, open flames or any other
and / or fuel storage containers, may be form of ignition (match, cigarette,
necessary. static electric source) well away when
refueling.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel • NEVER overfill the fuel tank.
engine manufacturers and the diesel fuel • Fill the fuel tank. Store any containers
injection equipment manufacturers, or bio- containing fuel in a well-ventilated
diesel fuels that have degraded as per the area, away from any combustibles or
precautions and concerns above, may affect sources of ignition.
the warranty coverage of your engine. See
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en

GENERAL SERVICE INFORMATION Diesel Fuel
A DANGER A DANGER

• Be sure to place the diesel fuel • Before you operate the engine, check
container on the ground when for fuel leaks. Replace rubberized fuel
transferring the diesel fuel from the hoses every two years or every 2000
pump to the container. Hold the hose hours of engine operation, whichever
nozzle firmly against the side of the comes first, even if the engine has
container while filling it. This prevents been out of service. Rubberized fuel
static electricity buildup which could lines tend to dry out and become
cause sparks and ignite fuel vapors. brittle after two years or 2000 hours of
engine operation, whichever comes
• NEVER place diesel fuel or other
first.
flammable material such as oil, hay or
dried grass close to the engine during • Failure to comply will result in death or
engine operation or shortly after serious injury.
shutdown. 0000015en

serious injury. CAUTION
0000014en
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en

Engine Oil GENERAL SERVICE INFORMATION
Note that a typical fuel tank is shown. The fuel tank 2. NEVER use the starter motor to crank the
on your equipment may be different. engine in order to prime the fuel system. This
may cause the starter motor to overheat and
1. Clean the area around the fuel cap damage the coils, pinion and / or ring gear.
(Figure 4-4, (1)).
2. Remove the fuel cap (Figure 4-4, (1)) from the
fuel tank (Figure 4-4, (2)). ENGINE OIL
3. Observe the fuel level sight gauge
(Figure 4-4, (3)) and stop fueling when the CAUTION
gauge shows the fuel tank is full. NEVER
overfill the fuel tank. • Only use the engine oil specified.
Other engine oils may affect warranty
4. Replace the fuel cap (Figure 4-4, (1)) and hand coverage, cause internal engine
tighten. Over-tightening the fuel cap will components to seize and / or shorten
damage it. engine life.
(1) • Prevent dirt and debris from
clean the oil cap / dipstick and the
surrounding area before you remove
(2) the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
(3)
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
0000002A
overspeed or internal damage.
Figure 4-4 0000005en
Priming the Fuel System Engine Oil Specifications

The fuel system needs to be primed under certain Use an engine oil that meets or exceeds the
conditions: following guidelines and classifications:
• Before starting the engine for the first time. Service Categories
• After running out of fuel and fuel has been added • API Service Categories CD or higher
to the fuel tank. (Grade CF or higher for EGR-equipped engines
4TNV84T-Z, 4TNV98-Z, 4TNV98-E, and
• After fuel system maintenance such as changing 4TNV98T-Z)
the fuel filter and draining the fuel filter / water
separator, or replacing a fuel system component. • ACEA Service Categories E-3, E-4, and E-5
To prime the fuel system: • JASO Service Category DH-1
1. Turn the key to the ON position for 10 - 15 Definitions

seconds. This will allow the electric fuel pump • API Classification (American Petroleum Institute)
to prime the fuel system.
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)

GENERAL SERVICE INFORMATION Engine Oil
• JASO (Japanese Automobile Standards Checking Engine Oil

Organization)
1. Make sure the engine is level.
Notes: 2. Remove the dipstick (Figure 4-6, (1)) and wipe
• Be sure the engine oil, engine oil storage it with clean cloth.
containers, and engine oil filling equipment are 3. Fully reinsert the dipstick.
free of sediment and water. 4. Remove the dipstick. The oil level should be
• Change the engine oil after the first 50 hours of between the upper (Figure 4-6, (2)) and lower
operation and then every 250 hours thereafter. (Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert the dipstick.
• Select the oil viscosity based on the ambient
temperature where the engine is being operated. (4)
See the SAE Service Grade Viscosity Chart
(Figure 4-5).
• Yanmar does not recommend the use of engine
oil “additives.”
Additional Technical Engine Oil

Requirements:
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
mgKOH/g test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI). (4)
Engine Oil Viscosity (5)

Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-5. (2)
(1)
SAE 10W
SAE 20W (3)
SAE 10W-30
0000007C
SAE 15W-40
Figure 4-6
SAE 20
SAE 30
SAE 40
SAE 20W - 50
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F

(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C)
0000005A
Figure 4-5

Engine Oil GENERAL SERVICE INFORMATION
Adding Engine Oil Engine Oil Capacity (Typical)
1. Make sure the engine is level. Note: These are the engine oil capacities
2. Remove the oil cap (Figure 4-6, (4)). associated with a “deep standard” oil
pan. The oil capacity will vary dependant
3. Add the indicated amount of engine oil at the upon which optional oil pan is used.
top or the side engine oil filler port Refer to the operation manual provided
(Figure 4-6, (5)). by the driven machine manufacturer for
4. Wait three minutes and check the oil level. the actual engine oil capacity of your
5. Add more oil if necessary. machine.
6. Reinstall the oil cap (Figure 4-6, (4)) and The following are the engine oil capacities for
hand-tighten. Over-tightening may damage the various Yanmar TNV engines.
cap.
Dipstick Upper
Engine Model
Limit / Lower Limit
5.8 / 3.8 qt
3TNV82A(-B)
(5.5 / 3.6 L)
7.1 / 4.1 qt
3TNV84,3TNV84T(-B)
(6.7 / 3.9 L)
7.1 / 4.1 qt
3TNV88(-B)(-U)
(6.7 / 3.9 L)
7.8 / 4.2 qt
4TNV84,4TNV84T(-Z)
(7.4 / 4.0 L)
7.8 / 4.2 qt
4TNV88(-B)(-U)
(7.4 / 4.0 L)
11.1 / 6.3 qt
4TNV94L
(10.5 / 6.0 L)
4TNV98(-Z)(-E), 11.1 / 6.3 qt
4TNV98T(-Z) (10.5 / 6.0 L)
4TNV106(CL), 14.8 / 5.3 qt
4TNV106T(CL) (14.0 / 5.0 L)
4TNV106(VM), 14.8 / 6.9 qt
4TNV106T(VM) (14.0 / 6.5 L)

GENERAL SERVICE INFORMATION Engine Coolant
ENGINE COOLANT
A CAUTION
A DANGER
COOLANT HAZARD!
• Wear eye protection and rubber gloves
SCALD HAZARD!
when you handle long life or extended
• NEVER remove the radiator cap if the life engine coolant. If contact with the
engine is hot. Steam and hot engine eyes or skin should occur, flush eyes
coolant will spurt out and seriously and wash immediately with clean
burn you. Allow the engine to cool water.
the radiator cap.
or moderate injury.
• Tighten the radiator cap securely after 0000005en
spurt out during engine operation if
the cap is loose. CAUTION
• ALWAYS check the level of the engine • Only use the engine coolant specified.
coolant by observing the reserve tank. Other engine coolants may affect
warranty coverage, cause an internal
• Failure to comply will result in death or buildup of rust and scale and / or
serious injury. shorten engine life.
0000002en
contaminating the engine coolant.
A WARNING Carefully clean the radiator cap and
remove the cap.
coolants. This may adversely affect the
properties of the engine coolant.
BURN HAZARD! 0000006en
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
or serious injury.
0000016en

Engine Coolant GENERAL SERVICE INFORMATION
Engine Coolant Specifications Filling Radiator with Engine Coolant
Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This
Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time
guidelines and specifications: or refilling it after it is flushed. Note that a typical
radiator is illustrated (Figure 4-7).
Additional Technical Coolant
Specifications:
(2)
• ASTM D6210, D4985 (US)
(5)
• JIS K-2234 (Japan)
• SAE J814C, J1941, J1034 or J2036 (3)
(International)
(6) FULL
Alternative Engine Coolant LOW
(4)
If an Extended or Long Life Coolant is not available,
alternatively, you may use an ethylene glycol or
propylene glycol based conventional coolant
(green). (1)
0000029A
Notes:
Figure 4-7
• ALWAYS use a mix of coolant and water.
NEVER use water only. 1. Check to be sure the radiator drain plug is
• Mix the coolant and water per the mixing installed and tightened or the drain cock
instructions on the coolant container. (Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the
• Water quality is important to coolant cylinder block is closed or the oil coolant hoses
performance. Yanmar recommends that soft, (Figure 4-9, (1)) are installed at the oil cooler.
distilled, or demineralized water be used to mix
with coolants.
• NEVER mix extended or long life coolants and
conventional (green) coolants.
• NEVER mix different types and / or colors of
extended life coolants.
• Replace the coolant every 1000 engine hours
or once a year.
(1)
0000027B
Figure 4-8

GENERAL SERVICE INFORMATION Engine Coolant
Engine Coolant Capacity (Typical)

Note: The capacities listed are for the engine
only without a radiator. Refer to the
operation manual provided by the driven
machine manufacturer for the actual
engine coolant capacity on your
machine.
The following are the engine coolant capacities for
various Yanmar TNV engines.
Engine Coolant
Engine Model
(1) 0001579B Capacity
3TNV82A(-B) 1.9 qt (1.8 L)
Figure 4-9
3TNV84,3TNV84T(-B) 2.1 qt (2.0 L)
2. Remove the radiator cap (Figure 4-7, (2)) by 3TNV88(-B)(-U) 2.1 qt (2.0 L)
turning it counter-clockwise about 1/3 of a turn. 4TNV84,4TNV84T(-Z) 2.9 qt (2.7 L)
3. Pour the engine coolant slowly into the radiator 4TNV88(-B)(-U) 2.9 qt (2.7 L)
until it is even with the lip of the engine coolant 4TNV94L 4.4 qt (4.2 L)
filler port. Make sure that air bubbles do not
4TNV98(-Z)(-E),
develop as you fill the radiator. 4TNV98T(-Z)
4.4 qt (4.2 L)
4. Reinstall the radiator cap (Figure 4-7, (2)). 4TNV106, 4TNV106T 6.3 qt (6.0 L)
Align the tabs on the back side of the radiator
cap with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.
5. Remove the cap on the reserve tank
(Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
Reinstall the cap.
6. Check the hose (Figure 4-7, (5)) that connects
the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, the engine coolant will leak out
instead of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at the FULL (HOT) mark (Figure 4-7, (6)). If
the engine coolant is not at the FULL (HOT)
mark (Figure 4-7, (6)), add additional engine
coolant to the reserve tank to bring the level to
the FULL (HOT) mark.

Specifications GENERAL SERVICE INFORMATION
SPECIFICATIONS
Description of Model Number
3 TNV 82 A T - Z 0 00
Customer Code
Rated RPM
Governor Type Symbol (Indicating Conformance to EPA Tier 3/Interim Tier
4 Standards)
Governor Type Symbol Governor Type Applicable engine
Z Electronic Governor (Eco-governor)
Non-derated engine
B Mechanical Governor
E Electronic Governor (Eco-governor)
Derated engine
U Mechanical Governor
Turbocharged (No symbol indicates naturally aspirated)
Engine Sub Series
Cylinder Bore (mm)
Engine Series
No. of Cylinders
Engine Speed Specifications

Notation Available Engine Speed Intended Uses
VH 3200 - 3600 RPM (min-1) Lawn Mower, Construction, Industrial Machine
VM 2000 - 3000 RPM (min-1) Agricultural, Construction, Industrial Machines
-1
CH 3000 or 3600 RPM (min ) 2-pole Generator Sets, Irrigation Pumps
-1
CL 1500 or 1800 RPM (min ) 4-pole Generator Sets, Irrigation Pumps
VH: Variable High Speed CH: Constant High Speed

VM: Variable Medium Speed CL: Constant Low Speed

GENERAL SERVICE INFORMATION Specifications
Engine General Specifications

Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Direct Injection Models Direct Injection
Combustion System
Indirect Injection Models Swirl Chamber (Ball-Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Notes:
1. The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer.
2. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77°F (25°C), Atmospheric pressure 29.53 in. Hg
(100 kPa, 750 mm Hg), Relative humidity 30%
• Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C)
• Fuel Feeding Pressure: 20 ± 10 kPa (net) after engine break-in has been performed with the
cooling fan, air cleaner and muffler installed to the engine.
• With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
• After the Engine Break-In Period. Output Allowable Deviation: ± 3%
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW

Principal Engine Specifications GENERAL SERVICE INFORMATION
PRINCIPAL ENGINE SPECIFICATIONS

3TNV82A (~ EPA Tier2)
Engine Model 3TNV82A
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 82 × 84mm
Displacement 1.331L
min-1 1500 1800
Continuous Rated Output kW 9.9 12.0
PS 13.5 16.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 11.0 13.2 14.6 16.0 17.5 19.0 20.4 21.9
PS 14.9 17.9 19.9 21.8 23.8 25.8 27.8 29.8
1600 1895 2180 2375 2570 2780 2995 3180
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
138kg 128 kg
*with Flywheel Housing
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Normal Oil Pressure at Rated
Engine Speed 0.34 - 0.49 MPa 0.39 - 0.54 MPa
Normal Oil Pressure at Low 0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (1.2 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 55Ah*** (5h rating)
Dimensions (L × W × H)* 553 × 489 × 565 mm 528 × 489 × 565 mm
5.5/3.6L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.8L Engine Only
Standard Cooling Fan 335mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
Fan V-pulley dia. φ120/ φ90mm *** φ110/ φ110mm ***
* Engine specifications without radiator.

** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

GENERAL SERVICE INFORMATION Principal Engine Specifications
3TNV84 (~ EPA Tier2)

Engine Model 3TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 3
Displacement 1.496L
min-1 1500 1800
PS 15.3 18.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 16.8 20.1 22.3 24.6 26.8 29.0 31.3 33.5
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 55 Ah*** (5h rating)
Dimensions (L × W × H)* 589 × 486 × 622mm 564 × 486 × 622mm
Engine Oil Pan Capacity** 6.7/3.9L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

3TNV84T (~ EPA Tier2)
Engine Model 3TNV84T
Version CL VM
Aspiration Turbocharged
No. of Cylinders 3
Displacement 1.496L
min-1 1500 1800
PS 19.0 22.5
min-1 1500 1800 2400 2600 2800 3000
Max. Rated Output (Net) kW 15.8 18.8 25.0 26.8 29.1 30.9
PS 21.5 25.5 34.0 36.5 39.5 42.0
High Idling min-1 1600 1895 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161 kg 155 kg
0.29 - 0.44 MPa 0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V,55 Ah*** (5h rating)
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.


Engine Model 3TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 3
Displacement 1.642L
min-1 1500 1800
PS 16.7 20.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 18.4 22.1 24.5 27.0 29.4 31.9 34.2 36.8
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 55Ah *** (5h rating)
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Engine Model 4TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
PS 20.3 24.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 22.3 26.5 29.8 32.8 35.8 38.7 41.7 44.7
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183kg 170kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Dimensions (L × W × H)* 683 × 498.5 × 617 mm 658 × 498.5 × 617mm
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.


Version CL VM
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
PS 26.0 33.0
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 29.0 36.5 38.0 41.5 45.5 48.5 52.5 56.0
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
0.29 - 0.44 MPa 0.36 - 0.5 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating)
Dimensions (L × W × H)* 683 × 498.5 × 713 mm 649 × 498.5 × 713 mm
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Engine Model 4TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 2.190L
min-1 1500 1800
PS 22.3 26.7
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 24.5 29.4 32.7 36.0 39.2 42.5 45.8 48.1
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Idle Speed 0.06 MPa
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating) ***
Dimensions (L × W × H)* 683 × 498.5 × 618 mm 658 × 498.5 × 618 mm
Engine Oil Pan Capacity** 7.4 / 4.0 L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

4TNV94L (~ EPA Tier2)

Engine Model 4TNV94L
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 3.054L
min-1 1500 1800
PS 35.5 42.5
min-1 1500 1800 2000 2200 2400 2500
PS 39.5 47.0 48.0 52.0 56.5 58.5
High Idling min-1 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry) 245 kg 235 kg
Normal Oil Pressure at Rated 0.29 - 0.39 MPa
Engine Speed
0.06 MPa
Idle Speed
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Crank V-pulley dia./ φ130/ φ130mm ***
Fan V-pulley dia.

Engine Model 4TNV98
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
PS 42.0 50.0
min-1 1500 1800 2000 2200 2400 2500
PS 47.0 56.0 57.0 62.0 67.0 69.5
High Idling min-1 1600 ± 25 1895 ±25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Speed
0.06 MPa
Idle Speed
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
Fan V-pulley dia.


Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
PS 51.5 62.0
min-1 1500 1800 2000 2200 2400 2500
PS 57.0 68.5 69.0 75.5 82.0 85.0
High Idling min-1 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 64Ah ***
Dimensions (L × W × H)* 719 × 575 × 804mm
10.5/6.0L
Standard Cooling Fan 430mm O.D., 8 Blade Suction-Type ***
Fan V-pulley dia.

Engine Model 4TNV106
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 4.412L
min-1 1500 1800
PS 56.0 67.0
min-1 1500 1800 2000 2200 2400 2500
PS 62.0 74.0 77.0 83.5 89.0 92.0
High Idling min-1 1600 ± 25 1895 ± 25 2205 ± 25 2420 ± 25 2615 ± 25 2725 ± 25
Engine Weight (Dry) 345kg 330kg
Normal Oil Pressure at Rated 0.31 - 0.49 MPa With balancer: 0.34-0.44 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 88 Ah***
14.0/5.0L 14.0/6.5L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D. 7 Blade Suction-Type ***
Fan V-pulley dia.


Version CL VM
No. of Cylinders 4
Displacement 4.412L
min-1 1500 1800
PS 70.0 84.0
min-1 1500 1800 2000 2200
Max. Rated Output (Net) kW 56.8 68.0 69.9 72.0
PS 77.2 92.5 95.0 97.9
High Idling min-1 1600 ± 25 1875 ± 25 2205 ± 25 2420 ± 25
Normal Oil Pressure at Rated 0.31 - 0.49 MPa With balancer: 0.34-0.44 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
0.06 MPa
Idle Speed
Electric Starting (Starter Motor DC12V (3.0 kW)) ***
Recommended Battery Capacity: 12V, 88 Ah***
14.0/5.0L 14.0/6.5L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D.7 Blade Suction-Type***
Fan V-pulley dia.

3TNV82A-B (complies with EPA Interim Tier4)
Engine Model 3TNV82A-B
Version CL VM
Aspiration Natural aspiration
No. of Cylinders 3
Bore × Stroke φ82 × 84mm
Displacement 1.331L
min-1
Continuous Rated
Output kW
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output kW 16.0 16.8 17.5 18.2 19.0 19.7 20.4 21.9
(Net) PS 21.8 22.8 23.8 24.8 25.8 26.8 27.8 29.8
23.0
High Idling min-1 2375 2485 2570 2675 2780 2890 2995 3180
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
128kg
Governor Mechanical governor (All-speed governor)
Rated Engine 0.36-0.51 (3.7-
Speed 0.31-0.46 (3.2-4.7) MPa 5.2) MPa
Normal Oil
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery
Capacity 12V-55Ah*** (5h rating)
Starting aid device Super-quick Heating Glow plug
5.5L/3.6L
Standard Cooling Fan Resin F type pusher fan - φ335(NF) x 6
Crank V-pulley dia./ φ110/ φ110mm
Fan V-pulley dia.

3TNV84T-B (complies with EPA Interim Tier4)

Engine Model 3TNV84T-B
Version CL VM
No. of Cylinders 3
Displacement 1.496L
min-1
Continuous Rated
Output kW
PS
min-1 2400 2500 2600 2700 2800
Max. Rated Output
(Net) kW 25.0 26.0 26.8 27.9 29.1
PS 34.0 35.3 36.5 38.0 39.5
2590 2700 2810 2920 2995
High Idling min-1
±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 155kg
Governor Electronic governor (All-speed governor)
Rated Engine 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-5.5) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery 12V-55Ah*** (5h rating)
Capacity
Starting aid device Air heater (12V DC 400W)
Dimensions (L × W × H)* 589 × 486 × 564 × 486 × 622mm
622mm
6.7L/3.9L
Standard Cooling Fan Resin F type pusher fan - φ350(QF) x 6
Fan V-pulley dia.

3TNV88-U (complies with EPA Interim Tier4)
Engine Model 3TNV88-U
Version CL VM
No. of Cylinders 3
Displacement 1.642L
min-1
Continuous Rated
Output kW
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 18.1 18.9 19.7 20.5 21.3 22.2 23.0 24.6
PS 24.6 25.7 26.8 27.9 29.0 30.2 31.3 33.5
2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
Rated Engine 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-
Normal Oil Speed 5.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
6.7L/3.9L
φ110/ φ110mm
Fan V-pulley dia.

3TNV88-B (complies with EPA Interim Tier4)

Engine Model 3TNV88-B
Version CL VM
No. of Cylinders 3
Displacement 1.642L
min-1 1500 1800
Continuous Rated
Output kW 12.3 14.8
PS 16.7 20.1
min-1 1500 1800 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 13.5 16.3 19.9 20.7 21.6 22.6 23.5 24.3 25.2 27.1
PS 18.4 22.1 27.0 28.2 29.4 30.7 31.9 33.1 34.2 36.8
1600 1895 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 161kg 155kg
Rated Engine 0.29-0.44 (3.0- 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-
Normal Oil Speed 4.5) MPa 5.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
622mm
6.7L/3.9L
Crank V-pulley dia./ φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV84T-Z (complies with EPA Interim Tier4)
Engine Model 4TNV84T-Z
Version CL VM
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
Continuous Rated
Output kW 19.1 24.3
PS 26.0 33.0
min-1 1500 1800 2400 2500 2700 2800 3000
Max. Rated Output
(Net) kW 21.3 26.9 33.5 34.5 37.1 38.6 41.2
PS 29.0 36.5 45.5 47.0 50.5 52.5 56.0
1600 1895 2590 2700 2850 2950 3150
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
Rated Engine 0.29-0.44 (3.0- 0.36-0.51 (3.7-5.2) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW) ***
Capacity
Starting aid device Air heater (12V DC 400W)
713mm
7.4L/4.0L
Standard Cooling Fan Resin F type pusher fan - φ370(EF) x 6
Crank V-pulley dia./ φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV88-U (complies with EPA Interim Tier4)

Engine Model 4TNV88-U
Version CL VM
No. of Cylinders 4
Displacement 2.190L
min-1
Continuous Rated
Output kW
PS
min-1 2700 2800
Max. Rated Output
(Net) kW 29.6 30.7
PS (40.2) (41.7)
2920 2995
High Idling min-1
±25 ±25
Engine Weight (dry)
Rated Engine 0.32-0.47 (3.3-4.8) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV88-B (complies with EPA Interim Tier4)
Engine Model 4TNV88-B
Version CL VM
No. of Cylinders 4
Displacement 2.190L
min-1 1500 1800
Continuous Rated
Output kW 16.4 19.6
PS 22.3 26.7
min-1 1500 1800 2000 2100 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 18.0 21.6 24.1 25.3 26.5 27.7 28.8 30.1 31.3 32.5 33.7 35.4
PS 24.5 29.4 32.7 34.4 36.0 37.6 39.2 40.9 42.5 44.2 45.8 48.1
1600 1895 2180 2290 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
Rated Engine 0.29-0.44 (3.0- 0.32-0.47 (3.3-4.8) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Capacity
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
φ120/ φ90 φ110/ φ110
Fan V-pulley dia.

4TNV98-E (complies with EPA Interim Tier4)

Engine Model 4TNV98-E
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1
Continuous Rated
Output kW
PS
min-1 2100 2200 2300 2400 2500
Max. Rated Output
(Net) kW 36.8 38.2 39.7 41.6 43.0
PS 50.0 52.0 54.0 56.5 58.5
High Idling min-1 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 240kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed 0.06 (0.6) MPa
Recommended Battery
12V-64Ah*** (5h rating)
Capacity
Starting aid device Air heater (12VDC/500W)
Engine Oil Pan Capacity** 10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
Fan V-pulley dia. φ130/ φ130mm


4TNV98-Z (complies with EPA Interim Tier4)
Engine Model 4TNV98-Z
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
Continuous Rated
Output kW 30.9 36.8
PS 42.0 50.0
min-1 1500 1800 2000 2100 2200 2300 2400 2500
Max. Rated Output
(Net) kW 34.6 41.2 41.9 43.8 45.6 47.4 49.3 51.1
PS 47.0 56.0 57.0 59.5 62.0 64.5 67.0 69.5
High Idling min-1 1530 ± 25 1830 ± 25 2150 ± 25 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 248kg 235kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed 0.06 (0.6) MPa
Recommended Battery
Capacity
Engine Oil Pan Capacity** 10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
Fan V-pulley dia. φ130/ φ130mm


4TNV98T-Z (complies with EPA Interim Tier4)

Engine Model 4TNV98T-Z
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
Continuous Rated
Output kW 37.9 45.6
PS 51.5 62.0
min-1 1500 1800 2200 2300 2400 2500
Max. Rated Output
(Net) kW 41.9 50.4 55.5 58.0 60.3 62.5
PS 57.0 68.5 75.5 78.8 82.0 85.0
High Idling min-1 1530 ± 25 1830 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 258kg 245kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed ≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ430(UX) x 6
Fan V-pulley dia.

Engine Service Standards GENERAL SERVICE INFORMATION
ENGINE SERVICE STANDARDS

Reference
Inspection Item Standard Limit
page
All models
except 0.006 - 0.010 in. See Measuring
-
4TNV106 and (0.15 - 0.25 mm) and Adjusting
Intake / Exhaust Valve Clearance 4TNV106T Valve Clearance
4TNV106 and 0.010 - 0.014 in. on page 6-66
-
4TNV106T (0.25 - 0.35 mm)
Fuel Injection
See Checking and Adjusting Fuel Injection Timing on page 7-30.
Timing
Fuel Injection
See Test and Adjustment Specifications on page 7-12.
Pressure
443 - 473 psi 340 - 370 psi
3TNV82A (3.06 - 3.26 MPa; (2.35 - 3.55 MPa;
30 - 32 kgf / cm²) 24 - 26 kgf / cm²)
455 - 485 psi 355 - 385 psi See
Compression 3TNV84, 4TNV84 (3.14 - 3.34 MPa; (2.45 - 2.65 MPa; Troubleshooting
Pressure at 32 - 34 kgf / cm²) 25 - 27 kgf / cm²) By Measuring
250 rpm 411 - 441 psi 340 - 370 psi Compression
(250 min¯¹) 3TNV84T, 4TNV84T (2.84 - 3.04 MPa; (2.35 - 2.55 MPa; Pressure on
29 - 31 kgf / cm) 24 - 26 kgf / cm²) page 15-187
3TNV88, 4TNV88, 4TNV94L, 483 - 513 psi 384 - 414 psi
4TNV98, 4TNV98T, 4TNV106, (3.33 - 3.53 MPa; (2.65 - 2.85 MPa;
4TNV106T 34 - 36 kgf / cm²) 27 - 29 kgf / cm²)
29 - 43 psi
Deviation Between Cylinders All Models (0.2 - 0.3 MPa; - -
2 - 3 kgf/cm²)
5.8 - 8.8 psi
Oil Pressure Switch Operating Pressure (0.04 - 0.06 MPa; - -
0.4 - 0.6 kgf / cm²)
Valve Opening Full Opening Lift
Temperature Temperature
0.32 in (8 mm) or
157°F - 163°F
All Models above See Thermostat
Thermostat (70°C - 73°C)
185°F (85°C) on page 8-11
0.39 in (10 mm) or
All Models 176°F - 183°F
above
Option (80°C - 84°C)
203°F (95°C)
See
225°F - 235°F Temperature
Coolant Temperature Switch -
(107°C - 113°C) Switch on
page 8-10

GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten
the fasteners on the machine. Applying excessive CAUTION
torque may damage the fastener or component and The tightening torque in the Standard
not enough torque may cause a leak or component Torque Chart (see General Service
failure. Information section) should be applied
only to the bolts with a “7” head. (JIS
strength classification: 7T)
• Apply 60% torque to bolts

that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
0000023enTNVDISM
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
7 - 9 ft-lb
(87 -104 in.-lb,
M6 x 1.0 mm
9.8 -11.8 N·m,
1.0 -1.2 kgf·m)
17 - 21 ft-lb
M8 x 1.25 mm (200 - 251 in.-lb,
22.6 - 28.4 N·m,
2.3 - 2.9 kgf·m)
33 - 40 ft-lb Use 80% of the value at left
M10 x 1.5 mm (44.1 - 53.9 N·m, when the tightening part is
Hexagon Bolt (7T) and
Nut 4.5 - 5.5 kgf·m) aluminum.
Use 60% of the value at left for
58 - 72 ft-lb 4T bolts and lock nuts.
M12 x 1.75 mm (78.4 - 98.0 N·m,
8.0 - 10 kgf·m)
94 - 108 ft-lb
M14 x 1.5 mm (127.5 - 147.1 N·m,
13 - 15 kgf·m)
159 - 174 ft-lb
M16 x 1.5 mm (215.7- 235.4 N·m,
22 - 24 kgf·m)
1/8 mm 7 ft-lb
(87 in.-lb, 9.8 N·m, 1.0 kgf·m)
14 ft-lb
1/4 mm
(173 in.-lb, 19.6 N·m, 2.0 kgf·m)
PT PLug -
22 ft-lb
3/8 mm (29.4 N·m, 3.0 kgf·m)
1/2 mm 43 ft-lb
(58.8 N·m, 6.0 kgf·m)

Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
9 - 12 ft-lb
(112 - 148 in.-lb,
M8
12.7 - 16.7 N·m,
1.3 - 1.7 kgf·m)
14 - 19 ft-lb
M10 (173 - 225 in.-lb,
19.6 - 18.734 N·m,
2.0 - 3.5 kgf·m)
Pipe Joint Bolt 18 - 25 ft-lb -
M12 (24.5 - 34.3 N·m,
2.5 - 3.5 kgf·m)
29 - 36 ft-lb
M14 (39.2 - 49.0 N·m,
4.0 - 5.0 kgf·m)
36 - 43 ft-lb
M16 (49.0 - 58.8 N·m,
5.0 - 6.0 kgf·m)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

GENERAL SERVICE INFORMATION Abbreviations and Symbols
ABBREVIATIONS AND JASO Japanese Automobile Standards

Organization
SYMBOLS k kelvin
kg kilogram
Abbreviations kgf/cm² kilogram force per square centimeter
kgf/m kilogram force per meter
A ampere km kilometers
AC alternating current kPa kilopascal
ACEA Association des Constructeurs kW kilowatt
Européens d’Automobilies L liter
Ah ampere-hour L/hr liter per hour
API American Petroleum Institute lb pound
lbf pound force
ARB Air Resources Board
m meter
ATDC after top dead center
mL milliliter
BDC bottom dead center
mm millimeter
BTDC before top dead center mmAq millimeter Aqueous (water)
°C degree Celsius MPa megapascal
CARB California Air Resources Board mV millivolt
CCA cold cranking amp N newton
cfm cubic feet per minute N·m newton meter
cm centimeter No. number
cm³ cubic centimeter O.D. outside diameter
cm³/min cubic centimeter per minute oz ounce
Pa pascal
cu in. cubic inch
PS horsepower (metric)
D diameter
psi pound per square inch
DC direct current
qt quart (U.S.)
DI direct injection R radius
DVA direct volt adapter rpm revolutions per minute
EPA Environmental Protection Agency SAE Society of Automotive Engineers
ESG electronic speed governor sec. second
°F degree Fahrenheit t short ton 2000 lb
fl oz fluid ounce (U.S.) TBN total base number
fl oz/min fluid ounce (U.S.) per minute TDC top dead center
ft foot V volt
VAC volt alternating current
ft-lb foot pound
VDC volt direct current
ft-lbf/min foot pound force per minute
W watt
g gram
gal gallon (U.S.) Symbols
gal/hr gallon (U.S.) per hour
gal/min gallon (U.S.) per minute ° degree
GL gear lubricant + plus
hp horsepower (U.S.) - minus
hr hour
± plus or minus
I.D. inside diameter
Ω ohm
ID identification μ micro
IDI indirect injection % percent
in. inch
in.Aq inches Aqueous (water)
in.Hg inches Mercury
in.-lb inch pound
j joule

Unit Conversions GENERAL SERVICE INFORMATION
UNIT CONVERSIONS Units of Torque

ft-lb x 1.3558 = N·m
Unit Prefixes ft-lb x 0.1383 = kgf/m
Prefix Symbol Power in.-lb x 0.1130 = N·m
mega M x 1,000,000 in.-lb x 0.0115 = kgf/m
kilo k x 1,000 kgf/m x 7.2330 = ft-lb
centi c x 0.01 kgf/m x 86.8000 = in.-lb
milli m x 0.001 kgf/m x 9.8070 = N·m
micro μ x 0.000001 N·m x 0.7376 = ft-lb
N·m x 8.8510 = in.-lb
Units of Length N·m x 0.1020 = kgf/m
mile x 1.6090 = km Units of Pressure
ft x 0.3050 =m
in. x 2.5400 = cm psi x 0.0689 = bar
in. x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm²
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in. bar x 100.0000 = kPa
mm x 0.0394 = in. bar x 29.5300 = inHg (60°F)
kPa x 0.1450 = psi
Units of Volume kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm²
gal (U.S.) x 3.78540 =L
kg/cm² x 98.0700 = psi
qt (U.S.) x 0.94635 =L
kg/cm² x 0.9807 = bar
cu in. x 0.01639 =L
kg/cm² x 14.2200 = kPa
cu in. x 16.38700 = mL
in.Hg (60°) x 0.0333 = bar
fl oz (U.S.) x 0.02957 =L
in.Hg (60°) x 3.3770 = kPa
fl oz (U.S.) x 29.57000 = mL
in.Hg (60°) x 0.0344 = kg/cm²
cm³ x 1.00000 = mL
mmAq x 0.0394 = in.Aq
cm³ x 0.03382 = fl oz (U.S.)
Units of Mass Units of Power

hp (metric x 0.9863201 = hp SAE
lb x 0.45360 = kg
or PS)
oz x 28.35000 =g
hp (metric x 0.7354988 = kW
kg x 2.20500 = lb
or PS)
g x 0.03527 = oz
hp SAE x 1.0138697 = hp (metric or PS)
Units of Force hp SAE x 0.7456999 = kW
kW x 1.3596216 = hp (metric or PS)
lbf x 4.4480 =N kW x 1.3410221 = hp SAE
lbf x 0.4536 = kgf
N x 0.2248 = lbf Units of Temperature
N x 0.1020 = kgf
°F = (1.8 x °C) + 32
kgf x 2.2050 = lbf
°C = 0.556 x (°F - 32)
kgf x 9.8070 =N

GENERAL SERVICE INFORMATION Unit Conversions

Section 5
PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ............................................................ 5-3
Introduction.................................................................................... 5-16
The Importance of Periodic Maintenance................................ 5-16
Performing Periodic Maintenance ........................................... 5-16
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance -USA Only........................ 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule.................................................... 5-17
Periodic Maintenance Procedures ................................................ 5-20
After Initial 50 Hours of Operation ........................................... 5-20
Every 50 Hours of Operation ................................................... 5-24
Every 250 Hours of Operation ................................................. 5-27
Every 500 Hours of Operation ................................................. 5-32
Every 1000 Hours of Operation ............................................... 5-36

PERIODIC MAINTENANCE

Before You Begin Servicing PERIODIC MAINTENANCE
BEFORE YOU BEGIN

A DANGER
SERVICING
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
EXPLOSION HAZARD! engine is hot. Steam and hot engine
coolant will spurt out and seriously
• NEVER check the remaining battery burn you. Allow the engine to cool
charge by shorting out the terminals. down before you attempt to remove
This will result in a spark and may the radiator cap.
hydrometer to check the remaining • Tighten the radiator cap securely after
battery charge. you check the radiator. Steam can
• If the electrolyte is frozen, slowly warm the cap is loose.
the battery before you recharge it.
• ALWAYS check the level of the engine
• Failure to comply will result in death or coolant by observing the reserve tank.
serious injury.
0000007en
serious injury.
0000002en
A DANGER

• Only use the key switch to start the
engine.
• NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
serious injury.
0000004en

PERIODIC MAINTENANCE Before You Begin Servicing
A DANGER A DANGER

• Only fill the fuel tank with diesel fuel. • Before you operate the engine, check
Filling the fuel tank with gasoline may for fuel leaks. Replace rubberized fuel
result in a fire and will damage the hoses every two years or every 2000
engine. hours of engine operation, whichever
comes first, even if the engine has
• NEVER refuel with the engine running.
been out of service. Rubberized fuel
• Wipe up all spills immediately. lines tend to dry out and become
• Keep sparks, open flames or any other brittle after two years or 2000 hours of
form of ignition (match, cigarette, engine operation, whichever comes
static electric source) well away when first.
refueling. • Failure to comply will result in death or
• NEVER overfill the fuel tank. serious injury.
0000015en
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or A DANGER
sources of ignition.
serious injury.
0000005en

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

A DANGER A DANGER

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

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

agent.
serious injury.
0000012en

A DANGER A DANGER

• When you remove any fuel system • Place an approved container under the
component to perform maintenance air bleed port when you prime the fuel
(such as changing the fuel filter) place system. Never use a shop rag to catch
an approved container under the the fuel. Wipe up any spills
opening to catch the fuel. immediately. ALWAYS close the air
• NEVER use a shop rag to catch the bleed port after you complete priming
fuel. Vapors from the rag are the system.
flammable and explosive. • Wear eye protection. The fuel system
• Wipe up any spills immediately. is under pressure and fuel could spray
out when you open the air bleed port.
• Wear eye protection. The fuel system
is under pressure and fuel could spray • If the unit has an electric fuel pump,
out when you remove any fuel system turn the key switch to the ON position
component. for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
• Failure to comply will result in death or of bubbles, to allow the electric fuel
serious injury. pump to prime the system.
0000009en
• If the unit has a mechanical fuel pump,
operate the fuel priming pump several
times until the fuel coming out of the
air bleed port is free of bubbles.
serious injury.
0000006en

A WARNING A WARNING
EXHAUST HAZARD! SEVER HAZARD!

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

A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
ALCOHOL AND DRUG HAZARD!
or serious injury. • NEVER operate the engine while you
0000006en
are under the influence of alcohol or
drugs.
A WARNING • NEVER operate the engine when you

are feeling ill.
or serious injury.
0000004en
BURN HAZARD!
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
or serious injury.
0000015en

A WARNING A WARNING
BURN HAZARD!
EXPOSURE HAZARD! • Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
• Wear personal protective equipment
with clothing, skin or eyes. Severe
such as gloves, work shoes, eye and
burns could result. ALWAYS wear
hearing protection as required by the
safety goggles and protective clothing
task at hand.
• NEVER wear jewelry, unbuttoned fluid contacts the eyes and / or skin,
cuffs, ties or loose-fitting clothing immediately flush the affected area
when you are working near with a large amount of clean water and
moving / rotating parts such as the obtain prompt medical treatment.
cooling fan, flywheel or PTO shaft.
• ALWAYS tie back long hair when you or serious injury.
are working near moving / rotating 0000007en
parts such as a cooling fan, flywheel,
or PTO shaft.
A WARNING
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
HIGH-PRESSURE HAZARD!
or serious injury.
0000005en
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
or serious injury.
0000008en

A WARNING A WARNING
BURN HAZARD!
SHOCK HAZARD!
• If you must drain the engine oil while it
• Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system. • ALWAYS wear eye protection.
• Check the electrical harnesses for • Failure to comply could result in death
cracks, abrasions, and damaged or or serious injury.
corroded connectors. ALWAYS keep 0000011en

• Failure to comply could result in death A WARNING
or serious injury.
0000009en
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
ENTANGLEMENT HAZARD! • Failure to comply could result in death
• Stop the engine before you begin to or serious injury.
service it. 0000016en
• NEVER leave the key in the key switch

when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away
or serious injury.
0000010en

A CAUTION CAUTION
warranty requirements.
COOLANT HAZARD! • Only use clean diesel fuel.
• Wear eye protection and rubber gloves • NEVER remove the primary strainer (if
when you handle long life or extended equipped) from the fuel tank filler port.
life engine coolant. If contact with the If removed, dirt and debris could get
eyes or skin should occur, flush eyes into the fuel system causing it to clog.
and wash immediately with clean 0000004en
water.
• Failure to comply may result in minor CAUTION
or moderate injury. • Only use the engine oil specified.
0000005en
coverage, cause internal engine
A CAUTION components to seize and / or shorten
engine life.
the cap.
FLYING OBJECT HAZARD! • NEVER mix different types of engine
• ALWAYS wear eye protection when oil. This may adversely affect the
servicing the engine and when using lubricating properties of the engine oil.
compressed air or high-pressure • NEVER overfill. Overfilling may result
water. Dust, flying debris, compressed in white exhaust smoke, engine
air, pressurized water or steam may overspeed or internal damage.
injure your eyes. 0000005en

or moderate injury.
0000003en

CAUTION CAUTION
• Only use the engine coolant specified. Observe the following environmental
Other engine coolants may affect operating conditions to maintain engine
warranty coverage, cause an internal performance and avoid premature
buildup of rust and scale and / or engine wear:
shorten engine life. • Avoid operating in extremely dusty
• Prevent dirt and debris from conditions.
contaminating the engine coolant. • Avoid operating in the presence of
Carefully clean the radiator cap and chemical gases or fumes.
remove the cap. • Avoid operating in a corrosive
atmosphere such as salt water spray.
coolants. This may adversely affect the • NEVER install the engine in a
properties of the engine coolant. floodplain unless proper precautions
0000006en
are taken to avoid being subject to a
flood.
CAUTION • NEVER expose the engine to the rain.

0000003en
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit CAUTION
control or the diesel fuel injection Observe the following environmental
quantity control. operating conditions to maintain engine
• Modifications may impair the engine’s performance and avoid premature
safety and performance engine wear:
characteristics and shorten the • The standard range of ambient
engine’s life. Any alterations to this temperatures for the normal operation
engine may void its warranty. Be sure of Yanmar engines is from +5°F (-15°C)
to use Yanmar genuine replacement to +113°F (+45°C).
parts.
• If the ambient temperature exceeds
0000079en
+113°F (+45°C) the engine may
overheat and cause the engine oil to
break down.
• If the ambient temperature is below
+5°F (-15°C) the engine will be hard to
start and the engine oil may not flow
easily.
• Contact your authorized Yanmar
industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en

CAUTION CAUTION
NEVER hold the key in the START New Engine Break-in:
position for longer than 15 seconds or • On the initial engine start-up, allow the
the starter motor will overheat. engine to idle for approximately 15
0000007en
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
CAUTION engine oil leaks, coolant leaks, and for
proper operation of the indicators
For maximum engine life, Yanmar
and / or gauges.
recommends that when shutting the
engine down, you allow the engine to • During the first hour of operation, vary
idle, without load, for five minutes. This the engine speed and the load on the
will allow the engine components that engine. Short periods of maximum
operate at high temperatures, such as engine speed and load are desirable.
the turbocharger (if equipped) and Avoid prolonged operation at
exhaust system, to cool slightly before minimum or maximum engine speeds
the engine itself is shut down. and loads for the next four to five
0000008en hours.
• During the break-in period, carefully
CAUTION observe the engine oil pressure and
engine temperature.
NEVER use an engine starting aid such
as ether. Engine damage will result. • During the break-in period, check the
0000009en
engine oil and coolant levels
frequently.
0000011en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
CAUTION
engine is installed at an angle greater NEVER engage the starter motor while
than (IDI = 25°, DI = 30°) in any direction the engine is running. This may damage
or if an engine runs for short periods of the starter motor pinion and / or ring
time (less than three minutes) at an gear.
angle greater than (IDI = 30°, DI = 35°) in 0000012en
any direction, engine oil may enter the

combustion chamber causing excessive CAUTION
engine speed and white exhaust smoke.
This may cause serious engine damage. It is important to perform daily checks.
0000010enTNV Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en

CAUTION CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
• ALWAYS be environmentally 0000016en
responsible.
• Follow the guidelines of the EPA or CAUTION
other governmental agencies for the NEVER attempt to adjust the low or high
proper disposal of hazardous idle speed limit screw. This may impair
materials such as engine oil, diesel the safety and performance of the
fuel and engine coolant. Consult the machine and shorten its life. If the idle
local authorities or reclamation facility. speed limit screws require adjustment,
• NEVER dispose of hazardous see your authorized Yanmar industrial
materials irresponsibly by dumping engine dealer or distributor.
them into a sewer, on the ground, or 0000017en
into ground water or waterways.

• Failure to follow these procedures may CAUTION
seriously harm the environment. Establish a periodic maintenance plan
0000013en according to the engine application and
make sure you perform the required
CAUTION periodic maintenance at the intervals
indicated. Failure to follow these
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
shorten the engine’s life and may affect
high-pressure water to clean the engine.
the warranty coverage on your engine.
0000014en
Warranty Section.
CAUTION
Consult your authorized Yanmar dealer
• NEVER overfill the engine with engine or distributor for assistance when
oil. checking items marked with a .
• ALWAYS keep the oil level between the 0000024enTNVDISM
upper and lower lines on the oil
cap / dipstick.
0000015en

CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
CAUTION
• When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
• NEVER operate the engine with the air
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
CAUTION
The maximum air intake restriction, in
terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
mentioned value.
0000046en

PERIODIC MAINTENANCE Introduction
INTRODUCTION Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
This section of the Service Manual describes the perform the procedures indoors to prevent
procedures for proper care and maintenance of the environmental conditions, such as rain, wind, or
engine. snow, from damaging the machine.
The Importance of Periodic Yanmar Replacement Parts
Maintenance Yanmar recommends that you use genuine Yanmar
Engine deterioration and wear occurs in proportion parts when replacement parts are needed.
to length of time the engine has been in service and Genuine replacement parts help ensure long
the conditions the engine is subject to during engine life.
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of Required EPA / ARB Maintenance -
accidents due to poor machine performance and USA Only
helps extend the life of the engine.
To maintain optimum engine performance and
Performing Periodic Maintenance compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
A WARNING California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-17 and
Periodic Maintenance Procedures on page 5-20.
EPA / ARB Installation

EXHAUST HAZARD! Requirements - USA Only
• NEVER operate the engine in an The following are the installation requirements for
enclosed area such as a garage, the EPA / ARB. Unless these requirements are met,
tunnel, underground room, manhole or the exhaust gas emissions will not be within the
ship’s hold without proper ventilation. limits specified by the EPA and ARB.
• NEVER block windows, vents, or other Maximum Exhaust Gas Restriction shall be:
means of ventilation if the engine is
• 3TNV84T(-B): 1.42 psi (9.81 kPa; 1000 mm
operating in an enclosed area. All
Aq) or less
internal combustion engines create
carbon monoxide gas during • 4TNV98T(-Z): 1.71 psi (11.77 kPa; 1200 mm
operation. Accumulation of this gas Aq) or Iess
within an enclosure could cause • 3TNV82A(-B),3TNV84,3TNV88(-B)(-U),
illness or even death. 4TNV94L,4TNV98(-Z)(-E): 2.22 psi (15.3 kPa;
• Make sure that all connections are 1560 mm Aq) or Iess
tightened to specifications after repair Maximum air intake restriction shall be 0.90 psi
is made to the exhaust system. (6.23 kPa; 635 mm Aq) or less. Clean or replace
• Failure to comply could result in death the air cleaner element if the air intake restriction
or serious injury. exceeds the above mentioned value.
0000003en

Periodic Maintenance Schedule PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
SCHEDULE
Daily and periodic maintenance is important to
keep the engine in good operating condition. The
following is a summary of maintenance items by
periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
application, loads, diesel fuel and engine oil used
and are hard to establish definitively. The following
should be treated only as a general guideline.
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at the intervals
indicated. Failure to follow these
shorten the engine’s life and may affect
the warranty coverage on your engine.
Warranty Section.
Consult your authorized Yanmar dealer
or distributor for assistance when
checking items marked with a .
0000024enTNVDISM

PERIODIC MAINTENANCE Periodic Maintenance Schedule
: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Check and Refill Engine Coolant

Check and Clean Radiator Fins
Check and Adjust Cooling Fan V-belt 1st time 2nd and
after
Cooling
System or
every 1
year
Drain, Flush and Refill Cooling System With New Coolant which-
ever
comes
first
Cylinder Adjust Intake / Exhaust Valve Clearance

Head Lap Intake / Exhaust Valve Seats. If necessary
Electrical Check Indicators

Equipment Check Battery
Check Engine Oil Level
Engine Oil Drain and Fill Engine Oil 2nd and

1st time
after
Replace Engine Oil Filter
Engine
Check and Adjust Governor Lever and
Speed Engine Speed Control
Control
Inspect, Clean And Test Fuel Injectors
Inspect Turbocharger
(Blower Wash as Necessary)
3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T,
3TNV84T-B, 4TNV84T-Z, 4TNV98T-Z
Emission Inspect, Clean and Test EGR Valve

Control 4TNV84T, 4TNV98T
Warranty
Clean EGR Lead Valve
4TNV84T, 4TNV98T
Clean EGR Cooler
(Clean to Blow Water/Air Passages)
4TNV84T, 4TNV98T
Inspect Crankcase Breather System
Check and Refill Fuel Tank Level
Drain Fuel Tank
Drain Fuel Filter / Water Separator
Fuel
Check Fuel Filter / Water Separator
Clean Fuel Filter / Water Separator
Replace Fuel Filter
Replace Fuel System and

Hoses Cooling System Hoses or every
2 yrs.

Periodic Maintenance Schedule PERIODIC MAINTENANCE
: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Intake and
Clean or Replace Air Cleaner Element
Exhaust
Complete
Engine Overall Visual Check Daily
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

PERIODIC MAINTENANCE Periodic Maintenance Procedures
PERIODIC MAINTENANCE CAUTION

PROCEDURES • Only use the engine oil specified.
After Initial 50 Hours of Operation coverage, cause internal engine
Perform the following maintenance after the initial engine life.
50 hours of operation. • Prevent dirt and debris from
• Replace Engine Oil and Engine Oil Filter contaminating the engine oil. Carefully
• Check and Adjust Cooling Fan V-Belt surrounding area before you remove
the cap.
Replace Engine Oil and Engine Oil Filter
A WARNING oil. This may adversely affect the
0000005en
BURN HAZARD!
• If you must drain the engine oil while it CAUTION
• ALWAYS wear eye protection.
or serious injury.
0000011en
• ALWAYS be environmentally
responsible.
A WARNING • Follow the guidelines of the EPA or

other governmental agencies for the
SUDDEN MOVEMENT HAZARD! proper disposal of hazardous
• Engaging the transmission or PTO at materials such as engine oil, diesel
an elevated engine speed could result fuel and engine coolant. Consult the
in unexpected movement of the local authorities or reclamation facility.
equipment. • NEVER dispose of hazardous
• Failure to comply could result in death materials irresponsibly by dumping
or serious injury. them into a sewer, on the ground, or
0000006en
• Failure to follow these procedures may
seriously harm the environment.
0000013en

Periodic Maintenance Procedures PERIODIC MAINTENANCE
The engine oil in a new engine becomes 7. After all oil has been drained from the engine,
contaminated from the initial break-in of internal reinstall the oil drain plug (Figure 5-2, (1)) and
parts. It is very important that the initial oil and filter tighten to 139.8 - 47.0 ft·lb (53.9 - 63.7 N·m;
change is performed as scheduled. 5.5 - 6.5 kgf·m).
Note: The oil drain plug may be in another 8. Dispose of used oil properly.
location if an optional oil pan is used. Remove the engine oil filter as follows:
Drain the engine oil as follows: 1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
1. Make sure the engine is level.
wrench.
2. Start the engine and bring it up to operating
temperature. (3)
3. Stop the engine.
(4)
4. Remove one of the oil filler caps
(Figure 5-1, (1)) to vent the engine crankcase
and allow the engine oil to drain more easily.
5. Position a container under the engine to collect
waste oil.
(2)
(1)
(1)
0000062B
Figure 5-2
(1) 0000084 2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (4)) until it contacts the mounting
surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5
N·m; 2.0 - 2.4 kgf·m) or one additional turn
using the filter wrench.
0000084B
Figure 5-1
6. Remove the oil drain plug (Figure 5-2, (1)) from
the engine oil pan. Allow oil to drain.

Engine Oil Filter Part No. (4)

Standard Dust proof *
3TNV82A
3TNV84
- 4TNV98
3TNV82A-B 129150-35153
3TNV88-B
- 4TNV98-Z 119005-35151
4TNV98-E
4TNV98T
4TNV98T-Z (4)
119005-35151
4TNV106,
4TNV106T (5)
* Consult the operation manual for the driven

machine for applicability of the dust proof
filter. (2)
(1)
4. Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-17.
(3)
CAUTION 0000007C
• NEVER overfill the engine with engine Figure 5-3

oil.
9. Reinstall the oil filler cap (Figure 5-3, (4)). If
• ALWAYS keep the oil level between the any engine oil is spilled, wipe it away with a
upper and lower lines on the oil clean cloth.
cap / dipstick.
0000015en Check and Adjust Cooling Fan V-Belt
The V-belt will slip if it does not have the proper
5. Warm up the engine by running it for five
tension. This will prevent the alternator from
minutes and check for any engine oil leaks.
generating sufficient power. Also, the engine will
6. After engine is warm, shut it off and let it sit for overheat due to the engine coolant pump pulley
10 minutes. slipping.
7. Recheck the engine oil level.
Check and adjust the V-belt tension (deflection) as
8. Add engine oil (Figure 5-3, (5)) as needed until follows:
the level is between the upper (Figure 5-3, (2))
and lower lines (Figure 5-3, (3)) shown on the 1. Press the V-belt down with your thumb with a
dipstick (Figure 5-3, (1)). force of approximately 22 ft·lb (98 N·m; 10 kgf)
to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-4, (A), (B) and (C)). You can
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is:

Used V-Belt Tension

A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
(2)
Note: A “Used V-Belt” refers to a V-belt which (1)

has been used on a running engine for
five minutes or more. 0000584
(B) Figure 5-6
(A)
(C)
0000063B
Figure 5-4
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Figure 5-5, (1)) and move
the alternator (Figure 5-5, (2)) with a pry bar
(Figure 5-5, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting bolt.
(3)
(1)
(2) 0000064B
Figure 5-5
3. Tighten the V-belt to the proper tension. There
must be clearance (Figure 5-6, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.

4. Check the V-belt for cracks, oil or wear. If any of

these conditions exist, replace the V-belt. Every 50 Hours of Operation
5. Install the new V-belt. Refer to the table for
proper tension. After you complete the initial 50 hour maintenance
procedures, perform the following procedures every
New V-Belt Tension 50 hours thereafter.
A B C
• Drain Fuel Filter / Water Separator
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm) • Check Battery
6. After adjusting, run the engine for 5 minutes or Drain Fuel Filter / Water Separator
more. Check the tension again using the
specifications for a used V-belt. A DANGER
Used V-Belt Tension
A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
• Wipe up any spills immediately.
is under pressure and fuel could spray
out when you remove any fuel system
component.
serious injury.
0000009en

The cup of the separator is made from semi-
CAUTION transparent material. In the cup is a red colored
If the fuel filter / water separator is float ring. The float ring will rise to the surface of the
positioned higher than the fuel level in water to show how much needs to be drained. Also,
the fuel tank, water may not drip out some optional fuel filter / water separators are
when the fuel filter / water separator equipped with a sensor to detect the amount of
drain cock is opened. If this happens, contaminants. This sensor sends a signal to an
turn the air vent screw on the top of the indicator to alert the operator.
fuel filter / water separator 2-3 turns
Drain the fuel filter / water separator as follows:
counterclockwise.
Be sure to tighten the air vent screw 1. Position an approved container under the fuel
after the water has drained out. filter / water separator (Figure 5-7, (1)) to
0000025en
collect the contaminants.
CAUTION (2)
(3)
(1)
responsible.
• Follow the guidelines of the EPA or (4) 0000012C
proper disposal of hazardous Figure 5-7
materials such as engine oil, diesel 2. Close (Figure 5-7, (2)) the fuel cock
fuel and engine coolant. Consult the (Figure 5-7, (3)).
local authorities or reclamation facility.
3. Loosen the drain cock (Figure 5-7, (4)) at the
• NEVER dispose of hazardous bottom of the fuel filter / water separator. Drain
materials irresponsibly by dumping any water collected inside.
them into a sewer, on the ground, or
into ground water or waterways. 4. Hand-tighten the drain cock.
• Failure to follow these procedures may CAUTION

If the fuel filter / water separator is
0000013en
positioned higher than the fuel level in
Drain the fuel filter / water separator whenever the fuel tank, water may not drip out
there are contaminants, such as water, collected in when the fuel filter / water separator
the bottom of the cup. NEVER wait until the drain cock is opened. If this happens,
scheduled periodic maintenance if contaminants turn the air vent screw on the top of the
are discovered. fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en

5. Open the fuel cock (Figure 5-7, (3)).

6. Be sure to prime the diesel fuel system when
A WARNING
you are finished. See Priming the Fuel System
on page 4-15.
7. Check for leaks.
Check Battery
BURN HAZARD!
A DANGER • Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
fluid contacts the eyes and / or skin,
EXPLOSION HAZARD! immediately flush the affected area
• NEVER check the remaining battery with a large amount of clean water and
charge by shorting out the terminals. obtain prompt medical treatment.
This will result in a spark and may
or serious injury.
hydrometer to check the remaining
0000007en
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it. CAUTION
serious injury.
0000007en
responsible.
• Follow the guidelines of the EPA or
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
• NEVER dispose of hazardous
materials irresponsibly by dumping
0000013en

• When the amount of fluid nears the lower limit
(Figure 5-8, (1)), fill with distilled water Every 250 Hours of Operation
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with Perform the following maintenance every 250 hours
insufficient battery fluid, the battery life is of operation.
shortened, and the battery may overheat and
explode. During the summer, check the fluid • Drain Fuel Tank
level more often than specified. • Replace Engine Oil and Engine Oil Filter
• Check and Clean Radiator Fins
(3) • Check and Adjust Cooling Fan V-Belt
(2) • Check and Adjust the Governor Lever and
Engine Speed Control
• Clean Air Cleaner Element
(1)
Drain Fuel Tank
A DANGER
0000067A
Figure 5-8
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery. FIRE AND EXPLOSION HAZARD!
• If the engine still will not start after charging, • Diesel fuel is flammable and explosive
have your authorized Yanmar industrial engine under certain conditions.
dealer or distributor check the battery and the • When you remove any fuel system
engine’s starting system. component to perform maintenance
• If operating the machine where the ambient (such as changing the fuel filter) place
temperature could drop to 5°F (-15°C) or less, an approved container under the
remove the battery from the machine at the end opening to catch the fuel.
of the day. Store the battery in a warm place • NEVER use a shop rag to catch the
until the next use. This will help start the engine fuel. Vapors from the rag are
easily at low ambient temperatures. flammable and explosive.
• Wipe up any spills immediately.
component.
serious injury.
0000009en

4. Drain the tank until clean diesel fuel with no

CAUTION water and dirt flows out. Reinstall and tighten
the drain plug firmly.
5. Reinstall the fuel cap.
6. Check for leaks.
Replace Engine Oil and Engine Oil Filter

responsible. CAUTION
• Follow the guidelines of the EPA or • Only use the engine oil specified.
other governmental agencies for the Other engine oils may affect warranty
proper disposal of hazardous coverage, cause internal engine
materials such as engine oil, diesel components to seize and / or shorten
fuel and engine coolant. Consult the engine life.
• NEVER dispose of hazardous contaminating the engine oil. Carefully
materials irresponsibly by dumping clean the oil cap / dipstick and the
them into a sewer, on the ground, or surrounding area before you remove
into ground water or waterways. the cap.
• Failure to follow these procedures may • NEVER mix different types of engine
seriously harm the environment. oil. This may adversely affect the
0000013en lubricating properties of the engine oil.
Note that a typical fuel tank is illustrated. • NEVER overfill. Overfilling may result
1. Position an approved container under the diesel overspeed or internal damage.
fuel tank (Figure 5-9, (1)) to collect the 0000005en
contaminates.
2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.
(3)
(1)
(2)
0000065A
Figure 5-9

Check and Clean Radiator Fins
CAUTION
A CAUTION
responsible.
• Follow the guidelines of the EPA or FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
• NEVER dispose of hazardous injure your eyes.
or moderate injury.
0000003en
seriously harm the environment. Dirt and dust adhering to the radiator fins reduce
0000013en
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
Change the engine oil every 250 hours of operation clean as needed.
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace Note that a typical radiator is shown in Figure 5-10
Engine Oil and Engine Oil Filter on page 5-20. for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa; 2 kgf/cm2) or less of
compressed air (Figure 5-10, (1)). Be careful
not to damage the fins with the compressed air.
• If there is a large amount of contamination on
the fins, apply detergent, thoroughly clean and
rinse with tap water.
CAUTION
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en

Checking and adjusting the governor lever:

1. Check that the governor lever (Figure 5-11, (1))
makes uniform contact with the high idle
(Figure 5-11, (2)) and low idle
(1) (Figure 5-11, (3)) speed limit screws when the
FULL
LOW
engine speed control is in the high idle speed or
low idle speed position.
0000085A
(2) (3)
Figure 5-10
Check and Adjust Cooling Fan V-Belt

(1)
Check and adjust the cooling fan V-belt every 250
hours of operation after the initial 50 hour V-belt
maintenance. See Check and Adjust Cooling Fan
V-Belt on page 5-22.
(4)
Check and Adjust the Governor Lever and
Engine Speed Control
0000069A
(This does not apply to the following
electronically controlled engines: 4TNV84T- Figure 5-11
Z, 4TNV98-E, Z, and 4TNV98T-Z.) 2. If the governor lever does not make contact with
The governor lever and engine speed control the high idle or low idle speed limit screw, adjust
(throttle lever, pedal, etc.) of the machine are the throttle cable.
connected together by a throttle cable or rod. If the 3. In some engine speed control applications,
cable becomes stretched, or the connections loosen the throttle cable lock nut
loosen, the governor lever may not respond to (Figure 5-11, (4)) and adjust the cable so the
change of engine speed control position. This may governor lever makes proper contact with the
make operation of the machine unsafe. Check the high / low idle speed limit screw.
cable periodically and adjust if necessary.
NEVER force the throttle cable or pedal to move. CAUTION
This may deform the governor lever or stretch the NEVER attempt to adjust the low or high
cable and cause irregular operation of the engine idle speed limit screw. This may impair
speed control. the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en

Clean Air Cleaner Element 3. Blow air (Figure 5-12, (3)) through the element
Note that a typical air cleaner is shown in from the inside out using 42 - 71 psi
Figure 5-12 and Figure 5-13 for illustrative (0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2)
purposes only. compressed air to remove the particulates. Use
the lowest possible air pressure to remove the
The engine performance is adversely affected dust without damaging the element.
when the air cleaner element is clogged with dust. 4. If the air cleaner is equipped with a double
Be sure to clean the air filter element periodically. element, only remove and replace the inner
1. Unlatch and remove the air cleaner cover element (Figure 5-13, (1)) if the engine lacks
(Figure 5-12, (1)). power or the dust indicator actuates (if
equipped).
(6) (4)
(2)
(5)
(3)
(1)
(1)
0000070A
Figure 5-12 0000071A
2. Remove the element (Figure 5-12, (2)) (outer Figure 5-13

element if equipped with two elements). 5. The inner element should not be removed when
cleaning or replacing the outer element. The
A CAUTION inner element is used to prevent dust from
entering the engine while servicing the outer
element.
FLYING OBJECT HAZARD!

injure your eyes.
or moderate injury.
0000003en

6. Replace the element with a new one if the

element is damaged, excessively dirty or oily. Every 500 Hours of Operation
7. Clean inside of the air cleaner cover.
Perform the following maintenance every 500 hours
8. Install the element into the air cleaner case of operation.
(Figure 5-12, (4)).
9. Reinstall the air cleaner cover making sure you • Replace Air Cleaner Element
match the arrow (Figure 5-12, (5)) on the cover • Replace Fuel Filter
with the arrow on the case (Figure 5-12, (6)). • Clean Fuel Filter / Water Separator
10. Latch the air cleaner cover to the case.
Replace Air Cleaner Element
CAUTION
• When the engine is operated in dusty
CAUTION
conditions, clean the air cleaner The maximum air intake restriction, in
element more frequently. terms of differential pressure
measurement, must not exceed 0.90 psi
• NEVER operate the engine with the air
(6.23 kPa; 635 mmAq). Clean or replace
cleaner element(s) removed. This may
the air cleaner element if the air intake
allow foreign material to enter the
engine and damage it.
mentioned value.
0000026en
0000046en
Replace the air cleaner element (Figure 5-12, (2))

every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the
air cleaner case (Figure 5-12, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-13, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.

Replace Fuel Filter
CAUTION
A DANGER
FIRE AND EXPLOSION HAZARD! • ALWAYS be environmentally

responsible.
under certain conditions. • Follow the guidelines of the EPA or
• When you remove any fuel system proper disposal of hazardous
component to perform maintenance materials such as engine oil, diesel
(such as changing the fuel filter) place fuel and engine coolant. Consult the
an approved container under the local authorities or reclamation facility.
• NEVER use a shop rag to catch the materials irresponsibly by dumping
fuel. Vapors from the rag are them into a sewer, on the ground, or
flammable and explosive. into ground water or waterways.
• Wipe up any spills immediately. • Failure to follow these procedures may
• Wear eye protection. The fuel system seriously harm the environment.
is under pressure and fuel could spray 0000013en

component. Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
• Failure to comply will result in death or diesel fuel flow.
serious injury.
0000009en
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
CAUTION separator.
For maximum engine life, Yanmar 3. Remove the fuel filter with a filter wrench,
recommends that when shutting the turning it to the left (Figure 5-14, (1)). When
engine down, you allow the engine to removing the fuel filter, carefully hold it to
idle, without load, for five minutes. This prevent the fuel from spilling. Wipe up all spilled
will allow the engine components that fuel.
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en

Clean Fuel Filter / Water Separator
A DANGER

(1) (2) • Diesel fuel is flammable and explosive
0000072A
agent.
Figure 5-14 • Failure to comply will result in death or
4. Clean the filter mounting surface and apply a serious injury.
small amount of diesel fuel to the gasket of the 0000012en
new fuel filter.

5. Install the new fuel filter. Turn to the right A DANGER
(Figure 5-14, (2)) and hand-tighten it only until
it comes in contact with the mounting surface.
Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m;
2.0 - 2.4 kgf·m) or one additional turn using the
filter wrench.
Applicable Fuel Filter Part No. • Diesel fuel is flammable and explosive
Standard Dust proof * under certain conditions.
3TNV82A, • When you remove any fuel system
-4TNV98 component to perform maintenance
119802-55801 (such as changing the fuel filter) place
3TNV82A-B,
-4TNV98-B 129907-55801 an approved container under the
4TNV98T,
4TNV98T-Z, 123907-55801 • NEVER use a shop rag to catch the
-4TNV106T fuel. Vapors from the rag are
* Consult the operation manual for the driven • Wipe up any spills immediately.
machine for applicability of the dust proof
filter. • Wear eye protection. The fuel system
6. Open the fuel cock of the fuel filter / water out when you remove any fuel system
separator. component.
7. Prime the fuel system. See Priming the Fuel • Failure to comply will result in death or
System on page 4-15. serious injury.
8. Check for leaks. 0000009en

Periodically clean the fuel filter / water separator
CAUTION element and inside cup.
1. Position an approved container under the cup
(Figure 5-15, (1)) of the fuel filter / water
separator to collect the contaminants.
(5) (9)
responsible.
(2)
other governmental agencies for the (10)
proper disposal of hazardous (6)
(3)
(8)
• NEVER dispose of hazardous (1)
materials irresponsibly by dumping (4)
0000013en
(7)
0000073A
Figure 5-15
2. Close (Figure 5-15, (2)) the fuel cock
(Figure 5-15, (3)).
3. Loosen the drain cock (Figure 5-15, (4)) and
drain the contaminants. See Drain Fuel
Filter / Water Separator on page 5-24.
4. Turn the retaining ring (Figure 5-15, (5)) to the
left (Figure 5-15, (10)) and remove the cup
(Figure 5-15, (6)). If equipped, disconnect the
sensor wire (Figure 5-15, (7)) from the cup
before removing the cup.
5. Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.

6. Remove the float ring (Figure 5-15, (8)) from

the cup. Pour the contaminants into the Every 1000 Hours of Operation
container and dispose of it properly.
7. Clean the element (Figure 5-15, (9)) and inside Perform the following maintenance every 1000
cup. Replace the element if it is damaged. hours of operation.
• Drain, Flush and Refill Cooling System With
Applicable Element Part No.
New Coolant
All Models 119802-55710
• Adjust Intake / Exhaust Valve Clearance
8. Install the element and O-ring in the bracket. Drain, Flush and Refill Cooling System With
9. Position the float ring in the cup. New Coolant
10. Check the condition of the cup O-ring. Replace
if necessary. A DANGER
11. Install the cup to the bracket by tightening the
retaining ring to the right (Figure 5-15, (6)) to a
torque of 11 - 15 ft·lb (15 - 20 N·m;
1.5 - 2.0 kgf·m).
12. Close the drain cock. Reconnect the sensor
wire if equipped. SCALD HAZARD!
13. Open the fuel cock (Figure 5-15, (3)). • NEVER remove the radiator cap if the
14. Prime the fuel system. See Priming the Fuel engine is hot. Steam and hot engine
System on page 4-15. coolant will spurt out and seriously
15. Check for leaks. burn you. Allow the engine to cool
the radiator cap.
the cap is loose.
coolant by observing the reserve tank.
serious injury.
0000002en

A WARNING CAUTION
BURN HAZARD! • ALWAYS be environmentally

• Wait until the engine cools before you responsible.
drain the engine coolant. Hot engine • Follow the guidelines of the EPA or
coolant may splash and burn you. other governmental agencies for the
• Failure to comply could result in death proper disposal of hazardous
or serious injury. materials such as engine oil, diesel
0000016en fuel and engine coolant. Consult the
A CAUTION • NEVER dispose of hazardous
0000013en
COOLANT HAZARD!
• Wear eye protection and rubber gloves Engine coolant contaminated with rust or scale
when you handle long life or extended reduces the cooling effect. Even when extended life
life engine coolant. If contact with the engine coolant is properly mixed, the engine
eyes or skin should occur, flush eyes coolant gets contaminated as its ingredients
and wash immediately with clean deteriorate. Drain, flush and refill the cooling
water. system with new coolant every 1000 hours or once
a year, whichever comes first.
or moderate injury. 1. Allow engine and coolant to cool.
0000005en
2. Remove the radiator cap (Figure 5-16, (1)).
3. Remove the drain plug or open the drain cock
(Figure 5-16, (2)) at the lower portion of the
radiator and drain the engine coolant.

(1)
FULL
LOW
(2) 0000074A
Figure 5-16
4. Drain the coolant from the engine block.
• On models not equipped with an oil cooler,
remove the coolant drain plug
(Figure 5-17, (1)) from the engine block.
(1)
0000027B
Figure 5-17

• On models equipped with an oil cooler, remove
the coolant hose (Figure 5-18, (1)) at the oil Every 1500 Hours of Operation
cooler.
Perform the following maintenance every 1500
hours of operation.
• Inspect, Clean and Test Fuel Injectors
• Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV84T, 4TNV98T
and 4TNV106T, 3TNV84T-B, 4TNV84T-Z,
4TNV98T-Z
• Inspect, Clean and Test EGR Valve
4TNV84T-Z, 4TNV98T-E, 4TNV98-Z,
4TNV98T-Z
• Inspect and Clean EGR Lead Valve
4TNV84T-Z, 4TNV98T-Z
(1) 0001579B
• Clean EGR Cooler
Figure 5-18 4TNV84T-Z, 4TNV98T-Z
5. After draining the engine coolant, flush the • Inspect Crankcase Breather System
radiator and engine block to remove any rust,
Inspect, Clean and Test Fuel Injectors
scale and contaminants. Then reinstall and
tighten the drain plug or close the drain cock in
the radiator. Reinstall and tighten the cylinder A WARNING
block drain plug or reconnect the coolant hose
at the oil cooler.
6. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-19. HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
Adjust Intake / Exhaust Valve Clearance high-pressure diesel fuel spray caused
Proper adjustment is necessary to maintain the by a fuel system leak such as a broken
correct timing for opening and closing the valves. fuel injection line. High-pressure fuel
Improper adjustment will cause the engine to run can penetrate your skin and result in
noisily, resulting in poor engine performance and serious injury. If you are exposed to
engine damage. See Intake / Exhaust Valve and high-pressure fuel spray, obtain
Guide on page 6-7. prompt medical treatment.
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
or serious injury.
0000008en

Proper operation of the fuel injectors is required to Clean EGR Cooler

obtain the optimum injection pattern for full engine 4TNV84T-Z, 4TNV98T-Z
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every The EGR cooler is apt to be contaminated with rust
1500 hours. See Testing of Fuel Injectors on and scale that deteriorate the cooling performance.
page 7-38. Carbon accumulation in the exhaust gas passage
of the cooler hinders circulation of exhaust gas,
This procedure is considered normal maintenance resulting in deterioration in exhaust gas cleanup
and is performed at the owner’s expense. This performance.
procedure is not covered by the Yanmar Limited
Warranty. To prevent such a problem, clean the cooler at least
every 1500 hours.
Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV98T, 4TNV84T, Consult your local Yanmar dealer for this service.
and 4TNV106T, 3TNV84T-Z, 4TNV84T-Z,
EGR cooler
4TNV98T-Z
Turbocharger service is required by the EPA / ARB
every 1500 hours. Inspect, clean and blower wash
the unit if necessary (see Periodic Inspection on
page 10-13). If you notice that the engine seems
sluggish or the exhaust color is abnormal NEVER
wait until the next service interval.
Inspect, Clean and Test EGR Valve

4TNV84T-Z, 4TNV98T-E, 4TNV98-Z, 4TNV98T-Z
The EGR valve is a key component for cleaning
exhaust gas.
EGR valve
To prevent the valve from deteriorating in exhaust EGR lead valve
gas recirculation performance due to carbon
accumulation, inspect, clean and test the valve at
least every 1500 hours.
Figure 5-19
Consult your local Yanmar dealer for this service.
Inspect Crankcase Breather System
Inspect and Clean EGR Lead Valve
Proper operation of the crankcase breather system
4TNV84T-Z, 4TNV98T-Z is required to maintain the emission requirements
The EGR lead valve is located in the passage of of the engine. The EPA / ARB requires that the
recirculated gas. crankcase breather system is inspected every 1500
hours.
To prevent carbon accumulation in or clogging of
the lead valve, inspect and clean the lead valve at There are three different crankcase breather
regular intervals. systems used on the TNV engines. Only the non-
turbo TNV engines crankcase breather system
Consult your local Yanmar dealer for this service. requires periodic maintenance.

The non-turbo TNV engines use a crankcase Failure of the diaphragm and / or spring will cause
breather system that has a spring-backed the loss of pressure control and allow an excessive
diaphragm (Figure 5-20, (1)) in the valve cover amount of crankcase fumes to be routed to the
(Figure 5-20, (2)). When the crankcase pressure intake manifold. This could result in excessive
reaches a predetermined value, the diaphragm deposits in the intake system, high engine exhaust
opens a passage that allows crankcase fumes to smoke levels, excessive engine oil consumption,
be routed to the intake manifold. and / or engine run-on due to the burning of the
engine oil.
To inspect the diaphragm and spring
(Figure 5-20, (3)):
1. Remove the bolts retaining the diaphragm cover
(Figure 5-20, (4)).
(4)
(3)
(5)
(1)
(2)
0002135
Figure 5-20
2. Remove the diaphragm cover, spring,
diaphragm plate (Figure 5-20, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.

Lap the Intake and Exhaust Valves

Every 2000 Hours of Operation
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
Perform the following maintenance every 2000 and Exhaust Valves on page 6-42.
hours of operation.
• Check and Replace Fuel Hoses and Engine
Coolant Hoses
• Lap the Intake and Exhaust Valves.
If necessary
Check and Replace Fuel Hoses and Engine

Coolant Hoses
CAUTION
responsible.
0000013en
Regularly check the fuel system and engine coolant

system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years.

Section 6
ENGINE
Page
Introduction...................................................................................... 6-6
Cylinder Head Specifications .......................................................... 6-6
Adjustment Specifications ......................................................... 6-6
Cylinder Head............................................................................ 6-6
Intake / Exhaust Valve and Guide ............................................. 6-7
Push Rod................................................................................... 6-9
Rocker Arm and Shaft ............................................................... 6-9
Valve Spring ............................................................................ 6-10
Camshaft and Timing Gear Train Specifications........................... 6-11
Camshaft ................................................................................. 6-11
Idler Gear Shaft and Bushing .................................................. 6-13
Timing Gear Backlash ............................................................. 6-13
Crankshaft and Piston Specifications............................................ 6-14
Crankshaft ............................................................................... 6-14
Thrust Bearing ......................................................................... 6-15
Piston....................................................................................... 6-16
Piston Ring .............................................................................. 6-18
Connecting Rod....................................................................... 6-22
Tappet ..................................................................................... 6-23
Cylinder Block Specifications ........................................................ 6-24
Cylinder Block.......................................................................... 6-24
Special Torque Chart .................................................................... 6-25
Torque for Bolts and Nuts........................................................ 6-25
Special Service Tools.................................................................... 6-28
Measuring Instruments.................................................................. 6-32
2-Valve Cylinder Head .................................................................. 6-34
2-Valve Cylinder Head Components ....................................... 6-34

ENGINE
Components of a two-valve cylinder head ............................... 6-35
Disassembly of 2-Valve Cylinder Head .................................... 6-36
Cleaning of Cylinder Head Components .................................. 6-40
Inspection of Cylinder Head Components................................ 6-40
Reassembly of Cylinder Head.................................................. 6-44
4-Valve Cylinder Head ................................................................... 6-49
4-Valve Cylinder Head Components ........................................ 6-49
Disassembly of 4-Valve Cylinder Head .................................... 6-50
Cleaning of Cylinder Head Components .................................. 6-55
Inspection of Cylinder Head Components................................ 6-56
Reassembly of Cylinder Head.................................................. 6-61
Measuring and Adjusting Valve Clearance .................................... 6-66
2-Valve Cylinder Heads............................................................ 6-67
4-Valve Cylinder Heads............................................................ 6-68
Crankshaft and Camshaft Components ......................................... 6-71
Disassembly of Engine............................................................. 6-72
Disassembly of Camshaft and Timing Components ................ 6-73
Disassembly of Crankshaft and Piston Components ............... 6-78
Inspection of Crankshaft and Camshaft Components.............. 6-82
Honing and Boring.................................................................... 6-88
Reassembly of Crankshaft and Piston Components................ 6-89
Reassembly of Camshaft and Timing Components ................. 6-95
Final Reassembly of Engine..................................................... 6-99
EGR system ................................................................................. 6-100
EGR system ........................................................................... 6-100
EGR system ........................................................................... 6-102
Inspecting/cleaning EGR related components ....................... 6-105

Before You Begin Servicing ENGINE
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
To prevent possible eye injury, always cleaners, primers, sealants and
wear SAFETY GLASSES while servicing sealant removers.
the engine.
0000013en
or serious injury.
A WARNING
0000014en
A CAUTION
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch FLYING OBJECT HAZARD!
when you are servicing the engine. • ALWAYS wear eye protection when
Someone may accidentally start the servicing the engine and when using
engine and not realize you are compressed air or high-pressure
servicing it. This could result in a water. Dust, flying debris, compressed
serious injury. air, pressurized water or steam may
• If you must service the engine while it injure your eyes.
is operating, remove all jewelry, tie • Failure to comply may result in minor
back long hair, and keep your hands, or moderate injury.
other body parts and clothing away 0000003en
• Failure to comply could result in death A CAUTION
or serious injury.
Be sure to secure the engine solidly to
0000010en
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en

ENGINE Before You Begin Servicing
CAUTION CAUTION
• Only use the engine oil specified. Any part which is found defective as a
Other engine oils may affect warranty result of inspection or any part whose
coverage, cause internal engine measured value does not satisfy the
components to seize and / or shorten standard or limit must be replaced.
engine life. 0000119en

contaminating the engine oil. Carefully CAUTION
the cap.
• NEVER mix different types of engine current rate of wear, should be replaced
oil. This may adversely affect the even though the part currently meets the
lubricating properties of the engine oil. service standard limit.
• NEVER overfill. Overfilling may result 0000120en

overspeed or internal damage. CAUTION
0000005en
Remove or install the high-pressure fuel
injection lines as an assembly whenever
CAUTION possible. Disassembling the
• Only use the engine coolant specified. high-pressure fuel injection lines from
Other engine coolants may affect the retainers or bending any of the fuel
warranty coverage, cause an internal lines will make it difficult to reinstall the
buildup of rust and scale and / or fuel lines.
shorten engine life. 0000047en

contaminating the engine coolant. CAUTION
Carefully clean the radiator cap and Do not loosen or remove the four bolts
the surrounding area before you retaining the fuel injection pump drive
remove the cap. gear to the fuel injection pump hub. Do
• NEVER mix different types of engine not disassemble the fuel injection pump
coolants. This may adversely affect the drive gear from the hub. Correct fuel
properties of the engine coolant. injection timing will be very difficult or
0000006en
impossible to achieve.
0000031en
CAUTION
an appropriate method. It is important
0000080en

Before You Begin Servicing ENGINE
CAUTION
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
CAUTION
motion.
0000090en

ENGINE Introduction
INTRODUCTION
This section of the Service Manual describes servicing of the engine.
CYLINDER HEAD SPECIFICATIONS

Adjustment Specifications
Valve Bridge Clearance
Model Valve Clearance
(4-Valve Head Only)
0.006 - 0.010 in.
All except 4TNV106, 4TNV106T 0
(0.15 - 0.25 mm)
0.010 - 0.014 in.
4TNV106, 4TNV106T 0
(0.25 - 0.35 mm)
Cylinder Head
Reference
Page
0.0020 in. 0.0059 in.
Combustion Surface Distortion (Flatness)
(0.05 mm) or less (0.15 mm)
0.0138 - 0.0217 in.
Intake 0.0315 in. (0.8 mm)
3TNV82A (0.35 - 0.55 mm)
(2-Valve Head) 0.0118 - 0.0197 in.
Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm)
3TNV84, 3TNV84T, 0.0118 - 0.0197 in.
Intake 0.0315 in. (0.8 mm)
3TNV88, 4TNV84, (0.30 - 0.50 mm)
4TNV84T, 4TNV88 See Valve
(2-Valve Head) 0.0118 - 0.0197 in. Recession on
4TNV84T (4-Valve Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm) page 6-42
Valve Recession Head) and 6-58.
0.0142 - 0.0220 in.
4TNV94L, 4TNV98, Intake 0.0315 in. (0.8 mm)
(0.36 - 0.56 mm)
4TNV98T
(4-Valve Head) 0.0138 - 0.0217 in.
(0.35 - 0.55 mm)
0.0197 - 0.0276 in.
Intake 0.0394 in. (1.0 mm)
4TNV106, 4TNV106T (0.50 - 0.70 mm)
(4-Valve Head) 0.0276 - 0.0354 in.
(0.70 - 0.90 mm)
Intake 120° - See Valve
Seat Angle Face and
Valve Seat Exhaust 90° -
Valve Seat
(2-Valve, 4-Valve)
Seat Correction Angle 40°, 150° - on page 6-43
and 6-59.

Cylinder Head Specifications ENGINE
Intake / Exhaust Valve and Guide
Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter
(7.000 - 7.015 mm) (7.08 mm)
Valve Stem Outside 0.2734 - 0.2740 in. 0.2717 in.
Intake
Diameter (6.945 - 9.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0071 in. See
Valve Stem Bend Inspection of
3TNV82A (0.040 - 0.070 mm) (0.18 mm)
Valve Guides
(2-Valve Head) 0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter on
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.3154 - 0.3159 in. 0.3189 in.
(8.010 - 8.025 mm) (8.10 mm)
Intake
Diameter (7.955 - 7.975 mm) (7.90 mm)
0.0014 - 0.0028 in. 0.0071 in. See
4TNV84, Valve Stem Bend
(0.035 - 0.070 mm) (0.18 mm) Inspection of
3TNV84, 3TNV84T,
Valve Guides
4TNV88, 4TNV88 0.3156 - 0.3161 in. 0.3189 in.
(2-Valve Head) (8.015 - 8.030 mm) (8.10 mm) page 6-41.
Valve Stem Outside 0.3132 -.3134 in. 0.3110 in.
Exhaust
Diameter (7.955 - 7.960 mm) (7.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm)
Intake
Diameter (5.960 - 5.975 mm) (5.90 mm)
0.0010 - 0.0022 in. 0.0059 in. See
4TNV84T (0.025 - 0.055 mm) (0.15 mm)
Valve Guides
(4-Valve Head) 0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm) page 6-41.
Exhaust
Diameter (5.945 - 5.960 mm) (5.90 mm)
0.0016 - 0.0028 in. 0.0067 in.
Valve Stem Bend
(0.040 - 0.070 mm) (0.17 mm)

ENGINE Cylinder Head Specifications
(Intake / Exhaust Valve and Guide Cont.)
Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
(7.000 - 7.015 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0067 in. See
4TNV94L Oil Clearance Inspection of
(0.040 - 0.070 mm) (0.17 mm)
4TNV98, 4TNV98T Valve Guides
(4-Valve Head) 0.2756 - 0.2762 in. 0.2787 in. on
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0067 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.17 mm)
0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.92 mm)
0.0019 - 0.0030 in. 0.0063 in. See
4TNV106T (0.048 - 0.075 mm) (0.16 mm)
Valve Guides
(4-Valve Head) 0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.960 - 6.975 mm) (6.90 mm)
0.0013 - 0.0024 in. 0.0071 in.
Valve Stem Bend
(0.033 - 0.060 mm) (0.18 mm)
0.4606 - 0.4724 in.
3TNV82A -
(11.70 - 12.00 mm)
3TNV84, 3TNV84T, 0.5791 -0.5905 in.
-
4TNV84, 4TNV88 (14.71 - 15.00 mm) See
Valve Guide Projection From 0.3228 - 0.3346 in. Reassembly
4TNV84T - of Valve
Cylinder Head (8.20 - 8.50 mm)
Guides on
4TNV94L, 4TNV98, 0.3819 - 0.3937 in. page 6-44
-
4TNV98T (9.70 - 10.00 mm) and 6-61.
0.5276 - 0.5354 in.
4TNV106, 4TNV106T -
(13.40 - 13.60 mm)
Valve Guide Installation Method Cold-fitted -

Cylinder Head Specifications ENGINE
Reference
Page
Valve Stem Seal Projection From Cylinder Head
0.618 - 0.629 in.
3TNV82A -
(15.7 - 16.0 mm)
2 Valves 4TNV84 -
0.736 - 0.748 in. See
3TNV84 (T) - Reassembly
(18.7 - 19.0 mm)
4TNV88 - of Intake and
0.389 - 0.401 in. Exhaust
4TNV84T - Valves on
(9.9 - 10.2 mm)
page 6-45.
4TNV94L 0.460 - 0.472 in. -
4 Valves
4TNV98 (T) (11.7 - 12.0 mm) -
0.606 - 0.614 in.
4TNV106 (T) -
(15.4 - 15.6 mm)
Push Rod
Reference
Page
See Push
Less than 0.0012 in. Rod Bend on
Push Rod Bend - All Models
0.0012 in. (0.03 mm) (0.03 mm) page 6-41
and 6-56.
Rocker Arm and Shaft

Reference
Model Inspection Item Standard Limit
Page
0.6299 - 0.6307 in. 0.6327 in.
Arm Shaft Hole Diameter
3TNV82A, 3TNV84, (16.000 - 16.020 mm) (16.07 mm)
3TNV84T, 3TNV88, 0.6286 - 0.6293 in. 0.6276 in.
Shaft Outside Diameter
4TNV84, 4TNV84T, (15.966 - 15.984 mm) (15.94 mm)
See
4TNV88 0.0006 - 0.0021 in. 0.0051 in.
Oil Clearance Inspection of
(0.016 - 0.054 mm) (0.13 mm) Rocker Arm
0.7283 - 0.7291 in. 0.7311 in. Assembly on
Arm Shaft Hole Diameter page 6-41
(18.500 - 18.520 mm) (18.57 mm)
4TNV94L, 4TNV98, and 6-56.
0.7272 - 0.7280 in. 0.7260 in.
4TNV98T, 4TNV106, Shaft Outside Diameter
(18.470 - 18.490 mm) (18.44 mm)
4TNV106T
0.0004 - 0.0020 in. 0.0051 in.
Oil Clearance
(0.010 - 0.050 mm) (0.13 mm)

ENGINE Cylinder Head Specifications
Valve Spring
Reference
Inspection Item Model Standard Limit
Page
1.7480 in. 1.7283 in.
3TNV82A (2-Valve Head)
(44.4 mm) (43.9 mm)
4TNV84, 3TNV84, 3TNV84T, 4TNV88 1.6535 in. 1.6339 in.
(2-Valve Head) (42.0 mm) (41.5 mm)
1.4724 in. 1.4528 in.
Free Length 4TNV84T (4-Valve Head)
(37.4 mm) (36.9 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 1.5630 in. 1.5433 in.
Head) (39.7 mm) (39.2 mm)
See
1.9921 in. 1.9724 in. Inspection of
4TNV106, 4TNV106T (4-Valve Head)
(50.6 mm) (50.1 mm) Valve
0.0551 in. Springs on
3TNV82A (2-Valve Head) - page 6-44
(1.4 mm)
and 6-60.
4TNV84, 3TNV84, 3TNV84T, 0.0551 in.
-
4TNV88 (2-Valve Head) (1.4 mm)
0.0551 in.
Squareness 4TNV84T (4-Valve Head) -
(1.3 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 0.0551 in.
-
Head) (1.4 mm)
0.0551 in.
4TNV106, 4TNV106T (4-Valve Head) -
(1.5 mm)

Camshaft and Timing Gear Train Specifications ENGINE
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Page
See Removal
0.0020 - 0.0079 in. 0.0118 in. of Camshaft
End Play
(0.05 - 0.20 mm) (0.030 mm) on
page 6-76.
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
3TNV82A, 3TNV84,
1.5197 - 1.5276 in. 1.5098 in. See
3TNV84T, 3TNV88, 4TNV84,
4TNV84T, 4TNV88
Camshaft on
Cam Lobe Height 4TNV94L, 4TNV98, 1.7087 - 1.7165 in. 1.6988 in. page 6-87.
4TNV98T (43.400 - 43.600 mm) (43.150 mm)
2.0039 - 2.0118 in. 1.9941 in.
4TNV106, 4TNV106T
(50.900 - 51.100 mm) (50.650 mm)
Shaft Outside Diameter / Bearing Inside Diameter
1.7713 - 1.7738 in. 1.7768 in.
Bushing Inside Diameter
(44.990 - 45.055 mm) (45.130 mm)
1.7687 - 1.7697 in. 1.7673 in.
Gear End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
3TNV82A, 1.7716 - 1.7726 in. 1.7756 in.
3TNV84, Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm) See
3TNV84T,
1.7681 - 1.7691 in. 1.7667 in. Inspection of
3TNV88, Intermediate Camshaft Outside Diameter
(44.910 - 44.935 mm) (44.875 mm) Camshaft on
4TNV84,
0.0026 - 0.0045 in. 0.0089 in. page 6-87.
4TNV84T, Oil Clearance
4TNV88 (0.065 - 0.115 mm) (0.225 mm)
1.7716 - 1.7726 in. 1.7756 in.
Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm)
1.7687 - 1.7697 in. 1.7673 in.
Flywheel End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil Clearance
(0.050 - 0.100 mm) (0.210 mm)

ENGINE Camshaft and Timing Gear Train Specifications
(Camshaft Cont.)
Reference
Page
1.9681 - 1.9707 in. 1.9736 in.
(49.990 - 50.055 mm) (50.130 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
4TNV94L,
1.9650 - 1.9659 in. 1.9636 in.
4TNV98, Intermediate Camshaft Outside Diameter
(49.910 - 49.935 mm) (49.875 mm)
4TNV98T
0.0026 - 0.0045 in. 0.0089 in;
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0020 - 0.0039 in. 0.0083 in. See
Oil Clearance
2.2827 - 2.2854 in. 2.2876 in. Camshaft on
Bushing Inside Diameter page 6-87.
(57.980 - 58.050 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0016 - 0.0055 in. 0.0098 in.
Oil Clearance
(0.040 - 0.140 mm) (0.250 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
4TNV106, 2.2793 - 2.2805 in. 2.2779 in.
Intermediate Camshaft Outside Diameter
4TNV106T (57.895 - 57.925 mm) (57.860 mm)
0.0030 - 0.0053 in. 0.0096 in.
Oil Clearance
(0.075 - 0.135 mm) (0.245 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0020 - 0.0047 in. 0.0091 in.
Oil Clearance
(0.050 - 0.120 mm) (0.230 mm)

Camshaft and Timing Gear Train Specifications ENGINE
Idler Gear Shaft and Bushing
Reference
Page
1.8091 - 1.8100 in. 1.8071 in.
Shaft Outside Diameter See
(45.950 - 45.975 mm) (45.900 mm)
Inspection of
1.8110 - 4.8120 in. 1.8140 in.
Bushing Inside Diameter Idler Gear
(46.000 - 46.025 mm) (46.075 mm)
and Shaft on
0.0010 - 0.0030 in. 0.0069 in. page 6-87.
Oil Clearance
(0.025 - 0.075 mm) (0.175 mm)
Timing Gear Backlash

Reference
Page
3TNV82A
3TNV84, 3TNV84T, Crank Gear, Cam Gear, Idler Gear,
0.0028 - 0.0059 in. 0.0067 in.
3TNV88, 4TNV84, Fuel Injection Pump Gear and PTO
(0.07 - 0.15 mm) (0.17 mm)
4TNV84T, Gear
4TNV88 See
Crank Gear, Cam Gear, Idler Gear, Checking
0.0031 - 0.0055 in. 0.0063 in. Timing Gear
Fuel Injection Pump Gear and PTO
4TNV94L (0.08 - 0.14 mm) (0.16 mm) Backlash on
Gear
4TNV98, 4TNV98T, page 6-73.
0.0035 - 0.0059 in. 0.0067 in.
4TNV106, Lubricating Oil Pump Gear
(0.09 - 0.15 mm) (0.17 mm)
4TNV106T
Balancer Drive Gear 0.0047 - 0.0071 in. 0.0079 in.
(Only for 4TNV106T) (0.12 - 0.18 mm) (0.20 mm)

ENGINE Crankshaft and Piston Specifications
CRANKSHAFT AND PISTON SPECIFICATIONS

Crankshaft
Note: Check appropriate parts catalog for various sizes of replacement main bearing inserts.
Reference
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
Journal Outside 1.6910 - 1.6914 in. 1.6891 in.
Diameter (42.952 - 42.962 mm) (42.902 mm)
Bearing Inside 1.6929 - 1.6946 in.
-
Diameter (43.000 - 43.042 mm)
3TNV82A
Bearing Insert 0.0585 -.0591 in.
-
Thickness (1.487 - 1.500 mm)
0.0015 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.038 - 0.090 mm) (0.150 mm)
Diameter (47.952 - 47.962 mm) (47.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.8898 - 1.8909 in.
-
3TNV88, Diameter (48.000 - 48.026 mm)
4TNV84, Bearing Insert 0.0587 - 0.0591 in.
4TNV84T - See
Thickness (1.492 - 1.500 mm)
4TNV88 Inspection of
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance Crankshaft
Connecting Rod (0.038 - 0.074 mm) (0.150 mm)
on
Journals Journal Outside 2.2816 - 2.2820 in. 2.2796 in. page 6-86.
Diameter (57.952 - 57.962 mm) (57.902 mm)
4TNV94L, -
Diameter (58.000 - 58.026 mm)
4TNV98,
4TNV98T Bearing Insert 0.0587 - 0.0591 in.
-
Thickness (1.492 - 1.500 mm)
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance
(0.038 - 0.074 mm) (0.150 mm)
Diameter (63.952 - 63.962 mm) (63.902 mm)
-
4TNV106, Diameter (64.016 - 64.042 mm)
-
Thickness (1.984 - 1.992 mm)
0.0021 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.054 - 0.090 mm) (0.150 mm)

Crankshaft and Piston Specifications ENGINE
(Crankshaft Cont.)
Reference
Page
Diameter (46.952 - 46.962 mm) (46.902 mm)
-
Diameter (47.000 - 47.032 mm)
3TNV82A
Bearing Insert 0.0782 - 0.0787 in.
-
Thickness (1.987 - 2.000 mm)
0.0015 - 0.0031 in. 0.0059 in.
Oil Clearance
(0.038 - 0.080 mm) (0.150 mm)
Journal Outside 1.9666-1.9670 in. 1.9646 in.
Diameter (49.952-49.962 mm) (49.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.9685 - 1.9693 in.
-
3TNV88, Diameter (50.000 - 50.020 mm)
4TNV84, Bearing Insert 0.0785 - 0.0791 in.
4TNV84T -
Thickness (1.995 - 2.010 mm)
4TNV88 See
0.0015 - 0.0027 in. 0.0059 in.
(0.038 - 0.068 mm) (0.150 mm)
Main Bearing Journal Crankshaft
Journal Outside 2.5572 - 2.5576 in. 2.5552 in. on
Diameter (64.952 - 64.962 mm) (64.902 mm) page 6-86.
4TNV94L, -
Diameter (65.000 - 65.020 mm)
4TNV98,
-
Thickness (1.995 - 2.010 mm)
0.0015 - 0.0027 in. 0.0059 in.
Oil Clearance
(0.038 - 0.068 mm) (0.150 mm)
Diameter (75.952 - 75.962 mm) (75.902 mm)
-
4TNV106, Diameter (76.014 - 76.034 mm)
-
Thickness (2.488 - 2.503 mm)
0.0020 - 0.0032 in. 0.0059 in.
Oil Clearance
(0.052 - 0.082 mm) (0.150 mm)
Thrust Bearing
Reference
Page
See Removal
0.0051 - 0.0091 in. 0.0110 in. of Crankshaft
Crankshaft End Play - All Models
(0.13 - 0.23 mm) (0.28 mm) on
page 6-80.

Piston
Reference
Page
3.2264 - 3.2275 in. 3.2246 in.
3TNV82A
(81.950 - 81.980 mm) (81.905 mm)
3TNV84, 3TNV84T, 3.3047 - 3.3059 in. 3.3029 in.
4TNV84, 4TNV84T (83.940 - 83.970 mm) (83.895 mm)
3.4622 - 3.4634 in. 3.4604 in.
3TNV88,4TNV88
Piston Outside Diameter (87.940 - 87.970 mm) (87.895 mm)
(Measure at 90° to the Piston Pin.) 3.6982 - 3.6994 in. 3.6968 in.
4TNV94L
(93.935 - 93.965 mm) (93.900 mm)
3.8555 - 3.8567 in. 3.8541 in.
4TNV98, 4TNV98T
(97.930 - 97.960 mm) (97.895 mm) See
4TNV106, 4TNV106T Pistons,
(105.930 - 105.960 mm) (105.880 mm)
Piston Rings
0.6299 in. and Wrist Pin
3TNV82A -
(16 mm) on
3TNV84, 3TNV84T, 0.9449 in. page 6-83.
-
4TNV84, 4TNV84T (24 mm)
0.9449 in.
Piston Diameter Measure Location 3TNV88,4TNV88 -
(24 mm)
(Upward From the Bottom of the
Piston.) 0.8661 in.
4TNV94L -
(22 mm)
0.8661 in.
4TNV98, 4TNV98T -
(22 mm)
1.1811 in.
4TNV106, 4TNV106T -
(30 mm)

(Piston Cont.)
Reference
Page
0.9055 - 0.9059 in. 0.9070 in.
Hole Inside Diameter
(23.000 - 23.009 mm) (23.039 mm)
0.9053 - 0.9055 in. 0.9041 in.
3TNV82A Pin Outside Diameter
(22.995 - 23.000 mm) (22.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil Clearance
(0.000 - 0.014 mm) (0.074 mm)
3TNV84, 1.0236 - 1.0240 in. 1.0252 in.

3TNV84T, (26.000 - 26.009 mm) (26.039 mm)
3TNV88, 1.0234 - 1.0236 in. 1.0222 in.
Pin Outside Diameter
4TNV84, (25.995 - 26.000 mm) (25.965 mm) See
4TNV84T 0.0000 - 0.0006 in. 0.0029 in. Inspection of
4TNV88 Oil Clearance Pistons,
(0.000 - 0.014 mm) (0.074 mm)
Piston Pin Piston Rings
1.1811 - 1.1815 in. 1.1826 in. and Wrist Pin
(30.000 - 30.009 mm) (30.039 mm) on
4TNV94L,
1.1807 - 1.1811 in. 1.1795 in. page 6-83.
4TNV98, Pin Outside Diameter
(29.989 - 30.000 mm) (29.959 mm)
4TNV98T
0.0000 - 0.0008 in. 0.0031 in.
Oil Clearance
(0.000 - 0.020 mm) (0.080 mm)
1.4567 - 1.4571 in. 1.4582 in.
(37.000 - 37.011 mm) (37.039 mm)
4TNV106, 1.4563 - 1.4567 in. 1.4551 in.
Pin Outside Diameter
4TNV106T (36.989 - 37.000 mm) (36.959 mm)
0.0000 - 0.0009 in. 0.0031 in.
Oil Clearance
(0.000 - 0.022 mm) (0.080 mm)

Piston Ring
Reference
Page
0.0813 - 0.0819 in.
Ring Groove Width -
(2.065 - 2.080 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0030 - 0.0043 in.
Side Clearance -
(0.075 - 0.110 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.0801 - 0.0807 in. 0.0846 in.
Ring Groove Width
(2.035 - 2.050 mm) (2.150 mm) See
3TNV82A, 0.0776 - 0.0783 in. 0.0768 in. Inspection of
3TNV84, Ring Width Pistons,
(1.970 - 1.990 mm) (2.150 mm)
3TNV84T, Second Ring Piston Rings
4TNV84, 0.0018 - 0.0031 in. 0.0079 in. and Wrist
Side Gap
4TNV84T (0.045 - 0.080 mm) (0.200 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 - 0.1571 in. 0.01555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

(Piston Ring Cont.)
Reference
Page
0.0811 - 0.0817 in.
Ring Groove Width -
(2.060 - 2.075 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0028 - 0.0041 in.
Side Clearance -
(0.070 - 0.105 mm)
0.0079 - 0.157 in. 0.0193 in.
End Gap
(0.200 -.0400 mm) (0.490 mm)
0.0797 - 0.0803 in. 0.0843 in.
Ring Groove Width
(2.025 - 2.040 mm) (2.140 mm) See
0.0776 -- 0.0783 in. 0.0768 in. Inspection of
Ring Width Pistons,
3TNV88, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV88 0.0014 - 0.0028 in. 0.0075 in.
Side Clearance and Wrist
(0.035 - 0.070 mm) (0.190 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 -.1571 in. 0.1555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

(Piston Ring Cont.)
Reference
Page
0.0803 - 0.0811 in.
Ring Groove Width -
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0756 in.
Ring Width
(1.940 - 1.960 mm) (1.920 mm)
Top Ring
0.0031 - 0.0047 in.
Side Clearance -
(0.080 - 0.120 mm)
0.0098 - 0.0177 in. 0.0213 in.
End Gap
(0.250 - 0.450 mm) (0.540 mm)
0.0819 - 0.0825 in. 0.0864 in.
Ring Groove Width
(2.080 - 2.095 mm) (2.195 mm) See
4TNV94L, Ring Width Pistons,
(1.970 - 1.990 mm) (1.950 mm)
4TNV98, Second Ring Piston Rings
4TNV98T 0.0035 - 0.0049 in. 0.0096 in. and Wrist
Side Clearance
(0.090 - 0.125 mm) (0.245 mm) Pin on
0.0177 - 0.0256 in. 0.0287 in. page 6-83.
End Gap
(0.450 - 0.650 mm) (0.730 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0098 - 0.0177 in. 0.0217 in.
End Gap
(0.250 - 0.450 mm) (0.550 mm)

(Piston Ring Cont.)
Reference
Page
0.0992 - 0.1000 in.
Ring Groove Width -
(2.520 - 2.540 mm)
0.0961 - 0.0969 in. 0.0953 in.
Ring Width
(2.440 - 2.460 mm) (2.420 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0118 - 0.0177 in. 0.0213 in.
End Gap
(0.300 - 0.450 mm) (0.540 mm)
0.0815 - 0.0821 in. 0.0860 in.
Ring Groove Width
(2.070 - 2.085 mm) (2.185 mm) See
Ring Width Pistons,
4TNV106, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV106T 0.0031 - 0.0045 in. 0.0093 in.
Side Clearance and Wrist
(0.080 - 0.115 mm) (0.235 mm) Pin on
0.0177 - 0.0236 in. 0.0268 in. page 6-83.
End Gap
(0.450 - 0.600 mm) (0.680 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0118 - 0.0197 in. 0.0236 in.
End Gap
(0.300 - 0.500 mm) (0.600 mm)

Connecting Rod
Connecting Rod Small End
Reference
Page
Wrist Pin Bushing 0.9065 - 0.9070 in. 0.9082 in.
Inside Diameter (23.025 - 23.038 mm) (23.068 mm)
Wrist Pin Outside 0.9053 - 0.9055 in. 0.9042 in.
3TNV82A
Diameter (22.995 - 23.000 mm) (22.967 mm)
0.0010 - 0.0017 in. 0.0040 in.
Oil Clearance
(0.025 - 0.043 mm) (0.101 mm)
3TNV84, 3TNV84T, 3TNV88, Wrist Pin Outside 1.0234 - 1.0236 in. 1.0223 in.
4TNV84, 4TNV84T, 4TNV88 Diameter (25.995 - 26.000 mm) (25.967 mm)
0.0010 - 0.0017 in. 0.0040 in. See
(0.025 - 0.043 mm) (0.101 mm)
Connecting
Wrist Pin Bushing 1.1821 - 1.1826 in. 1.1838 in. Rod on
Inside Diameter (30.025 - 30.038 mm) (30.068 mm) page 6-85.
4TNV94L, 4TNV98, 4TNV98T
Diameter (29.987 - 30.000 mm) (29.959 mm)
0.0010 - 0.0020 in. 0.0043 in.
Oil Clearance
(0.025 - 0.51 mm) (0.109 mm)
4TNV106, 4TNV106T
Diameter (36.989 - 37.000 mm) (36.961 mm)
0.0010 - 0.0019 in. 0.0042 in.
Oil Clearance
(0.025 - 0.049 mm) (0.107 mm)
Connecting Rod Big End

Reference
Page
See
Inspection of
0.0079 - 0.0157 in.
Side Clearance - All Models - Connecting
(0.20 - 0.40 mm)
Rod on
page 6-85.
See Special Torque Chart on page 6-25 for other specifications.

Tappet
Reference
Page
Tappet Bore (Block) Inside 0.4724 - 0.4734 in. 0.4742 in.
3TNV82A, 3TNV84, Diameter (12.000 - 12.025 mm) (12.045 mm)
3TNV84T, 3TNV88, 0.4715 - 0.4720 in. 0.4707 in.
Tappet Stem Outside Diameter
4TNV84, 4TNV84T, (11.975 - 11.990 mm) (11.955 mm)
4TNV88 0.0004 - 0.0020 in. 0.0035 in.
Oil Clearance
(0.010 - 0.050 mm) (0.090 mm)
Diameter (12.000 - 12.018 mm) (12.038 mm) See
4TNV94L, 4TNV98, 0.4715 - 0.4720 in. 0.4707 in. Inspection of
Tappet Stem Outside Diameter
4TNV98T (11.975 - 11.990 mm) (11.955 mm) Tappets on
0.0004 - 0.0017 in. 0.0033 in. page 6-85.
Oil Clearance
(0.010 - 0.043 mm) (0.083 mm)
Diameter (14.000 - 14.018 mm) (14.038 mm)
0.5498 - 0.5505 in. 0.5491 in.
4TNV106, 4TNV106T Tappet Stem Outside Diameter
(13.966 - 13.984 mm) (13.946 mm)
0.0006 - 0.0020 in. 0.0036 in.
Oil Clearance
(0.015 - 0.052 mm) (0.092 mm)

ENGINE Cylinder Block Specifications
CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection Item Model Standard Limit
Page
3.2283 - 3.2295 in. 3.2362 in.
3TNV82A
(82.000 - 82.030 mm) (82.200 mm)
3TNV84, 3TNV84T, 3.3071 - 3.3083 in. 3.3150 in.
4TNV84, 4TNV84T (84.000 - 84.030 mm) (84.200 mm)
3.4646 - 3.4657 in. 3.4724 in.
3TNV88, 4TNV88
(88.000 - 88.030 mm) (88.200 mm) See
Cylinder Inside Diameter Inspection of
3.7008 - 3.7020 in. 3.7059 in.
4TNV94L Cylinder
(94.000 - 94.030 mm) (94.130 mm)
Block on
3.8583 - 3.8594 in. 3.8634 in. page 6-83.
4TNV98, 4TNV98T
(98.000 - 98.030 mm) (98.130 mm)
4.1732 - 4.1744 in. 4.1783 in.
4TNV106, 4TNV106T
(106.000 - 106.030 mm) (106.130 mm)
Roundness 0.0004 in. (0.01 mm) 0.0012 in.
Cylinder Bore
Taper or less (0.03 mm)

Special Torque Chart ENGINE
SPECIAL TORQUE CHART

Torque for Bolts and Nuts
Lubricating Oil
Thread Diameter Application
Component Model Torque
and Pitch (Thread Portion and
Seat Surface)
46 - 49 ft·lb
3TNV82A M9 x 1.25 mm (61.7 - 65.7 N·m;
6.3 - 6.7 kgf·m)
3TNV82A, 3TNV84,
63 - 67 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (85.3 - 91.1 N·m;
4TNV84, 4TNV84T,
Cylinder 8.7 - 9.3 kgf·m)
4TNV88 Applied
Head Bolt
76 - 83 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (103.1 - 112.9 N·m;
4TNV98T
10.5 - 11.5 kgf·m)
139 - 146 ft·lb
4TNV106, 4TNV106T M13 x 1.5 mm (188.0 - 112.9 N·m;
19.0 - 20.0 kgf·m)
27 - 30 ft·lb
3TNV82A M8 x 1.0 mm (37.2 - 41.2 N·m;
3.8 - 4.2 kgf·m)
3TNV82A, 3TNV84,
33 - 36 ft·lb
3TNV84T, 3TNV88,
M9 x 1.0 mm (44.1 - 49.0 N·m;
4TNV84, 4TNV84T,
Connecting 4.5 - 5.0 kgf·m)
4TNV88 Applied
Rod Bolt
40 - 43 ft·lb
4TNV94L, 4TNV98,
M10 x 1.0 mm (53.9 - 58.8 N·m;
4TNV98T
5.5 - 6.0 kgf·m)
58 - 62 ft·lb
4TNV106, 4TNV106T M11 x 1.0 mm (78.5 - 83.4 N·m;
8.0 - 8.5 kgf·m)
3TNV82A, 3TNV84,
61 - 65 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (83.3 - 88.2 N·m;
4TNV84, 4TNV84T,
Flywheel 8.5 - 9.0 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 137 - 152 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (186.2 - 205.8 N·m;
4TNV106T 19 - 21 kgf·m)
83 - 91 ft·lb
EPA Flange
4TNV106, 4TNV106T M8 x 1.5 mm (113 - 123 N·m; Not Applied
Bolt
11.5 - 12.5 kgf·m)

ENGINE Special Torque Chart
(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
56 - 60 ft·lb
3TNV82A M10 x 1.25 mm (76.4 - 80.4 N·m;
7.8 - 8.2 kgf·m)
3TNV84, 3TNV84T, 69 - 72 ft·lb
3TNV88, 4TNV84, M12 x 1.5 mm (93.2 - 98.1 N·m;
Main Bearing Cap 4TNV84T, 4TNV88 9.5 - 10.5 kgf·m)
Applied
Bolt 80 - 87 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (108.1 - 117.9 N·m;
4TNV98T
11.0 - 12.0 kgf·m)
137 - 152 ft·lb
4TNV106, 4TNV106T M14 x 1.5 mm (186.2 - 205.8 N·m;
19 - 21 kgf·m)
3TNV82A, 3TNV84,
83 - 91 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (112.7 - 122.7 N·m;
4TNV84, 4TNV84T,
Crankshaft Pulley 11.5 - 12.5 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 80 - 94 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (107.9 - 127.5 N·m;
4TNV106T 11.0 - 13.0 kgf·m)
3TNV82A, 3TNV84,
18 - 21 ft·lb
3TNV84T, 3TNV88,
M8 x 1.25 mm (24.4 - 28.4 N·m;
4TNV84, 4TNV84T,
Fuel Injector 2.5 - 2.9 kgf·m)
4TNV88 Not Applied
Bolt
4TNV94L, 4TNV98, 17 - 21 ft·lb
4TNV98T, 4TNV106, M8 x 1.25 mm (22.6 - 28.4 N·m;
4TNV106T 2.3 - 2.9 kgf·m)
3TNV82A, 3TNV84,
58 - 65 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (78 - 88 N·m;
4TNV84, 4TNV84T,
Fuel Pump Drive 8 - 9 kgf·m)
4TNV88 Not Applied
Gear Nut
4TNV94L, 4TNV98, 83 - 90 ft·lb
4TNV98T, 4TNV106, M18 x 1.5 mm (113 - 123 N·m;
4TNV106T 11.5 - 12.5 kgf·m)
3TNV82A, 3TNV84,
22 - 25 ft·lb
3TNV84T, 3TNV88,
M12 x 1.5 mm (29.4 - 34.3 N·m;
4TNV84, 4TNV84T,
High-Pressure 3.0 - 3.5 kgf·m)
4TNV88 Not Applied
Fuel Lines Bolt
4TNV94L, 4TNV98, 174 - 217 in·lb
4TNV98T, 4TNV106, M12 x 1.5 mm (19.6 - 24.5 N·m;
4TNV106T 2.0 - 2.5 kgf·m)

Special Torque Chart ENGINE
(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
4TNV94L, 4TNV98, 70 - 86 in·lb
Fuel Return Line
4TNV98T, 4TNV106, M6 x 1.0 mm (7.8 - 9.8 N·m; Not Applied
Joint Bolt
4TNV106T 0.8 - 1.0 kgf·m)
Rocker Arm 148 - 199 in·lb
Cover 4TNV106, 4TNV106T M8 x 1.25 mm (16.7 - 22.5 N·m; Not Applied
Bolt 1.7 - 2.3 kgf·m)
3TNV82A-B, 133 - 177 in·lb
Glow Plug 3TNV88-B,-U, M10 x 1.25 mm (15 - 20 N·m Not Applied
4TNV88-B,-U 1.53 - 2.04 kgf·m)
3TNV82A-B,
Glow Connector 9 - 13 in·lb
3TNV88-B,-U, M4 x 0.7 mm Not Applied
Nut (1 - 1.5 N·m)
4TNV88-B,-U
See Tightening Torques for Standard Bolts and Nuts on page 4-46 for standard hardware torque values.

ENGINE Special Service Tools
SPECIAL SERVICE TOOLS

No. Tool Name Applicable Model and Tool Size Illustration
Model L1 L2 d1 d2
3TNV82A
4TNV94L,
4TNV98, 0.787 in. 2.953 in. 0.256 in. 0.394 in.
0000827
4TNV98T (20 mm) (75 mm) (6.5 mm) (10 mm)
4TNV106,
Valve Guide Tool 4TNV106T
1 (For Removing
Valve Guide) 4TNV84,
3TNV84,
0.787 in. 2.953 in. 0.295 in. 0.433 in.
3TNV84T,
(20 mm) (75 mm) (7.5 mm) (11 mm)
3TNV88,
4TNV88
0.787 in. 2.953 in. 0.217 in. 0.354 in.
4TNV84T
(20 mm) (75 mm) (5.5 mm) (9 mm)
Locally Manufactured
Model L1 L2 d1 d2
0.472 in. 2.362 in. 0.512 in. 0.748 in.
3TNV82A
(12 mm) (60 mm) (13 mm) (19 mm)
4TNV84,
3TNV84,
0.591 in. 2.559 in. 0.551 in. 0.787 in.
3TNV84T, 0000828
(15 mm) (65 mm) (14 mm) (20 mm)
Valve Guide Tool 4TNV88,
2 (For Installing 4TNV88
Valve Guide) 0.335 in. 2.362 in. 0.433 in. 0.669 in.
4TNV84T
(8.5 mm) (60 mm) (11 mm) (17 mm)
4TNV94L,
0.276 in. 2.362 in. 0.512 in. 0.630 in.
4TNV98,
(7 mm) (60 mm) (13 mm) (16 mm)
4TNV98T
4TNV106, 0.535 in. 2.559 in. 0.512 in. 0.630 in.
4TNV106T (13.6 mm) (65 mm) (13 mm) (16 mm)
Fuel Injector
3 Removal Tool Yanmar Part No. 129470-92305
(2-Valve Head)

Special Service Tools ENGINE
(Special Service Tools Cont.)
Model L1 L2 d1 d2
0.984 in. 3.346 in. 0.906 in. 1.024 in.
3TNV82A
(25 mm) (85 mm) (23 mm) (26 mm)
3TNV84,
Connecting Rod
3TNV84T,
Bushing
3TNV88, 0.787 in. 3.937 in. 1.024 in. 1.142 in.
Replacer 0000829
4TNV84, (20 mm) (100 mm) (26 mm) (29 mm)
4 (For Removal/
4TNV84T,
Installation of
4TNV88,
Connecting Rod
Bushing) 4TNV94L,
0.787 in. 3.937 in. 1.181 in. 1.299 in.
4TNV98,
(20 mm) (100 mm) (30 mm) (33 mm)
4TNV98T
4TNV106, 0.787 in. 3.937 in. 1.457 in. 1.575 in.
4TNV106T (20 mm) (100 mm) (37 mm) (40 mm)
Valve Spring
Compressor
Yanmar Part No.
5 (For Removal/
129100-92630
Installation of 0000830
Valve Spring)
Model d1 d2 d3 L1 L2 L3
0.598 0.827 0.472 0.622 2.559 0.157
in. in. in. in. in. in.
3TNV82A
(15.2 (21 (12 (15.8 (65 (4
mm) mm) mm) mm) mm) mm)
3TNV84,
0.638 0.866 0.531 0.740 2.559 0.157
3TNV84T,
3TNV88,
(16.2 (22 (13.5 (18.8 (65 (4
4TNV84,
Stem Seal 4TNV88
Installer 0.508 0.748 0.453 0.394 2.559 0.157
6
(for Installing in. in. in. in. in. in.
Valve Stem Seal) 4TNV84T
(12.9 (19 (11.5 (10 (65 (4
0.598 0.827 0.472 0.465 2.559 0.157
4TNV94L, 0000820
4TNV98,
(15.2 (21 (12 (11.8 (65 (4
4TNV98T
0.598 0.827 0.472 0.610 2.559 0.157
4TNV106, in. in. in. in. in. in.
4TNV106T (15.2 (21 (12 (15.5 (65 (4

ENGINE Special Service Tools

Filter Wrench
(For Removal /
7 Available Locally
Installation of
Engine Oil Filter) 0000821
Model L1 L2 d1 d2
3TNV82A,
3TNV84,
3TNV84T,
0.709 in. 2.756 in. 1.772 in. 1.890 in.
3TNV88,
Camshaft (18 mm) (70 mm) (45 mm) (48 mm)
4TNV84,
Bushing Tool 0000822
4TNV84T,
8 (For Extracting 4TNV88
Camshaft
4TNV94L,
Bushing) 0.709 in. 2.756 in. 1.968 in. 2.087 in.
4TNV98,
(18 mm) (70 mm) (50 mm) (553 mm)
4TNV98T
4TNV106, 0.709 in. 2.756 in. 2.283 in. 2.402 in.
4TNV106T (18 mm) (70 mm) (58 mm) (61 mm)
Allowance: d1 d2
Model Yanmar Part No. Cylinder Bore

3.071 - 3.307 in.
3TNV82A 129400-92420
(78 - 84 mm)
3TNV88,
Flex-Hone 3.268 - 3.740 in.
4TNV88, 129400-92430
9 (For Preparation (83 - 95 mm)
4TNV94L
of Cylinder Walls) 0000823
3.504 - 3.976 in.
4TNV98 129400-92440
(89 - 101 mm)
4TNV106, 3.740 - 4.252 in.
129400-92450
4TNV106T (95 - 108 mm)
Piston Ring
Yanmar Part No. 95550-002476
Compressor
10 The Piston Insertion Tool is Applicable for
(For Installing
2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons
Piston)
0000824
Piston Ring
Expander
11 (For Removal / Available Locally
Installation of
Piston Ring) 0000825

Special Service Tools ENGINE
Locally Manufactured 0000826

(1)
Crankshaft Pulley
12 (4TNV94L, 4TNV98(T) series)
Installing Tool
(Knurl knob (1))
0002134
6.3
0.05 A 0.1 A
(16) 36
20
5 M14 x 1.5
0.
C
0.
16 C
5
Pulley Installing 3TNV82A - 4TNV88 1

13 C
ø 35.4 -0.05
-0.15
Tool For all series

ø6
1
C
A
3
52
Knurling

ENGINE Measuring Instruments
MEASURING INSTRUMENTS
No. Instrument Name Application Illustration
1 Dial Indicator Locally Available Measure shaft bend and end play
0000831
Measurements of narrow or deep portions that

2 Test Indicator Locally Available
cannot be measured by dial gauge
0000832
3 Magnetic Stand Locally Available For holding the dial gauge when measuring
0000833
For measuring the outside diameters of

4 Micrometer Locally Available
crankshaft, pistons, piston pins, etc.
0000834
Cylinder Bore For measuring the inside diameters of cylinder

5 Locally Available
Gauge liners, bearing bores, etc.
0000835
For measuring outside diameters, depth,

6 Calipers Locally Available
thickness and width
0000836
7 Depth Micrometer Locally Available For measuring of valve recession
0000837
For measuring valve spring inclination and

8 Square Locally Available
straightness of parts
0000838

Measuring Instruments ENGINE
9 V-Block Locally Available For measuring shaft bend
0000839
For tightening nuts and bolts to the specified

10 Torque Wrench Locally Available
torque
0000840
For measuring piston ring gaps, piston ring

11 Feeler Gauge Locally Available
clearance, and valve adjustment clearance
0000841

ENGINE 2-Valve Cylinder Head
2-VALVE CYLINDER HEAD

2-Valve Cylinder Head Components
(3)
(1)
(2) (4)
(5)
(6) (7)
(34)
(8)
(32)
(33)
(9) (10)
(11)
(12)
(29)
(17) (13)
(30) (18) (14)
(28) (31) (15)
(19)
(20) (16)
(27)
(21)
(22)
(23)
(26)
(24)
(25) 0001919
Figure 6-1

2-Valve Cylinder Head ENGINE
1 – Valve Cover Nut Components of a two-valve cylinder
2 – Valve Cover Nut O-Ring
3 – Crankcase Breather Cover
head
4 – Diaphragm Spring Cylinder head with glow plugs (two-valve
5 – Diaphragm Plate type)Applicable Model
6 – Crankcase Breather Diaphragm 3TNV82A-B, 3TNV88-B,-U, 4TNV88-B,-U
(non-turbocharged engines only)
7 – Oil Fill Cap
8 – Valve Cover Gasket (3)
9 – Rocker Arm Shaft Spring
10 – Valve Adjusting Screw Lock Nut
11 – Valve Adjusting Screw
12 – Rocker Arm
13 – Rocker Arm Shaft (2)
14 – Rocker Arm Shaft Aligning Stud
15 – Support Bolt
16 – Rocker Arm Shaft Support
17 – Valve Cap
18 – Valve Keepers
19 – Spring Retainer
20 – Valve Spring (1)
21 – Valve Stem Seal
22 – Valve Guide
23 – Cylinder Head
Figure 6-2
24 – Intake Valve
25 – Exhaust Valve 1 – Cylinder Head
26 – Cylinder Head Gasket 2 – Glow plug
27 – Fuel Injector Retainer 3 – Harness, Glow plug
28 – Washer
29 – Fuel Injector Retainer Bolt
30 – Fuel Injector Nozzle Protector
31 – Fuel Injector Nozzle Seat
32 – Push Rod
33 – Crankcase Breather Components
34 – Valve Cover

Disassembly of 2-Valve Cylinder

Head
Prepare a clean, flat working surface on a (1)
workbench large enough to accommodate the
cylinder head assembly. Discard all gaskets,
O-rings and seals. Use new gaskets, O-rings and
seals on reassembly of the cylinder head.
1. Drain the coolant from the engine into a suitable
container. See Drain, Flush and Refill Cooling
System With New Coolant on page 5-36.
CAUTION
0002087A
an appropriate method. It is important Figure 6-4
position during the reassembly process. 4. Remove the intake manifold bolts
(Figure 6-5, (1)). Remove the intake manifold
0000080en
(Figure 6-5, (2)). Discard the intake manifold
2. Disconnect the electrical wire from the intake air gasket (Figure 6-5, (3)).
heater (Figure 6-3, (1)).
(5)
(4)
(1) (5)
(6)
(7)
(2) (3)
0001682
(1)
Figure 6-5
Figure 6-3
5. Remove the exhaust manifold bolts
3. Disconnect the coolant hoses from the cold (Figure 6-5, (4)) and nuts (Figure 6-5, (5)).
start device (Figure 6-4, (1)) on the fuel Remove the exhaust manifold (Figure 6-5, (6))
injection pump. and the exhaust manifold gasket
(Figure 6-5, (7)).
6. Remove the coolant pump. See Disassembly of
Engine Coolant Pump on page 8-10.
7. Remove the high-pressure lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 7-35.

Removing the glow plugs Removal of Valve Cover
1. Remove the glow plug harness 1. Remove the valve cover nuts (Figure 6-7, (1)).
(Figure 6-6, (2)) from each glow plug 2. Remove the O-ring (Figure 6-7, (2)) on each
(Figure 6-6, (1)). valve cover nut.
2. Remove the glow plug from the cylinder head.
(1)
(2)
(2)
(1) (3)
(4)
0001920
Figure 6-7
3. Remove the valve cover (Figure 6-7, (3)) and
the valve cover gasket (Figure 6-7, (4)).
Figure 6-6
Note: Removing the cylinder head from the
engine requires that the glow plugs be
removed in advance.
Failure to remove the glow plugs in
advance could result in damages to the
glow plugs because their tips are
protruding from the cylinder head
combustion chamber surface.

Removal of Rocker Arm Assembly

(7)
1. Remove the bolts (Figure 6-8, (1)) that retain (6)
the rocker arm shaft supports. (1)
(2)
2. Remove the rocker arm shaft assembly from
the cylinder head.
Note: Identify the push rods so they can be (3)
(4)
reinstalled in their original locations.
3. Remove the push rods and identify for
installation. (5)
0001951
Figure 6-9
(1)
3. Remove the valve adjusting screw
(Figure 6-9, (6)) and the lock nut
(Figure 6-9, (7)) from the rocker arms.
Removal of Cylinder Head

1. Loosen the cylinder head bolts following the
sequence shown in (Figure 6-10).
(2)
8 14 5
0001950 2 12 9 3
(1)
Figure 6-8 4 10 11 1
6 13 7
Disassembly of Rocker Arm Assembly

1. Remove the rocker arm shaft alignment stud (2)
(Figure 6-9, (4)) from support (Figure 6-9, (5)).
7 16 14 6
1 9 18 12 4
Note: The rocker arm shaft fits tightly in the
(1)
rocker arm supports. Clamp the support 3 11 17 10 2
in a padded vise. Twist and pull out on 5 13 15 8
the rocker arm shaft to remove. Reverse 0001864
this process when you reinstall the 1 – Cooling Fan End

rocker arm shaft into the supports. 2 – Camshaft Side
2. Slide the rocker arm shaft (Figure 6-9, (3)) out Figure 6-10
of the rocker arm supports (Figure 6-9, (5)),
springs (Figure 6-9, (1)), and rocker arms
(Figure 6-9, (2)).
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.

2. Remove the cylinder head bolts Removal of Intake / Exhaust Valves
(Figure 6-11, (1)). 1. Place the cylinder head on the work bench with
3. Lift the cylinder head away from the cylinder the combustion side down.
block. Discard the cylinder head gasket 2. Remove the valve cap (Figure 6-13, (1)) and
(Figure 6-11, (2)). Position the cylinder head on keep with the valve it was installed on.
the work bench to prevent damage to the
combustion surface. 3. Using the valve spring compressor tool,
compress one of the valve springs
(Figure 6-12).
(1)
0000191
Figure 6-12
4. Remove the valve keepers (Figure 6-13, (2)).
(2) 5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 6-13, (3))
and valve spring (Figure 6-13, (4)).
(1)
(2)
(3)
(4)
0001690 (5)
Figure 6-11
(6)
0001684
Figure 6-13
7. Repeat the procedure with all remaining valves.

Note: If the valves are to be reused, identify Cleaning of Cylinder Head

them so they can be installed in their
Components
original location.
8. Turn the cylinder head so the exhaust port side A WARNING
faces down. Remove the intake and exhaust
valves (Figure 6-13, (6)) from the cylinder
head.
9. Remove the valve stem seals
(Figure 6-13, (5)).
FUME / BURN HAZARD!
Removal of Valve Guides
Note: Removal of the valve guides should be precautions found on containers of
postponed until inspection and hazardous substances like parts
measurement procedures have been cleaners, primers, sealants and
performed. See Inspection of Valve sealant removers.
Guides on page 6-41.
1. If the valve guides were not within or serious injury.
specifications, use a drift pin and hammer to 0000014en
drive the valve guides (Figure 6-14, (1)) out of
the cylinder head. Thoroughly clean all components using a non-
metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other
debris.
(1)
Inspection of Cylinder Head
Components
Visually inspect the parts. Replace any parts that
are obviously discolored, heavily pitted or otherwise
damaged. Discard any parts that do not meet its
specified limit.
001689 CAUTION
Figure 6-14 Any part which is found defective as a
0000119en

Inspect the contact areas (Figure 6-16, (1)) for
CAUTION excessive wear or damage.
service standard limit.
0000120en
(1)
Inspection of Push Rods (1)
Push Rod Bend

Determine if the bend of the push rods are within 0001916
the specified limit.

Figure 6-16
1. Place the push rods on a flat inspection block or
layout bed. Rocker Arm Shaft Outside Diameter
2. Roll the push rods until a gap can be observed Use a micrometer to measure the rocker arm shaft
between a portion of the push rod and the diameter. Measure at each rocker arm location in
surface of the block or layout bed. two directions 90° apart (Figure 6-17). See Rocker
Arm and Shaft on page 6-9 for the service limit.
3. Use a feeler gauge to measure the gap
(Figure 6-15). See Push Rod on page 6-9 for
the service limit.
0001952
0000204
Figure 6-15 Figure 6-17
Inspection of Rocker Arm Assembly Inspection of Valve Guides

Visually inspect the valve guides for distortions,
Rocker Arm Shaft Hole Diameter scoring or other damage.
Use a test indicator and micrometer to determine if
the inside diameter of all the rocker arm support Note: Measure the valve guides while they are
brackets and the rocker arms (Figure 6-16) are installed in the cylinder head.
within the specified limits. See Rocker Arm and
Shaft on page 6-9 for the service limit.

Use a telescoping gauge and micrometer to Valve Stem Diameter

measure the inside diameter at each end of the Use a micrometer to measure the valve stem
valve guide. Measure in three places and 90° apart diameter. Measure the valve stem near the
(Figure 6-18). See Intake / Exhaust Valve and combustion end and near the opposite end
Guide on page 6-7 for the service limit. Replace (Figure 6-20, (1)). See Intake / Exhaust Valve and
valve guides if not within specification. Guide on page 6-7 for the service limit.
(1)
0001869 0000197

Inspection of Cylinder Head Valve Stem Bend
Cylinder Head Distortion Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
Place the cylinder head flat and inverted
observed between a portion of the valve stem and
(combustion side up) on the bench. Use a straight
the surface of the block or bed. Use a feeler gauge
edge and a feeler gauge to measure cylinder head
to measure the gap (Figure 6-21). See
distortion (Figure 6-19). Measure diagonally and
Intake / Exhaust Valve and Guide on page 6-7 for
along each side. See Cylinder Head on page 6-6
the service limit.
for the service limit.
0000199
Figure 6-21
0000192
Valve Recession
Figure 6-19
Note: The valve guides must be installed to
If distortion exceeds the service limit, resurface or perform this check.
replace the cylinder head. Remove only enough
material to make the cylinder head flat, but do not Insert the valves into their original locations and
remove more than 0.008 in. (0.20 mm). press them down until they are fully seated. Use a
depth micrometer (Figure 6-22) to measure the
Inspection of Intake and Exhaust Valves difference between the cylinder head gasket
surface and the combustion surface of each
Visually inspect the intake and exhaust valves.
exhaust and intake valve (Figure 6-23). See
Replace any valves that are obviously discolored,
Cylinder Head on page 6-6 for the service limit.
heavily pitted or otherwise damaged.

Coat the valve seat with a thin coat of bluing
compound. Install the valve and rotate it to
distribute bluing onto the valve face. The contact
pattern should be approximately centered on the
valve face (Figure 6-24, (1)) and even in width.
0000193
Figure 6-22
(1)
0001691B
Figure 6-24
Also visually inspect the valve seat for even
0001755 contact.
Figure 6-23
Light cutting can be performed by the use of a
Valve Face and Valve Seat hand-operated cutter (Figure 6-25, (3)).
Always check the clearance between the valve and
valve guide before grinding or lapping the valve (1)
seats. See Intake / Exhaust Valve and Guide on 150° 40°
page 6-7 for the service limit. If the clearance
exceeds the limit, replace the valve and / or valve (3)
guide to bring the clearance within the limit. (2)
Roughness or burrs will cause poor seating of a

valve. Visually inspect the seating surfaces of each 0001862
valve and valve seat to determine if lapping or Figure 6-25

grinding is needed.
The valve seat diameter can be adjusted by top-
Visually inspect all valve faces and valve seats for grinding with a 150° stone to make the seat
pitting, distortion, cracking, or evidence of diameter smaller, and bottom-grinding using a 40°
overheating. Usually the valves and the valve seats stone to make the seat diameter larger. Once the
can be lapped or ground to return them to seat location has been corrected, grind and lap the
serviceable condition. Severely worn or damaged seat angle (Figure 6-25, (1)) to specification. See
components will require replacement. Cylinder Head on page 6-6 for specifications.

Grind the valve face and / or valve seat only Free Length
enough to return them to serviceable condition. Use a caliper to measure the length of the spring
Grinding is needed if the valve and the valve seat (Figure 6-27). See Valve Spring on page 6-10 for
do not contact correctly. Check the recession after the service limit.
grinding.
If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
2
3
1
4
Be sure to thoroughly wash all parts to remove all
5
9
6
grinding powder or compound.
8
7
Inspection of Valve Springs
Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
limits, replace the springs. 0000200
Figure 6-27
Fractures
Check for fractures on the inside and outside Reassembly of Cylinder Head
portions of the springs. If the valve spring is
fractured, replace the valve spring. Use new gaskets, O-rings and seals for the
reassembly of the cylinder head.
Corrosion
IMPORTANT
Check for corrosion of the spring material caused Liberally oil all components during
by oxidation. reassembly to prevent premature wear or
Squareness damage.
Use a flat surface and a square to check each Reassembly of Valve Guides
spring for squareness (Figure 6-26). See Valve
Spring on page 6-10 for the service limit. 1. The valve guides are installed into the cylinder
head with an extremely tight press fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes
This will cause the valve guides to contract,
making it easier to install the valve guides into
place.
0000201
Figure 6-26

2. Immediately after removing the valve guides Reassembly of Intake and Exhaust Valves
from the freezer, insert the valve guides
(Figure 6-28, (1)) in their proper positions. IMPORTANT
Always install new valve stem seals.
The exhaust valve stem seals are different
than the intake valve stem seals and can be
(1) identified by either the paint marks on the
outside of the seals or by the color of the
seal spring (Figure 6-30, (4)). Ensure they
are installed in the correct locations.
Marking
Engine Model
Intake Exhaust
3TNV84, 3TNV88, Yellow (Paint
3TNV84T, 4TNV84, None on outside of
001689 4TNV88 seal)
Figure 6-28 Black (Seal
3TNV82A None
Spring)
3. Finish installing the valve guides
(Figure 6-29, (1)) into the cylinder head to the 1. Oil the lip of the valve stem seal
proper height (Figure 6-29, (3)) using the valve (Figure 6-30, (2)). Using the valve stem seal
guide installation tool (Figure 6-29, (2)). See installation tool (Figure 6-30, (1)), install a new
Valve Guide Projection specification starting on valve stem seal on each of the valve guides
page 6-7. (Figure 6-30, (3)).
(2)
(1)
(3)
(4)
(1) (2)
0001756A
(3)
Figure 6-29
0001873B
Figure 6-30
2. Measure the distance (Figure 6-31, (1)) from
the cylinder head to valve stem seal to ensure
proper clearance (Figure 6-31, (2)) between
the guide and the seal. See Valve Stem Seal
Projection specification on page 6-9.

7. Insert the valve keepers (Figure 6-32, (2)) and

slowly release the tension on the valve spring.
Install the valve cap (Figure 6-32, (1)). Repeat
the steps on all the remaining valves.
(2) Reassembly of Cylinder Head
(1)
1. Carefully clean both the combustion surface of
the cylinder head and the top surface of the
cylinder block. Then place a new cylinder head
gasket (Figure 6-33, (2)) on the cylinder block.
0001874
2. Position the cylinder head on the cylinder head
Figure 6-31 gasket.
3. Place the cylinder head assembly on its
exhaust port side. (1)
4. Place all the valves (Figure 6-32, (6)) in their
proper location in the cylinder head.
(1)
(2)
(3)
(4)
(5)
(2)
(6)
0001684
0001690
Figure 6-32
5. Place the cylinder head on the workbench with Figure 6-33
the combustion side down to install the valve
springs. Install the valve spring
(Figure 6-32, (4)) and the spring retainer
(Figure 6-32, (5)).
6. Using the valve spring compressor tool,
compress the valve spring.

3. Lightly oil the threads of the cylinder head bolts 1. Lubricate the rocker arm shaft. Slide the rocker
(Figure 6-33, (1)). Tighten the bolts to the arm supports (Figure 6-36, (5)), springs
specified torque in two steps as shown in the (Figure 6-36, (1)) and rocker arms
chart below. Tighten in the sequence shown in (Figure 6-36, (2)) onto the shaft.
(Figure 6-34). See Special Torque Chart on Note: The rocker arm shaft fits tightly in the
page 6-25 for specification. rocker arm supports. Clamp the support
First Step 1/2 of final torque
in a padded vise. Twist and push on the
rocker arm shaft to reinstall.
Second Step Final torque
Note: To properly align the rocker arm shaft
4. Insert the push rods in their respective with the rocker arm shaft supports, first
positions. reinstall a rocker arm support
(Figure 6-36, (5)) having a hole for the
(2) shaft alignment stud (Figure 6-36, (4)).
13
7
3
1
6
10
12
Align the hole in the rocker arm shaft and
(1) the hole in the rocker arm support.
11 5 4 14
Reinstall the alignment stud.
9 2 8
(7)
(6)
(2)
(1)
12 3 5 13 (2)
18 10 1 7 15
(1)
16 8 2 9 17
14 6 4 11 (3)
(4)
0001875
1 – Fan End
2 – Camshaft Side
(5)
Figure 6-34
Reassembly of Rocker Arm Reassembly

0001951
Note: Ensure the lubrication holes
(Figure 6-35, (1)) in the rocker arm shaft Figure 6-36
are oriented correctly with respect to the
Note: Figure 6-36 shows components for one
rocker arms (Figure 6-35, (2)).
cylinder. Components for all remaining
cylinders are assembled in the same
(2)
order.
2. Place the rocker arm shaft assembly onto the
(1)
cylinder head.
3. If removed, reinstall the valve adjusting screws
(Figure 6-36, (6)) and the lock the nuts
(Figure 6-36, (7)).
4. Align the push rods with their respective rocker
arms.
(1) 0001914
5. Reinstall and tighten the rocker arm shaft
Figure 6-35 retaining bolts to the specified torque.

6. Tighten the rocker arm shaft alignment studs. 6. Install each glow plug (Figure 6-38, (1)), and
7. Adjust the valve clearance. See Measuring and tighten it with the specified torque. Install each
Adjusting Valve Clearance on page 6-66. electrical harness (Figure 6-38, (1)), and
tighten it with the specified torque.
Reassembly of the Valve Cover
1. Lightly grease a new valve cover gasket (2)
(Figure 6-37, (4)). Place the gasket in the
groove of the valve cover (Figure 6-37, (3)).
2. Place the valve cover on the cylinder head. (1)
3. Be sure new O-rings (Figure 6-37, (2)) are
installed on the valve cover nuts. Reinstall and
tighten the valve cover nuts (Figure 6-37, (1)).
4. Reinstall the exhaust manifold using a new
gasket. Tighten the bolts to the specified
torque.
(1)
(2)
Figure 6-38
7. Reinstall the fuel injectors. See Installation of
the Fuel Injectors on page 7-42.
(3) 8. Reinstall the high pressure and the return fuel
injection lines. See Installation of the Fuel
Injectors on page 7-42
9. Reinstall the engine coolant pump. See
(4)
Reassembly of Engine Coolant Pump on
0001920 page 8-11.
Figure 6-37 10. Reinstall the coolant hoses on the cold start
5. Reinstall the intake manifold using a new device on the fuel injection pump.
gasket. Tighten the bolts to the specified 11. Reinstall the alternator. See Installation of
torque. Alternator on page 12-16.

4-VALVE CYLINDER HEAD

4-Valve Cylinder Head Components
(1)
(2)
(3)
(4) (5)
(36)
(6)
(7)
(35)
(8)
(34)
(9)
(11) (12)
(10)
(33)
(14) (15)
(31) (13)
(30) (32)
(29)
(28)
(27) (16)
(26)
(24)
(25)
(23) (17)
(18)
(22)
(19)
(21)
(20) 0001861
Figure 6-39

1 – Crankcase Breather Cover Disassembly of 4-Valve Cylinder

2 – Diaphragm Spring
3 – Diaphragm Cup Head
4 – Crankcase Breather Diaphragm Prepare a clean, flat working surface on a
5 – Oil Fill Cap workbench large enough to accommodate the
6 – Valve Cover Nut cylinder head assembly. Discard all gaskets,
7 – Valve Cover Nut O-Ring
O-rings and seals. Use new gaskets, O-rings and
8 – Valve Cover Gasket
9 – Support Bolt
seals on reassembly of the cylinder head.
10 – Rocker Arm Shaft Support 1. Drain the coolant from the engine into a suitable
11 – Wave Washer container. See Drain, Flush and Refill Cooling
12 – Fuel Injector Retainer Bolt
System With New Coolant on page 5-36.
13 – Valve Adjusting Screw (Primary)
14 – Valve Adjusting Screw Lock Nut (Primary)
15 – Rocker Arm Shaft Aligning Stud CAUTION
16 – Fuel Injector Retainer Identify all parts and their location using
17 – Valve Stem Seal an appropriate method. It is important
18 – Valve Guide that all parts are returned to the same
19 – Cylinder Head position during the reassembly process.
20 – Intake Valve
0000080en
21 – Exhaust Valve
22 – Cylinder Head Gasket 2. Remove the high pressure fuel injection lines
23 – Fuel Injector Nozzle Protector
(Figure 6-40, (1)). See Removal of Fuel
24 – Fuel Injector Nozzle Seat
25 – Valve Spring
Injectors on page 7-35.
26 – Valve Bridge Guide
27 – Spring Retainer
28 – Valve Keepers
29 – Valve Bridge (1)
30 – Valve Bridge Seat
31 – Valve Adjusting Screw Lock Nut
(Secondary)
32 – Valve Adjusting Screw (Secondary)
33 – Push Rod
34 – Rocker Arm Shaft
35 – Crankcase Breather Components
36 – Valve Cover (3)
(2)
0001876
Figure 6-40

CAUTION (2)
possible. Disassembling the (3) (6)
(1)
high-pressure fuel injection lines from (7)
the retainers or bending any of the fuel (5)
(4)
fuel lines.
0000047en
3. Disconnect the fuel return hose

(Figure 6-40, (2)) from the cylinder head. (12)
4. Disconnect the hoses (Figure 6-40, (3)) from
the cold start device on the fuel injection pump. (11) (8)
This cooling water pipe is not used in (10) (9)
0001860
electronically controlled engines 4TNV84T-Z,

Figure 6-41
4TNV98-Z, 4TNV98-E and 4TNV98T-Z.
Instead, these engines use a solenoid valve 10. Remove the engine coolant pump. See
and connecting coupler but, when removing the Disassembly of Engine Coolant Pump on
cylinder head only, it is not necessary to remove page 8-10.
the connecting coupler.
5. Remove the turbocharger-to-intake manifold
hose (Figure 6-41, (1)) (if equipped).
6. Disconnect the electrical wire from the intake air
heater (Figure 6-41, (12)).
7. Remove the intake manifold bolts
(Figure 6-41, (11)). Remove the intake
manifold (Figure 6-41, (10)). Discard the intake
manifold gasket (Figure 6-41, (9)).
8. Disconnect the turbocharger oil supply
(Figure 6-41, (2)) and the return lines
(Figure 6-41, (4)) (if equipped).
9. Remove the exhaust manifold bolts
(Figure 6-41, (7)). Remove the exhaust
manifold (Figure 6-41, (6)) with the
turbocharger attached. Discard the exhaust
manifold gasket. (Figure 6-41, (5)).

Removal of Valve Cover

Note: The high pressure fuel injection lines and (3)
valve cover grommets must be removed
prior to removing the valve cover. See (4)
Removal of Fuel Injectors on page 7-35.
(5)
1. Remove the high-pressure fuel lines.
2. Use a flat-blade screwdriver (Figure 6-42) to
remove the fuel injection line grommets
(Figure 6-43, (1)) from the valve cover
(Figure 6-43, (3)) and fuel injectors (2)
(6)
(Figure 6-43, (2)). There is a notch at the 3 (1)
o’clock position in the valve cover opening to
insert the screwdriver.
Figure 6-42
3. Remove the valve cover nuts (Figure 6-43, (4)). 0001877
4. Remove the O-ring (Figure 6-43, (5)) on each Figure 6-43

valve cover nut.
5. Remove the valve cover (Figure 6-43, (3)).
Discard the valve cover gasket
(Figure 6-43, (6)).
6. Inspect and clean the crankcase breather
assembly. See Inspect Crankcase Breather
System on page 5-40.

Removal of Rocker Arm Assembly Disassembly of Rocker Arm Assembly
1. Remove the fuel injectors from the cylinder Note: Identify the rocker arms so they can be
head. See Removal of Fuel Injectors on reinstalled with the original matching
page 7-35. valve and pushrod.
2. Remove the bolts (Figure 6-44, (1)) that retain 1. Remove the rocker arm shaft alignment studs
the rocker arm shaft supports to the cylinder (Figure 6-45, (5)) from the rocker arm shaft
head. supports (Figure 6-45, (6)).
3. Remove the rocker arm and shaft assembly 2. Slide the supports, wave washers
from the cylinder head. (Figure 6-45, (7)), rocker arms
Note: Identify the push rods and valve bridges (Figure 6-45, (8)), and fuel injector retainers
so they can be installed in their original (Figure 6-45, (4)) off the rocker shaft
locations. (Figure 6-45, (1)), leaving these parts in order
on the bench surface.
4. Remove the push rods (Figure 6-44, (2)).
5. Remove the valve bridge assemblies (1)
(Figure 6-44, (3)). Remove the seat
(Figure 6-44, (4)) from each valve bridge. (3)
6. Identify all parts so that they will be reinstalled (2)
(4) (5)
in their original locations.
(1)
(8)
(7)
(6)
0001866
(4)
(3) Figure 6-45
(2)
Note: Figure 6-45 shows components for one
order.
3. Remove the valve adjusting screw
(Figure 6-45, (2)) and the lock nut
000187
(Figure 6-45, (3)) from the rocker arms.
Figure 6-44

Removal of Cylinder Head

1. Loosen the cylinder head bolts following the (1)
sequence shown in (Figure 6-46).
(2)
8 14 5
2 12 9 3
(1)
4 10 11 1
6 13 7
(2)
7 16 14 6
1 9 18 12 4
(1)
3 11 17 10 2
5 13 15 8 (2)
0001864
1 – Cooling Fan End

2 – Camshaft Side
Figure 6-46 0001872
2. Remove the cylinder head bolts Figure 6-47

(Figure 6-47, (1)).
Removal of Intake and Exhaust Valves
3. Lift the cylinder head away from the cylinder
block. Discard the cylinder head gasket 1. Place the cylinder head on the work bench with
(Figure 6-47, (2)). Place the cylinder head on the combustion side down.
the work bench to prevent damage to the 2. Using the valve spring compressor tool,
combustion surface. compress one of the valve springs
(Figure 6-48).
0000191
Figure 6-48

3. Remove the valve keepers (Figure 6-49, (1)). Removal of Valve Guides
4. Slowly release the tension on the valve spring. Note: Removal of the valve guides should be
5. Remove the spring retainer (Figure 6-49, (2)), postponed until inspection and
valve spring (Figure 6-49, (3)). measurement procedures have been
performed. See Inspection of Valve
(1) Guides on page 6-57.
(7) (2) 1. Using a drift pin and hammer, drive the valve
(6) guides (Figure 6-50, (1)) out of the cylinder
(3) head.
(4)
(1)
(5)
0001867
0001868
Figure 6-49
Figure 6-50
6. Repeat the procedure with all the remaining
valves. Cleaning of Cylinder Head
Note: If the valves are to be reused, identify Components
them so they can be installed in their
original location.
A WARNING
7. Remove the injector nozzle protectors
(Figure 6-49, (6)) and the seats
(Figure 6-49, (7)).
8. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
valves (Figure 6-49, (5)) from the cylinder FUME / BURN HAZARD!
head. • Always read and follow safety related
9. Remove the valve stem seals precautions found on containers of
(Figure 6-49, (4)). hazardous substances like parts
sealant removers.
or serious injury.
0000014en

Thoroughly clean all components using a non- Inspection of Push Rods

metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other Push Rod Bend
debris. 1. Place the push rods on a flat inspection block or
layout bed.
Inspection of Cylinder Head 2. Roll the push rods until a gap can be observed
Components between a portion of the push rod and the
Visually inspect the parts. Replace any parts that surface of the block or layout bed.
are obviously discolored, heavily pitted or otherwise 3. Use a feeler gauge to measure the gap
damaged. Discard any parts that do not meet its (Figure 6-51). See Push Rod on page 6-9 for
specified limit. the service limit.
CAUTION
Any part which is found defective as a
0000119en
CAUTION
Any part determined to not meet the 0000204
service, as determined from the state of Figure 6-51
Inspection of Rocker Arm Assembly
service standard limit. Rocker Arm Shaft Hole Diameter
0000120en
1. Use a telescoping gauge and micrometer to
determine if the inside diameter of all the rocker
arm support brackets and the rocker arms
(Figure 6-52) are within the specified limits.
See Rocker Arm and Shaft on page 6-9 for the
service limit.
2. Inspect the contact areas (Figure 6-52, (1)) for
excessive wear or damage.

Inspection of Valve Guides
Valve Guide Inside Diameter
Visually inspect the valve guides for distortions,
scoring or other damage.
Note: Measure the valve guides while they are
(1) installed in cylinder head.
(1)
Use a telescoping gauge and micrometer to
measure the inside diameter at each end of the
0001916 valve guide. Measure in three places and 90° apart
(Figure 6-54). See Intake / Exhaust Valve and
Figure 6-52 Guide on page 6-7 for the service limit. Replace the
valve guides if not within specification.
Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm shaft
diameter (Figure 6-53). Measure at each rocker
arm location in two directions 90° apart
(Figure 6-53). See Rocker Arm and Shaft on
page 6-9 for the service limit. 0001869
Figure 6-54
Inspection of Cylinder Head

Cylinder Head Distortion
Place the cylinder head flat and inverted
(combustion side up) on the bench. Use a straight
edge and feeler gauge to measure cylinder head
distortion (Figure 6-55). Measure diagonally and
along each side. See Cylinder Head on page 6-6
for the service limit.
0001952
Figure 6-53
0000192
Figure 6-55

If distortion exceeds the service limit, resurface or Valve Stem Bend

replace the cylinder head. Remove only enough Place the valve stem on a flat inspection block or
material to make the cylinder head flat, but do not layout bed. Roll the valve until a gap can be
remove more than 0.008 in (0.20 mm). observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
Inspection of Intake and Exhaust Valves to measure the gap (Figure 6-57). See
Visually inspect the intake and exhaust valves. Intake / Exhaust Valve and Guide on page 6-7 for
Replace any valves that are obviously discolored, the service limit.
heavily pitted or otherwise damaged.
Valve Stem Diameter

Use a micrometer to measure the valve stem
diameter. Measure the valve stem near the
combustion end and near the opposite end
(Figure 6-56, (1)). See Intake / Exhaust Valve and
Guide on page 6-7 for the service limit.
(1) 0000199
Figure 6-57
0000197 Valve Recession
Note: The valve guides must be installed to
Figure 6-56 perform this check.
Insert the valves into their original locations and
press them down until they are fully seated. Use a
depth micrometer (Figure 6-58) to measure the
difference between the cylinder head gasket
surface and the combustion surface of each
exhaust and intake valve (Figure 6-59). See
Cylinder Head on page 6-6 for the service limit.
0000193
Figure 6-58
Note: 2-Valve cylinder head is shown. 4-Valve
cylinder head is similar.

Coat the valve seat with a thin coat of bluing
compound. Install the valve and rotate to distribute
bluing onto the valve face. The contact pattern
should be approximately centered on the valve face
(Figure 6-60, (1)) and even in width.
0001755
Figure 6-59
Valve Face and Valve Seat

Always check the clearance between the valve and
(1)
valve guide before grinding or lapping the valve
seats. See Intake / Exhaust Valve and Guide on
page 6-7 for the service limit. If the clearance
exceeds the limit, replace the valve and/or valve 0001691B
guide to bring the clearance within the limit.
Figure 6-60
Roughness or burrs will cause poor seating of a
Also visually inspect the valve seat for even
valve. Visually inspect the seating surfaces of each
contact.
valve and valve seat to determine if lapping or
grinding is needed. Light cutting can be performed by the use of a
hand-operated cutter (Figure 6-61).
Visually inspect all valves faces and valve seats for
pitting, distortion, cracking, or evidence of
overheating. Usually the valves and valve seats can (1)
be lapped or ground to return them to serviceable 150° 40°
condition. Severely worn or damaged components
will require replacement. (3)
(2)
0001862
Figure 6-61
Valve seat diameter can be adjusted by top-
grinding with a 150° stone to make the seat
diameter smaller, and bottom-grinding using a 40°
stone to make the seat diameter larger. Once the
seat location has been corrected, grind and lap the
seat angle (Figure 6-61, (1)) to specification. See
Cylinder Head on page 6-6 for specifications.

Grind the valve face and/or valve seat as necessary Free Length
to return them to serviceable condition. Grinding is Use a caliper to measure the length of the spring
needed if the valve and valve seat do not contact (Figure 6-63). See Valve Spring on page 6-10 for
correctly. Check the valve margin and valve the service limit.
recession after grinding.
If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
2
3
1
4
Be sure to thoroughly wash all parts to remove all
5
9
6
grinding powder or compound.
8
7
Inspection of Valve Springs
Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
limits, replace the springs. 0000200
Figure 6-63
Fractures
Check for fractures on the inside and outside Inspection of Valve Bridges
portions of the springs. If the valve spring is
Visually inspect the contact surface at both ends of
fractured, replace the valve spring.
the valve bridge (Figure 6-64, (2)) for excessive
Corrosion wear or mushrooming.
Check for corrosion of spring material caused by Remove and inspect the seat (Figure 6-64, (1)).
oxidation.
Measure the diameter of the valve bridge guide pin
Squareness bore in the valve bridge and guide pin
Use a flat surface and a square to check each (Figure 6-64, (3)). See Rocker Arm and Shaft on
spring for squareness (Figure 6-62). See Valve page 6-9 for the service limit.
Spring on page 6-10 for the service limit.
(1)
(2)
(3)
0000201
Figure 6-64
Figure 6-62

Reassembly of Cylinder Head 3. Finish installing the valve guides
(Figure 6-66, (1)) into the cylinder head to the
Use new gaskets, O-rings, and seals on proper height (Figure 6-66, (3)) using the valve
reassembly of the cylinder head. guide installation tool (Figure 6-66, (2)). See
IMPORTANT Intake / Exhaust Valve and Guide on page 6-7.
Liberally oil all components during
reassembly to prevent premature wear or (2)
damage.
Reassembly of Valve Guides

1. The valve guides are installed into the cylinder (3)
head with an extremely tight press fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes (1)
0001756A
This will cause the valve guides to contract,
making it easier to install the valve guides into Figure 6-66
place.
2. Immediately after removing the valve guides Reassembly of Intake and Exhaust Valves
from the freezer, insert the valve guides IMPORTANT
(Figure 6-65, (1)) in their proper positions. When installing valve stem seals, use new
ones instead of reusing removed seals.
(1)
Exhaust valve and intake valve stem seals
are different. They can be distinguished
based on the paint marks on the outer side
of the seal or the color of the seal spring
(Figure 6-67, (4)). When installing each
stem seal, take care to correctly position it.
Marking
Engine Model
Intake Exhaust
0001868 White (Seal Black (Seal
4TNV84
Spring) Spring)
Figure 6-65
4TNV94L,4TNV98,
Black (Seal
4TNV98T,4TNV106, None
Spring)
4TNV106T
1. Oil the lip of the valve stem seal

(Figure 6-67, (2)). Using the valve stem seal
installation tool (Figure 6-67, (1)), install a new
valve stem seal on each of the valve guides
(Figure 6-67, (3)).

(1)
(7) (2)
(6)
(1) (3)
(4)
(2)
(3)
(5)
0001873
Figure 6-67 0001867
2. Measure the distance (Figure 6-68, (1)) from Figure 6-69

the cylinder head to the valve stem seal to
ensure proper clearance (Figure 6-68, (2)) 5. Place the cylinder head on the workbench with
between the guide and seal. See the combustion side down. Install the valve
Intake / Exhaust Valve and Guide on page 6-7. spring (Figure 6-69, (3)) and spring retainer
(Figure 6-69, (2)).
6. Using the valve spring compressor tool,
compress the valve spring.
7. Insert the valve keepers (Figure 6-69, (1)) and
slowly release the tension in the valve spring.
(2)
(1) Repeat the steps on all the remaining valves.
Reassembly of Cylinder Head

1. Carefully clean both the combustion surface of
the cylinder head and the top surface of the
0001874 cylinder block. Then place a new cylinder head
Figure 6-68 gasket (Figure 6-70, (2)) on the cylinder block.
2. Position the cylinder head on the on the cylinder
3. Place the cylinder head assembly on its head gasket.
exhaust port side.
4. Place all the valves (Figure 6-69, (5)) in their
proper location in the cylinder head.

(2)
(1) 7 1 10
13 3 6 12
(1)
11 5 4 14
9 2 8
(2)
12 3 5 13
18 10 1 7 15
(1)
16 8 2 9 17
14 6 4 11
0001875
1 – Fan End
2 – Camshaft Side
Figure 6-71
(2)
Reassembly of Rocker Arm Assembly
1. Reinstall the valve bridges (Figure 6-72, (3)) in
their original locations and ensure each seat
0001872 (Figure 6-72, (4)) is in place.
Figure 6-70 2. Insert the push rods (Figure 6-72, (2)) in their
original locations.
3. Lightly oil the threads of the cylinder head bolts
(Figure 6-70, (1)). Tighten the bolts to the
specified torque in two steps as shown in the (1)
chart below. Tighten in the sequence shown in
(Figure 6-71). See Special Torque Chart on
page 6-25 for specification.
First Step 1/2 of final torque
Second Step Final torque
(4)
(3)
(2)
0001871
Figure 6-72

IMPORTANT Note: To properly align the rocker arm shaft

The wave washers (Figure 6-73, (2)) must with the rocker arm shaft supports, first
be installed with the bow facing the rocker reinstall one of the end rocker arm
arms (Figure 6-73, (1)). supports (Figure 6-75, (6)) with a hole
for the shaft alignment stud
(Figure 6-75, (5)). Align the hole in the
(1)
(2) rocker arm shaft and the hole in the
rocker arm support bracket. Reinstall the
alignment stud.
(1)
(3)
0001878
(2)
(4) (5)
Figure 6-73
IMPORTANT
Ensure the lubrication holes
(Figure 6-74, (1)) in the rocker arm shaft
are oriented correctly with respect to the
rocker arms (Figure 6-74, (2)). (8)
(7)
(6)
(2) 0001866
Figure 6-75
(1) Note: Figure 6-75 shows components for one
order.
4. Position the rocker arm assembly on a flat
surface. Reinstall the alignment studs
(1) 0001914 (Figure 6-75, (5)).
Figure 6-74 5. Place the rocker arm shaft assembly onto the
cylinder head.
3. Lubricate the rocker arm shaft. Slide the rocker
6. If removed, reinstall the valve adjusting screws
arm supports (Figure 6-75, (6)), wave washers
(Figure 6-75, (2)) and lock nuts
(Figure 6-75, (7)), rocker arms
(Figure 6-75, (3)).
(Figure 6-75, (8)), and fuel injector retainers
(Figure 6-75, (4)) onto the shaft. 7. Align the push rods with their respective rocker
arms.
8. Reinstall and tighten the rocker arm shaft
retaining bolts to the specified torque.
9. Tighten the rocker arm shaft alignment studs.
10. Adjust the valve clearance.
11. Reinstall the fuel injectors. See Installation of
the Fuel Injectors on page 7-42.

Reassembly of the Valve Cover 9. Reinstall the high pressure and fuel return lines.
1. Lightly grease a new valve cover gasket See Installation of the Fuel Injectors on
(Figure 6-76, (6)). Place the gasket in the page 7-42.
groove of the valve cover (Figure 6-76, (3)). 10. Reinstall the coolant pump. See Reassembly of
2. Place the valve cover on the cylinder head. Engine Coolant Pump on page 8-11.
3. Be sure new O-rings (Figure 6-76, (5)) are 11. Reinstall the alternator. See Installation of
installed on the valve cover nuts. Reinstall and Alternator on page 12-16.
tighten the valve cover nuts (Figure 6-76, (4)). 12. Reconnect the turbocharger oil supply and
drain lines.
13. Reconnect the air intake hose.
(3)
(4)
(5)
(2)
(6)
(1)
0001877
Figure 6-76
4. Reinstall the fuel injector grommets
(Figure 6-76, (1)).
5. Reinstall the exhaust manifold using a new
gasket. Tighten the bolts to specification.
6. Reinstall the intake manifold using a new
gasket. Tighten the bolts to specification.
7. Reconnect the fuel injector return hose and fuel
injection pump coolant hoses.
8. Reinstall the high-pressure fuel line grommets
into the valve cover.

ENGINE Measuring and Adjusting Valve Clearance
MEASURING AND ADJUSTING • If there is no valve clearance, and the cylinder

is at TDC of the compression stroke, extreme
VALVE CLEARANCE wear, or damage to the cylinder head or valves
Measure and adjust while the engine is cold. may be possible.
• If adjusting each cylinder individually, the
Notes:
cylinder to be adjusted first does not have to be
• The No. 1 piston position is on the flywheel end the No. 1 cylinder. Select and adjust the
of the engine, opposite the radiator. The firing cylinder where the piston is nearest to the top
order is 1-3-2 for 3-cylinder engines and dead center after turning. Make adjustment for
1-3-4-2 for 4-cylinder engines. the remaining cylinders in the order of firing by
• 3-cylinder engines fire every 240° of crankshaft turning the crankshaft each time.
rotation. • To decrease the number of rotations required
• 4-cylinder engines fire every 180° of crankshaft to check all cylinders, other cylinders can also
rotation. be checked as indicated in the chart below.
• Valve clearance of both the intake and exhaust Example: On a 3-cylinder engine, with the No. 1
valves can be checked with the piston for that piston at TDC on the compression stroke (both
cylinder at top dead center (TDC) of the valves closed), the valves indicated on the top line
compression stroke. When a piston is at TDC of the chart can be adjusted without rotating the
of the compression stroke, both rocker arms crankshaft. To adjust the remaining two valves,
will be loose and the cylinder TDC mark on the rotate the crankshaft until the No. 1 piston is at TDC
flywheel will be visible in the timing port of the on the exhaust stroke (exhaust valve only open).
flywheel housing.
3-Cylinder Engines
Cylinder No. 1 2 3
Valve Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 Cylinder at TDC
• • • •
Compression
No. 1 Cylinder at TDC Exhaust • •
4-Cylinder Engines
Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
• • • •
Compression
• • • •
Compression

Measuring and Adjusting Valve Clearance ENGINE
2-Valve Cylinder Heads
1. Remove the valve cover. See Removal of Valve (2)
Cover on page 6-52.
Note: If adjusting each cylinder individually, the
cylinder to be adjusted first does not
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is
nearest to the top dead center after
turning, and make adjustment for other
cylinders in the order of firing by turning
the crankshaft.
(1)
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to Figure 6-78
TDC on the compression stroke while watching
6. Insert a feeler gauge of the correct thickness
the rocker arm motion and timing grid on the
(Figure 6-79, (1)) (see Adjustment
flywheel. (Position where both the intake and
Specifications on page 6-6) between the rocker
exhaust valves are closed.)
arm and valve cap. Turn the valve adjustment
3. Insert a feeler gauge (Figure 6-77, (1)) screw to adjust the valve clearance so there is a
between the rocker arm and valve cap, and slight “drag” on the feeler gauge when sliding it
record the measured valve clearance. (Use the between the rocker arm and the valve cap. Hold
data for estimating the wear.) the adjusting screw while tightening the valve
adjusting screw lock nut (Figure 6-78, (1)).
(1) Recheck the clearance.
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that you make
the initial clearance adjustment slightly
on the “loose” side before tightening the
lock nut.
(1)
0001782A
Figure 6-77
4. If adjustment is required, proceed to the next
step.
Figure 6-79
5. Loosen the valve adjusting screw lock nut
(Figure 6-78, (1)) and valve adjusting screw 7. Apply oil to the contact surface between the
(Figure 6-78, (2)) on the rocker arm and check adjusting screw and push rod.
the valve for inclination of the valve cap,
8. Rotate the crankshaft. Measure and adjust the
entrance of dirt, or wear.
valves on the next cylinder. Continue until all
the valves have been measured and adjusted.

4-Valve Cylinder Heads IMPORTANT

Do not loosen or tighten the valve adjusting
The 4-valve cylinder head operates two valves with
screw lock nut without holding the valve
a single rocker arm by employing a valve bridge
bridge. Always hold the valve bridge using a
(Figure 6-80, (1)) between the two valves
wrench to prevent bending of the valve
(Figure 6-80, (2)). Clearance (Figure 6-80, (4))
stems.
between the valve bridge and valves must be set
before adjusting the clearance (Figure 6-80, (5)) 4. Loosen the valve bridge adjusting screw lock
between the rocker arm (Figure 6-80, (3)) and nut (Figure 6-81, (1)) while holding the bridge
valve bridge. (Figure 6-81, (3)) with a wrench
(Figure 6-81, (2)).
(5) (3)
(1) (1)
(4)
(3)
(2) (2) (2) 0001917A
Figure 6-81
0001918B
5. To assure the valve bridge contacts the rear

Figure 6-80
valve, apply light, downward (Figure 6-82, (4))
1. Remove the valve cover. See Removal of Valve finger pressure on the valve bridge
Cover on page 6-52. (Figure 6-82, (3), and loosen the valve bridge
adjusting screw (Figure 6-82, (1)), until there is
Note: If adjusting each cylinder individually, the
visible clearance (Figure 6-84, (2)) between the
cylinder to be adjusted first does not
adjusting screw and the front valve.
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is 6. To assure the valve bridge has equal contact
nearest to the top dead center after with the front and rear valves, apply light
turning, and make adjustment for other downward (Figure 6-82, (4)) pressure on the
cylinders in the order of firing by turning valve bridge (Figure 6-82, (3), adjust the valve
the crankshaft 180° each time. bridge adjusting screw ((Figure 6-82, (1)),
(Figure 6-84, (1))) so there is zero
2. Rotate the crankshaft clockwise as seen from “0” clearance (Figure 6-84, (2)) between the
the coolant pump end, to bring No. 1 piston to adjusting screw and the front valve.
TDC on the compression stroke while watching
the rocker arm motion and the timing grid on the (1)
flywheel. (Position where both the intake and (4)
exhaust valves are closed.)
3. Make sure there is clearance (Figure 6-80, (5))
between the valve bridge (Figure 6-80, (1)) and
the rocker arm (Figure 6-80, (3)). (3)
(2) 0001917C
Figure 6-82

Measuring and Adjusting Valve Clearance ENGINE
7. Tighten the lock nut (Figure 6-83, (1)), while
(2)
holding the valve bridge (Figure 6-83, (3)) with
a wrench (Figure 6-83, (2)). Verify that the
valve clearance (Figure 6-84, (2) is zero “0”.
(1)
(3)
.006 (1)
(2) 0001917A .152 m
m
Figure 6-83
(1) 0003566
(3)
Figure 6-85
9. If adjustment is required, proceed to the next
step.
(2)
10. Loosen the valve adjusting screw lock nut
(Figure 6-86, (5)) and valve adjusting screw
(Figure 6-86, (4)) on the rocker arm
0001918D (Figure 6-86, (3)) and check the clearance gap
Figure 6-84 (Figure 6-86, (2)) for evidence of dirt or wear.
Note: There is a tendency for the clearance to
Note: There is a tendency for the clearance to decrease slightly when the lock nut is
decrease slightly when the lock nut is tightened. It is suggested that you make
tightened. It is suggested that you make the clearance adjustment is made
the initial clearance adjustment is made slightly on the “loose” side before
slightly on the “loose” side before tightening the lock nut.
tightening the lock nut.
11. Adjust the valve clearance (Figure 6-86, (2)) by
8. To adjust the actual valve clearance between turning the adjusting screw (Figure 6-86, (4))
the rocker arm and the valve bridge, insert a until there is a slight “drag” on the feeler gauge
feeler gauge (Figure 6-85, (1)) of the correct when sliding it between the rocker arm and the
thickness (See Adjustment Specifications on valve bridge.
page 6-6) between the rocker arm
(Figure 6-85, (2)) and valve bridge
(Figure 6-85, (3)). Record the results and use
this value as an indication of wear.

(3)
(4)
(1) (2) (5)
0001918
Figure 6-86
12. Hold the adjusting screw (Figure 6-86, (4))
while tightening the valve adjusting screw lock
nut (Figure 6-86, (5)). Recheck the clearance.
13. Apply oil to the contact surface between the
adjusting screw and push rod.
14. Rotate the crankshaft to measure and adjust
the set of valves. Continue until all valves are
measured and adjusted.

Crankshaft and Camshaft Components ENGINE
CRANKSHAFT AND CAMSHAFT COMPONENTS

(6)
(1)
(5)
(7)
(3) (4)
(2)
(41)
(40)
(8)
(9)
(39) (10)
(8)
(38)
(37) (11)
(35) (12)
(36) (13)
(34) (14)
(32)
(33) (17)
(29) (16)
(31) (15)
(30) (18)
(19)
(20)
(21)
(22)
(28) (23)
(24)
(25)
(27) (26)
0001963
Figure 6-87

ENGINE Crankshaft and Camshaft Components
1 – Cylinder Block
2 – Camshaft Bushing CAUTION
3 – Gear Case (3TNV94 - 4TNV106) Identify all parts and their location using
4 – Dowel (2 used) an appropriate method. It is important
5 – O-Ring
6 – Front Plate (3TNV82 - 4TNV88)
7 – Gear Case Cover (3TNV82 - 4TNV88)
0000080en
8 – Front Crankshaft Seal
9 – Gear Case Cover (3TNV94 - 4TNV106)
If the engine will be completely disassembled, the
10 – Tappets
11 – Camshaft
following preliminary steps should be performed:
12 – Camshaft Gear Key 1. Disconnect the battery cables at the battery.
13 – Camshaft End Plate
Always disconnect the negative (-) cable first.
14 – Camshaft Gear
15 – Idler Gear Shaft 2. Remove the throttle cable, electrical
16 – Idler Gear Bushing connections, intake and exhaust system
17 – Idler Gear connections, and fuel supply lines from the
18 – Oil Pickup O-Ring engine.
19 – Oil Pickup
3. Remove the alternator. See Removal of
20 – Crankshaft
21 – Parallel Pin
Alternator on page 12-12.
22 – Crankshaft Gear Key 4. Drain the engine coolant from the radiator and
23 – Crankshaft Gear cylinder block. See Drain, Flush and Refill
24 – Crankshaft Pulley Cooling System With New Coolant on
25 – Main Bearing Inserts page 5-36. Remove the cooling system
26 – Main Bearing Cap components from the engine.
27 – Oil Pan
28 – Thrust Bearings 5. Remove the engine from the machine. Mount
29 – Flywheel the engine to a suitable engine repair stand
30 – Connecting Rod Cap having adequate weight capacity.
31 – Connecting Rod Bearing Inserts
32 – Connecting Rod A CAUTION
33 – Wrist Pin Bushing
34 – Circlip Be sure to secure the engine solidly to
35 – Wrist Pin prevent injury or damage to parts due to
36 – Piston the engine falling during work on the
37 – Oil Ring engine.
38 – Second Compression Ring 0000009en
39 – Top Compression Ring
40 – Crankshaft Rear Seal 6. Clean the engine by washing with solvent, air or
41 – Crankshaft Rear Seal Housing steam cleaning. Carefully operate so as to
prevent any foreign matter or fluids from
Disassembly of Engine entering the engine or any fuel system or
Prepare a clean, flat working surface on a electrical components remaining on the engine.
workbench large enough to accommodate the 7. Drain the engine oil into a suitable container.
engine components. Discard all used gaskets, Remove the oil filter.
O-rings and seals. Use new gaskets, O-rings and 8. Remove the cylinder head. See 2-Valve
seals on reassembly of engine. Cylinder Head on page 6-34 or 4-Valve Cylinder
Head on page 6-49.

9. Remove the fuel injection pump from the gear
case / front plate only if it must be sent out for
repair, or will interfere with other procedures
such as “hot tank” cleaning. If the fuel injection
pump does not need to be repaired, leaving it
mounted to the timing gear case or plate will
eliminate the need to re-time it during
reassembly. See Fuel Injection Pump on
page 7-19.
10. Remove the starter motor. See Removal of
Starter Motor on page 11-10.
Disassembly of Camshaft and Timing (1)
Components 0001641A
Discard all gaskets, O-rings and seals. Use new Figure 6-88
gaskets, O-rings and seals on reassembly of the
camshaft and timing components. Checking Timing Gear Backlash
Prior to removing the timing gears, measure the
Removal of Timing Gear Case Cover gear backlash and determine the gear wear.
1. Remove the bolt and washer retaining the Check the backlash between each pair of mating
crankshaft pulley. gears (Figure 6-89). If not within specification,
IMPORTANT replace both mating gears. See Timing Gear
Use care not to damage the threads in the Backlash on page 6-13 for service limits.
end of the crankshaft when removing the Note: Do not allow the gear being checked to
crankshaft pulley. move axially as excess end play could
2. Remove the crankshaft pulley using a gear cause a false reading.
puller.
3. Remove the bolts that retain the gear case
cover to the cylinder block and oil pan.
4. Remove the gear case cover (Figure 6-88, (1)).

Measuring Idler Gear-to-Camshaft Gear

(1)
(2) Backlash
1. Drive a small wooden wedge between the
crankshaft gear and idler gear to prevent the
B B
C C idler gear from rotating.
(7)
A 2. Install the dial indicator to read the camshaft
A
(3) gear backlash. Rotate the camshaft drive gear
against the idler gear to measure the backlash.
(6) (4)
(5) 0001709A
Record the measurement.
3. Check the idler gear-to-fuel injection pump
1 – Fuel Injection Pump Drive Gear drive gear backlash in the same manner as the
2 – Camshaft Drive Gear camshaft drive gear. Record the measurement.
3 – Auxiliary Drive Gear (Optional)
4 – Crankshaft Drive Gear Removal of Timing Gears
5 – Direction of Rotation 1. Remove the bolts from the idler gear shaft
6 – Oil Pump Drive Gear (4TNV94L - 4TNV106) (Figure 6-91, (1)). Remove the idler gear shaft,
7 – Idler Gear idler gear (Figure 6-91, (2)) and bushing
Figure 6-89 (Figure 6-91, (3)).
Note: 3TNV82A - 4TNV88: The oil pump is

driven directly by flats on the crankshaft
drive gear hub.
Measuring Idler Gear-to-Crankshaft Gear

Backlash (2)
1. Install a dial indicator as shown in Figure 6-90. (3)

(1)
0001728A
Figure 6-91
2. Do not remove the crankshaft gear unless it is
damaged and requires replacement. If the gear
must be removed, remove it using a gear puller.
3. Removal of the camshaft gear requires the
0002086
camshaft be removed and placed in a press. Do
not remove the camshaft gear unless it or the
Figure 6-90 camshaft is damaged and requires
2. Rotate the idler gear back and forth to check replacement. See Removal of Camshaft on
the idler gear-to-crankshaft gear backlash. The page 6-76.
total indicator reading is the backlash. Record
the measurement.

CAUTION
Do not loosen or remove the four bolts
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
drive gear from the hub. Correct fuel
injection timing will be very difficult or
0000031en
4. Do not remove the fuel injection pump drive

gear unless absolutely necessary to avoid
damage to the gear or pump. Do not loosen or
remove the four bolts (Figure 6-92, (3))
retaining the pump drive gear to the hub. Only
remove the nut (Figure 6-92, (1)) and washer
(1)
(Figure 6-92, (2)), leaving the hub attached to
the gear. Remove the pump drive gear and hub
as an assembly using a gear puller.
0001695A
Figure 6-93
(3)
(1)
(2)
0000162A
Figure 6-92
Removal of Oil Pan

1. Invert the engine (oil pan up) on the engine
stand.
2. Remove the oil pan (Figure 6-93, (1)).

3. Remove the oil pickup tube (Figure 6-94, (1)) (2)

and O-ring (Figure 6-94, (2)).
60
50 70
40 80
30 90
20 0
10
(1)
0002085A
Figure 6-95
• Method B: Use a feeler gauge to measure the
(2)
clearance between the thrust plate
(1) (Figure 6-96, (1)) and front camshaft bearing
(Figure 6-96, (2)). See Thrust Bearing on
page 6-15 for the service limit.
0001696A (1)
Figure 6-94
(2)
Removal of Camshaft
1. Before removing the camshaft, check the
camshaft end play.
• Method A: Install a dial indicator
(Figure 6-95, (1)) on the cylinder block. Move
the camshaft (Figure 6-95, (2)) back and forth
to measure the end play. Record the
measurement. See Camshaft on page 6-11 for 0001710B
the service limit.
Figure 6-96

2. Remove the two bolts (Figure 6-97, (3)) Removal of Gear Case or Front Plate
retaining the camshaft thrust plate Note: The camshaft must be removed before
(Figure 6-97, (1)). the gear case / front plate can be
removed. See Inspection of Camshaft on
page 6-87.
(2) (5) 1. TNV94 - TNV106: Remove the oil pump.

Note: It is not necessary to remove the fuel
(1) injection pump from the gear case / front
plate to remove the gear case / front
(3) (4) plate. If the fuel injection pump does not
need to be repaired, leaving it mounted
to the timing gear case / front plate will
eliminate the need to re-time it during
0001966
assembly. See Fuel Injection Pump on
page 7-19.
Figure 6-97
2. Remove the bolts (Figure 6-98, (4)).
3. Rotate the engine in the engine stand so that
3. Remove the gear case (Figure 6-98, (1)) or
gravity causes the tappets (Figure 6-97, (5)) to
front plate from the cylinder block. Thoroughly
drop away from the camshaft lobes.
clean all old sealant from the mating surfaces.
Note: Rotate the camshaft at least two turns to
4. Inspect and measure the camshaft bushing.
“bump” any sticking tappets away from
See Camshaft on page 6-11 for the service
the camshaft.
limit. If damaged or worn beyond service limits,
4. Slowly pull the camshaft (Figure 6-97, (2)) remove the camshaft bushing
assembly out of the engine being careful not to (Figure 6-98, (3)).
damage the front camshaft bushing. 5. TNV94 - TNV106: Remove two O-rings
Note: If the engine is not installed on an engine (Figure 6-98, (2)).
repair fixture, stand the engine upright on
the flywheel end mounting flange. Rotate
the camshaft at least two turns to bump
the tappets out of the way to prevent the
tappets from interfering with the removal
of the camshaft.
(3) (1)
Note: The tappets are “mushroom” shaped and
must be removed from inside the engine
crankcase.
(4)
5. Remove the tappets. Mark the tappets so they
can be reinstalled in the same location.
6. Remove the camshaft drive gear
(2)
(Figure 6-97, (4)) only if the gear or camshaft 0001737B
require replacement. Use a knife-edge puller
and a press to remove the gear. The gear is a Figure 6-98
shrink-fit and will need to be heated to
356° - 392°F (180° - 200°C) to remove.

6. TNV84 - TNV88: Remove the O-ring 1. Using a feeler gauge, measure the connecting
(Figure 6-99, (2)) and dowels rod side clearance as shown (Figure 6-100).
(Figure 6-99, (5)). See Connecting Rod on page 6-22 for the
standard limit. If the measurement is out of
specification, replace the crankshaft,
connecting rod, or both.
(3)
(1)
(2) (4)
(5 )
0002016
Figure 6-99
0000219
Disassembly of Crankshaft and Figure 6-100

Piston Components 2. Measure bearing oil clearance prior to removing
the pistons and connecting rods to determine
Removal of Pistons extent of wear. Record the measurements.
CAUTION
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
IMPORTANT
Engines with high operating hours may
have a ridge near the top of the cylinders
that will catch the piston rings and make it
impossible to remove the pistons. Use a
suitable ridge reamer to remove ridges and
carbon prior to removing the pistons.
Note: Pistons can fall from cylinder block if the
engine is inverted. Rotate the engine so
the connecting rods are horizontal before
removing the connecting rod caps.

IMPORTANT (g) Repeat with remaining connecting rods.
Mark the connecting rod caps and
connecting rods so the caps and connecting IMPORTANT
rods stay together. Do not allow the connecting rod to contact
the crankshaft journal during piston
(a) Remove the bearing cap. Do not remove the removal. Damage to the bearing journal
bearing inserts at this time. may result.
(b) Wipe oil from the bearing insert and 3. Use a wooden dowel against the connecting
crankshaft journal surfaces. rod and tap the piston / connecting rod
(c) Place a piece of PLASTIGAGE® assembly out of the cylinder.
(Figure 6-101, (1)) along the full width of the 4. Mark the cylinder number on the piston and
bearing insert. connecting rod.
5. Remove the bearing inserts (Figure 6-103, (2)).
(1)
6. Remove the compression rings
(Figure 6-103, (3)) from the piston using a
piston ring expander.
7. Remove the oil ring (Figure 6-103, (4)) from the
piston using a piston ring expander.
0001898
(3)
Figure 6-101
(4)
IMPORTANT
(5)
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result. (9) (6)
(5)
(d) Reinstall bearing cap and tighten to
specification. See Special Torque Chart on
page 6-25. (8)
(e) Remove bearing cap. (7)
(f) Compare the width of the flattened
PLASTIGAGE to the graduation marks on (2)
the package (Figure 6-102, (1)). The mark
that most closely matches the width of the (1)
flattened PLASTIGAGE will indicate the
bearing oil clearance.
0001960
Figure 6-103
8. Remove the circlips (Figure 6-103, (5)) from
(1) the wrist pin.
9. Remove the wrist pin (Figure 6-103, (6)) and
connecting rod (Figure 6-103, (8)) from the
piston (Figure 6-103, (9)).
0001899
10. Repeat the steps until all pistons are removed
Figure 6-102 and dissembled.

Removal of Crankshaft • Method B: Use a feeler gauge to measure the

1. Remove the flywheel (Figure 6-104, (1)) from clearance (Figure 6-106, (3)) between the
the crankshaft. thrust bearing (Figure 6-106, (1)) and
crankshaft (Figure 6-106, (2)). Record the
2. Remove the bolts from the rear oil seal measurement. See Thrust Bearing on
assembly (Figure 6-104, (2-3)). Remove the page 6-15 for the service limit.
assembly from the engine.
(2)
(3)
(1)
(1)
(2)
(3) 0001962
Figure 6-106
0001707A
Figure 6-104
3. Before removing the main bearing caps,
measure the crankshaft end play. Use either of
the following two methods.
• Method A: Install a dial gauge
(Figure 6-105, (1)) on the cylinder block. Move
the crankshaft (Figure 6-105, (2)) in and out to
measure the end play. Record the
measurement.
(1)
(2)
0001961
Figure 6-105

4. Remove the main bearing caps
(Figure 6-107, (3)). Be sure to note the (1)
markings on the main bearing caps, or mark
them yourself, so they can be reinstalled in the
same order as they were removed. Do not
remove the bearing inserts at this time.
Note: The “arrows” on the main bearing caps
point to the flywheel end of the engine. 0001898
Figure 6-108
IMPORTANT
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result.
(c) Reinstall bearing caps and tighten to
specification. See Special Torque Chart on
page 6-25.
(d) Remove bearing caps.
(e) Compare the width of the flattened
(2) PLASTIGAGE to the graduation marks on
the package (Figure 6-109, (1)). The mark
that most closely matches the width of the
flattened PLASTIGAGE will indicate the
bearing oil clearance.
(1)
(1)
(3)
0001752A
Figure 6-107 0001899
5. Measure bearing oil clearance prior to removing Figure 6-109

the crankshaft to determine extent of wear. 6. Remove the crankshaft from the engine.
Record the measurements.
7. Remove the bearing inserts (Figure 6-107, (1))
(a) Wipe oil from the bearing insert and and thrust bearings (Figure 6-107, (2)).
crankshaft journal surfaces.
Note: Do not remove the crankshaft gear
(b) Place a piece of PLASTIGAGE unless the gear or crankshaft are
(Figure 6-108, (1)) along the full width of damaged and require replacement.
each bearing insert.

8. If necessary, remove the crankshaft gear 2. Apply a continuous bead of ThreeBond Liquid
(Figure 6-110, (1)), parallel pin Gasket No. 1212, Yanmar Part No. 977770-
(Figure 6-110, (2)) and key (Figure 6-110, (3)). 01212 to the outside diameter of a new oil seal
If using a gear puller, be careful not to damage (Figure 6-111, (2)), and install in the gear case
the threads in the end of the crankshaft. cover. Apply lithium grease to the lip of the seal.
(2)
(3)
(1)
0001731A
(1)
Figure 6-110
Inspection of Crankshaft and

Camshaft Components (2)
A WARNING 0001735A
Figure 6-111
3. Remove the rear oil seal (Figure 6-112, (3))
from the seal housing (Figure 6-112, (2)).
4. Apply a continuous bead of ThreeBond Liquid
FUME / BURN HAZARD! Gasket No. 1212, Yanmar Part No. 977770-
• Always read and follow safety related 01212 to the outside diameter of a new oil seal
precautions found on containers of (Figure 6-112, (2)), and install in the housing.
hazardous substances like parts Apply lithium grease to the lip of the seal.
sealant removers.
(2)
or serious injury.
0000014en (3)
Thoroughly clean all components using a brush (1)

and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
debris.
Replacement of Crankshaft Oil Seals

1. Remove the seal (Figure 6-111, (2)) from the
cover (Figure 6-111, (1)). 0001707A
Figure 6-112

Measure Crankshaft Bearing Oil Clearance • On an engine with high hours, the pistons rings
Oil clearance should be checked during should be replaced and the cylinder honed
disassembly to determine the extent of wear, and (See Honing and Boring on page 6-88) or
during assembly to ensure long engine life. The replaced. The piston should be replaced as
same procedure is done for both connecting rods necessary.
and main bearings. 1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s
Inspection of Cylinder Block instructions for correct operation.
1. Ensure that oil passages are clear and 2. Wash the pistons in an appropriate solvent
unobstructed. using a soft brush.
2. Check for discoloration or evidence of cracks. If 3. Visually inspect each piston for cracks. Pay
a fracture is suspected, use the color check particular attention to the ring lands between
method or the Magnaflux method to determine the piston ring grooves.
if the cylinder block is fractured. 4. Measure the diameter of the piston skirt at 90°
3. Inspect cylinders for roundness, taper, or to the wrist pin bore as shown (Figure 6-114).
evidence of scoring. Collect and record the Measurements must be taken at a specified
measurements. Consider honing, reboring or distance (Figure 6-114, (1)) from the bottom of
replacing the cylinder block if the the piston, based on engine model. Record the
measurements are not within specification. measurements. See Piston on page 6-16 for
• Take measurements at three places specifications.
(Figure 6-113) (a, b, c), and in two directions (d
and e) in each cylinder.
a 20 mm
(0.75 in.)
d
e
b
(1)
c
20 mm
(0.75 in.) 0000230B
0000235
Inspection of Pistons, Piston Rings and 5. Subtract the piston measurement from the
greatest measurement acquired during cylinder
Wrist Pin
inspection (see Inspection of Cylinder Block on
Notes: page 6-83) to obtain piston-to-cylinder
• On an engine with low hours, the pistons, clearance. Record the measurements. See
piston rings may be reused if they are found to Piston on page 6-16 for specifications.
be within specifications. The pistons and piston 6. Measure the diameter of the wrist pin bore on
rings must be reinstalled in the same cylinders both sides of the piston (Figure 6-115). See
from which they were originally removed. Piston on page 6-16 for specifications. Record
the measurements.

0000237
0001892
Figure 6-115
7. Measure the outside diameter of the wrist pin in Figure 6-117
three places and at 90° (Figure 6-116). See
Piston on page 6-16 for specifications. Record
the measurements.
0001889
Figure 6-116
8. Using a micrometer, measure the thickness of
each piston ring. See Piston on page 6-16 for
specifications. Record the measurements.
Notes:
• On an engine with low hours, the pistons,
piston rings and cylinders may be reused if they
are found to be within specifications.
• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed
(see Honing and Boring on page 6-88) or
replaced. The piston should be replaced as
necessary.
9. Place each compression piston ring in the
groove as shown (Figure 6-117). Use a feeler
gauge to measure the clearance between the
piston ring and the piston ring land. Record the
measurements. See Piston Ring on page 6-18
for specifications. Replace the piston if not
within specification.

10. To measure piston ring end gap, insert each
compression piston ring (Figure 6-118, (1)),
one at a time, into the cylinder. Use a piston
with the piston rings removed to slide the ring
into the cylinder bore until it is approximately
1.18 in. (30 mm) (Figure 6-118, (2)) from the
bottom of the bore. Remove the piston.
Measure the end gap (Figure 6-118, (3)) of
each piston ring. Record the measurements.
See Piston Ring on page 6-18 for (1)
specifications.
(2)
0001724A
Figure 6-119
2. Place the connecting rod bearing inserts into
the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
(1) specified torque.
(2) 3. Measure the inside diameter. See Crankshaft
on page 6-14 for specifications.
Inspection of Tappets
(3) 1. Inspect the tappet contact surfaces for
0001964 abnormal wear (Figure 6-120, (1)). Normal
Figure 6-118 wear will be even as shown in
(Figure 6-120, (2)). Slight surface defects can
Note: Always check the piston ring end gap
be corrected using an oilstone.
when installing new piston rings. See
Piston Ring on page 6-18 for
specifications. Use a piston ring end gap
filing tool to adjust the piston ring end
gap on new piston rings.
11. Repeat the above steps for each cylinder and
piston assembly.
Inspection of Connecting Rod

1. Measure the wrist pin bushing bore using a (1) (2) 0001725
bore gauge (Figure 6-119, (1)). Replace the
Figure 6-120
bushing if not within specifications. If the
bushing has been removed, measure the inside
diameter of the connecting rod small end
(Figure 6-119, (2)). See Connecting Rod on
page 6-22 for specifications.

2. Measure the outside diameter of the tappet 4. Use the color check method or Magnaflux® to
stem (Figure 6-121, (1)). See Tappet on inspect the crankshaft for cracks. Replace the
page 6-23 for the service limit. crankshaft if evidence of fractures are found.
5. Measure the outside diameter of each crankpin
(Figure 6-123, (2)) and main bearing journal
(Figure 6-123, (1)). See Crankshaft on
page 6-14 for specifications. Take
measurements at several places around each
bearing surface. If not within specification, grind
the journals and install undersize bearings, or
replace the crankshaft.
(1)
0001726A
Figure 6-121
3. Measure the tappet bores in the cylinder block.
See Tappet on page 6-23 for the service limit.
Inspection of Crankshaft
1. Place the crankshaft end journals
(Figure 6-122, (4)) on V-blocks.
2. Place a dial indicator (Figure 6-122, (3)) on a
center main bearing surface.
(2) R
(1)
R
(1)
(3) (2) 0001733A
Figure 6-123
(4) (4) 0000232A
Figure 6-122
3. Rotate the crankshaft and observe runout. See
Crankshaft on page 6-14 for specifications.

Inspection of Camshaft (3)
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 6-124). Place the
indicator on the center bearing journal. (2)
(1)
0001713A
Figure 6-126
0001711
Inspection of Camshaft Bushing and Bores
Figure 6-124 1. Measure the I.D. of the front bushing and the
remaining bores in the cylinder block. See
2. Rotate the camshaft and observe the runout. Camshaft on page 6-11 for specifications.
See Camshaft on page 6-11 for specifications.
2. If the camshaft bushing is not within
3. Measure the height of each lobe specification, replace it using the appropriate
(Figure 6-125, (1)). See Camshaft on service tool. If the remaining bores are not
page 6-11 for specifications. within specification, the cylinder block will
require replacement as there are no bearing
inserts used.
(1)
Inspection of Idler Gear and Shaft
1. Measure the outside diameter
(Figure 6-127, (1)) of the idler gear shaft
(Figure 6-127, (2)). See Idler Gear Shaft and
Bushing on page 6-13 for specifications.
0001712A
2. Measure the inside diameter
Figure 6-125 (Figure 6-127, (3)) of the idler gear bushing
(Figure 6-127, (4)). See Idler Gear Shaft and
4. Measure the diameter of the gear end
Bushing on page 6-13 for specifications.
(Figure 6-126, (1)), intermediate
(Figure 6-126, (2)), and flywheel end
(Figure 6-126, (3)) bearing journals. See (4)
Camshaft on page 6-11 for specifications.
(1) (3)
(2)
0001714A
Figure 6-127

Honing and Boring

CAUTION
Pistons must move freely in the cylinders while
maintaining adequate compression and oil sealing.
If the cylinder walls are scuffed, scored,
out-of-round, or tapered beyond specifications,
rebore and hone to restore cylinders to usable
motion.
condition. Slight imperfections can be corrected by
0000090en
honing alone.
1. Boring - Significant cylinder damage may be (1)
corrected by boring the cylinder to an oversize
dimension. Refer to the appropriate parts
catalog for available oversize pistons and piston
rings.
• Boring a cylinder should always be done in a
properly equipped machine shop.
• A bored cylinder should always be finished with
a hone to properly prepare the cylinder surface
so the new piston rings will seat properly.
• After the cylinder has been bored and honed, 0000248A
install the appropriate oversize pistons and Figure 6-128
piston rings.
2. Honing - Minor cylinder imperfections may be • Use a 50:50 mixture of diesel fuel and engine
corrected by using a rigid cylinder hone oil as a honing fluid.
(Figure 6-129, (1)). Be sure not to exceed the • Use a 300-grit hone at 300 - 1200 rpm
maximum cylinder bore specification. (Figure 6-129).
Deglazing - A used cylinder that did not require
(1)
boring or honing, should always be deglazed with
a ball hone (Figure 6-129, (2)) before installing (2)
new piston rings. This will properly prepare the
cylinder surface to allow new piston rings to seat
properly.
Note: When honing a cylinder, with either a
ridged hone or a ball hone 0000249B
(Figure 6-128, (1)), move the rotating
hone up and down in the cylinder bore to Figure 6-129
accomplish a 30° to 40° crosshatch
pattern (Figure 6-128). This will provide IMPORTANT
the ideal surface for the proper seating of Solvents will not adequately remove honing
new piston rings. residue, resulting in premature piston and
ring wear. Always wash cylinders using hot,
soapy water.

• When honing is completed, wash the cylinder
block with hot water and soap. The cylinder wall (3)
is adequately cleaned when a white rag wiped
(4)
in cylinder comes out clean. Use brushes to
clean all passages and crevices. Rinse with hot (5)
water and dry with compressed air. Apply clean (9) (6)
engine oil to all steel surfaces to prevent (5)
rusting.
Reassembly of Crankshaft and (8)

Piston Components (7)
Notes:
(2)
• Proceed slowly. Make no forced assemblies
unless a pressing operation is called for. All (1)
parts must be perfectly clean and lightly
lubricated when assembled.
0001960
• Use new gaskets, seals and O-rings during
assembly. Figure 6-130
• Liberally apply clean engine oil to all internal 3. Reinstall one circlip (Figure 6-130, (5)) into the
parts during assembly. piston. Ensure the circlip is securely seated in
• All fasteners should be tightened to a given the groove.
torque. If a special torque is not provided in the
Special Torque Chart on page 6-25, tighten to IMPORTANT
standard torque specifications. See Tightening The piston and connecting rod must be
Torques for Standard Bolts and Nuts on assembled together in the correct
page 4-46. orientation. The orientation of the piston
and connecting rod are different depending
Reassembly of Pistons on engine model.
1. Select the parts needed to reassemble the
Piston to Connecting Rod Orientation - By Model
piston and connecting rod for one cylinder.
All TNV models - 82,
2. If removed, install a new wrist pin bushing Only TNV models - 106(T)
84(T), 88, 94, and 98(T)
(Figure 6-130, (7)) using a press and the Orient the piston Orient the piston
appropriate service tool. Be sure to align the oil identification mark identification mark
holes. stamped on top of the stamped on top of the
piston on the same side as piston on the opposite
the rod and cap match side as the rod and cap
marks stamped on the match marks stamped on
connecting rod. the connecting rod.

Note: The actual appearance of the match Piston Assembly - All TNV models - 82, 84(T),
marks on the piston and connecting rod 88, 94, and 98(T)
may vary, but they will always be in the When correctly assembled, the piston
same locations. identification mark (Figure 6-132, (2)) stamped
into the top of the piston will be on the same side
of the connecting rod as the match marks
(1) (Figure 6-132, (4)) stamped into the connecting
rod and connecting rod cap.
When installed in the cylinder, the piston
ML↓844V
identification mark (Figure 6-132, (2)) stamped

on the top of the piston must face the fuel
injection pump side (Figure 6-132, (1)) of the
engine and the embossed mark on the
(2) connecting rod (Figure 6-132, (3)) must face the
flywheel end (Figure 6-132, (5)) of the engine.
E106 R
(6) (1)
0002090
(2)
(3)
(5)
80 80 (3)
0002089 (4)
1 – Piston Identification Mark
2 – Embossed Mark on Connecting Rod
0001967
3 – Rod and Cap Match Marks
1 – Fuel Injection Pump Side of Engine
Figure 6-131 2 – Piston Identification Mark
5 – Flywheel End of Engine
6 – Camshaft Side of Engine
Figure 6-132

Piston Assembly - Only TNV models 106(T)
(3)
When correctly assembled, the identification mark
(Figure 6-133, (2)) stamped into the top of the (4)
piston will be on the opposite side of the connecting
(5)
rod as the match marks (Figure 6-133, (4))
stamped into the connecting rod and connecting (9) (6)
rod cap. (5)
When installed in the cylinder, the piston
identification mark (Figure 6-133, (2)) stamped on (8)
the top of the piston must face the camshaft side (7)
(Figure 6-133, (6)) of the engine and the
embossed mark on the connecting rod
(2)
(Figure 6-133, (3)) must face the flywheel end
(Figure 6-133, (5)) of the engine. (1)
(6) (1)
0001960
Figure 6-134
(2)
(5) Note: If installing new piston rings the end gap
must be checked and adjusted as
necessary. See Inspection of Pistons,
(3) Piston Rings and Wrist Pin on page 6-83
for specifications. Use a piston ring end
gap filing tool to adjust the piston ring
(4)
end gap on new piston rings.
0001967A
Note: Reinstall the top and second piston rings
with the stamped “makers mark”
1 – Fuel Injection Pump Side of Engine (Figure 6-135, (1)) facing the top of the
2 – Piston Identification Mark piston. The “makers mark” may vary in
appearance but will always be located on
the top surface of the piston ring
6 – Camshaft Side of Engine adjacent to the piston ring gap. The oil
ring and oil ring expander can be
Figure 6-133 installed either side up.
1. Lubricate and reinstall the wrist pin
(1)
(Figure 6-134, (3)) through the piston and
connecting rod.
2. Reinstall the second circlip (Figure 6-134, (4))
and ensure it is securely seated in the groove.
0000225A
Figure 6-135

IMPORTANT (1)
Always use a piston ring installation tool
(expander) when installing piston rings.
Never attempt to install piston rings by
hand. (2)
3. Reinstall the oil ring expander
(3)
(Figure 6-136, (4)). Reinstall the oil ring
(Figure 6-136, (3)) with the end gap at 180°
from the expander end gap.
4. Reinstall the second compression ring
(Figure 6-136, (2)). This ring is identified by its
dark color and tapered face profile.
5. Reinstall the top compression ring
(Figure 6-136, (1)). This ring is identified by its
silver color and barrel-shaped face profile.
0001968
IMPORTANT 1 – Top Compression Ring End Gap

The oil ring expander (Figure 6-136, (4)) 2 – Second Compression Ring End Gap
end gap must be located 180° from the oil 3 – Oil Ring End Gap
ring (Figure 6-136, (3)) end gap.
Figure 6-137
(1) Installation of Crankshaft

1. If removed, reinstall the keys and timing gear on
the crankshaft.
(2) 2. Reinstall new bearing inserts
(Figure 6-138, (1)) and thrust bearing
(Figure 6-138, (2)) in the cylinder block and
(3)
main bearing caps. Apply a liberal coat of clean
engine oil to the bearings and crankshaft
journals.
(4)
3. Place the crankshaft into the engine.
0001722B
Figure 6-136 IMPORTANT

The main bearing caps are numbered and
6. Stagger the piston ring end gaps at 120° have arrows for proper positioning. The
intervals (Figure 6-137, (1, 2, 3)). Do not No. 1 cap is at the flywheel end. The arrows
position the top piston ring end gap in line with point toward the flywheel end of the engine.
the wrist pin.
4. Reinstall the main bearing caps
(Figure 6-138, (3)).

5. Apply a light coat of clean engine oil to the Installation of Pistons
bearing cap bolts and tighten the bolts to the
specified torque in two stages (1/2 then full IMPORTANT
torque). See Special Torque Chart on Do not allow the connecting rod to contact
page 6-25 for specifications. the crankshaft journal during piston
installation. Damage to the crankshaft
bearing journal may result.
1. Lubricate the piston, piston rings, and cylinder
with clean engine oil or assembly lubricant.
2. Rotate the crankshaft so the crankpin for the
(2) piston being installed is near bottom dead
center.
IMPORTANT
Ensure the piston ring gaps are located
(1) correctly (Figure 6-140).
(1)
(3)
0001752A
(2)
Figure 6-138
(3)
6. Rotate the crankshaft to assure it turns freely.
7. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212 to the mounting
flange of the seal housing (Figure 6-139, (2)). 1 – Top Compression Ring End Gap
2 – Second Compression Ring End Gap
8. Align the seal housing with the two dowel pins.
3 – Oil Ring End Gap
9. Reinstall seal housing and seal assembly.
Figure 6-140
10. Reinstall the flywheel (Figure 6-139, (1)) and
tighten the bolts to the specified torque. See 3. Using a piston ring compressor, compress the
Special Torque Chart on page 6-25 for piston rings.
specifications.
IMPORTANT
The piston and connecting rod must be
installed in the correct orientation. The
(2) orientation of the piston to the cylinder is
different depending on engine model.
(3)
Piston Orientation to Cylinder - By Model
(1)
All TNV models - 82,
Only TNV models - 106(T)
84(T), 88, 94, and 98(T)
Figure 6-139

Orient the piston Orient the piston Piston Installation - Only TNV models 106(T)
identification mark identification mark When correctly assembled, the identification
stamped on top of the stamped on top of the mark (Figure 6-142, (2)) stamped into the top of
piston on the fuel injection piston on the camshaft
pump side of the engine side of the engine
the piston will be on the opposite side of the
connecting rod as the match marks
Piston Installation - All TNV models - 82, 84(T), (Figure 6-142, (4)) stamped into the connecting
88, 94, and 98(T) rod and connecting rod cap.
When correctly assembled, the piston When installed in the cylinder, the piston
identification mark (Figure 6-141, (2)) stamped identification mark (Figure 6-142, (2)) stamped
into the top of the piston will be on the same side on the top of the piston must face the camshaft
of the connecting rod as the match marks side (Figure 6-142, (6)) of the engine and the
(Figure 6-141, (4)) stamped into the connecting embossed mark on the connecting rod
rod and connecting rod cap. (Figure 6-142, (3)) must face the flywheel end
When installed in the cylinder, the piston (Figure 6-142, (5)) of the engine.
identification mark (Figure 6-141, (2)) stamped
(6) (1)
on the top of the piston must face the fuel
injection pump side (Figure 6-141, (1)) of the
engine and the embossed mark on the
connecting rod (Figure 6-141, (3)) must face the (2)
(5)
flywheel end (Figure 6-141, (5)) of the engine.
(6) (1)
(3)
(4)
(2)
(5)
(3) 3 – Embossed Mark on Connecting Rod
(4) 5 – Flywheel End of Engine
Figure 6-142
Figure 6-141

4. Reinstall the bearing inserts (Figure 6-143, (1)) Reassembly of Camshaft and Timing
in the connecting rod and cap.
Components
5. Apply a liberal coat of clean engine oil to the
bearing inserts and crankshaft journal. Installation of Gear Case or Front Plate
6. Apply a light coat of clean engine oil to the rod 1. If removed, install a new camshaft bushing
cap bolts. Reinstall the connecting rod cap (Figure 6-144, (3)) using the appropriate
(Figure 6-143, (2)). Tighten the connecting rod service tool.
bolts to the specified torque in two stages (1/2
then full torque). See Special Torque Chart on
Gasket No. 1212, Yanmar Part No. 977770-
page 6-25 for specifications.
01212 to the mounting area of the gear case or
front plate. Be sure to circle each bolt hole.
3. 4TNV94 - 4TNV106: Install two new O-rings
(Figure 6-144, (2)) in the cylinder block.
(1)
(2) (1)
(3)
(4)
0001965
Figure 6-143
7. Reinstall the remaining pistons in their (2)
respective cylinders. 0001737B
Figure 6-144

4. TNV84 - TNV88: Reinstall the dowels Note: The tappets are “mushroom” shaped and
(Figure 6-145, (5)) and a new O-ring must be installed from inside the engine
(Figure 6-145, (2)). crankcase.
3. Lubricate the tappets with clean oil or assembly
lube. Reinstall the tappets in their respective
(3) locations in the cylinder block. Push the tappets
fully into the tappet bores so they will not
(1) interfere with the installation of the camshaft.
4. Lubricate the camshaft (Figure 6-146, (2)) with
clean engine oil or assembly lube. Slowly insert
the camshaft through the front of the engine.
5. Reinstall and tighten the cap screws
(2) (Figure 6-146, (3)).
(4)
(5 )
0002016 (2) (5)

Figure 6-145
(1)
5. Reinstall the gear case (Figure 6-144, (1)) or
front plate (Figure 6-145, (1)). Tighten the bolts (3) (4)
to the specified torque.
Installation of Camshaft
Note: The gear housing or front plate must be 0001966
reinstalled prior to installing the
camshaft. See Installation of Gear Case Figure 6-146
or Front Plate on page 6-95. 6. If removed, reinstall the fuel injection pump.
1. If removed, reinstall the camshaft end plate Adjust the fuel injection timing the engine after
(Figure 6-146, (1)), key, and timing gear installation. See Adjusting Fuel Injection Timing
(Figure 6-146, (4)) onto the camshaft using a on page 7-34.
press.
Note: Heat the gear to 356 - 392°F
(180 - 200°C) and press onto the end of
the camshaft.
2. Rotate the cylinder block so that gravity will
keep the tappets (Figure 6-146, (5)) in place
and out of the way of the camshaft lobes when
the camshaft is being reinstalled.
Note: If the engine is not installed on an engine
repair fixture, stand the engine upright on
the flywheel end mounting flange.

Installation of Timing Gears 5. Reinstall the idler gear and idler gear shaft. Be
1. Set the No. 1 piston to top dead center. sure the oil hole in the bushing is facing toward
the top of the engine.
2. Rotate the camshaft until the mark
(Figure 6-147, (C)) is approximately at the 6. Ensure all three timing marks
9 o’clock position. (Figure 6-147, (A, B, C)) are aligned.
7. When all gears are properly aligned, tighten the
(1) idler gear retaining bolts to specified torque.
(2)
See Special Torque Chart on page 6-25 for
specifications.
B B
C C
Installation of Gear Case Cover
A
(7) 1. Apply a continuous bead of ThreeBond Liquid
A
(3) Gasket No. 1212, Yanmar Part No. 977770-
(4) 01212 to the mounting area of the gear case
(6)
(5) 0001709A cover (Figure 6-149, (1)). Be sure to circle the
bolt holes.
1 – Fuel Injection Pump Gear
2 – Camshaft Gear IMPORTANT
3 – Optional Accessory Drive Gear 3TNV84 - 4TNV88 engines: Be sure to
4 – Crankshaft Gear align the flats on the oil pump with the flats
5 – Direction of Rotation on the crankshaft gear when installing the
6 – Oil Pump Gear gear case cover.
7 – Idler Gear
2. Reinstall and tighten the gear case cover bolts.
Figure 6-147
3. Lubricate the idler gear (Figure 6-148, (2)),
bushing (Figure 6-148, (3)) and idler gear shaft
(Figure 6-148, (1)) with clean engine oil.
(2)
(3)
(1)
(1)
0001641A
Figure 6-149
0001728A 3. Reinstall the crankshaft pulley.
Figure 6-148
4. Align the timing gears as shown in
(Figure 6-147).

IMPORTANT Installation of Oil Pan

3TNV82A, 3TNV84, 3TNV84T, 3TNV88, 1. Reinstall the oil pickup tube (Figure 6-151, (1))
4TNV84, 4TNV84T, 4TNV88, 4TNV94L, using a new O-ring (Figure 6-151, (2)).
4TNV98, 4TNV98T: Use the crankshaft
pulley installation tool (Figure 6-150, (3))
when reinstalling the pulley
(Figure 6-150, (1)). The tool will guide the
pulley hub and protect the front seal
(Figure 6-150, (2)) from damage.
(1)
(2)
(2)
(1)
0001696A
Figure 6-151
(3)
Gasket No. 1212, Yanmar Part No.
977770-01212 to the mounting surface of the oil
0002133
pan (Figure 6-152, (1)). Be sure to circle each
bolt hole.
Figure 6-150
3. Reinstall the oil pan and tighten the bolts
4. Reinstall the washer and bolt. Tighten the bolt securely.
to the specified torque. See Special Torque
Chart on page 6-25 for specifications.
(1)
0001695A
Figure 6-152

Final Reassembly of Engine
1. Reinstall the starter motor.
2. Reinstall the cylinder head. See Reassembly of
Cylinder Head on page 6-46 for the 2-valve
cylinder head or 6-62 for the 4-valve cylinder
head.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
5. Reinstall the alternator.
6. Reconnect and adjust the throttle cable.
7. Reconnect all electrical connections.
8. Fill the engine with oil and coolant.
9. Reconnect the battery cables, negative (-) cable
last.

ENGINE EGR system
EGR SYSTEM
EGR system
Applicable engines : 4TNV98-E, 4TNV98-Z
(8) (11) (12)
(1) (4) (5)
Figure 6-153

EGR system ENGINE
Applicable engines : 4TNV84T-Z, 4TNV98T-Z
(11) (12)
(13)
(1) (8)
(6)
(7)
(2) (9) (3) (10) (4) (5)
Figure 6-154
1 – Exhaust manifold 8 – Intake manifold

2 – Elbow, EGR cooler inlet 9 – Cooling water hose, EGR cooler inlet
3 – EGR cooler 10 – Cooling water hose, EGR cooler outlet
4 – EGR pipe 11 – Cooling water hose, EGR valve inlet
5 – EGR valve 12 – Cooling water hose, EGR valve outlet
6 – Spacer, EGR lead valve 13 – Turbocharger
7 – Lead valve, EGR

ENGINE EGR system
EGR system
A WARNING
A DANGER
BURN HAZARD!
SCALD HAZARD! away from hot engine surfaces such
• NEVER remove the radiator cap if the as the muffler, exhaust pipe,
engine is hot. Steam and hot engine turbocharger (if equipped) and engine
coolant will spurt out and seriously block during operation and shortly
burn you. Allow the engine to cool after you shut the engine down. These
down before you attempt to remove surfaces are extremely hot while the
the radiator cap. engine is operating and could
seriously burn you.
you check the radiator. Steam can • Failure to comply could result in death
spurt out during engine operation if or serious injury.
the cap is loose. 0000015en

coolant by observing the reserve tank. A WARNING
serious injury.
0000002en
service it.
serious injury.
or serious injury.
0000010en

EGR system ENGINE
A WARNING A CAUTION
FUME / BURN HAZARD!

COOLANT HAZARD!
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the
eyes or skin should occur, flush eyes
sealant removers.
and wash immediately with clean
• Failure to comply could result in death water.
or serious injury.
0000014en
or moderate injury.
0000005en
A CAUTION
CAUTION
When it is necessary to replace an EGR
valve, be sure to replace the entire EGR
valve assembly. Neither attempt to
disassemble and repair the EGR valve,
nor replace its individual components.
• ALWAYS wear eye protection when CAUTION
compressed air or high-pressure The EGR system uses steel gaskets at
water. Dust, flying debris, compressed the joints between its
air, pressurized water or steam may components/parts. These steel gaskets
injure your eyes. are specific to the respective joints.
When you remove the system's
• Failure to comply may result in minor components/parts and reinstall them,
or moderate injury. replace the steel gaskets between them
0000003en with new correct ones.

ENGINE EGR system
1. Drain the engine cooling water. 4TNV84T-Z, 4TNV98T-Z

2. Remove the battery cable from the battery's 1. Disconnect the cooling water inlet and outlet
minus (-) terminal. hoses from the EGR cooler by loosening the
3. If there is any additional equipment (such as an hose clips.
air cleaner) installed above the EGR valves, When loosening the clips, put waste cloth or the
remove it in advance. like beneath the hose joints in case water leaks.
4. Remove the EGR valve connectors. 2. Loosen the nuts used to connect the exhaust
manifold with the EGR cooler elbow.
5. Disconnect the cooling water inlet and outlet
hoses from each EGR valve by loosening the 3. Loosen the bolts in the coupling flanges of the
hose clips. When loosening the clips, put waste EGR cooler and EGR pipe, and remove the
cloth or the like beneath the hose joints in case EGR cooler.
water leaks. 4. Remove the elbow from the EGR cooler.
5. Remove the EGR pipe from the EGR valve.
4TNV98-E, 4TNV98-Z
6. Remove the EGR valve.
1. Loosen the nuts in the coupling flanges of the
exhaust manifold and the EGR pipe. 7. Remove the spacer (for the lead valve).
2. Loosen the bolts in the coupling flanges of the 8. Remove the lead valve.
EGR pipe and EGR valve, and remove the EGR
pipe.
(1)
(2) (3)
(1)
1 – Elbow
1 – EGR pipe 2 – EGR cooler
3 – EGR pipe
Figure 6-155
Figure 6-156
3. Remove the EGR valve.

EGR system ENGINE
Inspecting/cleaning EGR related EGR valve operation checks
components 1. After removing each EGR valve from the
engine, connect the valve with the connector.
EGR Valve 2. Connect the valve to the battery's minus (-)
Each EGR valve has four built-in coils. The power terminal.
to each of the four coil is either ON or OFF at any 3. Turn on the key switch.(Note that turning on the
given time. Depending on which coil is ON and key switch causes the E-ECU to check whether
which coil is OFF, the step motor rotates to the valve functions properly by opening and
determine the valve lift. The power to each coil is shutting it.)
turned ON/OFF by the E-ECU based on the engine
4. From the exhaust gas inlet, visually check
speed and fuel injection rate. The resistances of
whether the valve operates correctly.
these coils should be as specified below when
measured between each pair of pins shown. If any Note: If the EGR valve fails to smoothly
of the actually measured values is beyond the operate, replace the entire valve
standard range, replace the entire EGR valve assembly with new one.
assembly. Note: If the EGR valve does not respond at all,
check whether there exists a voltage
(1) (EGR valve signal) between the
connector pins. If the voltage is within the
standard range, then replace the entire
valve assembly with new one.
IMPORTANT
Alternatively, you can remove the EGR pipe
from the engine and check the valve
operation through the gas inlet window,
instead of removing the EGR valve from the
1 – EGR valve connectors engine.
Figure 6-157
Standard value
Terminal Resistance (Ω)
1-2
2-3 15 ± 2
4-5 at 20 °C
5-6
Note: The higher the temperature, the higher

the coil resistance. Therefore, wait for the
EGR valve to return to normal state
before measuring the resistances.

ENGINE EGR system
Cleaning the EGR valves To remove deposited carbon, use compressed air
(0.19MPa(2kg/cm2) or lower). If the valves are
A WARNING heavily fouled, use carbon cleaner, kerosene, or
some other liquid capable of removing carbon as
well as a soft brush to clean the valves, taking care
not to damage their parts.
When cleaning the valves, take extreme care to
prevent water, solvent, cleaner, and other liquid
FUME / BURN HAZARD! from entering into the motor and coupler terminals;
• Always read and follow safety related otherwise, failure may result.
hazardous substances like parts CAUTION
sealant removers.
• Failure to comply could result in death (193 kPa; 19 686 mmAq) or a wire brush
or serious injury. to clean the radiator fins. Radiator fins
0000014en damage easily.
0000016en
A CAUTION Lead valves

Similarly to the EVR valves, the lead valves must
be periodically cleaned every 1500 hours because,
as exhaust gas circulates through them for a
prolonged time, carbon is deposited on their inner
surfaces, possibly deteriorating the EGR ratio.
FLYING OBJECT HAZARD! To remove carbon deposited inside the lead valves,
disassemble and clean them.
(1)
injure your eyes.
(2)
or moderate injury. (3) (4)
0000003en
1 – Case
The EGR valves must be periodically cleaned every 2 – Stopper
1500 hours because, as exhaust gas circulates 3 – Valve
through them for a prolonged time, carbon is 4 – Machine screw
deposited on their inner surfaces, possibly
Figure 6-158
deteriorating the EGR ratio.

EGR system ENGINE
To remove deposited carbon, use carbon cleaner, EGR cooler
kerosene, or some other liquid capable of removing The EGR cooler must be periodically cleaned every
carbon as well as a soft brush or cloth to clean the 1500 hours because the exhaust gas passage is
valves, taking care not to damage their parts. subject to carbon deposition and the cooling water
Upon completion of carbon removal, wipe off water transit portion to scale deposition and these
and liquid, make sure that the case, valve, and depositions gradually deteriorate the cooling of
stopper are free of foreign matter, and then reinstall recirculated gas, thus resulting in higher gas
the valve and related parts. temperatures and lower effective circulation
amounts (EGR ratio).
To remove deposited carbon from the gas passage,
use compressed air (0.19MPa(2kg/cm2) or lower).
Stopper chamfer Then dip the gas passage in carbon cleaner,
kerosene, or some other liquid capable of removing
Exhaust gas
passage hole 17.5
carbon; leave it dry and blow it with compressed air
again.
To clean the water transit portion, dip it in a solution
Assemble without of descaling detergent diluted with water and wash
misalignment.
it.
20 Valve plate
EGR pipe and other connecting elbows
Figure 6-159
The exhaust gas passage is subject to carbon
Precautions for installation deposition when used over time. To remove
deposited carbon from the gas passage, use
1. The valve and stopper must be installed in their compressed air (0.19MPa(2kg/cm2) or lower). If the
specific orientations. As shown in the figure exhaust gas passage is heavily fouled, clean it by
above, install the valve and stopper so that they dipping it in carbon cleaner, kerosene, or some
are located on the left-hand side of the lead other liquid capable of removing carbon.
valve.
2. Install the valve by tightening the machine
screw while ensuring that it is evenly positioned
inside the case window.
3. The machine screw must be tightened with
torque of 1.37±0.2N•m(14±2kgf•cm).
4. After tightening the machine screw, mark it with
a marker to indicate that it has already been
tightened.

ENGINE EGR system
Installing EGR related components/parts

CAUTION
To install these components/parts, reverse the
disassembly procedure described above: thus
install the lead valve, spacer, EGR valve, EGR pipe,
EGR cooler, elbow, cooler cooling water hose, and
EGR cooling water hose exactly in this order.
• ALWAYS be environmentally The EGR system uses steel gaskets at the joints
responsible. between its components/parts. When you remove
the system's components/parts and reinstall them,
• Follow the guidelines of the EPA or replace the steel gaskets between them with new
other governmental agencies for the correct ones.
0000013en

Section 7
FUEL SYSTEM
Page
Introduction...................................................................................... 7-8
Fuel Injection Pump................................................................... 7-8
Stop Solenoid ............................................................................ 7-9
Cold Start Device....................................................................... 7-9
Trochoid Fuel Pump ................................................................ 7-10
Electronically controlled governor............................................ 7-10
Fuel System Specifications ........................................................... 7-11
Special Torque Chart............................................................... 7-11
Test and Adjustment Specifications ........................................ 7-12
Special Service Tools.................................................................... 7-13
Measuring Instruments.................................................................. 7-13
Fuel System Diagram.................................................................... 7-14
Fuel System Components ............................................................. 7-15
2-Valve Cylinder Head............................................................. 7-15
4-Valve Cylinder Head............................................................. 7-17
Fuel Injection Pump....................................................................... 7-19
Removal of Fuel Injection Pump.............................................. 7-19
Installation of Fuel Injection Pump........................................... 7-24
Checking and Adjusting Fuel Injection Timing .............................. 7-30
Determining the Fuel Injection Timing Specification................ 7-30
Checking Fuel Injection Timing ............................................... 7-31
Adjusting Fuel Injection Timing................................................ 7-34

FUEL SYSTEM
Fuel Injectors.................................................................................. 7-35
Removal of Fuel Injectors......................................................... 7-35
Testing of Fuel Injectors ........................................................... 7-38
Disassembly and Inspection of Fuel Injectors .......................... 7-39
Adjusting Fuel Injector Pressure .............................................. 7-41
Reassembly of Fuel Injectors ................................................... 7-41
Installation of the Fuel Injectors................................................ 7-42

Before You Begin Servicing FUEL SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING • Never inject fuel toward you. Since the
fuel is injected at high pressure from
A WARNING the nozzle, it may penetrate the skin,
resulting in injury.
• Never inject fuel toward a fire source.
Atomized fuel is highly flammable and
may cause a fire or burn skin.
0000028en
service it. A WARNING
serious injury. FUME / BURN HAZARD!
sealant removers.
or serious injury.
or serious injury.
0000014en
0000010en
A WARNING A WARNING
• Never use the E-ECU for other
SUDDEN MOVEMENT HAZARD! purposes than intended or in other
• Engaging the transmission or PTO at ways than specified by Yanmar. Doing
an elevated engine speed could result so could result in the violation of
in unexpected movement of the emission control regulations and will
equipment. void the product warranty.
• Failure to comply could result in death • Improper use or misuse of the E-ECU
or serious injury. may result in death or serious injury
0000006en due to an abrupt and unexpected
9999999en

FUEL SYSTEM Before You Begin Servicing
A WARNING A WARNING
• Be sure to use the E-ECU in • Replacing the E-ECU involves
conjunction with the engines whose migrating the fuel injection data to the
models or serial numbers are existing E-ECU to the new unit.
specified by Yanmar. Be sure to contact your local Yanmar
Other E-ECU/engine combinations dealer before replacing the E-ECU.
than specified will void the engine Failure to migrate the fuel injection
warranty. data before replacing the E-ECU will
• Improper use or misuse of the E-ECU void the engine warranty.
may result in death or serious injury • Improper use or misuse of the E-ECU
due to an abrupt and unexpected may result in death or serious injury
increase in engine speed. due to an abrupt and unexpected
9999998en increase in engine speed.
9999996en
A WARNING
• Replacing the fuel injection pump
involves rewriting the fuel injection
data in the E-ECU.
Be sure to contact your local Yanmar
dealer before replacing the fuel
injection pump.
Failure to rewrite the fuel injection
data before replacing the fuel injection
pump will void the engine warranty.
• Improper use or misuse of the E-ECU
9999997en

A CAUTION CAUTION
• NEVER remove or attempt to remove
the tamper-proof devices from the
full-load fuel adjusting screw or the
high-speed throttle limit screw on the
fuel injection pump and governor
assembly. These adjustments have
FLYING OBJECT HAZARD! been made at the factory to meet all
• ALWAYS wear eye protection when then sealed.
compressed air or high-pressure • NEVER attempt to make any
water. Dust, flying debris, compressed adjustments to these sealed
air, pressurized water or steam may adjustment screws. If adjustments are
injure your eyes. required, they can be made only by a
qualified fuel injection shop that will
• Failure to comply may result in minor ensure the injection pump continues
or moderate injury. to meet all applicable emissions
0000003en regulations and then replace the
tamper-proof seals.
A CAUTION • Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.”
0000146en
CAUTION
PINCH HAZARD! Never use a steel wire brush to clean
Carefully rotate the alternator toward the fuel injectors. Damage to the nozzle and
cylinder block while loosening the other components is likely to result.
V-belt. Failure to comply may result in 0000172en
minor or moderate injury.

0000014en CAUTION
Allow the engine to warm-up for at least
five minutes and the idle speed of the
engine to return to normal before
Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the
equipment.
0000159en

FUEL SYSTEM Before You Begin Servicing
CAUTION CAUTION
Remove or install the high-pressure fuel Shut down the engine if the fault
injection lines as an assembly whenever indicator comes on.
possible. Disassembling the Continuing running the engine with the
high-pressure fuel injection lines from fault indicator being on may result in a
the retainers or bending any of the fuel serious malfunction of or damage to the
lines will make it difficult to reinstall the engine, and will void the engine
fuel lines. warranty.
0000047en
9999999en
CAUTION CAUTION
After marking the position of the pump Do not energize the starter for a period
drive gear, do not rotate the engine of longer than 15 seconds.
crankshaft. Rotating the crankshaft will
cause the fuel injection pump to become Take a pause of at least 30 seconds
misaligned. between energization of the starter.
0000048en Otherwise the starter could suffer
damage.
CAUTION 9999998en

retaining the fuel injection pump drive CAUTION
gear to the fuel injection pump hub. Do • High-pressure washing not
not disassemble the fuel injection pump recommended.
drive gear from the hub. Correct fuel
• Avoid using high-pressure washing for
electronic or electric devices installed
in, on or around the engine, including
0000031en
the E-ECU, relays and harness
couplers.
CAUTION Otherwise such devices may suffer
Do not rotate the crankshaft with the malfunction due to water ingress into
injection pump removed. them.
0000083en 9999997en
CAUTION
Each pressure adjusting shim removed
or added changes the pressure
threshold by approximately 275 psi
shims increases the threshold pressure.
pressure threshold.
0000081en

CAUTION
• Do not plug or unplug the E-ECU for a
period of at least 6 seconds after
power to the unit has been turned on
or off.
• Do not touch connector pins of the E-
ECU with bare hands.
Doing so may result in corrosion of the
connector pins and/or damage to the
internal circuits of the E-ECU due to
static electricity.
• Do not force a measuring probe into
the female coupler.
Doing so may cause contact failure of
• Take care to prevent water from
entering the couplers when plugging
or unplugging the connector.
Water inside the couplers may cause
corrosion, resulting in malfunction of
the E-ECU.
• Avoid plugging/unplugging the
connector more than approx. 10 times.
Frequent plugging/unplugging of the
connector may cause contact failure of
• Do not use the E-ECU that has ever
suffered drop impact.
9999996en
CAUTION
Always check the battery for proper
charge.
Otherwise the electronically controlled
engines may fail to start.
9999995en

FUEL SYSTEM Introduction
INTRODUCTION
This section of the Service Manual describes the
procedures necessary to remove, install, and time
the MP fuel injection pump and its associated
system components. This fuel injection pump is
representative of the fuel injection pumps used on
other TNV DI model engines. The descriptions
given in this section basically apply also to fuel
injection pumps used for electronically controlled
engines unless otherwise described herein.
Fuel Injection Pump 0000038
Note: If the MP fuel injection pump itself Figure 7-1

requires servicing, it must be taken to an The following describes the features of the MP fuel
authorized Yanmar FIE (Fuel Injection injection pump, manufactured by Yanmar.
Equipment) repair facility.
The fuel injection pump is a very important
component of the engine. It is capable of making
CAUTION
very precise fuel delivery adjustments according to
• NEVER remove or attempt to remove the varied loads applied to the engine.
full-load fuel adjusting screw or the All of the fuel injection pump components are very
high-speed throttle limit screw on the precisely machined. It is extremely important to
fuel injection pump and governor follow good service practices and maintain
assembly. These adjustments have cleanliness when servicing the fuel injection pump.
been made at the factory to meet all
The Yanmar MP “Mono-Plunger” Fuel Injection
Pump is a distributor type pump which consists of a
then sealed.
single fuel supply plunger, a distributor shaft, a
• NEVER attempt to make any hydraulic head and a pump housing. The hydraulic
adjustments to these sealed head has a delivery valve for each cylinder. The
adjustment screws. If adjustments are fuel injection pump housing contains a governor
required, they can be made only by a and an internal camshaft.
ensure the injection pump continues The fuel is pressurized by the up and down motion
to meet all applicable emissions of the camshaft-driven single plunger. It is then
regulations and then replace the distributed to the proper fuel injector by the rotating
tamper-proof seals. distributor shaft.
• Tampering with or removing these There are two versions and sizes of the MP Fuel
devices may void the “Yanmar Limited Injection Pump. The smaller of the two pumps, the
Warranty.” MP2 pump, is used on the 3TNV82A - 4TNV88
0000146en model engines. The larger pump, the MP4 pump,
which has a larger single plunger and a more
aggressive cam profile, is used on the
4TNV94L - 4TNV106T model engines.

Introduction FUEL SYSTEM
Stop Solenoid Electronically controlled engines 4TNV84T-Z,
4TNV98-Z, 4TNV98-E, and 4TNV98T-Z are
The MP fuel injection pumps are equipped with a designed so that, when the key is turned on or off,
stop solenoid that controls the fuel flow inside the the corresponding signal is sent to the E-ECU.
fuel injection pump. Thus the E-ECU controls the rack actuator to
With the starter switch in the OFF position, no provide a sufficient injection rate when the engine is
current flows to the stop solenoid and the solenoid started up (the key is turned on) or cut the fuel
plunger is extended holding the fuel injection pump supply and stop then engine when the key is turned
fuel rack in the “closed” position and not allowing off. Therefore, these electronically controlled
fuel to flow through the injection pump and to the engines does not have a stop solenoid.
engine.
Cold Start Device
When the starter switch is turned to the start
The Yanmar TNV model engines are equipped with
position, the “pull coil” (36.5 Amp draw / white wire)
a cold start device (CSD).
inside the solenoid is activated and pulls the
solenoid plunger into the solenoid. This releases The cold start device is located in the upper section
the fuel injection pump fuel rack, allowing fuel to of the fuel injection pump and is connected to the
flow through the injection pump and allowing the engine’s cooling system.
engine to start and run.
• The cold start device improves engine starting at
When the starter switch is returned to the ON or lower temperatures. At engine cooling system
RUN position, the “pull coil” no longer receives temperatures below 41°F (5°C), the cold start
current and the “hold coil” (0.5 Amp draw / red wire) device advances the fuel injection timing and
inside the solenoid is activated. The “hold coil” slightly increases the fuel injection volume.
holds the solenoid plunger in the RUN position,
allowing fuel to continue flowing and he engine to • For approximately the first 5 minutes of operation,
continue running. the idle speed of the engine will be slightly
elevated.
To stop the engine, the key switch is turned to the
OFF position. Current no longer flows to the stop
CAUTION
solenoid “hold coil”, and the solenoid plunger
extends and moves the injection pump fuel rack to Allow the engine to warm-up for at least
the “closed” position, shutting off the fuel flow and five minutes and the idle speed of the
stopping the engine. engine to return to normal before
Failure of the stop solenoid could result in the Engaging the transmission or PTO at an
engine not starting, the engine stopping suddenly, elevated engine speed could result in an
the engine not continuing to run with the key switch unexpected movement of the
returned to the ON or RUN position, or the engine equipment.
failing to stop when the key switch is turned to the 0000159en
OFF position. Use a multimeter or continuity light to
check for 12V at the stop solenoid connector in the • When the cold start device is activated, you may
correct sequence. notice a slight increase in the exhaust smoke of
the engine during engine warm-up.
Electronically controlled engines 3TNV84T-Z,
4TNV84T-Z, 4TNV98-Z, 4TNV98-E, and
4TNV98T-Z use a cold start device (CSD) that
consists of a fuel injection pump complete with a
solenoid valve (Figure 7-2, (1)).

FUEL SYSTEM Introduction
(2) (1) Electronically controlled governor

Electronically controlled engines 4TNV84T-Z,
(4) 4TNV98-Z, 4TNV98-E, and 4TNV98T-Z are
quipped with an electronically controlled governor
called "Eco Governor". Combined with the rack
(3) actuator (Figure 7-2, (3)), engine speed sensor
(Figure 7-2, (5)), and other parts, the electronically
controlled governor communicates with the engine
controller (E-ECU), whereby the engine speed and
fuel injection rate are controlled.
(6)
(5)
Figure 7-2
• When the engine is started with the cooling water
sensor detecting a low water temperature of 10Åé
or lower and the E-ECU receives the
corresponding signal, then the E-ECU causes the
CSD's solenoid valve to increase the injection
rate and advance the injection timing.
• Because of this, the engine speed increases by
approximately 75 min-1 while the CSD is
operating. When the water temperature becomes
10°C or higher, the CSD is turned off and the
engine returns to the normal speed.
Trochoid Fuel Pump

Note: The trochoid fuel pump located on the
side of the MP fuel injection pump is not
a “fuel supply” pump. The function of this
pump is to raise the pressure of the fuel
supplied by the electric fuel supply pump
to the internal fuel pressure required by
the MP fuel injection pump.
The use of an electric fuel supply pump is required
on all TNV model engines with the MP fuel injection
pump.

Fuel System Specifications FUEL SYSTEM
FUEL SYSTEM SPECIFICATIONS

Special Torque Chart
Lubricating Oil Application
Component Tightening Torque
(Thread Portion and Seat Surface)
29 ft·lb
Fuel Injector Retainer Bolt Not Applied
(39.2 N·m; 4 kgf·m)
3TNV82A
58 - 65 ft·lb
to Not Applied
(78 - 88 N·m; 8 - 9 kgf·m)
Fuel Pump Drive 4TNV88
Gear Nut 83 - 91 ft·lb
4TNV94 to
(113 - 123 N·m; Not Applied
4TNV106T
11.5 - 12.5 kgf·m)
22 - 25 ft·lb
High-Pressure Fuel Injection Line Nuts (29 - 34 N·m; Not Applied
3.0 - 3.5 kgf·m)
69 - 87 in·lb
Fuel Return Line Bolts (7.8 - 9.8 N·m; Not Applied
0.8 - 1.0 kgf·m)
17 - 21 ft·lb
Fuel Injection Pump Mounting Nuts (23 - 28 N·m; Not Applied
2.3 - 2.9 kgf·m)
30 - 33 ft·lb
Fuel Injector Nozzle Case Nut (39.2 - 44.1 N·m; Not Applied
4 - 4.5 kgf·m)
3TNV82A 22 - 26 ft·lb
to (30 - 35 N·m; Not Applied
Fuel Injection Pump Plunger 4TNV88 3.1 - 3.6 kgf·m)
Plug 30 - 33 ft·lb
4TNV94 to
(40 - 45 N·m; Not Applied
4TNV106T
4.1 - 4.6 kgf·m)

FUEL SYSTEM Fuel System Specifications
Test and Adjustment Specifications

Engine Injector ID
Model Fuel Injector Pressure Fuel Injection Timing
Class mark*
2843 - 2988 psi
3TNV82A - 4TNV88 CL W (19.6 - 20.6 MPa;
200 - 210 kgf/cm2)
2843 - 2988 psi
W** (19.6 - 20.6 MPa;
200 - 210 kgf/cm2)
3TNV82A - 4TNV88 See Checking and Adjusting Fuel
VM or or
3TNV84T - 4TNV84T Injection Timing on page 7-30
3133 - 3278 psi
V** (21.6 - 22.6 MPa;
220 - 230 kgf/cm2)
3133 - 3278 psi
4TNV94L - 4TNV106 CL
V (21.6 - 22.6 MPa;
4TNV98T - 4TNV106T VM
220 - 230 kgf/cm2)
Note: Fuel injection pressure of a new fuel injector is reduced approximately 72.5 psi (0.5 MPa; 5.0
kgf/cm2) after about 5 hours of operation due to the initial break in of the engine. When adjusting a
new fuel injector or after it has been disassembled for service, adjust the fuel injector 72.5 psi (0.5
MPa; 5.0 kgf/cm2) higher than the above standard.
Note: All fuel injectors have a three character identification mark (Figure 7-3, (1)). The first character
starts with “V” or “W”.
(1)
0004105
Figure 7-3
** Fuel injector identification is critical as each engine has a unique fuel injection pressure. The fuel
nozzle is specifically matched to the fuel injector by engine model and / or engine speed.

Special Service Tools FUEL SYSTEM

No. Tool Name Application Illustration
For tightening nuts and bolts to the specified

1 Torque Wrench Locally Available
torque
0000840
Used in conjunction with a slide hammer to

Fuel Injector Yanmar Part No.
2 remove the fuel injectors (2-valve cylinder
Removal Tool 129470-92305
heads)
MEASURING INSTRUMENTS
For observing injection spray pattern of fuel

1 Fuel Injector Tester Locally Available injection nozzle and measuring injection
OFF
P-
OFF
E-
ON AG
-G
pressure
Mituotoyo 2050SB -
Dial Indicator* Check and adjust fuel injection timing
Locally Available
2
0000831
Mituotoyo 303613 -
Extension Rod*
Locally Available
(M14) TNV82-88 -
Yanmar Part No.
158090-51831
Fuel Injection Pump
3 Mount dial indicator to fuel injection pump
Plunger Adapter* (M16) TNV94-106 -
Yanmar Part No.
158090-51841
0002690
Plunger Adapter Yanmar Part No.

4 Clamps stem of dial indicator in plunger adapter.
Clamp 23000-013000
0002691
* These special service tools may also be available as an “MP Fuel Injection Pump Special Tool Set”, under a
different part number, in territories serviced by Yanmar America and Yanmar Europe. Contact your authorized
Yanmar dealer or distributor for details.

FUEL SYSTEM Fuel System Diagram
FUEL SYSTEM DIAGRAM

(5) (20)
(21)
(4)
(18)
(17)
(19)
(16)
(3) (22)
(15)
(2)
(17)
(13) (14)
(11)
(1) (12)
(10)
(6)
(9)
(8)
(7)
0000034B
1 – Diesel Fuel Tank 12 – Engine Crankcase

2 – Fuel Filter / Water Separator 13 – Tappet
3 – Electric Fuel Pump 14 – High Pressure Gallery
4 – Fuel Filter 15 – Overflow Orifice
5 – Air Bleed Orifice 16 – Accumulator
6 – Fuel Supply Line 17 – Timer Piston
7 – Low Pressure Gallery 18 – Mono-Plunger
8 – Pressure Control Valve 19 – Distributor Shaft
9 – Trochoid Pump 20 – Fuel Return Line
10 – Oil Seal 21 – High-Pressure Fuel Injection Lines
11 – Fuel Injection Pump Cam 22 – Fuel Injector
Figure 7-4

Fuel System Components FUEL SYSTEM
FUEL SYSTEM COMPONENTS

2-Valve Cylinder Head
(16 )
(1)
(2)
(3)
(15 )
(14 )
(4)
(13)
(18)
(12) (10)
(17)
(9)
(8)
(11) (5)
(7)
(19) (6)
0002128
Figure 7-5

FUEL SYSTEM Fuel System Components
1 – High-Pressure Fuel Injection Lines 9 – Coolant Lines for Cold Start Device
2 – Fuel Return Line 10 – Fuel Injection Pump Insulator
3 – Fuel Injector 11 – Fuel Injection Pump
4 – Front Plate or Timing Gear Case 12 – Rear Fuel Injection Pump Support
5 – Gear Case Cover 13 – Fuel Filter / Water Separator
6 – Fuel Injection Pump Drive Gear Nut 14 – Electric Fuel Supply Pump
7 – Lock Washer 15 – Fuel Filter
8 – Fuel Injection Pump Drive Gear Assembly 16 – Fuel Filter Housing
(DO NOT remove or loosen the four bolts 17 – Stop Solenoid
that fasten the injection pump drive gear to 18 – Cold Start Device (CSD)
the injection pump drive gear hub!) 19 – Trochoid Fuel Pump

Fuel System Components FUEL SYSTEM
(18)
(1)
(2)
(3)
(5)
(4)
(17)
(16)
(6)
(15)
(12)
(20)
(14)
(19)
(11)
(10) (7)
(13)
(21) (9)
(8)
0002017
Figure 7-6

FUEL SYSTEM Fuel System Components
1 – High-Pressure Fuel Injection Lines 11 – Coolant Lines for Cold Start Device *
2 – Fuel Return Line 12 – Fuel Injection Pump Insulator
3 – Return Line-to-Cylinder Head Bolt 13 – Diesel Fuel Injection Pump
4 – Fuel Injector 14 – Rear Fuel Injection Pump Support
5 – Injection Line Grommet 15 – Fuel Filter / Water Separator
6 – Front Plate or Timing Gear Case 16 – Electric Fuel Supply Pump
7 – Gear Case Cover 17 – Fuel Filter
8 – Fuel Injection Pump Drive Gear Nut 18 – Fuel Filter Housing
9 – Lock Washer 19 – Stop Solenoid *
10 – Fuel Injection Pump Drive Gear Assembly 20 – Cold Start Device (CSD) **
(DO NOT remove or loosen the four bolts 21 – Trochoid Fuel Pump
that fasten the injection pump drive gear to
the injection pump drive gear hub!)
*: Not used for electronically controlled engines.
**: Electronically controlled engines are equipped with a solenoid valve. As shown in the following
figure, electronically controlled engines use an electronically controlled governor combined with a
solenoid valve (CSD), rack actuator, engine speed sensor, and other parts.
(2) (1)
(4)
(3)
(6)
(5)
Figure 7-7

Fuel Injection Pump FUEL SYSTEM
FUEL INJECTION PUMP CAUTION

Removal of Fuel Injection Pump Remove or install the high-pressure fuel
1. Loosen the cooling fan V-belt. possible. Disassembling the
2. Remove the engine coolant fan guard (if high-pressure fuel injection lines from
equipped), engine coolant fan (Figure 7-8, (2)), the retainers or bending any of the fuel
spacer (Figure 7-8, (3)) if equipped, V-pulley lines will make it difficult to reinstall the
(Figure 7-8, (4)) and cooling fan V-belt fuel lines.
(Figure 7-8, (1)). 0000047en
7. Finish loosening all the fuel line nuts and

remove the high-pressure fuel lines as an
assembly being careful not to bend any of the
fuel lines. Be sure to protect the fuel system
from contamination by covering all open
(3) (2) connections.
8. Disconnect the coolant lines from the cold start
device (Figure 7-9, (3)) on the fuel injection
pump. Plug the open ends of the lines to
minimize leakage and prevent contamination.
(1)
This cooling water pipe is not used in
electronically controlled engines 4ÇsNV84T-Z,
4TNV98-Z, 4TNV98-Z, and 4TNV98T-Z.
(4) 9. Disconnect the fuel return lines from the fuel
0000163A
return fitting (Figure 7-9, (2)). Plug the open
ends of the lines to minimize leakage and
Figure 7-8
prevent contamination.
3. Close any fuel valves in the fuel supply line.
4. Place a drain pan under the fuel injection pump
to catch any spillage.
5. Remove the high-pressure fuel injection lines
as an assembly (Figure 7-9, (1)).
(1)
Note: To prevent “rounding” the fuel line nuts
always use a “line” or “flare nut” wrench. (4)
When loosening the fuel line nuts,
(3)
always hold the fuel injection pump
delivery valves with a “back up” wrench
to prevent loosening of the delivery
(2)
valves.
6. First loosen the fuel line nuts at the fuel
injectors and then at the fuel injection pump.
0002094
Figure 7-9

FUEL SYSTEM Fuel Injection Pump
10. Remove the fuel supply line (Figure 7-9, (4)).

Plug the open end of the line to minimize
leakage and prevent contamination.
(2) (1)
(4) (1)
(3)
(2)
(6) 0000153A
Figure 7-11
(5)
14. Disconnect the lube oil line (Figure 7-12, (1))
Figure 7-10 and the clamp (Figure 7-12, (2)) from the
11. Remove the throttle cable from the fuel injection pump.
pump. IMPORTANT
12. Separate the stop solenoid wiring connector Take care to not damage or bend the oil
(Figure 7-11, (2)). line. In some applications, it may be
For electronically controlled engines 4TNV84T- preferable to remove the complete oil line
Z, 4TNV98-Z, 4TNV98-E, and 4TNV98T-Z, assembly from the engine before
remove the solenoid valve connector proceeding.
(Figure 7-10, (2)), rack actuator connector
(Figure 7-10, (4)), and engine speed sensor Note: On models 3TNV82-4TNV88, the fuel
connector (Figure 7-10, (6)). injection pump drive gear cover is
retained to the gear case cover by 4
13. Remove the rear fuel injection pump bracket(s) bolts. On models 4TNV94-4TNV106, the
(Figure 7-11, (1)) from the fuel injection pump. cover is larger and retained by 7 bolts.
Note: Configuration of the fuel injection pump
rear brackets may vary depending upon
engine model.

16. To position the fuel injection pump for easier
removal and installation, install a dial indicator
(see Checking and Adjusting Fuel Injection
Timing on page 7-30) into the injection pump
(1) plunger opening. Using a wrench on the
crankshaft pulley bolt, rotate the crankshaft until
the dial indicator shows that injection pump
plunger is at the bottom of it's stroke.
17. To aid in reassembly, make reference marks on
the fuel injection pump drive gear, and on either
the gear case cover or idler gear.
CAUTION
(2) 0000593B
After marking the position of the pump
Figure 7-12 drive gear, do not rotate the engine
crankshaft. Rotating the crankshaft will
15. Remove the fuel injection pump drive gear cause the fuel injection pump to become
cover (Figure 7-13, (1)) from the gear case misaligned.
cover (Figure 7-13, (2)).
0000048en
Note: The fuel injection pump drive gear cover
is secured with an adhesive sealant. Use • On TNV82-88 model engines, the idler gear is
a gasket scraper to separate the fuel not visible. Make a reference mark on the fuel
injection pump cover from the gear case injection pump drive gear (Figure 7-14, (1))
cover. and a matching mark on the bore of the gear
case opening (Figure 7-14, (2)).
(2)
(2)
(1)
0002039 (1)
0000575
0000575A
Note: TNV82-88 shown.

• On TNV94 - 106 model engines, the idler gear

is visible. Make a reference mark
(Figure 7-15, (1)) across both the fuel injection
pump drive gear and the idler gear.
(3)
(1)
(1) (2)
0000162A
Figure 7-16
Figure 7-15 19. Hold the gear train using a large socket wrench
on the crankshaft pulley nut. Loosen the fuel
CAUTION injection pump drive gear retaining nut
(Figure 7-16, (1)) and turn it out to the end of
the fuel injection pump shaft.
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do 20. Remove the pump drive gear and hub as an
not disassemble the fuel injection pump assembly using an appropriate two-bolt gear
drive gear from the hub. Correct fuel puller (Figure 7-17).
0000031en
18. Do not loosen or remove the four bolts

(Figure 7-16, (3)) retaining the pump drive gear
to the hub. Only remove the single drive gear
nut (Figure 7-16, (1)) and washer
(Figure 7-16, (2)), leaving the hub attached to
the gear.
0000574
Figure 7-17

Note: On TNV82 - 88 models the injection Note: Some model engines may require the
pump drive gear will remain “captured” in intake manifold and fuel injection pump
the gear case. On TNV94 - 106 models, insulator (Figure 7-20, (2)) be removed
the injection pump drive gear can be to access the inner fuel injection pump
removed through the gear case cover (Figure 7-20, (1)) retaining nuts.
opening.
21. Once the fuel injection pump drive gear and
hub assembly has “popped” loose from the
tapered fuel injection pump drive shaft, carefully
remove the drive gear nut (Figure 7-18, (1)) (2)
and lock washer (Figure 7-18, (2)).
(1)
(1)
0000263A
Figure 7-20
(2)
0000162B
23. If required, remove the intake manifold and fuel
pump insulator to access the fuel injection
Figure 7-18 pump mounting nuts.
22. Locate the mark stamped into the upper outside Note: The MP2 fuel injection pumps
mounting boss of the fuel injection pump. (TNV82 - 88 model engines) are
Highlight this mark and make a corresponding fastened to the gear case with three (3)
mark on the gear case or front plate studs and nuts. The MP4 fuel injection
(Figure 7-19, (1)). pumps (TNV94 - 106 model engines) are
fastened to the gear case with four (4)
studs and nuts.
24. Remove the fuel injection pump
(Figure 7-20, (1)). For purposes of future
injection timing purposes, record the fuel
injection pump timing index number located on
the boss on the engine side (back) of the of the
fuel injection pump (Figure 7-21, (1)).
(1)
0000593
0000593A
Figure 7-19

(1) CAUTION
• NEVER remove or attempt to remove
full-load fuel adjusting screw or the
high-speed throttle limit screw on the
fuel injection pump and governor
assembly. These adjustments have
been made at the factory to meet all
then sealed.
• NEVER attempt to make any
adjustments to these sealed
0002047 adjustment screws. If adjustments are
Figure 7-21 required, they can be made only by a
ensure the injection pump continues
CAUTION to meet all applicable emissions
Do not rotate the crankshaft with the regulations and then replace the
injection pump removed. tamper-proof seals.
0000083en
• Tampering with or removing these
25. If the fuel injection pump requires servicing, it devices may void the “Yanmar Limited
must be sent to an authorized Yanmar FIE Warranty.”
repair facility for repair and calibration, or 0000146en
replaced with a new fuel injection pump.

Installation of Fuel Injection Pump
For electronically controlled engine
A WARNING
• Replacing the fuel injection pump
involves rewriting the fuel injection
data in the E-ECU.
Be sure to contact your local Yanmar
dealer before replacing the fuel
injection pump.
Failure to rewrite the fuel injection
data before replacing the fuel injection
pump will void the engine warranty.
• Improper use or misuse of the E-ECU
9999997en

IMPORTANT
If installing a new or recalibrated fuel
injection pump, locate and record the timing
index number located on the pump housing
boss on the engine side of the new or
recalibrated fuel injection pump
(Figure 7-22, (1)). This number will be used
(1)
to calculate and adjust the final fuel injection
timing.
Note: If either or both of the fuel injection
pumps do not have a timing index
number, note the injection pump ID
(example: XK42) on the injection pump
ID label.
To locate the timing index number for the engine
0000575
0000575B
being serviced use the Timing Index Chart under
“FIE Specs” on the Yanmar Distributor Website Figure 7-23
(http://distributor.yanmar.co.jp).
If additional assistance is needed in locating the
engine timing index number See To Locate an
Authorized Yanmar Industrial Engine Dealer or
Distributor: on page 2-4 and follow the instructions
to locate an authorized Yanmar industrial engine
dealer or distributor for assistance.
Note: Treat the timing index number as if it has
a decimal point (68 = 6.8).
(1)
(1)
0002096
Figure 7-24
2. If installing the fuel injection pump on an engine
with the front gear case cover removed, the fuel
injection pump drive gear can be aligned with
the idler gear by aligning the stamped marks
Figure 7-22
(A, B, C) on the fuel injection pump drive gear,
1. Align the pump drive gear with the idler gear idler gear, and crankshaft drive gear. Ensure all
using the reference marks made earlier. three timing marks (Figure 7-25, (A, B, C)) are
TNV82 - 88 model engines (Figure 7-23, (1)). aligned.
TNV94 - 106 model engines (Figure 7-24, (1)).

(1)
(2)
B B
C C
A
(7) A
(3)
(6) (4)
(5) 0001709A
1 – Fuel Injection Pump Drive Gear (1)

2 – Camshaft Drive Gear
3 – Auxiliary Drive Gear (Optional)
4 – Crankshaft Drive Gear
5 – Direction of Rotation
(2)
6 – Oil Pump Drive Gear (4TNV94L - 4TNV106)
7 – Idler Gear 0000162B
3. Install a new O-ring on the pump mounting If reinstalling the original fuel injection pump:
flange. Apply grease to the O-ring to hold it in
• Align the reference marks (Figure 7-27, (1))
place during installation of the injection pump.
previously made on both the fuel injection
Note: Ensure the tapered surface of the fuel pump mounting flange and gear case or front
injection pump shaft is clean and dry. plate.
4. Align the key on the fuel injection pump shaft
with the keyway in the fuel injection pump drive
gear hub. Reinstall the fuel injection pump into
the fuel injection pump drive gear and gear
housing. Reinstall the pump retaining nuts
finger tight.
5. Reinstall the fuel injection pump drive gear lock
washer (Figure 7-26, (2)) and nut
(Figure 7-26, (1)). Do not lubricate the threads
of the nut or shaft. Hold the crankshaft pulley
bolt with a socket wrench and tighten the drive
(1)
gear nut to the specified torque. See Special
Torque Chart on page 7-11.
0000593
0000593A
Figure 7-27
• Tighten the fuel injection pump retaining nuts
to specification. See Special Torque Chart on
page 7-11.

If installing a new fuel injection pump: • Calculate the difference between the timing
index numbers (Figure 7-29, (1)) of the fuel
• Reinstall the timing grid sticker, provided with injection pump that you removed and the
the new fuel injection pump, onto the back of replacement fuel injection pump. See
the gear case / front plate (Figure 7-28). Align Calculation Example below.
the “standard mark” (Figure 7-28, (1)) with the
reference mark (Figure 7-28, (2)) made on the (1)
gear case during disassembly.
0002047
Figure 7-29
Adjusting the fuel injection timing to
compensate for the difference in pump timing
index numbers:
(2)
Calculation Example
Timing Index Number
(1) Original injection pump= 6.8
Replacement injection pump= 7.3
Difference= +0.5
• If the difference between the timing index

numbers is a positive number, the fuel injection
pump mounting position must be advanced
(Figure 7-30, (2)) (rotated away from the
engine) as compared to the “standard mark”
(Figure 7-30, (1)) by the calculated positive
amount, adjust the fuel injection pump to the
calculated value.
• If the difference between the timing index
numbers is a negative number, the
0002139 replacement injection pump must be retarded
(Figure 7-30, (3)) (rotated toward the engine)
Figure 7-28 by the calculated negative amount.
• Each mark on the timing sticker represents
0.5° timing change.

The above calculated difference indicates that Tighten the fuel injection pump mounting nuts to
the replacement fuel injection pump is to be specification. See Special Torque Chart on
installed at +0.5° (advanced) from the “Standard page 7-11.
Mark” (Figure 7-30, (1)) on the timing sticker.
6. Reinstall the rear bracket(s) (Figure 7-32, (1))
to the fuel injection pump. Tighten the rear
support bolts.
Note: Configuration of the fuel injection pump
rear brackets may vary depending on the
(3) model.
(1)
+0.5°
(1)
+1.0°
(2)
0002124A
(2)
Figure 7-30
0000153A
In this case, rotate the top of the fuel injection
pump away from the cylinder block until the mark Figure 7-32
on the outside upper mounting boss 7. Reconnect the throttle linkage and the stop
(Figure 7-31, (1)) of the fuel injection pump solenoid connector (Figure 7-33, (2)).
aligns with the +0.5° mark on the timing sticker.
8. Reconnect the lube oil line (Figure 7-33, (1))
and clamp (Figure 7-33, (2)).
(1) 0002125A
Figure 7-31

12. If equipped, verify the fuel injection pump
insulator (Figure 7-34, (2)) is not damaged.
Reinstall the insulator and intake manifold if
previously removed.
(1)
(2)
(1)
(2) 0000593B
Figure 7-33
0000263A
9. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212, or equivalent
Figure 7-34
sealant to the sealing surface of the pump
cover. Install the pump cover and tighten the 13. Reinstall the coolant pump V-pulley
cover bolts. (Figure 7-35, (4)), spacer (Figure 7-35, (3)) (if
10. Reconnect the fuel return lines, fuel supply line equipped) and engine coolant fan
and coolant lines to the fuel injection pump. (Figure 7-35, (2)).
11. Reinstall the fuel injection high-pressure lines.
Tighten the nuts to specification. See Special
Torque Chart on page 7-11.
(3) (2)
IMPORTANT
When reinstalling a new or repaired fuel
injection pump, it is important to add engine
oil to the fuel injection pump to provide
lubrication for initial start-up. Add 5-7 oz
(1)
(150-200 cc) of clean engine oil to the fuel
injection pump at the fill plug located in the
upper outside section of the governor
housing.
(4) 0000163A
Figure 7-35
14. Reinstall the cooling fan V-belt
(Figure 7-35, (1)). Adjust it as described in
Check and Adjust Cooling Fan V-Belt on
page 5-22.
15. Reinstall the cooling fan guard (if equipped).

FUEL SYSTEM Checking and Adjusting Fuel Injection Timing
16. Prime the fuel system. See Priming the Fuel 2. Using the FIR number for the engine being
System on page 4-15. serviced use the Fuel Injection Reference (FIR)
17. Operate the engine and check for fuel and Chart under “FIE Specs” on the Yanmar
coolant leaks. Distributor Website
(http://distributor.yanmar.co.jp).
The FIR number is determined by the complete
CHECKING AND ADJUSTING engine model number. The engine model
number is located on the engine nameplate
FUEL INJECTION TIMING (Figure 7-38).
Determining the Fuel Injection Timing

Specification
1. Locate and record the fuel injection pump
timing index number (Figure 7-37, (1)) stamped
into the boss on the engine side of the fuel
injection pump housing (Figure 7-36, (1)). Treat
this number as though there is a decimal point
between the two digits. i.e. 68 = 6.8
(1)
0003852
Figure 7-38
EXAMPLE: The following example is for an engine
model 3TNV82A-DSA.
0000040B
• Find the engine model number in the FIR chart.
Figure 7-36 Locate and record the FIR number (The FIR
number for this engine is 4).
(1) • Insert the numbers you have recorded into the
following equation:
(Fuel Injection Pump Timing Index Number X 2)
+ FIR Number = FIT° (Fuel injection Timing in
Degrees)
(6.8 X 2) = 13.6 + 4 = 17.6° Fuel injection

Timing
• Record the calculated fuel injection timing
specification.
0002047
Figure 7-37

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
Checking Fuel Injection Timing Note: Use the Yanmar part no. 158090-51831
M14 adapter for the MP2 fuel injection
Note: Some fuel may drain from the fuel pumps (TNV82 - 88 model engines) or
injection pump during this process. Make Yanmar part no. 158090-51841 for the
provisions to contain any such spillage. M16 adapter used on the MP4 fuel
1. Turn off the fuel valve in the fuel supply hose injection pumps (TNV94 - 106 model
and the fuel return hose. engines) and Yanmar part no. 23000-
013000 plunger adapter clamp
2. Clamp shut the fuel injection pump fuel return
(Figure 7-40, (1)).
hose leading to fuel filter (Figure 7-39, (1)).
(1)
(1)
(2)
0002068A
Figure 7-40
0002087
5. Install a dial indicator (Figure 7-41, (1)),
Figure 7-39 Mitutoyo No. 2050SB or equivalent, with a
30 mm extension, Yanmar part no.
IMPORTANT 158090-51870 or Mitutoyo No. 303613, into the
Clean the top of the fuel injection pump to adapter. Secure with the Yanmar part no.
prevent any contamination when the fuel 23000-013000 plunger adapter clamp
injection pump plunger plug is removed. (Figure 7-40, (1)) at approximately the mid-
3. Remove the forward fuel injection pump plunger point of its travel.
plug (Figure 7-39, (2)) on the top of the fuel
injection pump.
4. Install a dial indicator adapter and clamp into
the pump plunger opening.

The flywheel shown in Figure 7-43 is for a

(1) Yanmar “Standard Specification” DI engine.
Flywheels used on some “OEM Specific” DI
engines may be marked differently. You should
contact that specific OEM for information on the
identification of the timing marks.
(3)
(2)
(4)
(1)
14
(5)
0002069
Figure 7-41 0002071
Note: The following references to the direction- 1 – 10° BTDC (Before Top Dead Center)
of-rotation are facing the coolant pump 2 – 15° BTDC
end of the engine and are adjusted by 3 – 20° BTDC
turning the crankshaft pulley. 4 – Direction of Rotation
5 – TDC (Top Dead Center)
6. Using a wrench on the crankshaft pulley bolt,
rotate the crankshaft in a clockwise direction Figure 7-43
while looking through the flywheel inspection
port (Figure 7-42, (1)). Rotate the crankshaft Note: The TDC (Top Dead Center) mark can
until the injection timing marks on the flywheel be identified by the cylinder numbers
are visible. stamped near the TDC mark on the
flywheel.
If you are uncertain as to the timing degree
designation of the timing marks on the flywheel
timing grid, you can determine the timing degree
designation by measuring the timing grid.
• First measure the distance between two of the
“longer” marks on the timing grid. (They are 5°
apart.) Then measure the distance from the
TDC mark to the first “longer” mark on the
(1) 00020 timing grid. Divide that measurement by the
distance between the two “longer” marks. The
Figure 7-42 resulting answer will tell you how many
degrees there are between the TDC mark and
7. Typical flywheel markings are as shown in
the first “longer” mark.
(Figure 7-43, (1)).
Note: A typical flywheel will have multiple
timing grids depending on the number of
cylinders. Any grid can be used to check
the fuel injection timing.

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
• EXAMPLE: If the distance between the two
“longer” marks is approximately 2.0 cm and the
distance from the TDC mark is approximately
(1)
4.0 cm, the answer is approximately 2. This
(2)
indicates there is 10° (2 x 5°) between the TDC
mark and the first “longer” mark on the timing
grid. That means the first “longer” mark on the
timing grid indicates 10° BTDC, the second
“longer” mark indicates 15° BTDC and the third
timing mark indicates 20° BTDC. If the answer
is 3, that indicates there is 15° (3 x 15°)
between the TDC mark and the first “longer”
mark and that the first “longer” mark indicates 0002066
15° BTDC with the second and third “longer”
marks indicating 20° BTDC and 25° BTDC
respectively.
8. Highlight the timing reference mark (2)
(Figure 7-44, (2)) on the flywheel housing or (1)
engine back plate (Figure 7-45, (2)). Highlight
the TDC (Top Dead Center) mark
(Figure 7-44, (1)) on the flywheel.
9. Highlight the target timing mark
(Figure 7-45, (1)) on the flywheel as calculated
in Determining the Fuel Injection Timing
Specification on page 7-30.
0002142
Figure 7-45
(1)
(2) 10. Rotate the crankshaft counter-clockwise until
the dial indicator shows that the injection pump
plunger is at the bottom of its stroke. Rock the
1 4
crankshaft back and forth slightly to confirm a

point where the dial indicator shows no
movement. Zero the dial indicator.
11. Slowly rotate the crankshaft clockwise until the
dial indicator shows a pump plunger lift of
2.5 mm (0.098 in.).
0002065
12. Check the position of the flywheel target timing
Figure 7-44 mark (previously determined) (Figure 7-45, (1))
in relation to the timing reference mark
(Figure 7-45, (2)) on the flywheel housing or
engine back plate. If the two marks are aligned,
the fuel injection timing is correct. If the marks
do not align, the fuel injection timing must be
adjusted. See Adjusting Fuel Injection Timing
on page 7-34.

13. If the injection timing is correct, remove the dial 3. Note the reading on the dial indicator
indicator and adapter. Replace the pump (Figure 7-47, (1)). If the reading is less than
plunger plug and its copper gasket and tighten 2.5 mm (0.098 in.), the fuel injection timing is
to specifications. Replace the flywheel “retarded.” If the dial indicator reading is greater
inspection port cover. Open the fuel supply than 2.5 mm (0.098 in.), the fuel injection timing
valve and remove the clamp from the fuel is “advanced.”
supply hose and the fuel return hose.
(1)
14. Prime the fuel system. Operate the engine and
check for leaks.
Adjusting Fuel Injection Timing

If the timing marks did not align when performing
the Checking Fuel Injection Timing on page 7-31,
the following steps must be performed to properly
time the engine.
1. Leave the dial indicator installed in the fuel
injection pump. Do not disturb the reading on
the dial indicator.
2. Rotate the flywheel until the target timing mark
(Figure 7-46, (1)) and the timing reference 0002069
mark (Figure 7-46, (2)) on the flywheel housing Figure 7-47

or back plate are aligned.
Note: Some model engines require the intake
IMPORTANT manifold and fuel injection pump
Do not rotate the crankshaft during the insulator be removed to access the inner
remainder of this procedure. fuel injection pump retaining nuts.
4. Loosen the nuts fastening the fuel injection
pump to the gear case or front plate. Loosen
(1) the rear bracket(s) on the fuel injection pump.
(2) Note: Loosening the high-pressure injection
line nuts on the fuel injection pump may
make rotating the pump easier.
5. Rotate the fuel injection pump until the dial
indicator reads 2.5 mm (0.098 in.).
6. To “advance” the injection timing, rotate the top
of the fuel injection pump away from the engine.
7. To “retard” the injection timing, rotate the top of
0002066
the fuel injection pump toward the engine.
Figure 7-46
8. When the dial indicator reads 2.5 mm
(0.098 in.) of pump plunger lift and the target
timing mark on the flywheel aligns with the
reference mark on the flywheel housing or
engine back plate, the injection timing is
correct.

Fuel Injectors FUEL SYSTEM
9. Tighten the fuel injection pump mounting nuts Note: To prevent “rounding” the fuel line nuts
and rear bracket(s). always use a “line” or “flare nut” wrench.
10. Remove the dial indicator and adapter. Replace When loosening the fuel line nuts,
the plug in the pump plunger opening and always hold the fuel injection pump
tighten it to specification. If removed, install the delivery valves with a “back up” wrench
intake manifold and pump insulator. Tighten the to prevent loosening.
high-pressure injection line nuts to • Loosen the fuel line nuts at the fuel injectors
specification. Open the fuel supply valve, and then at the fuel injection pump.
remove the clamp from the fuel return line and
prime the fuel system. Operate the engine and CAUTION
check it for leaks.
possible. Disassembling the
FUEL INJECTORS high-pressure fuel injection lines from
Removal of Fuel Injectors lines will make it difficult to reinstall the
fuel lines.
2-Valve Cylinder Head 0000047en

• Finish loosening all the fuel line nuts and
2. Remove the high-pressure fuel injection lines remove the high-pressure fuel lines as an
as an assembly (Figure 7-48, (1)). assembly being careful not to bend any of the
(1) fuel lines. Be sure to protect the fuel system
from contamination by covering all open
connections.
3. Remove the return fuel hoses (Figure 7-49, (1))
from one side of each fuel injector.
4. Remove the bolts and washers that secure the
fuel injector retainers (Figure 7-49, (2)) to the
cylinder head.
5. Remove the fuel injector retainer.
0000154A
Figure 7-48

FUEL SYSTEM Fuel Injectors
(3)
(1)
(4)
(2) 0002092A
Figure 7-49
0000815
6. Remove the fuel injector.
Figure 7-50
Note: The fuel injectors can usually be
removed by manually pulling them out of • Tap the fuel injector out of the cylinder head
the fuel injector wells. If the fuel injectors using the slide hammer.
cannot be manually removed, use the 7. Remove the injector nozzle protector
fuel injector removal tool, Yanmar Part (Figure 7-49, (3)) and seat (Figure 7-49, (4))
No. 129470-92305, and a slide-hammer from the cylinder head.
puller (Figure 7-50).
8. Repeat the steps to remove the remaining fuel
• Attach a slide-hammer puller to the fuel injector injectors.
removal tool using a 3/8-16 puller rod.
2. Remove the valve cover. See Removal of Valve
Cover on page 6-37.
3. Remove the injector return line
(Figure 7-51, (1)). Be careful not to bend the
line.
4. Remove the fuel injector mounting clamp bolts
(Figure 7-51, (2)). Lift the injector mounting
clamps (Figure 7-51, (3)) away from injector.
5. Remove the fuel injector (Figure 7-51, (4)) from
the cylinder head.

(2)
(1)
(3)
(4)
(5)
(6)
Figure 7-51
Note: The fuel injectors can be removed by
manually pulling them out of the fuel
injector wells.
6. Remove the injector nozzle protector
(Figure 7-51, (5)) and seat (Figure 7-51, (6))
from the cylinder head. Discard both items.
7. Repeat steps to remove the remaining fuel
injectors.

Testing of Fuel Injectors

A CAUTION
CAUTION
Never use a steel wire brush to clean
fuel injectors. Damage to the nozzle and
other components is likely to result.
0000172en
1. Thoroughly clean the fuel injector nozzle using FLYING OBJECT HAZARD!
clean diesel fuel and a brass wire brush. • ALWAYS wear eye protection when
2. Visually inspect the fuel injectors and nozzle servicing the engine and when using
protectors for deposits or damage. Clean, repair compressed air or high-pressure
or replace as necessary. water. Dust, flying debris, compressed
Note: Test the fuel injector using an injection air, pressurized water or steam may
nozzle tester. Operate the tester injure your eyes.
following the information provided by the • Failure to comply may result in minor
tester manufacturer. Use clean, filtered or moderate injury.
fuel or FIE calibration fluid for the test. 0000003en
3. Using the correct adapter, connect a fuel

injector to a nozzle tester. Aim the fuel injector
into a suitable container to catch the fuel spray.
A WARNING ON AG
OFF
E-
OFF
P-
-G
• Never inject fuel toward you. Since the

fuel is injected at high pressure from
the nozzle, it may penetrate the skin,
resulting in injury.
• Never inject fuel toward a fire source. Figure 7-52
Atomized fuel is highly flammable and
may cause a fire or burn skin. 4. Pump the operating lever of the tester slowly,
0000028en observing the pressure reading at the point
where the fuel injector begins spraying fuel
(Figure 7-52).
See Figure 7-55 for injector ID location.
See Test and Adjustment Specifications on
page 7-12 for correct pressure readings.
Note: The opening pressure of a new fuel
injector will be approximately 725 psi
(5 MPa; 51 kgf/cm2) higher than one that
has been operated for five hours or
longer.

5. Pump the operating lever slowly to hold the Disassembly and Inspection of Fuel
pressure steady at a point just below the
Injectors
opening pressure and hold it for 5 seconds.
Observe the injector to see that it is sealing
properly and is not “dripping”. If fuel leaks from CAUTION
the return line fitting, check that the nozzle case Never use a steel wire brush to clean
nut is tight. Service or replace the injector if fuel fuel injectors. Damage to the nozzle and
continues to leak from either the return line other components is likely to result.
fitting or nozzle. 0000172en
6. Pump the operating lever more rapidly to

1. Clean carbon from used injectors using clean
repeatedly “pop” the injector and observe the
diesel fuel. Hardened deposits or varnish can
spray pattern. The pattern should be a very fine
be cleaned using a brass wire brush.
uniform spray (Figure 7-53). If a dripping or an
uneven pattern is seen (Figure 7-54), service (1)
or replace the injector.
(2)
(3)
(4)
0001336A
(5)
Figure 7-53
(6)
(7)
(8)
(9)
(10)
0001337A
Figure 7-54
1 – Fuel Return Passage
If the fuel injector fails any of these tests, it should 2 – Injector ID Location
be serviced or replaced as necessary. If the 3 – Injector Body
pressure is outside specified limits, adjust the 4 – Pressure Adjusting Shims
5 – Spring
pressure. See Adjusting Fuel Injector Pressure
6 – Spring Seat
on page 7-41. 7 – Valve Stop Spacer
8 – Nozzle Valve
9 – Nozzle Body
10 – Nozzle Case Nut
Figure 7-55

2. Place the fuel injector in a soft-jawed vise with

the nozzle pointing up.
3. Remove the nozzle case nut.
4. Carefully remove the injector from the vise.
5. Turn the injector over and remove the nozzle
body, nozzle valve, valve stop spacer, nozzle
spring seat, nozzle spring, and shims.
6. Inspect the sealing surfaces (Figure 7-56, (2))
between the valve stop spacer and nozzle body
for nicks or scratches. Check the contact area 0001332A
between the valve stop spacer and the nozzle

Figure 7-57
valve (Figure 7-56, (1)) for scoring, or pitting.
Use a magnifier glass to inspect the area. 8. Replace the fuel injector assembly if it fails any
inspection.
(1)
(2)
0001333A
Figure 7-56
7. Perform a nozzle valve slide test:
(a) Wash nozzle body and valve in clean diesel
fuel.
(b) While holding the nozzle body vertical, pull
the nozzle valve about 2/3 of the way out
(Figure 7-57).
(c) Release the valve. It should fall smoothly to
its seat by it’s own weight.

Adjusting Fuel Injector Pressure See the parts catalog for available shims.
The fuel injectors open when pressure reaches a
predetermined pressure threshold. They close CAUTION
when the pressure is reduced below that threshold. Each pressure adjusting shim removed
The pressure threshold can be adjusted by adding or added changes the pressure
or removing shims (Figure 7-58, (3)). threshold by approximately 275 psi
(1) shims increases the threshold pressure.
(2) pressure threshold.
0000081en
(3) 1. Disassemble the fuel injector assembly. See

Disassembly and Inspection of Fuel Injectors
on page 7-39.
2. Remove or add adjusting shims as needed.
(4)
3. Reassemble the fuel injector assembly. See
Reassembly of Fuel Injectors on page 7-41.
(5)
0002093 4. Retest the fuel injector. See Testing of Fuel
(6) Injectors on page 7-38. If the injector cannot be
(7) adjusted to the appropriate pressure, discard
the fuel injector.
(8)
Reassembly of Fuel Injectors
(9) 1. Secure the injector in a soft-jawed vise with the
nozzle end up.
2. Reinstall the shims, nozzle spring, nozzle
(10) spring seat, valve stop spacer, nozzle valve,
and nozzle body.
0002093 3. Reinstall the nozzle case nut. Tighten it to
1 – Fuel Return Passage specification. See Special Torque Chart on
2 – Injector ID Location page 7-11.
3 – Injector Body
4 – Pressure Adjusting Shims
5 – Spring
6 – Spring Seat
7 – Valve Stop Spacer
8 – Nozzle Valve
9 – Nozzle Body
10 – Nozzle Case Nut
Figure 7-58
The injection pressure will change by
approximately 275 psi (1.9 MPa; 19 kgf/cm2) for
every 0.1 mm (0.004 in.) in shim thickness.

Installation of the Fuel Injectors 4-Valve Cylinder Head

1. Reinsert a new nozzle seat (Figure 7-60, (6))
2-Valve Cylinder Head and nozzle protector (Figure 7-60, (5)) in the
1. Reinsert a new nozzle seat (Figure 7-59, (4)) cylinder head for each injector.
and nozzle protector (Figure 7-59, (3)) in the 2. Reinstall a O-ring on to each injector body.
cylinder head for each injector.
3. Reinsert each fuel injector (Figure 7-60, (4))
2. Reinstall a O-ring on to each injector body. into the cylinder head.
3. Reinsert each fuel injector into the cylinder 4. Reinstall the fuel injector retainers
head. (Figure 7-60, (3)) and torque the retaining bolts
4. Reinstall the fuel injector retainers (Figure 7-60, (2)) to specification.
(Figure 7-59, (2)) and torque the retaining bolts 5. Reinstall the fuel injector return line assembly
to specification. using new gaskets on each side of the injector
5. Reinstall the fuel return hoses line screws.
(Figure 7-59, (1)), one on each side of each 6. Reinstall the fuel high-pressure fuel lines to
injector. each injector and tighten the nuts using a “line”
6. Reinstall the fuel high-pressure fuel line or “flare nut” wrench.
assembly and tighten the nuts using a “line” or
“flare nut” wrench. (2)
(1)
(3)
(1)
(4)
(3)
(4)
(5)
(6)
(2) 0002092A
Figure 7-59
7. Prime the fuel system. See Priming the Fuel Figure 7-60
7. Prime the fuel system. See Priming the Fuel
8. Operate the engine and check for fuel and
coolant leaks.
8. Operate the engine and check for fuel and
coolant leaks.

Fuel injection system (for a four-valve
cylinder head)
The fuel injection system for a four-valve cylinder
head is different, not only in the nozzle valve
specifications, but also in the nozzle holder
specifications. Therefore, it is marked as follows;
take care not to install a wrong part when replacing
it with new one.
Identifying the fuel injector assembly

107.8
107.8
106.8
4TNV84T 4TNV94L,98,98T 4TNV98-Z,-E,98T-Z

Identification Identification Identification
groove: one groove: none groove: two
Figure 7-61


Section 8
COOLING SYSTEM
Page
Introduction...................................................................................... 8-6
Cooling System Diagram................................................................. 8-6
Engine Coolant Pump Components ................................................ 8-7
Engine Coolant System Check........................................................ 8-8
Engine Coolant Pump ..................................................................... 8-8
Removal of Engine Coolant Pump ............................................ 8-8
Disassembly of Engine Coolant Pump .................................... 8-10
Cleaning and Inspection .......................................................... 8-10
Reassembly of Engine Coolant Pump..................................... 8-11
Installation of Engine Coolant Pump ....................................... 8-12

COOLING SYSTEM

Before You Begin Servicing COOLING SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING
A DANGER
service it.
SCALD HAZARD! • NEVER leave the key in the key switch

• NEVER remove the radiator cap if the Someone may accidentally start the
engine is hot. Steam and hot engine engine and not realize you are
coolant will spurt out and seriously servicing it. This could result in a
burn you. Allow the engine to cool serious injury.
the radiator cap. • If you must service the engine while it
• Tighten the radiator cap securely after back long hair, and keep your hands,
you check the radiator. Steam can other body parts and clothing away
spurt out during engine operation if from moving / rotating parts.
the cap is loose.
• ALWAYS check the level of the engine or serious injury.
coolant by observing the reserve tank. 0000010en

serious injury.
0000002en
A WARNING
A WARNING
FUME / BURN HAZARD!

BURN HAZARD! hazardous substances like parts
• Wait until the engine cools before you cleaners, primers, sealants and
drain the engine coolant. Hot engine sealant removers.
• Failure to comply could result in death or serious injury.
or serious injury. 0000014en
0000016en

COOLING SYSTEM Before You Begin Servicing
A WARNING A CAUTION
BURN HAZARD!
• If you must drain the engine oil while it
PINCH HAZARD!
is still hot, stay clear of the hot engine Carefully rotate the alternator toward the
oil to avoid being burned. cylinder block while loosening the
V-belt. Failure to comply may result in
• ALWAYS wear eye protection. minor or moderate injury.
• Failure to comply could result in death 0000014en
or serious injury.
0000011en
CAUTION
• Only use the engine coolant specified.
A CAUTION Other engine coolants may affect
buildup of rust and scale and / or
shorten engine life.
FLYING OBJECT HAZARD! the surrounding area before you
• ALWAYS wear eye protection when remove the cap.
servicing the engine and when using • NEVER mix different types of engine
compressed air or high-pressure coolants. This may adversely affect the
water. Dust, flying debris, compressed properties of the engine coolant.
air, pressurized water or steam may 0000006en
injure your eyes.
• Failure to comply may result in minor CAUTION
or moderate injury.
If the engine coolant pump must be
0000003en
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant
pump or replace individual components.
0000041en

Before You Begin Servicing COOLING SYSTEM
CAUTION
Use a new special O-ring between the
engine coolant pump and the joint. Be
sure to use the special O-ring for each
engine model. Although the O-ring
dimensions are the same as a
commercially available O-ring, the
material is different.
0000042en

COOLING SYSTEM Introduction
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 4TNV84 engine
coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model
engines. For specific part detail, see the parts catalog for the engine you are working on.
COOLING SYSTEM DIAGRAM

(1)
(2)
(3)
(4)
(7)
FULL
LOW
(6)
(5)
0000573A
1 – Cylinder Head 5 – Coolant Recovery Tank

2 – Thermostat 6 – Engine Oil Cooler*
3 – Engine Coolant Pump 7 – Cylinder Block
4 – Radiator
* Not standard on all models.
Figure 8-1

Engine Coolant Pump Components COOLING SYSTEM
ENGINE COOLANT PUMP COMPONENTS
(1)
(2)
(3)
(5)
(4)
(8) (14)
(7)
(6)
(9)
(12)
(10)
(11)
(13)
0000031A-01
1 – Thermostat Cover 8 – Gasket

2 – Thermostat Cover Gasket 9 – Engine Coolant Pump Gasket
3 – Thermostat 10 – V-Belt
4 – Thermostat O-Ring 11 – Engine Coolant Pump V-Pulley
5 – Special O-Ring 12 – Spacer
6 – Engine Coolant Pump 13 – Engine Coolant Fan
7 – Temperature Switch 14 – Water temperature sensor
(Electronically controlled engine)
Figure 8-2

COOLING SYSTEM Engine Coolant System Check
ENGINE COOLANT SYSTEM 1. Before removing the engine coolant pump or

thermostat, it will be necessary to drain the
CHECK engine coolant. Drain the coolant into a clean
Check the engine coolant system for leakage. container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
1. With the radiator properly filled, install a cooling
2. Remove the radiator cap (Figure 8-4, (1)).
system tester (Figure 8-3, (1)).
3. Remove the drain plug or open the drain cock
(Figure 8-4, (1)) at the lower portion of the
radiator and drain the coolant.
(1)
(1)
0000577A
Figure 8-3
FULL
LOW
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05

kgf/cm²) to the cooling system. If the pressure
reading drops, the engine coolant system is
leaking. Identify the source of the leak and
repair it.
(2) 0000074A
ENGINE COOLANT PUMP Figure 8-4

Removal of Engine Coolant Pump 4. Drain the coolant from the engine block.
Verify the condition of the engine coolant pump • On models equipped with an oil cooler, remove
before disassembling it from the engine. Check the the coolant hose (Figure 8-5, (1)) at the oil
engine coolant pump shaft bearing for abnormal cooler.
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these conditions
are present.
CAUTION
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant
pump or replace individual components.
0000041en
IMPORTANT
Make sure the engine and engine coolant (1) 0001579B
are not hot. Figure 8-5

Engine Coolant Pump COOLING SYSTEM
• On models not equipped with an oil cooler,
remove the coolant drain plug (Figure 8-6, (1))
from the engine block.
(2) (1)
(4)
(1)
(3)
0000163B
0000027B
Figure 8-7
Figure 8-6
7. Disconnect the coolant hoses and the
5. Loosen the alternator mounting bolts. Loosen temperature switch lead wire from the engine
and remove the V-belt and rotate the alternator coolant pump.
away from the engine and out of the way.
8. Remove the engine coolant pump
A CAUTION (Figure 8-7, (4)). Discard the gasket.
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the
0000014en
6. Remove the engine coolant fan guard (if

equipped), engine coolant fan (Figure 8-7, (1)),
spacer (Figure 8-7, (2)) and engine coolant
pump V-pulley (Figure 8-7, (3)).

COOLING SYSTEM Engine Coolant Pump
Disassembly of Engine Coolant

Pump (3) (1)
1. Remove the thermostat cover (Figure 8-8, (1)).
Discard the gasket.
(2)
(1)
(4) (2)
(3) 0000577A
Figure 8-9
2. Place the temperature switch and an accurate
thermometer (Figure 8-9, (3)) in engine
coolant.
3. Slowly increase temperature of the fluid using
an external heat source.
4. The temperature switch is operating properly if
the continuity light or ohmmeter indicates
continuity when the fluid temperature reaches
225°F - 235°F (107°C - 113°C).
0000267A
Water temperature sensor
Figure 8-8 1. Inspect the water temperature sensor to make
2. Remove the thermostat (Figure 8-8, (2)). sure that it is properly operating. As shown in
Discard the O-ring. Remove the temperature the following figure, connect an electric resistor
switch (Figure 8-8, (3)) and gasket to the coupler of the water temperature sensor
(Figure 8-8, (4)). Discard the gasket. (Figure 8-10, (1)).
Cleaning and Inspection

Temperature Switch (1)
1. Check for proper operation of the temperature
(2)
switch. Connect a continuity light or ohmmeter
to the temperature switch. Connect one lead to
the terminal of the switch (Figure 8-9, (1)) and
the other lead to the metal portion of the switch
(Figure 8-9, (2)).
Figure 8-10

2. Dip the water temperature sensor and an Radiator Cap
accurate thermometer (Figure 8-10, (2)) into 1. Check for proper operation of the radiator cap.
the cooling water. Install the radiator cap (Figure 8-12, (1)) on a
3. Measure the electric resistance value while cooling system tester.
slowly raising the cooling water temperature
using an external heat source.
4. The resistance value at each of the following
temperatures is within the permissible range
specified, the water temperature sensor is
correctly operating.
(1)
Cooling water
Resistance (kΩ)
temperature (°C) 0000577A
20 2.45 +0.14
-0.13 Figure 8-12
80 0.318 ± 0.008 2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05
100 (0.1836) kgf/cm²) to the radiator cap. The radiator cap
relief valve must open within the specified
Thermostat range.
1. Check for proper operation of the thermostat.
Place the thermostat (Figure 8-11, (1)) and an Reassembly of Engine Coolant Pump
accurate thermometer (Figure 8-11, (2)) in 1. Reinstall the thermostat (Figure 8-13, (1)) and
warm water. a new O-ring.
(2)
(2)
(5) (1)
(1)
(4)
(3)
0000577A
Figure 8-11
2. Slowly increase the temperature of the water
using an external heat source.
3. The thermostat is operating properly if it starts
to open at the temperature value stamped on
the flange of the thermostat, and fully opens as 0001623A
the temperature of the water is increased.
Figure 8-13

2. Reinstall the thermostat cover

(Figure 8-13, (2)) and a new gasket. Tighten
the thermostat cover bolts.
3. Reinstall the temperature switch
(Figure 8-13, (3)) and a new gasket
(2) (3)
(Figure 8-13, (4)).
Installation of Engine Coolant Pump

1. Position the engine coolant pump on the engine
and install a new gasket. Install a new special
O-ring (Figure 8-13, (5)) on assembly between
the engine coolant pump and the joint.
CAUTION (1)
0000163C
Use a new special O-ring between the
engine coolant pump and the joint. Be Figure 8-14
sure to use the special O-ring for each
engine model. Although the O-ring 5. Inspect the condition of the V-belt. There must
dimensions are the same as a be clearance (Figure 8-15, (1)) between the
commercially available O-ring, the V-belt and the bottom of the pulley groove. If
material is different. there is no clearance (Figure 8-15, (2))
between the V-belt and the bottom of the pulley
0000042en
groove, replace the V-belt.
2. Reinstall the engine coolant pump bolts.
Tighten the bolts.
3. Inspect and reinstall the coolant hoses and the
temperature switch lead wire.
4. Reinstall the engine coolant pump V-pulley (2)
(Figure 8-14, (1)), spacer (Figure 8-14, (2))
(1)
engine coolant fan (Figure 8-14, (3)) and
engine coolant fan guard (if equipped).
0000584
Figure 8-15
6. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and Adjust Cooling
Fan V-Belt on page 5-30.
7. Reinstall and tighten the drain plug or close the
drain cock in the radiator. Reinstall and tighten
the engine block drain plug or reconnect the
coolant hose at the oil cooler.
8. Fill the radiator and engine with engine coolant.
See Drain, Flush and Refill Cooling System
With New Coolant on page 5-36.

CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
buildup of rust and scale and / or
shorten engine life.
remove the cap.
coolants. This may adversely affect the
properties of the engine coolant.
0000006en


Section 9
LUBRICATION
SYSTEM
Page
Introduction...................................................................................... 9-5
Oil Pump Service Information.......................................................... 9-5
Lubrication System Diagram ........................................................... 9-8
Checking Engine Oil Pressure ........................................................ 9-9
Trochoid Oil Pump........................................................................... 9-9
3TNV82A to 4TNV88 Oil Pump Components............................ 9-9
Disassembly of Oil Pump ........................................................ 9-10
Reassembly of Oil Pump ......................................................... 9-12
Trochoid Oil Pump......................................................................... 9-13
3TNV82A-B, 3TNV88-B, 3TNV88-U, 4TNV88-B4TNV88-U,
3TNV84T-Z, 4TNV84T-Z Oil Pump Components.................... 9-13
Cleaning and inspection .......................................................... 9-14
Trochoid Oil Pump......................................................................... 9-17
4TNV94L/98/106 Oil Pump Components ................................ 9-17

LUBRICATION SYSTEM

Before You Begin Servicing LUBRICATION SYSTEM
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
BURN HAZARD!
ENTANGLEMENT HAZARD! as the muffler, exhaust pipe,
• Stop the engine before you begin to turbocharger (if equipped) and engine
service it. block during operation and shortly
seriously burn you.
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000015en
back long hair, and keep your hands, A WARNING
or serious injury.
0000010en
FUME / BURN HAZARD!

sealant removers.
or serious injury.
0000014en

LUBRICATION SYSTEM Before You Begin Servicing
A CAUTION CAUTION
• Only use the engine oil specified.
coverage, cause internal engine
engine life.
• ALWAYS wear eye protection when clean the oil cap / dipstick and the
servicing the engine and when using surrounding area before you remove
compressed air or high-pressure the cap.
oil. This may adversely affect the
injure your eyes.
or moderate injury.
0000003en
0000005en
A CAUTION
If any oil pump component clearance CAUTION
If the oil pump must be replaced, replace
it as an assembly only. Do not replace
0000015en
individual components.
0000030en

Introduction LUBRICATION SYSTEM
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 3TNV82A to
4TNV88, and 4TNV94L/98/106 Trochoid oil pumps.
See Replace Engine Oil and Engine Oil Filter on page 5-28 for engine oil and engine oil filter replacement
procedures.
OIL PUMP SERVICE INFORMATION

Engine Oil Pressure
At Rated Engine RPM
Model 1500 - 1800 2000 - 2500 2600 2700 2800 2900 - 3000 At Low Idle Speed
min-1 min-1 min-1 min-1 min-1 min-1
0.34 - 0.49MPa 0.39 - 0.54MPa
3TNV82A
(3.5 - 5.0kgf/cm2) (4.0 - 5.5kgf/cm2)
0.31 - 0.46MPa 0.36 - 0.51MPa
3TNV82A-B -
(3.2 - 4.7kgf/cm2) (3.7 - 5.2kgf/cm2)
3TNV84
3TNV88 0.34 - 0.49MPa 0.39 - 0.54MPa
4TNV84 (3.5Å`5.0kgf/cm2) (4.0 - 5.5kgf/cm2)
4TNV88
3TNV88-B 0.29 - 0.44MPa 0.34 - 0.49MPa 0.39 - 0.54MPa
3TNV88-U (3.0 - 4.5kgf/cm2) (3.5 - 5.0kgf/cm2) (4.0 - 5.5kgf/cm2)
4TNV88-B 0.29 - 0.44MPa 0.32 - 0.47MPa
4TNV88-U (3.0 - 4.5kgf/cm2) (3.3 - 4.8kgf/cm2) 0.06MPa
3TNV84T 0.29 - 0.44MPa 0.34 - 0.49MPa 0.39 - 0.54MPa (0.6kgf/cm2)
3TNV84T-Z (3.0 - 4.5kgf/cm2) (3.5 - 5.0kgf/cm2) (4.0 - 5.5kgf/cm2) or greater
4TNV84T 0.29 - 0.44MPa 0.36 - 0.51MPa

4TNV84T-Z (3.0 - 4.5kgf/cm2) (3.7 - 5.2kgf/cm2)
4TNV94L
4TNV98
4TNV98-Z 0.29 - 0.39MPa
4TNV98-E (3.0 - 4.0kgf/cm2)
4TNV98T
4TNV98T-Z
With balancer: Without balancer:
4TNV106 0.31 - 0.49MPa
0.34 - 0.44MPa 0.39 - 0.49MPa
4TNV106T (3.2 - 5.0kgf/cm2)
(3.5 - 4.5kgf/cm2) (4.0 - 5.0kgf/cm2)

LUBRICATION SYSTEM Oil Pump Service Information
Outer Rotor Outside Clearance

Reference
Model Standard Limit
Page
Check Outer
3TNV82A, 3TNV84, 3TNV84T
0.0047 - 0.0083 in. 0.0118 in. Rotor Outside
3TNV88, 4TNV84, 4TNV88,
(0.12 - 0.21 mm) (0.30 mm) Clearance on
4TNV84T
page 9-11
3TNV82A-B Check Outer
3TNV88-B, 3TNV88-U 0.0035 - 0.0063 in. 0.0098 in. Rotor Outside
4TNV88-B, 4TNV88-U (0.09 - 0.16 mm) (0.25 mm) Clearance on
3TNV84T-Z, 4TNV84T-Z page 9-14
0.0039 - 0.0061 in. 0.0098 in. Check Outer
4TNV98-Z, 4TNV98-E
(0.100 - 0.155 mm) (0.25 mm) Rotor Outside
4TNV98T-Z
Clearance on
0.0039 - 0.0065 in. 0.0098 in. page 9-18
4TNV106, 4TNV106T
(0.100 - 0.165 mm) (0.25 mm)
Outer Rotor Side Clearance

Model Standard Limit Reference Page
3TNV82A, 3TNV84, 3TNV84T
0.0008 - 0.0028 in. 0.0047 in. Check Outer Rotor Side
3TNV88, 4TNV84, 4TNV88,
(0.02 - 0.07 mm) (0.12 mm) Clearance on page 9-12
4TNV84T
3TNV82A-B
3TNV88-B, 3TNV88-U 0.0020 - 0.0039 in. 0.0059 in. Check Outer Rotor Side
4TNV88-B, 4TNV88-U (0.05 - 0.10 mm) (0.15 mm) Clearance on page 9-15
0.0020 - 0.0039 in. 0.0059 in.
4TNV98-Z, 4TNV98-E
(0.05 - 0.10 mm) (0.15 mm) Check Outer Rotor Side
4TNV98T-Z
Clearance on page 9-18
0.0012 - 0.0047 in. 0.0067 in.
4TNV106, 4TNV106T
(0.03 - 0.12 mm) (0.17 mm)
Outer Rotor to Inner Rotor Tip Clearance

Model Standard Limit Reference Page
3TNV82A, 3TNV84, 3TNV84T Outer Rotor to Inner
0.0063 in.
3TNV88, 4TNV84, 4TNV88, - Rotor Tip Clearance on
(0.16 mm)
4TNV84T page 9-11
3TNV82A-B
Outer Rotor to Inner
3TNV88-B, 3TNV88-U 0.0063 in.
- Rotor Tip Clearance on
4TNV88-B, 4TNV88-U (0.16 mm)
page 9-15
0.0063 in.
4TNV98-Z, 4TNV98-E - Outer Rotor to Inner
(0.16 mm)
4TNV98T-Z Rotor Tip Clearance on
0.0063 in. page 9-18
4TNV106, 4TNV106T -
(0.16 mm)

Oil Pump Service Information LUBRICATION SYSTEM
Inner Rotor and Gear Boss Clearance
<Multiple tooth trochoid type 3TNV82A - 4TNV88>
Standard
Standard Standard Reference
Item Parts Clearance
Dimension Clearance Page
Limit
2.0886 - 2.0925 in.
Gear Boss Diameter
Inside Clearance of (53.05 - 53.15 mm) 0.012 - 0.020 in. 0.024 in.
Inner Rotor 2.1043 - 2.1083 in. (0.3 - 0.5 mm) (0.6 mm) Check Inner
Rotor Diameter Rotor and
(53.45 - 53.55 mm)
Gear Boss
Width Across Flat of 1.9468 - 1.9587 in. Clearance on
Inner Rotor Width Gear Boss (49.45 - 49.75mm) 0.008 - 0.020 in. 0.028 in. page 9-12
Across Flat
Width Across Flat of 1.9665 - 1.9705 in. (0.2 - 0.5 mm) (0.7 mm)
Clearance
Rotor (49.95 - 50.05 mm)
Rotor Shaft Clearance

<Trochoid type 3TNV82A-B - 4TNV88-B, 4TNV94L - 4TNV106T>
Reference
Page
0.3937 - 0.3943 in. 0.3953 in.
3TNV82A-B ÉvÉåÅ[ÉgéðéÛì‡åa
(10.000 - 10.015 mm) (10.040 mm) Check Rotor
3TNV88-B, 3TNV88-U
0.3919 - 0.3924 in. 0.3913 in. Shaft
4TNV88-B, 4TNV88-U Rotor Shaft O.D.
(9.955 - 9.967 mm) (9.940 mm) Clearance on
3TNV84T-Z, 4TNV84T-
0.0013 - 0.0024 in. 0.0039 in. page 9-15
Z Rotor Clearance
(0.033 - 0.060 mm) (0.100 mm)
0.5110 - 0.5126 in. 0.5138 in.
ÉMÉÑÉPÅ[ÉXéðéÛì‡åa
4TNV94L, 4TNV98, (12.980 - 13.020 mm) (13.050 mm)
4TNV98T 0.5100 - 0.5104 in. 0.5096 in.
Rotor Shaft O.D.
4TNV98-Z, 4TNV98-E (12.955 - 12.965 mm) (12.945 mm)
4TNV98T-Z 0.0006 - 0.0026 in. 0.0041 in.
Rotor Clearance Check Rotor
(0.015 - 0.065 mm) (0.105 mm) Shaft
0.5118 - 0.5126 in. 0.5138 in. Clearance on
ÉMÉÑÉPÅ[ÉXéðéÛì‡åa page 9-19
(13.000 - 13.020 mm) (13.050 mm)
0.5100 - 0.5104 in. 0.5096 in.
4TNV106, 4TNV106T Rotor Shaft O.D.
(12.955 - 12.965 mm) (12.945 mm)
0.0014 - 0.0026 in. 0.0041 in.
Rotor Clearance
(0.035 - 0.065 mm) (0.105 mm)

LUBRICATION SYSTEM Lubrication System Diagram
LUBRICATION SYSTEM DIAGRAM
Oil Filter
Turbocharger*
Bypass Valve
Oil Cooler* Fuel

Injection Pump
Oil Pressure
Switch
Cylinder Body - Main Gallery

Pressure
Regulator Valve
Idle Gear Camshaft Crank
Oil Pump Shaft Bearing Journal
Piston Cooling Rocker Arm Crank Pin

Oil Suction Pipe Nozzles* Bearing
Strainer
Rocker Arm
Tappet
Cam Face
Oil Pan
0000042
Figure 9-1
Note: Items marked * are not standard equipment on all models.

Checking Engine Oil Pressure LUBRICATION SYSTEM
CHECKING ENGINE OIL TROCHOID OIL PUMP

PRESSURE
3TNV82A TO 4TNV88 Oil Pump
Perform an engine oil pressure check if there is any
indication of low oil pressure such as the oil
Components
pressure indicator is on or the oil pressure gauge On these model engines, the oil pump is located
indicates low oil pressure. See Engine Oil Pressure inside the front gear case cover and is driven by a
on page 9-5. boss on the front crankshaft gear. You must remove
the front gear case cover to gain access to the oil
1. Disconnect the wire lead from the oil pressure pump.
switch or sending unit (Figure 9-2, (1)).
(1)
(2) (5) (6)
(1) (3)
(4)
0000028B
0000075A
Figure 9-2
2. Remove the oil pressure switch. 1 – Crankshaft
2 – Oil Pump Cover
3. Install a mechanical oil pressure gauge in the 3 – Oil Pressure Regulator
oil pressure switch port. 4 – Gear Case Cover
4. Start the engine: 5 – Outer Rotor
6 – Inner Rotor
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty Figure 9-3
oil pressure switch or sending unit, or faulty
machine oil pressure gauge in instrument
panel.
• If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the
lubrication system to locate the cause of the
low oil pressure. See Failure Diagnosis Table
on page 15-191. Repair as necessary.

LUBRICATION SYSTEM Trochoid Oil Pump
Disassembly of Oil Pump (1) (2)
CAUTION
0000030en
1. Remove the engine cooling fan guard (if

equipped), engine cooling fan (Figure 9-4, (3)),
spacer (Figure 9-4, (2)), engine coolant pump
V-pulley (Figure 9-4, (1)) and V-belt.
0001625
Figure 9-5
4. Remove the oil pump cover (Figure 9-5, (1))
(2) (3)
from the gear case cover.
5. Remove the outer rotor (Figure 9-6, (2)) and
inner rotor (Figure 9-6, (1)) from the gear case
cover.
(2)
(1)
(1)
0000163C
Figure 9-4
2. Remove the crankshaft pulley and gear case
cover. See Removal of Timing Gear Case
Cover on page 6-73.
3. Remove the seven oil pump cover
(Figure 9-5, (1)) screws (Figure 9-5, (2)). 0001626
Note: The oil pump cover screws are installed

Figure 9-6
using a liquid thread lock. It may be
necessary to use a “localized heat”
(small propane torch) and an
impact-type screwdriver or air tool to
remove these screws.

Trochoid Oil Pump LUBRICATION SYSTEM
6. Remove the oil pressure regulator valve Record the measurement(s) and see Outer
(Figure 9-7, (1)) from the oil pump cover Rotor Outside Clearance on page 9-6 for the
(Figure 9-7, (2)). service limits.
(1)
(2)
(2)
(1) 0001151A
Figure 9-8
0001642
Figure 9-7
Determine the outer rotor to inner rotor tip
Cleaning and Inspection clearance. Insert a feeler gauge between the top of
an inner rotor tooth (Figure 9-9, (1)) and the top of
Wash the oil pump cover, the oil pressure regulator
an outer rotor tooth (Figure 9-9, (2)) and measure
valve, the oil pump cavity and the inner and outer
the clearance.
rotors. Inspect the parts for wear or damage.
Replace as necessary.
Note: If the oil pump cavity is damaged, the
gear case cover must be replaced.
A CAUTION
(1)
If any oil pump component clearance
0000015en
(2) 0001150A
Check Outer Rotor Outside Clearance
Figure 9-9
1. Reinstall the outer and inner rotors. The dots on
the rotor faces must face “up.” Make sure that Record the measurement(s) and see Outer Rotor
the pilot on the back of the inner rotor fits into to Inner Rotor Tip Clearance on page 9-6 for the
the bore of the oil pump cavity and the top service limits.
surface of the inner rotor is flush with the top
surface of the outer rotor.
2. Determine the outside clearance of the outer
rotor. Insert a feeler gauge between the outer
rotor (Figure 9-8, (1)) and the gear case oil
pump cavity (Figure 9-8, (2)).

Check Outer Rotor Side Clearance Record the measurement(s) and see Inner Rotor
Determine the side clearance of the outer rotor and Gear Boss Clearance <Multiple tooth trochoid
across the pump cavity. While pressing down on type 3TNV82A - 4TNV88> on page 9-7 for the
the outer rotor, measure the depression using a service limits.
depth micrometer (Figure 9-10).
Reassembly of Oil Pump
1. Lubricate the outer rotor (Figure 9-12, (1)),
10
25 20 15
inner rotor (Figure 9-12, (2)) and pump bore in

the gear case cover with clean engine oil.
(5)
(3)
0001152 (1)
(2)
Figure 9-10
Record the measurement(s) and see Outer Rotor
Outside Clearance on page 9-6 for the service
limits.
Check Inner Rotor and Gear Boss (4)

Clearance 0000044A
Using appropriate measuring instruments, measure Figure 9-12

the outside dimensions of the crankshaft gear boss
and the inside dimensions of the inner rotor 2. Reinstall the outer rotor in the gear case. The
(Figure 9-11). dot mark on the face of the outer rotor must
face up toward the oil pump cover.
(5) 3. Reinstall the inner rotor into the gear case cover
with the dot mark also facing up. Make sure that
(3) the pilot on the back side of the inner rotor fits
into the bore in the gear case cover and the top
surface of the inner rotor is flush with the top
surface of the outer rotor.
4. Reinstall the oil pressure regulator valve into
the oil pump cover. Apply LOCTITE® 242 (red)
(1) (6) to the valve plug. (Follow LOCTITE package
(4)
(2) instructions.)
0000076A
5. Reinstall the oil pump cover (Figure 9-12, (3)).
1 – Crank Gear Apply LOCTITE 290 (green) or LOCTITE 262
2 – Inner Rotor (red) to the oil pump cover screws. (Follow
3 – Inside Width Across Flats of Inner Rotor
LOCTITE package instructions.) Tighten the
4 – Overall Inside Diameter of Inner Rotor
pump cover screws to 61 ± 13 in·lb
5 – Outside Width Across Flats of Gear Boss
6 – Overall Outside Diameter of Gear Boss (6.9 ± 1.5 N·m, 0.7 ± 0.15 kgf·m).
Figure 9-11

6. Reinstall the gear case cover and crankshaft TROCHOID OIL PUMP
pulley. See Installation of Gear Case Cover on
page 6-97. 3TNV82A-B, 3TNV88-B, 3TNV88-
7. Reinstall the engine coolant pump V-pulley
(Figure 9-13, (1)), spacer (Figure 9-13, (2)),
U, 4TNV88-B4TNV88-U,
engine cooling fan (Figure 9-13, (3)) and 3TNV84T-Z, 4TNV84T-Z Oil Pump
engine cooling fan guard (if equipped). Components
The oil pump on these model engines is located in
the front gear case and is driven by the same gear
train that drives the camshaft and fuel injection
(2) (3) pump. You must remove the front gear case cover
to gain access to the oil pump.
(3) (7) (1) (2) (6)
(1)
0000163C
Figure 9-13
8. Reinstall the V-belt. Tighten the V-belt to the (5) (4)
proper tension as described in Check and
Adjust Cooling Fan V-Belt on page 5-22.
1 – Body
2 – Shaft
3 – Inner rotor
4 – Outer rotor
5 – Cover
6 – Drive gear
7 – Pressure regulator valve
Figure 9-14

Disassembly of Oil Pump
CAUTION
0000030en
Remove the cooling water fan guard (if equipped),

cooling fan (Figure 9-15, (3)), spacer
(Figure 9-15, (2)), cooling water pump V-pulley
(Figure 9-15, (1)), and V-belt.
(1)
(2) (3)
(2)
Figure 9-16
Cleaning and inspection

Clean the lubricating oil pump, pressure regulator
(1) valve (Figure 9-14, (7)), and rotor inserting portion.
0000163C
Check the parts for wear or flaw. Replace the parts
Figure 9-15 with new ones as needed.
1. Remove the crank shaft pulley and gear case
cover. See Removal of Timing Gear Case CAUTION
Cover on page 6-73. • NEVER overfill the engine with engine
2. Remove the lubricating oil pump assembly oil.
mounting bolts. Remove the lubricating oil • ALWAYS keep the oil level between the
pump assembly (Figure 9-16, (1)) from the upper and lower lines on the oil
gear case flange (Figure 9-16, (2)). cap / dipstick.
3. You can remove by hand the lubricating oil 0000015en
pump cover (Figure 9-14, (5)) and outer rotor

(Figure 9-14, (4)). Check Outer Rotor Outside Clearance
Inspect the outside diameter clearance of the outer
rotor. To inspect this, insert a feeler gauge between
the outer rotor (Figure 9-17, (1)) and the lubricating
oil pump body (Figure 9-17, (2)).

to Inner Rotor Tip Clearance on page 9-6 for the
(1) service limits.
Check Outer Rotor Side Clearance

Inspect the side clearance between the lubricating
oil pump body and the outer rotor. To measure the
side clearance, use a straight edge and feeler
gauge (as shown in Figure 9-19) or a depth
(2) micrometer.
Figure 9-17
limits.

Inspect the tip clearance between the outer and
inner rotors. To inspect this, insert a feeler gauge
between the inner rotor tooth tip (Figure 9-18, (1))
and the outer rotor tooth tip (Figure 9-18, (2)), and
measure the clearance. Figure 9-19
limits.
(1)
Check Rotor Shaft Clearance
Inspect the rotor shaft clearance. Measure the
outside diameter of the rotor shaft
(Figure 9-20, (1)) and the inside diameter of the
cover.
Determine the clearance by subtracting the outside
diameter of the rotor from the inside diameter of the
(2) cover.
Figure 9-18

(1)
(2) (3)
(2)
Figure 9-20
Record the measurement(s) and see Rotor Shaft (1)
0000163C
Clearance <Trochoid type 3TNV82A-B - 4TNV88-B,
4TNV94L - 4TNV106T> on page 9-7 for the service Figure 9-21
limits. 8. Install the V-belt. Adjust the belt to uniform
tensile strength in accordance with the
Reassembly of Oil Pump instructions given in Check and Adjust Cooling
1. Apply clean lubricating oil to the lubricating oil Fan V-Belt on page 5-22.
pump body and inner rotor assembly as well as
to the outer rotor.
2. Insert the outer rotor into the lubricating oil
pump body and inner rotor assembly and install
the cover.
3. Replace the packing with new one.
4. Install the lubricating oil pump assembly to the
gear case flange by tightening the bolts with
the specified torque.
5. Install the gear case cover. For more
information, See Installation of Gear Case
Cover on page 6-97.
6. Install the crank shaft pulley.
7. Install the cooling water pump V-pulley
(Figure 9-21, (1)), spacer (Figure 9-21, (2)),
cooling water fan (Figure 9-21, (3)), and fan
guard (if equipped).

TROCHOID OIL PUMP Disassembly of Oil Pump
4TNV94L/98/106 Oil Pump CAUTION

Components If the oil pump must be replaced, replace
The oil pump on these model engines is located in individual components.
the front gear case and is driven by the same gear
0000030en
train that drives the camshaft and fuel injection
pump. You must remove the front gear case cover Remove the engine cooling fan guard (if equipped),
to gain access to the oil pump. engine cooling fan (Figure 9-23, (3)), spacer
(Figure 9-23, (2)), engine coolant pump V-pulley
(Figure 9-23, (1)) and V-belt.
(1)
(2)
(5)
(2) (3)
(3)
(4) 0000043A
1 – Gear Case Housing

2 – Outer Rotor
3 – Inner Rotor
4 – Cover Plate
5 – Drive Gear (1)
0000163C
Figure 9-22
Figure 9-23
1. Remove the crankshaft pulley and the gear
case cover. See Removal of Timing Gear Case
Cover on page 6-73.
2. Remove the oil pump assembly bolts. Remove
the oil pump assembly (Figure 9-24, (1)) from
the gear case housing (Figure 9-24, (2)).


Determine the outer rotor to inner rotor tip
clearance. Insert a feeler gauge between the top of
an inner rotor tooth (Figure 9-26, (1)) and the top
of an outer rotor tooth (Figure 9-26, (2)) and
measure the clearance.
(1)
(1)
(2)
(2) 0000049D
Figure 9-24

Wash the oil pump, oil pressure regulator and oil
pump cavity. Inspect for wear or damage. Replace 0001153A
as necessary.
Figure 9-26
A CAUTION Record the measurement(s) and see Outer Rotor

If any oil pump component clearance to Inner Rotor Tip Clearance on page 9-11 for the
exceeds its limit, the oil pump must be service limits.
Check Outer Rotor Side Clearance
0000015en
Determine the side clearance of the outer rotor
Check Outer Rotor Outside Clearance across the pump cavity. Measure the depression
using a depth micrometer (Figure 9-27, (1)).
Determine the outside clearance of the outer rotor.
Insert a feeler gauge between the outer rotor
(Figure 9-25, (1)) and gear case oil pump cavity (1)
(Figure 9-25, (2)).
(1)
(2)
0000045A
Figure 9-25 0001615A
Figure 9-27
Record the measurement(s) and see Check Outer
Rotor Outside Clearance on page 9-11 for the Record the measurement(s) and see Check Outer
service limits. Rotor Side Clearance on page 9-12 for the service
limits.

Check Rotor Shaft Clearance 3. Reinstall the oil pump assembly
Determine the rotor shaft clearance. Measure the (Figure 9-30, (1)) into the gear case housing
outside diameter of the rotor shaft (Figure 9-30, 2). Tighten the bolts to specified
(Figure 9-28, (1)) and the bore diameter in the gear torque.
case housing (Figure 9-28, (2)).
Calculate the difference between the two
measurements to determine the clearance.
(1)
(1)
(2) 0000049D
Figure 9-30
(2) 4. Reinstall the gear case cover and crankshaft
0000047A pulley. See Installation of Gear Case Cover on
Figure 9-28 page 6-97.
5. Reinstall the engine coolant pump V-pulley
Record the measurement(s) and see Rotor Shaft (Figure 9-31, (1)), spacer (Figure 9-31, (2)),
Clearance <Trochoid type 3TNV82A-B - 4TNV88-B, engine cooling fan (Figure 9-31, (3)) and
4TNV94L - 4TNV106T> on page 9-7 for the service engine cooling fan guard (if equipped).
limits.
Reassembly of Oil Pump

1. Lubricate the outer rotor and pump bore in the
gear case with clean engine oil. (2) (3)
2. Reinstall the outer rotor in the gear case
housing. The punch mark (Figure 9-29, (1)) on
the end of the outer rotor must face away from
the gear case housing (Figure 9-29, (2)).
(1)
0000163C
Figure 9-31
1
0000048A Adjust Cooling Fan V-Belt on page 5-22.
Figure 9-29


Section 10
TURBOCHARGER
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-5
Specifications ................................................................................ 10-5
Turbocharger Service Information ........................................... 10-5
Troubleshooting............................................................................. 10-6
Excessive Exhaust Smoke ...................................................... 10-6
Generates White Smoke ......................................................... 10-7
Sudden Oil Decrease .............................................................. 10-7
Decrease in Output.................................................................. 10-7
Poor (Slow) Response (Starting) of Turbocharger .................. 10-7
Abnormal Sound or Vibration .................................................. 10-7
Turbocharger Components ........................................................... 10-8
Turbocharger Component Functions........................................... 10-10
Theory of Operation............................................................... 10-11
Compressor Side Sealing Mechanism .................................. 10-11
Waste Gate Modulation ......................................................... 10-11
Washing Procedure..................................................................... 10-12
Periodic Inspection ...................................................................... 10-13
Visual Inspection ................................................................... 10-13
Inspection of Rotor Rotation .................................................. 10-13
Inspection of Rotor Play ........................................................ 10-13
Removal of Turbocharger...................................................... 10-13
Checking Rotor Play.............................................................. 10-14
Waste Gate Valve Test.......................................................... 10-14
Waste Gate Actuator Leak Test ............................................ 10-15
Installation of Turbocharger................................................... 10-15

TURBOCHARGER

Before You Begin Servicing TURBOCHARGER
BEFORE YOU BEGIN

A WARNING
SERVICING Never apply over 40 psi (2.8 kgf/cm) to
the waste gate actuator.
A WARNING 0000026en
A CAUTION
service it.
Someone may accidentally start the • ALWAYS wear eye protection when
engine and not realize you are servicing the engine and when using
servicing it. This could result in a compressed air or high-pressure
serious injury. water. Dust, flying debris, compressed
injure your eyes.
back long hair, and keep your hands, • Failure to comply may result in minor
other body parts and clothing away or moderate injury.
from moving / rotating parts. 0000003en

or serious injury. CAUTION
0000010en For maximum engine life, Yanmar
recommends that when shutting the
A WARNING engine down, you allow the engine to
idle, without load, for five minutes. This
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
FUME / BURN HAZARD!
0000008en
sealant removers.
or serious injury.
0000014en

TURBOCHARGER Before You Begin Servicing
CAUTION
Avoid damage to the turbocharger or the
engine. Do not spray blower wash fluid
or water too quickly.
Use short strokes from a spray bottle to
inject blower wash fluid or water into the
turbocharger.
Spraying too much wash fluid or water,
or spraying too quickly will damage the
turbocharger.
0000063en
CAUTION
Do not allow any material to fall into the
oil lines or the oil inlet and outlet ports
of the turbocharger.
0000064en
CAUTION
If the waste valve does not meet
specifications, replace the turbocharger
or have it repaired by a qualified repair
facility.
0000078en

Introduction TURBOCHARGER
INTRODUCTION
This section of the Service Manual describes the servicing of the RHF5, RHB31 and RHB51 model
turbochargers.
SPECIFICATIONS
Turbocharger Service Information
3TNV84T (CL,
4TNV106T
Applicable Engine Model (application) VM) 3TNV84T (VM) 4TNV98T
(CL, VM)
4TNV84T (CL)
Turbocharger Model RHB31 RHB51 RHF5 RHF5
Turbocharger Specification Standard (w/waste gate)
Turbine Type Radial flow
Blower (Compressor) Type Centrifugal
Lubrication External lubrication
Maximum Continuous Allowable Speed 250,000 180,000
Maximum Continuous Allowable Gas Inlet
750°F (399°C)
Temperature
5.4 lb 9.2 lb 10.3 lb 10.3 lb
Weight (Dry)
(24 N; 2.4 kgf) (41 N; 4.2 kgf) (46 N; 4.7 kgf) (46 N; 4.7 kgf)
Note: VM application is provided with the waste gate.

TURBOCHARGER Troubleshooting
TROUBLESHOOTING
The following troubleshooting procedures apply to problems identified as turbocharger related. Consider all
other troubleshooting possibilities before cleaning or removing the turbocharger.
Excessive Exhaust Smoke

Cause Corrective action
Clogged air cleaner element Clean or replace the air cleaner element
Blocked air intake port Correct the condition
Leak from a joint in intake line Correct the condition

1. Compressor impeller dirty
1. Wash the impeller blades.
2. Deposit of impurities in oil sticking on the turbine side seal
2. Repair the turbocharger. Send to a qualified repair facility.
portion to make turbine revolution heavy
3. Sticking bearing:
3a. Repair turbocharger. Send to qualified repair facility.
3a. Insufficient lubrication or clogged lubrication piping
3b. Inspect the lubricating oil line for problem. Correct the
3b. Excessively high oil temperature
condition and replace lubricating oil.
3c. Repair the turbocharger. Send to a qualified repair
3c. Unbalanced rotating part
facility.
3d. Improper operation of the machine. Refer to the
3d. Insufficient warming up or sudden stop from loaded
Operation Manual.
operation (no-load operation)
4. Contact or breakdown of turbine wheel or blower vane: 4a. Inspection and repair of each engine part
4a. Excessive revolution 4b. Inspection and repair of each engine part
4b. Excessive exhaust temperature rise 4c. Clean the air cleaner and engine compartment. Repair
4c. Foreign matter within turbocharger the turbocharger. Send to a qualified repair facility.
4d. Repair the turbocharger. Send to a qualified repair
4d. Worn bearing facility.
4e. Repair the turbocharger. Send to a qualified repair
4e. Incorrect assembly of turbocharger facility.

Exhaust system gas leak prior to the turbocharger. Condition
Inspect the exhaust system for leaks. Correct the condition.
will decrease turbocharger revolutions.
Deformed or clogged exhaust pipe. Condition will decrease
Correct the condition.
turbocharger revolutions.

Troubleshooting TURBOCHARGER
Generates White Smoke
Clogged or deformed oil return pipe causing oil flow to the Correct the condition
blower on the turbine side
Excessive bearing wear causing abnormal wear or damage of
the seal ring Repair the turbocharger. Send to a qualified repair facility.
Sudden Oil Decrease

Excessive bearing wear causing abnormal wear or damage of
Repair turbocharger. Send to qualified repair facility.
the seal ring
Decrease in Output
Gas leak from any part in exhaust piping Correct the condition
Air leak from discharge side of blower Correct the condition
Clogged air cleaner element Clean or replace the air cleaner element
Damaged turbocharger Repair the turbocharger. Send to a qualified repair facility
Poor (Slow) Response (Starting) of

Turbocharger
Hard carbon deposit on the turbine side (wheel sealing portion)
Repair the turbocharger. Send to a qualified repair facility
causing abnormal revolution of the turbine shaft
Incomplete combustion Correct the condition
Abnormal Sound or Vibration

Excessively narrowed gas path due to clogged nozzle in the
turbine wheel chamber or reverse flow of blower discharge in Repair the turbocharger. Send to a qualified repair facility
acceleration (generally called surging)
Contact rotating part Repair the turbocharger. Send to a qualified repair facility

Loosened intake, exhaust or oil pipe connection with the
Correct the condition
turbocharger
Damaged bearing, contact between rotating part and adjacent
part, or chipping of the turbine wheel or blower vane due to Repair the turbocharger. Send to a qualified repair facility
foreign matter within the turbocharger
Unbalanced rotating part Repair the turbocharger. Send to a qualified repair facility

TURBOCHARGER Turbocharger Components
TURBOCHARGER COMPONENTS
Note: The following illustration is provided for informational purposes only. Yanmar does not offer individual
service parts for turbochargers. If the turbocharger is worn or damaged, it should be replaced or
repaired by a qualified repair facility.
(12)
(15)
(14) (8) (7)
(13) (9)
(4)
(5)
(11) (3) (22)
(2) (23)
(20) (21)
(28)
(10) (29)
(24)
(27)
(6)
(19)
(1) (29)
(14)
(13)
(17)
(18) (26)
(16) (32)
(25) (31) (30)
0000078A
Figure 10-1

Turbocharger Components TURBOCHARGER
1 – Turbine Shaft 17 – Bolt
2 – Thrust Bearing 18 – Lock Plate
3 – Oil Thrower 19 – Bearing Housing
4 – Seal Ring 20 – Retaining Ring
5 – Seal Ring 21 – Bolt
6 – Seal Ring (Turbine Side) 22 – Bolt
7 – Lock Nut 23 – Lock Washer
8 – Impeller 24 – Heat Protector
9 – Seal Plate 25 – Liquid Gasket
10 – Journal Bearing 26 – Waste Gate Actuator
11 – Thrust Bearing 27 – Hose
12 – Compressor Housing 28 – Adapter
13 – Flanged Bolt 29 – Clip
14 – Spring Washer 30 – Retaining Ring
15 – Clamp 31 – Waste Gate Valve
16 – Turbine Housing 32 – Link Plate

TURBOCHARGER Turbocharger Component Functions
TURBOCHARGER COMPONENT FUNCTIONS

D
(13) (14) (12) (15) (8) (9) (10) (17)
B C
(19)
(18)
F
(2)
(11) (1) (20) (3) (5) (16) (6) (4) (7)
A 0000077A
1 – Turbine Shaft 11 – Turbine Housing

2 – Oil Thrower 12 – M6 Hex Bolt
3 – Turbine Side Seal Ring 13 – Turbine Side Clamp
4 – Seal Plate 14 – Lock Washer
5 – Journal Bearing 15 – Bearing Housing
6 – Thrust Bearing 16 – Retaining Ring
7 – Compressor Housing 17 – M3 Countersunk Flat-Head Bolt
8 – M5 Hex Bolt 18 – Compressor Wheel
9 – M5 Spring Washer 19 – Shaft End Nut
10 – Compressor Side Clamp 20 – Heat Protector
A. Exhaust Gas Inlet D. Air Outlet

B. Exhaust Gas Outlet E. Oil Inlet
C. Air Inlet F. Oil Outlet
Figure 10-2

Turbocharger Component Functions TURBOCHARGER
Theory of Operation Bearings
Normally aspirated engines produce horsepower Thrust Bearing
that is limited by the atmospheric pressure of the A thrust force is continuously imposed on the
induction air. The turbocharger is an exhaust gas turbine shaft during engine operation. A thrust
pressure driven device that adds to the bearing prevents the shaft from moving laterally
atmospheric pressure, resulting in a boost in under this thrust force.
pressure at the combustion chambers. This
substantially increases the amount of fuel that can Radial Bearing
be injected into the combustion chambers, while A floating radial bearing moves with the turbine
maintaining the proper fuel-to-air ratio. A slight shaft as oil films form on the inside and outside
parasitic loss is imposed on the engine because of bearing surfaces. The bearing slipping speed is
added back pressure in the exhaust system. That slower than the turbine shaft speed, resulting in
loss is offset by horsepower gains. The net result is higher dynamic stability and reduced mechanical
substantially increased overall horsepower over noise.
normally aspirated engines.
Lubrication
The turbocharger consists of two main
components: The oil pump delivers oil from the engine to the
turbocharger for cooling and lubrication of the
• Turbine bearings. As oil leaves the turbocharger, it is
• Compressor returned to the engine.
Turbine Compressor Side Sealing Mechanism

The turbine is driven by exhaust gas pressure from A seal ring and a seal plate form a double wall
the engine and is coupled to a shaft on the structure at the rear of the compressor impeller.
compressor side of the turbocharger. The seal ring and seal plate prevent Intake air and
oil leakage.
Exhaust gas velocity is accelerated at the nozzle
portion in the turbine housing where the Waste Gate Modulation
cross-sectional area is reduced. As exhaust passes
Excessive boost pressure that cannot be
over the turbine impeller at high linear velocity, the
accommodated by the engine can damage the
turbine shaft is rotated at proportionally high rpm.
turbocharger. The waste gate is a component that
Compressor monitors intake boost pressure on the compressor
side and diverts exhaust gases around the
The compressor is driven by a shaft on the turbine turbocharger turbine. The amount of exhaust gas
side of the turbocharger and increases the diverted is varied to limit turbine rpm and maintain
induction air pressure at the intake manifold. the intake pressure equal to, or less than the
The compressor impeller draws induction air into specified maximum level. This improves the
the turbocharger, compresses it and directs it into response to load variation in the low to medium rpm
the engine at high pressure. range and minimizes black smoke.
A seal ring and heat insulating plate thermally Waste Gate Control
isolate heat energy, at the turbine side, from the A mechanical pressure sensor in the outlet of the
bearings and the induction air, at the compressor compressor side of the turbocharger opens and
side. closes the waste gate to maintain the specified
intake pressure at the intake manifold.

TURBOCHARGER Washing Procedure
WASHING PROCEDURE
Note: Inspection, cleaning and repair of the
internal turbocharger components must
be performed by a qualified repair facility.
The washing procedure described in this section is
intended to clean the impeller on the compressor
only if the engine loses rpm, seems sluggish or has
insufficient boost pressure. The process does not
require disassembling any portion of the
turbocharger.
Since washing is quick and easy, perform this
procedure before considering replacement.
1. Start the engine and allow it to reach the
0000860
normal operating temperature.
Figure 10-3
CAUTION
3. Continue to operate the engine under the same
Avoid damage to the turbocharger or the
load for three to four minutes.
engine. Do not spray blower wash fluid
or water too quickly. 4. While the engine is still operating at normal load
(75 - 80% of maximum), slowly and evenly
Use short strokes from a spray bottle to spray 2 - 3 oz (60 - 90 cc) of clean water over a
inject blower wash fluid or water into the period of ten to fifteen seconds into the air inlet.
turbocharger.
5. Continue to operate the engine under the same
Spraying too much wash fluid or water, load for at least ten minutes to completely dry
or spraying too quickly will damage the the air intake system and turbocharger.
turbocharger.
6. Test the engine performance. If engine
0000063en
performance has not improved, repeat steps 2
2. While the engine is operating at normal load through 6. If the engine performance does not
(75 - 80% of maximum), slowly and evenly improve after executing the washing process
spray 2 - 3 oz (60 - 90 cc) of blower wash fluid three times, replace the turbocharger or have it
over a period of ten to fifteen seconds into the repaired by a qualified repair facility.
air inlet (Figure 10-3).

Periodic Inspection TURBOCHARGER
PERIODIC INSPECTION
Inspect the turbocharger at regularly scheduled intervals.
Inspection interval
Application
200 hours 400 hours 500 hours 800 hours 1000 hours 2000 hours
First 6 First 12 Every 24
Construction Equipment months months months
or 500 hrs or 1000 hrs or 2000 hrs
First 6 First 12 Every 24
Farm Equipment months months months
or 200 hrs or 400 hrs or 800 hrs
Engine Oil and Filter Replacement Based on engine operation manual
Visual Inspection Inspection of Rotor Play

1. Check for indications of oil leaks at the oil inlet To inspect the rotor, the turbocharger must be
and outlet lines. Repair or replace the oil lines removed. Inspect for maximum rotor end play and
as needed. run-out limits before reinstalling.
2. Inspect the air inlet connection to the
turbocharger’s turbine side for cracks or broken
Removal of Turbocharger
hardware. Repair or replace the connection as 1. Shut down the engine and allow the
needed. turbocharger to cool. Remove the exhaust
3. Inspect the exhaust outlet connection to the outlet connection from the turbocharger
turbocharger’s compressor side for cracks or housing.
broken hardware. Repair or replace the 2. Remove the air inlet connection from the
connection as needed. turbocharger housing.
Inspection of Rotor Rotation CAUTION

1. With the engine cool and not operating, Do not allow any material to fall into the
manually rotate the rotor. Smooth rotation is oil lines or the oil inlet and outlet ports
normal. Any catching or resistance to rotation is of the turbocharger.
an indication of abnormal operation. Replace 0000064en
the turbocharger or have it repaired by a
qualified repair facility. 3. Remove the inlet and outlet oil lines from the
turbocharger. Plug the lines and ports with tape
2. Start the engine.
to prevent contamination. Discard the sealing
3. After the engine reaches normal operating washers and O-rings. Inspect the oil lines and
temperature, place a stethoscope firmly against replace if damaged.
the turbocharger case.
4. Remove the turbocharger mounting nuts from
4. Increase the rpm gradually. A high-pitched the mounting studs. Lift the turbocharger from
sound, occurring at intervals of two or three the engine and place it on a clean, level working
seconds, is an indication of abnormal operation. surface.
Replace the turbocharger or have it repaired by
5. Discard the turbocharger exhaust manifold
a qualified repair facility.
gasket.

TURBOCHARGER Periodic Inspection
Checking Rotor Play

Note: If rotor play measurements are not within specification, replace the turbocharger assembly or have it
repaired by a qualified facility.
Standard Dimension Wear Limit

Rotor Play
RHF5 RHB31 RHB51 RHF5 RHB31 RHB51
0.0011 - 0.0024 in. 0.0009 - 0.0021 in. 0.0012 - 0.0024 in. 0.0044 in. 0.0028 in. 0.0035 in.
End Play
(0.03 - 0.06 mm) (0.022 - 0.053 mm) (0.03 - 0.06 mm) (0.09 mm) (0.07 mm) (0.09 mm)
0.0031 - 0.0051 in. 0.0024 - 0.0037 in. 0.0031 - 0.0051 in. 0.007 in. 0.0047 in. 0.0067 in.
Run-out
(0.08 - 0.13 mm) (0.061 - 0.093 mm) (0.08 - 0.13 mm) (0.17 mm) (0.12 mm) (0.17 mm)
To Check Rotor End Play:

1. Set up a dial indicator as shown (Figure 10-4). (1)
(2)
2. Manually move the rotor end-to-end while
observing indicated readings. Replace the (4)
turbocharger if end play measurements are
outside specified limits. See table above.
(1)
(2)
(3)
(3)
0000081A
Figure 10-5
Waste Gate Valve Test

0000080A
Before reinstalling the turbocharger, verify the
operation of the waste gate valve. Poor waste gate
Figure 10-4 operation will adversely affect the engine
To Check Rotor Run-out: performance.
1. Set up a dial indicator as shown (Figure 10-5).

CAUTION
2. Manually rotate the rotor while observing
indicated limits. Replace the turbocharger if If the waste valve does not meet
run-out measurements are outside specified specifications, replace the turbocharger
limits. See table above. or have it repaired by a qualified repair
facility.
0000078en

Periodic Inspection TURBOCHARGER
1. Connect a hand-operated air pump to the waste • If the pressure reading is equal to or greater
gate actuator pipe (Figure 10-6, (1)). The pump than 15.9 psi (0.11 MPa; 1.1 kgf/cm2), the
should be equipped with a 30 psi (0.21 MPa; waste gate actuator is not leaking and is
2.21 kgf/cm2) pressure gauge operating properly.
(Figure 10-6, (2)), and a pressure release valve • If the pressure reading is less than 15.9 psi
to release any pressure pumped into the (0.11 MPa; 1.1 kgf/cm2), the waste gate
system. (Similar pumps are used to check for actuator is leaking. Replace the turbocharger
leaks in marine gear cases.) or have it repaired by a qualified repair facility.
A WARNING Installation of Turbocharger

Never apply over 40 psi (2.8 kgf/cm) to 1. Pour 2 oz (60 cc) of clean engine oil in the oil
the waste gate actuator. inlet port at the top of the turbocharger. Rotate
0000026en the compressor wheel to ensure the shaft
bearings are lubricated.
2. Flush the oil lines to ensure that they are free of
containments.
3. Put a new turbocharger exhaust manifold
gasket in place and reinstall turbocharger on
the exhaust manifold.
(1 4. Apply anti-seize compound to the turbocharger
(2) mounting studs.
5. Reinstall the mounting nuts. Torque the nuts to
the specified torque.
6. Install new sealing washers and O-rings and
reinstall the inlet and outlet oil lines to the
turbocharger.
(3) 00001617 CAUTION

Figure 10-6 Do not allow any material to fall into the
oil lines or the oil inlet and outlet ports
2. Apply 17 psi (0.12 MPa; 1.2 kgf/cm2) to the of the turbocharger.
waste gate actuator (Figure 10-6, (3)) circuit. 0000064en
Observe if the waste gate valve is open fully. If
the waste valve does not open fully, replace the 7. Reinstall the air inlet connection to the
turbocharger or have it repaired by a qualified turbocharger turbine housing.
repair facility. 8. Reinstall the exhaust connection to the
turbocharger compressor housing.
Waste Gate Actuator Leak Test
Allow the pressure, 17 psi (0.12 MPa; 1.2 kgf/cm2)
to remain in the circuit for one minute. After one
minute, observe the pressure reading.

TURBOCHARGER Periodic Inspection

Section 11
STARTER MOTOR
Page
Introduction.................................................................................... 11-5
Starter Motor Information .............................................................. 11-5
3TNV82A to 4TNV88 - Standard and Optional........................ 11-5
Starter Motor Specifications .......................................................... 11-7
Starter Motor Troubleshooting....................................................... 11-8
Starter Motor Components ............................................................ 11-9
Starter Motor ............................................................................... 11-10
Removal of Starter Motor ...................................................... 11-10
Disassembly of Starter Motor ................................................ 11-10
Cleaning and Inspection ........................................................ 11-12
Reassembly of Starter Motor................................................. 11-17
Check Pinion Projection Length ............................................ 11-18
No-Load Test......................................................................... 11-19
Installation of Starter Motor ................................................... 11-20

STARTER MOTOR

Before You Begin Servicing STARTER MOTOR
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
SHOCK HAZARD!
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
• Check the electrical harnesses for
cracks, abrasions, and damaged or
0000009en
or serious injury.
0000010en
FUME / BURN HAZARD!
sealant removers.
or serious injury.
0000014en

STARTER MOTOR Before You Begin Servicing
A CAUTION CAUTION
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general
cleaning. Do not use high-pressure
wash or submerse the starter motor in
water.
FLYING OBJECT HAZARD! 0000055en

servicing the engine and when using CAUTION
compressed air or high-pressure Use a specialized battery charger to
water. Dust, flying debris, compressed recharge a battery with a voltage of
air, pressurized water or steam may 8 volts or less. Booster starting a battery
injure your eyes. with a voltage of 8 volts or less will
• Failure to comply may result in minor generate an abnormally high voltage
or moderate injury. and destroy electrical equipment.
0000056en
0000003en
CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated on the wiring diagram. The
starter motor will malfunction or break
down if the resistance is higher than the
specified value.
0000054en

Introduction STARTER MOTOR
INTRODUCTION
This section of the Service Manual covers the servicing of the starter motor. Yanmar Part No. 129900-
77010 is standard equipment on 4TNV94-98 model engines and is used in this section to show the service
procedures for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the
engine you are working on.
STARTER MOTOR INFORMATION

3TNV82A to 4TNV88 - Standard and Optional
YANMAR Mfg. No Load Loaded
Part Mfg. Part Specification Terminal Amperag Terminal Amperag
Number Number rpm Torque rpm
Voltage e Draw Voltage e Draw
87 in.-lb
129129- 228000- DC12V-1.6 hp
Denso 11.5 90A MAX 3000 8 280 Max (9.81N·m; 900
77010 0251 (1.2 kW)
1.0 kgf·m)
117 in.-lb
129407- 228000- DC12V-1.9 hp
Denso 11.5 90A MAX 3000 8.5 350 Max (13.2 N·m; 1000
77010 3732 (1.4 kW)
1.4 kgf·m)
74 in.-lb
129608- S114- DC12V-1.9 hp
Hitachi 11 90A MAX 2700 8.4 250 Max (8.3 N·m; 1000
77010 817A (1.4 kW)
0.9 kgf·m)
134 in.-lb
129242- S114- DC12V-2.3 hp
Hitachi 11 90A MAX 2300 8 370 Max (15.1 N·m; 880
77010 883 (1.7 kW)
1.5 kgf·m)
97 in.-lb
129136- DC12V-3.1 hp 140A
Hitachi S13-332 11 4100 7.7 400 Max (11.0 N·m; 1400
77011 (2.3 kW) MAX
1.1 kgf·m)
269 in.-lb
129612- S25- DC24V-5.3 hp 100A
Hitachi 24 3500 18 400 Max (30.4 N·m; 1000
77011 166A (4.0kW) MAX
3.1 kgf·m)

STARTER MOTOR Starter Motor Information
4TNV94L to 4TNV106T - Standard and Optional

YANMAR Mfg. No Load Loaded
Part Mfg. Part Specification Terminal Amperag Terminal Amperag
Number Number rpm Torque rpm
Voltage e Draw Voltage e Draw
97 in.-lb
129900- DC12V-3.1 hp 140A
Hitachi S13-204 11 4100 7.7 400 Max (11.0 N·m; 1400
77010 (2.3 kW) MAX
1.1 kgf·m)
60 in.-lb
129940- DC12V-4.0 hp 160A
Hitachi S14-102 12 3600 10.85 300 Max (6.9 N·m; 2000
77010 (3.0 kW) MAX
0.7 kgf·m)
130 in.-lb
119131- DC24V-4.8 hp
Hitachi S24-13 23 90A MAX 3100 20.2 250 Max (14.7 N·m; 1300
77010 (3.5 kW)
1.5 kgf·m)
130 in.-lb
129900- DC24V-4.8 hp
Hitachi S24-14 23 90A MAX 3100 20.2 250 Max (14.7 N·m; 1300
77030 (3.5 kW) Wet
1.5 kgf·m))
97 in.-lb
129910- S13- DC12V-3.1 hp 140A
Hitachi 11 4100 7.7 400 Max (11.0 N·m; 1400
77022 2050 (2.3 kW) Wet MAX
1.1 kgf·m)

Starter Motor Specifications STARTER MOTOR
STARTER MOTOR SPECIFICATIONS

Yanmar Part Number 129900-77010
Nominal Output 3.0 hp (2.3 kW)
12.1 lb
Weight
(5.5 kg)
Revolution Direction (As Viewed From Pinion) Clockwise
Engagement System Magnetic Shift
Terminal Voltage / Current 11 V / 140 A max
No-load
Revolution 4100 rpm (min-1)
Terminal Voltage / Current 2.5 V / 1050 A max
Loaded 18 ft-lb
Torque
(24.5 N·m; 2.5 kgf·m) minimum
Clutch System Overrunning
Pinion Projection Voltage at 212°F (100 °C) 8.6 V max
Pinion DP or Module / Number of Teeth M3/9
Difference (O-ring, Oil Seal) Dry (none)
Application Standard
Spring Force 7.868 lbf (35 N; 3.6 kgf)
Brush Standard 0.591 in. (15 mm)
Height
Limit 0.354 in. (9 mm)
Magnetic Series Coil Resistance 0.27 W at 68°F (20°C)
Switch Shunt Coil Resistance 0.60 W at 68°F (20°C)
Standard 1.437 in. (36.5 mm)
Outside Diameter
Limit 1.398 in. (35 mm)
Commutator Run-Out
Limit 0.008 in. (0.2 mm)
Standard 0.020 - 0.031 in. (0.5 - 0.8 mm)
Insulation Depth
Limit 0.008 in. (0.2 mm)
Armature Run-Out
Limit 0.008 in. (0.02 mm)
Armature Front 6903DDU
Bearing Armature Rear 608DDU
Nominal Number
Type Pinion Front 60004DDU
Pinion Rear 6904DDU
Pinion Projection Length (Length L) 0.012 - 0.059 in. (0.3 - 1.5 mm)

11-8
Is the shift lever at NO Move shift lever to Is battery fully charged NO • Charge or replace battery.
NEUTRAL position? NEUTRAL position. and terminals clean? • Clean terminals.
YES
Engine does not start? Inspect wiring up to solenoid switch
Is starter motor solenoid and repair if necessary.
NO • Key switch
switch actuating sound
STARTER MOTOR
YES heard? • Safety relay

• Solenoid switch assembly
NO NO • Electrical connections
Does engine crank? Is starter motor operating? YES
YES
• Adjust / pinion projection length.
• Inspect shift lever for deformation,
Pinion and ring gear NO return spring for fatigue and pinion
meshing normal? for sliding.
YES • Repair meshing between pinion and
ring gear or replace as needed.
YES
Connect M terminal of starter NO • Inspect brush and replace if worn.
Pinion roller clutch or motor directly to battery. • If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.
YES
Solenoid switch assembly If starter motor becomes wet, replace solenoid switch
contact defective. Repair assembly even if function is normal.
NO or replace.
STARTER MOTOR TROUBLESHOOTING
(slow revolution) NO
Is revolution normal? Is battery fully charged • Charge or replace battery. If a problem occurs:
and terminals clean? • Clean terminals. Immediately disconnect battery negative terminal.
YES YES
Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES
Does engine turn when YES Repair or replace

Repair or replace key switch, starting
starter motor is replaced? starter motor. motor relay or magnetic switch assembly.
Slow Revolution
Inspect condition of engine.
0000102
Starter Motor Troubleshooting
Starter Motor Components STARTER MOTOR
STARTER MOTOR COMPONENTS

(13)
(12) (14)
(11)
(10)
(9)
(8)
(7)
(6)
(5)
(4)
(23)
(3)
(2)
(1) (15)
(18)
(22)
(21)
(19)
(20)
(17)
(16) 0000103A
1 – Pinion Shaft 13 – Magnetic Switch Assembly (Solenoid)

2 – M4 Bolts (3 used) 14 – Cover
3 – Bearing Retainer 15 – M6 Bolts (2 used)
4 – Pinion Clutch Assembly 16 – Armature Assembly
5 – Return Spring 17 – Field Coil Assembly
6 – Pinion Stop 18 – Positive (+) Brushes
7 – Retaining Ring 19 – Negative (-) Brushes
8 – Gear Housing 20 – Brush Holder Assembly
9 – Shift Lever 21 – Rear Cover
10 – Torsion Spring 22 – M5 Through Bolts (2 used)
11 – Plunger 23 – M4 Bolts (2 used)
12 – Dust Covers (Shims)
Figure 11-1

STARTER MOTOR Starter Motor
STARTER MOTOR (1)
A WARNING
SHOCK HAZARD!
equipped) or disconnect the negative 0002126
battery cable before servicing the Figure 11-2

electrical system.
• Check the electrical harnesses for Disassembly of Starter Motor
cracks, abrasions, and damaged or 1. Loosen the M8 nut from the magnetic switch
corroded connectors. ALWAYS keep (solenoid) assembly (Figure 11-3). Disconnect
the connectors and terminals clean. the wire from the magnetic switch.
or serious injury.
0000009en
Note: While starter motor design varies

between models, the basic repair
procedures are the same. The following
procedures are typical and may differ
from the stater being serviced.
Removal of Starter Motor

1. Disconnect the battery cables at the battery,
negative (-) cable first. 0000104
2. Remove the electrical wires from the magnetic Figure 11-3

switch assembly. 2. Remove the two M4 bolts (Figure 11-4, (1))
3. Remove the starter mounting bolts securing the rear cover (Figure 11-4, (2)) to the
(Figure 11-2, (1)). Remove the starter motor brush holder assembly (Figure 11-4, (3)).
from the flywheel housing.

Starter Motor STARTER MOTOR
(7) (1)
(4)
(1)
(2) (3)
0000107A
Figure 11-6
(6) (5) (3) (2) 6. Pull the armature assembly (Figure 11-6, (3))
0000105A
out from the field coil assembly
Figure 11-4 (Figure 11-6, (2)).
3. Remove the two M5 through bolts 7. Remove the two M6 bolts (Figure 11-7, (1))
(Figure 11-4, (4)). Separate the rear cover retaining the magnetic switch assembly
(Figure 11-4, (2)), field coil assembly (Figure 11-7, (2)) to the gear housing. Remove
(Figure 11-4, (5)) with the armature assembly the magnetic switch assembly, dust cover(s)
(Figure 11-4, (6)) from the gear housing (Figure 11-7, (3)) and torsion spring
(Figure 11-4, (7)). (Figure 11-7, (4)) from the gear housing.
4. Pull the brush springs up using a brush spring (1)
puller. On the negative (-) side, bring the brush
spring into contact with the side of the brush for
lifting from the commutator surface. On the
positive (+) side, remove the brush from the (2) (4)
brush holder assembly (Figure 11-5, (1)).
(3)
0000108A
Figure 11-7
8. Disassemble the dust cover (Figure 11-8, (3))
and shift the lever (Figure 11-8, (4)) from the
(1) gear housing.
0000106A
(1)
Figure 11-5
5. Remove the brush holder assembly
(Figure 11-6, (1)) from the armature assembly
(Figure 11-6, (3)).
(2)
0000109A
Figure 11-8

9. Remove the three M4 bolts (Figure 11-9, (1))

(4)
securing the bearing retainer assembly (1)
(Figure 11-9, (2)) to the gear housing. Remove
the bearing retainer assembly from the gear (5)
housing. (2)
(3)
(2)
0000112A
Figure 11-11
(3)
Armature
(1)
Commutator Surface Inspection
0000110A If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth
Figure 11-9
(Figure 11-12).
10. Remove the pinion clutch assembly
(Figure 11-9, (3)) from the bearing retainer
assembly.
11. Using a flat-blade screwdriver, remove the
retaining ring (Figure 11-10, (1)) from the shaft
of the pinion.
(1)
0000117
Figure 11-12
Measure Commutator Outside Diameter

0000111A Measure the commutator outside diameter
(Figure 11-13). Replace the armature if the
Figure 11-10
measurement is less than the limit.
12. Disassemble the pinion stop
(Figure 11-11, (3)), return spring
(Figure 11-11, (4)), pinion clutch assembly
(Figure 11-11, (1)), and pinion shaft
(Figure 11-11, (5)).

Armature Coil Continuity Test
Check for continuity between the commutator
segments using a multimeter (Figure 11-15). The
multimeter should indicate continuity.
0000113
Figure 11-13
See Starter Motor Specifications on page 11-7 for
the service limit.
0000114
Measure Commutator Insulation Depth
Figure 11-15
Measure the depth of the insulating material
(Figure 11-14, (1)) between commutator segments If the multimeter does not indicate continuity,
(Figure 11-14, (2)). If the depth measures less replace the armature.
than the limit, use a hacksaw blade
(Figure 11-14, (3)) to remove the insulating Armature Coil Insulation Test
material until the depth is within the limit. Check for continuity between a commutator
segment and the shaft or armature using a
A normal commutator condition is indicated in multimeter (Figure 11-16). The multimeter should
(Figure 11-14, (4)). An abnormal commutator not indicate continuity.
condition is indicated in (Figure 11-14, (5)).
(3)
(2)
(1)
0000115
Figure 11-16
(5) (4) If the multimeter indicates continuity, replace the
0000118
armature.
Figure 11-14
the service limit.

Measure Armature and Commutator Run-Outs Field Coil Insulation Test

Measure the armature core run-out and the Check for continuity between the field coil terminal
commutator run-out using a dial indicator and the yoke using a multimeter (Figure 11-19).
(Figure 11-17). Replace the armature if either of The multimeter should not indicate continuity.
the measurements is less than the limit.
If the multimeter indicates continuity, replace the
field coil assembly.
0000116
Figure 11-17
See Starter Motor Specifications on page 11-7 for 0000120
the service limit.
Figure 11-19
Field Coil
Measure Brush Length
Field Coil Continuity Test Measure the length of the brush (Figure 11-20).
Check for continuity between the field coil terminals Replace the brush if the length is less than the limit.
using a multimeter (Figure 11-18). The multimeter
should indicate continuity.
If the multimeter does not indicate continuity,
replace the field coil assembly.
0000121
Figure 11-20
0000119 the service limit.
Figure 11-18

Magnetic Switch Series Coil Continuity Test
If the starter motor becomes wet, replace the Check for continuity between the “S” and “M”
magnetic switch even if the magnetic switch terminals using a multimeter (Figure 11-22). The
assembly function is normal. multimeter should indicate continuity.
Shunt Coil Continuity Test If the multimeter does not indicate continuity,
replace the magnetic switch.
Check for continuity between the “S” terminal and
the switch body using a multimeter (Figure 11-21).
The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
0000125
Figure 11-22
Coil Resistance Test

0000124 the service limit.
Figure 11-21

Contact Continuity Test Slide the pinion clutch assembly on the shaft. It
Depress the plunger at the bottom of the magnetic should slide smoothly on the shaft (Figure 11-25).
switch. Check for continuity between the “B” and Rust, too much grease or damage could prevent
“M” terminals using a multimeter (Figure 11-23). the pinion clutch from sliding smoothly. If the pinion
The multimeter should indicate continuity. clutch assembly does not slide smoothly, clean the
shaft and pinion clutch assembly or replace the
If the multimeter does not indicate continuity, damaged component.
0000128
Figure 11-25
0000126 Ball Bearing Inspection
Figure 11-23 Rotate each ball bearing while holding the pinion
clutch assembly (Figure 11-26). Replace the ball
Pinion Clutch Assembly bearing if it does not rotate smoothly or has
excessive play.
Pinion Clutch Assembly Inspection
Manually rotate the pinion clutch assembly in the
drive direction (Figure 11-24). It should rotate
freely in the drive direction and is locked by turning
it in the opposite direction. Replace the pinion
clutch assembly if the results are different.
0000129
Figure 11-26
0000127
Figure 11-24

Reassembly of Starter Motor (3)
1. Apply the appropriate starter bendix grease
(obtain locally) to the pinion shaft. Reassemble
the pinion shaft (Figure 11-27, (5)), pinion (2)
(1)
clutch assembly (Figure 11-27, (1)), return
spring (Figure 11-27, (4)) and pinion stop
(Figure 11-27, (3)). Reinstall the retaining ring
(Figure 11-27, (2)) in the groove in the pinion
shaft. Slide the piston stop over the retaining (5)
ring.
(4)
(4)
0000268
(1)
(5) Figure 11-28
(2) 5. Reassemble the magnetic switch assembly to
(3) the gear housing. Pry the pinion away from the
gear housing to allow installation of the
0000112A magnetic switch assembly (Figure 11-29).
Figure 11-27
2. Reinstall the pinion clutch assembly into the
bearing retainer assembly.
3. Reinstall the bearing retainer assembly and
pinion assembly to the gear housing. Reinstall
and tighten the three M4 bolts.
4. Apply a small amount of high temperature
lithium grease (obtain locally) to the sliding
portions of the shift lever (Figure 11-28, (1)). 0000131
Reassemble the torsion spring
Figure 11-29
(Figure 11-28, (2)), shift lever and dust cover(s)
(Figure 11-28, (3)), plunger (Figure 11-28, 4) 6. Secure the magnetic switch assembly to the
and magnetic switch assembly gear housing using the two M6 bolts.
(Figure 11-28, (5)).

7. Carefully install the armature assembly 12. Reinstall the two M4 through bolts
(Figure 11-30, (1)) into the field coil assembly (Figure 11-32). Securely tighten the through
(Figure 11-30, (2)). bolts. Reconnect the wire to the magnetic
switch assembly. Tighten the M8 nut. Reinstall
the cover over the connection.
(1)
(2)
0000269
Figure 11-30
8. Position the brush springs in brush holders
(Figure 11-31). Reinstall the brushes in the
brush holders. Reversing the brushes will cause 0000104
the starter motor to turn backwards.

Figure 11-32
Check Pinion Projection Length

1. Connect the positive (+) lead from a battery to
the “S” terminal.
2. Connect the negative (-) lead to the “M”
terminal.
3. Lightly pull the pinion away from the gear
housing.
4. Turn the switch ON and measure the pinion
0000106 moving distance L in the thrust direction
Figure 11-31 (Figure 11-33). Perform this test within 10
seconds. See Starter Motor Specifications on
9. Carefully install the brush holder assembly to page 11-7 for the service limit.
the armature assembly.
10. Reinstall the field coil assembly with the
armature assembly to the gear housing.
11. Reinstall the rear cover to the brush holder
assembly. Securely tighten the two bolts.
0000132
Figure 11-33

5. If the measured L dimension is outside the
standard range, adjust the dust covers to obtain
the standard range. Dust covers (3)
(Figure 11-34, (1)) are available in 0.020 in (0.5 (6) (1)
mm) and 0.031 in (0.8 mm) thicknesses.
M (8)
(2)
(7)
(1)
(5)
(4)
0002127A
Figure 11-35
3. Connect a wire lead between the mounting
base of the starter motor (Figure 11-35, (4))
and the battery negative terminal
0000133
(Figure 11-35, (5)).
Figure 11-34 4. Connect a voltmeter (Figure 11-35, (7)) to the
battery negative (-) terminal (Figure 11-35, (5))
No-Load Test and the main positive (+) battery terminal
(Figure 11-35, (3)) on the starter motor.
Test the characteristics of the starter motor by
performing a no-load test. 5. Install a switch (Figure 11-35, (6)) in a circuit
between the battery positive (+) terminal
(Figure 11-35, (2)) and the starter magnetic
CAUTION switch (solenoid) terminal (Figure 11-35, (8))
The starter motor can be damaged if on the starter motor.
operated continuously longer than 6. Use a suitable tachometer to monitor the rpm of
10 seconds while performing the the starter.
no-load test.
7. Turn the switch to the ON position. Monitor the
0000034en
rpm, amperage draw and voltage. For test
1. Secure the starting motor in a vise or other specifications, see 3TNV82A to 4TNV88 -
suitable fixture. Standard and Optional and 4TNV94L to
4TNV106T - Standard and Optional on
2. Connect an ammeter (Figure 11-35, (1)) in
page 11-5 for the appropriate starter motor.
series between the battery positive (+) terminal
(Figure 11-35, (2)) and the main positive (+)
terminal (Figure 11-35, (3)) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to or
greater than the amperage draw
specification for the starter motor being
tested.

Installation of Starter Motor

1. Reinstall the starter motor to the flywheel
housing.
2. Reinstall the starter mounting bolts
(Figure 11-36, (1)). Tighten the bolts to
specification. See Tightening Torques for
Standard Bolts and Nuts on page 4-46.
(1)
0002126
Figure 11-36
3. Reconnect the electrical wires to the magnetic
switch assembly (solenoid). Be sure to place
the cover over the battery positive (+) cable
connection.
4. Reconnect the battery cables at the battery.

Section 12
ALTERNATOR
Page
Introduction.................................................................................... 12-6
Dynamo and Alternator Information .............................................. 12-6
3TNV82A to 4TNV106T - Standard and Optional Dynamos ... 12-6
3TNV82A to 4TNV106T - Standard and Optional Alternators . 12-6
Alternator Specifications................................................................ 12-7
Dynamo Specifications.................................................................. 12-7
Alternator Troubleshooting ............................................................ 12-8
Alternator Components ................................................................. 12-9
Alternator Wiring Diagram ........................................................... 12-10
Alternator Standard Output ........................................................ 12-11
Alternator .................................................................................... 12-12
Removal of Alternator............................................................ 12-12
Disassembly of Alternator...................................................... 12-12
Reassembly of Alternator ...................................................... 12-14
Installation of Alternator......................................................... 12-16
Dynamo Component Location..................................................... 12-17
Dynamo Wiring Diagram ............................................................. 12-18
Operation of Dynamo .................................................................. 12-18
Dynamo Standard Output ........................................................... 12-19
Testing of Dynamo ...................................................................... 12-20
Testing Stator Coil Continuity ................................................ 12-20
Testing Stator Coil Short-to-Ground ...................................... 12-20
Testing Dynamo Regulated Output ....................................... 12-20

ALTERNATOR
Dynamo........................................................................................ 12-20
Removal of Dynamo............................................................... 12-20
Disassembly of Dynamo......................................................... 12-21
Reassembly of Dynamo ......................................................... 12-21
Installation of Dynamo............................................................ 12-22

Before You Begin Servicing ALTERNATOR
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
SHOCK HAZARD!
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
electrical system.
service it.
cracks, abrasions, and damaged or
0000009en
or serious injury.
0000010en
BURN HAZARD!
block during operation and shortly
seriously burn you.
or serious injury.
0000015en

ALTERNATOR Before You Begin Servicing
A WARNING A CAUTION
FUME / BURN HAZARD!

PINCH HAZARD!
precautions found on containers of Carefully rotate the alternator toward the
hazardous substances like parts cylinder block while loosening the
cleaners, primers, sealants and V-belt. Failure to comply may result in
sealant removers. minor or moderate injury.
0000014en
or serious injury.
0000014en
CAUTION
A CAUTION
NEVER permit anyone to operate the

engine or driven machine without proper
training.
FLYING OBJECT HAZARD! • Read and understand this Operation

Manual before you operate or service
• ALWAYS wear eye protection when the machine to ensure that you follow
servicing the engine and when using safe operating practices and
compressed air or high-pressure maintenance procedures.
air, pressurized water or steam may • Machine safety signs and labels are
injure your eyes. additional reminders for safe operating
and maintenance techniques.
or moderate injury. • See your authorized Yanmar industrial
engine dealer or distributor for
0000003en
additional training.
0000002en
CAUTION
Do not short-circuit the charging system
between alternator terminals IG and L.
Damage to the alternator will result.
0000035en

Before You Begin Servicing ALTERNATOR
CAUTION CAUTION
Do not connect a load between Using a non-specified V-belt will cause
alternator terminals L and E. Damage to inadequate charging and shorten the
the alternator will result. belt life. Use the specified belt.
0000036en 0000052en
CAUTION CAUTION
Do not remove the positive (+) battery Agricultural or other chemicals,
cable from alternator terminal B while especially those with a high sulfur
the engine is operating. Damage to the content, can adhere to the IC regulator.
alternator will result. This will corrode the conductor and
0000037en result in battery over-charging (boiling)
and charging malfunctions. Consult
Yanmar before using the equipment in
CAUTION such an environment or the warranty is
Do not turn the battery switch OFF while voided.
the engine is operating. Damage to the 0000053en
alternator will result.
0000038en
CAUTION
Do not use a high-pressure wash
CAUTION directly on the alternator. Water will
Do not operate the engine if the damage the alternator and result in
alternator is producing unusual sounds. inadequate charging.
Damage to the alternator will result. 0000049en
0000039en
CAUTION
Do not reverse the positive (+) and
negative (-) ends of the battery cable.
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
When the battery indicator goes out, it
should not come on again. The battery
indicator only comes on during
operation if the alternator fails. However,
if an LED is used in the battery indicator,
the LED will shine faintly during normal
operation.
0000051en

ALTERNATOR Introduction
INTRODUCTION
This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part
No. 129423-77200 alternator is used in this section to show the service procedures for the representative
alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures
for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working
on.
DYNAMO AND ALTERNATOR INFORMATION

3TNV82A to 4TNV106T - Standard and Optional Dynamos
YANMAR Part Number Mfg. Mfg. Part Number Specification
171301-77201 Kokusan GP8138 DC12V-15A
119910-77200 Kokusan GP9191 DC12V-20A
3TNV82A to 4TNV106T - Standard and Optional Alternators

YANMAR Part Number Mfg. Mfg. Part Number Specification
119620-77201 Denso 100211-4531 DC12V-40A
129423-77200 Denso 101211-1170 DC12V-40A with Pulse
129961-77200 Denso 101211-2591 DC12V-55A
119626-77210 Denso 101211-2951 DC12V-55A with Pulse
129612-77290 Hitachi LR180-772 DC12V-80A with Pulse
129900-77240 Hitachi LR235-705 DC24V-35A with Pulse

Alternator Specifications ALTERNATOR
ALTERNATOR SPECIFICATIONS
Nominal Output (13.5 Volts Heat) 40 Amps
Weight 6.17 lb (2.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 5000 rpm (min-1)
Operating Range 1350 - 18000 rpm (min-1)
Grounding Characteristics Negative (-) Side of Circuit
Integrated Regulator IC Regulator
Outside Diameter of Pulley 2.724 in. (69.2 mm)
Belt Shape Type A
DYNAMO SPECIFICATIONS
Nominal Output 20 Amps
Weight 3.97 lb (1.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 3500 rpm
Operating Range 1400 - 6600 rpm
Grounding Characteristics Negative (-) Side of Circuit
Current Limiter (Yanmar Part No.
Regulator
119653-77710)
A-Belt 2.56 in. (65 mm)
Outside Diameter of Pulley
Special M-Belt 2.28 in. (58 mm)
Belt Shape Type A or Type Special M

12-8
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF Replace the battery indicator.
Does battery indicator and IG terminal at alternator L terminal. Does battery Battery indicator is available from
ALTERNATOR
turn ON? indicator turn on? driven machine manufacturer.
ON ON Inspect rotor assembly and

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

Battery indicator ON. Inspect alternator.
At idle, does battery Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?
Battery indicator
OFF is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
ALTERNATOR TROUBLESHOOTING
Battery voltage minus

L terminal voltage is Excessive voltage drop between
greater than 0.5 volt. BAT and batt ( + side) terminal.
Does battery indicator Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.
Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?
OFF

Notes: Not abnormal.
1) Use a fully charged battery
2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test
Alternator Troubleshooting
Alternator Components ALTERNATOR
ALTERNATOR COMPONENTS
Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.
14
12 13
10 11
8 9
6
5
29
4
3 7 19
2
16 18
1 17
25
15 28
27
26
24
23
22 0000255
21
20
1 – Nut 17 – Insulation Bushing
2 – Pulley 18 – Spring (2 used)
3 – Collar 19 – Brush Holder
4 – Front Frame Housing 20 – Rear Frame Housing
5 – Stator Assembly 21 – Bolt (2 used)
6 – Stud (2 used) 22 – Holder
7 – Front Frame Housing Bearing 23 – IC Regulator Assembly
8 – Bearing Cover 24 – Bolt (2 used)
9 – Bearing Cover Bolt (4 used) 25 – Bolt
10 – Rotor Assembly 26 – Brush (2 used)
11 – Rear Frame Housing Bearing 27 – Bolt
12 – Bearing Cover 28 – Rear Cover
13 – Thrust Washer 29 – Bolt (3 used)
14 – Thrust Washer
15 – Nut (2 used)
16 – Nut
Figure 12-1

ALTERNATOR Alternator Wiring Diagram
ALTERNATOR WIRING DIAGRAM
IG 1
IG P
B
PI P L
2
F
IC
L
0.5μF 3 3
B
4A
E T
5 6
1 – Key Switch 4 – Battery

2 – Charge Lamp (3.4 Watts Max.) 5 – Alternator Assembly
3 – Load 6 – IC Regulator Assembly
Figure 12-2
CAUTION CAUTION
Do not short-circuit the charging system Do not remove the positive (+) battery
between alternator terminals IG and L. cable from alternator terminal B while
Damage to the alternator will result. the engine is operating. Damage to the
0000035en alternator will result.
0000037en
CAUTION
Do not connect a load between
alternator terminals L and E. Damage to
the alternator will result.
0000036en

Alternator Standard Output ALTERNATOR
ALTERNATOR STANDARD OUTPUT
Output Current
60
Cold
50
13.5 Volts, Constant Ambient
Temperature at 77˚F (25˚C) Hot
40
30
20
10
0 1 2 3 4 5 6 7 8
Alternator RPM (x10³ min¯¹)
Figure 12-3

ALTERNATOR Alternator
ALTERNATOR 4. Remove the nut (Figure 12-4, (2)) from the

gear case stud. Remove the alternator.
A WARNING
SHOCK HAZARD!
2 1
0000264
equipped) or disconnect the negative
battery cable before servicing the Figure 12-4
electrical system.
Disassembly of Alternator
cracks, abrasions, and damaged or 1. Remove the nut (Figure 12-5, (1)) from the
corroded connectors. ALWAYS keep shaft of the rotor assembly. Remove the pulley
the connectors and terminals clean. (Figure 12-5, (2)).
or serious injury.
0000009en
Removal of Alternator
1. Disconnect the electrical wires from the
alternator.
2. Loosen the V-belt.
A CAUTION
2
1 0000256
PINCH HAZARD! Figure 12-5

Carefully rotate the alternator toward the
cylinder block while loosening the
0000014en
3. Remove the V-belt adjuster from the alternator

bolt (Figure 12-4, (1)).

Alternator ALTERNATOR
2. Remove the three bolts (Figure 12-6, (1)) 5. Remove the bolts retaining the holder
retaining the rear cover (Figure 12-6, (2)) to the (Figure 12-7, (2)) to the rear frame housing.
rear frame assembly. Remove the holder.
6. Remove the nut (Figure 12-7, (3)) retaining the
insulation bushing (Figure 12-7, (4)). Remove
the insulation bushing.
7. Remove the two bolts (Figure 12-8, (1)) and
3 1 two nuts (Figure 12-8, (2)) securing the rear
frame housing to the front frame housing.
4 2
5
1
0000257A
Figure 12-6
3. Remove the brush holder (Figure 12-6, (3)).
0000265A
Remove the brush springs (Figure 12-6, (4))
and brushes (Figure 12-6, (5)). Figure 12-8
4. Remove the bolt retaining the regulator 8. Using a press, remove the rotor assembly
assembly (Figure 12-7, (1)) to the holder (Figure 12-9, (1)) from the front frame housing
(Figure 12-7, (2)). (Figure 12-9, (2)) and rear frame housing
(Figure 12-9, (1)).
3 3
1
4
1
2
100266A
Figure 12-9
0000258A
Figure 12-7

9. Remove the stator assembly

(Figure 12-10, (1)) from the front frame
housing.
4
3
2
3 1
0000260A
1 Figure 12-11
Reassembly of Alternator
0000259A
1. If removed, reinstall the two trust washers
(Figure 12-12, (3)) and bearing cover
Figure 12-10 (Figure 12-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new bearing
10. If it is necessary to replace the bearing (Figure 12-12, (1)). Press the bearing into the
(Figure 12-10, (2)) in the front frame housing, rear frame housing.
remove the four bolts (Figure 12-10, (3))
securing the plate (Figure 12-10, (4)) to the
front frame housing. Remove the plate. Use a
puller to remove the bearing. Discard the
bearing.
11. If it is necessary to replace the bearing
(Figure 12-11, (1)) in the rear frame housing, 3
use a puller to remove. Discard the bearing. 2
Remove the bearing cover (Figure 12-11, (2)) 1
and two thrust washers (Figure 12-11, (3)).
0000260A
Figure 12-12

Alternator ALTERNATOR
2. If removed, lubricate the outside diameter of a 5. Align the front frame housing with the rear
new front frame housing bearing. Press the frame housing. Reinstall the two bolts
bearing (Figure 12-13, (2)) into the front frame (Figure 12-15, (1)) and two nuts
housing. Reinstall the plate (Figure 12-13, (4)) (Figure 12-15, (2)).
to the front housing. Tighten the four bolts
(Figure 12-13, (3)). 2
1
3
0000265A
1 Figure 12-15
6. Reinstall the insulation bushing
0000259A (Figure 12-16, (4)) and nut (Figure 12-16, (3)).
Figure 12-13
3. Position the stator assembly (Figure 12-13, (1)) 3
on the front frame housing studs. 1
4
4. Lubricate the shaft of the rotor assembly
(Figure 12-14, (1)). Press the rotor assembly
into the front frame housing (Figure 12-14, (2))
and rear frame housing (Figure 12-14, (3)).
1
2
2
0000258A
Figure 12-16
7. Reassemble the regulator assembly
(Figure 12-16, (1)) to the holder
100266A
(Figure 12-16, (2)).
Figure 12-14

8. Reinstall the brush holder (Figure 12-17, (3)), Installation of Alternator

springs (Figure 12-17, (4)) and brushes
(Figure 12-17, (5)). 1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 12-19, (2)) on
9. Reattach the regulator assembly and holder to the gear case stud and the V-belt adjuster bolt
the rear frame housing. (Figure 12-19, (1)).
3 1
2 1
0000264
Figure 12-19
4 2
5 2. Reconnect the electrical wires to the alternator.
Tighten the nuts to 15 - 20 in.-lb (1.7 - 2.3 N·m;
17-23 kgf·m).
0000257A
Figure 12-17 Adjust Cooling Fan V-Belt on page 5-22.
4. Start the engine. Listen for any unusual sounds
10. Reinstall the rear cover (Figure 12-17, (2)) to from the alternator.
the rear frame housing with three bolts
(Figure 12-17, (1)). CAUTION
11. Reassemble the pulley (Figure 12-18, (2)) and Do not operate the engine if the
nut (Figure 12-18, (1)) to the shaft of the rotor alternator is producing unusual sounds.
assembly. Tighten the nut. Damage to the alternator will result.
0000039en
5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
2
1 0000256
Figure 12-18

Dynamo Component Location ALTERNATOR
DYNAMO COMPONENT
LOCATION
Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on.
(1)
(2)
(3)
(4)
(7)
(5)
(8) (9)
(6) (10)
(11) (12)
(13)
(14)
0002140
1 – Rear Cover 8 – Spacer

2 – Nut 9 – Stator Assembly
3 – Lock Washer 10 – Front Bearing (2 used)
4 – Flat Washer 11 – Flat Washer
5 – Rear Bearing 12 – Flywheel Assembly
6 – Output Wire and Connector 13 – Pulley Half
7 – Plate 14 – Through Bolt
Figure 12-20

ALTERNATOR Dynamo Wiring Diagram
DYNAMO WIRING DIAGRAM
(3)
(5) (6)
(2) (4)
(1)
0002137
1 – Dynamo
2 – Current Limiter
3 – Key Switch
4 – Charge Lamp (3.4 Watts Max.)
5 – Battery
6 – Load
Figure 12-21
OPERATION OF DYNAMO
The dynamo consists of a series of permanent
magnets that rotate around a stationary stator coil.
The magnets are attached to the flywheel which is
rotated via the engine cooling fan drive belt. The
resultant output is an AC (alternating current)
signal. The AC is converted to DC (direct current)
by the current limiter. The current limiter outputs
charging DC current to the battery.

Dynamo Standard Output ALTERNATOR
DYNAMO STANDARD OUTPUT
0002138
Figure 12-22

ALTERNATOR Testing of Dynamo
TESTING OF DYNAMO DYNAMO

Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo
1. Disconnect the output wire connector from the
Testing Stator Coil Continuity dynamo.
1. Disconnect the dynamo output wire connector. 2. Loosen the V-belt.
2. Connect one meter lead to each of the stator
wire terminals and read the meter. A CAUTION
Results: The meter reading should indicate
continuity. If continuity is not indicated, the windings
are open and the stator must be replaced.
Testing Stator Coil Short-to-Ground

1. Disconnect the dynamo output wire connector. PINCH HAZARD!
2. Test continuity between each stator wire Carefully rotate the alternator toward the
terminal and engine ground. cylinder block while loosening the
Results: The meter reading should infinity. If the V-belt. Failure to comply may result in
meter reading indicates continuity, the windings are minor or moderate injury.
shorted to ground and the stator must be replaced. 0000014en
Testing Dynamo Regulated Output 3. Remove the V-belt adjuster from the dynamo
bolt (Figure 12-23, (1)).
1. Test and record the battery voltage with the
engine not running. 4. Remove the nut (Figure 12-23, (2)) from the
gear case stud. Remove the dynamo.
2. Start the engine and operate it at normal
operating rpm.
3. Again, check the battery voltage with the engine
running.
Results: The meter reading with the engine
running must be higher than with the engine not
running.
• If results are not correct, test the stator for
(1) 0002141
continuity and shorts to the ground. (2)
• Check the charging system wiring. Figure 12-23
• If no problems are found in previous checks,
replace the IC regulator.

Dynamo ALTERNATOR
Disassembly of Dynamo 4. Remove the screws (Figure 12-26, (1)) and the
stator assembly (Figure 12-26, (2)).
1. Remove the rear cover (Figure 12-24, (1)).
5. Remove the rear bearing (Figure 12-26, (3)).
2. Remove the nut (Figure 12-24, (2)), lock
washer (Figure 12-24, (3)), and flat washer
(3)
(Figure 12-24, (4)).
(1)
(2)
(3)
(4)
(2)
(1)
0002145
Figure 12-26
0002143
Figure 12-24 Reassembly of Dynamo

1. Reinstall the rear bearing (Figure 12-27, (3)).
3. Remove the through bolt (Figure 12-25, (1)),
pulley half (Figure 12-25, (2)), flywheel 2. Reinstall the stator (Figure 12-27, (2)) and
(Figure 12-25, (3)), flat washer screws.
(Figure 12-25, (4)), bearings
(Figure 12-25, (5)), and spacer (3)
(Figure 12-25, (6)).
(6) (2)
(5)
(4) (1)
(3)
(2)
(1)
0002145
Figure 12-27
0002144
Figure 12-25

ALTERNATOR Dynamo
3. Reinstall the front bearings (Figure 12-28, (5)) Installation of Dynamo

and spacer (Figure 12-28, (6)).
1. Position the dynamo on the gear case. Loosely
4. Reinstall the flat washer (Figure 12-28, (4)), reinstall the nut (Figure 12-30, (2)) on the gear
flywheel (Figure 12-28, (3)), pulley half case stud and the V-belt adjuster bolt
(Figure 12-28, (2), and through bolt (Figure 12-30, (1)).
(Figure 12-28, (1)).
(6)
(5)
(4)
(3)
(2) (1) 0002141
(2)
(1)
Figure 12-30
2. Reconnect the dynamo output wire connector.
0002144 3. Reinstall the V-belt. Tighten the V-belt to the
Figure 12-28
Adjust Cooling Fan V-Belt on page 5-22.
5. Reinstall the flat washer (Figure 12-29, (4)), 4. Start the engine. Listen for any unusual sounds
lock washer (Figure 12-29, (3)), and nut from the alternator.
(Figure 12-29, (2)). Tighten the nut to the
specified torque. CAUTION
6. Reinstall the rear cap (Figure 12-29, (1)). Do not operate the engine if the
alternator is producing unusual sounds.
(1) Damage to the alternator will result.
(2)
(3) 0000039en
(4)
5. Verify that the charge indicator is ON while the
engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
0002143
Figure 12-29

Section 15
TROUBLESHOOTING
Page
Special Service Tools................................................................ 15-186
Troubleshooting By Measuring Compression Pressure ............ 15-187
Compression Pressure Measurement Method .................... 15-187
Quick Reference Table For Troubleshooting ............................ 15-190

TROUBLESHOOTING Special Service Tools
For measuring compression pressure

Yanmar Gauge Set Part No. TOL-97190080
0000849
Adapter for direct injection 2-valve cylinder head

Yanmar Adapter Part No. 119802-92950
130
Compression Gauge Kit
0000850
Adapter for direct injection 4-valve cylinder head for

4TNV94L/98/98T
165
0000851
Adapter for direct injection 4-valve cylinder head for

4TNV106(T)
179
0000852

Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING
TROUBLESHOOTING BY For engines with 4 valve cylinder heads
MEASURING COMPRESSION 4. Remove the valve cover assembly. See

Removal of Valve Cover on page 6-52. Remove
PRESSURE the fuel injector from the cylinder to be tested.
Compression pressure drop is one of the major See Removal of Fuel Injectors on page 7-35.
causes of increasing blow-by gas (engine oil 5. Turn off the fuel supply valve in the fuel supply
contamination or increased engine oil consumption line. Disconnect the fuel injection pump stop
as a resultant phenomenon) or starting failure. The solenoid at the connector. This prevents the fuel
compression pressure is affected by the following injection pump from injecting fuel during
factors: compression testing.
1. Degree of clearance between the piston and 6. Before installing the compression gauge
cylinder ((Figure 15-1, (1)) 2 valve engine,
(Figure 15-2, (1)) 4 valve engine) adapter,
2. Degree of clearance at the intake / exhaust crank the engine with the stop solenoid
valve seat disconnected for a few seconds to clear the
3. Gas leak from the nozzle gasket or cylinder cylinder of any residual fuel.
head gasket 7. Install a nozzle seat at the tip end of the
The pressure will drop due to increased parts wear. compression gauge adapter. Install the
Pressure drop reduces the durability of the engine. compression gauge and the compression
gauge adapter at the cylinder to be measured.
A pressure drop may also be caused by a
scratched cylinder or piston, dust entrance from the 8. Crank the engine until the compression gauge
dirty air cleaner element or a worn or broken piston reading is stabilized.
ring. Measure the compression pressure to
(1)
determine the condition of the engine.
Compression Pressure Measurement

Method
1. Warm up the engine.
2. Stop the engine. Remove the high-pressure fuel
injection lines as an assembly from the engine.
For engines with 2 valve cylinder heads
3. Remove the fuel injector from the cylinder to be
measured. See Removal of Fuel Injectors on
page 7-35. Figure 15-1
CAUTION
possible. Disassembling the
high-pressure fuel injection lines from
fuel lines.
0000047en

TROUBLESHOOTING Troubleshooting By Measuring Compression Pressure
(1)
Figure 15-2
9. After performing the compression check
remove the compression gauge and
compression gauge adapter from the cylinder.
10. Reinstall the fuel injector, high-pressure fuel
injection lines, and reconnect the stop solenoid.
See Reassembly of Fuel Injectors on
page 7-41.
11. Install the fuel valves. See Installation of the
Fuel Injectors on page 7-42. See Inspection of
Valve Guides on page 6-57. Then install the
valve covers and injection high pressure lines. .
Then connect the stop solenoid..
12. Turn on the fuel supply valve and reconnect the
injection pump stop solenoid.
13. Prime the fuel system. Check for leaks. Test the
engine.

Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING
Standard Compression Pressure (Reference Value)
Compression Pressure
Engine Model at 250 rpm (250 min-1) Deviation Between Cylinders
Standard Limit
443 - 473 psi 340 - 370 psi
3TNV82A
(3.06 - 3.26 MPa; 30 - 32 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²)
3TNV84 455 - 485 psi 355 - 385 psi
4TNV84 (3.14 - 3.34 MPa; 32 - 34 kgf/cm²) (2.45 - 2.65 MPa; 25 - 27 kgf/cm²)
3TNV84T 411 - 441 psi 340 - 370 psi
4TNV84T (2.84 3.04 MPa; 29 - 31 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²) 29 - 43 psi
3TNV88 (0.2 - 0.3 MPa; 2 - 3 kgf/cm²)
4TNV88
4TNV94L
483 - 513 psi 384 - 414 psi
4TNV98
(3.33 - 3.53 MPa; 34 - 36 kgf/cm²) (2.65 - 2.85 MPa; 27 - 29 kgf/cm²)
4TNV98T
4TNV106
4TNV106T
Engine Speed and Compression Pressure (Use for Reference)
3TNV88
4TNV88
4TNV94L
4TNV98
569 psi 4TNV98T
(4 MPa)
(40 KgF/cm2) 3TNV84
4TNV106
4TNV106T
498 psi 4TNV84
(35 KgF/cm2)
427 psi
(30 KgF/cm2) (3 MPa)
356 psi
(25 KgF/cm2) 3TNV82A
3TNV84T
284 psi
4TNV84T (2 MPa)
(20 KgF/cm2)
200 250 300 350 400

Engine speed (min-1)
Figure 15-3

TROUBLESHOOTING Quick Reference Table For Troubleshooting
Measured Value and Troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective Action

Clogged element Clean the element.
1 Air Cleaner Element Broken element
Replace the element.
Defect at element seal portion
2 Valve Clearance Excessive or no clearance Adjust the valve clearance.
3 Valve Timing Incorrect valve clearance Adjust the valve clearance.
Replace the gasket.
4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake / Exhaust Valve Sticking valve Replace the intake / exhaust valve.
5 Gas leak due to worn valve seat

Valve Seat or foreign matter trapped in Lap the valve seat.
valve
Piston
Gas leak due to scratching or
6 Piston Ring Perform honing and use an oversized part.
wear
Cylinder
QUICK REFERENCE TABLE

FOR TROUBLESHOOTING
The following table summarizes the general trouble
symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a
serious problem so as not to shorten the engine
service life.

TNV DI Service Manual TROUBLESHOOTING
Failure Diagnosis Table
Starting failure Engine stall Speed control error Engine Noise and Lubricating oil Cooling Intake air Exhaust gas Fuel Electrical parts
Symptoms and conditions of failure after start up output low vibration water
Starter does Starter
ECU failure lamp stops flashing immediately (within 2 seconds) after turning off the key
not rotates rotates Smoke No load Workload Smoke color Workload
Revolution speed cannot be changed with accelerator (stays at a constant speed)

ECU failure lamp goes on immediately (within 2 seconds) after turning on the key
ECU failure lamp does not go on immediately after turning on the key
Engine does not start up (it stops immediately after initial ignition)
Abnormal sound (other than combustion sound) from engine
Fuel mixed with water (oil-water separator warning lamp lit)

Corrective Action Referenced page number
Engine does not start up (without initial ignition)
Oil pressure low (oil pressure warning lamp lit)
Overheat (water temperature warning lamp lit)

It takes longer than before to start up engine
Pressure low (air cleaner warning lamp lit)

High knocking sound at combustion time
Fuses get blown or broken (repeatedly)

Does not smoothly return to low speed
Battery charge error (charge lamp lit)

Too much lubricating oil consumed
Specific ECU control functions fail.

Cannot be set to particular speed
Lubricating oil mixed with water

Lubricating oil diluted with fuel
Exhaust gas temperature high

Uneven combustion sound
Too much fuel consumed
ECU failure lamp flashes

Engine vibrates heavily
Water temperature low
Fuel filter fouled shortly

Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
Intake/exhaust valves with improper See "Measuring and Adjusting Valve

Adjust the valve clearances.
clearances Clearances" (on page 6-50).
See "Correcting the Valve Seats" (on
Compressed air leaks from a valve seat Lap the valve seat. page 6-30) for two-valve head or
"Correcting The Valve Seats" (on page 6-
44) for four-valve head.
Repair or replace the intake/exhaust See "Removing the Intake/Exhaust
Intake/exhaust valve seized
valves. Valves" (on page 6-26).
See "Removing the Cylinder Head" (on
Cylinder head gasket blown Replace the gasket.
page 6-40).
See "Installing the Pistons" (on page 6-
Piston ring stuck or broken Replace the piston rings.
70).
Piston rings piston, or cylinder worn Apply honing, and use oversized parts. See "Honing and Boring" (on page 6-69).
See "Inspecting the Crank Shaft" (on
Crank pin metal and bearing seized Repair or replace.
page 6-67).
Engine system

Piston ring joint not correctly positioned Correct the joint position.
70).
Piston ring reverse-installed Reinstall.
70).
See "Inspecting the Crank Shaft" (on
Crank pin metal and journal metal worn Measure and replace.
page 6-67).
See "Tightening Torques for Main Bolts
Connecting rod bolt loose Tighten with specified torque.
and Nuts" (on page 6-15).
See "Disassembling the Engine" (on
Foreign matter in a combustion chamber Disassemble and repair.
page 6-55).
See "Inspecting the Timing Gear
Gear backlash too large Adjust the gear engagement.
Backlash" (on page 6-70).
See "Inspecting the Valve Guide" (on
Intake/exhaust valve guide worn Measure and replace.
page 6-29).
See "Inspecting and Adjusting Governor
Governor not properly adjusted Adjust.
Lever and Accelerator" (on page 5-27).
Intake/exhaust valves with improper See "Measuring and Adjusting Valve
Adjust the valve clearances.
opening/closing timings Clearances" (on page 6-50).
Engine's mounting loosened or damaged Repair or replace the faulty part(s).

TROUBLESHOOTING Failure Diagnosis Table
Smoke No load Workload Smoke color Workload
not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
See "Cleaning Procedures" (on page 10-

Supercharger
Floor fouled Clean the floor.

11).
See "Testing the Waste Gate Valve" (on
Waste gate malfunctioning Disassemble and inspect.
page 10-14).
Radial metal worn Disassemble and inspect. See "Radial Metal" (on page 10-10).
See "Disassembling the Cooling Water
Radiator overcooling Replace the thermostat.
Pump" (on page 8-9).
Replace the thermostat. Pump" (on page 8-9) or
Cooling water system
Radiator cooling insufficient Or check the fan belt for looseness. "Adjusting the Cooling Fan V-belt
Tension" (on page 5-21).
Check the cooling water system for water See "Inspecting the Cooling Water
Cooling water low
leakage. System" (on page 8-7).
Water jacket cracked Repair or replace.
See "Adjusting the Cooling Fan V-belt
Fan belt elongated Adjust the belt tension.
Tension" (on page 5-21).
Thermostat faulty Inspect or replace.
See "Engine Oil Standards" (on page 4-
Improper lubricating oil Use the proper lubricating oil.
13).
See "Disassembling the Lubricating Oil
Leakage from lubricating oil system Repair.
Lubricating oil system

Trochoid pump discharge rate insufficient Inspect and repair.
See "Replacing the Engine Oil and
Lubricating oil filter clogged Clean or replace.
Engine Oil Filter" (on page 5-19).
Pressure regulator valve faulty Clean, adjust, or replace.
See "Filling the Engine Oil" (on page 4-
Lubricating oil low Fill the proper lubricating oil. 14).
See "Inspecting the Engine Oil" (on page
Crank case excessively lubricated Inspect the engine oil. 4-14).

Failure Diagnosis Table TROUBLESHOOTING
not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
Stop solenoid faulty Inspect and replace. See "Stop Solenoid" (on page 7-7).
Fuel injection pump's injection timing See "Inspecting and Adjusting Fuel
Inspect and adjust.
advanced excessively Injection Timing" (on page 7-25).
Fuel injection pump's injection timing See "Inspecting and Adjusting Fuel
Inspect and adjust.
delayed excessively Injection Timing" (on page 7-25).
See "Diesel Fuel Standards" (on page 4-
Improper fuel oil Use the proper fuel oil. 9).
See "Draining the Oil-Water Separator"
Water flown into the fuel system Drain the fuel filter. (on page 5-22).
"Cleaning the Oil-Water Separator" (on
Fuel filter clogged Clean or replace.
page 5-31).
See "Oil Feed to the Fuel System" (on
Air contained in the fuel system Bleed.
page 4-12).
Fuel pipe clogged or cracked Clean or replace.
Fuel system
Insufficient fuel supply to the fuel injection Inspect the fuel tank cock, fuel filter, fuel
pump pipe, and fuel feed pump.
Uneven injection by the fuel injection pump Inspect and adjust. See "Testing the Fuel Injectors" (on page
7-32).
See "Testing the Fuel Injectors" (on page
Fuel injected excessively Inspect and adjust.
7-32).
Fuel injection nozzle spray failure Inspect and adjust. See "Testing the Fuel Injectors" (on page
7-32).
Remove dirt caught in the priming pump
See "Fuel System Components" (on page
Priming fails internal valve
7-12).
(disassemble and clean).
Feed pump inlet strainer clogged Clean the strainer.
Replace the pump.
CSD valve malfunctioning
Replace the CSD valve.
Inspect the fuel tank and lid;
Fuel tank airtightness deteriorated replace with the genuine parts if
necessary.
See "Cleaning the Air Cleaner Element"
Intake/exhaust
Air filter clogged Clean the air filter.

(on page 5-28).
gas system
Engine used at high temperatures or high Examine the relationship between output
altitudes reduction and load
Exhaust pipe clogged Clean the exhaust pipe.

not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
Fuse blown or broken Replace the fuse.

Starter faulty Repair or replace the starter. See "Starter" (on page 11-9).
See "Removing the Alternator" (on page
Alternator faulty Repair or replace the alternator.
12-12).
Repair or replace the disconnected
Wires disconnected
wire(s) of the harness.
Wires short-circuited (sheathing broken); Inspect, repair, or replace the harnesses
overloaded by the power consumption by and wires as needed.
additional devices Reexamine the additional devices.
See "Inspecting the Electrolyte Level and
Battery voltage low – Inspect and charge the battery.
Charging the Battery" (on page 5-23).
Repair or replace the harness.
Key switch faulty or disconnected
Replace the key switch.
Key switch instantly cut off Replace the key switch.
Starter relay faulty, disconnected, or short- Repair or replace the harness.
circuited Replace the starter relay.
Electrical system
Main relay faulty Repair or replace the harness.

(except for sticking of the contact, which is
Replace the main relay.
undetectable by ECU)
Actuator relay faulty
? ? Replace the actuator relay.
(contact failure undetectable by ECU)
Start assist relay faulty
∆ Replace the start assist relay.
(contact failure undetectable by ECU)
Accelerator sensor signal error
(an error undetectable by ECU) Repair or replace the accelerator sensor.
Water temperature sensor signal error

Replace the water temperature sensor.
(an error undetectable by ECU)
Speed sensor signal error (an error
Monitor the engine speed using the
undetectable by ECU, such as caused by Repair or replace the fuel injection pump.
noise) diagnosis tool.
Rack position sensor signal error Monitor the rack position sensor signal
Repair or replace the fuel injection pump.
(an error undetectable by ECU) using the diagnosis tool.
Rack actuator malfunctioning Monitor the rack actuator using the
(an error undetectable by ECU) diagnosis tool.
Replace the lamp.
ECU failure lamp disconnected
ECU faulty (ECU self diagnosis failure) Replace the ECU.

Failure Diagnosis Table TROUBLESHOOTING
not rotates rotates











Too much blow-bye
White exhaust gas
Black exhaust gas

Poor acceleration
Hunting occurs
Hunting occurs
Pressure high
Remarkable
Normal
White
Slight
Black
None
Possible causes
This is not a failure.

ECU control function active Refer to the control manual.
Switch to the normal mode.
Water temperature sensor disconnected or Repair or replace the harness.
Engine stopped or restricted by ECU failure diagnosis function
short-circuited Replace the water temperature sensor.

Accelerator sensor disconnected or short- Repair or replace the harness.
circuited Replace the accelerator sensor.
Speed sensor signal error Repair or replace the harness.

Rack position sensor signal error Repair or replace the harness.

Rack actuator malfunctioning
Check for idle rotations caused by the
Engine overspeed occurs working machine.
Check the speed sensor signal.
CAN Communication error
Replace the ECU.
The EGR valve motor disconnected or short- Repair or replace the harness.
circuited. Replace the EGR valve.
CSD solenoid valve disconnected or short- Repair or replace the harness.
circuited. Replace the CSD valve solenoid.
Start assist relay disconnected or short- Repair or replace the harness.
∆
circuited. Replace the relay.
Main relay cannot be turned off Replace the relay.
Rack actuator relay disconnected or short- Repair or replace the harness.
?
circuited Replace the relay.
Error detected by ECU self diagnosis ? Replace the ECU.


Electrical Wiring TNV DI Service Manual WIRING DIAGRAM
ELECTRICAL WIRING
Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine
manufacturer for specific information.
KEY SWITCH* 30A

FUSE*
EMERGENCY
STOP
SWITCH*
Items marked with * are

not provided by Yanmar.
0000864A

WIRING DIAGRAM Electrical Wiring

CX36B Mini Excavator

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CX31B

Printed in U.S.A. Part number S5PW0032E02

Book Code No.S5PW0032E02

2) WARNING- Indicates a potentially hazardous

The proper and safe lubrication and maintenance

2010-03 & ASSEMBLY

When ordering replacement or service parts, refer to

1.1 GENERAL PRECAUTIONS FOR REPAIRS ........................................................1-3

Book Code No. S5PA0105E01

Issue Date of Issue Applicable Machines Remarks

1.1 GENERAL PRECAUTIONS FOR REPAIRS

1.1.1 PREPARATION BEFORE DISASSEMBLING 1

Read Operator's Manual

(1) Understanding operating procedure

(2) Cleaning machines

(3) Inspecting machines

1. Inspection date and place.

(5) Arrangement and cleaning in service shop

1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING

1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

(1) Removing hydraulic equipment

(2) Disassembling hydraulic equipment

(3) Inspecting parts

(4) Reassembling hydraulic equipment

(5) Installing hydraulic equipment

1.1.4 ELECTRICAL EQUIPMENT

(1) Do not disassemble electrical equipment.

Battery electrolyte is hazardous.

1.1.5 HYDRAULIC PARTS

(2) Flexible hose (F hose)

1.1.6 WELDING REPAIR

1.1.7 ENVIRONMENTAL MEASURES

1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS'

Introduction Base units

(1) Base units (4) Derived Units bearing Peculiar Designations

Density kilogram per cubic meter kg/m3 Illuminance lux lx l m/m2

(5) Prefixes of SI (6) Unit Conversion

2.1 COMPONENTS NAME ........................................................................................2-3

Book Code No. S5PW0232E02

Issue Date of Issue Applicable Machines Remarks

2.1 COMPONENTS NAME

RUBBER CRAWLER SHOE

2.2 MACHINE DIMENSIONS

(1) CX31B (CANOPY) Unit: mm (ft-in)

300 1550 {5'1.0"}

(2) CX31B (CAB)

300 1550 {5'1.0"}

(3) CX36B (CANOPY) Unit:mm(ft-in)

(4) CX36B (CAB)

2.3 SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY

Model CX31B CX36B

Model (YANMAR) 3TNV88-BPYB

Hydraulic Pump Variable displacement axial piston + gear pump

SIDE DIGGING & DOZER

Type Boom swing by hydraulic cylinder

Rubber shoe Iron shoe Rubber shoe Iron shoe

This figure is calculated with Japanese standard bucket.

2.4 MACHINE & COMPONENTS WEIGHT (DRY)

Bucket weight is shown with Japanese standard bucket weight.

ATTACHMENT ASSEMBLY 460 (1020) <-- <-- <--

Bucket weight is shown with Japanese standard bucket weight.

(1) LOADING MACHINE ON A TRAILER

Do not put chains over or against hydraulic lines or hoses.