Professional Documents
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TL130 English CT8E002
TL130 English CT8E002
1
NOTICE OF REVISIONS
LIST OF REVISIONS
Rev.1
Symbol Page Rev. Symbol Page Rev. Symbol Page Rev. Symbol Page Rev. Symbol Page Rev.
A 0-1 1 R II-16 1 R III-26 1 A III-54 1 A III-95 1
A 0-2 1 II-17 R III-27 1 A III-55 1 A III-96 1
A 0-3 1 II-18 R III-28 1 A III-56 1 IV-1
A 0-4 1 II-19 A III-28-1 1 A III-57 1 R IV-2 1
A 0-5 1 II-20 A III-28-2 1 A III-58 1 R IV-3 1
A 0-6 1 II-21 R III-29 1 A III-59 1 IV-4
A 0-7 1 II-22 R III-30 1 A III-60 1 R IV-5 1
A 0-8 1 III-1 III-31 A III-61 1 IV-6
I-1 R III-2 1 III-32 A III-62 1 IV-7
R I-2 1 R III-3 1 III-33 A III-63 1 IV-8
R I-3 1 A III-3-1 1 R III-34 1 A III-64 1 R IV-9 1
R I-4 1 R III-4 1 A III-34-1 1 A III-65 1 R IV-10 1
R I-5 1 A III-4-1 1 A III-34-2 1 A III-66 1 R IV-11 1
R I-6 1 III-5 R III-35 1 A III-67 1 R IV-12 1
R I-7 1 R III-6 1 R III-36 1 A III-68 1 R IV-13 1
R I-8 1 A III-6-1 1 A III-36-1 1 A III-69 1 R IV-14 1
R I-9 1 R III-7 1 A III-36-2 1 A III-70 1 A IV-14-1 1
R I-10 1 A III-7-1 1 A III-36-3 1 A III-71 1 R IV-15 1
R I-11 1 A III-7-2 1 A III-36-4 1 A III-72 1 R IV-16 1
R I-12 1 R III-8 1 A III-36-5 1 A III-73 1 R IV-17 1
R I-13 1 III-9 R III-37 1 A III-74 1 R IV-18 1
R I-14 1 III-10 R III-38 1 A III-75 1 R IV-19 1
X I-15 1 III-11 R III-39 1 A III-76 1 R IV-20 1
X I-16 1 III-12 III-40 A III-77 1 R IV-21 1
X I-17 1 A III-12-1 1 R III-41 1 A III-78 1 R IV-22 1
X I-18 1 III-13 III-42 A III-79 1 A IV-22-1 1
II-1 III-14 R III-43 1 A III-80 1 R IV-23 1
II-2 R III-15 1 R III-44 1 A III-81 1 R IV-24 1
II-3 III-16 R III-45 1 A III-82 1 R IV-25 1
R II-4 1 III-17 A III-45-1 1 A III-83 1 R IV-26 1
R II-5 1 R III-18 1 A III-45-2 1 A III-84 1 R IV-27 1
R II-6 1 R III-19 1 A III-45-3 1 A III-85 1 A IV-27-1 1
R II-7 1 R III-20 1 R III-46 1 A III-86 1 R IV-28 1
R II-8 1 A III-20-1 1 A III-46-1 1 A III-87 1 A IV-28-1 1
II-9 R III-21 1 A III-47 1 A III-88 1 IV-29
II-10 R III-22 1 A III-48 1 A III-89 1 IV-30
II-11 R III-23 1 A III-49 1 A III-90 1 R IV-31 1
II-12 A III-23-1 1 A III-50 1 A III-91 1 IV-32
II-13 A III-23-2 1 A III-51 1 A III-92 1 R IV-33 1
II-14 R III-24 1 A III-52 1 A III-93 1 IV-34
II-15 III-25 A III-53 1 A III-94 1 IV-35
REV. 1 0-2
Symbol Page Rev. Symbol Page Rev. Symbol Page Rev. Symbol Page Rev. Symbol Page Rev.
IV-36 IV-86 A ENGINE Model 1
IV-37 IV-87 4TNV98
IV-38 IV-88
IV-39 IV-89
R IV-40 1 IV-90
R IV-41 1 IV-91
R IV-42 1 R IV-92 1
IV-43 IV-93
IV-44 IV-94
IV-45 IV-95
IV-46 R IV-96 1
IV-47 A IV-96-1 1
IV-48 IV-97
IV-49 IV-98
IV-50 IV-99
IV-51 R IV-100 1
IV-52 R IV-101 1
IV-53 R IV-102 1
IV-54 R IV-103 1
IV-55 R IV-104 1
IV-56 A IV-104-1 1
IV-57 IV-105
IV-58 R IV-106 1
IV-59 IV-107
IV-60 IV-108
IV-61 V-1
IV-62 V-2
IV-63 V-3
IV-64 V-4
IV-65 V-5
IV-66 V-6
IV-67 V-7
IV-68 V-8
IV-69 V-9
IV-70 V-10
R IV-71 1 R V-11 1
IV-72 V-12
IV-73 V-13
IV-74 V-14
IV-75 R V-15 1
IV-76 V-16
IV-77 V-17
IV-78 R V-18 1
A IV-78-1 1 V-19
A IV-78-2 1 V-20
A IV-78-3 1 V-21
A IV-78-4 1 V-22
A IV-78-5 1 V-23
A IV-78-6 1 R V-24 1
IV-79 V-25
IV-80 V-26
IV-81 V-27
IV-82 V-28
IV-83 ENGINE Model
IV-84 4TNE98
IV-85
0-3 REV. 1
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.
REV. 1 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 REV. 1
REV. 1 0-6
I . GENERAL
II . SPECIFICATIONS
III . MACHINE CONFIGURATION
IV . HYDRAULIC UNITS
V. TROUBLESHOOTING
VI . ENGINE
0-7 REV. 1
REV. 1 0-8
I . GENERAL
I-1
GENERAL
CONTENTS
REV. 1 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 REV. 1
GENERAL
Provide a fire extinguisher and first aid Anti-explosive lighting
kit
REV. 1 I-4
GENERAL
Always clean the machine Securely block the machine or any
component that may fall
Stay clear of moving parts Secure the engine hood or cover when
opened
I-5 REV. 1
GENERAL
Cautions on working on the machine Handling of hoses
REV. 1 I-6
GENERAL
Be careful with fluids under pressure High pressure nitrogen gas is enclosed in the accumu-
lator and incorrect handling could possibly bring
about serious injury due to explosion. The following
matters should be strictly observed:
• Do not disassemble.
• Do not bring close to fire or throw into a fire.
• Do not make hole, weld, or fuse.
• Do not subject to shock such as hitting or rolling.
• At time of disposal, it will be necessary to release
the enclosed gas. Please contact a Takeuchi sales or
service agent.
Pressure can be maintained in the hydraulic circuit Be careful with grease under pressure
long after the engine has been shut down.
• Release all pressure before working on the hydrau-
lic system.
• Hydraulic fluid under pressure can penetrate the
skin or eyes and cause injury, blindness or death.
Fluid escaping from a small hole can be almost
invisible. Wear a safety goggles and heavy gloves
and use a piece of cardboard or wood to search for
suspected leaks. E3A6201
Handling of the Accumulator Disconnect the battery before working on the electri-
cal system or doing any welding. Remove the nega-
tive (–) battery cable first. When reconnecting the
battery, connect the negative (–) battery cable last.
N0A005
I-7 REV. 1
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
REV. 1 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 REV. 1
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
REV. 1 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 REV. 1
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
REV. 1 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
M8 × 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 REV. 1
GENERAL
REV. 1 I-14
II . SPECIFICATIONS
II-1
I-15
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.
II-2
II-16
NAMES OF COMPONENTS SPECIFICATIONS
NAMES OF COMPONENTS
"
#
!
'
'
&
&
!
%
"
#
$
6&*
II – 3
SPECIFICATIONS SPECIFICATION DIAGRAMS
SPECIFICATION DIAGRAMS
Machine Dimensions
Unit: mm
Standard Bucket
D Rubber Crawler
Canopy Cab
L A 3430 ←
K B 2740 ←
C 1390 ←
H
J D 2235 (2120∗) 2235
E 310 ←
F 1580 ←
G 320 ←
H 1430 ←
J 985 (980∗) 985
M E
K 1675 ←
C G L 510 ←
B F M 30° ←
A ∗: 21300004~21301098
T7K0011A
Operating Range
Unit: mm
E
Standard Bucket
Rubber Crawler
Canopy Cab
A 3905 ←
F G
B 3030 ←
C 2370 ←
D 730 ←
E 2080 ←
F 1375 ←
G 1585 ←
D H 30° ←
A B C
T7K0021A
REV. 1 II – 4
SPECIFICATION TABLES SPECIFICATIONS
SPECIFICATION TABLES
SPECIFICATIONS
II – 5 REV. 1
SPECIFICATIONS SPECIFICATION TABLES
SPECIFICATIONS OF DEVICE
21300004~
Serial Number
21300004~21301932 21301933~
Engine
Model Yanmar 4TNE98-TBL Yanmar 4TNV98-YTBL
Type 4-Cycle, vertical, water-cooled, in-line, 4-cylinder diesel engine ←
Number of Cylinders-Bore × Stroke mm 4-98 × 110 ←
Total Displacement mL 3318 3319
Compression Ratio 18.0 18.5
Performance
Rated Output kW/min-1 50/2450 49.2/2450
Maximum Torque N·m/min-1 224.6~245.2/1600 236/1470
Maximum No-load R.P.M. min-1 2650 ±25 ←
Minimum No-load R.P.M. min-1 1150 ±25 ←
Specific Fuel Consumption g/kW·h 245 235
Starter V–kW 12–3.0 ←
Generator V–kW 12–0.48 ←
Battery V–A·h 12–80 ←
HST Pump
Model PVM2828
Type Variable displacement type double axial piston
Displacement cm3/rev 28.0 + 28.0
Delivery L/min 68.6 + 68.6
Relief Valve Pressure Setting MPa 34.5
Charge Relief Valve Pressure Setting MPa 1.9 ±0.07
Gear Pump
Model DDG1A27·16F9H7-R916
Type Tandem gear
Displacement cm3/rev 27.8 + 16.2
Delivery L/min 68.1 + 39.7
Control Valve
Model 07886-00000
Number of Circuits 3
Main Relief Valve Pressure Setting MPa@L/min 20.6 @68
Port Relief Valve Pressure Setting MPa@L/min 24.5 @68
Control Valve (Sub)
Model 07903-0000B
Rated Flow L/min 41.6
Relief Valve Pressure Setting MPa@L/min 3.3 @40
Pilot Valve (R. H.)
Model TH40K1267A
Secondary Side Pressure MPa 0.49~1.96
Operating Angle : Single (Ports 1, 3) degree 19
: Single (Ports 2, 4) degree 25
Pilot Valve (L. H.) 21300004~21300090 21300091~
Model TH40K1271A TH40K1271B
Secondary Side Pressure MPa 0.49~1.91 ←
Operating Angle : Single degree 19 ←
: Simultaneous degree 25 ←
REV. 1 II – 6
SPECIFICATION TABLES SPECIFICATIONS
II – 7 REV. 1
SPECIFICATIONS MASS TABLES
MASS TABLES
UNIT WEIGHT (DRY MASS)
Unit: kg
Serial Number 21300004~21301932 21301933~
Engine 250 255
Radiator 14.5 7
Oil Cooler 20 5.5
HST Pump 69 ←
Gear Pump 8 ←
Hydraulic Tank Assembly 39 ←
Fuel Tank Assembly 9 10
Control Valve 12 ←
Control Valve (Sub) 13 ←
Pilot Valve: R. H. 5 ←
: L. H. 4.8 ←
Self-Level Valve 5 5.9
Canopy/Cab 140/240 ←
Lift Arm 250 ←
Quick Attachment 80 (61∗) ←
Bucket 181 ←
Arm Cylinder 27 × 2 ←
Bucket Cylinder 20 × 2 ←
Crawler Belt 157 × 2 ←
Travel Motor 71 (65∗∗) × 2 ←
Sprocket 23 × 2 ←
Track Roller A 19 × 8 ←
Track Roller B 35 × 2 ←
Idler 35 × 2 ←
Track Adjuster 25 × 2 ←
∗: 21300004~21300570
∗∗: 21300004~21300311
REV. 1 II – 8
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
Use a clean, Quality fuel for performance and optimum engine life.
• To prevent fuel flow problems in cold weather, use diesel fuel with
Fuel tank Diesel fuel a pour point of at least -12°C (10°F) below the lowest expected
Tank level: 75 L
ambient temperature.
• Minimum cetane number is 45. Low temperature or high altitude
operation may require the use of fuel with a higher cetane number.
Mobil gear
Track Roller B 140 mL
SHC 680
* If the percentage of the traveling time within the total operating time is high, replace the gear oil earlier than
the specified time.
** 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.
*
) 6&*
II – 9
SPECIFICATIONS SERVICE STANDARDS
SERVICE STANDARDS
TRAVEL SYSTEM
Track Roller A
Unit: mm
Servicing
Code Item Designated Standard Procedure
Basic Dimension Allowable Value
A Tread Outer Diameter
200 194 Replace
B Width of Tread 48 45
II – 10
SERVICE STANDARDS SPECIFICATIONS
Track Roller B
A D C
T7B003
Unit: mm
Servicing
Code Item Designated Standard Procedure
Basic Dimension Allowable Value
A Tread Outer Diameter
328 320 Replace
B Width of Tread 52 48
II – 11
SPECIFICATIONS SERVICE STANDARDS
Drive Sprocket
Unit: mm
Code Item Designated Standard Servicing Procedure
II – 12
SERVICE STANDARDS SPECIFICATIONS
Idler
Unit: mm
Servicing
Code Item Designated Standard Procedure
Basic Dimension Allowable Value
A Outer Diameter Tread
400 394 Replace
B Width of Tread 32 26
II – 13
SPECIFICATIONS SERVICE STANDARDS
Track Adjuster
A B
T7B006
II – 14
SERVICING STANDARDS SPECIFICATIONS
Pin and Bushing Clearance
Unit: mm
Servicing
Code Item Designated Standard Procedure
Basic Allowable Tolerance Standard Allowable
Dimensions Shaft Hole Clearance Clearance
-0.02 +0.15
A Lift Arm & Frame 40 -0.05 +0.10 0.12~0.20 1.0
-0.02 +0.15
B Arm Cylinder & Frame 40 -0.05 +0.05 0.07~0.20 1.0
-0.02 +0.15 Replace
C Arm Cylinder & Lift Arm 40 -0.05 +0.05 0.07~0.20 1.0
-0.02 +0.15
D Bucket Cylinder & Lift Arm 35 -0.05 +0.05 0.07~0.20 1.0
II – 15
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
REV. 1 II – 16
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS
Measuring Method
• Engine : Rated R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Insert the pressure gauge into the pressure detec-
tion port and fit pipe (1) over the travel motor
sprocket to disable the motor. Next start up the
hydraulic circuit to be tested and measure the
relief pressure.
T7B007
Measuring Method P4
• Engine : Rated R.P.M.
• Hydraulic Oil Temp. : 50~60°C R3
• Mount the pressure gauge on the pressure detec-
tion port, operate the desired hydraulic circuit
and measure the relief pressure.
II – 17
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
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-
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.
6&*'
Measuring Method P4
• Engine : Rated R.P.M.
• Hydraulic Oil Temp : 50~60˚C R3
• Mount the pressure gauge on the pressure detec-
tion port, operate the desired hydraulic circuit
and measure the pilot pressure.
II – 18
STANDARDS FOR JUDGING PERFORMANCE SPECIFICATIONS
Travel Speed (5 Revolutions)
• Engine : Rated R.P.M.
• Hydraulic Oil Temp. : 50~60°C
• Measurement Posture : Place blocks (1) under
the rear of the body of the vehicle and use the lift
arm and bucket to raise the vehicle up from the
ground. Be sure that you always perform this
operation in a stable, level location.
• Begin rotating the treads of both right and left
side and count from the second rotation to mea-
sure the time required until the treads rotate a
total of five revolutions. (This test should be
performed at the same speed in which the ma-
chine was last operated.)
■ Travel Posture
The arm and bucket cylinders should be re-
tracted as far as possible.
Travel Curve
• Engine : 1500 ±100 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 – 19
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
II – 20
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).
Crawler Tension
• In a stable, level location, lower the lift arm, tilt
the bucket forward, and lift the front of the
crawler slightly off the ground. Measure the
distance between the ground, the center track
rollers, and the crawler track rollers.
II – 21
SPECIFICATIONS STANDARDS FOR JUDGING PERFORMANCE
II – 22
III . MACHINE CONFIGURATION
III – 1
MACHINE CONFIGURATION
CONTENTS
REV. 1 III – 2
DRIVE SYSTEM MACHINE CONFIGURATION
DRIVE SYSTEM
CONSTRUCTION
Engine Mount
Serial No. 21300004~21301932
III – 3 REV. 1
MACHINE CONFIGURATION DRIVE SYSTEM
A: Wind the seal tape around the sensor thread and apply
the liquid packing (ThreeBond 1104) over the seal
tape.
4.9 N·m
III – 4 REV. 1
MACHINE CONFIGURATION DRIVE SYSTEM
A: Wind the seal tape around the sensor thread and apply
the liquid packing (ThreeBond 1104) over the seal
tape.
4.9 N·m
REV. 1 III-4-1
DRIVE SYSTEM MACHINE CONFIGURATION
Pump Coupling
*
.
:
: )
"
,
+ !
-
/
6&+
P1 Left Travel
P2 Right Travel
P3 Lift Arm, Bucket, Auxiliary
P4 Charge Pressure, Pilot Pressure
III – 5
MACHINE CONFIGURATION DRIVE SYSTEM
X 6
X
1
TO INJECTION
PUMP
T8C103E
1. Fuel Tank
2. Cap
3. Strainer
4. Drain Plug
5. Fuel Sender
6. Water Separator
7. Feed Pump
REV. 1 III – 6
DRIVE SYSTEM MACHINE CONFIGURATION
Serial No. 21301933~
1. Fuel Tank
2. Cap
3. Strainer
4. Drain Plug
5. Fuel Sender
6. Water Separator
7. Feed Pump
III-6-1 REV. 1
MACHINE CONFIGURATION DRIVE SYSTEM
Engine Control
Serial No. 21300004~21300774
"
$
!
6&+"
A: Apply molybdenum disulfide grease.
1. Lever
2. Bracket
3. Accelerator Wire
4. Plate
5. Wire Stopper
6. Wire Stopper
7. Conical Washer
REV. 1 III – 7
DRIVE SYSTEM MACHINE CONFIGURATION
Serial No. 21300775~21301932
1. Lever
2. Bracket
3. Accelerator Wire
4. Plate
5. Wire Stopper
6. Wire Stopper
7. Conical Washer
III-7-1 REV. 1
MACHINE CONFIGURATION DRIVE SYSTEM
1. Lever
2. Bracket
3. Accelerator Wire
4. Plate
5. Wire Stopper
6. Wire Stopper
7. Conical Washer
REV. 1 III-7-2
DRIVE SYSTEM MACHINE CONFIGURATION
DISASSEMBLY AND ASSEMBLY
11. Disconnect the battery cable (7) and all the con-
nections on the engine side of the electric wirings
(8).
• Attach identification labels to individual wir-
&
ings.
• Disconnect the wirings from the clamp and the %
band.
14. Remove the bolts (12) and then the cushion rub-
bers.
Bolt: 256N·m; Apply thread-locking com-
pound.
III – 8 REV. 1
MACHINE CONFIGURATION DRIVE SYSTEM
4
7
5
6
T8C108
RIGHT ANGLE
III – 9
DRIVE SYSTEM MACHINE CONFIGURATION
Removing the Hydraulic Pump
1. Drain out the oil from the hydraulic tank.
“Removing the Hydraulic Tank” 5 7
2
2. Disconnect the drain hoses (1) and HST hoses (2).
1
5
Installing the Hydraulic Pump
Follow the same procedure as for removal in the
reverse order.
7
T8C110
WARNING
When refitting the HST pump after repair or
replacement, be sure to purge air before starting 1
the operation. Failure to do so can cause injury or
death due to unexpected machine movement.
M5 M15
1. Before installing the HST pump on the machine,
fill the servo control chambers with hydraulic oil. X2 X12
a. Plug the pilot ports (X1), (X2), (X11) and
(X12) temporarily. X1 X11
b. Supply hydraulic oil through the servo pres-
sure gauge ports (M4), (M5), (M14) and (M15) T6C101
to fill the servo control chambers.
III – 10
MACHINE CONFIGURATION DRIVE SYSTEM
X1 X11
4. Remove the plugs in the pilot ports (X1) and
(X11) and immediately connect the respective T6C102
III – 11
DRIVE SYSTEM MACHINE CONFIGURATION
Removing the Fuel Tank
1. Remove the floor frame.
“Removing the Floor Frame”
6&+
%
%
"
#
#
%
6&+
III – 12
MACHINE CONFIGURATION DRIVE SYSTEM
3. Secure the wire (2) with the wire lock pin (6).
Control Force
1. Loosen the lock nut (9), and turn the nut (1) to
adjust the control force.
Control force: 44.1 N
REV. 1 III-12-1
TRAVEL SYSTEM MACHINE CONFIGURATION
TRAVEL SYSTEM
CONSTRUCTION
Track Roller A
1. Roller
2. Shaft
3. Cover
4. Floating Seal
5. Snap Ring
6. O-ring
7. Oil Filler Plug
Track Roller B
1. Roller
5 1 2. Shaft
7
3. Cover A
4. Cover B
B 5. Bearing
A
6. Floating Seal
7. Oil Filler Plug
C 2
3 4
T7C300
A: 156 N·m; Apply thread-locking compound.
B: 55 N·m; Apply thread-locking compound.
C: 20 N·m
III – 13
MACHINE CONFIGURATION TRAVEL SYSTEM
Idler
1. Idler
2. Shaft
3. Cover A
4. Cover B
5. Bearing
6. Floating Seal
7. Oil Filler Plug
T8C300
A: 102 N·m
Track Adjuster
# ) 1. Yoke
$ 2. Reach Rod
3. Spring
4. Piston
" 5. Cylinder
6. Grease Valve
6&+!
A: 59 N·m
III – 14
TRAVEL SYSTEM MACHINE CONFIGURATION
Travel Motor
1. Travel Motor
2. Sprocket
3. Ring
III – 15 REV. 1
MACHINE CONFIGURATION TRAVEL SYSTEM
III – 16
TRAVEL SYSTEM MACHINE CONFIGURATION
Removing the Track Roller
1. Loosen the crawler tension.
TRACK ROLLER A
1
Installing the Track Roller
1. Tighten the roller (2) installation bolts (1) tempo-
rarily. 2
T7C304E
T7C305E
III – 17
MACHINE CONFIGURATION TRAVEL SYSTEM
pound.
REV. 1 III – 18
FRAME MACHINE CONFIGURATION
FRAME
CONSTRUCTION
Frame
1. Frame
2. Under Cover A
3. Under Cover B
4. Cover L
5. Cover R
6. Under Cover C
7. Cover
8. Cover
III – 19 REV. 1
MACHINE CONFIGURATION FRAME
Floor Frame
Serial No. 21300004~21300774
1. Floor Plate
2. Floor Mat
3. Cover R
4. Cover L
5. Foot Rest
6. Cover C
7. Floor Stay
8. Cover
9. Floor Stay
10. Harness Cover
REV. 1 III – 20
FRAME MACHINE CONFIGURATION
Serial No. 21300775~
1. Floor Plate
2. Floor Mat
3. Cover R
4. Cover L
5. Foot Rest
6. Cover C
7. Floor Stay
8. Cover
9. Floor Stay
10. Harness Cover
III-20-1 REV. 1
MACHINE CONFIGURATION FRAME
Safety Bar
1. Safety Bar
2. Bracket L
3. Bracket R
4. Stopper
5. Proximity Switch
6. Cover L
7. Cover R
8. Gas Spring
REV. 1 III – 21
FRAME MACHINE CONFIGURATION
Cover
III – 22 REV. 1
MACHINE CONFIGURATION FRAME
Canopy
Serial No. 21300004~2131098
1. Canopy 8. Collar
2. Glass [rear] 9. Washer
3. Glass [roof] 10. Plate
4. Plate 11. Washer
5. Bolt Assembly 12. Cushion Rubber
6. Cushion Rubber 13. Gas Spring
7. Pin Assembly 14. Light
REV. 1 III – 23
FRAME MACHINE CONFIGURATION
Serial No. 21301099~
1. Canopy 6. Washer
2. Bolt Assembly 7. Cushion Rubber
3. Cushion Rubber 8. Washer
4. Pin Assembly 9. Gas Spring
5. Collar 10. Cushion Rubber
III-23-1 REV. 1
MACHINE CONFIGURATION FRAME
Cab
1. Cab 6. Washer
2. Bolt Assembly 7. Cushion Rubber
3. Cushion Rubber 8. Washer
4. Pin Assembly 9. Gas Spring
5. Collar 10. Cushion Rubber
REV. 1 III-23-2
FRAME MACHINE CONFIGURATION
Titing Up the Canopy
For inspection and maintenance, the platform is de-
signed so that it can be tilted up.
WARNING
• Raising or lowering the canopy while the en-
gine is running may cause the machine to
move, and cause serious injury or death. Stop B A
the engine before raising or lowering the
canopy.
• When the canopy is tilted up, support it firmly
with the stopper to prevent it from falling.
Lowering
1. Remove the sopper pin (B).
T9C408
III – 24 REV. 1
MACHINE CONFIGURATION FRAME
III – 25
FRAME MACHINE CONFIGURATION
Removing the Covers
1. Disconnect the negative battery cable from the
battery. 1
4
2. Tilt up the canopy.
“Tilting up the Canopy” 2
3
3. Open the engine hood (1), lifting it up with cables.
Remove the gas spring (2), plate (3) and hinges
(4) to remove the engine hood (1).
III – 26 REV. 1
MACHINE CONFIGURATION FRAME
T7C412
REV. 1 III – 27
FRAME MACHINE CONFIGURATION
Lift Arm Stop
Serial No. 21300004~21300510
WARNING
• If you must work beneath the raised lift arms,
securely engage the lift arm stop.
Never get under the lift arms and bucket if it is
not sufficiently supported.
• Service the lift arm stop if damaged or if parts
are missing. Using a damaged lift arm stop or
with missing parts can cause the lift arms to
drop causing injury or death.
Engagement 2
1. Before raising the lift arm, pull out the inside R-
pin of locking pin (1).
4. Start the engine and slowly raise the lift arm until
it is fully raised.
5. Lower the lift arm a little and fix the lift arm stop
(2) to the cylinder tube. 2
1
6. Check that the lift arm is securely locked.
7. Insert the locking pin (1) to the lift arm stop (2),
and insert the R-pin to the locking pin (1).
T7B026A
Releasing
1. Pull out the R-pin of the locking pin (1), and pull
out the locking pin (1) from lift arm stop (2).
5. Return the lift arm stop (2) to the original position T7B025A
III – 28 REV. 1
MACHINE CONFIGURATION FRAME
4. Support the lift arm stop (2) by hand and pull out
the locking pin (1).
7. Raise the lift arms slowly until the lift arm stop (2)
drops onto the cylinder rod. 2
8. Lower the lift arms slowly until the lift arm stop T9C410
T9C411
REV. 1 III-28-1
FRAME MACHINE CONFIGURATION
Disengagement
1. Remove the rear R-pin (4) from the locking pin
(1).
2. Pull out the locking pin (1) from the lift arm stop 2 1
(2).
3. Hook the end part of the spring (3) onto the hook
(5) of the lift arm stop (2).
5
4. Sit in the seat, fasten the seat belt, start the engine
and lower the safety bar. 3 4
5. Raise the lift arms slowly until the spring (3) will T9C412
lift the lift arm stop (2) off the cylinder rod.
T9C413
III-28-2 REV. 1
MACHINE CONFIGURATION CONTROL SYSTEM
CONTROL SYSTEM
CONSTRUCTION
REV. 1 III – 29
CONTROL SYSTEM MACHINE CONFIGURATION
Hydraulic Pilot Unit (2/2)
III – 30 REV. 1
MACHINE CONFIGURATION CONTROL SYSTEM
III – 31
CONTROL SYSTEM MACHINE CONFIGURATION
III – 32
MACHINE CONFIGURATION ATTACHMENTS
ATTACHMENTS
CONSTRUCTION
"
6&+$
1. Bucket
2. Quick Attachment
3. Lift Arm
4. Bucket Cylinder
5. Arm Cylinder
III – 33
ATTACHMENTS MACHINE CONFIGURATION
Piping
Srial No. 21300004~21301932
1. Bracket
2. Bracket
3. Bracket
4. Bracket
5. Pipe [Bucket]
6. Pipe [Bucket]
7. Pipe [Auxiliary]
8. Pipe [Auxiliary]
9. Control Valve
10. Self-Level Valve
11. Solenoid Valve
12. Stop Valve
13. Hydraulic Tank
III – 34 REV. 1
MACHINE CONFIGURATION ATTACHMENTS
1. Bracket
2. Bracket
3. Bracket
4. Bracket
5. Pipe [Bucket]
6. Pipe [Bucket]
7. Pipe [Auxiliary]
8. Pipe [Auxiliary]
9. Control Valve
10. Self-Level Valve
11. Solenoid Valve
12. Stop Valve
13. Hydraulic Tank
REV. 1 III-34-1
ATTACHMENTS MACHINE CONFIGURATION
Serial No. 21302047~
1/2
2/2
III-34-2 REV. 1
MACHINE CONFIGURATION ATTACHMENTS
General Cautions
• Always be sure to work on a stable, level surface. • When all the hydraulic equipment such as hydrau-
• When disconnecting hydraulic hoses, be sure to lic cylinders and piping have been removed and the
bleed off any residual pressure in the hoses. hydraulic cylinders are being operated for the first
• Plug openings which are opened up when piping is time after reassembly, be sure the bleed the air out
disconnected to prevent dust and mud, etc. from of the hydraulic circuits by the following proce-
getting in. dure.
• During assembly, be sure to adjust all the parts with Air Bleeding Operation
shims so that there will be no looseness in the 1. Start the engine and let it idle for about 5 minutes.
mounts. 2. With the engine running at slow speed, extend
• When aligning pin hole positions, absolutely do and retract the cylinders 4 or 5 times.
not insert a finger in any pin holes. • Move the piston rods to a position 100 mm
• When fastening the lock bolt with double nuts, before the end of the stroke, taking care not to
maintain a clearance between the nuts and the allow any relief whatsoever.
bushing of 0.5~1.0mm when tightening the double 3. Perform the operation in (2) with the engine at top
nuts. speed, then with the engine at slow speed, move
the piston rods to the stroke end, allowing relief.
0.5~1.0mm C4C601
5
T7C605
REV. 1 III – 35
ATTACHMENTS MACHINE CONFIGURATION
Removing the Lift Arm 2 1
1. Remove hydraulic hoses (1) from pipes [bucket]
(2).
III – 36 REV. 1
MACHINE CONFIGURATION ATTACHMENTS
DANGER WARNING
When the lift arm is raised, never position your- • Park the machine on a flat and solid ground for
self under it without making sure that the lift arm work.
is securely supported by the lift arm stopper. • Be sure to be seated on the cab when operat-
ing the machine, including the starting and
For the adjustment, the pin hole (1) of the lift arm must stopping the engine.
be supported by the arm stopper (2) at the height of • Set the engine speed to low when operating
approximately 1600 mm above the ground. The fol- the control lever.
lowing arm stopper (2) and lock pin (3) must be
prepared for safety operation.
3. Hook the arm stopper (2) on the steel bar (4) of the
lift arm, and place it on the cylinder.
4. Start the engine, and raise the lift arm until the arm
stopper (2) falls on the cylinder rod.
REV. 1 III-36-1
ATTACHMENTS MACHINE CONFIGURATION
5. Lower the lift arm until the arm stopper (2) hits
against the edge of the cylinder tube and becomes
fixed, and stop the engine.
6. Insert the lock pin (3) in the front hole of the arm
stopper (2) and pass it through under the cylinder
rod to the back hole.
III-36-2 REV. 1
MACHINE CONFIGURATION ATTACHMENTS
REV. 1 III-36-3
ATTACHMENTS MACHINE CONFIGURATION
Adjusting the Arm Stopper
DANGER WARNING
When the lift arm is raised, never position your- • Park the machine on a flat and solid ground for
self under it without making sure that the lift arm work.
is securely supported by the lift arm stopper. • Be sure to be seated on the cab when operat-
ing the machine, including the starting and
stopping the engine.
• Set the engine speed to low when operating
the control lever.
1. Raise the lift arm, and securely lock it with the lift
arm stopper (2).
“III-28~28-2”
III-36-4 REV. 1
MACHINE CONFIGURATION ATTACHMENTS
REV. 1 III-36-5
HYDRAULIC SYSTEM MACHINE CONFIGURATION
HYDRAULIC SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
Standard
Serial No. 21300004~21301932
III – 37 REV. 1
MACHINE CONFIGURATION HYDRAULIC SYSTEM
REV. 1 III – 38
HYDRAULIC SYSTEM MACHINE CONFIGURATION
CONSTRUCTION
Hydraulic Tank
A: 47.1 N·m
B: Apply thread-locking compound.
1. Hydraulic Tank
2. Suction Pipe
3. Bracket
4. Bracket
5. Suction Strainer
6. Air Breather
7. Sight Gauge
8. Flange
9. Plug
10. Plug
III – 39 REV. 1
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.
III – 40
HYDRAULIC SYSTEM MACHINE CONFIGURATION
DISASSEMBLY AND ASSEMBLY
• 6 hoses.
III – 41 REV. 1
MACHINE CONFIGURATION HYDRAULIC SYSTEM
Hydraulic pump
1. Tilt up the canopy.
Cylinders
1. Start the engine and run it at low idle for 10
minutes.
III – 42
ELECTRICAL SYSTEM MACHINE CONFIGURATION
ELECTRICAL SYSTEM
ELECTRICAL WIRING DIAGRAM
T8C800
III – 43 REV. 1
MACHINE CONFIGURATION ELECTRICAL SYSTEM
REV. 1 III – 44
ELECTRICAL SYSTEM MACHINE CONFIGURATION
Serial No. 21300004~21300083
III – 45 REV. 1
MACHINE CONFIGURATION ELECTRICAL SYSTEM
REV. 1 III-45-1
ELECTRICAL SYSTEM MACHINE CONFIGURATION
Serial No. 21300451~21301932
III-45-2 REV. 1
MACHINE CONFIGURATION ELECTRICAL SYSTEM
REV. 1 III-45-3
ELECTRICAL SYSTEM MACHINE CONFIGURATION
Serial No. 21300004~21301932
1. Box
2. Resistor
3. Relay
4. Relay
5. Timer Unit
6. Detector
7. Relay
III – 46 REV. 1
MACHINE CONFIGURATION ELECTRICAL SYSTEM
1. Box
2. Resistor
3. Relay
4. Relay
5. Timer Unit
6. Relay
7. Detector
8. Timer Unit
REV. 1 III-46-1
AIR CONDITIONER SYSTEM MACHINE CONFIGURATION
AIR CONDITIONER SYSTEM
Compressor Assembly (1/4)
III – 47 REV. 1
MACHINE CONFIGURATION AIR CONDITIONER SYSTEM
1. Hose
2. Hose
3. Hose
4. Hose
5. Bracket
6. Receiver-Dryer
7. Pressure Switch
8. Condenser
9. Wire Harness
REV. 1 III – 48
AIR CONDITIONER SYSTEM MACHINE CONFIGURATION
Compressor Assembly (3/4)
A: 1.8 N·m
B: Apply thread-locking compound.
1. Cover 9. Panel
2. Cover 10. Control Cable
3. Cover 11. Tube
4. Bracket 12. Box
5. Bracket 13. Hose
6. Bracket 14. Louver
7. Adapter 15. Adapter
8. Air Conditioner Unit 16. Cushion Rubber
III – 49 REV. 1
MACHINE CONFIGURATION AIR CONDITIONER SYSTEM
1. Condenser Assembly
2. Condenser
3. Motor
4. Guard
5. Air Conditioner Unit
6. Core
7. Core
8. Filter
9. Louver
10. Motor
11. Thermostat
12. Valve
13. Box
14. Filter
REV. 1 III – 50
Overview of System Operation
• Truck and Heavy Equipment Systems
Click on any of these
subject headings to go • Air Conditioner-System Operation
directly to the page • Heater System Operation
• Environmental Effects on System Operation
• Chapter Review
III-51 REV. 1
System Operation
Figure 2-1
These illustrations show a
basic heater, HVAC system,
the combo system with
sleeper unit, add on AC roof
top and in cab units, roof
mounted condenser and
auxiliary units.
By law, all trucks have a heater/defroster as part of the standard equipment. When there
is a reason to add air conditioning, there are options to meet different needs. The available
space in the cab, operating environment, and owner preference can all play a part in the
type of AC unit selected. You will probably encounter roof-mounted and in-cab add on
systems, and even systems where the condenser is mounted on the roof and the
evaporator is attached to the back panel or mounted under the dash. In cooler climates
you may come across a cab with two heaters, the original and an auxiliary unit.
REV. 1 III-52
Air Conditioner—System Operation
Figure 2-2
Air Conditioner components
are connected together to
illustrate system operation.
The components shown are
not to scale. The refrigerant
and refrigerant oil are clear
in color and not visible in
this drawing. The small
arrows inside the compo-
nents and connecting hoses
show the direction of
refrigerant flow (refrigerant
circuit).
1. Compressor/Clutch Assembly
The compressor/clutch assembly is the heart of the system. When the clutch is
engaged, the compressor pumps refrigerant and oil around the system. It raises the
temperature and pressure of the refrigerant gas, and forces it to the condenser where
it changes state and becomes a liquid. The compressor also sucks the vaporized
refrigerant out of the evaporator and back inside itself in the form of gas. One way
valves inside the compressor separate the compressed gas (high pressure) side of the
system from the suction (low pressure) side. Figure 2-3 shows a cutaway view of a
compressor with the high and low pressure sides noted.
III-53 REV. 1
System Operation
Figure 2-3
The compressor inlet is low
pressure and the outlet is
high pressure. The reed
valves are one way. They
open to allow refrigerant gas
to enter the compressor on
the down stroke and exit on
the upstroke. Note the open
valves in the illustrations.
The clutch is mounted on the shaft of the compressor and is engaged by electromagnetic
action. Part of the clutch assembly is an electromagnetic wire coil. The coil is energized
through a thermostat that senses the temperature in the evaporator coil. If the evaporator
is too warm the electrical contacts close and allows power to flow to the clutch. The
compressor shaft is engaged and moves the refrigerant around inside the system. Figure
2-4 is a cutaway view of the clutch mounted on the compressor.
Figure 2-4
The clutch shown here has
its electromagnetic coil
mounted on the compressor
body. When the coil is
energized, magnetic force
pulls the clutch drive plate
into the pulley. This action
locks the pulley to the
compressor drive shaft and
drives the compressor.
2. Condenser
The refrigerant gas leaves the compressor and moves through a high pressure hose to the
condenser. Inside the condenser the gas “changes state” and becomes a liquid. It is still
hot and under pressure. Remember in Chapter 1 when we talked about water at 212
degrees Fahrenheit? Heat energy was involved in the “change of state,” but the
temperature did not change. The same kind of action happens inside the AC system. The
refrigerant gas gives up a lot of heat energy to the outside air as it “changes state” in the
condenser. Figure 2-5 illustrates a condenser. Air moving through the condenser absorbs
heat from the refrigerant. The amount of air flow through the condenser is the major
factor in how well the condenser functions.
REV. 1 III-54
Air Conditioner—System Operation
Figure 2-5
As the refrigerant gas moves
through the tubing coil from
top to bottom, it condenses
(changes state) into a liquid.
For ease of installation,
condenser fittings are often
routed close together.
3. Receiver-Drier
The liquid refrigerant continues to move inside the system, out of the condenser through
a tube or hose to the receiver-drier. The receiver-drier serves as a small storage tank and
filter for the refrigerant. It is also a good location to mount pressure switches and often
contains a sight glass (small window) used to view activity inside the system. The
receiver-drier, Figure 2-6, also separates gas (bubbles) from the liquid with a pick-up
tube as shown in this illustration. Some receiver-driers have a spring to preload the
desiccant pack.
Figure 2-6
This cutaway view of a
receiver-drier shows the
filter elements, inlet, outlet
and refrigerant path. The
sight glass is a small
window into the system used
in diagnosis and when
adding refrigerant (charging
the system).
III-55 REV. 1
System Operation
Figure 2-7
This block type expansion
valve cutaway view will
give you a better idea how
these valves work. Spring
pressure holds the valve
closed.
5. Evaporator Coil
The expansion valve or other type of metering device bleeds high pressure refrigerant
into the evaporator coil, where the pressure is low. The refrigerant expands rapidly in this
low pressure environment. When it expands it “changes state”. The sudden drop in
pressure brings the refrigerant temperature down quickly inside the evaporator coil.
Figure 2-8 shows an evaporator coil and thermostat. Refrigerant is sprayed into the
evaporator by the high side pressure when the expansion valve opens. The refrigerant
absorbs heat from the air when the blower forces the air through the fins. When the
thermostat probe senses the upper limit of the thermostat heat setting, a circuit closes.
The compressor clutch engages and the compressor operates and moves more refrigerant
to the high side of the system.
REV. 1 III-56
Air Conditioner—System Operation
Figure 2-8
The evaporator coil as
shown is of fin and tube
construction. The thermostat
probe is positioned in
between the evaporator fins
and senses the temperature.
III-57 REV. 1
System Operation
Figure 2-9
This view of a heater system
shows the main components
and how they are connected.
Additional heater controls, ducts, air vents, blend-air doors, temperature regulating
devices and auxiliary heaters may be installed as part of a heater system. These may
be air, vacuum, electrical or mechanically operated.
REV. 1 III-58
Environmental Effects
1. Heater Core
Heater cores are like small radiators. The fin and tube construction is designed
to route coolant flow for the best possible heat energy transfer from coolant to
cab air. Hoses from and to the engine are connected to the core with clamps. The
core outlet may be larger or the same size as the inlet.
2. Water Valves
Water valves may be cable, vacuum or air controlled. The valve can be either
open, closed or set part way open. Some valves have a bypass design to return
coolant to the engine. Most are manually controlled although electronic
systems are now being installed.
III-59 REV. 1
System Operation
• On a cold day the temperature can drop below zero. The engine may
run cooler so the engine coolant is cooler when it circulates through
the heater. The heat in the cab moves out of the cab faster (remember
heat always moves to a cooler area until both are the same tempera-
ture—nature’s law). To maintain cab comfort you have to increase the
flow of coolant through the heater, increase coolant temperature, and/
or move more air through the heater core.
• On a hot day, an off-road vehicle experiences cooling at a slower rate
than an on-road vehicle. This is a result of high sun-load, large window
area and often less insulation.
It is important for you to keep environmental effects in mind when you are servicing
or diagnosing heater or air conditioner systems. If you work in Denver the altitude will
affect system function and pressure. In Houston the heat and humidity may lower heat
transfer to the air at the condenser and increase system operating pressures.
Chapter Review
• HVAC systems range from simple cab heaters to multi-function
combination systems. The multi-function system can heat and cool
the cab and sleeper unit, and have separate auxiliary components and
controls for driver and passenger comfort.
• Both heater (engine) coolant and air conditioner refrigerant circulate
inside sealed, pressurized systems. The normal air conditioner oper-
ating pressure ranges from 150 to 250 pounds per square inch,
sometimes higher with a different refrigerant.
• Air conditioners have a high and a low pressure side within the system.
The compressor is the starting point of the high side. Pressure drops
at the expansion valve opening to the evaporator.
• The basic components of an AC system are the compressorclutch
assembly, high pressure lines, condenser, receiver-drier, expansion
valve, evaporator, thermostat, blower assembly, and suction lines.
There may be other controls installed for more complex systems.
• The basic components of a heater system are the inlet and outlet hoses,
a water valve and valve control, heater core and fan or blower
assembly. There may be other controls for more complex systems.
• An air conditioner system uses the “change of state” of refrigerant
inside the system to move heat from the cab air to the outside air.
Refrigerant changes from a gas to a liquid in the condenser, and back
to a gas in the evaporator.
• A heater system uses the heat from the engine, carried to the heater
core by the action of the water pump, to warm the air in the cab. There
is no change of state within the heater system.
• Environmental conditions affect how both heaters and air condition-
ers work. Weather, driving conditions, color of the vehicle are factors.
All contribute to heat gain or loss inside a cab and how much heat
energy must be moved to maintain occupant comfort.
REV. 1 III-60
Inspection and Maintenance-
without gauges
Click on any of these • Discussion of Inspection & Maintenance Survey Results
subject headings to go
directly to the page • Visual Inspection - System Off
• Electrical System Inspection
• Performance Inspection - Engine Running
• Heater System Inspection
• Preventive Maintenance Worksheet
• Chapter Review
About half of all heavy duty vehicles have air conditioners. Surveys of AC system
owners find that over 30% of the systems are serviced every six months or less, and
another 62% are serviced at least once a year.
The survey also covered how often the different components required mainte-
nance. Figure 7.1 below shows survey finding percentages. Failure of any of the AC
components listed in the survey could cause a system to malfunction or stop cooling.
Note: The above survey results may not apply to your situation. Actual
operating conditions for the vehicles you service will determine
or influence maintenance frequency and requirements.
The following inspection procedures should take about 15 to 20 minutes, longer
if corrective steps, part replacement or adding refrigerant is necessary. There is a
“Preventive Maintenance Worksheet” you may use at the end of this chapter,
Figure 7-9
III-61 REV. 1
Inspection & Maintenance
Use the following procedures as a general rule in performing a visual inspection with
the AC system off:
CAUTION Even when someone has told you what is wrong with an
HVAC system, you should perform a visual inspection.
Always make a visual inspection before you hook up the
manifold gauge set. Never add refrigerant to a system until
you have made a complete visual and performance inspec-
tion.
2. Inspect Parts
Look at the system for what might come loose, leak, wear out or become dirty
and not function the way it should. The main points for visual inspection of the
system are emphasized in Figure 7-2.
REV. 1 III-62
Visual Inspection
Figure 7-2
This system illustration
notes the main points for
visual inspection.
Figure 7-3
Engine and compressor
vibration can work mounting
bolts loose. Tighten all
mounting bolts as you
inspect the system. Slots in
the mounting bracket are
used to move the compres-
sor clutch assembly in order
to adjust belt tension or
alignment.
III-63 REV. 1
Inspection & Maintenance
C. Drive Belt – The drive belt should be tight and in good condition. Use a belt
tension gauge to check tension (120 pounds maximum). With experience, you
can feel belt tension by twisting the belt. Try feeling belt tension after using the
gauge, when you know the tension is correct. Replace belts if they are frayed
or look worn.
If the clutch pulley/belt alignment is obviously off, you need to loosen the
compressor or mounting bracket, or both—and use the alignment bar to line up
the clutch pulley with the drive pulley. Tighten compressor mounting bolts
first, then the bolts holding the bracket. The mounting bracket should have slots
or other means of adjustment to allow you to adjust the tension of the drive belt.
When you use a pry bar to apply tension, be sure you do not pry against the
compressor. Pry against the mounting bracket.
Note: You can add inexpensive dry nitrogen gas to the system instead of R-
12 if system pressures are low. Dispense the gas at no more than 200-
250 PSI as this is sufficient pressure to cause or indicate a leak point
in the AC system. AC service procedures for complete system
recovering of refrigerant, evacuating, and recharging are covered
and illustrated in Chapter 9.
Note: A leaking heater core could also result in coolant at the condensate
drain.
REV. 1 III-64
Electrical System Inspection
You can feel for oil at the bottom of all connections (see Figure 7-4) if the
system is not too hot. Of course, a few minutes with an electronic leak detector
is the best way to check for leaks. Keep in mind that pressure is different in a
system at rest, so small leaks may be hard to find. Pressure in a system at rest,
will equalize at from 60 to 95 PSI, depending on outside air temperature. This
means there is more pressure in the low side of the system at rest than during
normal system operation. Just the opposite is true of the high side; at rest, high
side pressure is lower. You may want to use the detector to check for leaks in
the high side when the air conditioner is operating, if you suspect a leak and
can’t find it when the system is at rest.
Figure 7-4
This illustration shows a
potential refrigerant leak
point at the condenser
fitting.
A. Turn the Ignition On – To check current flow the ignition must be on.
III-65 REV. 1
Inspection & Maintenance
B. Turn the AC System On – This will power the thermostat and clutch.
If it does not come on, use the AC mode switch to check the leads to the
switch. You should be able to hear a “click” from the thermostat and hear
the clutch drive plate “snap” against the clutch pulley. You can not check
thermostat cycling on and off until you do the performance inspection.
Figure 7-5 illustrates a typical AC electrical system and the places you
should inspect.
Figure 7-5
The electrical system
inspection points are noted
with check marks (✔) on
this wiring diagram
(electrical schematic).
C. Check Fuses – If there is a failure and you have made sure all
connections are clean and tight, you need to check fuses—in-cab as well
as in-line.
D. Check Clutch Engagement – Since you can’t see and may not hear the
clutch engage, get out and look at the clutch. If it’s engaged, you will see
that the drive plate is against the pulley and not slightly spaced from it. If
you are not sure the clutch is engaged, look for the lead wire connector near
the clutch. Break and close that connection. The clutch will disengage and
engage again.
REV. 1 III-66
Electrical System Inspection
III-67 REV. 1
Inspection & Maintenance
These readings at the vents will be higher and temperature swing slower
and not as obvious. Also blower speed will cause the temperature, levels
to read higher (high air speed) or lower (low air speed) at the same
thermostat setting. When you measure air temperature, an electronic
thermometer/pyrometer is a great tool to have. You can easily measure
cab air temperature at several locations quickly.
Swing temperatures vary depending on where you measure tempera-
ture, and on outside temperature, humidity and altitude. The chart in
Figure 7-6, shows some examples of typical temperature variables. Don’t
forget that cab and sleeper area temperatures can vary within the same
vehicle. Also, electronic controls used in newer HVAC systems often
keep the temperature spread within a narrower range.
OUTLET AIR TEMP. 40° 41° 41° 43° 46° 47° 48° 50°
RANGE DEGREES F. to to to to to to to to
41° 44° 45° 47° 52° 54° 55° 56°
Note: If the condenser is hood mounted you may not have adequate air
flow through it.
B. Touch suction and discharge lines – Soon after system start up you
can safely feel the suction and discharge lines and note their change in
temperature. The discharge line will get hot (after a while it may be to hot
to touch) and the suction line will get cooler.
REV. 1 III-68
Performance Inspection
Figure 7-7
These drawings illustrate
conditions you may observe
in the sight glass window.
A. Cool engine – Start with the engine cool, set the temperature to cold
and leave the fan off. As the engine warms up, feel the heater return hose.
If the hose feels warm or hot, the heater control valve is leaking internally.
This type of leak can seriously reduce air conditioning performance.
III-69 REV. 1
Inspection & Maintenance
Figure 7-8
Heater/cooling system
potential problem areas and
checks are indicated in this
drawing.
REV. 1 III-70
Chapter Review
Chapter Review
The purpose of these brief inspection procedures is for vehicle system maintenance
and to determine if further, more detailed service is required. The uses of a manifold
gauge set, system troubleshooting, recovery, flushing, evacuating and charging are
explained in the next chapter.
High usage and operating condition variations are tough on air conditioning and
heater components. You should establish and follow regular inspection and mainte-
nance procedures to improve overall system function and component service life.
The typical inspection should not take more than 15 to 20 minutes unless
component replacement and/or complete system evacuation and recharging is
warranted. The survey results shown in Figure 7-1, indicate belts, compressor clutch
assembly, condenser and the refrigerant lines are the most frequent problem areas.
However, your own experience with service and maintenance may vary from survey
results.
Inspection should first be visual and by feel. Some of your electrical system
inspection will be done as you inspect other components (checking leads, connec-
tions and for loose wires). When you check the electrical circuit, begin with the
engine off but ignition on. A system performance inspection with the engine running
and system on really combines electrical and AC or heater system function.
III-71 REV. 1
REV. 1 III-72
Troubleshooting
& Service Procedures
Click on any of these • Troubleshooting Overview
subject headings to go
directly to the page • Understanding System Function
• A Troubleshooting Example
• Manifold Gauge Set Installation
• Troubleshooting by Manifold Gauge Set Readings
• Review of Frequent Problem Areas
• Conclusion
Can you fix an air conditioner or heater system without finding and correcting
the cause of the problem? You bet you can! It happens every day and it’s not good
for business. Here is an example. A truck pulls in off the road and the operator asks
to have his rig serviced in a hurry. He tells you the air conditioner isn’t cooling like
it should and dashes into the restaurant for lunch.
You tip the hood, and check the sight glass on top of the receiver-drier. You see
bubbles, not a lot but a fairly constant stream of them. It is obvious the system is low
on refrigerant so you hook up the manifold gauge set, purge the gauge set hoses of
air, and add refrigerant until the sight glass clears. Then you check evaporator
temperature and it’s OK. The air conditioner is repaired right? Wrong! What you
did is add refrigerant and the problem went away. You did not find and fix the cause
of the problem.
Component failure in an air conditioning system may be the result of a problem
elsewhere in the system. For example, a belt or clutch failure might be caused by a
dirty condenser restricting air flow and increasing head pressures. High head
pressures commonly create problems with other system components. Take time to
look beyond the obvious for a potential hidden problem.
Troubleshooting Overview
Troubleshooting includes collecting enough information to locate the cause of the
problem, then correcting the problem and its cause by replacement, adjustment, and/
or repairing. You begin by gathering information from the most to the least important
sources.
Starting with the most important:
1. Your personal knowledge and experience with AC systems.
2. The vehicle operator's knowledge and experience—question him or her.
3. The work order.
4. Good test equipment and the HVAC system
The routine you follow when troubleshooting should proceed from the most to least
productive way of locating the problem and fixing the cause.
III-73 REV. 1
Troubleshooting & Service Procedures
Experienced troubleshooters talk to the operator if they can, then personally verify
the symptoms of the problem whenever possible. They attempt quick fixes on the
basis of their knowledge of common system problems and causes when appropriate.
They know where components are located, and make repairs when they have a good
idea of what the problem is. They fix the cause or causes as well as the problem. They
are confident of their knowledge and ability.
Note: The best troubleshooters all know who to call when they get
stuck. They know someone who knows more than they do and
are not too proud to ask for help or suggestions when needed.
The key—understanding system function
Figure 8-1
An illustration of the typical
HVAC system. The numbers
follow the action when the
AC part of the system is
working properly (moving
heat out of the cab and into
the outside air).
REV. 1 III-74
Understanding System Function
When you turn on the air conditioner at the control panel (1), the thermostat (2), is
supposed to sense a warm temperature at the evaporator. A circuit in the thermostat
should close, allowing current to flow through the thermostat to the compressor
clutch field coil (3). When this happens, the clutch field coil becomes an electromag-
net and pulls the clutch drive plate (4) tight against the clutch pulley (5).
Note: The same AC switch (1) may also turn on the fan or blower
motor (2a) to circulate air in the cab. The air feels warm at first
but will cool quickly.
A belt connects the clutch pulley to a drive pulley (6) on the engine. The engine
provides the power to turn the clutch pulley and drive the compressor (7) when the
clutch is engaged. When operating, the compressor compresses and pushes refrig-
erant gas to the condenser (8), through the receiver-drier (9), and to the expansion
valve (10) orifice. When it does, it puts a lot of pressure on the gas. The compressor
raises the temperature and pressure of the refrigerant inside the high side of the
system.
At the same time, the compressor is also sucking in low pressure refrigerant gas
from the expansion valve orifice, evaporator and through the low side of the system.
The movement of the refrigerant inside the system transfers heat energy from the cab
to the outside air for occupant comfort.
The automatic functions of the thermostat (or the pressure valve on some
accumulators), and the expansion valve, help maintain pressures and temperatures
inside the system at safe and efficient operating levels. Pressure and temperature are
constantly changing due to compressor and expansion valve action, the amount of
heat energy being moved and the environment or weather conditions.
The engine cooling system fan and clutch (11), and the evaporator blower motor
(2a), move a sufficient amount of air through the condenser and evaporator. On the
road, vehicle speed provides most of the (ram) air required for the condenser to work
right. In a parked or slow moving vehicle the engine fan (or roof or remote mounted
condenser and fans) moves sufficient air through the condenser fins.
A Troubleshooting Example
Remember the story at the beginning of this chapter? The vehicle operator pulled in
off the road and asked you to repair the rig. He was in such a hurry he didn’t tell you
anything except that the air conditioner wasn’t cooling. Here is the best way to handle
that kind of situation.
III-75 REV. 1
Troubleshooting & Service Procedures
Use your knowledge and experience. Ask yourself what could have caused a lack of
cooling in that rig! Did the compressor drive belt break? Did a pressure switch or
relief valve cutout the compressor because of high or low system pressure? Does the
switch or valve in this type of system reset itself? Could there be a superheat switch
and thermal limiter with a melted fuse. Did someone else service the system recently
and put in too much refrigerant?
Could there be contaminants in the system blocking the expansion valve (expan-
sion tube)? If there is a leak, why and how did refrigerant get out of the system? You
know if refrigerant can get out, air and moisture may get inside as well, especially
if the leak is on the suction side of the system. Could there be a restriction to
refrigerant flow in one of the high pressure lines because of a kink? From your
knowledge and experience, you already know about these possibilities and others
when you talk to the operator (before he has the chance to leave).
The right kind of questions can speed up troubleshooting and your service work
by pinpointing the problem(s) that needs fixing. Your conversation with the operator
might be as follows:
• What steps did you take when you noticed the lack of cooling?
Answer: I put it on maximum cool.
• Do you still get air flow at the vents from the blower?
Answer: Yes.
• Has the heater been used recently and did it work OK?
Answer: Yes.
REV. 1 III-76
A Troubleshooting Example
• Have you had other service problems in the last few months?
Answer: No.
• Finally, ask the operator if he or she has a wiring diagram for the
system.
Now let’s look at the information you have gathered from the operator and what you
know from experience. He believes the problem is that the AC system quits cooling
after it has been on for a while! You know that the AC system has not been maintained
since the rig was purchased a year ago. Because of that, there could be several causes
for the problem (lack of cooling) and there may be other potential problems about
to develop.
It is possible that some refrigerant has leaked. Moisture and other contamination
may be inside the system. You have been told there are no heater problems, but that
doesn’t mean there are none that might affect AC system operation. The AC system
has quit cooling several times in the last few days. The problem may have become
more severe than when it quit cooling the first time.
If enough refrigerant or oil has leaked out, a low pressure cutout switch may have
cut the circuit to the clutch, protecting the compressor. Because the system has not
been maintained in a year, there may be other components that should be serviced.
You could fix the probable causes, and the system might work and then break down
again as the rig drives out of your place. From your knowledge and what the operator
has just told you, you know this may not be a quick fix problem.
It’s up to you to describe the service situation to the operator. Tell him you need
to do a complete system maintenance inspection to find and correct the problem or
other potential problems. He can give you the go ahead for full service and repair
now, wait till you have inspected the system to determine cause and cost, or delay
repair until he has some down time available.
Normally when the operator can tell you what the problem is, you would first
operate the system to verify the problem. In this situation your troubleshooting (your
own knowledge added to what the operator told you), indicates the next step. You
need to do a complete maintenance inspection instead! Proceed as described in
Chapter 7. Correct any obvious problems and check carefully for leaks. Leak testing
should be visual, by feel and with a leak detector. Next, do your performance test with
the engine running and the AC system on.
Note: Don’t forget to check the heater system too! If the water valve
is not closed, then hot engine coolant flowing through the heater
core would warm the air at the same time the evaporator was
trying to cool it. The result would be the appearance of an AC
problem.
III-77 REV. 1
Troubleshooting & Service Procedures
If your AC and heater visual, electrical and leak inspections don’t turn up any
problems, save time by hooking up the manifold gauge set before you make the
performance test. If you find a leak and can correct it easily by tightening a
connection, do so. But if too much refrigerant leaked out, you may have to add some
refrigerant to the system for an effective performance test. We will get into detail on
troubleshooting with gauges after we explain manifold gauge set installation and
adding refrigerant.
CAUTION Never hook up the gauge set when the engine and air
conditioner are running. Be sure all the valves on the mani-
fold are closed all the way (turn them clockwise). Check the
hose connections on the manifold for tightness.
Locate the low and high side system service fittings and remove their protective caps.
Position or hang the manifold gauge set in a convenient location. Figure 8-2
illustrates a good example of manifold gauge set hookup in one service situation.
Figure 8-2
A typical manifold gauge set
hookup is shown in this
illustration. The center hose
on the gauge set is con-
nected to the vacuum pump.
REV. 1 III-78
Manifold Gauge Set Installation
Figure 8-3
The purging setup for
manifold gauge set and
compressor service valves
are shown here.
Note: The manifold gauges read system pressure when the hand
valves are closed if the hose end valves, and the stem type
service valves (if included) are open.
When adding refrigerant to the system, connect the center hose from the
manifold gauge set to the refrigerant dispensing valve on the container. Figure
8-4 illustrates this connection.
III-79 REV. 1
Troubleshooting & Service Procedures
Figure 8-4
In this illustration we have
noted how refrigerant is
added to the air conditioner.
Before adding refrigerant to the system you should study the sight glass while
the engine is running and the air conditioner is on. Even if you found a leak
during the system inspection and corrected it, you have no way of knowing how
much refrigerant has leaked. You will not be able to tell how much refrigerant
is in there, but you can see if bubbles are present.
Then check the gauges for unusually high or low readings, or a lack of
pressure. Following this procedure, and using your knowledge and experience,
decide if it is safe and makes sense to add refrigerant in order to make your full
performance inspection.
You are now ready to add refrigerant to the system. For your safety and to
prevent system damage use the following procedure.
1. Turn on the engine and set the idle at 1200 to 1500 RPM and then
turn on the air conditioner.
CAUTION Do not open the high pressure hand valve on the manifold
gauge set. The compressor could pump refrigerant into the
container and cause it to BURST. Be sure to keep the
refrigerant container upright to prevent liquid refrigerant
from entering the compressor.
2. Open the refrigerant dispensing valve on the container and then the
low pressure hand valve on the manifold. This allows refrigerant to
enter the system as a gas on the low pressure or suction side of the
compressor. The compressor will pull refrigerant into the system.
REV. 1 III-80
Manifold Gauge Set Installation
3. Add refrigerant until the gauges read in the normal range and the
sight glass appears clear. The sight glass may not be clear for a
moment just before or after the clutch cycles on and off but should
generally be clear. Gauge readings will fluctuate as the compressor
cycles on and off.
Note: Pressures within the air conditioning system vary with ambient
temperature. A normal pressure range is defined as follows:
Low side 15–30 PSIG
High side 150–280 PSIG
If R-134a is used in place of R-12 the high side readings will be
about 20 PSI higher. For this reason many OEMs are recom-
mending an increase in condenser capacity when retrofitting to
the new refrigerant, R-134a.
4. When the gauges show normal, close the hand valve on the
manifold, the hose end shutoff valve, and the valve on the refriger-
ant container. You can now proceed with the performance inspec-
tion.
CAUTION Be sure your tools and test equipment are clear of all moving
parts of the engine and air conditioner.
III-81 REV. 1
Troubleshooting & Service Procedures
Start the engine and set to a fast idle of 1200 to 1500 RPM. Turn on the air
conditioner. After a quick in-cab performance test of control function, blower
speeds and air flow, set the AC system controls to maximum cooling and blower
speed on high. All windows must be closed. If cab temperature is hot (rig has
been sitting in the sun with the windows closed), open the windows for a minute
or so to let the hot air out. Run the engine and air conditioner about five minutes
for the system to stabilize. In hot humid weather or where the AC condenser
can’t receive adequate air flow from the engine fan you may have to use a floor
mounted fan to force sufficient air flow through condenser fins. This helps to
stabilize the system by simulating ram air flow found under normal operating
conditions.
When a vehicle has a tilt cab or hood and the condenser is part of the grill,
you must use the floor fan to get air to the condenser. You could tilt the cab or
hood back to normal position, carefully routing the manifold gauge set and
hoses away from moving parts. Then place the gauges so you can read system
pressure.
Tip: You see bubbles in the sight glass. The air from vents in
the cab is only slightly cool.
REV. 1 III-82
Manifold Gauge Set Readings
Repair Procedure:
Check for leaks with your leak detector. If you find a leak
at a connection, tighten it then add refrigerant as neces-
sary. If a component or line is leaking (defective), recover
all refrigerant from the system. Replace the defective part
and then check the compressor oil level and replace
missing oil. Evacuate and recharge with refrigerant, then
check AC operation and performance.
Figure 8-6
Gauge reading, extremely Extremely Low Refrigerant Charge in the System
low refrigerant charge in
system.
Tip: The sight glass is clear or shows oil streaks. The air from
vents in the cab seems warm. If there is a low pressure or
Trinary™ switch in the system it may have shut off the
compressor (clutch).
Repair Procedure:
Add refrigerant to the system, at least half of the normal
full charge amount. Then perform your leak test. As an
alternative to a refrigerant, add dry nitrogen gas to the
system and then test for leaks.
III-83 REV. 1
Troubleshooting & Service Procedures
Tip: The sight glass may be clear or show some bubbles. The
air from vents in the cab is only slightly cool. In a cycling
clutch type system with a thermostatic switch, the switch
may not cycle the clutch on and off, so the low pressure
gauge will not fluctuate.
RepairProcedure:
Test for leaks, especially around the compressor shaft seal
area. When the leak is found, recover refrigerant from the
system and repair the leak. Replace the receiver-drier or
accumulator because the desiccant may be saturated with
moisture (there is no way to tell). Check the compressor
and replace any refrigeration oil lost due to leakage.
Evacuate and recharge the system with refrigerant, then
check AC operation and performance.
REV. 1 III-84
Manifold Gauge Set Readings
Repair Procedure:
Test for leaks, recover refrigerant from the system and
repair the leak. Depending on the type of system, replace
the receiver-drier or accumulator. The desiccant is satu-
rated with moisture. Check and replace any compressor
oil lost due to leakage. Evacuate and recharge the system,
then check AC operation and performance.
Tip: Air from vents in the cab is only slightly cool. The
expansion valve body is frosted or sweating.
III-85 REV. 1
Troubleshooting & Service Procedures
Repair Procedure:
Inspect the expansion valve screen (except block type
valves). To do this you must recover all refrigerant from
the system. Disconnect the inlet hose fitting from the
expansion valve. Remove, clean and replace the screen,
then reconnect the hose. Any signs of contamination will
require flushing the system. Next, replace the
receiverdrier. Then evacuate and recharge the system
with refrigerant, and check AC operation and perfor-
mance.
REV. 1 III-86
Manifold Gauge Set Readings
Note: If the expansion valve tests did not cause the low
pressure gauge needle to rise and drop, and if the other
procedures described did not correct the problem, the
expansion valve is defective. You must recover all
refrigerant from the system again, and replace the ex-
pansion valve and receiver-drier. Evacuate and recharge
the system with refrigerant, then check AC operation
and performance.
Tip: Air from vents in the cab is warm or only slightly cool.
III-87 REV. 1
Troubleshooting & Service Procedures
Repair Procedure:
If the test did not result in proper operation of the expan-
sion valve, the valve is defective and must be replaced.
Recover all refrigerant from the system and replace the
expansion valve and the receiver-drier. Evacuate and
recharge the system with refrigerant, then check AC
operation and performance.
Tip: Air from vents in the cab is only slightly cool. Look for
sweat or frost on high side hoses and tubing, and frost
appearing right after the point of restriction. The hose or
line may be cool to the touch near the restriction.
REV. 1 III-88
Manifold Gauge Set Readings
Repair Procedure:
After you locate the defective component containing the
restriction, recover all of the refrigerant. Replace the
defective component and the receiver-drier. Evacuate and
recharge the system with refrigerant, then check AC
operation and performance.
Repair Procedure:
If you find the belt worn or loose, replace or tighten it and
recheck system performance and gauge readings. To
inspect and service the compressor, you must isolate
(front seat the stem type compressor service valves) and
recover refrigerant, or fully recover R-12 from systems
containing Schrader valves. Remove the compressor cyl-
inder head and check the appearance of the reed valve
plate assembly. If defective, replace the valve plate and
install with new gaskets, or replace the compressor assem-
bly.
III-89 REV. 1
Troubleshooting & Service Procedures
Tip: The air from vents in the cab may be warm. In R-12
systems there can be bubbles in the sight glass. The high
pressure hoses and lines will be very hot. Don’t forget to
check the engine cooling system components—fan and
drive belt, fan clutch operation, and the radiator shutter.
REV. 1 III-90
Manifold Gauge Set Readings
Repair Procedure:
Inspect the condenser for dirt, bugs or other debris and
clean if necessary. Be sure the condenser is securely
mounted and there is adequate clearance (about 1-1/2
inches) between it and the radiator. Check the radiator
pressure cap and cooling system, including the fan, fan
clutch, drive belts and radiator shutter assembly. Replace
any defective parts and then recheck AC system opera-
tion, gauge readings and performance.
III-91 REV. 1
Troubleshooting & Service Procedures
Tip: The low side gauge needle may fluctuate in a very narrow
range compared to a normal range. The compressor clutch
may be cycling on and off more frequently than it should.
Repair Procedure:
Replace the thermostatic switch. When you remove the
old thermostat, replace it with one of the same type. (They
operate in a factory preset temperature range.) Take care
in removing and handling the thermostat and thin capil-
lary tube attached to it. Don’t kink or break the tube.
REV. 1 III-92
Review of Frequent Problem Areas
III-93 REV. 1
Troubleshooting & Service Procedures
2. Condenser
Condensers get dirty and the dirt reduces heat movement by insulating the
condenser. The fittings come loose or break from stress if the condenser or
connecting hoses are not secured properly to keep the effects of vibration at a
minimum.
Heat transfer efficiency and pressure in the condenser are affected by the
amount of outside air flowing through condenser fins. A lack of air flow can
mean the refrigerant doesn’t give up enough heat energy to the outside air (it
doesn’t change state). The refrigerant arrives at the evaporator as a gas and can’t
pick up any heat energy from cab air. In the cab, air from the vents is only
slightly cool or warm.
One possible cause of condenser malfunction could be the engine cooling
system. This is why fan clutches and radiator shutters are often controlled or
overridden by AC switch function. In fact, we can add fan clutch, radiator
shutters and also fan motors to condenser problems. If they don’t function to
allow sufficient air through the condenser, pressure inside the system may
become dangerously high. A lack of air through the condenser fins can raise
high side pressure and blow out the weakest point in a system, or damage the
compressor.
REV. 1 III-94
Conclusion
Conclusion
What could the air conditioning problem and it’s cause have been at the beginning
of this chapter? The operator was in a hurry, but you were able to start your
troubleshooting with the answers he gave you. Problems your inspection may have
turned up are a very low refrigerant charge, a contaminated system or defective
compressor. Those are not quick fix jobs.
On the other hand, you might have found enough debris on the condenser fin
surface to boost high side pressures to an abnormal level during the hottest part of
the day. So the Trinary™ or high pressure switch would cut out from high pressure—
but reset itself. You cleaned the condenser, added a half pound of refrigerant and AC
system pressures and function returned to normal. Service and repair took a half hour.
But there was no way to tell without using your knowledge and experience. By now
you are pretty familiar with AC system problems, the reasons for some of them,
troubleshooting and repair. In Chapter 9 we will describe complete system purging,
evacuation, flushing and recharging.
III-95 REV. 1
MACHINE CONFIGURATION
TB1140 III-96
IV . HYDRAULIC UNITS
IV – 1
HYDRAULIC UNITS
CONTENTS
REV. 1 IV – 2
HST PUMP HYDRAULIC UNITS
HST PUMP
CONSTRUCTION
IV – 3 REV. 1
HYDRAULIC UNITS HST PUMP
11
16
2 12
15 13
5
14
4 SECTION "L-L"
3
SECTION "E-E"
1
SECTION "C-C"
C C
L
L
E
E
8 7 6 9 17 10
T8D101E
IV – 4
HST PUMP HYDRAULIC UNITS
Pump Assembly (3/4)
IV – 5 REV. 1
HYDRAULIC UNITS HST PUMP
6 5
K K
8 3 1 2 9 10 11 7
1. Plug
2. Plug
3. Plug
4. Plug
5. Screw
6. Seal Nut
7. Plug
8. Cap Screw
9. Bolt
10. Spring Washer
11. Washer
IV – 6
HST PUMP HYDRAULIC UNITS
OPERATION
Hydraulic Pump $ %
Cylinder block (1) has been constructed with nine
pistons (2) built in, and the end surface comes in
contact with the valve plate (5) containing intake port
(3) and exhaust port (4). Cylinder block (1) rotates
freely and is connected to drive shaft (6) via the spline.
Swash plate (7), on the other hand, is connected to the
housing and tilted somewhat, and piston (2) is con-
structed to follow swash plate (7) in its rotation.
Rotating drive shaft (6) at this point causes cylinder
block (1) to rotate, causes piston (2) connection to
cylinder block (1) to follow along with swash plate (7) # 6$,&
to move in a back-and-forth motion, and causes the
intake and exhaust pumps to begin working.
Thus the nine pistons (2) perform approximately a
single intake (A) or exhaust (B) sweep for each
rotation of cylinder (1), and operating drive shaft (6)
in continuous rotations allows you to perform a con-
tinuous stream of intake and exhaust operations.
Note that since the sweep capacity of piston (2)
depends on the degree of tilt of swash plate (7), the tilt
of the plate may be changed to modify the total
quantity of exhaust.
6$,'
IV – 7
HYDRAULIC UNITS HST PUMP
6$,
X2 X1
T6D111E
Flushing Valve
This valve is used to replace the oil in the closed )
circuit with a new one to prevent the oil temperature
from increasing and to remove contaminants from the
circuit.
Upon travel stop, the shuttle (1) is in the neutral
position as the pressures applied to the pilot chambers
(A and B) of the flushing valve are at the same level.
6$,
6$,!
IV – 8
HST PUMP HYDRAULIC UNITS
Charge Check and High Pressure Relief Valve
This valve has two functions: a charge check valve
and a high-pressure relief valve. The charge check
valve function supplies the closed circuit with the oil
from the charge pump to replenish the oil flushed into
the tank by the flushing valve. The high pressure relief
valve function prevents the hydraulic circuit from
being damaged by the increased pressure due to the oil
supplied from the pump in succession and keeps the
hydraulic circuit at an appropriate pressure.
6$,"
5
T6D115
)
6$,$
IV – 9 REV. 1
HYDRAULIC UNITS HST 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.
Disassembly Pump P1
Pump 4
1. Disassemble the pumps P1 and P2, and the gear
Pump P2
pump.
• Before starting, make match marks on the
components to be disassembled for accurate 3
later reassembling.
a. Remove the two cap screws (25), and remove
the gear pump (2) from the A pad adapter (3).
Then remove the O-ring from the A pad adapter
(3). 1
b. Remove the two bolts (4) to separate the hy- 25
draulic pumps P1 and P2 from each other. 2 S3F305E
S3F306E
6$,&
REV. 1 IV – 10
HST PUMP HYDRAULIC UNITS
3. Remove the retaining ring (6).
• Use a flat head driver.
6
4. Remove the seal carrier. A
a. Pull up the shaft and remove the seal carrier 7
(7).
• If the seal carrier is hard to remove, insert
8
the flat head driver under the convex part
(A) of the seal carrier and try again.
b. Remove the seal from the seal carrier (7).
c. Remove the O-ring (8).
S3F307
S3F308E
9
B
B S3F309E
11
S3F310E
IV – 11 REV. 1
HYDRAULIC UNITS HST PUMP
6$, !
!
"
6$, "
S3F343
13. Remove the adjusting seal nut (18) from the tie
bolt (16). Mark
• Hold the tie bolt by an Allen wrench to prevent
it from turning.
• Replace the adjusting seal nut with the new one 16
when reassembling. 18
S3F312E
REV. 1 IV – 12
HST PUMP HYDRAULIC UNITS
14. Remove the servo cover (19).
a. Remove the five cap screws.
b. Remove the servo cover (19) and the gasket 17
(17). 19
c. Remove the servo cover (19) from the tie bolt
(16).
16
S3F313
20
16
S3F314E
17. Remove the A pad adapter (on the side of the < Pump P2 >
hydraulic pump P2).
a. Remove the seven cap screws, and take out the
A pad adapter (24).
• If the adapter is hard to remove, slightly tap 24
on the adapter with a rubber hammer.
b. Remove the gasket (23).
23
S3F316E
IV – 13 REV. 1
HYDRAULIC UNITS HST PUMP
27
S3F317
29
!$
6$,!
WARNING !$
Always wear appropriate protective items such
as safety goggles, as component parts can jump
out and cause serious bodily injury. !%
REV. 1 IV – 14
HST PUMP HYDRAULIC UNITS
22. Disassemble the servo piston.
The servo piston should not be disassembled
unless required for cleaning up foreign mat-
16
49
ter or replacing damaged components. 50 48
a. Remove the piston rings (21) from the servo
piston (20).
b. Remove the nuts (49 and 50) from the tie bolt 21
(16).
20
21
S3F318
S3F319
16
51
52
53
S3F320
Valves
1. Remove the charge check and high pressure relief
valve.
a. Remove the valve seat plugs (1) from the pump
housing.
b. Remove the check poppet or relief valve as-
semblies (2) from the pump housing.
• The smaller end of each conical spring (3) is
crimped to retain it on the check poppet or
relief valve. Do not remove.
IV – 15
IV-14-1 REV. 1
HYDRAULIC UNITS HST PUMP
REV. 1 IV – 16
15
HST PUMP HYDRAULIC UNITS
Assembly
Pump
1. Assemble the servo piston.
a. Install the spring guide (53), the spring (52) 49
and the spring guide (51) to the tie bolt (16). 16
b. Attach the nut (50), and tighten it manually 50
until it contacts the spring guide (51). 51
c. Attach the nut (49), and tighten it until it
contacts the nut (50). 52
53
S3F321
S3F322
!&
!'
" 6$,!
!$
6$,!
IV – 16 REV. 1
HYDRAULIC UNITS HST PUMP
36
S3F323
29
T7D105
S3F317
REV. 1 IV – 17
HST PUMP HYDRAULIC UNITS
7. Install the A pad adapter (on the side of the
hydraulic pump P2). < Pump P2 >
a. Install the gasket (23).
• Use a new gasket.
b. Install the A pad adapter (24), and tighten it
with the seven cap screws. 24
Cap Screw: 36~43 N·m
23
S3F316E
S3F314E
S3F325
IV – 18 REV. 1
HYDRAULIC UNITS HST PUMP
16
S3F313
S3F343
10. Install the adjusting seal nut (18) to the tie bolt
(16). Mark
• The adjusting seal nut (18) should be tightened
until the seal contacts the servo cover.
16
18
S3F312E
14
S3F326
REV. 1 IV – 19
HST PUMP HYDRAULIC UNITS
12. Install the valve plate (13) over the needle bearing
of the housing.
• Foreign matter under the valve plate could
cause a pump failure.
• Make sure that the valve plate can be pushed in
by hand and engages with the timing pin.
• Lubricate the upper surface of the valve plate
with hydraulic oil.
13
S3F327
Needle bearing
S3F328E
14. Install the swash plate (10) into the bearing hole
of the servo piston.
• Lubricate the bearing surface and the rear
surface of the swash plate with hydraulic oil.
6$, !
15. Install the cylinder block (11) by lifting the edges Lift
of the swash plate (10).
• Lubricate the sliding surface of the cylinder
block with hydraulic oil.
10
11
S3F310E
IV – 20 REV. 1
HYDRAULIC UNITS HST PUMP
S3F308E
S3F329E
REV. 1 IV – 21
HST PUMP HYDRAULIC UNITS
19. Assemble the seal carrier.
a. Press-fit the seal (56) into the seal carrier (7). #$
• Use a new seal.
• Apply sealant over the seal perimeter.
Sealant: Loctite #59231
• Be careful not to insert the seal in the wrong
direction.
• Lubricate the inside of the seal with grease.
b. Attach the O-ring (8) to the seal carrier (7). %
6$,"
S3F307
6$,&
IV – 22 REV. 1
HYDRAULIC UNITS HST PUMP
Valves
1. Replace the charge check and high pressure relief
valve.
a. Install a outer O-ring, backup ring, and inner
O-ring on each valve seat plug.
b. Check that the conical springs (3) are properly
retained on the check poppets or relief valves.
Install the check poppet or high pressure relief
valve assemblies (2) into the pump housing.
• The conical springs MUST be correctly
positioned on the check poppets or relief
valves after installation for proper pump
operation.
c. Install the valve seat plugs or valve seat /
bypass plugs (1) into the pump housing and
torque.
Plug: 40~95 N·m
REV. 1 IV-22-1
HST PUMP HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
Cylinder Block
• The sliding surface or the surface that contacts the
valve plate must be smooth and free from any
damage or burrs.
• The flatness of the sliding surface of the cylinder
block must be 0.000079 in. (0.002 mm) TIR.
• The maximum diameter of the cylinder bore must
be 0.5631 in. (14.30 mm), and the minimum height
of the cylinder block must be 1.968 in. (50.00 mm).
Valve Plate
• The thickness (A) of the valve plate must be at least
0.196 in. (4.97 mm).
• The sliding surface and the rear surface must be
smooth.
• The parallel accuracy must be at least 0.00098 in.
(0.0249 mm).
• The flatness of the valve plate must be 0.00015 in.
(0.0038 mm) TIR.
• Perform the magnetic particle inspection (nonde-
structive testing) to see if there is any cracking. No
cracking must be found on any surface.
• Inspect the seal land surface for damage by touch-
ing it with a prong such as the tip of a nail or pencil
and by moving it in the direction of diameter.
• Check if there is any contamination on the surface
where the valve plate and the housing contact.
Even slight contamination can cause reduced flow
rate.
Servo Cover
• The servo cover’s surface that contacts the gasket
must be clean and smooth.
• No scratch or foreign matter should be allowed on
the surface. Sealing land
surface
S3F333E
IV-23 REV. 1
HYDRAULIC UNITS HST PUMP
Input Shaft
• The shaft and its spline must be straight and free
from any damage or wear.
• No annular groove should be found on the shaft
surface that contacts the shaft seal.
• No spalling should be found on the surface where
the shaft and the bearing contact.
Non-serviceable items
S3F334E
Swash Plate
• The surface of the swash plate must be smooth and A
free from any projections or unusual wear.
• The diameter of the contact surface of the swash
plate bearing must be at least 1.007 in. (25.58 mm).
• The difference of the thickness at both ends must
be at most 0.00200 in. (0.0508 mm).
• The flatness of the surface of sliding with the
S3F345
slipper must be 0.00100 in. (0.0254 mm) or less.
REV. 1 IV-24
HST PUMP HYDRAULIC UNITS
Adjustment of Rotational Torque of the Servo
Piston 16
The adjustment should be performed so that the load 49
48
of the spring (52) is applied to the snap ring (48), and 50
the tie bolt (16) rotates freely.
1. Secure the nut (50) with a wrench, and tighten the 52
tie bolt (16) manually by turning it to the left until
firm.
2. With the nut (50) secured, tighten the tie bolt (16)
by a wrench by turning it to the left.
• Tighten the bolt until the spring (52) starts
compressing.
S3F335
S3F337
IV-25 REV. 1
HYDRAULIC UNITS HST PUMP
WARNING
• Be sure to do these adjustments on the level
ground.
• The hydraulic oil and the tank are hot and
under pressure at operating temperature.
• Never adjust the pump immediately after the
engine stops to prevent bodily injuly, because
all the components are hot.
• Do not allow hot oil and components to contact
your skin.
• When removing the hydraulic hose, slowly
loosen the hydraulic hose.
6. Turn the tie bolt (16) until the reading of the other
16
pressure gauge becomes higher than that increased
in 5 above. 18
• Record the position of the tie bolt.
S3F341
REV. 1 IV-26
HST PUMP HYDRAULIC UNITS
7. Turn the tie bolt (16) until it is positioned at the
middle of the two positions recorded in 5 and 6
above.
• Make sure the readings on the two pressure
gauges are equal.
IV-27 REV. 1
HYDRAULIC UNITS HST PUMP
WARNING
• Be sure to do these adjustments on the level
ground.
• The hydraulic oil and the tank are hot and
under pressure at operating temperature.
• Never adjust the pump immediately after the
engine stops to prevent bodily injuly, because
all the components are hot.
• Do not allow hot oil and components to contact
your skin.
• When removing the hydraulic hose, slowly
loosen the hydraulic hose.
• Failure to adjust the displacement limiter may
result in uncontrollable operations of the ma-
chine during traveling.
Displacement limiter
Forward A
Left travel motor
Reverse B
Forward C
Right travel motor
Reverse D
1. Remove the lock nut (2) and turn the setscrew (1) 1
to adjust the motor speed as follows:
Turning to the right ... Decelerate. 2
Turning to the left ..... Accelerate.
• A single rotation will generate the speed of 6.2
cm3/rpm.
REV. 1 IV-28
IV-27-1
HST PUMP HYDRAULIC UNITS
TROUBLESHOOTING
HST System
Sympotom Probable Causes Remedy
Difficult or impos- • Pilot valve out of line. • Repair or replace.
sible to find neutral • HST pump adjustment screws have been • Tighten or loosen the HST pump adjust-
position. improperly or insufficiently tightened. ment screws to readjust the neutral posi-
tion. Replace the HST pump if the adjust-
ment cannot be performed properly.
Machine can only • Bad pilot valve. • Repair or replace .
operate in forward • Insufficient pressure being supplied to pi- • Check the gear pump P4 and the (sub)
or reverse. lot valve. control valve; repair or replace.
• Insufficient charge pressure. • Check the gear pump P4, the (sub) control
valve, and the low-pressure relief valve;
repair or replace.
• Orifice plugged. • Clean
• Bad high-pressure relief valve. • Repair or replace.
• Pilot spool has been nicked or burned. • Repair or replace.
• Bad travel motor. • Repair or replace.
Machine operates • The level in the hydraulic tank is low. • Fill up the tank with hydraulic oil to the
neither in forward required level.
nor reverse. • Bad pilot valve. • Repair or replace.
Fails to move in a • Insufficient pressure being supplied to pi- • Check the gear pump P4 and the (sub)
straight line in for- lot valve. control valve; repair or replace.
ward. • Insufficient charge pressure. • Check the gear pump P4, the (sub) control
valve, and the low-pressure relief valve;
repair or replace.
• Orifice plugged. • Clean
• Bad high-pressure relief valve. • Repair or replace.
• Pilot spool has been nicked or burned. • Repair or replace.
• Bad travel motor. • Repair or replace.
System is overheat- • The level in the hydraulic tank is low. • Fill up the tank with hydraulic oil to the
ing during opera- required level.
tion. • Bad oil cooler. • Repair or replace.
• Bad high-pressure relief valve. • Repair or replace.
• Release pressure for parking brake is too • Check the gear pump P4 and the (sub)
low. control valve; repair or replace.
• Travel motor overheated. • Repair or replace.
• HST pump overheated. • Repair or replace.
IV-29
IV-28 REV. 1
HYDRAULIC UNITS HST PUMP
Hydraulic Pump
Trouble Probable Causes Remedy
Noise is loud. Abnor- • The suction hose is pinched or the suction • Remove the dirt or eliminate the pinched
mal noise is generated. filter is clogged. condition of the hose.
• The suction side joint is loose and air is • Retighten each joint.
being sucked in.
• The hydraulic oil’s viscosity is too high • Replace the hydraulic oil with oil of the
and cavitation is occurring. proper viscosity.
• The pump is off center with respect to the • Center the pump with respect to the en-
engine. gine.
• There are bubbles in the hydraulic oil. • Investigate the cause of the bubbles and
repair it.
• The engine’s speed is higher than the • Operate the engine at the specified speed.
specified speed.
• The bearing, etc. is mechanically dam- • Replace the damaged parts or replace the
aged. pump.
Discharge is insuffi- • The engine’s speed is too low. • Operate the engine at the specified speed.
cient. • The oil temperature is abnormally high. • Stop the machine and let the oil cool off,
then check again.
• The hydraulic oil’s viscosity is too high. • Replace the hydraulic oil with oil of the
proper viscosity.
• The pump’s volumetric efficiency has • Replace the pump.
dropped.
• The oil level in the tank is low. • Replenish the tank with hydraulic oil to
the specified level.
• The suction side pipe or the suction filter • Clean the piping.
is clogged.
• The amount of leakage from hydraulic • Repair the hydraulic device or replace it.
devices other than the pump is increas-
ing.
Pressure doesn’t rise. • The relief valve setting has dropped. • Reset the relief valve setting.
• The amount of leakage from hydraulic • Repair the hydraulic device or replace it.
devices other than the pump is increas-
ing.
• The pump’s volumetric efficiency has • Replace the pump.
dropped.
Abnormal heat is gen- • Leakage from the pump is increasing. • Replace the pump.
erated. • The bearings, etc. are mechanically dam- • Replace the damaged parts or replace the
aged. pump.
• There is seizing of sliding parts. • Replace the damaged parts or replace the
pump.
Hydraulic oil is leak- • Seals are damaged. • Replace the seals.
ing. • The shaft surface which slides against the • Replace the shaft or replace the pump.
oil seal is worn.
• The plug or bolts are loose. • Tighten them or replace the seals.
REV. 1 IV-30
IV-28-1
GEAR PUMP HYDRAULIC UNITS
GEAR PUMP
CONSTRUCTION
# " & ! #
"
' ! $ %
6&,#
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 – 29
HYDRAULIC UNITS GEAR PUMP
General Cautions
• Carry out disassembly and assembly operations in • Replace all seals with new ones each time the pump
a clean place and provide clean containers to place is disassembled, coating them lightly with grease.
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. • Adjust adjustment screws only when required.
• Clean each of the disassembled parts with a clean-
ing oil such as diesel fuel.
• Make match marks on each part so that they will be
assembled in the same positions when assembled.
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 T7D151
4 1
T7D152
IV – 30
GEAR PUMP HYDRAULIC UNITS
5. Remove the rear cover (5).
6&,#
IV – 31 REV. 1
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
A
Bushing
The ideal situation is for the sliding surfaces to have
no roughness and for the suction side half to be
lustrous. Also, it is satisfactory 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.
• 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.
• There are marks from foreign matter biting into the
sliding surface of the bearing inner diameter and
the side surface.
Dirty hydraulic oil is one likely cause of such wear. In
such a case, replace the hydraulic oil and flush out
affected hydraulic circuit completely.
IV – 32
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.
3. None of the points coming into contact with the
oil seal should be abraded to a depth in excess of
0.1 mm.
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 – 33 REV. 1
HYDRAULIC UNITS GEAR PUMP
IV – 34
GEAR PUMP HYDRAULIC UNITS
TROUBLESHOOTING
IV – 35
HYDRAULIC UNITS GEAR PUMP
IV – 36
CONTROL VALVE HYDRAULIC UNITS
CONTROL VALVE
CONSTRUCTION
8
4 4 4 7
2 12 3 3 11 3 10 6 9
1 5 3 3 3
4 4 4
T7D200
1. Tie Rod
2. Outlet Housing
3. Port Relief Valve
4. O-ring
5. Nut
6. Main Relief Valve
7. O-ring
8. O-ring
9. Inlet Housing
10. Lift Arm Section Assembly
11. Bucket Section Assembly
12. Auxiliary Section Assembly
IV – 37
HYDRAULIC UNITS CONTROL VALVE
SECTION "X-X"
3 5 6 4 7 5 10 8 10 8 4 3 T7D201E
Bucket Section
9 1. Load Check Valve
2. Spring
3. Cover
4. Screw
5. Spring Holder
6. Spring
7. Cap Screw
8. O-ring
7
X X 2 9. O-ring
10. O-ring
1
SECTION "X-X"
3 5 6 4 7 5 10 8 10 8 4 3 T7D201E
Auxiliary Section
9 1. Load Check Valve
2. Spring
3. Cover
4. Screw
5. Spring Holder
6. Spring
7. Cap Screw
8. O-ring
7
X X 2 9. O-ring
10. O-ring
1
SECTION "X-X"
3 5 6 4 7 5 10 8 10 3 T7D203E
IV – 38
CONTROL VALVE HYDRAULIC UNITS
Main Relief Valve
1. Housing 9. Lock Nut
2. Plug 10. Spring
3 4 11 1 6 10 2 7 9 3. Sleeve 11. Spring
4. Main Poppet 12. O-ring
5. O-ring 13. O-ring
6. Needle Valve 14. O-ring
7. Set Screw 15. O-ring
8. Gasket
14 15 5 12 13 8
T7D204
17 15 11 14 16 12 13
T7D205
IV – 39
HYDRAULIC UNITS CONTROL VALVE
OPERATION
P T T9D201
Auxiliary Section
When the pressure is applied to the pilot chamber (3),
the spool (2) is moved to the right of the neutral 2 5
position and the center bypass passage (4) is closed. A B
The oil that flows from port P lifts the poppet (5) and Z
flows through port A to be supplied to the actuator.
On the other hand, the oil returned from the actuator
Z
flows into port B and flows via the tank passage T to
return to the tank. 4
When the spool (2) is moved to the left of the neutral SECTION Z-Z
3 T 4
position, the oil is supplied to the actuator through
port B, and the oil returned from the actuator flows
into port A. T9D203E
REV. 1 IV – 40
CONTROL VALVE HYDRAULIC UNITS
Load Check Valve
This valve prevents oil from flowing backward due to 6
the load pressure C from the actuator port (6) during C
switching of the spool.
T9D204
IV – 41 REV. 1
HYDRAULIC UNITS CONTROL VALVE
T
T7D207
T
T7D208
Suction Operation
When the cylinder is operated at high speed, and the
supply of oil cannot keep up with it, creating a vacuum A2 8 A3
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 A2 and A3 cause the poppet (8) to
open. Thus, sufficient oil from the tank passage T
enters chamber B, filling the empty space.
B T
T7D209
REV. 1 IV – 42
CONTROL VALVE HYDRAULIC UNITS
DISASSEMBLY AND ASSEMBLY
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 each of the disassembled parts and apply as a unit.
clean hydraulic oil to them. • 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
them.
Disassembly
Valve Assembly
1. Loosen the nuts and remove the tie rods, then
remove the sections.
Nut: 39.23 ±3.92 N·m
G4D223
IV – 43
HYDRAULIC UNITS CONTROL VALVE
K3D217
IV – 44
CONTROL VALVE HYDRAULIC UNITS
Main Relief Valve
1. Remove the sleeve (1).
Sleeve: 49.04 ±4.90 N·m
1
2. Remove the O-rings from sleeve (1).
T7D210
T7D211
T7D212
IV – 45
HYDRAULIC UNITS CONTROL VALVE
IV – 46
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 – 47
HYDRAULIC UNITS CONTROL VALVE
IV – 48
CONTROL VALVE (SUB) HYDRAULIC UNITS
CONTROL VALVE (SUB)
CONSTRUCTION
30 2 10 9 15 14 14 13 8
29 22
20 27 4 21 1 23
3
12 12
31
7 28
X
SECTION "X-X"
11
11 17
3
18
Z
16
30 2
SECTION "Z-Z"
Y Y 19 5 25 26 6 24
Z SECTION "Y-Y"
T7D900E
IV – 49
HYDRAULIC UNITS CONTROL VALVE (SUB)
OPERATION
T7D901
The port P and the circuit of the port 2 are shut off by
the poppet (6). 6
The hydraulic oil from the port 2 pushes up the 3
plunger (7), flows into the circuit of the port 1, and
enters together with the oil from the port 1 into port T.
7 P
T7D902
10
T7D903
T7D904
IV – 50
CONTROL VALVE (SUB) HYDRAULIC UNITS
The hydraulic oil from the port 1 flows through the
bore on the side panel of the spool (11) and through
the wire clearance into the chamber D, which consists 5
of the spool (11) and piston (12). When the pressure 3
in the chamber D becomes higher than the set pres-
12
sure, the spool (11) moves downward, releasing the
oil from the port 1 to port 2, keeping the pressure in the
port 1 at the set pressure.
The hydraulic oil in the port 2 pushes up the poppet (5)
and flows into the port 3. 2
P
D
11
T7D905
1B
P
13
T7D906
1B
P
13
T7D907
IV – 51
HYDRAULIC UNITS CONTROL VALVE (SUB)
General Cautions
• Carry out disassembly and reassembly operations • The spool and body are selectively fitted, so if one
in a clean place and place disassembled parts in is found to be damaged, replace the valve assem-
clean containers. bly.
• Before disassembly, clean thoroughly around the • Apply a thin coating of hydraulic oil to sliding
ports and remove paint or thread lock, etc. from all surfaces and a thin coating of grease to seals when
joints with a wire brush. assembling them.
• Clean the disassembled parts with appropriate clean- • Replace seals with new parts each time disassem-
ing oils. bly is done.
Disassembly
Solenoid Valve A
1. Remove the solenoid valve.
a. Remove the cap screw and remove the sole-
noid A (21).
Cap Screw: 10.8 ±0.98 N·m
21
b. Remove the O-ring from the solenoid A.
T7D908
24 23
T7D910
IV – 52
CONTROL VALVE (SUB) HYDRAULIC UNITS
Solenoid Valve B
1. Loosen the nut and remove the solenoid coil (1).
Nut: 29.4 ±2.94 N·m
2. Remove the shaft (2) from the body.
• Take care not to miss the push rod.
Shaft: 37.3 ±3.92 N·m
!
"
& %
3. Remove the spring (6) and washer (7). $
' #
4. Loosen the plug (8) from the body.
Plug: 75.5 ±7.85 N·m
Relief Valve
1. Loosen the plug (10) from the body.
Plug: 75.5 ±7.85 N·m
6$,'"
IV – 53
HYDRAULIC UNITS CONTROL VALVE (SUB)
6$,'#
Check Valve
#
1. Loosen the plug (15) from the body.
$
Plug: 49.0 ±4.9 N·m %
2. Remove the O-ring from the plug (15).
6$,'$
6$,'%
IV – 54
CONTROL VALVE (SUB) HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
TROUBLESHOOTING
IV – 55
HYDRAULIC UNITS CONTROL VALVE (SUB)
IV – 56
PILOT VALVE HYDRAULIC UNITS
PILOT VALVE
CONSTRUCTION
23
26
24
25
13
12
11
8
14
15 16
17
18
21
22 20
10
9
7 19
6 1
4
2
3
5
T7D300
IV – 57
HYDRAULIC UNITS PILOT VALVE
OPERATION
The pilot valve casing contains a vertical shaft hole The casing also contains an inlet port for hydraulic oil
with a reducing valve incorporated into it. When the port P (primary pressure) and an outlet port, port T
handle is tilted, the push rod and spring seat are (tank) and secondary pressure is taken from 4 ports,
pushed down changing the secondary pressure spring’s port 1, port 2, port 3 and port 4, on the bottom of the
pressure. vertical shaft hole.
IV – 58
PILOT VALVE HYDRAULIC UNITS
DISASSEMBLY AND ASSEMBLY
0.5 × 15°
42
R12
25
17
R4 C0.5
Ø26.5
Ø30
Ø25
Ø21
Ø28
23.5
Ø19
12
1 2
15
.2
9.5
R5
19 C0.5
50 13
65 10.4 4
14.5
MATERIAL A; S45C
MATERIAL B; SCM415N WITH CEMENTATION HARDENING MATERIAL B; SCM415N WITH CEMENTATION HARDENING
Y1-D302E Y1-D303E
General Cautions
• Since all parts in the pilot valve are precision • Replace all seals with new ones each time the pilot
machined, carry out disassembly and reassembly valve is disassembled.
operations in a clean place and take special care not • During assembly, remove all the foreign matter
to scratch the parts. from each part and check them to make sure there
• Before disassembly, clean the outside surfaces of are no burrs, bruises using or other marks on them.
the pilot valve. Remove all burrs and bruises using an oil stone.
• Clean each of the disassembled parts and apply • Apply thin coating of grease to seals when assem-
clean hydraulic oil to them. bling them.
Disassembly
1. Remove the lock nut and the adjust nut (1), then
remove the disc (2).
• Using copper or lead plates, fasten the valve in
a vise.
IV – 59
HYDRAULIC UNITS PILOT VALVE
3. Take out the plug (5) then remove the push rod (6)
from the plug (5).
• If the plug is difficult to remove, use (–) screw
driver to remove it.
• Be careful not to let the plug fly out from the
spring’s force.
4. Remove the O-ring (7) and seal (8) from the plug.
IV – 60
PILOT VALVE HYDRAULIC UNITS
b. Remove the spring seat (14), spring (15) and
washer 2 (16) from the spool (17).
IV – 61
HYDRAULIC UNITS PILOT VALVE
Assembly
1. Fit the bushing (20) and O-ring (19), then install
the port plate (18).
• Align the positions of the spring pin (21) and
the casing hole.
b. Install washer 1.
• Stand the valve on a flat work bench with the
bottom of the spool down, then push the
spring seat down. (It cannot be pushed down
more than 6 mm.)
• Hook the head of the spool with the sharp
edge of washer 1.
IV – 62
PILOT VALVE HYDRAULIC UNITS
4. Install the spring (13) and reducing valve (12).
• Install them in the positions they were in be-
fore disassembly.
5. Install the O-ring (7) and seal (8) in the plug (5).
7. Install the plug (5) and plate (4), then install the
joint.
• Use installation jigs (A) and (B) to install the
joint.
Joint: 47.1 ±2.9 N·m
IV – 63
HYDRAULIC UNITS PILOT VALVE
8. Install the disc (2), the adjust nut (1) and the lock
nut.
• Tighten the adjust nut to the point where all 4
push rods are uniformly making contact.
• During tightening, the disc should not be
moved.
Adjust Nut: 68.6 ±4.9 N·m
Lock Nut: 49 ±3.4 N·m
IV – 64
PILOT VALVE HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
IV – 65
HYDRAULIC UNITS PILOT VALVE
TROUBLESHOOTING
IV – 66
PILOT VALVE HYDRAULIC UNITS
PILOT VALVE (Auxiliary)
CONSTRUCTION
13
16 14
6 15
9
12
11
10
L3D350
IV – 67
HYDRAULIC UNITS PILOT VALVE
OPERATION
“IV-58”
General Cautions
“IV-59”
Disassembly
1. Remove the boot from the cover.
• Use a copper or iron sheet to fasten the valve to
the vice.
• Apply grease to the cam and push rods.
L2D301
L2D302
L2D303
IV – 68
PILOT VALVE HYDRAULIC UNITS
4. Loosen the cap screws and remove the cover (2).
• The cover and plug will rise from the surface if
the rebound spring is too strong, so loosen the
cap screws alternately so that the cover is flat. 2
• Mark the cover and casing so that they can be
reassembled in the same positions.
Cap screw: 8.8 N·m
L2D304
L3D351
L3D352
L2D306
IV – 69
HYDRAULIC UNITS PILOT VALVE
“IV-65”
TROUBLESHOOTING
“IV-66”
IV – 70
SELF-LEVEL VALVE HYDRAULIC UNITS
SELF-LEVEL VALVE (Serial No. 21300004~21301932)
CONSTRUCTION
23 21 20 22 9 12 4 5 13 14
24 3
15
17
18
19
16 6 2 25 11 10
SECTION “A-A”
T7D950E
IV – 71 REV. 1
HYDRAULIC UNITS SELF-LEVEL VALVE
OPERATION
Self-Leveling Operation
<Arm Spool Out, Bucket Spool Neutral>
Oil ejected from the rod side of the arm cylinder (1)
flows into port A of the self-leveling valve, where the
difference in the area of adjust double orifice A1 (2)
and fixed orifice A2 (3) causes the oil to split and flow
to ports D and B.
Relative flow: QD/QB = A1/A2
Oil ejected from port D then heads into the head side
of bucket cylinder (4), while oil ejected from port B
returns to the tank. When the pressure of the right
edge of rod spool (5) increases to the point where it
exceeds the force exerted by spring (6), the oil which
has been ejected from the rod side of bucket cylinder
(4) flows out of port B, coming out of port C and
passing along the surface of unloading spool (5)
before returning to the tank.
A portion of the oil which has thus run out from the rod
side of the arm cylinder will then enter the head side
of the bucket cylinder and cause the bucket to tip
forward as the arm rises, ensuring that the bucket
always remain horizontal to the ground while it di-
vides the flow of the oil.
IV – 72
SELF-LEVEL VALVE HYDRAULIC UNITS
At Lowering of the Arm
<Arm Spool In, Bucket Spool Neutral>
Oil ejected from port B opens up plunger (8) and
flows out from port A to go into the rod side of arm
cylinder (1). The oil flowing out from the head side
returns to the tank.
IV – 73
HYDRAULIC UNITS SELF-LEVEL VALVE
General Cautions
• Carry out disassembly and reassembly operations • Apply a thin coating of hydraulic oil to sliding
in a clean place and place disassembled parts in surfaces and a thin coating of grease to seals when
clean containers. assembling them.
• Before disassembly, clean thoroughly around the • Replace seals with new parts each time disassem-
ports and remove paint or thread lock, etc. from all bly is done.
joints with a wire brush.
• Clean disassembled parts with light oil or other
cleaning oil.
IV – 74
SELF-LEVEL VALVE HYDRAULIC UNITS
4. Remove cover (18), nut (17), and set screw (16)
from cap.
• Make a record of the measurements for A (see
diagram below), and make sure that these
measurements do not change during assembly.
Nut: 5.4~7.8 N·m
5. Remove cap (15) and then take O-ring (14) off the
cap.
Cap: 13.6~16.3 N·m
6. Remove pin (12) and then take O-ring (13) off the
pin.
IV – 75
HYDRAULIC UNITS SELF-LEVEL VALVE
IV – 76
SELF-LEVEL VALVE HYDRAULIC UNITS
TROUBLESHOOTING
IV – 77
HYDRAULIC UNITS SELF-LEVEL VALVE
IV – 78
SELF-LEVEL VALVE HYDRAULIC UNITS
SELF-LEVEL VALVE (Serial No. 21301933~)
CONSTRUCTION
4 3 1 2 3 4 15
5 5
7 3 16
6 SECTION J-J
13
7 8 9 10 11 12 14
SECTION A-A
J A
A
T9D900
IV-78-1 REV. 1
HYDRAULIC UNITS SELF-LEVEL VALVE
OPERATION
Self-Leveling Operation
<Arm Spool Out, Bucket Spool Neutral> 1
A
Oil ejected from the rod side of the arm cylinder (1)
3
flows into port A of the self-leveling valve, where the
difference in the area of orifice A1 (2) and orifice A2 B 5
A2
(3) causes the oil to split and flow to ports D and B.
Oil ejected from port D then heads into the head side A1
of bucket cylinder (4), while oil ejected from port B 2
returns to the tank. When the pressure of the right
edge of unloading spool (5) increases to the point C D
where it exceeds the force exerted by spring (6), the 6
4
oil which has been ejected from the rod side of bucket
T9D901
cylinder (4) flows out of port B, coming out of port C
and passing along the surface of unloading spool (5)
before returning to the tank.
A portion of the oil which has thus run out from the rod
side of the arm cylinder will then enter the head side
of the bucket cylinder and cause the bucket to tip
forward as the arm rises, ensuring that the bucket
always remain horizontal to the ground while it di-
vides the flow of the oil.
REV. 1 IV-78-2
SELF-LEVEL VALVE HYDRAULIC UNITS
At Lowering of the Arm
<Arm Spool In, Bucket Spool Neutral>
Oil ejected from port B opens up plunger (9) and 1
flows out from port A to go into the rod side of arm A
cylinder (1). The oil flowing out from the head side 9
returns to the tank. B
C D
4
T9D903
C D 10
4
T9D904
IV-78-3 REV. 1
HYDRAULIC UNITS SELF-LEVEL VALVE
General Cautions
• Carry out disassembly and assembly operations in • The spool and body are selectively fitted, so if one
a clean place and place disassembled parts in clean is found to be damaged, replace the valve assem-
containers. bly.
• Before disassembly, clean thoroughly around the • Apply a thin coating of hydraulic oil to sliding
ports and remove paint or thread lock, etc. from all surfaces and a thin coating of grease to seals when
joints with a wire brush. assembling them.
• Clean disassembled parts with light oil or other • Replace seals with new parts each time disassem-
cleaning oil. bly is done.
• Do not turn adjusting screws if not required.
The following describes the disassembly procedure.
For assembly, follow the disassembly procedure in
the reverse order.
Disassembly
1. Remove plug (1), spring (3), and unloading spool
(4) before taking O-ring (2) off of plug (1).
Plug: 71 ±2.9 N·m
1 2 3 4
T9D906
5 6 7 6 5
6','%
12 11 10 13 9
T9D908
REV. 1 IV-78-4
SELF-LEVEL VALVE HYDRAULIC UNITS
4. Remove plug (14), spring (15), and poppet (16)
before taking O-ring (17) off of plug (14).
Plug: 71 ±2.9 N·m 17 14
15
16
T9D909
IV-78-5 REV. 1
HYDRAULIC UNITS SELF-LEVEL VALVE
TROUBLESHOOTING
REV. 1 IV-78-6
CYLINDERS HYDRAULIC UNITS
CYLINDERS
CONSTRUCTION
Arm Cylinder
28 26 24 23 22 20 21 19 1 19 18 25 17 15 7 5 6 5 8 13 3 27 28
10 12
9 16 14 2 4 11
6&,"
Bucket Cylinder
7
19 20 17 18 14 1 14 12 15 5 4 16 6 11 3 8
10 13 2 19
9 6&,"
IV – 79
HYDRAULIC UNITS CYLINDERS
OPERATION
Cushion Mechanism
PORTION A
DETAIL OF
PORTION A
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.
IV – 80
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 in a clean • Clean all disassembled parts thoroughly with clean-
place and place the disassembled parts in a place ing oil.
where they will be kept clean at all times. • Replace all seals with new parts.
• Before disassembly, clean the outside surface of • Apply a thin coating of hydraulic oil to seals before
the cylinder thoroughly. fitting them in place.
• In the disassembly and assembly operations, be • After fitting, make sure the O-rings are not twisted.
careful not to scratch any part. Take particular • Apply clean hydraulic oil to each sliding portion
caution with the sliding surfaces of parts. before assembling them.
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 – 81
HYDRAULIC UNITS CYLINDERS
2
E5D408
IV – 82
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 – 83
HYDRAULIC UNITS CYLINDERS
Clevis
1. Remove the dust seals from the tube and piston
rod.
IV – 84
CYLINDERS HYDRAULIC UNITS
Assembly
Clevis
1. Using installation jig (B), pressure fit the bush-
ings (44) in the piston rod and tube.
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 – 85
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.
IV – 86
CYLINDERS HYDRAULIC UNITS
c. Since the slipper ring (51) is extended when it
is installed, correct it using the corrective jig
(E).
2
E5D408
IV – 87
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.
IV – 88
CYLINDERS HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
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 it won’t a. Support the portion of the rod with the same
move smoothly, replace the rod if it makes a diameter at both ends on V-blocks.
squeaking sound in the operation test after reas- b. Set a dial gauge at the center between the two
sembly or if it catches during movement. blocks.
• If the inner diameter of the clevis bushing is worn, c. Rotate the rod and take a reading of the maximum
replace the bushing. and minimum runout indicated by the dial gauge.
Tube
• If there are cracks in the welded portion, replace 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.
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 – 89
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.
IV – 90
CYLINDERS HYDRAULIC UNITS
TROUBLESHOOTING
IV – 91
HYDRAULIC UNITS CYLINDERS
6&,"
Unit: mm
Sliding Jig (C) Fitting Jig (D)
A B C D E A B C
Arm 15.7 65.5 63.0 45.0 25.0 70.0 68.0 60.0
Bucket 15.7 65.5 63.0 45.0 25.0 70.0 68.0 60.0
REV. 1 IV – 92
CYLINDERS HYDRAULIC UNITS
Corrective Jig (E)
Unit: mm
A B
Arm 80 65
Bucket 80 65
MATERIAL: STKM13C
IV – 93
HYDRAULIC UNITS CYLINDERS
IV – 94
TRAVEL MOTOR HYDRAULIC UNITS
TRAVEL MOTOR
CONSTRUCTION
Hydraulic Motor
8 21 10 9 4 7 19 5 24
18 20 15 11 12 14 13 3 2 17 16 22 23 1 6
6&,#
IV – 95
HYDRAULIC UNITS TRAVEL MOTOR
Reduction Gears
Serial No. 21300004~21300311
26 15 31 17 24 27 30
5 4 19 25 18 11 13 17 12 32
33
8 3 3 10 7 6 23 22 23 9 16 21 14 28 1 29 34 2 20
0-3
0-4
REV. 1 IV – 96
TRAVEL MOTOR HYDRAULIC UNITS
Serial No. 21300312~
IV-96-1
IV – 97 REV. 1
TRAVEL MOTOR HYDRAULIC UNITS
2-speed Control Valve
3 2 9
7 5 6
4
1
Y Y
X
8
IV – 97
HYDRAULIC UNITS TRAVEL MOTOR
OPERATION
3 1 2 5 4
Hydraulic Motor
9 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
housing. A
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
plate (5) is divided into force F1, which pushes the F1
plate, and force F2, which rotates the cylinder block F2
(1). The total sum of the components in the direction F
of rotation of the high pressure side piston generates F
a rotational force in the cylinder block (1) and via the
spline, torque is transmitted to the shaft (4), turning it. F2
Conversely, if high pressure oil is introduced to port
C, rotation is the reverse of the above.
B C
F
F2
C4D553
2-Speed Mechanism
1st speed
When the pilot pressure is not supplied from port A,
the valve (1) is pushed to the left side by the force of
the spring (2) and the hydraulic oil of supply port B is
cut off. At this time, the oil in chamber C is released
into the motor case (3) via the valve (1).
Because of this, the swash plate (4) is set to the
maximum angle of inclination a, the motor’s piston
stroke capacity is the maximum, and the motor turns
at 1st (low) speed.
6%,#!
2nd speed
When the pilot pressure is supplied from port A, the
pilot pressure overcomes the force of the spring (2),
and the valve (1) is pushed to the right side. The
hydraulic oil of supply port B flows into chamber C
through the valve (1), the piston (5) pushes up the
swash plate (4) until it touches surface “b” of the
spindle (6) and keeps it against this surface.
At this time, the swash plate (4) is set to the minimum
angle of inclination β, the motor’s piston stroke
capacity is the minimum, and the motor turns at 2nd
(high) speed.
When the engine is stopped, the pilot pressure is cut
off, so the speed switches to 1st. 6%,#"
IV – 98
TRAVEL MOTOR HYDRAULIC UNITS
Parking Brake
The center discs (1) are connected to the flange holder
and the friction discs (2) are connected to the cylinder
block (3) via the spline, respectively. The center discs
(1) and friction discs (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.
ers the spring force and moves the brake piston (5) to
the right. This generates a clearance between the
center discs (1) and friction discs (2) to release the
parking brake. When the motor stops, the spool re-
turns to the neutral position to close the parking brake
release port (7). The pressure oil in the brake piston
chamber (8) is introduced into the motor case and the
spring (4) operates the parking brake.
2 1 8 7 5 4
C4D558
motor.
IV – 99
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.
Disassembly
1. Remove plugs (1), (2) and drain the gear oil.
• Amount of Gear Oil: 1.1 L
Plug: 58.8 ±9.8 N·m
6&,#!
6&,#"
6&,##
IV-100 REV. 1
HYDRAULIC UNITS TRAVEL MOTOR
6&,#$
T9D503
5
T9D504
7
T9D505
REV. 1 IV-101
TRAVEL MOTOR HYDRAULIC UNITS
13. Remove the bolts and thrust plate (8).
• When re-assembling, confirm that the screw
hole for the bolt of the flange holder is clean out
of any grease.
Bolt: 29.4 ±4.9 N·m
15. Remove the collar, the inner ring and the collar. 8
T9D506
C4D582
T9D508
T9D509
IV-102 REV. 1
HYDRAULIC UNITS TRAVEL MOTOR
T9D510
T9D513
T9D515
REV. 1 IV-103
TRAVEL MOTOR HYDRAULIC UNITS
26. Remove the center discs (23) and friction discs
(24) from flange holder.
• Total number of center discs: 5
• Total number of friction disc: 5
• When assembling, install the friction discs
after dipping them in the hydraulic oil.
23 24
T9D517
T9D516
T9D518
29. Remove the guide (27) and pins (28) from the
cylinder block.
T9D519
IV-104 REV. 1
HYDRAULIC UNITS TRAVEL MOTOR
T9D520
REV. 1 IV-104-1
TRAVEL MOTOR HYDRAULIC UNITS
INSPECTION AND ADJUSTMENT
IV-105 REV. 1
HYDRAULIC UNITS TRAVEL MOTOR
Test Driving
Upon completion of travel motor maintenance, con-
firm the performance by the testing according to the
following procedure:
1. Install the travel motor and the hydraulic piping
on the body.
• Do not install the crawler.
Left Travel
B A
(forward)
G 3/4
Right Travel
A B
(forward)
REV. 1 IV – 106
TRAVEL MOTOR HYDRAULIC UNITS
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.
IV – 107
HYDRAULIC UNITS TRAVEL MOTOR
IV – 108
V . TROUBLESHOOTING
IIIV––109
1
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.
VV––110
2
TROUBLESHOOTING
CONTENTS
OVERALL MACHINE
Complete failure of all systems. ............................................................................................................................ 4
All systems working, but with insufficient power. ................................................................................................ 7
Lift arms and bucket fail to move/Speed of operation poor. ................................................................................. 9
MACHINE TRAVEL
Travel train fault. ................................................................................................................................................. 10
Speed falls and machine veers to one side. ......................................................................................................... 12
The travel system is operating at an unusually high temperature. ...................................................................... 14
Machine will not travel in second speed. ............................................................................................................ 16
LIFT ARMS
Lift Arm cylinders fail to move. .......................................................................................................................... 18
Movement of the lift arm cylinders is slow or lacks power. ............................................................................... 20
Slowly pulling the control lever of the lift arms causes the lift arms to drop momentarily. ............................... 22
The amount of lift arms natural drop is great. ..................................................................................................... 23
BUCKET
Bucket cylinders fail to move. ............................................................................................................................. 24
Movement of the bucket cylinders is slow or lacks power. ................................................................................ 26
The amount of bucket natural drop is great. ........................................................................................................ 28
V–3
TROUBLESHOOTING OVERALL MACHINE
Normal
Normal
Normal
Faulty
4 Inspect the fuse. Replace fuse.
Normal
Normal
Inspect the lever lock so- Faulty Repair or replace lever lock
6
lenoid. solenoid.
Normal
Normal
V–4
OVERALL MACHINE TROUBLESHOOTING
1. Inspect the hydraulic oil level.
“III. Machine Configuration, Hydraulic
Tank”
Always be sure to use the same brand as that
currently being used when adding hydraulic oil.
“Specifications, Fluid Capacities”
!
#
!
6&-
V–5
TROUBLESHOOTING OVERALL MACHINE
4
ON 3
T7E002
T7E003
V–6
OVERALL MACHINE TROUBLESHOOTING
ALL SYSTEMS WORKING, BUT WITH INSUFFICIENT POWER.
Normal
Noise
3 Inspect the line filter. Replace the filter element.
No Noise
Normal
V–7
TROUBLESHOOTING OVERALL MACHINE
V–8
OVERALL MACHINE TROUBLESHOOTING
LIFT ARMS AND BUCKET FAIL TO MOVE/SPEED OF OPERATION POOR.
Normal
Normal
V–9
TROUBLESHOOTING MACHINE TRAVEL
Faulty
1 Inspect the pilot valve. Repair or replace pilot valve.
Normal
Inspect the charge pres- Pressure low Repair or replace HST pump
2
sure. charge relief valve.
Normal
Pressure low
V – 10
MACHINE TRAVEL TROUBLESHOOTING
1. Inspect the pilot valve.
Measure the secondary pressure of the pilot valve.
a. Disconnect the hose connecting the HST pump
(P1, P2) and the pilot valve at the pump.
b. Fit a pressure gauge to the hose.
c. Engage the travel lever and measure the pres-
sure.
• The pilot valve is working properly if pressure
varies from 0 to 3.0 MPa in accordance with
movement of the angle of the travel lever.
V – 11 REV. 1
TROUBLESHOOTING MACHINE TRAVEL
Faulty
3 Inspect the pilot valve. Repair or replace pilot valve.
Normal
Pressure low
The direction of travel curve
Perform replacement test changes to the opposite side
Repair or replace high pres-
5 for the high pressure re-
sure relief valve.
lief valves.
No change
V – 12
MACHINE TRAVEL TROUBLESHOOTING
1. Is the amount of travel curve within stan-
dard?
If the amount of travel curve is within standards,
then operation is normal and the variation de-
pends on the combination of equipment.
“II. Specifications, Standards for Judging
Performance”
V – 13
TROUBLESHOOTING MACHINE TRAVEL
Level normal
Inspect high pressure re- Faulty Repair or replace the high pres-
3
lief valves. sure relief valve.
Normal
Inspect the release pres- Pressure low Inspect the control valve (sub),
4
sure for the parking brake. filter, and hydraulic pump P4.
Normal
V – 14
MACHINE TRAVEL TROUBLESHOOTING
1. Inspect the hydraulic oil level.
Check the oil level in the hydraulic tank.
“IV. Hydraulic Units, Hydraulic Tank”
T7E004
V – 15 REV. 1
TROUBLESHOOTING MACHINE TRAVEL
Normal
Normal
Normal
Normal
V – 16
MACHINE TRAVEL TROUBLESHOOTING
3. Inspect the travel speed switch.
Press the switch to turn it “ON”. While it is in this
condition, check if there is continuity with a
tester.
T7E005
T7E006
V – 17
TROUBLESHOOTING LIFT ARMS
Faulty
2 Inspect the pilot valve. Repair or replace pilot valve.
Normal
Normal
Operation be-
Perform replacement test came normal. Problem lies with port Repair or replace port relief
4
for the port relief valves. relief valve. valve.
No change
Inspect the arm float so- Faulty Repair or replace arm float
5
lenoid valve. solenoid valve.
Normal
Inspect the lift arm cylin- Repair or replace lift arm cyl-
6
ders. inder.
T7E007
REV. 1 V – 18
LIFT ARMS TROUBLESHOOTING
3. Inspect movement of the spool.
a. Disconnect one of the hoses connected to the
lift arm section of the control valve.
b. Fit a pressure gauge to the lift arm section.
c. Engage the lever to operate the lift arms and
measure the pressure.
• The lift arms are working properly if the pres-
sure is within the specified values.
B1
A1
T7E008
T7E009
T7E010
V – 19
TROUBLESHOOTING LIFT ARMS
Faulty
2 Inspect the pilot valve. Repair or replace pilot valve.
Normal
Normal
Operation be-
Perform replacement test came normal. Port relief valve is at Repair or replace port relief
4
for the port relief valves. fault. valve.
No change
Inspect the arm float so- Faulty Repair or replace arm float
5
lenoid valve. solenoid valve.
Normal
Inspect for leaks within Faulty Repair or replace lift arm cyl-
6
the lift arm cylinders. inder.
V – 20
LIFT ARMS TROUBLESHOOTING
6. Inspect for leaks within the lift arm cylinders.
a. Tilt the bucket slightly forward (about 10 de-
grees) and bring the front edge of the bucket
down and into contact with the ground.
b. Check the left and right lift arm cylinders
individually. Disconnect the hose from the
cylinder not being checked and insert a plug in
place of the removed hose.
c. Disconnect the hose to the rod end from the
cylinder to be checked and release the oil in the
pipes within. Be sure to insert a plug into the
hose just removed.
d. Tilt the bucket backward and bring it up off of
the ground.
• If oil comes out of the rod piping and the lift
arms come down, you may assume that there is
a leak within the cylinder. If the lift arms come
down but no oil comes out, you may assume
that there is a leak in the control valve.
V – 21
TROUBLESHOOTING LIFT ARMS
SLOWLY PULLING THE CONTROL LEVER OF THE LIFT ARMS CAUSES THE LIFT ARMS TO
DROP MOMENTARILY.
Normal
Inspect for leaks inside Faulty Repair or replace lift arm cyl-
2
the lift arm cylinders. inder.
V – 22
LIFT ARMS TROUBLESHOOTING
THE AMOUNT OF LIFT ARMS NATURAL DROP IS GREAT.
Inspect for leaks within Faulty Repair or replace lift arm cyl-
2
the lift arm cylinders. inder.
Normal
Inspect the arm float so- Faulty Repair or replace arm float
3
lenoid valve. solenoid valve.
Normal
Operation be-
Perform replacement test came normal. Problem lies with port Repair or replace port relief
4
for the port relief valves. relief valve. valve.
No change
V – 23
TROUBLESHOOTING BUCKET
Faulty
2 Inspect the pilot valve. Repair or replace pilot valve.
Normal
Normal
Operation be-
Perform replacement test came normal. Problem lies with port Repair or replace port relief
4
for the port relief valves. relief valve. valve.
No change
T7E011
REV. 1 V – 24
BUCKET TROUBLESHOOTING
3. Inspect movement of the spool.
a. Disconnect one of the hoses connected to the
bucket section of the control valve.
b. Fit a pressure gauge to the bucket section.
c. Engage the lever to operate the bucket cylin-
ders and measure the pressure.
• The spool is working properly if the pressure is
within the specified values.
T7E012
T7E009
T7E013
V – 25
TROUBLESHOOTING BUCKET
Faulty
2 Inspect the pilot valve. Repair or replace pilot valve.
Normal
Normal
Operation be-
Perform replacement test came normal. Problem lies with port Repair or replace port relief
4
for the port relief valves. relief valve. valve.
No change
V – 26
BUCKET TROUBLESHOOTING
1. Is the speed of the bucket cylinders within the
specified range?
“II. Specifications, Standards for Judging
Performance”
V – 27
TROUBLESHOOTING BUCKET
Normal
V – 28
VI . ENGINE
III – 29 REV. 1
/'
series
(Direct Injection System)
Publication No. M9961-02E050
History of Revision
Manual Name Service Manual for Industrial Diesel Engine
Engine Model: 3TNV, 4TNV series (Direct Injection System)
Number
Date of Reason for Correction item Corrected
of Outline of correction
revision correction No (page) by
revision
New edition Oct 2003
R.1 June, Revision, 1) Revision of the fuel injection 1) P46,47,48-1,48-2 Quality
2004 addition & timing adjustment Assurance
correction 2) Addition of the compression 2) P64 Dept.
gauge adopter Small
3) Addition of C.S.D. 3) P117 Engine
4) Addition of copy right 4) (Preface) Factory
5) Revision of the long storage 5) P52
6) Addition of tip clearance 6) P110
7) Revision of cover page 7) Cover page
8) Revision of FO,LO & coolant 8) P14,15-1,15-2
9) Addition of starting moter. 9) 175-1,175-2,
10) Other corrections 175-3
10) P5,20,50,57,61,
41,79,84,92,94,
81,102,103,108,
109-1,109-2,
111-1,111-2,109,
185-1,185-2,188,
193,195,196
Printed in Japan
M9961-02E050
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 housing
Pump flange
Don't disassemble! Fuel pump drive gear Crankshaft
gear
Flange bolt
ԛGear case
ԣOil seal
ԚCrankshaft pulley
Note) This figure shows the 3TNV84.
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 ............................................................................................................. 53
3.1 Preparation before troubleshooting ........................................................................................53
3.2 Quick reference table for troubleshooting ..............................................................................54
3.3 Troubleshooting by measuring compression pressure ..........................................................57
4. Disassembly, inspection and reassembly of engines .................................................... 59
4.1 Complete disassembly and reassembly .................................................................................59
4.1.1 Introduction ..................................................................................................................................... 59
4.1.2 Special service tools ....................................................................................................................... 60
4.1.3 Complete disassembly.................................................................................................................... 65
4.1.4 Precautions before and during reassembly .................................................................................... 69
4.1.5 Adjusting operation ......................................................................................................................... 69
4.2 Cylinder head: Disassembly, inspection and reassembly ......................................................70
4.2.1 Components (2-valve cylinder head) .............................................................................................. 70
4.2.2 Disassembly procedure: ................................................................................................................. 70
4.2.3 Reassembly procedure: .................................................................................................................. 71
4.2.4 Servicing points............................................................................................................................... 72
4.2.5 Parts Inspection and measurement ................................................................................................ 76
4.2.6 Valve seat correction ...................................................................................................................... 80
4.2.7 Valve guide replacement ................................................................................................................ 81
4.2.8 Valve stem seal replacement.......................................................................................................... 82
4.3 Gear train and camshaft .........................................................................................................83
4.3.1 Components.................................................................................................................................... 83
4.3.2 Disassembly procedure: ................................................................................................................. 83
4.3.3 Reassembly procedure: .................................................................................................................. 83
4.3.4 Servicing points............................................................................................................................... 84
4.3.5 Parts inspection and measurement ................................................................................................ 87
4.3.6 Oil seal replacement (Gear case side)............................................................................................ 89
4.3.7 Camshaft bushing replacement ...................................................................................................... 89
4.4 Cylinder block .........................................................................................................................90
4.4.1 Components.................................................................................................................................... 90
4.4.2 Disassembly procedure: ................................................................................................................. 90
4.4.3 Reassembly procedure: .................................................................................................................. 90
4.4.4 Servicing points............................................................................................................................... 91
4.4.5 Parts inspection and measurement ................................................................................................ 95
4.4.6 Cylinder bore correction................................................................................................................ 106
4.4.7 Piston pin bushing replacement.................................................................................................... 107
4.4.8 Oil seal replacement (Flywheel housing side) .............................................................................. 107
1. General
1.1 Engine nomenclature
T: With turbocharger
None: Natural aspirated engine
Model series
Number of cylinders
Ú The engine specification class (CL or VM) is described in the specifications table.
1.2 Specifications
NOTE:
1)The information described in the engine specifications tables (the next page and after) is for "standard"
engine. To obtain the information for the engine installed in each machine unit, refer to the manual pro-
vided by the equipment manufacturer.
2)Engine rating conditions are as follows (SAE J1349, ISO 3046/1)
• Atmospheric condition: Room temp. 25 °C, Atmospheric press. 100 kPa (750 mm Hg), Relative humidity
30 %
• Fuel temp: 25 °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) 3TNV82A
Engine name Unit 3TNV82A
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 82 × 84
Displacement L 1.331
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 9.9 12.0
Output -
(ps) (13.5) (16.3)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 11.0 13.2 14.6 16.0 17.5 18.2 19.0 20.4 21.9
Output
(ps) (14.9) (17.9) (19.9) (21.8) (23.8) (24.8) (25.8) (27.8) (29.8)
Max. no-load speed (± 25) min-1 1600 1895 2180 2375 2570 2675 2780 2995 3180
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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 5.5
(oil pan) * Effective L 1.9
Cooling water capacity
L 1.8
(engine only)
Overall
mm 553 528
Engine Dimensions ** length
(with flyw Crankshaft Overall
mm 489
V pulley diameter & width
heel housing) *
Overall
mm 565
height
Engine mass (dry) *,**
kg 138 128
(with flywheel housing)
Cooling fan (std.) * mm 335 mm O/D, 6 blades pusher type F
Fun V pulley diameter (std.) * mm 120 × 90 110 × 110
* Items marked * may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
2
1. General
(2) 3TNV84
Engine name Unit 3TNV84
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.496
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 11.3 13.5
Output -
(ps) (15.3) (18.3)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 12.4 14.8 16.4 18.1 19.7 20.5 21.3 23.0 24.6
Output
(ps) (16.8) (20.1) (22.3) (24.6) (26.8) (27.9) (29.0) (31.3) (33.5)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2690 2810 2995 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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD
Lubricant capacity Total L 6.7
(oil pan) * Effective L 2.8
Cooling water capacity
L 2.0
(engine only)
Overall
mm 589 564
length
*
Overall
Engine dimensions ** mm 486
width
(with flywheel housing)
Overall
mm 622
height
Engine mass (dry) *,**
kg 161 155
(with flywheel housing)
Cooling fan (std.) * mm 335 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 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
3
1. General
(3) 3TNV84T
Engine name Unit 3TNV84T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.496
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 14.0 16.5
Output -
(ps) (19.0) (22.5)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 15.8 18.8 25.0 26.0 26.8 29.1 30.9
Output
(ps) (21.5) (25.5) (34.0) (35.3) (36.5) (39.5) (42.0)
Max. no-load speed (± 25) min-1 1600 1895 2590 2700 2810 2995 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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 6.7
(oil pan) * Effective L 2.8
Cooling water capacity
L 2.0
(engine only)
Overall
mm 589 564
length
*
Overall
Engine dimensions ** mm 486
width
(with flywheel housing)
Overall
mm 622
height
Engine mass (dry) *,**
kg 161 155
(with flywheel housing)
Cooling fan (std.) * mm 350 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 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
4
1. General
(4) 3TNV88
Engine name Unit 3TNV88
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 3
Cylinder bore × stroke mm × mm 88 × 90
Displacement L 1.642
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 12.3 14.8
Output -
(ps) (16.7) (20.1)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 13.5 16.3 18.0 19.9 21.6 22.6 23.5 25.2 27.1
Output
(ps) (18.4) (22.1) 24.5) (27.0) (29.4) (30.7) (31.9) (34.2) (36.8)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810 2995 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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 6.7
(oil pan) * Effective L 2.8
Cooling water capacity
L 2.0
(engine only)
Overall
mm 589 564
length
*
Overall
Engine dimensions ** mm 486
width
(with flywheel housing)
Overall
mm 622
height
Engine mass (dry) *,**
kg 155
(with flywheel housing)
Cooling fan (std.) * Mm 335 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
Mm 120 × 90 110 × 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)
5
1. General
(5) 4TNV84
Engine name Unit 4TNV84
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.995
Revolving
speed Min-1 1500 1800 -
Continuous
Rating kW 14.9 17.7
Output -
(ps) (20.3) (24.1)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 16.4 19.5 21.9 24.1 26.3 27.4 28.5 30.7 32.9
Output
(ps) (22.3) (26.5) (29.8) (32.8) (35.8) (37.3) (38.7) 41.7) (44.7)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810 2995 3210
Ignition order - 1-3-4-2-1 (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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 7.4
(oil pan) * Effective L 3.4
Cooling water capacity
L 2.7
(engine only)
Overall
mm 683 658
length
*
Overall
Engine dimensions ** mm 498.5
width
(with flywheel housing)
Overall
mm 617
height
Engine mass (dry) *,**
kg 183 170
(with flywheel housing)
Cooling fan (std.) * mm 370 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 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
6
1. General
(6) 4TNV84T
Engine name Unit 4TNV84T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 84 × 90
Displacement L 1.995
Revolving
speed Min-1 1500 1800 -
Continuous
rating KW 19.1 24.3
Output -
(ps) (26.0) (33.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2600 2800 3000
Rated output
KW 21.3 26.9 27.9 30.5 33.5 35.7 38.6 41.2
Output
(ps) (29.0) (36.5) (38.0) (41.5) (45.5) (48.5) (52.5) (56.0)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2810 2995 3210
Ignition order - 1-3-4-2-1 (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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 7.4
(oil pan) * Effective L 3.4
Cooling water capacity
L 3.2
(engine only)
Overall
mm 683 649
length
Engine Overall
mm 498.5
dimensions *,** width
Overall
mm 713
height
Engine mass (dry) *,**
kg 183 170
(with flywheel housing)
Cooling fan (std.) * mm 370 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 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
7
1. General
(7) 4TNV88
Engine name Unit 4TNV88
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 88 × 90
Displacement L 2.190
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 16.4 19.6
Output -
(ps) (22.3) (26.7)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600 2800 3000
Rated output
kW 18.0 21.6 24.1 26.5 28.8 30.1 31.3 33.7 35.4
Output
(ps) (24.5) (29.4) (32.7) (36.0) (39.2) (40.9) (42.5) (45.8) (48.1)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810 2995 3210
Ignition order - 1-3-4-2-1 (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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 7.4
(oil pan) * Effective L 3.4
Cooling water capacity
L 2.7
(engine only)
Overall
mm 683 658
length
*
Overall
Engine dimensions ** mm 498.5
width
(with wheel housing)
Overall
mm 618
height
Engine mass (dry) *,**
kg 183 170
(with flywheel housing)
Cooling fan (std.) * mm 370 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 120 × 90 110 × 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
8
1. General
(8) 4TNV94L
Engine name Unit 4TNV94L
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 94 × 110
Displacement L 3.054
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 26.1 31.3
Output -
(ps) (35.5) (42.5)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500
Rated output
kW 29.1 34.6 35.3 38.2 41.6 43.0
Output
(ps) (39.5) (47.0) (48.0) (52.0) (56.5) (58.5)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700
Ignition order - 1-3-4-2-1 (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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 10.5
(oil pan) * Effective L 4.5
Cooling water capacity
L 4.2
(engine only)
Overall
mm 719
length
*
Overall
Engine dimensions ** mm 498
width
(with flywheel housing)
Overall
mm 742
height
Engine mass (dry) *,** 245 235
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 4)
Cooling fan (std.) * mm 410 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 130 × 130
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
9
1. General
(9) 4TNV98
Engine name Unit 4TNV98
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 98 × 110
Displacement L 3.319
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 30.9 36.8
Output -
(ps) (42.0) (50.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500
Rated output
kW 34.6 41.2 41.9 45.6 49.3 51.1
Output
(ps) (47.0 (56.0) (57.0) (62.0) (67.0) (69.5)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700
Ignition order - 1-3-4-2-1 (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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 10.5
(oil pan) * Effective L 4.5
Cooling water capacity
L 4.2
(engine only)
Overall
mm 719
length
*
Overall
Engine dimensions ** mm 498
width
(with flywheel housing)
Overall
mm 742
height
Engine mass (dry) *,** 248 235
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 4)
Cooling fan (std.) * mm 410 mm O/D, 6 blades pusher type F
Crankshaft V pulley diameter &
mm 130 × 130
Fun V pulley diameter (std.) *
* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.
** Engine mass and dimensions without radiator
10
1. General
(10)4TNV98T
Engine name Unit 4TNV98T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 88 × 110
Displacement L 3.319
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 37.9 45.6
Output -
(ps) (51.5) (62.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500 2600
Rated output
kW 41.9 50.4 50.7 55.5 60.3 62.5 64.0
Output
(ps) (57.0) (68.5) (69.0) (75.5) (82.0) (85.0) (87.0)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700 2810
Ignition order - 1-3-4-2-1 (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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 10.5
(oil pan) * Effective L 4.5
Cooling water capacity
L 4.2
(engine only)
Overall
mm 715
length
*
Overall
Engine dimensions ** mm 575
width
(with flywheel housing)
Overall
mm 804
height
Engine mass (dry) *,** 258 245
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 4)
Cooling fan (std.) mm 430 mm O/D, 8 blades suction type
Crankshaft V pulley diameter &
mm 130 × 130
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
11
1. General
(11)4TNV106
Engine name Unit 4TNV106
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 106 × 125
Displacement L 4.412
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 41.2 49.3
Output -
(ps) (56.0) (67.0)
Revolving
speed Min-1 1500 1800 2000 2200 2400 2500
Rated output
kW 45.6 54.4 56.6 61.4 65.5 67.7
Output
(ps) (62.0 (74.0) (77.0) (83.5) (89.0) (92.0)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400 2590 2700
Ignition order - 1-3-4-2-1 (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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 14.0
(oil pan) * Effective L 9.0 7.5
Cooling water capacity
L 6.0
(engine only)
Overall
mm 808 776
length
*
Overall
Engine dimensions ** mm 629 629
width
(with flywheel housing)
Overall
mm 803 803
height
Engine mass (dry) *, ** 345 330
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 3)
500 mm O/D, 500 mm O/D,
Cooling fan (std.) * mm
7 blades pusher type 7 blades suction type
Crankshaft V pulley diameter &
mm 150 × 150
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
12
1. General
(12)4TNV106T
Engine name Unit 4TNV106T
Engine specification class - CL VM
Type - Vertical, in-line, 4-cycle, water-cooled diesel engine
Combustion chamber - Direct injection
Number of cylinders - 4
Cylinder bore × stroke mm × mm 106 × 125
Displacement L 4.412
Revolving
speed Min-1 1500 1800 -
Continuous
rating kW 51.5 61.8
Output -
(ps) (70.0) (84.0)
Revolving
speed Min-1 1500 1800 2000 2200
Rated output
kW 56.8 68.0 69.9 72.0
Output
(ps) (77.2 (92.5) (95.0) (97.9)
Max. no-load speed (± 25) min-1 1600 1895 2180 2400
Ignition order - 1-3-4-2-1(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-ISO 8217 DMA, BS 2869 A1 or A2
Applicable fuel -
(Cetane No.45 min.)
Applicable lubricant - API grade class CD or CF
Lubricant capacity Total L 14.0
(oil pan) * Effective L 9.0 7.5
Cooling water capacity
L 6.0
(engine only)
Overall
mm 808 776
length
*
Engine dimensions ** Overall
mm 629 629
(with flywheel width
housing) Overall
mm 866 866
height
Engine mass (dry) *, ** 355 340
kg
(with flywheel housing) (equivalent to SAE # 3) (equivalent to SAE # 3)
500 mm O/D, 500 mm O/D,
Cooling fan (std.) * mm
7 blades pusher type 7 blades suction type
Crankshaft V pulley diameter &
mm 150 × 150
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
13
1. General
Outlet
(to engine)
Drain cock
(R.1))
14
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)
15-1
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)
15-2
1. General
Lifting eye
Governor lever
Fuel injection pump
Cooling fan
Flywheel
Alternator
Exhaust manifold
Starter motor
16
1. General
Emission Reduction
Emission Reduction
New fuel injection pump
Cylinder Head
Mono Plunger
Optimal Nozzle Angle
Higher Injection Pressure
Optimal Swirl Ratio
Injection Timing Control
Optimal Valve Timing
Speed Timer, _oad Timer,
Cold Start timer
Emission Reduction
Noise Reduction Piston
Higher Stiffness Cylinder Block New Combustion
Chamber
Noise Reduction
Higher Stiffness Gear-Case
17
1. General
18
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
$ %
&
' ( )
'%&+4'%6+8'
#
$
%
19
1. General
Plate
Copper gasket
Nut Injection quant
limit bc
(R.1)
20
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 Inspections".
21
2. Inspection and adjustment
22
2. Inspection and adjustment
23
2. Inspection and adjustment
(Unit: liter)
Model Total volume (L) Effective volume (L)
3TNV82A 5.5 1.9
3TNV84 (T)•88 6.7 2.8
4TNV84 (T)•88 7.4 3.4
4TNV94L98•(T) 10.5 4.5
4TNV106 (T) (CL class) 14.0 9.0
4TNV106 (T) (VM class) 14.0 7.5
Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit.
[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
radiator is cooled down after the engine has stopped, wrap the filler cap with
a rag piece and turn the cap slowly to gently release the pressure inside the
radiator.
•Securely tighten the filler cap after checking the radiator. Steam can spurt
out during operation, if the cap is tightened loosely.
(a)Checking coolant water volume
Check the coolant water level in the Coolant recovery tank. If the water level is close to the LOW mark, open
the Coolant recovery tank cap and replenish the Coolant recovery tank with clean soft water to the FULL
mark.
Standard
The water level of the Coolant recovery tank shall be between the upper and lower limit lines.
IMPORTANT:
If the coolant 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 Coolant water volume In an engine
3TNV82A 1.8
3TNV84 (T)
2.0
3TNV88
4TNV84 (T)
2.7
4TNV88
4TNV94L
4.2
4TNV98 (T)
4TNV106 (T) 6.0
Engine coolant water capacity may differ from the above
volume depending on an engine installed on a machine unit.
(5) Fuel pipe and coolant water pipe inspection and maintenance
Check the rubber hoses for fuel and coolant water pipes cracked. If the cracked hose is found, replace it with
new one. Check the loosened clamp. If found, tighten it.
When an engine is still hot, be careful with a splash of engine oil which may
cause burns. Replace engine oil after the engine oil becomes warm. It is
most effective to drain the engine oil while the engine is still warm.
25
2. Inspection and adjustment
IMPORTANT:
Do not overfill the oil pan with engine oil.
Be sure to keep the specified level between upper
and lower limit on the dipstick.
(Unit: mm)
Direction A B C
For used V-belt 10 to 14 7 to 10 9 to 13
For new V-belt 8 to 12 5 to 8 7 to 11
27
2. Inspection and adjustment
Drain plug
OPTION
NOTE:
If no drain drips when the drain cock is opened, loosen the air bleeding bolt on the top of the water separator
by turning counter-clockwise 2 to 3 times using screw driver.
(This may occur in case of the water separator position is higher than the fuel oil level in the fuel tank). After
draining, be sure to tighten the air bleeding bolt.
28
2. Inspection and adjustment
29
2. Inspection and adjustment
Battery structure
Terminal Cap
Cover
Cathode
plate
Separator
Glass mat
Battery
case
Anode plate
30
2. Inspection and adjustment
S20 = St + 0.007(t-20)
Electrolyte temperature
at measurement
Specific gravity at measurement
Converted specific gravity at 20͠
Battery charge measurement
with a hydrometer
1.24 20 80
1.23 25 75
Hydrometer structure
(3) Terminals
Clean if corroded or soiled.
31
2. Inspection and adjustment
(1) Lube oil and filter replacement (The second replacement and after)
Replace the engine oil every 250 hours operation from 2nd time and on. Replace the engine oil filter at the
same time. Refer to 2.2.1.(1).
32
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
33
2. Inspection and adjustment
IMPORTANT:
• When the engine is operated in dusty conditions,
clean the element more frequently.
• Do not run the engine with removed air cleaner or
element, as this may cause foreign material to enter
and damage the engine.
34
2. Inspection and adjustment
(Disconnect the coupler of the lead wire for drain Float ring
sensor before removing the cup if it is with drain
Drain cock
sensor). Water separator
5)Wash the element and inside cup with clean fuel oil.
Replace the element with new one if any damaged.
35
2. Inspection and adjustment
IMPORTANT:
Be sure to use genuine Yanmar part (super fine mesh
filter). Otherwise, it results in engine damage, uneven
engine performance and shorten engine life.
36
2. Inspection and adjustment
Beware of scalding
by hot water FULL
Coolant (Max.limit)
Wait until the temperature recovery tank
goes down before draining
the coolant water. Otherwise,
hot water may splash to
cause scalding. LOW
(Min.limit)
Drain plug
(Drain plug location depends on the machine unit)
1)Remove the radiator cap.
2)Loosen the drain plug at the lower portion of the radi-
ator and drain the cooling water.
3)After draining the cooling water, tighten the drain
plug.
4)Fill radiator and engine with cooling water.
a)Before filling, check to be sure the drain plug is closed.
b)Remove the radiator cap of the radiator by turning the radiator cap counter-clockwise about 1/3 of a
turn.
c)Pour the cooling water slowly into the radiator up to the lip of the filler port so that air bubbles do not
develop.
d)After supplying the cooling water, surely tighten the radiator cap. To fasten the radiator cap, align the
detents on the back face of the radiator cap with the slot of the filler port and turn clockwise pushing it
downward approx. 1/3 of a turn until contact with each other.
e)Remove the cap of the coolant recovery tank, supply the cooling water to the FULL mark and fasten the
cap.
f)Check the rubber hose connecting the coolant recovery tank to the radiator. Be sure the rubber is
securely connected and there is no looseness or damage. When the rubber hose is not water tight, an
excessive amount of cooling water will be consumed.
37
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 self-bleeded 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.
Daily check of the cooling water level and refilling can be done by observing the coolant recovery
tank.
The cooling water capacity of the radiator depends on the machine unit. Refer to the operation
manual provided by the equipment manufacturer.
Check the cooling water level when the engine is cold. Cooling water flows to the coolant
recovery tank when the radiator is still hot and makes accurate checks impossible.
38
2. Inspection and adjustment
It causes an accident when large quantity of washing liquid is poured rapidly into a turbocharger.
2)Pour the same amount of clear water as washing liquid/water into the blower about 3-5 minutes later after
the washing liquid/water injection and wash it.
It causes an accident when large quantity of water is poured rapidly into a turbocharger.
3)Repeat the washing after then minutes when there is no change with the boost pressure or the exhaust
gas temperature after washing.
When there is no change at all even if it repeats 3-4 times, disassemble and maintain the turbocharger
because of the cruel dirt of the blower or other causes.
4)Operate the engine at load for at least 15 minutes after washing, and dry.
39
2. Inspection and adjustment
40
2. Inspection and adjustment
The cylinder to be adjusted first does not have to be the No.1 cylinder. Select and adjust the cylinder
where the piston is the nearest to the top dead center after turning, and make adjustment for other cylin-
ders in the order of ignition by turning the crankshaft 240° each time.
The adjustment method of reducing the flywheel turning numbers (for reference):
For 3 cylinder engines
Set No.1 cylinder to the compression T.D.C.and adjust the clearance of the z mark of the below table.
Next, turn the flywheel once (the suction / exhaust valve of No.1 cylinder is in the position of the overlap
T.D.C. at this time), and adjust the clearance of the c mark.
Ignition order of 3 cylinder engines: 1J3J2
Cylinder No. 1 2 3
Valve Suction Exhaust Suction Exhaust Suction Exhaust
No.1
compression z z z z The first time
T.D.C
No.1
overlap c c The second time
T.D.C
wear.
Normal Abnormal
[NOTICE]
Valve
When loosening a locknut of a valve bridge, loosen bridge
the locknut while fixing the valve bridge with a Wrench
wrench so that the valve may not lean. 4 Valve cylinder head
(R.1)
41
2. Inspection and adjustment
Adjust
clearance
to 0
mm
Model Standard valve clearance
3TNV82A to 98 0.15 to 0.25
4TNV106 (T) 0.25 to 0.35
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.
Standard
Model
MPa (kgf/cm2)
19.6-20.6
3TNV82A to TNV88 (CL)
(200-210)
Nozzle tester
3TNV82A to TNV88 (VM) 21.6-22.6
4TNV94L4 to TNV106(T) (220-230)
[NOTICE]
As for the opening pressure of the brand-new fuel Injection nozzle
0.13, 0.15, 0.18, 0.4, 0.5, 0.8 The injection pressure is increased by approx. l.9 MPa (l9 kgf/cm2),
when the adjusting shim thickness is increased by 0.l mm.
43
2. Inspection and adjustment
44
2. Inspection and adjustment
YANMAR
Punch mark
45
2. Inspection and adjustment
Operation side
(R.1)
46
2. Inspection and adjustment
Marking
0.5 cam
Mark sticker
(R.1)
47
2. Inspection and Adjustment
4)Remove a fuel pump, and read the fuel injection angle recorded in that fuel pump.
5)Read the injection angle recorded on a newly assembled fuel pump and calculate the difference from the
injection angle of the disassembled fuel pump. (When re-installation does the same fuel pump, the angu-
lar difference is zero.)
Fuel injection angle difference ∆ θi (cam angle) = (the fuel injection angle θi2 of a new fuel pump)
- (the fuel injection angle θi1 of a disassembled previous fuel pump)
Calculation example
Fuel injection angleFuel injection angle Fuel injection angle
difference of a new fuel pump of a disassembled
Fuel pump installation method
θi2 fuel pump θi1
(degree, cam angle) (degree, cam angle) (degree, cam angle)
Turn the fuel pump body in the outside
directon of the cylinder block at 0.5
+0.5 8.5 8.0
degree(cam angle).
[Advanced injection timing]
Turn the fuel pump body in the inside
direction of the cylinder block at 0.3
-0.3 7.7 8.0
degree(cam angle).
[Delayed injection timing]
[NOTICE]
Tell the fuel pump number to Yanmar, and inquire the injection angle of the pump when it is hard to find out.
6)Put the fuel pump on the gear case temporarily and install the drive gear on the cam shaft with checking
the ID marks, which were put on the fuel pump drive gear and the idle gear at the time of the disassem-
bling.
(R.1)
48-1
2. Inspection and Adjustment
(Supplementary explanation 1)
ǰ
The installation angle of the fuel pump is as follows.
Installation angle
Model
θ (deg.)
3TNV82A to TNV88 25 Cylinder block side
4TNV94L/98/106 (T) 13
4TNV106 (T) 11.5
(Supplementary explanation 2)
When fuel injection timing is advanced or delayed, the Delayed
installation angle of the fuel pump is adjusted. Advanced
When fuel injection timing is advanced for example at
0.5 degrees(cam), loosen the nuts, which fix the fuel
Cylinder block side
pump on the gear case, and turn the fuel pump body in
the inside direction of the cylinder block at 0.5
degree(cam), and tighten the pump installation nuts.
And, when fuel injection timing is delayed, a pump is
turned in that reverse direction.
(R.1)
48-2
2. Inspection and Adjustment
49
2. Inspection and Adjustment
Tester probes
Continuity test
Thermo switch
Hot water
(R.1)
50
2. Inspection and Adjustment
Radiator cap
Thermo switch
Thermometer
Thermostat
51
2. Inspection and Adjustment
Note:
Check the levels of the lubricating oil and coolant water again after test running (for about 5 minutes) and add
as required.
2)Start the engine, and carry out idling at a low revolution (700 to 900 rpm) for a few minutes.
3)Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak
and existence of abnormal vibration or noise. Also check the oil pressure, coolant water temperature and
exhaust gas color.
4)Adjust the no-load minimum and maximum revolutions according to the specifications.
5)Perform loaded operation as required.
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)
52
3. Troubleshooting
3. Troubleshooting
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.
• lInvestigate 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.
• lWhen was the engine maintained last time?
• lHow much period and/or time has it been used after it was maintained last time?
• lWhat kind of problem was there on the engine last time, and what kind of maintenance was dane?
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)
• lWhen did the trouble happen at what kind of time?
• lWas there anything changed before the trouble?
• lDid the trouble occur suddenly, or was there what or a sign?
• lWas 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.
53
3. TROUBLESHOOTING
Poor
Excessive consumption
Pressure drop
Pressure rise
During idling
During work
Overheat
Ordinary
Cause
White
White
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 (4) 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 4.2.2-12) in Chapter4.)
Seized or broken piston ring c 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 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.)
Engine system
54
3. TROUBLESHOOTING
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 2.2.7 in Chapter2.)
Defective thermostat (kept opened) (See 2.2.7 in Chapter2.)
Cooling Water System
Improper properties of lubricating oil c c c c c c Use proper lubricating 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 Perform draining from the fuel filter. (See 2.2.3 and 2.2.5 in Chapter2.)
Clogged fuel filter c c c Clean or replace. (See 2.2.5 in Chapter2.)
Air entrance in fuel system c c c Perform air bleeding. (See 2.2.3 in Chapter2.)
Fuel system
55
3. TROUBLESHOOTING
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 c Clean. (See 2.2.4 in Chapter2.)
Air/Exhaust Gas System
Engine used at high temperatures or at high altitude c 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 in Chapter2.)
56
3. TROUBLESHOOTING
(R.1)
57
3. TROUBLESHOOTING
3/4TNV88㨪4TNV106(T)
Compression pressure (kgf/cm2)
40 4
30 3
3TNV82A
25
3/4TNV84T
20 2
58
4. Disassembly, inspection and reassembly of engines
Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.
2)Remove the coolant water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven
machine and engine, and drain coolant water, lubricating 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.
59
4. Disassembly, inspection and reassembly of engines
̪Locally manufactured
Valve guide tool
(for inserting valve চ
guide) Model L1 L2 d1 d2
3TNV82A 12 60 13 19
4TNV84
3TNV84(T) 15 65 14 20
3/4TNV88
2
4TNV84T 8.5 60 11 17
4TNV94L 98(T) 7 60 13 16
4TNV106(T) 13.6 65 13 16
̪Locally manufactured
Connecting rod
bushing replacer চ
(for removal / Model L1 L2 d1 d2
installation of 3TNV82A 25 85 23 26
connecting rod
bushing) TNV84 88 20 100 26 29
3 4TNV94L 98 20 100 30 33
4TNV106(T) 20 100 37 40
̪Locally manufactured
Valve spring
compressor
(for removal /
installation of valve
spring) yanmar code No.
4
129100-92630
60
4. Disassembly, inspection and reassembly of engines
Filter wrench
(for removal /
6 Available on the market
installation of L.O.
filter)
Camshaft bushing
tool চ
(for extracting Model L1 L2 d1 d2
camshaft bushing) TNV82A 88 18 70 45 48
7 4TNV94L 98 18 70 50 53
4TNV106(T) 18 70 58 61
Allowance: d1 -- 00..36 d2 -- 00..36
̪Locally manufactured
Flex-Hone
(For re-honing of Cylinder
cylinder liner) Model Parts No. bore
(চ)
TNV82A 129400-92420 78 84
8
TNV88 4TNV94L 129400-92430 83 95
Piston insertion
tool Yanmar code No. 95550-002476
9 (for inserting ̪The above piston insertion tool is applicable
piston) to 60-125 mm diameter pistons.
Crankshaft pulley
installing tool Locally manufactured
11 (for 4TNV94L)
(Refer to 4.3.6 in detail)
(R.1)
61
4. Disassembly, inspection and reassembly of engines
1 Dial gage
2 Test indicator
3 Magnetic stand
4 Micrometer
5 Cylinder gage
6 Calipers
7 Depth micrometer
62
4. Disassembly, inspection and reassembly of engines
9 V-block
10 Torque wrench
11 Thickness gage
12 Cap tester
14 Nozzle tester
abcdefghijklmn
abcdefghijklmn
abcdefghijklmn
15 Digital thermometer
abcdefghijklmnabcdefghijklmn
abcdefghijklmnabcdefghijklmn
Float
63
4. Disassembly, inspection and reassembly of engines
Contact type
16 Speedometer
For measuring revolution by sensing
Revolving shaft
the reflecting mark on the outer
periphery of the revolving shaft
Photoelectric type
Reflection mark
17 Circuit tester
130
18 Compression gage kit
(R.1)
64
4. Disassembly, inspection and reassembly of engines
1)Remove valve rocker arm shaft assembly. 1)Attach a tag to push rod for each cylinder No. to
2)Remove push rod. put the push rod in order.
2)Remove valve cap from the intake/exhaust
valve head.
5 3)Note that tappet of the indirect injection system
can be removed at the same time when push
rod is extracted.
4)Attach a tag to tappet for each cylinder No. to
put the tappet 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 adjusting bolt for the V-belt adjuster, and be nipped and alternator broken.
6
then remove V-belt.
3)Remove alternator.
4)Remove the spacer for cooling fan and V-pulley.
1)Remove lubricating oil filter assembly.
7 2)Extract dipstick form the oil dip-stick hole.
65
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
Fan side
7 16 14 6
1 9 18 12 4
3 11 17 10 2
5 13 15 8
1)Remove oil pan mounting bolt under gear case. 1)Never fail to removes stiffener bolt at the center
2)Remove gear case mounting bolt. of the gear case.
12
3)Remove gear case. 2)When removing the gear case, carefully protect
oil seal from damage.
1)Remove the nut from fuel injection pump drive 1)Before removing fuel injection pump, make sure
gear. Extract fuel injection pump drive gear of the position of the arrow of the pump body for
13 using a puller. adjusting fuel injection timing as well as the posi-
tion of the scribed line of the gear case flange.
(Applies only to direct injection system.)
66
4. Disassembly, inspection and reassembly of engines
1)Remove flywheel mounting bolt. 1)Carefully protect the ring gear from damage
16 2)Remove flywheel. mage.
1)Remove flywheel housing. 1)Carefully protect the oil seal from damage.
2)Remove oil seal case with a screwdriver or the
17
like by utilizing grooves on both sides of oil seal
case.
1)Remove oil pan and spacer. 1)Put the cylinder block with the attaching surface
of the cylinder head facing down.
2)Carefully protect the combustion surface of the
cylinder block from damage.
18
3)For indirect injection system, be careful to the
possibility of the tapped to drop off when the cyl-
inder block is turned upside down, because the
tappet is cylindrical in shape.
1)Remove idle gear shaft, and then remove idle 1)Turn the cylinder block aside and carefully pre-
gear. vent tappet from jamming on the cam.
19 2)Remove mounting bolt of thrust bearing through 2)Preheat camshaft gear and camshaft assembly
the hole of the camshaft gear. Remove cam- to 180° to 200° which are shrink fitted, before
shaft assembly. removing them.
1)Remove gear case flange.
20
1)Remove crankpin side cap of the connecting 1)Before extracting piston, remove carbon depos-
rod. its from the upper wall of the cylinder using fine
While turning crankshaft, place piston in the sandpaper, while taking care not to damage the
bottom dead center (BDC). inner surface of the cylinder.
22
2)Make sure than cap No. of connecting rod
agrees with cylinder No.
3)Take care not to let crankpin metal fall when
removing connecting rod crankpin side cap.
67
4. Disassembly, inspection and reassembly of engines
Dial gauge
23 Crankshaft
68
4. Disassembly, inspection and reassembly of engines
69
4. Disassembly, inspection and reassembly of engines
Cylinder head
ԛFuel filter ԘOil cooler
Joint
ԚThermostat
ԟIntake maniforld
Head gasket
Thermo switch Cooling water pump
Oil/water separator
ԙV-pulley
Cylinder block
Spacer
ԙFan
Rocker arm
cover
Rocker arm suport
Rocker arm
cover
Cylinder head
Cylinder head
Exhaust valve
71
4. Disassembly, inspection and reassembly of engines
C.W. pump
V belt
Crank pulley
V-belt tention
Point2
[Reassemble]
• Check the thermostat function. (See3.9 in Chapter 3
for the check procedure.)
Pont3
[Reassemble]
• Replace the fuel filter element with a new one.
[Disassemble]
• Cover the fuel pipe opening with tape to prevent
intrusion of foreign matters.
Point4
[Reassemble]
• Replace the oil filter with a new one.
• After fully tightening the filter manually, retighten it
with a filter wrench (see 11.1-6 in Chapter 11) by 3/4
turn.
Point5
[Disassemble]
• Cover the fuel injection pipe and pump inlets and out-
lets with tape or the like to prevent intrusion of foreign
matters.
72
4. Disassembly, inspection and reassembly of engines
Point6
Pipe seal
1)Removing pipe seals of 4 valve head.
[Disassemble]
• Take off a rocker arm cover in case of 4 valve head
after removing fuel injection pipes and pipe seals.
[NOTICE] Fuel injection pipe
Attention is necessary because a fuel nozzle is caught Fuel nozzle
in a pipe seal and the pipe seal is damaged when a
rocker arm cover is lifted with a pipe seal sticking to
the rocker arm cover. Slit of bonnet
Pipe seal
• Insert a minus driver in the slit part of the rocker arm
cover, and remove it when removing a pipe seal.
Minus driver
[Reassemble]
• Replace the used pipe seal with a new one when
removing a pipe seal.
Cap nut of fuel injection pipe
Pipe seal replacement
73
4. Disassembly, inspection and reassembly of engines
[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 lubricating oil replacement or lube oil supply
The amount of lubricating oil isn't to be beyond the standard upper limit (in the engine horizontally, the
upper limit mark of the dip stick). Since the blowby gas redactor 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
lubricating 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.
Point7
Disassembly
[Disassemble] Camshaft side
• Keep the removed push rods by attaching tags show-
8 14 5
Fan side
ing corresponding cylinder Nos. 2 12 9 3
[Reassemble]
4 10 11 1
• Always apply oil to the contact portions of the push 6 13 7
rods and clearance adjusting screws.
Head bolt disassembly order
Point8
3 cylinder head
[Disassemble] Assembly
Camshaft side
• Loosen the cylinder head bolts in two steps in the
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
9 2 8
[Reassemble]
• Remove the head gasket with a new one. Head bolt tightning order
• Uniformly install the head bolts manually after apply- 3 cylinder head
Disassembly
ing oil on the threaded and seat portions. Camshaft side
• They shall be tightened in two steps in the reverse of
Fan side
7 16 14 6
1 9 18 12 4
the order for disassembly.
• Tightening torque 3 11 17 10 2
5 13 15 8
N•m (kgf•m)
Head bolt disassembly order
TNV82A TNV84-88
4 cylinder head
30.0 to 34.0 41.1 to 46.9
First step Assembly
(3.1 to 3.5) (4.2 to 4.8) Camshaft side
61.7 to 65.7 85.3 to 91.1
Fan side
12 3 5 13
Second step
(6.3 to 6.7) (8.7 to 9.3) 18 10 1 7 15
16 8 2 9 17
14 6 4 11
4TNV94L/98 4TNV106 (T)
49.0 to 58.8 88.3 to 98.1 Head bolt tightning order
First step
(5.0 to 6.0) (9.0 to 10.0) 4 cylinder head
103.1 to 112.9 188.0 to 197.8
Second step
(10.5 to 11.5) (19.0 to 20.0)
74
4. Disassembly, inspection and reassembly of engines
Point9
[Disassemble]
• Carefully remove the fuel injection valve so as not to
leave the top end protector from being left inside the
cylinder.
[Reassemble]
• Replace the fuel injection valve protector with a new
one.
Point10
[Disassemble]
• When removing each intake/exhaust valve from the
cylinder head, use a valve spring compressor (see
11.1-4 in Chapter 11) and compress the valve spring
and remove the valve cotter.)
• Keep each removed intake/exhaust valve after
Valve spring compressor
attaching a tag showing the corresponding cylinder
No.
• If cotter burr is seen at the shaft of each intake/
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.
75
4. Disassembly, inspection and reassembly of engines
(c)Valve sink
Measure with the valve inserted to the cylinder head. Depth micrometer
mm
Standard Limit
3TNV82A Intake 0.35 to 0.55 0.8
(2-valve head) Exhaust 0.30 to 0.50 0.8
4TNV84 Intake 0.30 to 0.50 0.8
3TNV84 (T)
3/4TNV88 Exhaust 0.30 to 0.50 0.8 Valve sink
(2-valve head)
4TNV84T Intake 0.36 to 0.56 0.8
4TNV94/98 (T) Valve sinking depth
(4-valve head) Exhaust 0.35 to 0.55 0.8
(d)Seat contact
Apply a thin coat of minimum on the valve seat. Insert
the valve in the cylinder and push it against the seat to
check seat contact.
Standard: Continuous contact all around
Seat
76
4. Disassembly, inspection and reassembly of engines
77
4. Disassembly, inspection and reassembly of engines
mm
Model Part Standard Limit
3TNV82A to 88 Intake 1.24-1.44 0.8
4TNV84
(2-valve head) Exhaust 1.35-1.55 0.8 Thickness
mm
Standard Limit
3TNV82A Intake/Exhaust 97.2-97.8 97.0
3/4TNV84 to 88 Intake/Exhaust 108.7-109.3 108.5
4TNV84T Intake/Exhaust 100.0-100.6 99.8
4TNV94L Intake 102.3-103.1 102.1 Free length
4TNV98(T) Exhaust 102.4-103.2 102.2
Intake 117.3-118.1 117.1
4TNV106(T)
Exhaust 117.1-117.9 116.9
Valve spring
mm
Free length Inclination
Standard Limit limit
3TNV82A 44.4 43.9
1.4
3/4TNV84 to 88 42.0 41.5
4TNV84T 37.4 36.9 1.3 Valve spring
4TNV94L•98(T) 39.7 39.2 1.4
4TNV106(T) 50.6 50.1 1.5
78
4. Disassembly, inspection and reassembly of engines
mm
Model Items Standard Limit
Arm hole
16.00 to 16.02 16.07
3TNV82A diameter
3/4TNV84(T)
Shaft O.D. 15.97 to 15.98 15.94
3/4TNV88
Clearance 0.016 to 0.054 0.13 Rocker arm hole diameter
Arm hole
18.50 to 18.52 18.57
diameter
4TNV94L/98(T)
4TNV106(T) Shaft O.D. 18.47 to 18.49 18.44
Clearance 0.01 to 0.05 0.13
(R.1)
79
4. Disassembly, inspection and reassembly of engines
Seat cutter
80
4. Disassembly, inspection and reassembly of engines
Do not touch the cooled valve guide with bare hands to avoid skin damage.
mm
Model Number of valves Projection Projection
3TNV82A 11.7 to 12.0
Cylinder head
4TNV84 2 valves
3TNV84 (T) 14.7 to 15.0
4TNV88
4TNV84T 8.2 to 8.5 Valve guide
4TNV94L
4 valves 9.7 to 10.
4TNV98(T) Valve guide replacement
4TNE106(T) 13.4 to 13.6
(R.1)
81
4. Disassembly, inspection and reassembly of engines
Stem seal
Valve guide
Cylinder head
4TNV84 2 valves
3TNV84 (T) 18.7 to 19.0
4TNV88
Valve guide
4TNV84T 9.9 to 10.2
4TNV94L
4 valves 11.7 to 12.0
4TNV98 (T)
4TNE106 (T) 15.4 to 15.6
82
4. Disassembly, inspection and reassembly of engines
4.3.1 Components
ԠFlywheel
Flywheel housing
Pump flange
Don't disassemble! Fuel pump drive gear Crankshaft
gear
Flange bolt
ԛGear case
ԣOil seal
ԚCrankshaft pulley
Note) This figure shows the 3TNV84.
83
4. Disassembly, inspection and reassembly of engines
(R.1)
Gear train (3TNV82A to 4TNV88)
84
4. Disassembly, inspection and reassembly of engines
Point4
[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.
• Install the idle gear shaft with the oil hole facing
upward.
Point5
[Reassemble]
• Install the PTO drive gear with its inner spline side
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)
Model Tightening torque
3TNV82A to 88 83.3 to 88.2 (8.5 to 9.0) Fuel injection pump
drive gear
4TNV94L/98/106 (T) 186.2 to 205.8 (19.0 to 21.0) Camshaft gear
Point7
[Disassemble]
B
• Measure the camshaft side gap. B C C
mm A
Idle gear
Item Standard Limit PTO gear
Side gap 0.05 to 0.20 0.30
Crankshaft gear
• If the measured side gap exceeds the limit, replace Direction of rotation
the thrust metal.
Gear train (3TNV82A to 4TNV88)
85
4. Disassembly, inspection and reassembly of engines
[Disassemble]
• Since the camshaft gear is shrink-fit, heat it to
180°C to 200°C for extraction.
• For camshaft removal, raise the engine with its mount-
ing flange at the bottom. After removing the thrust
metal mounting bolt from the camshaft gear hole,
extract the camshaft carefully so as not to damage the
bearing bushing.
• Rotate the camshaft a few turns before extracting it to
prevent the tappet from being caught by the cam.
• After removing the camshaft, set the engine horizontal
and fix it on the base.
86
4. Disassembly, inspection and reassembly of engines
87
4. Disassembly, inspection and reassembly of engines
mm
Model Place Item Standard Limit
Bushing I.D. 44.990 to 45.055 45.130
Gear side Camshaft O.D. 44.925 to 44.950 44.890
Oil clearance 0.040 to 0.130 0.240
Bushing I.D. 45.000 to 45.025 45.100
3TNV82A to TNV88 Intermediate position Camshaft O.D. 44.910 to 44.935 44.875
Oil clearance 0.065 to 0.115 0.225
Bushing I.D. 45.000 to 45.025 45.100
Wheel side Camshaft O.D. 44.925 to 44.950 44.890
Oil clearance 0.0500.100 0.210
Bushing I.D. 49.990 to 50.055 50.130
Gear side Camshaft O.D. 49.925 to 49.950 49.890
Oil clearance 0.040 to 0.130 0.240
Bushing I.D. 50.000 to 50.025 50.100
TNV94L/98 (T) Intermediate position Camshaft O.D. 49.910 to 49.935 49.875
Oil clearance 0.065 to 0.115 0.225
Bushing I.D. 50.000 to 50.025 50.100
Wheel side Camshaft O.D. 49.925 to 49.950 49.890
Oil clearance 0.05 to 0.100 0.210
Bushing I.D. 57.980 to 58.050 58.105
Gear side Camshaft O.D. 57.910 to 57.940 57.875
Oil clearance 0.040 to 0.140 0.250
Bushing I.D. 58.000 to 58.030 58.105
4TNV106(T) Intermediate position Camshaft O.D. 57.895 to 57.925 57.860
Oil clearance 0.075 to 0.135 0.245
Bushing I.D. 58.000 to 58.030 58.105
Wheel side Camshaft O.D. 57.910 to 57.940 57.875
Oil clearance 0.050 to 0.120 0.230
measurement
mm
Item Standard Limit
Shaft outside diameter 45.950 to 49.975 45.900
Bushing inside diameter 46.000 to 46.025 46.075
Clearance 0.025 to 0.075 0.175 Idle gear
88
4. Disassembly, inspection and reassembly of engines
Crankshaft pulley
25
Oil seal with doule lips dust seal
0.2 A
46
Guiding
26 20 M141.5
Knurled head
(Rollet) 1.6
1 A
Ǟ39
Ǟ35
C1
.5
C0
C0
C0
.5
.5
Ǟ # 16 17
89
4. Disassembly, inspection and reassembly of engines
4.4.1 Components
ԡPiston ring
ԝFlywheel hausing
ԠTappet
Oil seal
ԢOil seal case
Oil filter
ԛOil suction pipe
ԞBearing cap
ԚOil pan
90
4. Disassembly, inspection and reassembly of engines
[Reassemble]
• Apply oil especially carefully to the sliding contact
surfaces of the pistons, rods and rings.
• Use the piston insertion tool (see 12.1-9 in Chapter
12) to insert each piston w/rod in the cylinder block
and install the bearing metal cap.
91
4. Disassembly, inspection and reassembly of engines
[Reassemble]
Apply sealant (code No.977770-01212) and install the
mounting flange by matching the two dowel pins. After
assembly, raise the engine with its mounting flange on
the bottom side.
(R.1)
92
4. Disassembly, inspection and reassembly of engines
[Disassemble]
• Remove the bearing caps, cap side bearings, and
Wheel side
Block side main
thrust metals. Place each thrust metal with identifica- bearing metals
Cap side main
tion of the position and direction. bearing metals
The position number of reassembling is punched on
a metal cap (except for both ends) and a cylinder
block.
Gear side
Thrust metals
Main bearing
[Reassemble]
Upper main bearing metal
• Carefully install each thrust metal so that the grooved
Oil hole
one is positioned away from the cap.
Lower
• Do not confuse the upper and lower main bearing Thrust metal
metals. The upper main bearing metal (block side)
has an oil hole, and the lower one does not. The
“arrow” marks on the cap shall face the flywheel.
Tighten main bearing cap bolts. Groove
Point5: Crankshaft
[Disassemble]
Journal bearing cap
• Remove the crankshaft. Remove each main bearing
metal upper (block side) and pair it with the metal cap
side lower metal.
93
4. Disassembly, inspection and reassembly of engines
Expander joint
[Reassemble]
Ring joints
• When installing the piston pin to the rod and piston,
the punched match mark on the big end of the con-
necting rod shall be opposite to the size mark on the Piston ID mark
Camshaft side
piston top.
Nozzle side
[Reassemble]
• Install the piston in the cylinder clock with the
punched mark on the big end of the rod on the nozzle
side. (The embossed mark at the connecting rod I-
(Flywheel side)
beam section shall be on the flywheel side.)
Cylinder size mark
Embossed mark
(Flywheel side)
Match mark
Flywheel side
(R.1)
94
4. Disassembly, inspection and reassembly of engines
(a)Appearance inspection
Check if there is any discoloration or crack. If crack is
suspected, perform color check. Sufficiently clean the oil
holes and check they are not clogged.
mm
Item Model Standard Limit
3TNV82A 82.000 to 82.030 82.200
TNV84 84.000 to 84.030 84.200
TNV88 88.000 to 88.030 88.200
Cylinder inside diameter
4TNV94L 94.000 to 94.030 94.130
4TNV98 98.000 to 98.030 98.130
4TNV106(T) 106.000 to 106.030 106.130
Roundness
Cylinder bore all TNV 0.01 or less 0.03
Cylindricity
95
4. Disassembly, inspection and reassembly of engines
96
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 runout at the Bend
center journal while rotating the shaft to inspect the
bend.
V-block V-block
Crankshaft bend measurement
Limit (Diameter)
Item
(mm)
Roundness
0.01
Taper
97
4. Disassembly, inspection and reassembly of engines
Crankpin mm
Model & Item Standard Limit
Pin outside diameter 42.952 to 42.962 42.902
3TNV82A Metal thickness 1.487 to 1.500 -
Oil clearance 0.038 to 0.090 0.150
Pin outside diameter 47.952 to 47.962 47.902
TNV84 to 88 Metal thickness 1.492 to 1.500 -
Oil clearance 0.038 to 0.074 0.150
Pin outside diameter 57.952 to 57.962 57.902
4TNV94L•98 Metal thickness 1.492 to 1.500 -
Oil clearance 0.038 to 0.074 0.150
Pin outside diameter 63.952 to 63.962 63.902
4TNV106(T) Metal thickness 1.984 to 1.992 -
Oil clearance 0.054 to 0.090 0.150
If the oil clearance exceeds the limit, use an undersized bearing.
98
4. Disassembly, inspection and reassembly of engines
Crank journal mm
Model Item Standard Limit
Journal O.D. 46.952 to 46.962 46.902
3TNV82A Metal thickness 1.987 to 2.000 -
Oil clearance 0.038 to 0.080 0.150
Journal O.D. 53.952 to 53.962 53.902
TNV84 to 88
Metal thickness 1.995 to 1.990 -
(Selective assembly)
Oil clearance 0.038 to 0.068 0.150
Journal O.D. 64.952 to 64.962 64.902
4TNV94•98
Metal thickness 1.995 to 2.010 -
(Selective assembly)
Oil clearance 0.038 to 0.068 0.150
Journal O.D. 75.952 to 75.962 75.902
4TNV106(T)
Metal thickness 2.488 to 2.503 -
(Selective assembly)
Oil clearance 0.052 to 0.082 0.150
99
4. Disassembly, inspection and reassembly of engines
pin: R
R
R
Ry=0.8S super polishing R
R
Surface finishing precision standard on the thrust
Crank Pin Crank Journal
side of crankshaft arm: 1.6
Crankshaft R machining
mm
Finishing precision standard
Model
of dimension R
3TNV82A
3.5 +0.3/ 0
3/4TNV84(T) to 88
4TNV94L/98(T)
4.0 +0.3/ 0
4TNV106(T)
[NOTICE]
1)If the oil clearance is excessive though the thicknesses of the journal and crankpin metals are normal or if
partial uneven wear is observed, re-grind the crankshaft and use an oversized metals.
2)If 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 con-
tact surface is insufficient, the metal interference is insufficient. Replace the metal with a new one.
100
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
Piston outside diameter
Piston outside diameter
mm
Outside diameter Clearance between Measurement
Model Limit
Standard piston and cylinder position (H)
3TNV82A 81.950 to 81.980 81.905 0.040 to 0.060 16
3,4TNV84(T) 83.940 to 83.970 83.895 24
0.050 to 0.070
3,4TNV88 87.940 to 87.970 87.895 24
4TNV94L 93.935 to 93.965 93.900 0.055 to 0.075 22
4TNV98 (T) 97.930 to 97.960 97.895 22
0.060 to 0.080
4TNV106 (T) 105.930 to 105.960 105.880 30
If the piston outside diameter exceed the limit, replace the piston with new one.
If the clearance between piston and cylinder exceeds the limit, use an oversized piston. (Refer to the tables of
oversized pistons, oversized piston rings and cylinder boring dimension in (1) (c) above.)
Selective pairing of cylinder and piston
Piston must be paired with cylinder according to the below table. The size mark of a piston is shown on
the top surface of the piston and the size mark of a cylinder block is shown on the non-operating side of
the cylinder block. The service parts of pistons are provided.
101
4. Disassembly, inspection and reassembly of engines
state.
Cylinder block
Pistonring
Approx.
Width 30mm
(R.1)
103
4. Disassembly, inspection and reassembly of engines
mm
Item Standard dimension Limit dimension Mandrel
Twist and 0.03 or less
0.08
parallelism per 100 mm
Twist and parallelism measurement
(c)Rod small end measurement
Measure the pin outside diameter according to
4.4.5.(4) (a) described above.
mm
Model Item Standard Limit
Piston pin
23.025 to 23.038 23.068
I.D. bushing
3TNV82A
Pin O.D. 22.995 to 23.000 22.967
Clearance 0.025 to 0.043 0.101
Piston pin Connecting rod
26.025 to 26.038 26.068 aligner
I.D. bushing
TNV84 to 88
Pin O.D. 25.995 to 26.000 25.967
Clearance 0.025 to 0.043 0.101
Piston pin
30.025 to 30.038 30.068
I.D. bushing
4TNV94L•98
Pin O.D. 29.987 to 30.000 29.959
Clearance 0.025 to 0.051 0.109 Twist measurement using
a connecting rod aligner
Piston pin
37.025 to 37.038 37.068
I.D. bushing
4TNV106 (T)
Pin O.D. 36.989 to 37.000 36.961
Clearance 0.025 to 0.049 0.107
104
4. Disassembly, inspection and reassembly of engines
105
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.
(a)Tappet stem outside diameter measurement
mm
Model Item Standard Limit
Tappet
12.000 to 12.025 12.045 Abnormal contact Normal contact
hole I.D.
surface surface
TNV82A to 88
Stem O.D. 11.975 to 11.990 11.955
Tappet
Clearance 0.010 to 0.050 0.090
Tappet
12.000 to 12.018 12.038
hole I.D.
4TNV94L•98
Stem O.D. 11.975 to 11.990 11.955
Clearance 0.010 to 0.043 0.083
Tappet
14.000 to 14.018 14.038
hole I.D.
4TNV106 (T)
Stem O.D. 13.966 to 13.984 13.946
Clearance 0.015 to 0.052 0.092
Tappet stem outside diameter measuremen
106
4. Disassembly, inspection and reassembly of engines
107
5. Lubrication system
5. Lubrication system
5.1 Lubrication system diagram
̪
Turbo charger
̪Oil cooler
Oil pressure
swich
Rocker arm
Tappet
Cam face
Oil pan
Note: It varies in the specifications of each model whether Oil cooler, Piston and Turbo charger of the * mark
are attached.
(R.1)
108
5. Lubrication System
1)3TNV82A-88
• Apply lube oil to rotor (outer/inner) insertion part.
• Assemble the outer rotor so that the mark of the end face may become a cover side when inserting it in the
gear case.
• Fasten a lube oil pump cover by the standard torque.
• Tightening torque: 6.9 ± 1.5 N•m (0.7 ± 0.15 kgf•m)
• When replacing the lube oil pump, replace the whole assy.
2)4TNV94L/98/106
• Apply lube oil to lube oil pump insertion part of gear case.
• Install the outer rotor in the gear case so that the punch mark on the end face is seen.
• When replacing the lube oil pump, replace the whole assy.
109-1
5. Lubrication System
Point 2
[Disassemble-Reassemble]
• Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation
is detected.
33
M141.5
(3TNV82A㨪4TNV88)
(R.1)
109-2
5. Lubrication System
Insert a gap gage between a outer rotor and a pump Gear case
Outside clearance mm
Model Standard Limit
3TNV82A to 88 0.12 to 0.21 0.30 Outer diameter clearance
4TNV94L/98 0.100 to 0.155 0.25
4TNV106(T) 0.100 to 0.165 0.25
Side clearance mm
Model Standard Limit
3TNV82A to 88 0.02 to 0.07 0.12
4TNV94L/98 0.05 to 0.10 0.15
4TNV106(T) 0.03 to 0.12 0.17
(R.1)
110
5. Lubrication System
Width across
flat of rotor
Crank gear
Rotor inner
diameter
Inner rotor
Bearing
I.D.
Gear case
Lube oil pump bearing
mm
Model Inspection item Standard Limit
Gear case bearing I.D. 12.980 to 13.020 13.05
4TNV94L/98 Rotor shaft O.D. 12.955 to 12.970 12.945
Rotor clearance 0.035 to 0.065 0.105
Gear case bearing I.D. 13.000 to 13.020 13.05
4TNV106(T) Rotor shaft O.D. 12.955 to 12.965 12.945
Rotor clearance 0.035 to 0.065 0.105
111-1
5. Lubrication System
Unit
Part No. - 129150-35152
Type - Full flow, paper element
Filtration area m2 0.12
Discharge volume l/min 30
MPa 0.02-0.04
Pressure loss (0.2-0.4)
(kgf/cm2)
By-pass valve MPa 0.08-0.12
regulating pressure (kgf/cm2) (0.8-1.2)
(R.1)
111-2
6. Cooling system
6. Cooling system
6.1 Cooling water system
Thermostat
Cylinder head
Bypass
Radiator
Coolant recovery tank
Cylinder block
L.O. cooler
Cylinder head
Thermostat cover
Joint
Thermostat
Thermo switch
V-pulley
Spacer
112
6. Cooling system
[NOTICE]
Replace the O-ring of the cooling water pump with
new one when disassembling. And, be sure to use the O-Ring
special O-ring for each engine model, because the
material is different, although the dimension is the
Joint
same as a commercial part. (Refer to the right figure.)
113
7. Fuel injection pump / Governor
7.1 Introduction
It is described about the features of the fuel injection
pump, YDP-MP, manufactured by Yanmar, disassembly,
assembly and adjustment procedure.
Yanmar YDP-MP Pump is a distributor type pump which is unified of Mono-plunger, a distributing shaft, a
hydraulic head which equipped the delivery valve for each cylinder, pump housing which has a cam shaft
internally and governor.
The fuel, which is pressurized by the up and down movement of the plunger driven by the cam-rotation, is
supplied through the distributor shaft, which is rotating accordingly.
There are a model YDP-MP2 and a model YDP-MP4, and plunger diameter and fuel cam speed are different.
114
7. Fuel injection pump / Governor
Cylinder head
Fuel
filter
Water separator
ԜFuel pump spacer
Camshaft driving gear
ԟFuel injection pump
Crankshaft gear
Pump flange
Don't disassemble!
ԛFuel pump drive gear
ԜDrive gear nut
Gear case
Oil seal
115
7. Fuel injection pump / Governor
Engine
2 2
Engine
Governor
side
3 3
B C
Drive side
A D
Drive side
Fuel pump (3 cylinder)
Fuel pump (4 cylinder)
Point 2
[Disassemble]
Gear
• After putting the I.D. marks on the gearing part of the installation nut
pump drive gear and the idle gear with paint and so Idle gear
on, remove the gear installation nut. Fuel pump driving gear
Fuel pump driving gear
[NOTICE]
Don't remove four flange bolts.
[Reassemble]
• Reassemble the pump driving gear while checking the I.D. marks on the driving gear and idle gear.
Tightening torque of the gear installation nut
Lubricating oil application
Model N•m (kgf•m)
(thread portion, and seat surface)
TNV82A to 88 78 to 88 (8 to 9)
Not applied
4TNV94 to 106 (T) 113 to 123 (11.5 to 12.5)
116
7. Fuel injection pump / Governor
Point 3
[Disassemble]
There is an acoustic material part to name as fuel pump spacer between the fuel pump and the cylinder
block. Loosen fuel pump installation bolts with a closed wrench when disassembling a fuel pump.
[NOTICE]
An intake manifold may obstruct the disassembly of the fuel pump by the engine model. Remove the fuel
pump after removing the intake manifold first.
Closed wren
Fuel pump
[Reassemble]
When installing a fuel pump on the gear case, put a fuel pump spacer between the cylinder blocks, and
install it.
(R.1)
117
8. TURBOCHARGER
8.1.2 Construction
13 14 12 15 8 9 10 17
Air outlet
Oil inlet
Air inlet
Gas outlet
19
18
Oil outlet
2
Gas inlet 11 1 20 3 5 16 6 4 7
118
8. TURBOCHARGER
(1) Turbine
The exhaust gas from the engine is accelerated at the nozzle portion in the turbine housing and blown onto
the turbine impeller to rotate the turbine shaft.
This is called the turbine. A seal ring and heat insulating plate are installed to prevent the bearing from
adverse influence of the gas.
(2) Compressor
The compressor impeller installed on the turbine shaft rotates with the shaft to suck and compress air for
feeding into the intake manifold.
This is called the blower or compressor.
(3) Bearings
Thrust bearing
As the turbine shaft is constantly applied with a thrust force, this bearing prevents the shaft from being
moved by the thrust force.
Radial bearing
A floating bearing is adopted. Since the bearing moves with the turbine shaft as the oil films are formed
both inside and outside the bearing, the bearing sliding speed is slower than the turbine shaft speed,
resulting in higher dynamic stability.
(4) Compressor side sealing mechanism
To prevent the intake air and oil form leaking, a seal ring and a seal plate are provided to form a double wall
structure on the rear side of the compressor impeller.
(5) Waste gate
When the blower side pressure (intake air pressure) exceeds the specified level, the exhaust gas at the
turbine inlet is partially bypassed to the exhaust discharge side to control the turbine rpm so as to maintain the
intake pressure at the specified level for improving the response to load variation in the low to medium speed
range and to minimize black smoke generation. It consists of a control assembly separated from the
turbocharger and a valve assembly installed in the turbine impeller chamber.
119
8. TURBOCHARGER
8.1.4 Components
12
15 8 7
14
13 9
45
11 3
2 23 22
20
21
28
10 29
24
27
6
19
1 29
14
13
17
18 26
16 32
25 31 30
120
8. TURBOCHARGER
F
B D C A H2 H1
K
Turbine side Compresson side
E G1 G2
121
8. TURBOCHARGER
122
8. TURBOCHARGER
123
8. TURBOCHARGER
Magnet base
124
8. TURBOCHARGER
Dial gage
Magnet base
Oil outlet
Oil inlet
It is indispensable to adjust the waste gate valve opening pressure and lift after its overhaul or inner parts
replacement.
Negligence of this adjustment will adversely affect the engine performance.
[NOTICE]
If the adjustment is impossible, give up overhaul but replace the whole turbocharger assembly.
(1) Method for checking the waste gate valve opening pressure and lift
(a)Equipment
Prepare the equipment shown in the figure below.
125
8. TURBOCHARGER
Manometer
(c)Check method
1)Set the manometer control pressure (Pc) applied to the waste gate actuator to 0 and set the dial gage to
the zero point.
2)Gradually open the pressure regulating valve and measure the Pc value when the actuator rod is oper-
ated by 2 mm.
3)For the hysteresis, let the rod move to 3 mm first. The gradually close the pressure regulating valve, mea-
sure the pressure when the rod is moved to 2mm and obtain the difference from the pressure measured in
b. above.
4)Precautions
• Set the dial gage on the extension line of the actuator rod.
• The piping and joints shall completely be free from leak.
• Fix the turbocharger and dial gage securely.
• If an electric manometer is used, it shall have sufficient precision.
• Even when an electric manometer is used, use of a mercury column type manometer in combination is
recommended for calibration and daily check.
• The speed for increasing/decreasing Pc by means of the pressure regulating valve shall be very slow near
the measuring point. If the mm position is exceeded, restart from the beginning.
• Do not apply over 0.49 MPa (5 kgf/cm2) to the actuator.
126
8. TURBOCHARGER
Pliers
Pliers
M2.6 1(0.0393)
P0.45 8 40 10 15
(1.5748) (0.3937) (0.5905) Mount to dial gauge
(0.3149)
127
8. TURBOCHARGER
8.4.3 Disassembly
The mounting angles of the turbine housing, bearing housing and compressor housing are determined
according to its mounting state on the engine. Put match marks before starting disassembly.
Note: The number after each part is the one described in the structural drawing in 8.1(2).
128
8. TURBOCHARGER
129
8. TURBOCHARGER
c)Blower blade •Tools 1)Immerse in the washing bucket until the deposit is
and chamber 1)Bucket (500 × 500) softened.
2)Brush 2)Use a plastic scraper or hard hair scrubber to remove
the softened deposits.
•Detergent Never use a wire brush.
d)Others 1)Wash all other parts with diesel oil.
2)Clean the lubricating oil path by blowing with compressed air.
3)Be especially careful so as not to damage or corrode the parts.
130
8. TURBOCHARGER
131
8. TURBOCHARGER
132
8. TURBOCHARGER
(10)Seal rings
Replace seal rings with new ones.
133
8. TURBOCHARGER
8.6.2 Reassembly
(1) Floating bearing installation
1)Use the snap ring pliers and install inner circlip 16 on
bearing housing 15.
2)Install floating bearing 5 in bearing housing 15. For all other than above
3)Use the snap ring pliers and install outer circlip 16 on
bearing housing 15.
Note:
1)The circlip joint shall be positioned as shown in the
figure at right above.
The rounded side of the circlip shall face the
bearing.
2)Apply lubricating oil on the floating bearing before
reassembly.
134
8. TURBOCHARGER
135
8. TURBOCHARGER
136
8. TURBOCHARGER
Lubrication system
1)Pour new lubricating oil through the oil filler port before installation on the engine, and manually turn the
turbine shaft to lubricate the floating and thrust bearings.
2)Flush the oil inlet pipe from the engine and outlet pipe, and check no crushed pipe nor dirt or foreign mat-
ter remaining in the pipes.
3)Connect the pipes securely so as to ensure no oil leak from joints.
Intake system
1)Check no foreign matter or dirt in the intake line.
2)Connect securely to prevent any air leak from joints with the intake duct and air cleaner.
Exhaust system
1)Check no dirt or foreign matter in the exhaust system.
2)Since heat resistant steel is used for the bolts and nuts, do not use general bolts and nuts for installation.
Always apply anti-seizure agent on fastening bolts and nuts to be tightened.
(Use heat-resistant hexagon bolts for the turbine housing.)
3)Connect exhaust pipes securely to prevent gas leak from each pipe joint.
137
8. TURBOCHARGER
8.8 Troubleshooting
Sufficient turbocharger performance and required engine output cannot be obtained if there is any fault. In
such a case, first check each engine part to see there is no engine fault. Then inspect the turbocharger for
troubleshooting according to the procedure shown below.
3)Contact or breakdown of turbine wheel or blower •Inspection and repair of each engine part
vane •Perfect foreign matter elimination in disassembled
•Excessive revolution state, followed by inspection and repair of individual
•Excessive exhaust temperature rise air cleaner and engine components
•Foreign matter invasion •Turbocharger overhaul (disassembly and repair)
•worn bearing •Reassembly
•Assembly defect
138
8. TURBOCHARGER
(2) Vibration
Cause Corrective action
1)Loosened intake, exhaust or oil pipe connection with •Turbocharger installation status check and repair of
the turbocharger defective portion
2) Damaged bearing, contact between rotating part and •Turbocharger disassembly with repair or replace-
adjacent part, or chipping of turbine wheel or blower ment, or perfect removal of foreign matters in case
vane due to foreign matter in version of foreign matter invasion
3) Unbalanced rotating part •Repair or replacement of rotating part
139
9. Starting motror
9. Starting motror
As a representative example of starter, the one for 4TNV94L98 and 4TNV106 (T) is shown in this chapter.
9.1.1 Specifications
140
Magnetic switch
9.1.2 Components
Brush
Oil seal
141
Pinion shaft
Through bolt
O-ring
9. Starting motror
NO Set the shift lever at Are the battery charge and NO ٨Charge or replace the battery
Is the shift lever at terminal connection normal ٨Connect the battery terminal and
the neutral position? the neutral position
without any corrosion? repair corrosion.
YES
Engine starting failure? Inspect the wiring up to the magnetic
9. Starting motror
142
YES
Magnetic switch con- ψWhen the starting motor is wetted with water,
tact defect. Replace it. always replace the magnetic switch even if the
function is normal.
NO
(slow revolution) Are the battery charge
and terminal connection NO For an abnormality (Immediately disconnect the
Is the revolution normal? ̪
normal without any battery negative terminal.)
corrosion?
YES YES
Inspect the fuel systems Is the Lube oil NO The motor does not stop
Replace the Lube oil.
viscosity normal? even when the key switch is
turned OFF.
YES
Does the engine run
when the starting motor YES Repair or replace the Repair or replace the key switch, starting
is replaced with a starting motor. motor relay or magnetic switch.
new one?
Slow revolution
14 12
8
10
1
11 3
15
16
17
19
13 2
18
4
5
143
9. Starting motror
Connecting wire
Fig. 1
2)Screw M4 (2)
4)Rear cover
Remove the M4 screw fastening the brush holder
and remove through bolt M5 for rear cover removal.
2
4
Fig. 2
5)Brush holder
Pull the brush spring up with the brush spring puller.
On the negative (-) side, bring the brush spring into
contact with the side of the brush for lifting from the
commutator surface. On the positive (+) side, extract
the brush from the brush holder.
Fig. 3
144
9. Starting motror
6)Yoke Assy.
5
7)Armature
Remove the brush holder. The armature and yoke
assy can now be removed.
7
Fig. 4
8)Bolt M6 (2)
9
9)Magnetic switch 8
Remove bolt M6 (10 mm), and the magnetic switch
can be removed.
Fig. 5
10)Dust cover
11)Shift lever 10
Take the dust cover out from the gear case. The shift
lever can be removed.
11
Fig. 6
145
9. Starting motror
12)Screw M4 (3)
13)Bearing retainer 14
14)Gear case 19
Remove screw M4, and the bearing retainer and
clutch assy can be removed.
12
13
Fig. 7
Fig. 8
16)Pinion stopper
15 16 17 19
17)Return spring
18
18)Pinion shaft
19)Clutch Assy
Remove the pinion stopper clip. The pinion stopper, 13
return spring, pinion shaft and bearing retainer can
Fig. 9
be removed.
146
9. Starting motror
Fig. 11
Fig. 12
147
9. Starting motror
exceeded.
mm
Standard Limit
Armature 0.03 0.2
Commutator 0.03 0.2
Fig. 13
Fig. 14
Abnormal Normal
Fig. 15
148
9. Starting motror
Fig. 16
Fig. 17
(3) Brush
Measure the length of the brush. Replace with a good
one if the length is less than the limit.
mm
Standard Limit
15 9 Brush
Fig. 18
149
9. Starting motror
Fig. 19
Fig. 20
Fig. 21
150
9. Starting motror
Fig. 22
Fig. 23
Fig. 24
151
9. Starting motror
Fig. 25
Fig. 26
152
9. Starting motror
9.1.7 Assembly
The assembly procedure is the reverse of the
disassembly procedure, but pay attention to the
following points:
(1) Grease application points
• Gears in the gear case
• Shift lever operating portion
• Pinion sliding portion
• Magnetic switch plunger sliding portion
Use the specified grease as below table at all points.
Pinion and magnetic switch plunger sliding portions NPCFG-6A
Gears MALTEMP SRL
Shift lever operating portion ALBANIA No.1
Fig. 27
Fig. 28
153
9. Starting motror
Dust cover
(adjusting shim:
0.5mm, 0.8mm)
Fig. 30
154
9. Starting motror
SW
Ammeter
S
Voltmeter
Battery
Fig. 31
155
9. Starting motror
Magnetic switch
Gear case
Shift lever
Pinion
Brush Gear shaft
O-ring
Ball bearing
156
Engine does not start.
Inspect pinion
٨Connection state
Does the gear shift YES roller clutch for YES
revolve? damage and
replace if necessary.
Is the starting motor NO ٨Inspect the wiring up to the magnetic
NO magnetic switch actuating switch and repair if necessary.
sound heard?
Inspect the reduction gear
(armature, gear shaft) for YES
damage and replace if ٨Adjust the dimension.
necessary. ٨Inspect the shift lever for deformation,
Are pinion and ring gear NO the return spring for fatigue and the
engaging normally? pinion for sliding.
٨Repair engagement between pinion and
157
NO Does the motor ravolve ٨Inspect the brush and replace if worn.
when M terminal of NO
(slow ٨If brushes are not worn, replace the
revolution) starting motor is connected motor (yoke assy or armature).
to the battery?
Are the battery charge
and terminal connection NO
Is the revolution normal? ̪ YES
normal without any
corrosion?
Are pinion and ring gear
YES YES engaging normally?
Inspection Causes and
Inspect the ignition and item remedies
fuel systems. Is the engine oil NO
Replace the engine oil. Upon abnormality:
viscosity normal?
Immediately disconnect the battery negative terminal.
ԟ ԝ
Ԟ
Ԙ
Ԛ
158
9. Starting motror
159
9. Starting motror
160
9. Starting motror
161
9. Starting motror
162
9. Starting motror
163
9. Starting motror
164
9. Starting motror
165
9. Starting motror
166
9. Starting motror
(1) Armature
1)Check the commutator for rough surface. If so, smooth the surface using #500 to #600 emery cloth.
If the outside periphery of the commutator has been deflected over 0.2 mm, repair by a lathe.
2)Measure the depth of the insulating material between commutator segments, and correct if it is less than
0.2 mm.
0.5㨪0.8 OO
Undercutmethod
167
9. Starting motror
Replace if needed
.
168
9. Starting motror
Replace if needed
.
169
9. Starting motror
(3) Brush
1)Check wear of the brush and the brush spring force.
12
18
6 Limit
New Used
3.5 kg
2.9 kg
170
9. Starting motror
3)Check the continuity between the insulated brush holder (positive (+)) and the brush holder base (nega-
tive (-)).
If they are electrically continuous, replace since the holder is grounded.
171
9. Starting motror
Replace if needed.
C
S13-138
Resistance (at 20°C)
B
Shunt coil 0.6
Series coil 0.218
M
172
9. Starting motror
(5) Pinion
1)Check the pinion teeth for wear and damage. Replace with a new one, if necessary.
2)Check if the pinion slides smoothly. If it is damaged or rusted or does not slide smoothly, repair.
3)Check springs for damage, and replace if necessary.
9.2.7 Assembly
The assembly procedure is reverse of the disassembly procedure, but pay attention to the following points.
173
9. Starting motror
9.2.8 Adjustment
Switch
Battery
Measure the pinion moving distance L (0.3 to 1.5 mm) in the thrust direction when the pinion is protruded by
the magnetic switch.
If the distance L is outside the standard range, adjust by the dust cover as shown below.
174
9. Starting Motor
Dust cover
175-1
9. Starting Motor
9.3.2 Characteristics
REVOLUTION (min-1)
m)
O)
(kW)
(V)
STARTER PERFORMANCE
(kgf
(N
BATTERY 6V-400A
12V 1.2kW
VOLTAGE
TOROUE
TOROUE
OUTPUT
CURRENT (A)
(R.1)
175-2
9. Starting Motor
Yoke
Armature
Switch
Pinion
Housing
Clutch
Pinion
(R.1)
175-3
10. Alternator
10. Alternator
As a representative example of alternator, the alternator of 40A is shown in this chapter.
176
10. Alternator
10.1.2 Specifications
Manufacturer’s model (Hitachi) - ACFA68
Yanmar code - 129423-77200
Rating - Continuous
Battery voltage V 12
Nominal output (13.5 V heat) A 40
Rated revolution min-1 5,000
Operating revolution min-1 1,350 to 18,000
Grounding characteristics - Minus side grounding
Direction of revolution (viewed from pulley) - Clockwise
Integrated regulator IC regulator
Weight kg 2.8
Pulley (outside diameter) mm 69.2
Belt shape - Type A
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 miss-wiring and short-circuit of each terminal.
2)Don’t short-circuit between IG and L. (Connect it through the charge lamp.)
3)Don’t connect a load between L and E.
4)Don't remove a battery terminal and a B terminal when rotating.
5)Shut out a battery switch during the alternator stop.
6)Tightening torque of each terminal: 1.7-2.3 N•m (17-23 kgf•cm)
177
10. 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)
10.1.5 Inspection
(1) V belt inspection
Normal Defect
1)Inspect the matter whether there are not crack, stickiness
and wear on the belt visually.
Check that a belt doesn't touch the bottom part of the pul-
ley groove. If necessary, replace the V belt set.
2)V belt tension: Clearance
Push the center of the V belt and check the belt deflec-
tion. The V belt tension is normal if the deflection is within
the standard. If not, adjust the V belt tension by the alter- Inspection of V pulley
nator adjuster.
(Refer to 2.2.2 in Chapter 2.)
178
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)
come ON? Does the charge lamp
come ON? The charge lamp is available from
the driven machine manufacturer.
179
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. Alternator
11. Electric wiring
180
11. ELECTRIC WIRING
181
11. ELECTRIC WIRING
11.2.2 Starter
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.
(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 starter 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.
182
11. ELECTRIC WIRING
183
11. ELECTRIC WIRING
184
12. Service standards
185-1
12. Service standards
Reference
No. Inspection item Standard Limit
page
- Rated speed at rated speed at low idle speed -
0.392(+0.098/-0.049)
1500∼2700rpm
(4.0(+1.0/-0.5))
3TNV82A
0.441(+0.098/-0.049)
2800~3000rpm
(4.5(+1.0/-0.5))
0.392(+0.098/-0.049)
1500~1800rpm
(4.0(+1.0/0.5))
3TNV84
0.441(+0.098/-0.049)
2000~3000rpm
(4.5(+1.0/-0.5))
0.392(+0.098/-0.049)
1500~1800rpm
(4.0(+1.0/0.5))
3TNV88
0.441(+0.098/-0.049)
2000~3000rpm
(4.5(+1.0/-0.5))
0.343(+0.098/-0.049)
1500~1800rpm
Lubricating oil (3.5(+1.0/0.5))
pressure 0.392(+0.098/-0.049)
3TNV84T 2400~2700rpm
(4.0(+1.0/0.5))
MPa (kgf/cm2)
0.441(+0.098/-0.049)
2800~3000rpm
at lube oil (4.5(+1.0/-0.5))
0.392(+0.098/-0.049)
7 temperature 1500~1800rpm
(4.0(+1.0/0.5)) 0.06 (0.6)
80 deg.C 3TNV84 5.6
0.441(+0.098/-0.049) or above
for 3TNV82A- 2000~3000rpm
4TNV98(T) (4.5(+1.0/-0.5))
0.392(+0.098/-0.049)
1500~1800rpm
100 deg.C for 4TNV88 (4.0(+1.0/0.5))
4TNV106(T) 0.441(+0.098/-0.049)
2000~3000rpm
(4.5(+1.0/-0.5))
0.343(+0.098/-0.049)
1500~1800rpm
(3.5(+1.0/0.5))
4TNV84T
0.412(+0.098/-0.049)
2000~3000rpm
(4.2(+1.0/0.5))
4TNV94L 1500~2500rpm 0.34(+/0.05) (3.5(+/0.5))
4TNV98 1500~2500rpm 0.34(+/0.05) (3.5(+/0.5))
4TNV98T 1500~2500rpm 0.34(+/0.05) (3.5(+/0.5))
0.44(+0.05/0.10)
1500~1800rpm
4TNV106 (4.5(+0.5/-1.0))
2000~2500rpm 0.44(+/0.05) (4.5(+/0.5))
0.44(+0.05/-0.10)
1500~1800rpm
4TNV106T (4.5kgf/.cm2(+0.5/-1.0))
2000~2200rpm 0.44(+/0.05) (4.5(+/0.5))
Oil pressure switch operating pressure 0.05 ± 0.01
8 - -
MPa (kgf/cm2) (0.5 ± 0.1)
valve opening Full opening lift
temperature (mm)
deg. C (temperature)
9 Thermostat 8 or above 2.7
All models 69.5 to 72.5
(85 deg.C)
All models 10 or above
80 to 84
option (95 deg.C)
Thermo switch actuating temperature
10 107 to 113 - 2.4.2
(deg.C)
(R.1)
185-2
12. Service Standards
186
12. Service Standards
187
12. Service Standards
(R.1)
188
12. Service Standards
(1) Camshaft
mm
Reference
Inspection item Standard Limit
page
Side gap 0.05 to 0.20 0.30 4.3.4
Bending (1/2 the dial gage reading) 0 to 0.02 0.05
3TNV82A-TNV88 38.600 to 38.800 38.350
4.3.5.(1)
Cam height 4TNV94L•98 43.400 to 43.600 43.150
4TNV106(T) 50.900 to 51.100 50.650
Shaft outside diameter / Metal inside diameter
Bushing inside diameter 44.990 to 45.055 45.130
Gear side Camshaft outside diameter 44.925 to 44.950 44.890
Clearance 0.040 to 0.130 0.240
Bushing inside diameter 45.000 to 45.025 45.100
TNV82A to TNV88 Intermediate Camshaft outside diameter 44.910 to 44.935 44.875
Clearance 0.065 to 0.115 0.225
Bushing inside diameter 45.000 to 45.025 45.100
Wheel side Camshaft outside diameter 44.925 to 44.950 44.890
Clearance 0.050 to 0.100 0.210
Bushing inside diameter 49.990 to 50.055 50.130
Gear side Camshaft outside diameter 49.925 to 49.950 49.890
Clearance 0.040 to 0.130 0.240
Bushing inside diameter 50.000 to 50.025 50.100
4TNV94L/98(T) Intermediate Camshaft outside diameter 49.910 to 49.935 49.875 4.3.5.(1)
Clearance 0.065 to 0.115 0.225
Bushing inside diameter 50.000 to 50.025 50.100
Wheel side Camshaft outside diameter 49.925 to 49.950 49.890
Clearance 0.05 to 0.100 0.210
Bushing inside diameter 57.980 to 58.050 58.105
Gear side Camshaft outside diameter 57.910 to 57.940 57.875
Clearance 0.040 to 0.140 0.250
Bushing inside diameter 58.000 to 58.030 58.105
4TNV106(T) Intermediate Camshaft outside diameter 57.895 to 57.925 57.860
Clearance 0.075 to 0.135 0.245
Bushing inside diameter 58.000 to 58.030 58.105
Wheel side Camshaft outside diameter 57.910 to 57.940 57.875
Clearance 0.050 to 0.120 0.230
189
12. Service Standards
190
12. Service Standards
(2) Crankshaft
mm
Reference
Inspection item Standard Limit
page
Bending (1/2 the dial gauge reading) - 0.02
Pin outside diameter 42.952 to 42.962 42.902
Metal inside diameter 43.000 to 43.042 -
3TNV82A
Metal thickness 1.487 to 1.500 -
Clearance 0.038 to 0.090 0.150
Pin outside diameter 47.952 to 47.962 47.902
Metal inside diameter 48.000 to 48.026 -
TNV84 to 88
Metal thickness 1.492 to 1.500 -
Clearance 0.038 to 0.074 0.150
Crank pin
Pin outside diameter 57.952 to 57.962 57.902
Metal inside diameter 58.000 to 58.026 -
4TNV94L•98
Metal thickness 1.492 to 1.500 -
Clearance 0.038 to 0.074 0.150
Pin outside diameter 63.952 to 63.962 63.902
Metal inside diameter 64.016 to 64.042 -
4TNV106(T)
Metal thickness 1.984 to 1.992 -
Clearance 0.054 to 0.090 0.150 4.4.5.(2)
Journal outside diameter 46.952 to 46.962 46.902
Metal inside diameter 47.000 to 47.032 -
3TNV82A
Metal thickness 1.987 to 2.000 -
Clearance 0.038 to 0.080 0.150
Journal outside diameter 53.952 to 53.962 53.902
TNV84 to 88 Metal inside diameter 54.000 to 54.020 -
191
12. Service Standards
192
12. Service Standards
Piston ring
mm
Reference
Model Inspection item Standard limit
page
Ring groove width 2.065 to 2.080 2.170
Ring width 1.970 to 1.990 1.950
Top ring
Side clearance 0.075 to 0.110 0.200
End clearance 0.200 to 0.400 0.490
Ring groove width 2.035 to 2.050 2.150
3TNV82A Ring width 1.970 to 1.990 1.950
Second ring
TNV84 Side clearance 0.045 to 0.080 0.200
End clearance 0.200 to 0.400 0.490
Ring groove width 4.015 to 4.030 4.130
Ring width 3.970 to 3.990 3.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.200 to 0.400 0.490
Ring groove width 2.060 to 2.075 2.170
Ring width 1.970 to 1.990 1.950
Top ring
Side clearance 0.070 to 0.105 0.200
End clearance 0.200 to 0.400 0.490
Ring groove width 2.025 to 2.040 2.140
Ring width 1.970 to 1.990 1.950
TNV88 Second ring
Side clearance 0.035 to 0.070 0.190
End clearance 0.200 to 0.400 0.490
Ring groove width 4.015 to 4.030 4.130
Ring width 3.970 to 3.990 3.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.200 to 0.400 0.490
4.4.5.(4)
Ring groove width 2.040 to 2.060 -
Ring width 1.940 to 1.960 1.920
Top ring
Side clearance 0.080 to 0.120 -
End clearance 0.250 to 0.450 0.540
Ring groove width 2.080 to 2.095 2.195
Ring width 1.970 to 1.990 1.950
4TNV94L/98 Second ring
Side clearance 0.090 to 0.125 0.245
End clearance 0.450 to 0.650 0.730
Ring groove width 3.015 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.250 to 0.450 0.550
Ring groove width 2.520 to 2.540 -
Ring width 2.440 to 2.460 2.420
Top ring
Side clearance 0.060 to 0.100 -
End clearance 0.300 to 0.450 0.540
Ring groove width 2.070 to 2.085 2.185
Ring width 1.970 to 1.990 1.950
4TNV106(T) Second ring
Side clearance 0.080 to 0.115 0.235
End clearance 0.450 to 0.600 0.680
Ring groove width 3.015 to 3.030 3.130
Ring width 2.970 to 2.990 2.950
Oil ring
Side clearance 0.025 to 0.060 0.180
End clearance 0.300 to -0.500 0.600
(R.1)
193
12. Service Standards
(6) Tappet
mm
Reference
Inspection item Standard Limit
page
Tappet hole (block) inside diameter 12.000 to 12.025 12.045
TNV82A-88 Tappet stem outside diameter 11.975 to 11.990 11.955
Clearance 0.010 to 0.050 0.090
Tappet hole (block) inside diameter 12.000 to 12.018 12.038
4TNV94L•98 Tappet stem outside diameter 11.975 to 11.990 11.955 4.4.5.(6)
Clearance 0.010 to 0.043 0.083
Tappet hole (block) inside diameter 14.000 to 14.018 14.038
4TNV106(T) Tappet stem outside diameter 13.966 to 13.984 13.946
Clearance 0.015 to 0.052 0.092
194
12. Service Standards
(R.1)
195
13. Tightening torque for bolts and nuts
(R.1)
196
13. Tightening torque for bolts and nuts
197
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