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TB108服务手册
TB108服务手册
TB108 0-2
0-3 TB108
FOREWORD
This manual is intended for persons who engage in maintenance operations, and explains
procedures for disassembly and reassembly of the machine, check and maintenance procedures,
maintenance reference values, troubleshooting and outline specifications, etc. Please use this
manual as a reference in service activities to improve maintenance techniques.
Further, please be advised that items contained in this manual are subject to change without notice
due to design modifications, etc.
MANUAL CONTROL
Information on those to whom this manual is distributed is recorded in the ledger in the section
in charge at this company, so please decide on a person to be in charge of it and control it. When
there are updates or additions, etc., we will notify the person in charge.
TB108 0-4
FOOT OF THE PAGE
L4A100E
1. Page number
The following page numbers are assigned to each respective page. And if there are additional pages, the addition
codes are supplied. Please file the sheets in the order of the page numbers.
Page No.
X–XX
Page number within chapter
Chapter Number
Page Addition
X–XX–X
Addition Code
Example: II-8
II-9
II-9-1 ............... A page is added between page 9 and page 10.
II-10
2. Revision number
Indicates the number of revisions made to this manual. This number is printed on the page that reflects this
revision.
If a page has been revised, it is to be used in place of the page used before revision and it is not necessary to keep
the old page.
3. Model(s)
SYMBOLS
means “Please refer to the section quoted.”
Indicates the tightening torque at the specific section that requires special attention in designing.
0-5 TB108
TB108 0-6
I . GENERAL
II . SPECIFICATIONS
III . MACHINE CONFIGURATION
IV . HYDRAULIC UNITS
V. TROUBLESHOOTING
VI . ENGINE
0-7 TB108
TB108 0-8
I . GENERAL
I-1 TB108
GENERAL
CONTENTS
TB108 I-2
GENERAL
SAFETY PRECAUTIONS
■ SIGNAL WORDS
Safety messages appearing in this manual and on machine decals are identified by the words “DANGER”,
“WARNING” and “CAUTION”. These signal words mean the following:
IMPORTANT: The word “IMPORTANT” is used to alert against operators and maintenance personnel
about situations which can result in possible damage to the machine and its components.
This manual is intended for trained and qualified personnel only. Warnings or cautions described in this manual do
not necessarily cover all safety measures. For maintenance work, each person must take adequate safety precautions
against possible hazards present in the respective working environment.
I-3 TB108
GENERAL
Provide a fire extinguisher and first aid Anti-explosive lighting
kit
TB108 I-4
GENERAL
Always clean the machine Securely block the machine or any
component that may fall
I-5 TB108
GENERAL
Place heavy objects in a stable position Handling of hoses
TB108 I-6
GENERAL
Be careful with fluids under pressure Be careful with grease under pressure
I-7 TB108
GENERAL
Avoid battery hazards Checks after maintenance
• Batteries contain sulfuric acid which will damage • Gradually raise the engine speed from a low idle to
eyes or skin on contact. maximum speed and check that no oil or air is
• If acid contacts eyes, flush immediately with leaking from serviced parts.
clean water and get prompt medical attention. • Move the controls and check that the machine is
• If acid is accidentally swallowed, drink large operating properly.
quantities of water or milk and call a physician
immediately.
• If acid contacts skin or clothing, wash off imme-
diately with clean water.
• Wear safety glasses and gloves when working with Disposing of wastes
batteries.
• Batteries generate flammable and explosive gases.
Keep arcs, sparks, flames and lighted tobacco
away.
• Use a flashlight to check battery electrolyte level.
• Stop the engine and shut off electrical equipment
while inspecting or handling the battery.
• Do not short circuit the battery posts with metal
items.
• Always unfasten the negative (–) battery cable first
when disconnecting the battery cable. Always con- • Funnel spent fluids from the machine into contain-
nect the negative (–) battery cable last when fasten- ers. Disposing of fluids improperly destroys the
ing the battery cable. environment.
• Loose battery terminals may result in sparks. Be • Follow the prescribed regulations when disposing
sure to fasten terminals tightly. of oil, fuel, engine coolant, refrigerant, solvents,
• Make sure the vent caps are tightened securely. filters, batteries or other harmful substances.
• Do not charge a battery or jump-start the engine if
the battery is frozen. Warm to 15°C (60°F) or the
battery may explode.
Safety signs
TB108 I-8
GENERAL
CAUTIONS DURING DISASSEMBLY AND CAUTIONS DURING REMOVAL AND
ASSEMBLY INSTALLATION OF THE HYDRAULIC UNITS
1. Clean the machine before disassembly operation. 1. Make sure that the temperature of the hydraulic
oil has dropped.
2. Before disassembly, check the machine condi-
tions and record them. 2. To prevent a loss of flow of the hydraulic oil, the
• Model, Machine Serial Number, Hourmeter residual pressure in the piping and the internal
• Reason for Repairs, Repair History pressure in the hydraulic tank should be released.
• Dirtiness of Filters
• Fuel and Oil Conditions 3. Be sure to install caps or plugs on all openings in
• Damage to each parts, etc. the hydraulic unit to prevent dirt from getting into
the unit through the openings.
3. To make reassembly operations easy, make match-
PLUG
ing marks at the necessary points.
I-9 TB108
GENERAL
CAUTIONS DURING REMOVAL AND HANDLING OF SEALS
INSTALLATION OF PIPING
1. Clean the grooves for O-rings and if there is any
1. When hydraulic hoses are installed, tighten them burr, etc., remove it.
once to the prescribed torque, then loosen them
slightly and retighten them to the prescribed
torque.
• Tighten the fittings after the installation sur- BURR
faces fit snugly together.
• Pieces wrapped with seal tape are excluded.
GREASE
TB108 I-10
GENERAL
TIGHTENING TORQUES
Hydraulic Hoses
Torque
UNION NUT
Hose Fitting Size Union Nut (G) Taper Thread (R)
N·m ft-lb N·m ft-lb
+4.9 +3.5
1/8 9.8 0 7.3 0 11.8 ±1.2 8.7 ±0.8
+4.9 +3.5
1/4 24.5 0 18.1 0 29.4 ±2.9 21.7 ±2.1 TAPER THREAD
+4.9 +3.5
3/8 49 0 36.2 0 53.9 ±5.4 39.8 ±3.9
1/2 58.8 +4.9
0 43.4 +3.5
0 88.3 ±8.8 65.1 ±6.4
+4.9 +3.5
3/4 117.7 0 86.8 0 147.1 ±14.7 108.5 ±10.7
+4.9 +3.5
1 137.3 0 101.3 0 196.1 ±19.6 144.7 ±14.3
I-11 TB108
GENERAL
Joints for Piping
Torque
Nominal Thread
Diameter Steel Cast Steel
(R) N·m ft-lb N·m ft-lb
1/8 11.8 ±1.2 8.7 ±0.8 10.8 ±1.1 8.0 ±0.7
1/4 29.4 ±2.9 21.7 ±2.1 24.5 ±2.5 18.1 ±1.7
3/8 53.9 ±5.4 39.8 ±3.9 49 ±4.9 36.2 ±3.5
1/2 88.3 ±8.8 65.1 ±6.4 73.5 ±7.4 54.3 ±5.3
3/4 147.1 ±14.7 108.5 ±10.7 127.5 ±12.7 94.1 ±9.3
1 196.1 ±19.2 144.7 ±14.3 171.6 ±17.2 126.6 ±12.5
TB108 I-12
GENERAL
Bolts and Nuts (for ISO Strength Category 10.9)
Torque
Thread Size × Pitch General Tightening Points Special Tightening Points
N·m kgf·m ft-lb N·m kgf·m ft-lb
M6 × 1.0 9.8 ±0.5 1.0 ±0.05 7.2 ±0.4 11.8 ±0.6 1.2 ±0.06 8.7 ±0.4
M 8 × 1.25 22.6 ±1.1 2.3 ±0.11 16.6 ±0.8 26.5 ±1.3 2.7 ±0.13 19.5 ±0.9
M10 × 1.5 47.1 ±2.4 4.8 ±0.24 34.7 ±1.7 54.9 ±2.7 5.6 ±0.28 40.5 ±2.0
Coarse M12 × 1.75 83.4 ±4.1 8.5 ±0.42 61.5 ±3.0 97.1 ±4.8 9.9 ±0.49 71.6 ±3.5
M14 × 2.0 134.4 ±6.7 13.7 ±0.68 99.1 ±4.9 155.9 ±7.7 15.9 ±0.79 115.0 ±5.7
M16 × 2.0 207.9 ±10.4 21.2 ±1.06 153.3 ±7.7 241.2 ±12.1 24.6 ±1.23 177.9 ±8.9
M20 × 2.5 410.9 ±20.5 41.9 ±2.09 303.1 ±15.1 475.6 ±23.7 48.5 ±2.42 350.8 ±17.5
M8 × 1.0 24.5 ±1.2 2.5 ±0.12 18.1 ±0.9 28.4 ±1.4 2.9 ±0.14 21.0 ±1.0
M10 × 1.25 50.0 ±2.5 5.1 ±0.25 36.9 ±1.8 58.8 ±2.9 6.0 ±0.30 43.4 ±2.2
M12 × 1.5 87.3 ±4.3 8.9 ±0.44 64.4 ±3.2 102.0 ±5.1 10.4 ±0.52 75.2 ±3.8
Fine
M14 × 1.5 135.3 ±6.8 13.8 ±0.69 99.9 ±5.0 157.9 ±7.8 16.1 ±0.80 116.5 ±5.8
M16 × 1.5 220.6 ±11.0 22.5 ±1.12 162.7 ±8.1 256.0 ±12.7 26.1 ±1.30 188.8 ±9.4
M20 × 1.5 452.1 ±22.6 46.1 ±2.30 333.4 ±16.6 524.7 ±26.1 53.5 ±2.66 387.0 ±19.2
1. General Tightening Points (Non-lubricated) 4. If tightening torque values are provided in this
• All securing points other than the special tight- manual, then tightening should be done accord-
ening points. ing to those values.
(This indicates that the tightening torque differs
2. Special Tightening Points (Grease with molyb- from the values given in this table.)
denum disulfide applied.)
• Points where particularly necessary due to 5. In order to tighten bolts and nuts evenly, they
function. should be tightened alternately top, bottom, left,
Special tightening positions and associated right.
instructions are given in the text.
I-13 TB108
GENERAL
TB108 I-14
II . SPECIFICATIONS
II-1
I-15 TB108
SPECIFICATIONS
CONTENTS
Standard Value ......... This indicates the standard value for the new machine at the time of shipping from the factory.
It should be used as the target value for maintenance work after operation.
Allowable Value ....... The dimensions of parts change during use because of wear and deformation. Also, the
performance of pumps, motors, and other hydraulic equipment drops, and this is the
estimated value indicating the use limit for the respective part. It is decided under reference
to the standard at the time of shipping, the results of various tests, etc. As the use conditions,
the degree of repairs, etc., differ for each machine, these should be combined and used as
reference for servicing standards and standards for judging performance.
* Do not use the standard values and the allowable values as standards for customer claims.
TB108 II-2
II-16
NAMES OF COMPONENTS SPECIFICATIONS
NAMES OF COMPONENTS
3
11
7
10
8 2
6
9
25
24 4
23
5
26 12
22
16
20
15 28
21
27 14
19 18
17 13 B5B000
II-3 TB108
SPECIFICATIONS DIMENSIONS
DIMENSIONS
Machine Dimensions
T Unit: mm
L Standard Arm Long Arm
A 2710 2740
N
X P B 740 ←
M C 2110/2195* ←
Y
D D 800 ←
Z
U E 385 ←
F 900 ←
B
X G 1220 ←
H 900 ←
J 180 ←
K 160 ←
L 790 825
C
M 440 ←
V N 340 ←
P 900 ←
E
K S Q 1920 1955
J F R 740 ←
W G
H Q R S 200 ←
A T 90° ←
B5B001
U 90° ←
V 1375 ←
W 680 ←
X 680 ←
Y 1080 1125
Z 880 915
* Option: With Lift Eyes
Operating Range
Unit: mm
Standard Arm Long Arm
E A 2825 2970
F B 2730 2880
C 1530 1680
G D 1220 1370
J E 2860 2975
F 2030 2145
K G 900 760
H 1890 1915
D
C J 155 ←
K 120 ←
H
B
A
B5B002
TB108 II-4
LIFTING CAPACITIES SPECIFICATIONS
LIFTING CAPACITIES
Rated Lift Capacity Chart
• The loads in the charts do not exceed 87% of
hydraulic lift capacity or 75% of tipping load.
• Rated lift capacities limited by rated hydraulic lift
capacity are identified by an asterisk(*)
• The mass of slings and any auxiliary lifting devices
shall be deducted from the rated load to determine
the net load that may be lifted.
• The load point is the bucket hinge pin, and the
bucket posture is with the standard bucket com-
pletely retracted under the arm.
• Units: daN (lbs.)
WARNING
• DO NOT attempt to lift or hold any load that is
greater than these rated values at their speci-
fied load radii and height.
• All rated lift capacities are based on the ma-
chine being level and on a firm supporting
surface. For safe working loads, the user is
expected to make due allowance for the par-
ticular job conditions such as soft or uneven
ground, non-level condition, side loads, haz-
ardous conditions, experience of personnel,
etc. The operator and other personnel should
fully acquaint themselves with the operator’s
manual furnished by the manufacturer before
operating this machine, and rules for safe
operation of equipment shall be adhered to at
all times.
II-5 TB108
SPECIFICATIONS LIFTING CAPACITIES
B5B004
TB108 II-6
LIFTING CAPACITIES SPECIFICATIONS
Equipped with Long Arm Unit: daN (lbs.)
B5B006
II-7 TB108
SPECIFICATIONS SPECIFICATION TABLES
SPECIFICATION TABLES
SPECIFICATIONS
TB108 II-8
SPECIFICATION TABLES SPECIFICATIONS
II-9 TB108
SPECIFICATIONS SPECIFICATION TABLES
SPECIFICATIONS OF DEVICE
Engine
Model Yanmar 2TNV70-PTB
Type 4-Cycle, vertical, water-cooled, in-line, 2-cylinder diesel engine
Number of Cylinders-Bore × Stroke mm 2-70 × 74
Total Displacement L 0.569
Compression Ratio 23.4 : 1
Performance
Maximum Torque N·m/min-1 31.4~34.3/1800 ±100
Maximum No-load R.P.M. min-1 2570 ±25
Minimum No-load R.P.M. min-1 1100 ±25
Specific Fuel Consumption g/kW·h <
= 287
Starter V–kW 12–1.0
Generator V–kW 12–0.18
Battery V–A·h 12–34
Hydraulic Pump
Model DDG05A4.5·4.5F2H1-R256
Type Double gear
Delivery: P1 L/min 10.7
P2 L/min 10.7
Rated Pressure:P1 MPa 15.7
P2 MPa 15.7
Boom Cylinder
Bore Diameter × Rod Diameter mm 50 × 25
Stroke mm 300
Fully Retracted Length (Pitch) mm 560
Cushion Mechanism Rod Side
Arm Cylinder
Bore Diameter × Rod Diameter mm 55 × 30
Stroke mm 320
Fully Retracted Length (Pitch) mm 540
Cushion Mechanism
TB108 II-10
SPECIFICATION TABLES SPECIFICATIONS
Bucket Cylinder
Bore Diameter × Rod Diameter mm 50 × 25
Stroke mm 285
Fully Retracted Length (Pitch) mm 505
Cushion Mechanism
Swing Cylinder
Bore Diameter × Rod Diameter mm 50 × 25
Stroke mm 370
Fully Retracted Length (Pitch) mm 590
Cushion Mechanism
Spanner Cylinder
Bore Diameter × Rod Diameter mm 50 × 25
Stroke mm 220
Fully Retracted Length (Pitch) mm 440
Cushion Mechanism
Travel Motor
Model PHK-80-25B-1-8032A
Type Piston Motor
Total Displacement cm3/rev 288
Motor Displacement cm3/rev 11.4
Reduction Gear Ratio 1/25.26
Parking Brake Torque N·m 17.6
Parking Brake Release Pressure MPa 1.5
Amount of Reduction Gear Lubricant L 0.33
Slew Motor
Model 2-200DOS-E3792
Type Orbit Motor
Total Displacement cm3/rev 195
Relief Valve Pressure Setting MPa 6.4
Swivel Joint
Model YV-7108B
II-11 TB108
SPECIFICATIONS MASS TABLES
MASS TABLES
UNIT MASS (Dry Mass)
Unit: kg
Serial Number 10820001~
Upper Machinery
Engine 84
Radiator 3.2
Gear Pump 3.6
Hydraulic Tank 13
Fuel Tank 8
Control Valve 11
Slew Motor 15
Canopy 40
Counterweight 36
Swing Bracket 16
Swing Cylinder 9
Lower Machinery
Swivel Joint 13
Slew Bearing 18
Crawler Belt 24
Travel Motor 14
Track Roller 2.2
Idler 6.4
Sprocket 3.9
Track Adjuster 1.4
Dozer Blade 33
Dozer Blade Cylinder 5.5
Hoe Attachment
Boom 33
Arm: Standard/Long 14/16
Bucket: Standard 15
Boom Cylinder 9
Arm Cylinder 9.3
Bucket Cylinder 7.5
TB108 II-12
RECOMMENDED LUBRICANTS SPECIFICATIONS
RECOMMENDED LUBRICANTS
Use different fuels, lubricants and greases according to the temperature, referring to the chart below.
• Change the lubricant earlier than as show in the table if it is extremely dirty or its performance has deteriorated
severely.
• Whenever possible, use the same brand of lubricant as before. If changing with a different brand, replace the entire
quantity – do not mix different brands.
Type by temperature
Replacement
Part Type -22 -4 14 32 50 68 86 104°F Capacity
interval
-30 -20 -10 0 10 20 30 40°C
Total system:
ISO VG68
Antiwear 14 L
Hydraulic tank ISO VG46 Every 2000 hrs.
hydraulic oil Tank level:
ISO VG32 7.3 L
Use a clean, Quality fuel for performance and optimum engine life.
• To prevent fuel flow problems in cold weather, use diesel
fuel with a pour point of at least -12°C (10°F) below the
Fuel tank Diesel fuel lowest expected ambient temperature. 8L
• Minimum cetane number is 45. Low temperature or high
altitude operation may require the use of fuel with a
higher cetane number.
* For water, use tap water (soft). Do not use well or river water.
** When the ambient temperature drops below 0°C, add coolant (antifreeze). Follow the coolant manufacture’s
instructions to determine the mixture ratio.
II-13 TB108
SPECIFICATIONS SERVICING STANDARDS
SERVICING STANDARDS
TRAVEL SYSTEM
Track Roller
Unit: mm
Code Designated Standard
B 25
B5B007
Drive Sprocket *
Unit: mm
Code Designated Standard
."*!
Idler
Unit: mm
Code Designated Standard
B5B008
TB108 II-14
SERVICING STANDARDS SPECIFICATIONS
ATTACHMENTS
O L M B
D A
N C
P
Q
E
G
F
T
S
R
B5B014
II-15 TB108
SPECIFICATIONS SERVICING STANDARDS
Unit: mm
Servicing
Code Item Designated Standard Procedure
Basic Allowable Tolerance Standard Allowable
Dimensions Shaft Hole Clearance Clearance
A Connection Between Bucket & 25 -0.02 +0.15 0.12~0.20 1.0
Arm -0.05 +0.10
B Connection Between Bucket & 25 -0.02 +0.15 0.12~0.20 1.0
Link -0.05 +0.10
C Connection Between Arm & 25 -0.02 +0.15 0.12~0.20 1.0
Link -0.05 +0.10
D Connection Between Bucket 25 -0.02 +0.15 0.07~0.20 1.0
Cylinder & Link -0.05 +0.05
E Connection Between Bucket 25 -0.02 +0.15 0.07~0.20 1.0
Cylinder & Arm -0.05 +0.05
F Connection Between Arm & 25 -0.02 +0.15 0.12~0.20 1.0
Boom -0.05 +0.10
G Connection Between Arm Cyl- 25 -0.02 +0.15 0.07~0.20 1.0
inder & Arm -0.05 +0.05
H Connection Between Arm Cyl- 25 -0.02 +0.15 0.07~0.20 1.0
inder & Boom -0.05 +0.05
I Connection Between Boom & 25 -0.02 +0.15 0.12~0.20 1.0
Swing Bracket -0.05 +0.10
J Connection Between Boom Cyl- 25 -0.02 +0.15 0.07~0.20 1.0
inder & Boom -0.05 +0.05
Replace
K Connection Between Boom Cyl- 35 -0.02 +0.15 0.07~0.20 1.0
inder & Swing Bracket -0.05 +0.05
L Connection Between Swing 45 -0.02 +0.15 0.12~0.20 1.0
Bracket & Turntable -0.05 +0.10
M Connection Between Swing 25 -0.02 +0.15 0.12~0.20 1.0
Bracket & Link -0.05 +0.10
N Connection Between Swing 25 -0.02 +0.15 0.12~0.20 1.0
Arm & Link -0.05 +0.10
O Connection Between Swing 25 -0.02 +0.15 0.12~0.20 1.0
Arm & Turntable -0.05 +0.10
P Connection Between Swing 30 -0.02 +0.15 0.07~0.20 1.0
Cylinder & Swing Arm -0.05 +0.05
Connection Between Swing -0.02 +0.15
Q 25 -0.05 +0.05 0.07~0.20 1.0
Cylinder & Turntable
Connection Between Dozer -0.02 +0.15
R 25 -0.05 +0.10 0.12~0.20 1.0
Blade & Lower Frame
Connection Between Dozer -0.02 +0.15
S 25 -0.05 +0.05 0.07~0.20 1.0
Blade Cylinder & Dozer Blade
Connection Between Dozer -0.02 +0.15
T Blade Cylinder & Lower Frame 25 -0.05 +0.05 0.07~0.20 1.0
TB108 II-16
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS
STANDARDS FOR JUDGING PERFORMANCE
REFERENCE VALUE TABLE
II-17 TB108
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
TB108 II-18
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS
METHODS FOR INSPECTING PERFORMANCE
WARNING
When inspecting the performance of the ma-
chine that has an extendible crawler, it should be
done with the crawler fully extended.
Measuring Method
• Engine : Rated r.p.m.
• Hydraulic Oil Temp. : 50~60°C
• Mount the pressure gauge on the pressure detec-
tion port, operate the desired hydraulic circuit
and measure the relief pressure.
R1 R2
B5B009
B5B010
Adjusting Method
1
1. Loosen locknut (2), then begin adjusting pressure
by turning setting screw (1). 2
Turning clockwise ................ raises the set pressure.
Turning counterclockwise .... lowers the set pressure.
2. In order to keep the setting screw from turning
after pressure has been adjusted, tighten the lock-
nut while at the same time holding the setting
screw firmly in place.
3. Operate the relief valve once more to confirm that
the pressure that has been set it stabilized.
B5B011
II-19 TB108
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
Measuring Method R1
• Engine : Rated r.p.m. Av
• Hydraulic Oil Temp. : 50~60°C
• Connect the pressure gauge to the pressure de- A1
tection port. Fully retract the arm cylinder and R2
B1 Bv
turn it to the right or left to measure the relief
pressure. Before measurement, allow the relief
pressure to become stable by the actuation of the
slewing relief valve.
B5B012
B5B010
Adjusting Method
1. Loosen locknut (2), then begin adjusting pressure
by turning setting screw (1).
Turning clockwise ................ raises the set pressure.
Turning counterclockwise .... lowers the set pressure.
2. In order to keep the setting screw from turning
after pressure has been adjusted, tighten the lock- 2 1
nut while at the same time holding the setting
screw firmly in place.
3. Operate the relief valve once more to confirm that
the pressure that has been set it stabilized.
B5B013
TB108 II-20
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS
Travel Speed (5 Revolutions)
• Engine : Rated r.p.m.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Excavator body raised
using both hoe attachment and dozer blade.
• Set crawler belts in motion. Starting after one
full revolution, measure the time required for 5
revolutions. (To measure speed after it has sta-
bilized.)
■ Travel Posture
Fully extend the arm and bucket cylinders and
adjust the hoe attachment so that its lowest part
is even with the excavator’s minimum ground
clearance level. The hoe attachment, of course, MIN. GROUND
should be in a no-load state and the dozer blade CLEARANCE
should not be touching the ground.
Travel Curve
• Engine : Rated r.p.m.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Travel Posture
• Starting after an approach of 5 meters, drive the
excavator in a turn for 10 meters, then measure
the distance of X (5 m point). Do this on level
ground.
II-21 TB108
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
Slew Time
• Engine : Rated r.p.m. BUCKET PIN BOOM FOOT PIN
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Completely retract the
arm cylinder, fully extend the bucket cylinder
and adjust so that boom foot pin and bucket pin
are at matching height. Rest the dozer blade on
the ground.
• With the hoe attachment in a no-load state, wait
1 rotation, then measure the time required for
the next 2 rotations.
TB108 II-22
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS
Boom Cylinder Speed
• Engine : Rated r.p.m.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Completely retract the
arm cylinder, fully extend the bucket cylinder
and rest the dozer blade on the ground.
• Then measure the time required for the bucket to
reach its highest elevation point (lowest point)
from its lowest point (highest point) resting on
the ground. (Do not include the cushioning
time.)
II-23 TB108
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
Swing Cylinder
• Engine : Stopped
• Hydraulic Oil Temp. : 50~60˚C
• Grade : 15˚
• Measurement Posture : Same as that for mea-
suring slew time.
• Rotate the upper machinery so that it is directly
abeam of the grade, then measure the change in
rod length after 5 minutes.
TB108 II-24
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS
Lever Operating Force
• With the engine stopped, attach a push-pull
scale to the center of the operation lever’s handle
grip, or in the case of a pedal, position a push-
pull scale to its tip and record the measurement
at the point the lever/pedal reaches full stroke.
Lever Play
• Measure any discernible play at the tip of the
lever (pedal).
Backlash
• Measurement Posture : Completely retract the
arm cylinder and fully extend the bucket cylin-
der.
• Move the tips of the bucket teeth from side to
side (left and right) and measure the play.
II-25 TB108
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
Crawler Tension
• Raise the excavator completely off the ground
using the hoe attachment and dozer blade.
Then measure the distance (of droop) between
the center point on the crawler frame and top of
the crawler shoe.
Note: For the rubber crawler, the measuring
should be performed after placing the
joint portion with “M” mark to the top
center.
TB108 II-26
III . MACHINE CONFIGURATION
III-1 TB108
MACHINE CONFIGURATION
CONTENTS
TB108 III-2
DRIVE SYSTEM MACHINE CONFIGURATION
DRIVE SYSTEM
CONSTRUCTION
Engine Mount
A: 66 N·m
Apply thread-locking compound. 1. Engine Foot 9. Air Cleaner
B: 26 N·m
2. Engine Foot RR 10. Pipe
C: 21 N·m
3. Engine Foot RL 11. Pipe
4. Bracket 12. Muffler Pipe
5. Plate 13. Pipe
6. Cushion Rubber 14. Fuel Filter
7. Cushion Rubber 15. Water Separator
8. Ground Cable
III-3 TB108
MACHINE CONFIGURATION DRIVE SYSTEM
Radiator
A: 9.8 N·m
Pump Coupling
2
C
A
B
3
B5C103
TB108 III-4
DRIVE SYSTEM MACHINE CONFIGURATION
The pump coupling connects the engine flywheel and
the hydraulic pump’s drive shaft. It is constructed so
that it absorbs vibrations, torsions, impact and out of
center of the engine and hydraulic pump.
III-5 TB108
MACHINE CONFIGURATION DRIVE SYSTEM
Engine Control
TB108 III-6
DRIVE SYSTEM MACHINE CONFIGURATION
DISASSEMBLY AND ASSEMBLY
III-7 TB108
MACHINE CONFIGURATION DRIVE SYSTEM
RIGHT ANGLE
TB108 III-8
DRIVE SYSTEM MACHINE CONFIGURATION
Removing the Hydraulic Pump
1. Remove the canopy.
III-9 TB108
MACHINE CONFIGURATION DRIVE SYSTEM
TB108 III-10
SLEW SYSTEM MACHINE CONFIGURATION
SLEW SYSTEM
CONSTRUCTION
5 6 2 3 9
A,D
D
RIGHT OF
MACHINE
A B,D
A,C A,D
4 7 8 1
B5C200E
III-11 TB108
MACHINE CONFIGURATION SLEW SYSTEM
Slew Bearing
TB108 III-12
SLEW SYSTEM MACHINE CONFIGURATION
DISASSEMBLY AND ASSEMBLY
3
Removing the Slew Motor
1. Open the engine hood and remove the center 1
cover.
III-13 TB108
MACHINE CONFIGURATION SLEW SYSTEM
S MARK B5C202E
TB108 III-14
TRAVEL SYSTEM MACHINE CONFIGURATION
TRAVEL SYSTEM
CONSTRUCTION
Track Roller
1 1. Roller
3 4 2 2. Shaft
3. Bearing
4. Oil Filler Plug
B5C300
Idler
1. Idler
1 2. Shaft
3. Bearing
4. Oil Filler Plug
4 5. Slide
B5C301
III-15 TB108
MACHINE CONFIGURATION TRAVEL SYSTEM
Track Adjuster
7,6 1 4 5 3 2
B5C302
1. Cylinder 5. O-ring
2. Piston 6. Packing
3. Oil Seal 7. Check Valve
4. Backup Ring
Travel Motor
1. Sprocket
1
2. Travel Motor
A,B
A,B
B5C303
TB108 III-16
TRAVEL SYSTEM MACHINE CONFIGURATION
DISASSEMBLY AND ASSEMBLY
1
Removing the Rubber Crawler
1. Loosen the tension of the crawler (1). 4
When loosening the check valve (2), turn it slowly.
Do not loosen it beyond the point where grease
starts to ooze out. If it is difficult for the grease to 2
come out, move the machine forward and in
reverse.
Check Valve: 177 N·m
III-17 TB108
MACHINE CONFIGURATION TRAVEL SYSTEM
TB108 III-18
TRAVEL SYSTEM MACHINE CONFIGURATION
Removing the Travel Motor
1. Remove the crawler.
“Removing the Crawler”
4
B5C306
III-19 TB108
MACHINE CONFIGURATION TRAVEL SYSTEM
TB108 III-20
UPPER FRAME MACHINE CONFIGURATION
UPPER FRAME
CONSTRUCTION
Turntable
A: 102 N·m
Apply thread-locking compound. 1. Turntable
2. Counterweight
3. Bushing
III-21 TB108
MACHINE CONFIGURATION UPPER FRAME
Cover
TB108 III-22
UPPER FRAME MACHINE CONFIGURATION
Grease Piping
1. Nipple 5. Tube
2. Connector 6. Tube
3. Elbow 7. Grease Nipple
4. Tube 8. Elbow
III-23 TB108
MACHINE CONFIGURATION UPPER FRAME
TB108 III-24
UPPER FRAME MACHINE CONFIGURATION
Removing the Covers
1. Remove the canopy.
3
2
3. Take off the bolts and remove the rear cover (4).
B5C407
5. Take off the bolts and remove the side cover L (6).
6. Take off the bolts and remove the side cover R (7).
6
5 B5C408
III-25 TB108
MACHINE CONFIGURATION UPPER FRAME
TB108 III-26
CONTROL SYSTEM MACHINE CONFIGURATION
CONTROL SYSTEM
CONSTRUCTION
Travel Lever
Operating Lever
III-27 TB108
MACHINE CONFIGURATION CONTROL SYSTEM
TB108 III-28
CONTROL SYSTEM MACHINE CONFIGURATION
Lever Stand
III-29 TB108
MACHINE CONFIGURATION CONTROL SYSTEM
TB108 III-30
ATTACHMENTS MACHINE CONFIGURATION
ATTACHMENTS
CONSTRUCTION
11
8
7
9
5
4
2 13
1
10
12
14 B5C600
1. Bucket 8. Boom
2. Bucket Link 9. Boom Cylinder
3. Guide Link R 10. Swing Bracket
4. Guide Link L 11. Swing Cylinder
5. Bucket Cylinder 12. Dozer Blade Cylinder
6. Arm 13. Dozer Blade
7. Arm Cylinder 14. Extension Blade
III-31 TB108
MACHINE CONFIGURATION ATTACHMENTS
3
2. Pull out the pin (5) over the ring (4), then take out
the bucket hinge pin (6).
TB108 III-32
ATTACHMENTS MACHINE CONFIGURATION
Removing the Link
• Fully retract the bucket cylinder and lower the 6
front end of the arm to the ground.
2
1. Suspend the bucket link (2) temporarily and take
out the pin (3).
• Place pillow blocks under the bucket cylinder
to support it.
• Since the end of the guide link will drop when 3
the pin is taken out, exercise caution.
2. Take out the pin (4), then remove the guide link L
(5), R (6). 5
4 B5C601
4. Take out the split pin and remove the castle nut 3
(7). B5C602
9
7
B5C603
III-33 TB108
MACHINE CONFIGURATION ATTACHMENTS
6
Installing the Boom 7
Follow the procedure used for removal in reverse 10 B5C605
order.
TB108 III-34
ATTACHMENTS MACHINE CONFIGURATION
Removing the Swing Bracket
1. Disconnect the hydraulic hoses from the boom
cylinder.
2. Take out the head side pin and remove the boom 1
cylinder (1).
• The cylinder should be suspended temporarily 6
before it is removed.
4. Take out the pin and disconnect the swing arm (3)
and link (4). B5C606
5. Take out the pin and remove the swing arm (3).
5
6. Take out the pin and remove the link (4).
7. Take out the pivot pins (5) and remove the swing
bracket (6).
• The bracket should be suspended temporarily
before being removed.
• Be careful not to damage the hoses in any way.
Swing Bracket: Approx. 16 kg
III-35 TB108
MACHINE CONFIGURATION ATTACHMENTS
TB108 III-36
HYDRAULIC SYSTEM MACHINE CONFIGURATION
HYDRAULIC SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
III-37 TB108
MACHINE CONFIGURATION HYDRAULIC SYSTEM
TB108 III-38
HYDRAULIC SYSTEM MACHINE CONFIGURATION
CONSTRUCTION
Hydraulic Tank
A: 47 N·m
Apply thread-locking compound.
1. Hydraulic Tank 6. Strainer
2. Flange 7. O-ring
3. Adapter 8. Valve
4. Plug 9. Cover
5. Sight Gauge 10. Cartridge
III-39 TB108
MACHINE CONFIGURATION HYDRAULIC SYSTEM
Function
1. This tank stores the quantity of hydraulic oil
necessary to operate the cylinders and hydraulic
motors.
Reference
If the amount of hydraulic oil is insufficient, the
disturbances in the flow of oil can not be calmed, and
this will result in air bubbles getting in the hydraulic
oil. If these bubbles are sucked into the hydraulic
pumps, they could cause cavitation. Heat dissipation
time would also become shorter and would result in a
rise in the oil temperature.
If more than the specified amount of hydraulic oil is
supplied, the amount of air in the tank will become
small and changes in the oil level could cause the
pressure fluctuation in the tank to become severe.
TB108 III-40
HYDRAULIC SYSTEM MACHINE CONFIGURATION
DISASSEMBLY AND ASSEMBLY
7. Take off the fixing bolts (6), and suspend the tank
and remove it.
Bolt: 47 N·m
• Apply thread lock to the bolts.
Tank: 13 kg
III-41 TB108
MACHINE CONFIGURATION HYDRAULIC SYSTEM
Tank Pressurization
1. Extend all the cylinders fully, then in that condi-
tion, close the filler inlet. (The dozer blade should
be lowered to the ground.)
• When filling of the hydraulic tank is com-
pleted, be sure to pressurize the tank.
TB108 III-42
ELECTRICAL SYSTEM MACHINE CONFIGURATION
ELECTRICAL SYSTEM
ELECTRICAL WIRING DIAGRAM
III-43 TB108
MACHINE CONFIGURATION ELECTRICAL SYSTEM
TB108 III-44
ELECTRICAL SYSTEM MACHINE CONFIGURATION
Travel Alarm
III-45 TB108
MACHINE CONFIGURATION ELECTRICAL SYSTEM
TB108 III-46
IV . HYDRAULIC UNITS
IV-1 TB108
HYDRAULIC UNITS
CONTENTS
TB108 IV-2
GEAR PUMP HYDRAULIC UNITS
GEAR PUMP
CONSTRUCTION
14
4 15 16 3 8 5 13 12
1 7
9 10 11 B5D100
Gear Pump
The gear pump consists of a single gear case, inside of
which is a drive gear (1) and a driven gear (2) engaged
with each other. By turning the drive shaft (3), the
space between the case and the gears is filled with oil.
This oil is thus sent through the pump from the inlet
to the outlet.
INLET OUTLET
Y1-D101E
IV-3 TB108
HYDRAULIC UNITS GEAR PUMP
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
the disassembled parts in. • Check each part to make sure there is no abnormal
• Before disassembly, clean around the ports and wear or seizing and use sandpaper, etc. to remove
remove the paint from each joint using a wire any burrs, sharp edges, etc.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
assembled in the same positions when assembled.
4
3
4. Remove snap ring (3) and oil seal (4) from flange
(1).
• Be careful not to scratch or otherwise damage
the flange.
• When re-assembling, install the oil seal using *#,#
the jigs A and B.
4 1
T7D152
TB108 IV-4
GEAR PUMP HYDRAULIC UNITS
5. Remove the rear cover (5).
B5D101
10
B5D102E
B5D103
IV-5 TB108
HYDRAULIC UNITS GEAR PUMP
Checking Parts
After checking the disassembled parts for dirt or
discoloration, clean them with diesel fuel. However,
do not let diesel fuel get on rubber parts. Check each
part for the following points and if there is any trouble,
repair or replace the part.
Housing
SUCTION SIDE
Bushings
The ideal situation is for the sliding surface of the
bearing inner diameter to have no roughness and for
the suction side half to be lustrous. Also, it is satisfac-
tory if strong contact marks can be seen on the side
surface on the suction side and minute contact marks
can be seen on the discharge side.
Replace the bushings if their condition is as follows. DISCHARGE SIDE
• Contact marks can be seen on the sliding surface of
the entire bearing inner diameter and it is so rough
that it looks like it has been clawed.
• There is a large number of scratches around the
circumference of the side surface and it is so rough
that it looks like it has been clawed. GEAR SIDE SUCTION SIDE
• There are marks from foreign matter biting into the
sliding surface of the bearing inner diameter and
the side surface. CONTACT MARKS
Dirty hydraulic oil is one likely cause of such wear. In B5D104E
TB108 IV-6
GEAR PUMP HYDRAULIC UNITS
Other likely causes are as follows.
• Excessive load due to damage to the relief valve.
• Cavitaion or aeration.
• Hydraulic oil temperature is too high.
• Hydraulic oil is deteriorated.
• Hydraulic oil’s viscosity is low.
If it is necessary to replace the bushings, this means
that the gear shaft and gear side surfaces are also
rough or worn severely, so replace the gears at the
same time as the bushings are replaced.
Gear
Replace a gear if it is in the following condition.
1. The shaft or the gear side surfaces ar so rough that
they look like they have been clawed.
2. There are cracks in the tooth roots and there is
extreme abnormal wear in the tooth surfaces.
Seals
• Check oil seals for scratches in the seal surface,
wear, deformation or deterioration of the rubber’s
elasticity. If a seal is abnormal, replace it.
• Replace seals when the hydraulic pump is disas-
sembled.
• Check the backup ring for scaling and cutting. If it
is abnormal, replace it.
Test Operation
The best method for testing the pump’s operation is to 4. Next, run the pump so that it reaches the rated
mount it in a test stand. However, if that cannot be pressure ( “II. Specifications, Specification
done, test it under the conditions it would be subjected Tables”) for 5 minutes at a time for each addi-
to if it were installed in the machine. tional 1.96~2.94 kPa of pressure.
Also, if any abnormal wear is discovered during Afterward, after operating each ciruit for about 5
disassembly, be sure to replace the hydraulic oil and minutes, replace the return filter or clean it.
return filter. In addition, during the process of raising the pressure,
1. Install a pressure gauge in the high pressure pay careful attention to the oil temperature, the pump’s
piping near the pump. surface temperature and the operating noise. If the oil
2. Run the engine at 500~1,000 min-1 and set the temperature or the pump’s surface temperature be-
control valve in the neutral position. come abnormally high, eliminate the load from the
3. Run the pump for 10 minutes under the conditions pump and let the temperature drop before resuming
in (2), then increase the engine’s speed to the test.
1,500~2,000 min-1 and run it for another 10 min-
utes.
IV-7 TB108
HYDRAULIC UNITS GEAR PUMP
TB108 IV-8
GEAR PUMP HYDRAULIC UNITS
TROUBLESHOOTING
IV-9 TB108
HYDRAULIC UNITS GEAR PUMP
TB108 IV-10
CONTROL VALVE HYDRAULIC UNITS
CONTROL VALVE
CONSTRUCTION
14,15
1 16,17 9 10 11
19
20,21
18
P1 P2
IV-11 TB108
HYDRAULIC UNITS CONTROL VALVE
6 5 4 3 2 1 13,14 7 8 9 B5D201
Dozer Blade
13 10 12 11 1. O-ring
2. Backup Ring
3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
14 7. O-ring
8. Backup Ring
9. Seal Holder
10. Poppet
11. Spring
12. O-ring
13. Plug
14. Cover
15. O-ring
6 5 4 3 2 1 15,16,17 7 8 9 B5D203 16. O-ring
17. O-ring
TB108 IV-12
CONTROL VALVE HYDRAULIC UNITS
Boom Block, Bucket Block
1. O-ring
13 10 12 11 15 2. Backup Ring
16 3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
7. O-ring
8. Backup Ring
9. Seal Holder
14 10. Poppet
11. Spring
12. O-ring
13. Plug
14. Cover
7 8 9 15. O-ring
6 5 4 3 2 1 17,18 B5D204 16. Plug
17. O-ring
18. O-ring
Slew Block
13 10 12 11 1. O-ring
2. Backup Ring
3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
14 7. O-ring
8. Backup Ring
9. Seal Holder
10. Poppet
11. Spring
12. O-ring
13. Plug
14. Cover
15. O-ring
6 5 4 3 2 1 15,16 7 8 9 B5D205 16. O-ring
IV-13 TB108
HYDRAULIC UNITS CONTROL VALVE
Auxiliary Block
1. O-ring
13 10 12 11 2. Backup Ring
3. Seal Holder
4. Spring Holder
5. Spring
6. Screw
7. O-ring
8. Backup Ring
9. Seal Holder
10. Poppet
14 11. Spring
12. O-ring
13. Plug
14. Cover
15. O-ring
1 2 3 4 5 6
9 8 7 15,16 B5D207 16. O-ring
G4D211
Anti-Cavitation Valve
2 1 7 6 8 3 4 5 1. Sleeve
2. Poppet
3. Spring
4. O-ring
5. Plug
6. Backup Ring
7. O-ring
8. O-ring
G4D212
TB108 IV-14
CONTROL VALVE HYDRAULIC UNITS
OPERATION
IV-15 TB108
HYDRAULIC UNITS CONTROL VALVE
Relieving Operation B A A1 5
When the pressure in the circuit is low with respect to
the set value, the relief valve is maintained at equilib-
rium. Pressure from the pump passes from chamber B
to the orifice in piston (4), then reaches chamber C and
the needle valve (5). On the other hand, forces F and
F1 are acting in the arrow directions on both sides of
the main poppet (6).
F = P × A F1 = P × A1 6 4 C
P: Pressure A, A1: Sectional Area
Since the sectional area of A is less than that of A1, the G4D214
TB108 IV-16
CONTROL VALVE HYDRAULIC UNITS
If the pressure in the circuit becomes higher than the
force of the spring (7), the needle valve (5) is pushed T 7 5
to the right by hydraulic pressure, opening. Oil then
flows around the circumference of the needle valve
(5) and passes through the slits, flowing into the tank
passage (T).
G4D215
6 C
G4D216
Suction Operation A A1
When the cylinder is operated at high speed, and the T
supply of oil cannot keep up with it, creating a vacuum
in chamber B, oil is supplied from the tank side,
preventing the occurrence of cavitation.
When the pressure in chamber B is lower than the
pressure in the tank passage (T), the differences in the
sectional areas A and A1 cause the main poppet (6) to B
open. Thus, sufficient oil from the tank passage (T)
enters chamber B, filling the empty space. 6
G4D217
Anti-Cavitation Valve 1
When a cylinder is operated at high speed and when
the supply of hydraulic oil can't keep up with it, T
causing a vacuum to form at the cylinder port, this
valve supplies oil from the tank, preventing cavitation
from occurring. In the normal cylinder port, pressure
is brought to bear, so the poppet (1) is closed. If a
vacuum is generated at the cylinder port (P) and the
pressure in the tank passage (T) drops as a result, it
pushes on the poppet (1) and oil flows from the tank
P
passage to the cylinder port.
G4D218
IV-17 TB108
HYDRAULIC UNITS CONTROL VALVE
General Cautions
• Since all parts in control valves are precision • Replace all seals with new ones each time the
machined, carry out disassembly and assembly valves are disassembled.
operations in a clean place. • Spools and section bodies are specially selected for
• Before disassembly, clean the outside surfaces a precise fit. Therefore, if any damage is found in
around the valves. either of these parts, replace the section assembly
• Clean all disassembled parts in cleaning solvent. as a unit.
Use a lint free cloth, or air dry the parts. • Be sure to number each section and spool to avoid
• Apply hydraulic oil to sliding surfaces and apply a mistakes during assembly.
thin coating of grease to seals when assembling • Do not turn adjusting screws if not required.
them.
Disassembly
Valve Assembly
1. Loosen the nuts and remove the tie rods, then
remove the sections.
Nut: 13.7~14.7 N·m
G4D223
TB108 IV-18
CONTROL VALVE HYDRAULIC UNITS
4. Remove the anti-cavitation valve (1) and remove
the O-ring (2) from the valve.
Valve: 39.2 N·m
2
1
B5D209
G4D224
B5D210
IV-19 TB108
HYDRAULIC UNITS CONTROL VALVE
TB108 IV-20
CONTROL VALVE HYDRAULIC UNITS
TROUBLESHOOTING
The following items are a list of all the problems that compound the trouble. It is therefore desirable to
might occur individually, but in actual practice, 2 or proceed so that the causes can be eliminated one at a
3 of these problems might occur simultaneously to time.
IV-21 TB108
HYDRAULIC UNITS CONTROL VALVE
TB108 IV-22
CYLINDERS HYDRAULIC UNITS
CYLINDERS
CONSTRUCTION
Boom Cylinder
22 23 21 1 21 20 24 7 5 6 5 8 15 3
12 13 14
11 10 9 19 18 17 16 2 4 B5D400
Arm Cylinder
17 18 16 1 16 15 5 4 6 13 3
9 8 7 2 14 10 12 11
B5D401
IV-23 TB108
HYDRAULIC UNITS CYLINDERS
Bucket Cylinder
18 17 16 1 16 15 5 4 6 13 3 11 12 10
9 8 7 2 14
B5D402
8 9 7 18 17 16 1 16 15 5 4 6 13 3 11 12 10
2 14
B5D403
TB108 IV-24
CYLINDERS HYDRAULIC UNITS
Swing Cylinder
17 16 15 1 15 14 5 4 6 12 3
8 7 2 13 9 11 10 B5D404
Spanner Cylinder
14 13 12 1 12 11 7 8 5 4 6 9 3
2 10 B5D405
IV-25 TB108
HYDRAULIC UNITS CYLINDERS
OPERATION
Cushion Mechanism
PORTION A
DETAIL OF
PORTION A
B5D406E
Before the piston (1) nears the stroke end and collides
with the cover (2), the cushion bearing (3) which
precedes it enters the cushion seal (4), shutting off the
return passage for the hydraulic oil on the rear end of
the piston and making it possible for oil to be expelled
only along the groove provided in the cushion bearing
(3). This causes the piston (1) back pressure to be-
come high, slowing the speed of the piston.
TB108 IV-26
CYLINDERS HYDRAULIC UNITS
DISASSEMBLY AND ASSEMBLY
Special Tools
See the table of special tools at the back of this section
for the jigs and tools used for disassembly and assem-
bly.
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
the disassembled parts in. • Check each part to make sure there is no abnormal
• Before disassembly, clean around the ports and wear or seizing and use sandpaper, etc. to remove
remove the paint from each joint using a wire any burrs, sharp edges, etc.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
assembled in the same positions when assembled.
Disassembly
Cylinder Assembly
1. Fasten the clevis of the tube in a vice and place the
other end on a support black made of wood to
fasten the cylinder in a horizontal condition.
IV-27 TB108
HYDRAULIC UNITS CYLINDERS
TB108 IV-28
CYLINDERS HYDRAULIC UNITS
Piston
1. Remove the wear ring (27), then remove the
piston packing (28).
• Spread the wear ring at the cut portion the
minimum amount necessary for it to be re-
moved. Remove it in the direction of the shaft.
• Either cut the piston packing off or use a flat
bladed screwdriver, etc. to take it off.
Rod Cover
1. Remove the O-ring (34) from the outer diameter
of the rod cover, then remove the backup ring
(35).
IV-29 TB108
HYDRAULIC UNITS CYLINDERS
Clevis
1. Remove the bushings using a setting tool (43).
TB108 IV-30
CYLINDERS HYDRAULIC UNITS
Assembly
Clevis
1. Using a setting tool (45), pressure fit the bushings
(44) in the piston rod and tube.
45
44
B5D407
Rod Cover
1. Using an installation jig (A), pressure fit the
bushing.
• Hydraulic fluid should be applied to the inside
surface of the rod cover before assembly.
• After installation, make sure there are no level
differences with the bushing.
IV-31 TB108
HYDRAULIC UNITS CYLINDERS
4. Install the backup ring (35) and fit the O-ring (34).
• The cut portions of the backup ring should
overlap correctly.
Piston
1. Assemble the piston assembly.
a. Fit the O-ring (50).
• If the O-ring is twisted after it is fitted,
correct it.
TB108 IV-32
CYLINDERS HYDRAULIC UNITS
2. Install the wear ring (27).
a. Spread the wear ring (27) at the cut portion the
minimum amount necessary, installing it on
the piston from the shaft direction.
IV-33 TB108
HYDRAULIC UNITS CYLINDERS
Cylinder Assembly
1. Fasten the tube in a horizontal position, then
insert the piston rod assembly in the tube.
• During insertion, align the center of the piston
rod with the center of the tube, inserting it
straight so that the seals will not be scratched.
TB108 IV-34
CYLINDERS HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
1. Piston Rod
• Replace the rod if there are cracks. Measuring the Bend
• If the threads are damaged, repair them or
replace it.
• If the plating layer of the plated portion is
broken, rusted or scratched, replace it.
• If the rod is bent more than the limit of 1 mm
in 1 m, replace it. (Measure by the method
shown in the figure at right.
If the bending of the rod is within the above
limit, yet is bent a lot in a small distance so that a. Support the portion of the rod with the same
it won’t move smoothly, replace the rod if it diameter at both ends on V-blocks.
makes a squeaking sound in the operation test b. Set a dial gauge at the center between the two
after reassembly or if it catches during move- blocks.
ment. c. Rotate the rod and take a reading of the maxi-
• If the inner diameter of the clevis bushing is mum and minimum runout indicated by the
worn, replace the bushing. dial gauge.
2. Tube
• If there are cracks in the welded portion, re-
place it.
• Replace the tube if the inside surface is scratched
or if it leaks hydraulic oil.
• If the inner diameter of the clevis bushing is
worn, replace the bushing.
3. Rod Cover
• If the bushing inner diameter is worn and the
clearance with the piston rod is greater than
0.25 mm, replace the bushing.
• If the inside surface of the bushing is scratched,
and the scratches are deeper than the depth of
the coating layer, replace the bushing.
IV-35 TB108
HYDRAULIC UNITS CYLINDERS
Leak Test
• External Leakage
1. Apply test pressure for 3 minutes each to the
retraction side and the extension side.
2. Make sure there are no abnormalities such as
external leakage or permanent deformation, etc.
in the rod seal, the rod cover mount, or in any
welded portion.
• Internal Leakage
1. Disconnect the extension side hose.
2. Apply test pressure to the retraction side for 3
minutes.
3. Measure the amount of oil that has leaked from
the extension side.
• The amount of leakage should be 1 cm3 / 3min
or less.
TB108 IV-36
CYLINDERS HYDRAULIC UNITS
TROUBLESHOOTING
IV-37 TB108
HYDRAULIC UNITS CYLINDERS
Unit: mm
Installation Jig (A)
A B C D E F
Boom 29.0 24.9 10.0 30.0
Arm 34.0 29.9 10.0 12.0 20.0 45.0
Bucket 29.0 24.9 10.0 12.0 20.0 40.0
Dozer Blade 29.0 24.9 10.0 12.0 20.0 40.0
Swing 29.0 24.9 10.0 12.0 20.0 40.0
Spanner 29.0 24.9 10.0 12.0 20.0 40.0
Unit: mm
Sliding Jig (C) Fitting Jig (D)
A B C D E A B C
Boom 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Arm 12.3 55.5 53.0 35.0 15.0 60.0 58.0 50.0
Bucket 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Dozer Blade 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Swing 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
Spanner 12.3 50.5 48.0 30.0 10.0 55.0 53.0 45.0
TB108 IV-38
CYLINDERS HYDRAULIC UNITS
Corrective Jig (E)
Unit: mm
A B
Boom 65 50
Arm 70 55
Bucket 65 50
Dozer Blade 65 50
Swing 65 50
Spanner 65 50
IV-39 TB108
HYDRAULIC UNITS CYLINDERS
TB108 IV-40
TRAVEL MOTOR HYDRAULIC UNITS
TRAVEL MOTOR
CONSTRUCTION
Hydraulic Motor
3
1
14
2
10 15 26
27
21
17
22
18 28
24
16
23
20 19
13
12
13 4
25 9 8
6
5
11
7 B5D500
IV-41 TB108
HYDRAULIC UNITS TRAVEL MOTOR
Reduction Gears
29
19 3
6
9 2
7 16 5
11
28
25
27
26
25
24
15
23 18
14 21 4
13 17
1 8
12
10 20
22
B5D501
TB108 IV-42
TRAVEL MOTOR HYDRAULIC UNITS
Counterbalance Valve
2
5
1
3
4
3
1
5
2 B5D502
1. Spring 5. O-ring
2. Plug 6. Bearing
3. Ring 7. Spring Pin
4. O-ring 8. Spool
IV-43 TB108
HYDRAULIC UNITS TRAVEL MOTOR
OPERATION
3 1 2 5 4
Hydraulic Motor
7 pistons (2) are fitted in the cylinder block (1) and
there is a valve plate (3) with two half moon ports, B
and C in the end. Also, the cylinder block (1) rotates
freely and is joined to the shaft (4) via the spline. On
the other band, the swash plate (5) is fastened to the
A
housing.
When high pressure oil is introduced into port B, one
piston (2) makes contact and force F bears on the
swash plate (5).
F = P × A P: Pressure A: Piston Sectional Area
The force F which the piston (2) applies to the swash F1
F2
plate (5) is divided into force F1, which pushes the
plate, and force F2, which rotates the cylinder block F
(1). The total sum of the components in the direction F
of rotation of the high pressure side piston generates
a rotational force in the cylinder block (1) and via the F2
spline, torque is transmitted to the shaft (4), turning it. B F C
Conversely, if high pressure oil is introduced to port
C, rotation is the reverse of the above. F2
F F2
VIEW A
E5D503E
Counterbalance Valve
If high pressure oil is introduced to port P1, the oil
pushes the check valve (6) up. This causes oil to flow
through the motor port M1 and to flow into chamber
B of the pilot portion and fill it. When hydraulic oil
flows the motor from port M1 and acts to turn the
motor, even if oil returns from the motor and flows
into port M2, since the flow is cut off by the check
valve (6), the pressure at port P1 and in chamber B
rises. If the pressure in chamber B becomes higher
than the set valve of the spring (7), the spool (8) moves
to the left side and ports M2 and P2 open up, causing B C4D554
the motor to turn.
C4D555
TB108 IV-44
TRAVEL MOTOR HYDRAULIC UNITS
When the motor is slowed, the pressure in port P1 and
chamber B rises again and the spool (8) moves to the B
left aide, eliminating the back pressure generated at
port M2. In this way, the motor is controlled so that it
rotates at a speed appropriate for the amount of oil
flowing into it.
Parking Brake
The center disc (1) are connected to the flange holder
and the friction disc (2) are connected to the cylinder
block (3) via the spline, respectively. The center disc
(1) and friction disc (2) are pressed against the flange
holder (6) by the springs (4) via the brake piston (5).
The friction force between these discs generates the
brake torque to prevent the cylinder block (3) from
rotating.
2 1 87 5 4 B5D504
IV-45 TB108
HYDRAULIC UNITS TRAVEL MOTOR
Reduction Gears
The reduction gear has a simple planetary two-stage a1,a2
configuration. It decelerates the high speed rotary
motions of the hydraulic motor, converts them into B1 B2
low speed high torque, and rotates the case. The
output shaft of the hydraulic motor is connected to the
gear S2 via the spline. The rotation of the gear S2 is S1 1
decelerated by one stage among the gears S2, B2 and S2
a2. This one-stage decelerated rotation is further
decelerated by two stages among the gears S1, B1 and
a1 that are connected to the carrier 2 (1) via the spline.
This rotation is conveyed to the rotary main body via
the inner gears a1 and a2 as the driving force of the
motor. C4D560
TB108 IV-46
TRAVEL MOTOR HYDRAULIC UNITS
DISASSEMBLY AND ASSEMBLY
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
the disassembled parts in. • Check each part to make sure there is no abnormal
• Before disassembly, clean around the ports and wear or seizing and use sandpaper, etc. to remove
remove the paint from each joint using a wire any burrs, sharp edges, etc.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
assembled in the same positions when assembled.
Assembly
Counterbalance Valve and Hydraulic Motor
1. Fix the body with a vise and mount the spool on
the body.
• To prevent the outer surface of the body from
being damaged, insert a protector such as an
aluminum plate between the body and the vise.
• Do not disassemble the spool assembly into
parts. B5D505
1
2
B5D506
B5D507
IV-47 TB108
HYDRAULIC UNITS TRAVEL MOTOR
4. Press fit the oil seal (6) into the flange holder.
• As the oil seal is to be inserted, do not disas-
semble it unless necessary. 6
• Fill between the lips of the oil seal with grease.
B5D508
C4D567
C4D568
8
C4D570
C4D569
TB108 IV-48
TRAVEL MOTOR HYDRAULIC UNITS
8. Fit the three pins (10) to the cylinder block.
10
C4D571
12
C4D572
C4D573
C4D575
IV-49 TB108
HYDRAULIC UNITS TRAVEL MOTOR
C4D576
C4D577
C4D578
B5D512
TB108 IV-50
TRAVEL MOTOR HYDRAULIC UNITS
16. Mount the valve plate (16) on the body and insert
ten springs into the spring holes.
• The dot in the figure shows the spring installa- 16
tion positions.
• Assemble the valve plate in such a manner that
the copper surface is on the cylinder block side.
• Apply grease to the valve plate and springs,
and be careful not to drop them.
B5D513
C4D581
B5D514
17
B5D515
IV-51 TB108
HYDRAULIC UNITS TRAVEL MOTOR
18
17
B5D517
B5D516
B5D519
B5D520
22. Fit the O-ring to the seal ring and install them in
the housing.
• Install the seal ring with the seal faced upward.
• Apply grease to the O-ring.
B5D521
C4D588 B5D522
TB108 IV-52
TRAVEL MOTOR HYDRAULIC UNITS
24. Mount the housing on bearing (19) and the bear-
ing inner ring (18).
19
18
19
B5D524
B5D523
B5D525
B5D526
27. Mount the thrust plate and fix them with the snap
ring.
• Be careful not to expand the snap ring more
than necessary.
• Install the snap ring with its edge positioned
upside (cover side).
B5D527
IV-53 TB108
HYDRAULIC UNITS TRAVEL MOTOR
28. Mount the gear S1 on the carrier and fix them with
the snap ring.
• Be careful not to expand the snap ring more
than necessary.
• Install the snap ring with its edge positioned
upside (cover side).
C4D590
C4D591
C4D593
31. Mount the gear S2 on the shaft and fix them with
the snap ring.
• Be careful not to expand the snap ring more
than necessary.
• Install the snap ring with its edge positioned
upside (cover side).
C4D594
TB108 IV-54
TRAVEL MOTOR HYDRAULIC UNITS
32. Fit the O-ring to the housing.
• Apply grease to the O-ring.
C4D595
B5D528
35. Wind the seal tape around the plugs and mount it
on the cover.
Plug: 46~51 N·m
B5D529
IV-55 TB108
HYDRAULIC UNITS TRAVEL MOTOR
TB108 IV-56
TRAVEL MOTOR HYDRAULIC UNITS
IV-57 TB108
HYDRAULIC UNITS TRAVEL MOTOR
TROUBLESHOOTING
Hydraulic Motor
Symptom Probable Causes Remedy
Does not move. • Equipment other than the motor, coun- • Check if the proper pressure is reached
terbalance valve or speed reducer is on the motor inlet port side, then check
malfunctioning. each device and repair if necessary.
• Hydraulic oil is escaping due to ab- • Replace the abnormally worn parts.
normal wear of motor sliding parts.
• Principal motor parts are malfunc- • Replace the damaged parts.
tioning due to damage.
Motor won’t speed up. • The proper volume of hydraulic oil is • Check if the proper pressure is reached
not being supplied to the motor due to on the motor inlet port side, then check
the hydraulic pump, control valve, each device and repair if necessary.
etc.
• The motor’s volumetric efficiency is
• Check if the sliding parts are abnor-
dropping. mally worn, then repair or replace the
worn parts.
Changes in rotational speed • High pressure hydraulic oil is leaking • Replace the abnormally worn parts.
are great. and flowing out of the drain port due
to wear of the motor's sliding parts.
• Bearings are worn. • Replace the bearings if they are abnor-
mally worn.
Oil is leaking. • Oil is leaking due damage to oil seals • Replace the oil seals and O-rings.
or O-rings.
Counterbalance Valve
Symptom Probable Causes Remedy
Does not move or rotation is Spool does not switch.
slow. • No hydraulic oil is arriving. • Repair or replace the damaged piping.
• Foreign matter is caught. • Remove the foreign matter and repair
or replace the damaged parts.
• The orifice is clogged up. • Clean it.
Won’t stop or stopping is The spool won’t return.
slow. • Foreign matter gets caught. • Remove the foreign matter and repair
or replace the damaged parts.
• A spring is missing. • Install the spring.
• A spring is damaged. • Replace the spring.
• The orifice is clogged up. • Clean it.
Shock is great when stopping. Spool return is fast.
• The spring seat is missing. • Install the spring seat.
Valve makes an abnormal The spool does not return.
noise. • Foreign matter gets caught. • Remove the foreign matter and repair
or replace the damaged parts.
• A spring is damaged. • Replace the spring.
• The orifice is clogged up. • Clean it.
TB108 IV-58
SLEW MOTOR HYDRAULIC UNITS
SLEW MOTOR
CONSTRUCTION
6 8 23 10
18
13
19
12
21
20
15
7 27
4 5 1 3 2 16 9 22 24 17 14 29 25
11 26 30 28
B5D600
IV-59 TB108
HYDRAULIC UNITS SLEW MOTOR
Brake Valve
8 7
6 5 10
9 11 4 12 2 3 1
B5D601
1. Cap Nut
2. Lock Nut
3. Set Screw
4. Housing
5. Spring Seat
6. Spring
7. Needle Valve
8. Valve Seat
9. Packing
10. Piston
TB108 IV-60
SLEW MOTOR HYDRAULIC UNITS
OPERATION
Hydraulic Motor 1
High pressure hydraulic oil flowing in the main port In this way, orbiting of the rotor (6) of the geroller is
(1) enters the geroller (4) via the valve (2) and valve started by hydraulic pressure, with only the rotations
plate (3). The geroller (4) consists of a stator (5) and which take place in the orbiting action being picked
rotor (6), and the stator (5) contains 7 rollers inside it up by the drive gear (7), causing the shaft (8) to rotate.
and is fixed to the housing. The inner rotor has 6 Also, the rotations of the rotor (6) are transmitted via
external gears. For this reason, 7 chambers are formed the valve drive gear (9) to the valve (2).
inside the geroller. The rotor (6) is constructed so that The rotations of the valve (2) cause the oil holes in the
it orbits around inside the stator. valve which connect with the oil holes in the valve
On the other hand, there are 12 holes in the valve (2) plate (3) to shift in sequence. For this reason, high
for hydraulic oil, with high pressure hydraulic oil or pressure oil flowing in the geroller (4) also flows into
returning oil flowing through half of these holes at a sequentially differing chambers. This causes the motor
time. In the same way, there are oil holes made in the to rotate continuously.
valve plate (3) in 7 places. These oil holes connect
with the 7 chambers in the geroller (4). Thus, since the
7 oil holes in the valve plate (3) connect with some of
the 12 oil holes in the valve (2), a circuit is formed for
oil to flow to the geroller (4).
IV-61 TB108
HYDRAULIC UNITS SLEW MOTOR
Hydraulic Motor 2
B5D602E
In Fig. 1, when high pressure oil is introduced into cycle of shifting the chambers where high pressure oil
chambers B, C and D, the rotor (6) rotates in the arrow is introduced.
direction while making contact with the inside of the At this time, the • mark on the rotor (6) rotates 1/6
stator (5). The valve (2) rotates along with this, so the revolution in the reverse direction.
chambers in which high pressure oil is introduced also From this, we can see that 1 revolution of the output
shift sequentially, but in the direction opposite the shaft is achieved by introduction of high pressure oil
arrow direction. In Fig. 2, the rotor (6) has turned 1/ into 42 chambers, that is, 7 chambers × 6 cycles = 42
14 revolution. This cause the chambers where high chambers.
pressure oil is introduced to shift to A, G and F. At this
time, the center of the rotor Y shifts in a circle about
point X to point Y’. In Fig. 3, Y’ shifts to Y”.
That is, the center of the rotor (6) rotates in a circle
around point X, 6/7 revolution, from Y to Y’ to Y”. In
Fig. 4, point Y” has returned to point Y, making 1
TB108 IV-62
SLEW MOTOR HYDRAULIC UNITS
Brake Valve
Pressure in the circuit is introduced into chamber A.
This pressure is transmitted to chamber E via the
orifice (1) and acts as a force to push the needle valve A E 2 3
(2) to the right. When the pressure acting on the needle
valve (2) is higher than the strength of the spring (3),
the needle valve (2) moves to the right and the
pressure is directed to port M1 and port M2.
1
B5D603
IV-63 TB108
HYDRAULIC UNITS SLEW MOTOR
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
the disassembled parts in. • Check each part to make sure there is no abnormal
• Before disassembly, clean around the ports and wear or seizing and use sandpaper, etc. to remove
remove the paint from each joint using a wire any burrs, sharp edges, etc.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
assembled in the same positions when assembled.
Disassembly
Hydraulic Motor
1. Remove the installation bolts of the valve hous-
ing.
C4D605
C4D606
TB108 IV-64
SLEW MOTOR HYDRAULIC UNITS
4. Remove the geroller and drive gear.
C4D607
C4D608
C4D609
C4D610
IV-65 TB108
HYDRAULIC UNITS SLEW MOTOR
C4D611
C4D612
C4D613
TB108 IV-66
SLEW MOTOR HYDRAULIC UNITS
Valve
1. Remove the plugs, springs and balls from the
valve housing.
C4D614
2. Remove the cap nut (4), lock nut (5) and set screw
(6).
5 4
6
B5D604
8
9
7 B5D605
10
11 12
B5D606
IV-67 TB108
HYDRAULIC UNITS SLEW MOTOR
13
7 B5D607
TB108 IV-68
SLEW MOTOR HYDRAULIC UNITS
Assembly
Hydraulic Motor
1. Install the ball bearing in the bearing housing by
using a press or plastic hammer.
C4D615
C4D616
C4D617
C4D618
IV-69 TB108
HYDRAULIC UNITS SLEW MOTOR
C4D609
6. Fit the shaft face seal (10) to the wear plate (9).
10
9 C4D620
C4D619
C4D621
10. Fit the large and small O-rings to the wear plate,
and install the geroller.
• Align the drain hole of the wear plate with that
of the geroller.
C4D622
TB108 IV-70
SLEW MOTOR HYDRAULIC UNITS
11. Mount the valve drive gear on the geroller.
C4D623
12. Fit the large and small O-rings to the valve plate,
and then install the valve plate.
• Align the drain hole of the valve plate with that
of the geroller.
C4D624
B5D608E
IV-71 TB108
HYDRAULIC UNITS SLEW MOTOR
C4D626
15. Mount the inner face seal (11) and outer face seal
(12) on the balancing ring (5).
12 11
5 C4D627
16. Align the notch of the balancing ring (5) with pin 13
and mount on the valve housing (13).
12
11
C4D628
TB108 IV-72
SLEW MOTOR HYDRAULIC UNITS
18. Align the bolt with the bolt hole and tighten the
bolt.
Bolt: 53 N·m
C4D605
Valve
1. Fit the O-rings to the plugs.
B5D610
10
11 12
B5D606
8
9
B5D611
IV-73 TB108
HYDRAULIC UNITS SLEW MOTOR
13
7 B5D607
5 4
6
B5D604
TB108 IV-74
SLEW MOTOR HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
Hydraulic Motor
Part Judgment Criteria Treatment
Shaft • If pitting or peeling off, etc. are occurring on gear tooth surfaces. • Replace
• If flaking or pitting are occurring on rolling surfaces. • Replace
Ball Bearing • If there is an abnormality in turning (abnormal noise, not turning • Replace
smoothly, etc.).
• If flaking, peeling off, etc. are occurring on rolling surfaces. • Replace
Valve Drive Gear, • If pitting or peeling off, etc. are occurring on gear tooth surfaces. • Replace
Drive Gear • If the amount of wear in the spring is great. • Replace
Inner Face Seal, • If there are scratches where leakage of oil occurs. • Replace
Outer Face Seal
Ball • If there are scratches where leakage of oil occurs. • Replace
Geroller • If pitting or peeling off, etc. are occurring on gear tooth surfaces. • Replace
• If there is an abnormality in turning (abnormal noise, not turning • Replace
smoothly, etc.).
Brake Valve
Adjusting the Relief Valve Pressure
“II. Specifications, for Judging Performance”
IV-75 TB108
HYDRAULIC UNITS SLEW MOTOR
TROUBLESHOOTING
TB108 IV-76
SWIVEL JOINT HYDRAULIC UNITS
SWIVEL JOINT
CONSTRUCTION
B5D700E
IV-77 TB108
HYDRAULIC UNITS SWIVEL JOINT
OPERATION
Selector (1)
1. When the selector spool is pushed up, hydraulic TRAVEL MOTOR (RIGHT)
oil from pump P1 flows to the right travel motor
SELECTOR(1)
and hydraulic oil from pump P2 flows to the left
travel motor, then returns to the tank. P2
P1
SWIVEL JOINT
SWIVEL JOINT
TB108 IV-78
SWIVEL JOINT HYDRAULIC UNITS
DISASSEMBLY AND ASSEMBLY
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the
a clean place and provide clean containers to place hydraulic units is disassembled.
the disassembled parts in. • Check each part to make sure there is no abnormal
• Before disassembly, clean around the ports and wear or seizing and use sandpaper, etc. to remove
remove the paint from each joint using a wire any burrs, sharp edges, etc.
brush. • Do not turn adjusting screws if not required.
• Clean all disassembled parts in cleaning solvent. • Apply hydraulic oil to sliding surfaces and apply a
Use a lint free cloth, or air dry the parts. thin coating of grease to seals when assembling
• Make match marks on each part so that they will be them.
assembled in the same positions when assembled.
B5D703
DUST SEAL
2
3
4
B5D704E
B5D705
IV-79 TB108
HYDRAULIC UNITS SWIVEL JOINT
B5D706
B5D707
B5D708
11
B5D709
TB108 IV-80
SWIVEL JOINT HYDRAULIC UNITS
8. Remove the plug (12), spring (13) and ball (14)
from the cover.
Plug: 9.8 N·m
13
12
14
B5D710
15
17
B5D711
10. Remove the O-ring (18) and backup ring from the
cover.
• Use a miniature screwdriver, etc. to remove
them.
18
B5D712
11. Take out the cap screws (19) and remove the
flange (20) from the hub.
Cap Screw: 31.4 N·m
• During assembly, place a pipe on the shaft lock
pin and check if the shaft rotates.
20
19
B5D713
IV-81 TB108
HYDRAULIC UNITS SWIVEL JOINT
12. Remove the O-ring (21), snap ring (22) and thrust
ring (23).
• During assembly, make sure the snap ring fits
23
snugly in the groove.
21
22
B5D714
MATERIAL : S35C or
equivalent B5D716E
B5D715
B5D717
TB108 IV-82
SWIVEL JOINT HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
Flange
Parts Judgment Standard Treatment
Portions which slide • Parts which are worn 0.5 mm or more, or abnormally Replace with new parts
against the shaft end worn parts
• Parts with less than 0.5 mm of wear Repair so that it is smooth
• Parts with scratches due to seizing, biting in or Repair so that it is smooth
foreign matter, etc., which are within the wear limit
of 0.5 mm and which can be repaired
IV-83 TB108
HYDRAULIC UNITS SWIVEL JOINT
Thrust Ring
Judgment Standard Treatment
• Parts which are worn 0.5 mm or more, or abnormally worn parts Replace with new parts
• Parts with less than 0.5 mm of wear Repair so that it is smooth
• Parts with scratches due to seizing, biting in or foreign matter, etc., which are Repair so that it is smooth
within the wear limit of 0.5 mm and which can be repaired
TB108 IV-84
SWIVEL JOINT HYDRAULIC UNITS
TROUBLESHOOTING
IV-85 TB108
HYDRAULIC UNITS SWIVEL JOINT
TB108 IV-86
V . TROUBLESHOOTING
V-1
IV-87 TB108
TROUBLESHOOTING
(1) Do not begin disassembling the equipment immediately just because it has broken down.
Conduct a thorough preliminary check before attempting disassembly.
a. Ask the user the following questions.
• What were the conditions when the machine broke down?
• Did anything abnormal happen before breakdown occurred?
• Are there any other places which were functioning poorly other than the part that broke
down?
• Are there any parts which have been repaired previous to the breakdown? What were
they?
• Has the same thing happened before?
b. Run the machine yourself and confirm the breakdown conditions.
• Judge whether the machine is really broken down or not following the judgment
standards.
The judgment on whether the machine has broken down may differ between individu-
als.
IMPORTANT: When running the machine, it is possible that moving the machine could
make the breakdown worse than it already is, so do not forget to ask the user if there is
anything to prevent your operating the machine.
c. Based on the information that you have gathered from the user and the information
obtained from running the machine yourself, judge the cause of the trouble. Also keep in
mind that it is difficult to reproduce the conditions of the breakdown again once the
machine has been disassembled, and early disassembly may make it impossible to
determine the true cause of the trouble. Therefore be sure to find the true cause of the
trouble before attempting disassembly.
(2) When it is thought that the trouble has more than one cause, begin investigating from the
simplest cause.
(3) Think over why the trouble could have occurred and try to correct the root cause of that
problem.
TB108 V-2
V-88
TROUBLESHOOTING
CONTENTS
OVERALL MACHINE
No operations can be done. ................................................................................................................................... 4
All operation can be done, but there is no power. ................................................................................................. 5
MACHINE TRAVEL
Right or left travel is impossible. .......................................................................................................................... 7
Speed drops in the left or right travel, causing the machine to travel in a curve. ................................................. 9
Machine won’t accelerate during travel. ............................................................................................................. 11
SLEWING
No slewing can be done. ...................................................................................................................................... 12
Right or left slewing cannot be done. .................................................................................................................. 14
Slewing speed is low, or there is no power. ........................................................................................................ 15
The machine slews, but overrun when slewing stops is great, or it cannot be stopped. ..................................... 16
When stopped on a slope, the slewing body cannot maintain its posture after stopping. ................................... 17
BOOM
The boom cylinder doesn’t move. ....................................................................................................................... 18
Boom cylinder operation is slow, or there is no power. ...................................................................................... 20
When the boom operation lever is pulled gently, the boom drops temporarily. ................................................. 23
The amount of boom natural drop is great. ......................................................................................................... 24
ARM
The arm cylinder doesn’t move. .......................................................................................................................... 25
Arm cylinder operation is slow, or there is no power. ........................................................................................ 26
The amount of arm natural drop is great. ............................................................................................................ 28
BUCKET
The bucket cylinder doesn’t move, or there is no power. ................................................................................... 29
The amount of bucket natural drop is great. ........................................................................................................ 30
BOOM SWING
The swing cylinder doesn’t move. ....................................................................................................................... 31
DOZER BLADE
The dozer blade cylinder doesn’t move, or there is no power. ............................................................................ 32
The amount of dozer blade natural drop is great or the dozer blade won’t hold the machine up. ...................... 34
SPANNER
The spanner cylinder doesn’t move, or there is no power. .................................................................................. 36
V-3 TB108
TROUBLESHOOTING OVERALL MACHINE
Proper Amount
B5E002
TB108 V-4
OVERALL MACHINE TROUBLESHOOTING
ALL OPERATIONS CAN BE DONE, BUT THERE IS NO POWER.
Proper Amount
No Noise
Normal
V-5 TB108
TROUBLESHOOTING OVERALL MACHINE
TB108 V-6
MACHINE TRAVEL TROUBLESHOOTING
RIGHT OR LEFT TRAVEL IS IMPOSSIBLE.
Normal
Normal
Normal
Normal
V-7 TB108
TROUBLESHOOTING MACHINE TRAVEL
TRAVEL
B5E008E
B5E004
B5E005
TB108 V-8
MACHINE TRAVEL TROUBLESHOOTING
SPEED DROPS IN THE LEFT OR RIGHT TRAVEL, CAUSING THE MACHINE TO TRAVEL IN A CURVE.
Within
Is the amount of travel standard Depends on the com-
1 Normal
curve within standard? bination of equipment.
Normal
The direction of travel curve
• Repair the pump or replace it.
Switch the left and right changes to the opposite side.
4 • Replace the hydraulic oil
pump discharge hoses.
and filter.
No change
The direction of travel
Switch the left and right curve changes to the
opposite side. Inspect the main relief Repair or replace the main
5 main relief valves and
valve. relief valve.
test.
No change
Normal
Normal
V-9 TB108
TROUBLESHOOTING MACHINE TRAVEL
B5E006
B5E007
TB108 V-10
MACHINE TRAVEL TROUBLESHOOTING
MACHINE WON’T ACCELERATE DURING TRAVEL.
Normal
Normal
Normal
V-11 TB108
TROUBLESHOOTING SLEWING
Normal
Normal
TB108 V-12
SLEWING TROUBLESHOOTING
2. Inspect the operation of the spool.
a. Operate the slew lever, inspecting if the spool
stroke is 6 mm.
b. Inspect the linkage. LEVER
• In the linkage inspect, remove the link ball
connecting the spool and lever and inspect LINK BALL
6mm
B5E009E
V-13 TB108
TROUBLESHOOTING SLEWING
Normal
TB108 V-14
SLEWING TROUBLESHOOTING
SLEWING SPEED IS LOW, OR THERE IS NO POWER.
Slow
Normal
Normal
V-15 TB108
TROUBLESHOOTING SLEWING
THE MACHINE SLEWS, BUT OVERRUN WHEN SLEWING STOPS IS GREAT, OR IT CANNOT BE
STOPPED.
Normal
TB108 V-16
SLEWING TROUBLESHOOTING
WHEN STOPPED ON A SLOPE, THE SLEWING BODY CANNOT MAINTAIN ITS POSTURE AFTER
STOPPING.
V-17 TB108
TROUBLESHOOTING BOOM
Normal
Operation
Perform a port relief became normal. The port relief valve Repair or replace the port re-
3
valve switching test. is faulty. lief valve.
B5E012
TB108 V-18
BOOM TROUBLESHOOTING
4. Inspect the boom cylinder.
a. Disconnect the hose between the control valve
and the boom cylinder at the control valve side.
b. Connect the disconnected hose to the arm
block or the bucket block.
c. Try operating the boom cylinder. If the cylin-
der doesn’t operate, the cylinder is faulty.
V-19 TB108
TROUBLESHOOTING BOOM
Normal
Operation
Perform a port relief became normal. The port relief valve Repair or replace the port re-
3
valve switching test. is faulty. lief valve.
B5E010E
TB108 V-20
BOOM TROUBLESHOOTING
b. Disconnect the rod side hose (A) only and let
the oil in the piping run out.
Insert a plug (1) in the disconnected hose.
V-21 TB108
TROUBLESHOOTING BOOM
TB108 V-22
BOOM TROUBLESHOOTING
WHEN THE BOOM OPERATION LEVER IS PULLED GENTLY, THE BOOM DROPS TEMPORARILY.
Normal
V-23 TB108
TROUBLESHOOTING BOOM
Normal
Perform a port relief Faulty The port relief valve is Repair or replace the port re-
3
valve switching test. faulty. lief valve.
Normal
TB108 V-24
ARM TROUBLESHOOTING
THE ARM CYLINDER DOESN’T MOVE.
Normal
Operation
Perform a port relief became normal. The port relief valve is Repair or replace the port re-
3
valve switching test. faulty. lief valve.
V-25 TB108
TROUBLESHOOTING ARM
Normal
Operation
Perform a port relief became normal. The port relief valve is Repair or replace the port re-
3
valve switching test. faulty. lief valve.
TB108 V-26
ARM TROUBLESHOOTING
b. Disconnect the two hoses connected to the
cylinder. Insert plugs (1) in the disconnected
hoses and the cylinder piping.
V-27 TB108
TROUBLESHOOTING ARM
Normal
TB108 V-28
BUCKET TROUBLESHOOTING
THE BUCKET CYLINDER DOESN’T MOVE, OR THERE IS NO POWER.
Normal
V-29 TB108
TROUBLESHOOTING BUCKET
Normal
TB108 V-30
BOOM SWING TROUBLESHOOTING
THE SWING CYLINDER DOESN’T MOVE.
Normal
Normal
V-31 TB108
TROUBLESHOOTING DOZER BLADE
Normal
Normal
Normal
TB108 V-32
DOZER BLADE TROUBLESHOOTING
4. Inspect the swivel joint.
a. Inspect the spool stroke of selector (2) of the
swivel joint and inspect if the spool definitely SPANNER DOZER BLADE
switches to the dozer blade side.
Spool Stroke: 6 mm
b. Disconnect the hose between the swivel joint
and the dozer blade cylinder. Set a pressure
gauge in the disconnected hose and operate the 2
dozer blade operation lever.
If the pressure gauge reading is not the follow-
ing value, the swivel joint is faulty.
Supply Pressure: 15.7 MPa
SPOOL STROKE : 6mm
B5E011E
V-33 TB108
TROUBLESHOOTING DOZER BLADE
THE AMOUNT OF DOZER BLADE NATURAL DROP IS GREAT OR THE DOZER BLADE WON’T
HOLD THE MACHINE UP.
Normal
TB108 V-34
DOZER BLADE TROUBLESHOOTING
c. Raise the boom and apply a load on the dozer
blade.
• If the machine’s body drops while oil drains
out of the cylinder’s piping, the cylinder is
faulty.
If the body drops even though no oil drains out,
the control valve or the swivel joint is faulty.
V-35 TB108
TROUBLESHOOTING SPANNER
Normal
Normal
Normal
Normal
TB108 V-36
VI . ENGINE
TB108
/'
series
(Indirect Injection System)
Publication No. M9961-02E070
History of Revision
Manual Name Service Manual for Industrial Diesel Engine
Engine Model: 2TNV, 3TNV series (Indirect Injection System)
Number
Date of Reason for Correction item Corrected
of Outline of correction
revision correction No (page) by
revision
New edition September 2003
R.1 June, Revision, 1) Correction of engine output 1) P2,4 Quality
2004 addition & 2) Correction of FO pump drive 2) P69,95,119 Assurance
correction gear nut (Lube oil) Dept.
3) Addition of tip clearance 3) P90,118 Small
(Lube oil pump) Engine
4) Addition of copy right 4) (Preface) Factory
5) Revision of FO,LO & coolant 5) P7,8-1,8-2
6) Other corrections 6) (Precautions),P13,
35,41,59,66,68,71,
72,76,77,78,81,84,
86,88,94,115,116,
117
Printed in Japan
M9961-02E070
PREFACE
This manual describes the service procedures for the TNV series engines of indirect injection system that
have been certified by the US EPA, California ARB and/or the 97/68/EC Directive for industrial use.
Please use this manual for accurate, quick and safe servicing of the said engine. Since the explanation in this
manual assumes the standard type engine, the specifications and components may partially be different from
the engine installed on individual work equipment (power generator, pump, compressor, etc.). Please also
refer to the service manual for each work equipment for details.
The specifications and components may be subject to change for improvement of the engine quality without
notice. If any modification of the contents described herein becomes necessary, it will be notified in the form of
correction information each time.
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(R.1)
SAFETY LABELS
• Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it
is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully under-
stand safety precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
• It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient consider-
ation for safety is required in addition to the matters marked . Especially for safety precautions
in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable
leader.
• Safety marks used in this manual and their meanings are as follows:
• NOTICE-indicates that if not observed, the product performance or quality may not be guaranteed.
Safety Precautions
•Sufficient Ventilation
Inhalation of exhaust fumes and dust particles may be hazardous to ones
health. Running engines welding, sanding, painting, and polishing tasks
should be only done in well ventilated areas.
•Safety Equipment
Fire extinguisher(s), first aid kit and eye wash / shower station should be
close at hand (or easily accessible) in case of an emergency.
(2) WORK – WEAR (GARMENTS
(3) TOOLS
•Appropriate Tools
Always use tools that are designed for the task at hand. Incorrect usage of
tools may result in damage to the engine and or serious personal injury.
•Genuine Parts
Always use genuine YANMAR parts or YANMAR recommended parts and
goods. Damage to the engine, shortened engine life and or personal injury
may result.
(5) FASTENER TORQUE
•Torquing Fasteners
Always follow the torque values and procedures as designated in the service
manual. Incorrect values, procedures and or tools may cause damage to the
engine and or personal injury.
(6) ELECTRICAL
•Short Circuits
Always disconnect the (-) Negative battery cable before working on the
electrical system. An accidental “short circuit” may cause damage, fire and or
personal injury. Remember to connect the (-) Negative battery cable (back
onto the battery) last.
Fasten the terminals tightly.
•Charging Batteries
Charging wet celled batteries produces hydrogen gas. Hydrogen gas is
extremely explosive. Keep sparks, open flame and any other form of ignition
away. Explosion may occur causing severe personal injury.
•Battery Electrolyte
Batteries contain sulfuric acid. Do NOT allow it to come in contact with
clothing, skin and or eyes, severe burns will result.
•Fueling / Refueling
Keep sparks, open flames or any other form of ignition (match, cigarette, etc.)
away when fueling/refueling the unit. Fire and or an explosion may result.
•Hot Surfaces.
Do NOT touch the engine (or any of its components) during running or shortly
after shutting it down. Scalding / serious burns may result. Allow the engine to
cool down before attempting to approach the unit.
•Rotating Parts
Be careful around moving/rotating parts. Loose clothing, jewelry, ties or tools
may become entangled causing damage to the engine and or severe
personal injury.
ԠFlywheel
Flywheel hausing
Crankshaft gear
Pump flange
Don't disassemble! Fuel pump drive gear
Flange bolt
ԛGear case
ԣOil seal
The job contents are described in the disassembly procedure for Nos. not shown in the illustration.
• Disassembly procedure
1)Follow steps (1) to (15) of the cylinder head disassembly procedure.
2)Remove the cooling water pump.
3)Remove the crankshaft pulley. (Point 1) I Operation point to be explained on a later page.
• Operation points
Disassemble: Service point for removal
Reassemble: Service point for installation
Disassemble-Reassemble: Service point required in both removal and installation.
• Contents omitted in this manual
Though the following jobs are omitted in the explanation in this manual, they should be conducted in actual
work:
3)Jacking up and lifting
4)Cleaning and washing of removed parts as required
5)Visual inspection
(4) Abbreviations
3. Troubleshooting ............................................................................................................. 42
3.1 Preparation before troubleshooting ........................................................................................42
3.2 Quick reference table for troubleshooting ..............................................................................43
3.3 Troubleshooting by measuring compression pressure ..........................................................46
4. Disassembly, inspection and reassembly of engines .................................................... 48
4.1 Complete disassembly and reassembly .................................................................................48
4.1.1 Introduction ..................................................................................................................................... 48
4.1.2 Special service tools ....................................................................................................................... 49
4.1.3 Complete disassembly.................................................................................................................... 54
4.1.4 Precautions before and during reassembly .................................................................................... 58
4.1.5 Adjusting operation ......................................................................................................................... 58
4.2 Cylinder head: disassembly, inspection and reassembly .......................................................59
4.2.1 Components (2-valve cylinder head) .............................................................................................. 59
4.2.2 Disassembly procedure: ................................................................................................................. 59
4.2.3 Reassembly procedure: .................................................................................................................. 59
4.2.4 Servicing points............................................................................................................................... 60
4.2.5 Parts inspection and measurement ................................................................................................ 63
4.2.6 Valve seat correction ...................................................................................................................... 66
4.2.7 Valve guide replacement ................................................................................................................ 67
4.2.8 Valve stem seal replacement.......................................................................................................... 67
4.3 Gear train and camshaft .........................................................................................................68
4.3.1 Components.................................................................................................................................... 68
4.3.2 Disassembly procedure: ................................................................................................................. 68
4.3.3 Reassembly procedure: .................................................................................................................. 68
4.3.4 Servicing points............................................................................................................................... 69
4.3.5 Parts inspection and measurement ................................................................................................ 71
4.3.6 Oil seal replacement ....................................................................................................................... 72
4.3.7 Camshaft bushing replacement ...................................................................................................... 72
4.4 Cylinder block .........................................................................................................................73
4.4.1 Components.................................................................................................................................... 73
4.4.2 Disassembly procedure: ................................................................................................................. 74
4.4.3 Reassembly procedure: .................................................................................................................. 74
4.4.4 Servicing points............................................................................................................................... 75
4.4.5 Parts inspection and measurement ................................................................................................ 78
4.4.6 Cylinder bore correction.................................................................................................................. 87
4.4.7 Piston pin metal replacement.......................................................................................................... 87
4.4.8 Oil seal replacement (Flywheel housing side) ................................................................................ 87
1. General
1.1 Engine nomenclature
3 TNV ٤٤ - ٤ ٤٤
Destination code
Model series
Number of Cylinders
1.2 Specifications
NOTE:
1)The information described in the engine specifications tables (the next page and after) is for "standard"
engine. To obtain the information for the engine installed in each machine unit, refer to the manual pro-
vided by the equipment manufacturer.
2)Engine rating conditions are as follows (SAE J1349, ISO 3046/1)
• Atmospheric condition: Room temp. 25 °C, Atmospheric press. 100 kPa (750 mm Hg), Relative humidity
30%
• Fuel temp: 40 °C (Fuel injection pump inlet)
• With cooling fan, air cleaner, exhaust silencer (Yanmar standard parts)
• After running-in hours. Output allowable deviation: ± 3%
1
1. General
(1) 2TNV70
Engine name Unit 2TNV70
Engine specification class - VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Indirect injection
Number of cylinders - 2
Cylinder bore × stroke mm × mm 70 × 74
Displacement L 0.570
Revolving
speed min-1 -
Continuous
rating kW
Output (NET) -
(ps)
Revolving
speed min-1 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Rated output
kW 6.0 6.3 6.6 7.0 7.3 7.6 7.9 8.2 8.5 8.8 9.1
Output (NET)
(ps) (8.1) (8.6) (9.0) (9.5) (9.9) (10.3) (10.7) (11.1) (11.6) (12.0) (12.4)
Max. no-load speed (± 25) min-1 2160 2250 2355 2460 2570 2675 2780 2890 2995 3100 3210
Ignition order - 1-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 1.7
(oil pan) * Effective L 0.7
Cooling water capacity
L 0.6
(engine only)
Engine Overall length mm 415
Dimensions
Overall width mm 427
(with flywheel
housing) * ** Overall height mm 484
Engine mass (dry) * **
kg 84
(with flywheel housing)
Cooling fan (std.) * mm 260 mm O/D, 5 blades pusher type F
Crankshaft V pulley diameter*
mm ø 110 & ø 110
& Fun V pulley diameter (std.)
* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
(R.1)
2
1. General
(2) 3TNV70
Engine name Unit 3TNV70
Engine specification class - CH VH
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Indirect injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 70 × 74
Displacement L 0.854
Revolving
speed min-1 3000 3600 -
Continuous
rating kW 12.1 14.5
Output (NET) -
(ps) (16.5) (19.7)
Revolving
speed min-1 3000 3600 3100 3200 3300 3400 3500 3600
Rated output
kW 13.3 16.0 13.5 14.0 14.3 14.7 15.0 15.4
Output (NET)
(ps) (18.1) (21.7) (18.4) (19.0) (19.4) (20.0) (20.4) (21.0)
Max. no-load speed (± 25) min-1 - 3800 3290 3400 3500 3600 3710 3815
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD
Lubricant capacity Total L 3.8 2.8
(oil pan) * Effective L 1.7 1.3
Cooling water capacity
L 0.9
(engine only)
Engine Overall length mm 463
Dimensions
Overall width mm 436
(with flywheel
housing) * ** Overall height mm 536 506
Engine mass (dry) * **
kg 98
(with flywheel housing)
Cooling fan (std.) * mm 310 mm O/D, 5 blades pusher type F
Crankshaft V pulley diameter*
mm ø 110 & ø 100
& Fun V pulley diameter (std.)
* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
3
1. General
3TNV70 (continue)
Engine name Unit 3TNV70
Engine specification class - VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Indirect injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 70 × 74
Displacement L 0.854
Revolving
speed min-1 -
Continuous
rating kW
Output (NET) -
(ps)
Revolving
speed min-1 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Rated output
kW 9.0 9.5 9.9 10.5 11.0 11.4 11.8 12.4 12.8 13.2 13.7
Output (NET)
(ps) (12.2) (12.9) (13.5) (14.3) (14.9) (15.5) (16.1) (16.8) (17.4) (18.0) (18.6)
Max. no-load speed (± 25) min-1 2160 2250 2355 2460 2570 2875 2780 2890 2995 3100 3210
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD
Lubricant capacity Total L 2.8
(oil pan) * Effective L 1.3
Cooling water capacity
L 0.9
(engine only)
Engine Overall length mm 504
Dimensions
Overall width mm 427
(with flywheel
housing) * ** Overall height mm 506
Engine mass (dry) * **
kg 98
(with flywheel housing)
Cooling fan (std.) * mm 310 mm O/D, 5 blades pusher type F
Crankshaft V pulley diameter*
mm ø 110 & ø 100
& Fun V pulley diameter (std.)
* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
(R.1)
4
1. General
(3) 3TNV76
Engine name Unit 3TNV76
Engine specification class - CH VH
Type - Vertical, in-line, 4-cycle water-cooled diesel engine
Combustion chamber - Indirect injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 76 × 82
Displacement L 1.115
Revolving
3000 3600 -
Continuous speed
rating kW 15.1 17.7
Output (NET) -
(ps) (20.5) (24.1)
Revolving
speed min-1 3000 3600 3100 3200 3300 3400 3500 3600
Rated output
kW 16.5 19.5 17.7 18.2 18.7 19.3 19.3 19.5
Output (NET)
(ps) (22.5) (26.5) (24.0) (24.8) (25.4) (26.2) (26.3) (26.5)
Max. no-load speed (± 25) min-1 - 3800 3290 3400 3500 3600 3710 3815
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 4.4 3.5
(oil pan) * Effective L 2.1 1.6
Cooling water capacity
L 0.9
(engine only)
Engine Overall length mm 485
Dimensions
Overall width mm 436
(with flywheel
housing) * ** Overall height mm 559 535
Engine mass (dry) * **
kg 112
(with flywheel housing)
Cooling fan (std.) * mm 335 mm O/D, 5 blades pusher type F
Crankshaft V pulley diameter*
mm ø 110 & ø 100
& Fun V pulley diameter (std.)
* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
5
1. General
3TNV76 (continue)
Engine name Unit 3TNV76
Engine specification class - VM
Type - Vertical, in-line, 4-cycle water-cooled diesel engine
Combustion chamber - Indirect injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 76 × 82
Displacement L 1.115
Revolving
-
Continuous speed
rating kW
Output (NET) -
(ps)
Revolving
speed min-1 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000
Rated output
kW 11.8 12.5 13.2 13.8 14.3 14.9 15.5 16.1 16.7 17.3 17.9
Output (NET)
(ps) (16.1) (17.0) (17.9) (18.7) (19.5) (20.3) (21.1) (21.9) (22.7) (23.5) (24.3)
Max. no-load speed (± 25) min-1 2160 2250 2355 2460 2570 2675 2780 2890 2995 3100 3210
Ignition order - 1-3-2-1 (No.1 cylinder on flywheel side)
Power take off - Flywheel
Direction of rotation - Counterclockwise (viewed from flywheel)
Cooling system - Radiator
Lubrication system - Forced lubrication with trochoid pump
Starting system - Electric
Diesel oil, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 3.5
(oil pan) * Effective L 1.6
Cooling water capacity
L 0.9
(engine only)
Engine Overall length mm 485
Dimensions
Overall width mm 436
(with flywheel
housing) * ** Overall height mm 535
Engine mass (dry) * **
kg 112
(with flywheel housing)
Cooling fan (std.) * mm 335 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter*
mm ø 110 & ø 100
& Fun V pulley diameter (std.)
* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
6
1. General
Outlet
(to engine)
Drain cock
(R.1)
7
1. General
The oil must be changed when the Total Base Number (TBN) has been reduced to 2.0.
*TBN(mgKOH/g) test method; JIS K-2501-5.2-2(HCI), ASTM D4739(HCI)
Reason
API CG-4, CH-4
In case CG-4, CH-4 is to be used for YANMAR TNV diesel engine series, there is a possibility that
excessive wears occur on the valve train system due to the content of oil.
ACEA E-1,E-2, B
These fuels are developed for the different type of diesel engines.
• DO NOT add any additives to the engine oil. ޓ ޓ ޓ ޓ ޓ ޓ ޓ
• DO NOT mix the different types (brand) of engine Atmospheric temperature ( C)
oil.
• DO NOT use synthetic oil.
15W-40/10W-30 can be used
almost throughout the year.
(R.1)
8-1
1. General
Contact with engine oil may result in the roughened skin. Care should be taken
so as not to contact with engine oil wearing protective gloves and clothing.
If contact, wash with soap and water thoroughly.
When handling the engine oil, make sure to use the protective gloves at any
time.
In case of contact, wash your hand or body with soap and water thoroughly.
(R.1)
8-2
1. General
Lifting eye
Cooling water pump
Lifting eye
Fuel filter
Air intake port
(from air cleaner)
Intake manifold
Governor lever
Cooling fan
V-belt
Engine oil filter V-pulley
Dipstick (lube oil)
Fuel priming lever Filler port (lube oil)
Mechanical fuel feeding pump Drain plug (lube oil)
Fuel oil inlet
Alternator
Flywheel
Exhaust manifold
Starter motor
9
1. General
㧔㧔
Emission Reduction
㨯New small in-line fuel pump
1.5 Structural description
(Revised ML type)
㨯Precision improvement of fuel injection
quantity in production
㨯Precision improvement of fuel injection
timing in production
10
Noise Reduction
㨯LO pump with more teeth
Quality improvement
㨯Governor performance up
Noise Reduction
㨯Cylinder block of higher stiffness
㨯Gear with smaller module (m=1.5) 㨯Applying a V-belt of A type Main change points
1. General
11
1. General
# /1&'.;'#475'2#4')7.#6+105 # /1&'.;'#475'2#4')7.#6+105
01041#&%+'0)+0'5%1056#0652''&10.; 01041#&%1/24'55+10+)0+6+10'0)+0'5
"75&"(7'. "75&"(7'.
% & % &
' ( ' (
) * + ) * +
EPA label for constant speed engines EPA label for variable speed engines
$ %
&
' ( )
12
1. General
Plate
Copper gasket
Nut Injection quant
limit bc
(R.1)
13
1. General
(5) Maintenance period and quality guarantee period for exhaust emission related parts
The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period
as shown in the below table.
A guarantee period is that either the operation hours or years shown in the table come first in the condition
that the maintenance inspection was carried out based on the “List of Periodic Maintenance Schedule”.
14
2. Inspection and adjustment
*) EPA allows to maintain the emission related parts as shown in 1.6.3 of chapter1.
15
2. Inspection and adjustment
16
2. Inspection and adjustment
(Unit: liter)
Model Class Total volume Effective volume
2TNV70 VM 1.7 0.7
VM/VH 2.8 1.3
3TNV70
CH 3.8 1.7
VM/VH 3.5 1.6
3TNV76
CH 4.4 2.1
Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit.
(b)Replenishing oil pan with lube oil
If the remaining lube oil level is low, fill the oil pan with the specified lube oil to the specified level through the
filler port.
[NOTICE]
The oil should not be overfilled to exceed the upper limit line. Otherwise a naturally-aspirated engine may
intake lube oil in the combustion chamber during the operation, then white smoke, oil hummer or urgent
rotation may occur, because the blowby gas is reduced in the suction air flow.
In case of turbo-charged engine oil may jet out from the breather or the engine may become faulty.
•Never open the radiator filler cap while the engine and radiator are still hot.
Steam and hot water will spurt out and seriously burn you. Wait until the radia-
tor is cooled down after the engine has stopped, wrap the filler cap with a rag
piece and turn the cap slowly to gently release the pressure inside the radia-
tor.
•Securely tighten the filler cap after checking the radiator. Steam can spurt out
during operation, if the cap is tightened loosely.
17
2. Inspection and adjustment
IMPORTANT:
If the cooling water runs short quickly or when the radiator runs short of water with the coolant recovery
tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the coolant
recovery tank water level during operation is not abnormal.
The increased water in the coolant recovery tank returns to the radiator when the engine is cooled down.
If the water level is normal in the coolant recovery tank but low in the radiator, check loosened clamping of
the rubber hose between the radiator and coolant recovery tank or tear in the hose.
Standard
Engine: The radiator shall be filled up.
(Unit: liter)
Model Cooing water volume in an engine
2TNV70 0.6
3TNV70
0.9
3TNV76
(5) Fuel pipe and cooling water pipe inspection and maintenance
Check the rubber hoses for fuel and cooling water pipes cracked. If the cracked hose is found, replace it with
new one.
Check the loosened clamp. If found, tighten it.
18
2. Inspection and adjustment
When an engine is still hot, be careful with a splash of lube oil which may
cause burns. Replace lube oil after the lube oil becomes warm. It is most
effective to drain the lube oil while the engine is still warm.
• Moisten the new oil filter gasket with the lube oil and
Tigh
19
2. Inspection and adjustment
20
2. Inspection and adjustment
Alternator
Tension adjustment
21
2. Inspection and adjustment
Drain plug
22
2. Inspection and adjustment
feed fuel until the fuel surface inside the fuel filter Q
23
2. Inspection and adjustment
Battery structure
Terminal Cap
Cover
Cathode
plate
Separator
Glass mat
Battery
case
Anode plate
24
2. Inspection and adjustment
S20 = St + 0.007 ( t - 20 )
Measured electrolyte
temperature
Measured specific gravity
Battery charge measurement
Specific gravity converted with a hydrometer
to 20͠
Hydrometer structure
(3) Terminals
Clean if corroded or soiled.
25
2. Inspection and adjustment
(1) Lube oil and filter replacement (The second replacement and after)
Replace the lube oil every 250 hours operation from 2nd time and on. Replace the lube oil filter at the same
time. Refer to 2.2.2.(1).
unsafe. Check the wire periodically and adjust if Low idling speed
limiting bolt
necessary.
Do not strongly move the accelerating wire or
accelerating pedal. It may deform the governor lever or
stretch the wire to cause irregular engine speed control.
26
2. Inspection and adjustment
Never release the limiting bolts. It will impair the safety and performance of the product and functions and
result in shorter engine life.
(5) Air cleaner cleaning and element replacement
Fuel filter
28
2. Inspection and adjustment
29
2. Inspection and adjustment
30
2. Inspection and adjustment
g)When filling with the cooling water for the first time
or replacing, the air contains in the cooling water
system. So as the air in the cooling water system
is made self-bleeding during engine operation, the
cooling water level in the radiator and coolant
recovery tank will be lowered. Replenish the
cooling water into the radiator and coolant
recovery tank until it reaches the FULL mark of the
coolant recovery tank.
31
2. Inspection and adjustment
Normal Abnormal
32
2. Inspection and adjustment
Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection
nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or
injury if coming into careless contact with it.
33
2. Inspection and adjustment
Nozzle holder
Nozzle spring
Nozzle valve
Nozzle
Nozzle body
34
2. Inspection and adjustment
ǰ5q
㨪10q
Design code
Throttle type
Size: size P
Injection angle
NP- 9
BOSCH D NOPD N 1 5
Identification
number
(R.1)
35
2. Inspection and adjustment
(2) Fuel pipe and cooling water pipe inspection and maintenance
Regularly check the rubber hoses of the fuel system and cooling water system. If cracked or degraded,
replace them with new one. Replace the rubber hoses at least every 2 years even if 2,000 hours doesn’t
come.
(4) Fuel injection timing adjustment / Fuel injection pump inspection and adjustment
The fuel injection timing and the fuel injection pump are
adjusted so that engine performance may become the Flywheel
housing
best condition. As for the inspection and adjustment of
the fuel pump, it is based on the service manual of the
ML pump of the separate volume. The fuel injection
timing is adjusted by the following procedure.
1)Complete air bleeding from the fuel line and set the
engine ready for starting.
Inspection hole
2)See that the timing marks on fuel pump mounting
flange and gear case are aligned.
3)Set the speed control lever at the operating position.
4)Disconnect the injection pipe on the fuel pump side
for the No.1 cylinder. (Do not remove the delivery
holder.)
5)Check the fuel discharge from the delivery holder Timing marck
while turning the crankshaft clockwise as seen from
the radiator, and stop turning it at the same time
when the fuel comes out. Wipe out the fuel of the Timing scale
delivery holder exit. Next, turn the crankshaft in the
opposite direction (counterclockwise), and return it
to about 20 degrees before top dead center.
6)Check again the fuel discharge from the delivery
holder while turning the crankshaft clockwise, and
stop turning it at the same time when the fuel comes
out.
36
2. Inspection and adjustment
7)Read the timing scale on the flywheel from the hole on the flywheel housing. It is standard fuel injection
timing if the timing mark position meets the fuel injection timing of the below table.
Class VM CH VH
Model 2000 2300 2700 3000 3100 3500
name Engine speed min-1 to 2200 to to / to to
2100 2600 3000 3600 3400 3600
2TNV70 15 16 18 - - -
Injection timing
3TNV70 (FID) bTDC Deg. 15 16 18 21 20 21
± 1 deg.
3TNV76 15 16 18 21 20 21
37
2. Inspection and adjustment
Note) The engine speed may differ from the above standard depending on an engine installed on a machine unit.
38
2. Inspection and adjustment
Tester probes
Continuity test
Thermo switch
Hot water
When the cap doesn't open, it is abnormal. Replace the Radiator cap inspection
cap with new one.
39
2. Inspection and adjustment
Thermo switch
Thermometer Cooling water pump
Thermostat
40
2. Inspection and adjustment
2)Remove the mud, dust and oil deposit and clean the outside.
3)Perform the nearest periodic inspection before the storage.
4)Drain or fill the fuel oil fully to prevent condensation in the fuel tank.
5)Disconnect the battery cable from the battery negative (-) terminal.
6)Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from deposit-
ing or entrance.
7)Select a well-ventilated location without moisture and dust for storage.
8)Perform recharging once a month during storage to compensate for self-discharge.
9)When storing an engine for long time, run the engine or do motoring periodically according to the following
procedure. Because the rust occurrence inside the engine, the rack agglutination of the fuel pump, and so
on are likely to occur. (In case that the engine is equipped with a machine unit,)
a)Replace the lube oil and the filter before the engine running.
b)Supply fuel if the fuel in the fuel tank was removed, and bleed the fuel system.
c)Confirm that there is the coolant in the engine.
d)Operate the engine at the low idling speed for about five minutes. (If it can be done, one a month)
(R.1)
41
3. Troubleshooting
3. Troubleshooting
3.1 Preparation before troubleshooting
If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before
becoming a big accident not to shorten the engine life.
When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the
next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and
prevent the recurrence of the trouble.
1)What’s the occurrence phenomenon or the trouble situation? ⋅⋅⋅⋅⋅ (e.g. Poor exhaust color)
2)Investigation of the past records of the engine
Check a client control ledger, and examine the history of the engine.
• Investigate the engine model name and the engine number. (Mentioned in the engine label.)
Examine the machine unit name and its number in the same way.
• When was the engine maintained last time?
• How much period and/or time has it been used after it was maintained last time?
• What kind of problem was there on the engine last time, and what kind of maintenance was done?
3)Hear the occurrence phenomenon from the operator of the engine in detail.
5W1H of the occurrence phenomenon : the investigation of when (when), where (where),
who (who), what (what), why (why) and how (how)
• When did the trouble happen at what kind of time
• Was there anything changed before the trouble?
• Did the trouble occur suddenly, or was there what or a sign?
• Was there any related phenomenon
⋅⋅⋅⋅⋅.(e.g. Poor exhaust color and starting failure at the same time)
4)After presuming a probable cause based on the above investigation, investigate a cause systematically by
the next troubleshooting guide, and find out the cause of sincerity.
42
3. TROUBLESHOOTING
Insufficient Poor
Excessive consumption
Pressure drop
Pressure rise
During idling
During work
Overheat
Ordinary
White
White
Cause
Black
Black
Much
None
Little
Improper clearance of intake/exhaust valve c c c c c c Adjust the valve clearance. (See 2.2.6(3) in Chapter2.)
Compression leakage from valve seat c c c c c c c c Lap the valve seat. (See 4.2.6 in Chapter4.)
Seizure of intake/exhaust valve c c c c c c c c c c c Correct or replace.
Blowout from cylinder head gasket c c c Replace the gasket. (See 4.2.2-11) in Chapter4.)
Seized or broken piston ring c c c c c c c c c c c Replace the piston ring. (See 4.4.2-5), 10) in Chapter4.)
Perform honing and use oversize parts.
Worn piston ring, piston or cylinder c c c c c c
(See 4.4.5-(1),(4) and 4.4.6 in Chapter4.)
Seized crankpin metal or bearing c c c c c c c Repair or replace.
Improper arrangement of piston ring joints c c c c Correct the ring joint positions. (See 4.4.4 point 6 in Chapter4.)
Reverse assembly of piston rings c c c Reassemble correctly. (See 4.4.4 point 6 in Chapter4.)
Worn crankpin and journal bearing c c c c c c Measure and replace. (See 4.4.5-(2) in Chapter4.)
Loosened connecting rod bolt c c c Tighten to the specified torque. (See 4.4.4-point 2 in Chapter4.)
Engine system
43
3. TROUBLESHOOTING
Insufficient Poor
Excessive consumption
Pressure drop
Pressure rise
During idling
During work
Overheat
Ordinary
Cause
White
White
Much
Black
Black
None
Little
Excessive cooling effect of radiator c c c Defective thermostat (kept closed) (See 2.7 in Chapter2.)
Defective thermostat (kept opened) (See 2.7 in Chapter2.)
Cooling water System
Improper properties of lube oil c c c c c c Use proper lube oil. (See 1.3.2 in Chapter1.)
Lubricating System
Too early timing of fuel injection pump c c c c Check and adjust. (See 2.2.7-(4) in Chapter2.)
Too late timing of fuel injection pump c c c c c c Check and adjust. (See 2.2.7-(4) in Chapter2.)
Improper properties of fuel oil c c c c c c Use proper fuel oil. (See 1.3.1 in Chapter1.)
Water entrance in fuel system c c c c c c c Drain from the fuel system. (See 2.2.3 (1)(2) and 2.2.5(1)(2) in Chapter2.)
Clogged fuel filter c c c Clean or replace. (See 2.2.5(2) in Chapter2.)
Air entrance in fuel system c c c Perform air bleeding. (See 2.2.3(3) in Chapter2.)
Fuel system
44
3. TROUBLESHOOTING
Insufficient Poor
Excessive consumption
Pressure drop
Pressure rise
During idling
During work
Overheat
Ordinary
Cause
White
White
Much
Black
Black
None
Little
Clogged air filter c c c c Clean. (See 2.2.4(5) and 2.2.5(3) in Chapter2.)
Air/Exhaust Gas System
Engine used at high temperatures or at high altitude c c c c Study output drop and load matching.
Clogged exhaust pipe c c c c Clean.
Battery voltage drop c Inspect and change the battery. (See 2.2.3(4) in Chapter2.)
45
3. TROUBLESHOOTING
46
3. TROUBLESHOOTING
35
3.43
30 2.94
2/3TNV70
25 2.45
20 1.96
(MPa)
200 250 300 350 400
47
4. Disassembly, inspection and reassembly of engines
4.1.1 Introduction
Make preparation as follows before starting engine inspection and service:
1)Fix the engine on a horizontal base.
Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
2)Remove the cooling water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain cooling water, lube oil and fuel.
3)Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as
to prevent any foreign matter from entering the engine.
Always wear glasses or other protectors when using compressed air or steam to prevent any foreign matter
from getting in the eyes.
[NOTICE]
• Any part which is found defective as a result of inspection or any part whose measured value does not sat-
isfy the standard or limit shall be replaced.
• Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of
use should be replaced even when the measured value then satisfies the standard or limit.
48
4. Disassembly, inspection and reassembly of engines
̪Locally manufactured
Connecting rod
mm
bushing replacer
(for removal / L1 L2 d1 d2
installation of 25 85 22 25
3 connecting rod
bushing) - -
Tolerance: d1- 00..36 d2 - 00..63
̪Locally manufactured
Valve spring
compressor
(for removal /
installation of valve yanmar code No.
4
spring) 129100-92630
49
4. Disassembly, inspection and reassembly of engines
Camshaft bushing
tool
(for extracting mm
camshaft bushing) L1 L2 d1 d2
18 70 45 48
7
- -
Tolerance: d1- 00..36 d2 - 00..63
̪Locally manufactured
Flex-Hone
mm
(For re-honing of
cylinder liner) Parts No. Cylinder bore
129400-92410 70-76
8
Crankshaft pulley
installing tool
Locally manufactured
11 (for 4TNV94L)
(Refer to 4.3.6 in detail)
50
4. Disassembly, inspection and reassembly of engines
1 Dial gage
2 Test indicator
3 Magnetic stand
4 Micrometer
5 Cylinder gage
Vernier
6
Calipers
7 Depth micrometer
51
4. Disassembly, inspection and reassembly of engines
8 Square
9 V-block
10 Torque wrench
12 Cap tester
abcdefghijklmn
abcdefghijklmn
abcdefghijklmnabcdefghijklmn abcdefghijklmn
abcdefghijklmnabcdefghijklmn
15 Digital thermometer
Float
52
4. Disassembly, inspection and reassembly of engines
Revolving shaft
For measuring revolution by sensing the
Photoelectric
reflecting mark on the outer periphery of
type
16 Speedometer the revolving shaft
Reflection mark
Fuel
For measuring the revolution regardless
high-pressure
of the center or periphery of the revolving
pipe clamp
object.
type
53
4. Disassembly, inspection and reassembly of engines
1)Close the fuel cock valve of the fuel tank. 1)If nozzle seat is left in the cylinder head, remove
2)Remove high-pressure fuel pipes. the cylinder head before extracting nozzle seat.
3)Remove fuel return pipe. 2)To prevent dust from entering fuel injection noz-
4)Remove fuel injection nozzles zles, fuel injection pump and high-pressure fuel
3
*) Fuel injection nozzle for Indirect injection pipes, seal their respective threads with a tape
system is screwed type. or the like.
3)Whenever extracting fuel injection nozzle,
replace nozzle protector with a new one.
1)Remove rocker arm cover assembly.
4
1)Remove valve rocker arm shaft assembly. 1)Attach a tag to a push rod for each cylinder No.
2)Remove push rods. to put the push rods in order.
2)Remove valve cap from the intake/exhaust valve
head.
5
3)Tappet can be removed at the same time when
push rod is extracted.
4)Attach a tag to a tappet for each cylinder No. to
put the tappets in order.
1)Remove fan mounting bolt, and then remove 1)Never turn down alternator vigorously toward
fan. the cylinder block. Otherwise, your finger may
2)Loosen a adjusting bolt for the V-belt adjuster, be nipped and alternator broken.
6
and then remove V-belt.
3)Remove alternator.
4)Remove the spacer for cooling fan and V-pulley.
1)Remove lube oil filter assembly.
7 2)Extract a dipstick from the oil dip-stick hole.
54
4. Disassembly, inspection and reassembly of engines
Disassembly
Camshaft side
8 14 5
Fan side
2 12 9 3
4 10 11 1
6 13 7
Head bolt disassembly order
3 cylinder head
Disassembly
10 Camshaft side
8 5
Fan side
4 10 1
2 9 3
6 7
Head bolt disassembly order
2 cylinder head
55
4. Disassembly, inspection and reassembly of engines
1)Remove a flywheel housing. 1)Carefully protect the oil seal from damage.
17 2)Remove a oil seal.
1)Put a cylinder block upside down and remove a 1)Carefully protect the combustion surface of the
oil pan and a spacer. cylinder block from damage.
18 2)Be careful not to drop tappets off when the cyl-
inder block is turned upside down, because the
tappet is cylindrical in shape.
1)Remove a idle gear shaft, and then remove a 1)Turn the cylinder block aside and carefully pre-
idle gear. vent tappet from jamming on the cam.
19 2)Remove a mounting bolt of thrust bearing 2)Preheat a camshaft gear and a camshaft
through the hole of the camshaft gear. Remove assembly to 180°-200° before removing them,
camshaft assembly. because they are shrink fitted.
1)Remove a gear case flange.
20
1)While turning a crankshaft, place piston at the 1)Remove carbon deposits from the upper wall of
bottom dead center (BDC). the cylinder using fine sandpaper before
2)Remove the crankpin cap of a connecting rod. extracting pistons.
Take care not to damage the inner surface of
the cylinder.
22
2)Make sure that the cap No. of connecting rod
meets the cylinder No.
3)Take care not to drop the crankpin metal when
removing the crankpin cap of the connecting
rod.
1)Remove main bearing cap bolts. While shaking 1)Before extracting a crankshaft, measure the
a main bearing cap, remove it together with the side gap of it.
lower main bearing metal.
2)Extract a crankshaft, taking care not to damage
it.
3)Remove upper main bearing metal.
23
Dial gauge
Crankshaft
56
4. Disassembly, inspection and reassembly of engines
57
4. Disassembly, inspection and reassembly of engines
58
4. Disassembly, inspection and reassembly of engines
59
4. Disassembly, inspection and reassembly of engines
Deflection
% #
V-belt
Crankshaft Press with thumb
V-pulley
Point 2
[Reassemble]
• Check the thermostat function. (See 2.7 in Chapter 2
for the check procedure.)
Point 3
[Reassemble]
• Replace the fuel filter element with a new one.
[Disassemble]
• Cover the fuel pipe opening with tape to prevent
intrusion of foreign matters.
Point 4
[Reassemble]
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it
with a filter wrench (see 4.1.2(1) No.6 in Chapter 4)
by 3/4 turn.
Point 5
[Disassemble]
• Cover the fuel injection pipe and pump inlets and out-
lets with tape or the like to prevent intrusion of foreign
matters.
60
4. Disassembly, inspection and reassembly of engines
Point 6
Breather system (A reductor to intake air system of Diaphragm cover
Rocker arm cover
blowby gas) Spring
Center plate
Emitting blowby gas is harmful to natural Diaphragm
environment. Therefore blowby gas reductor is
adopted to TNV series engines as breather system.
Breather baffle
The system of model 3TNV76 is shown as a
representative of that breather system in the right Baffle plate
Intake maniforld
figure. Some of the combustion gas passes through
the clearance between the cylinder and the piston, Breather system componert
piston ring, and flows to the crankcase. This is said as
blowby gas. While it passes into the cylinder head and
the rocker arm cover, the blowby gas mixes with
splash oil, and becomes oil mist-blowby gas. Next, oil
is separated from mist-blowby gas with passing
through the baffle plate inside a rocker arm cover.
And it passes through a diaphragm assy and a intake
Blowby gas
manifold, and is reduced in the combustion chamber. Diaphragm
Pressure inside a crankcase is controlled by the Spring
Diaphragm cover
function of the diaphragm assy, and suitable amount Baffle plate
of blowby gas is reduced in intake air system. Rocker arm
cover
[Disassembly] Cylinder head
When a rocker arm cover is taken off, check whether
oil or the like enter the diaphragm space from a small
hole on the side of a diaphragm cover or not without Blowby gas flow
disassembling the diaphragm.
[NOTICE]
1)When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles
occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring,
much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect
by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.
When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and
so on, it is considered that oil leakage from the joint of a oil pan, a oil seal and so on will occur. When a
diaphragm is damaged, blowby is discharged from the breathing hole on the side of diaphragm cover, and
not reduced in the intake manifold. Therefore, be careful of the diaphragm trouble.
2)At lube oil replacement or lube oil supply
The amount of lube oil isn't to be beyond the standard upper limit (in the engine horizontality, the upper
limit mark of the dip stick). Since the blowby gas reductor is adopted, be careful that the amount of oil mist
may be inducted in the combustion chamber and the oil hammer sometimes may occur, when the lube oil
quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an
engine.
[Reassembly]
Replace the diaphragm with new one, when it is damaged.
61
4. Disassembly, inspection and reassembly of engines
Point 7
[Disassemble] Disassembly
Camshaft side
• Keep the removed push rods by attaching tags show-
8 14 5
ing corresponding cylinder Nos.
Fan side
2 12 9 3
[Reassemble]
• Always apply oil to the contact portions of the push 4 10 11 1
6 13 7
rods and clearance adjusting screws.
Point 8 Head bolt disassembly order
3 cylinder head
[Disassemble] Assembly
• Loosen the cylinder head bolts in two steps in the Camshaft side
illustrated order. 7 1 10
Fan side
13 3 6 12
• Place the cylinder head assy on a paper board to pre-
vent the combustion face from any damage. 11 5 4 14
[Reassemble] 9 2 8
• Remove the head gasket with a new one. Head bolt tightning order
• Uniformly install the head bolts manually after apply- 3 cylinder head
ing oil on the threaded and seat portions Disassembly
Camshaft side
• They shall be tightened in two steps in the reverse of
8 5
Fan side
the order for disassembly. 4 10 1
N•m (kgf•m)
Tightening torque 2 9 3
First step 26.0 to 30.0 (2.7 to 3.1) 6 7
Second step 53.9 to 57.9 (5.5 to 5.9) Head bolt disassembly order
Point 9 2 cylinder head
Assembly
[Disassemble] Camshaft side
• Carefully remove the fuel injection valve so as not to 3 6
Fan side
leave the top end protector from being left inside the 7 1 10
cylinder. 2 8
9
[Reassemble] 5 4
• Replace the fuel injection valve protector with a new
Head bolt tightning order
one.
Point 10 2 cylinder head
[Disassemble]
• When removing each intake/exhaust valve from the
cylinder head, use a valve spring compressor
(see 4.1.2.No.4 in Chapter 4) and compress the valve
spring and remove the valve cotter.)
• Keep each removed intake/exhaust valve after attach-
ing a tag showing the corresponding cylinder No.
• If cotter burr is seen at the shaft of each intake/ Valve spring compressor
exhaust valve stem, remove it with an oilstone and
extract the valve from the cylinder head.
[Reassemble]
• Replace the stem seal with a new one when an intake/exhaust valve is disassembled.
• Carefully install each valve after oil application so as not to damage the stem seal.
• Different stem seals are provided for the intake and exhaust valves. Do not confuse them since those for
exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, stem seal, valve spring, seat, and cotter, tap the head of the
valve stem lightly for settling.
• Do not forget to install the valve cap.
62
4. Disassembly, inspection and reassembly of engines
(c)Valve sink
Measure with the valve inserted to the cylinder head.
mm
Standard Limit
Intake 0.4 to 0.6 0.8 Valve sink
Exhaust 0.4 to 0.6 0.8
Valve sinking depth
(d)Seat contact
Apply a thin coat of minimum on the valve seat. Insert
the valve in the cylinder and push it against the seat to
check seat contact.
Seat
63
4. Disassembly, inspection and reassembly of engines
119717-11800
Stool
64
4. Disassembly, inspection and reassembly of engines
Valve spring
Inclination
Valve spring
65
4. Disassembly, inspection and reassembly of engines
(R.1)
66
4. Disassembly, inspection and reassembly of engines
Valve guide
10.9 to 11.2
67
4. Disassembly, inspection and reassembly of engines
4.3.1 Components
ԠFlywheel
Flywheel hausing
ԢGear case
ԟStarter ԝIdle gear
ԡCamshaft
Crankshaft gear
Pump flange
Don't disassemble! Fuel pump drive gear
Flange bolt
ԛGear case cover
ԣOil seal
Point2
Fuel injection pump drive gear
[Reassemble]
• When installing the gear case, do not forget to install
the two reinforcing bolts at the center.
• Measure the backlash of each gear.
C
B
C
B
mm
Standard Limit A
Crankshaft gear, Camshaft gear
Idle gear A
Camshaft gear,
0.06 to 0.12 0.14
Fuel injection pump gear,
Idle gear, PTO gear, Crankshaft gear
• Apply sealant after checking that oil doesn't stick on either surface of the cylinder block and the gear case
flange and also the gear case flange and the gear case. Install the gear case by correctly positioning the
two dowel pins.
Point3 (Refer to 7.2.5 in chapter 7)
[Disassemble]
• Remove the mounting nut of the fuel injection pump
Fuel injection pump
drive gear, remove the gear using the gear puller, and
Flange
remove the fuel injection pump. When extracting the
Fuel injection
gear using the gear puller, use a pad at the shaft and drive gear
carefully operate so as not to damage the thread. Flange bolt
Spring
[NOTICE] washer
Be sure to remove a flange and a drive gear with a
Don't disassemble
pair without loosening flange installation bolts.
[Reassemble] Pump drive gear nut
• Tightening torque for fuel pump drive gear nut
(without lube. Oil)
N•m (kgf•m)
Tightening torque
58.8 to 68.8 (6 to 7)
(R.1)
69
4. Disassembly, inspection and reassembly of engines
Point4
Fuel injection pump drive gear
[Reassemble]
• Assemble crankshaft gear A, fuel injection pump
drive gear B and camshaft gear C at the same time
by aligning with idle gear A, B and C marks.
B
C
B
• Install the idle gear shaft with the oil hole facing
upward. A
Point5 A
Camshaft gear
Idle gear
[Reassemble]
• Install the PTO drive gear with its inner spline side Crankshaft gear
facing the flywheel.
Point6
[Disassemble]
• Install a bolt as a handle in the hole at the end face of the flywheel and remove carefully so as not to dam-
age the ring gear.
[Reassemble]
Flywheel mounting bolt: apply lube oil
N•m (kgf•m)
Tightening torque
80.4 to 86.4 (8.2 to 8.8)
Point7
Camshaft gear
[Disassemble]
• Measure the camshaft side gap. Thrust metal
mm
Item Standard Limit
Side gap 0.05 to 0.15 0.25
Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the
horizontal position. Proceed carefully so as not to lose balance.
Point8
[Reassemble]
• Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case.
• Apply sealant (code No.977770-01212) and install the gear case by matching the two dowel pints.
70
4. Disassembly, inspection and reassembly of engines
(c)Camshaft outside diameter and bearing hole diameter measurement Measure the camshaft
outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the
measured camshaft outside diameter from the camshaft metal inside diameter after insertion to
the cylinder measured with a cylinder gage.
mm
Place Item Standard Limit
Metal I.D. 40.000 to 40.075 40.150
Gear side Camshaft O.D. 39.940 to 39.960 39.905
Oil clearance 0.040 to 0.135 0.245
Metal I.D. 40.000 to 40.025 40.100
Intermediate position Camshaft O.D. 39.910 to 39.935 39.875
Oil clearance 0.065 to 0.115 0.225
Metal I.D. 40.000 to 40.025 40.100
Flywheel side Camshaft O.D. 39.940 to 39.960 39.905
Oil clearance 0.04 to 0.085 0.195
(R.1)
71
4. Disassembly, inspection and reassembly of engines
Idle gear
M
mm
Item Standard Limit
Shaft outside diameter 36.950 to 36.975 36.900
Metal inside diameter 37.000 to 37.025 37.075
Clearance 0.025 to 0.075 0.175
Oil seal
(R.1)
72
4. Disassembly, inspection and reassembly of engines
ԡPiston ring
ԝFlywheel hausing
Oil seal
ԠTappet
Camshaft
Oil filter
ԚOil pan
73
4. Disassembly, inspection and reassembly of engines
74
4. Disassembly, inspection and reassembly of engines
Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Carefully
operate so as not to lose balance.
75
4. Disassembly, inspection and reassembly of engines
mm
Thrust metal assy code Standard thickness
119810-02940 2.055 to 2.105 Side gap measurement2
[Disassemble]
• Remove the bearing caps, cap bearings, and thrust Main bearing cap
Flywheel side
has an oil hole, and the lower one does not. The Main bearing cap bolt
“wheel and arrow” marks on the cap shall face the fly-
Main bearing
wheel.
Main bearing cap bolt tightening torque (apply lube oil)
N•m (kgf•m)
Standard
75.5 to 81.5 (7.7 to 8.3)
(9
(R.1)
76
4. Disassembly, inspection and reassembly of engines
Point5: Crankshaft
[Disassemble]
• Remove the crankshaft. Remove each main bearing metal upper (block side) and pair it with the metal cap
side lower metal.
Carefully prevent the bearing from being damaged or finger injury when removing the crankshaft because it
is heavy.
Point 6: Piston pin and rings
[Disassemble]
• Using the piston ring replacer (see 4.1.2(1) No.10 in Make the punched manufacturer's
mark face upward.
Chapter 4), remove the piston rings.
• Remove the circlip and remove the piston pin by
Piston ring
pushing it out.
[Reassemble] Oil ring joint
• Install each piston ring on the piston, with the
punched manufacturer’s mark facing upward. 120q
Second 120q
[Reassemble] ring joint
120q
• The piston ring joints shall be staggered at by 120 °C Top ring joint
intervals. Do not position the top ring joint vertical to
the piston pin. The coil expander joint shall be oppo-
site to the oil ring joint.
Expander joint
Ring joints
[Reassemble]
Piston ID mark
• When installing the piston pin to the rod and piston,
Camshaft side
Embossed mark
(Flywheel side)
Match mark
mm
Item Model Standard Limit
2/3TNV70 70.000 to 70.030 70.200
Cylinder inside diameter
3TNV76 76.000 to 76.030 76.200
Roundness
Cylinder bore all TNV 0.01 or less 0.03
Cylindricity
(R.1)
78
4. Disassembly, inspection and reassembly of engines
(2) Crankshaft
Mainly check seizure and wear of the crankpins and
journals. Since the crankshaft gear is shrink-fitted, heat
to 180 to 200 °C when extraction is necessary.
(a)Shaft portion color check
After washing the crankshaft, inspect it by means of
color check or a magnaflux inspector. Replace it if
cracked or heavily damaged. Slight defects shall be
corrected by grinding.
(b)Crankshaft bend
Support the crankshaft journals at both ends with V-
blocks. Use a dial gage and measure the run-out at the Bend
center journal while rotating the shaft to inspect the
bend. The bend is half of the run-out value.
Limit 0.01 mm or less
Deflection
Dial gage
V-block V-block
Crank journal
mm
Item Standard Limit
Journal O.D. 46.952 to 46.962 46.902
Oil clearance 0.020 to 0.050 0.120
Roundness 0.01 or less 0.02
80
4. Disassembly, inspection and reassembly of engines
R
R
Finishing precision standard of dimension R
R
+ 0 .3
R
0
3.5
Crank Pin Crank Journal
Surface finishing precision standard on journal and
Crankshaft R machining
pin:
Ry=0.8S super polishing
Surface finishing precision standard on the thrust side
1.6
of crankshaft arm:
[NOTICE]
1)lf the oil clearance is excessive though the thickness
of the journal and crankpin metals are normal or if
partial uneven wear is observed, re-grind the crank-
shaft and use an undersized metals.
2)lf rust or surface roughening exists on the rear side
of the metals, coat it with blue or minimum.
Then assemble the crankpin metal to the connecting
rod, and tighten the rod bolt to the specified torque to
check the metal for contact. If the contact surface
occupies 75 % or more, the metal is normal. If the
contact surface is insufficient, the metal interference
is insufficient. Replace the metal with a new stan-
dard one.
(R.1)
81
4. Disassembly, inspection and reassembly of engines
(4) Piston
Especially clean the combustion surface, circumference,
ring grooves and piston pin bosses, and check after
removing any carbon deposit. Any burr at a ring groove
or snap ring groove shall be removed. If crack is
suspected, inspect by color check.
(a)Piston outside diameter measurement
Measure the long diameter at H mm from the bottom end
of the piston of the oval hole in the vertical direction to Measurement
position
the piston pin hole.
H mm
The clearance between a piston and a cylinder is
calculated by using a measured piston outside diameter Piston outside diameter
and a cylinder inside diameter measured according to
4.4.5(1) (b).
mm
Clearance between Measurement position
Model Piston outside diameter Limit
piston and cylinder (H)
2/3TNV70 69.960 to 69.990 69.915 0.030 to 0.050 22 to 25
3TNV76 75.955 to 75.985 75.910 0.035 to 0.055 22 to 25
If the piston outside diameter exceeds the limit, replace the piston with new one.
If necessary, use an oversized piston. (Refer to the tables of oversized pistons, oversized piston rings and
cylinder boring dimension in 4.4.5(1)(c).)
(mm)
Model Cylinder inside diameter Piston outside diameter.
D1 D2
2/3TNV70 70 69.975
3TNV76 76 75.970
82
4. Disassembly, inspection and reassembly of engines
mm B
Item Standard Limit
Piston pin outside diameter
Pin I.D. 22.000 to 22.009 22.039
Pin O.D. 21.995 to 22.000 21.965 Measure at positions a and b
in directions A and B.
Clearance 0.000 to 0.014 0.074
a b A
state.
Cylinder block
Pistonring
Approx.
30mm
Width
(R.1)
84
4. Disassembly, inspection and reassembly of engines
mm
Standard Limit Mandrel
Item
dimension dimension
Twist and 0.03 or less
0.08
parallelism per 100 mm Twist and parallelism measurement
Connecting rod
aligner
85
4. Disassembly, inspection and reassembly of engines
(6) Tappet
Mainly check the tappet contact surface with the cam
and push rod. Slight surface defects shall be corrected
with an oilstone.
Tappet stem outside diameter measurement
The outside diameter of the tappet stem is measured by
a micrometer.
The clearance is calculated from the measured tappet Abnormal contact Normal contact
surface surface
hole and the measured stem diameter.
Tappet
mm
Item Standard Limit
Tappet hole I.D. 21.000 to 21.021 21.041
Stem O.D. 20.927 to 20.960 20.907
Clearance 0.040 to 0.094 0.134
(R.1)
86
4. Disassembly, inspection and reassembly of engines
• Electric drill
• Honing fluid (50:50 mixture of lube oil and diesel oil) Flex-Hone Honing fluid
(c)Apply the honing fluid to the Flex-Hone and turn Items to be prepared for honing
the electric drill at 300 to 1200 min-1. Then insert
the Flex-Hone into the cylinder bore while turning
it, and move it up and down for about 30 sec. to
obtain a honing mark with a cross hatch angle of
30 to 40°.
[NOTICE]
1)Avoid faster revolution than 1200 min-1 since it may 㨪40q
30q
cause breakdown.
2)Do not insert or extract the Flex-Hone in stopped
state because the cylinder will be damaged.
87
5. Lubrication system
5. Lubrication system
5.1 Lubrication system diagram
Oil pressure
swich
Rocker arm
Tappet
Cam face
Oil pan
Cover
Outer rotor
Control
valve Inner rotor
Gear case cover
(R.1)
88
5. Lubrication system
• When replacing the lube oil pump, replace the whole assy including the outer/inner rotor.
[NOTICE]
Always check if the pump rotates smoothly after installation on the gear case cover.
Running the engine when the pump rotation is heavy may cause the pump to be burnt.
Point 2
[Disassemble-Reassemble]
• Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation
is detected.
89
5. Lubrication system
Side clearance mm
Standard Limit
0.02 to 0.07 0.12
Outer rotor
Side clearance
(R.1)
90
6. Cooling system
6. Cooling system
6.1 Cooling water System
Thermostat
Cylinder head
Bypass
Radiator
Sub-tank
Cylinder block
Thermo switch
V-pulley
Spacer
91
6. Cooling system
Point2
O-Ring
[Disassemble]
• Check the thermostat function. See 2.7 in Chapter 2
for the inspection method.
92
7. Fuel injection pump / Governor
To fuel tank
Fuel injection pump
93
7. Fuel injection pump / Governor
Exhaust manifold
Rocker arm cover
Fuel injection pipe
Fuel injection
valve
Cylinder head
Crankshaft gear
Fuel filter
Crankshaft
Crankshaft pulley
Note) This figure shows the 3TNV76.
(R.1)
94
7. Fuel injection pump / Governor
(R.1)
95
7. Fuel injection pump / Governor
[NOTICE]
Monitor the oil and fuel leakage from the fuel pump system or the oil leakage from the fuel pump flange
during the engine running.
96
8. The specifications of a starting motor and the characteristics
8.1.1 Specifications
Manufacturer’s model (Denso) - P1.1
Yanmar code - 119717-77010
Nominal output kW 1.1
Weight kg 3.0
Revolution direction (as viewed from pinion) - Clockwise
Engagement system - Magnetic shift
Terminal voltage/current V/A 11.5/90 or less
No-load
Revolution min-1 3000 or above
Terminal voltage/current V/A 2.5/325 or less
Loaded
Torque N•m (kgf•m) 8.24 (0.84)
Clutch system - Overrunning
Pinion projection voltage (at 100 °C) V 8.0 or less
Pinion DP or module/number of teeth - M2.54/9
Application - Standard
8.1.2 Characteristics
TOROUE (Nm)
SPEED (min-1)
STARTER
OUTPUT (kW)
VOLTAGE (V)
6000 24 1.2 12
V kW
5000 20 1.0 10
Nm
4000 16 0.8 8
3000 12 0.6 6
2000 8 0.4 4
min-1
1000 4 0.2 2
0 0 0 0
0 100 200 300 400 500
CURRENT (A)
97
8. The specifications of a starting motor and the characteristics
Lever
Gear
Bearing
Clutch Assy
Housing Flame
Needle bearing
Gear
Yoke Assy
Armature Assy
Bearing
Plate
Shaft
(2) Structure
When the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. The pinion
engages with the ring gear of a engine, and the engine is started.
Magnetic switch
Shift lever
Armature Assy
98
8. The specifications of a starting motor and the characteristics
8.3 Performance
The specified characteristics of a starting motor (at 20 deg. C)
1)No load: Less than electric current 90 A, more than rotation speed 3000 min-1 at voltage 11.5 V.
2)Load: More than rotation speed 1130 min-1, torque 6.86 N•m (0.70 kg•fm) at voltage 8.7 V and electric
current 230 A.
3)Restraint: Less than electric current 325 A, torque 8.2 N•m (0.84 kgf•m) at voltage 2.5 V.
4)Operation voltage: In the position of a ring gear, less than 8 V.
Since the characteristics of a starting motor can be confirmed easily in the no-load test comparatively, perform
the test by the next point.
No-load test
Fix the starting motor on a test bench and connect wiring. When the switch is closed, a current flows in the
starting motor, which is rotated at no-load. Measure the current, voltage and number of revolutions then
and check if they satisfy the specified characteristics.
99
9. Alternator
9. Alternator
As a representative example of alternator, the alternators of 20A and 40A are shown in this chapter.
100
9. Alternator
9.1.2 Structure
Coil Plate
FW Assy
Stator
22.5 22.5
)0
(1
Collar
Clamp
Washer (3)
0)
3
(R
Spring washer
Nut
(15q
)
Bearing
Tube (red)
Coupler
101
9. Alternator
KEY SW
Load
IC Regurator
12V
Charge lamp Battery
Generator
[NOTICE]
1)Don't do mis-connecting and short-circuit of each terminal.
2)Don't remove a battery terminal and a B terminal when rotating.
3)Shut out a battery switch during the alternator stop.
25
20
OUTPUT CURRENT (A)
15
10
0
1 2 3 4 5 6 7103
102
9. Alternator
9.1.5 Inspection
103
9. Alternator
9.2.1 Components
V-belt adjuster
Alternator
Rotor Assy
Flame Assy
Washer
Bearing cover
Bearing
Retainer plate
Collar Bearing
Pulley
Nut
Brush holder
Insulation bushing
Regulator Assy
Holder
104
9. Alternator
9.2.2 Specifications
WIRING DIAGRAM
IG Key switch
IG P
B
PI P L
Charge lamp
F (Max. 3.4W)
IC
L
L L
O O
0.5ǴF
A B A
D Battery A D
E T
[NOTICE]
1)Don't do mis-wiring and short-circuit of each terminal.
2)Don't remove a battery terminal and a B terminal when rotating.
3)Shut out a battery switch during the alternator stop.
105
9. Alternator
Cold
50
Hot
OUTPUT CURRENT
40
30
20
(A)
10
0 1 2 3 4 5 6 7 8
ALTERNATOR SPEED (X103 min-1)
9.2.5 Inspection
Perform the same procedure as that of 9.1.5 in Chapter 9.
106
Ground L-terminal of the
Turn key switch to ON. OFF Disconnect GN coupler driven machine side coupler OFF
Does the charge lamp (L, IG). Replace the charge lamp
(L, IG)
9. Alternator
107
Excessive voltage drop between
VB - VL > 0.5V BAT and batt ( + side) terminal
Does the charge lamp The lamp is lit Measure VB and VL at
come ON? dimly BAT L-terminal during
idling
VB - VL < 0.5V L-terminal defective conduction
Inspect the diode ( - side)
OFF
VB = 13㨪15 Turn the light switch Does the charge lamp ON Inspect the auxiliary diode
to ON during idling come ON?
OFF
̪ Remarks Explanation on abbreviations: Not abnormal
1) Use a fully charged battery GN : Alternator
2) DC voltmeter: 0 to 30 V, 0.5 class IC-RG : IC regulator
3) The check method is also applicable to VB : BAT terminal voltage
the bench test VL :L-terminal voltage
10. Electric wiring
108
10. ELCTRIC WIRING
10.1.1 Alternator
In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions
carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage
to the user.
109
10. ELECTRIC WIRING
(2) When the resistance of the battery cable exceeds the specified value
The combined total resistance of the battery cable in both directions between the starting motor and battery
should be within the value indicated on the wiring diagram. The starting motor will malfunction or break down
if the resistance is higher than the specified value.
(3) When the resistance of the starting motor circuit exceeds the specified value
The combined total resistance of the wiring between the starting motor and key switch (or power relay or
safety relay, depending on the application) should be within the value indicated on the wiring diagram. Engine
starting will be difficult if the resistance is higher than the specified value. This can also cause welding of the
magnet switch at the point of contact and resultant burning of the armature coil.
(5) When there is too much rust due to the entry of water
The water-proofing of the starting motor is equivalent to R2 of JIS D 0203. This guarantees that there will be
no damage from the sort of exposure encountered in rain or when water is poured on from a bucket. You
should, however, avoid the use of high-pressure washing and steeping in water.
110
10. ELCTRIC WIRING
111
10. ELECTRIC WIRING
112
11. Service standards
*Lube oil capacity may differ from the above depending on an engine installed on a machine unit.
113
11. Service standards
114
11. Service standards
(1) Camshaft
mm
Inspection item Standard Limit Reference page
Side gap 0.05 to 0.15 0.25 4.3.4
Bending (1/2 the dial gage reading) 0 to 0.02 0.05
4.3.5 (1)
Cam height 34.135 to 34.265 33.89
Shaft outside diameter / Metal inside diameter
Bushing inside diameter 40.000 to 40.075 40.150
Gear side Camshaft outside diameter 39.940 to 39.960 39.905
Clearance 0.040 to 0.135 0.245
Bushing inside diameter 40.000 to 40.025 40.100
Intermediate
Camshaft outside diameter 39.910 to 39.935 39.875 4.3.5 (1)
(No bushing)
Clearance 0.065 to 0.115 0.225
Bushing inside diameter 40.000 to 40.025 40.100
Wheel side
Camshaft outside diameter 39.940 to 39.960 39.905
(No bushing)
Clearance 0.04 to 0.085 0.195
(R.1)
115
11. Service standards
(2) Crankshaft
mm
Inspection item Standard Limit Reference page
Bending (1/2 the dial gauge reading) - 0.02
Roundness 0.01 or less 0.02
Pin outside diameter 41.952 to 41.962 42.902
Metal inside diameter 41.982 to 42.002 -
Crank pin
Metal thickness 1.503 to 1.509 -
4.4.5.(2)
Clearance 0.020 to 0.050 0.110
Journal outside diameter 46.952 to 46.962 46.902
Metal inside diameter 46.982 to 47.002 -
Crank journal
Metal thickness 2.009 to 2.014 -
Clearance 0.020 to 0.050 0.120
(R.1)
116
11. Service standards
Piston diameter
measure position 2/3TNV70
22 to 25 -
(Upward from the bottom 3TNV76 4.4.5.(4)
end of the piston)
Hole inside diameter 22.000 to 22.009 22.039
Piston pin Pin outside diameter 21.995 to 22.000 21.965
Clearance 0.000 to 0.014 0.074
Piston ring
mm
Model Inspection item Standard limit Reference page
Ring groove width 1.550 to 1.570 -
Ring width 1.470 to 1.490 1.450
Top ring
Side clearance 0.060 to 0.100 -
End clearance 0.15 to 0.30 0.39
Ring groove width 1.540 to 1.560 1.660
Ring width 1.470 to 1.490 1.450
2/3TNV70 Second ring
Side clearance 0.050 to 0.090 0.210
End clearance 0.18 to 0.33 0.42
Ring groove width 3.010 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.020 to 0.060 0.180
End clearance 0.15 to 0.35 0.44
4.4.5.(4)
Ring groove width 1.550 to 1.570 -
Ring width 1.470 to 1.490 1.450
Top ring
Side clearance 0.060 to 0.100 -
End clearance 0.15 to 0.30 0.390
Ring groove width 1.580 to 1.595 1.695
Ring width 1.430 to 1.450 1.410
3TNV76 Second ring
Side clearance 0.013 to 0.165 0.285
End clearance 0.18 to 0.33 0.420
Ring groove width 3.010 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.020 to 0.060 0.180
End clearance 0.20 to 0.45 0.540
(R.1)
117
11. Service standards
(6) Tappet
mm
Inspection item Standard Limit Reference page
Tappet hole (block) inside diameter 21.000 to 21.021 21.041
Tappet stem outside diameter 20.927 to 20.960 20.907 4.4.5.(6)
Clearance 0.040 to 0.094 0.134
(R.1)
118
12. Tightening torque for bolts and nuts
Lube oil
Thread diameter Tightening torque application Reference
Part and engine model
× pitch (thread portion, and page
mm N•m (kgf•m) seat surface)
53.9 to 57.9
Cylinder head bolt M9 × 1.25 Applied 4.2.4
(5.5 to 5.9)
22.6 to 27.5
Connecting rod bolt M7 × 1.0 Applied 4.4.4
(2.3 to 2.8)
80.4 to 86.4
Flywheel set bolt M10 × 1.25 Applied 4.3.4
(8.2 to 8.8)
75.5 to 81.5
Bearing cap set bolt M10 × 1.25 Applied 4.4.4
(7.7-8.3)
83.3 to 93.3
FC250
Crankshaft (8.5 to 9.5)
M12 × 1.25 Applied 4.3.4
pulley set bolt 113 to 123
S48C
(11.5 to 12.5)
58.8 to 68.8
Fuel pump drive gear nut M12 × 1.75 Not applied 4.3.4
(6.0 to 7.0)
32.3 to 36.3
Fuel pump gear bolt M8 × 1.0 Not applied -
(3.3 to 3.7)
29.4 to 34.4
Fuel injection pipe sleeve nut M12 × 1.25 Not applied -
(3.0 to 3.5)
49.0 to 53.0
Fuel injection nozzle nut M20 × 1.5 Not applied -
(5.0 to 5.4)
68.7 to 73.7
Governor weight support nut M12 × 1.25 Applied -
(7.0 to 7.5)
14.7 to 19.6
Glow plug M10 × 1.25 Not applied -
(1.5 to 2.0)
(R.1)
119
12. Tightening torque for bolts and nuts
Note) Lube oil is not applied to threaded portion and seat surface.
120
YANMAR AMERICA CORP.
951 CORPORATE GROVE DRIVE, BUFFALO GROVE, IL 60089-4508, U.S.A.
TEL : 1-847-541-1900
FAX : 1-847-541-2161
Printed in Japan