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Hitachi - Service Manual Hitachi ZAXIS ZX10U-2 - ZX8-2 Excavator-Hitachi Construction Machinery Co., Ltd. (2007)

Hitachi Service Manual

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0% found this document useful (0 votes)

219 views887 pages

Hitachi - Service Manual Hitachi ZAXIS ZX10U-2 - ZX8-2 Excavator-Hitachi Construction Machinery Co., Ltd. (2007)

Hitachi Service Manual

Uploaded by

Gilart A C Kerr

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 887

PART NO.

T1MR-E-00

8-2 10U-2 Excavator

Technical Manual

TECHNICAL MANUAL
8-2
10U-2
Excavator

URL:http://www.hitachi-c-m.com

Service Manual (Manual No. KM-1MR-E) consists of the following separate Volumes;
Technical Manual : Vol. No. T1MR-E
Workshop Manual : Vol. No. W1MR-E

PRINTED IN SINGAPORE (YS) 2006.12

T1MR-E-00.p65 1 29/11/06, 19:46

INTRODUCTION
TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
• This manual contains the revision information
to the 23, January 2008.

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • The Engine Manual
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.

• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which could,
potential for personal injury of machine damage. if not avoided, result in personal injury or death.

This is the safety alert symbol. When you see this • IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. • NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting heavy know-how.
parts.

UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

this manual, be alert to the potential for personal in-
jury.
• Follow recommended precautions and safe operating
practices.

SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious in-
jury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
• To avoid confusing machine protection with personal SA-1223

safety messages, a signal word IMPORTANT indicates a

situation which, if not avoided, could result in damage to
the machine.

• NOTE indicates an additional explanation for an

element of information.

SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine

as well as all safety messages in this manual.
• Safety signs must be installed, maintained and replaced
if damaged.
• If a safety sign or this manual is damaged or missing,
order a replacement from your nearest Hitachi dealer
in the same way you order other replacement parts
(be sure to state machine model and serial number
when ordering).
• Allow only properly trained, qualified, authorized per-
SA-003
sonnel to operate the machine.
• Learn how to correctly operate and service the machine.
• Keep your machine in proper working condition.
• Always operate the machine within the specification.
• Unauthorized modifications of the machine may impair
the functions and/or safety and affect machine life and
the warranty will become void.
• The safety messages in this SAFETY chapter are in-
tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every possible hazardous situation you may en-
counter. If you have any questions concerning safety,
you should first consult your supervisor and/or your
nearest Hitachi dealer before operating or performing
maintenance work on the machine.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on
the fire extinguisher and use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to cope
with any fire or accidents which may occur. SA-437

• Keep emergency numbers for doctors, ambulance

service, hospitals, and fire department posted near
your telephone.

SA-2
SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat
Safety belt
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

Respirator or filter mask.

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator.

• Do not wear radio or music headphones while oper-

ating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.

SA-434

INSPECT MACHINE

• If any abnormality is found, be sure to repair it immedi-

ately before operating the machine.

• In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.

SA-435

SA-3
SAFETY
USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the
machine.
• Maintain a three-point contact with the steps and
handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms, SA-439

thoroughly remove such material.

FASTEN YOUR SEAT BELT

(ROLL BAR EQUIPPED MACHINES)

• If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.

• Be sure to remain seated with the seat belt securely

fastened whenever operating the machine.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine. Replace the seat belt at SA-237

least once every 3 years regardless of appearance

SA-4
SAFETY
MOVE AND OPERATE MACHINE SAFELY

• Always be aware that there is a potential danger around

the machine while operating the machine.

• Take extra care not to run over bystanders. Confirm

signal person so that the operator can always witness

the signal person.
• Coordinate the meanings of all safety signs, hand
signals and marks before starting the machine. Ap-
point a person who is responsible to make a signal
and/or guidance.
• Never allow any persons or obstacles to enter the
machine operation areas.
• Use appropriate illuminations.

SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury
or death.

• Start the engine only when seated in the operator's

seat.
• NEVER start the engine while standing on the tracks
or on ground.
• Do not start engine by shorting across starter termi-
nals. A hazardous situation may be created and/or
possible damage to the machine may result. SA-444

• Before starting the engine, confirm that all control lev-

ers are in neutral.

JUMP STARTING

• Failure to follow correct jump starting procedures could

result in a battery explosion or a runaway machine.

• If the engine must be jump started, be sure to follow

the instructions shown in the “OPERATING THE EN-
GINE” chapter.
• The operator must be seated in the operator’s seat so
that the machine will be under control when the engine
starts. Jump starting is a two-person operation.
• Never use a frozen battery.
SA-032
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway ma-
chine.

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the
machine.

• Riders also obstruct the operator’s view, resulting in

the machine being operated in an unsafe manner.
• Only allow the operator is allowed on the machine.
Keep riders off.

SA-612

SA-6
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road

shoulder, the machine could tip over due to collapse of
the ground, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder,
SA-613
employ a signal person as required.
• Never allow bystanders to enter the working area such
as swing radius or traveling range.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing may become
loose and slippery.
• When operating the machine near open flame, sparks,
and/or dead grass, a fire may easily break out. Use
special care not to cause a fire.

SA-7
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

• In case more than one machine is operated in the same

job site, accidental collision between machines may
cause serious injury or death.

• For jobs involving multiple numbers of machines, provide

signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s direc-
tions.

SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN

• Incorrect travel pedal/lever operation may result in seri-

ous injury death.

• Before driving the machine, confirm the position of the

undercarriage in relation to the operator’s position.
• If the travel motors are located towards the front of the
cab, the machine will move in the reverse direction
when travel pedals/levers are operated.

SA-614

SA-8
SAFETY
DRIVE MACHINE SAFELY

• Driving the machine in the incorrect direction may result

in serious injury or death and/or severe damage to
property.

• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding di-
rection you wish to travel.

• Avoid passing over any obstructions. Failure to do so

may cause soil, rock fragments and/or metal pieces to
be scatter around the machine. Keep bystanders away SA-615

from the machine.

• Traveling on a grade may cause the machine to slip or to
overturn, possibly resulting in serious injury or death.

• When traveling up or down a grade, keep the bucket in

the direction of travel, approximately 100 to 200 mm
(3.9 to 7.9 in) (A) above the ground so that lowering
the bucket onto the ground can quickly stop the ma-
chine.
• If machine starts to skid or becomes unstable, lower
the bucket immediately.

• Traveling across the face of slope or steering on a

slope may cause the machine to skid or to turnover. If
the direction must be changed on a slope, first move SA-616

the machine to level ground, then, change the travel-

ing direction to ensure safe operation.

SA-441

SA-442

SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS

• Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.

• Park the machine in compliance with the safe parking

procedures described on page S-16 to prevent the ma-
chine from running away.

• Block both tracks and lower the bucket to the ground,

thrust the bucket teeth into the ground if you must park
on a grade.
• Park a reasonable distance from other machines.

SA-617

SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

• If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals are SA-384

clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings
used on the job and confirm who has the responsibility
for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494-8

SA-11
SAFETY
KEEP PERSONNEL CLEAR FROM WORKING
AREA

• If a person is present near the operating machine, the

person may come in contact with the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
• Make sure that no personnel other than the signal
person or no obstacles are present in the working area
before operating the machine.

SA-618

NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a

truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

• Never allow the bucket to pass over anyone to avoid

personal injury or death.

SA-619

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if the

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic raise the front attachment with a
panic. Lowering the front attachment may be safer in
most cases.

SA-620

SA-12
SAFETY
AVOID TIPPING

• The danger of tipping is always present when operating

on a grade, possibly resulting in serious injury or death.

To avoid tipping:
• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than SA-621

15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging
loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E01A-0540-4

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.

SA-622

SA-13
SAFETY
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in
serious injury or death.

• Before digging check the location of cables, gas lines,

and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in SA-262
serious eye injury.
• Contact your local “diggers hot line” if available in your
area, and/or the utility companies directly.
Have them mark all underground utilities.

OPERATE WITH CAUTION

• If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the

boom or arm.

SA-263

AVOID POWER LINES

• Serious injury or death can result if the machine or front

attachments are not kept a safe distance from electric
lines.

• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all SA-265

bystanders or co-workers away from the site.

SA-14
SAFETY
DO NOT USE FOR CRANING OPERATIONS

• NEVER use the machine for craning operations. If the

machine is used for craning operations, the machine
may tip over and/or lifted load may fall, possibly resulting
in serious injury or death.
• This machine has been exclusively designed to engage
in excavation and loading works.
• This machine is not equipped with any of the necessary
safety devices that could allow the machine to be used
for craning operation.

SA-014

PROTECT AGAINST FLYING DEBRIS

• If flying debris such as soil, rock fragments or metal

pieces hit eyes or any other part of the body, serious
injury may result.

• Guard against such injuries when working in a job site

where possibility of flying pieces of metal or debris
exist, or when removing or installing pins using a
hammer; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
SA-432

SA-15
SAFETY
PARK MACHINE SAFELY

• Unless the machine is not correctly parked, any

hazardous situations such as running away of the
machine or damage by vandalism may result, causing
the machine to operate unsafely when the engine is
re-started. Follow instructions described below when
parking the machine.

• Park the machine on solid level surface to prevent the

machine from running away.
• Lower the bucket and/or blade to the ground.
• Pull the lock lever to the LOCK position.
SA-623
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine. Remove the
key from the key switch.
• Before leaving the machine, close all windows, roof
vent, and cab door. Lock all access doors and
compartments

HANDLE FLUIDS SAFELY --- AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur, possibly
resulting in serious injury or death.

• Do not refuel the machine while smoking or when near

open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are

flammable. SA-018

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.

SA-019

SA-16
SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting

the machine on public roads.
• Provide an appropriate truck or trailer for transporting
SA-624
the machine.
• Be sure to have a signal person.
• Take the following precautions when
loading/unloading the machine.
1. Select firm level ground.
2. Be sure to use a loading dock or ramp strong enough
to support the machine weight.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have a gradient
of less than 15 degrees.
5. Slowly drive the machine.
6. Avoid steering while driving up or down the ramp as it
is extremely dangerous. If steering is unavoidable,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
7. The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it.
8. Wedge the front and rear of tracks. Securely fasten
the machine to the trailer bed with chain or cables.
9. Do not operate any levers besides the travel levers
when driving up or down the ramp.
10. Prevent possible injury from machine tipping while the
upperstructure is rotating.
11. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.

Refer to "transporting" chapter in this manual for details

SA-17
SAFETY
PRACTICE SAFE MAINTENANCE

• Inspection/maintenance work may produce hazardous

connectors, and the cab inside using water and/or

steam.
• Wait to begin to work until the engine and hydraulic oil
temperatures have cooled down to the safety range.
• In case inspection/maintenance must be performed
with the engine runnning, be sure to appoint an
overseer.
• Never lubricate or service the machine while moving it. 90 to 110°
• Repair the cracked windowpane before servicing the
machine. Failure to do so may cause personal injury.
• Whe raising the machine above the ground using the
front attachment function, maintain the angle between
the boom and the arm in the range of 90 to 110°.
Never allow anyone to enter under the machine raised SA-268

with the front attachment function.

• In case working under the machine raised above the
ground is unavoidably required, securely hold the
machine with stays or blocks strong enough to support
the machine weight.
• Never work under the raised bucket.
• Keep all parts in good condition and properly installed.
• Always use the specified tools correctly.
• Always use a clean tool.
• Fix any damage found immediately. Replace worn or
broken parts.
• Remove any buildup of grease, oil, or debris.
• When cleaning parts, use a non-combustible cleaning SA-527
solvent. Never use an inflammable fluid such as
dieasel fuel, or gasoline.

SA-18
SAFETY
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before welding on
the machine.
• Sufficiently illuminate the work site. Use a
maintenance work light when working under or inside
the machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, antifreeze
fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

• Before performing any work on the machine, attach a

“Do Not Operate” tag in an easy-to-see place such as
on the cab door or control lever.
• Never attempt to operate the machine with a “Do Not
Operate” tag attached.
• Make it a rule for the inspection/service person to hold
the engine start key during inspection/service work.
SA-287

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing

the machine first.

• Always lower the attachment to the ground before you

work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment with stays
or blocks strong enough to support the machine
and/or attachment weight.

SA-527

SA-19
SAFETY
STAY CLEAR OF MOVING PARTS

• Contact with moving parts can cause serious injury or

death due to amputation or entanglement.

• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating
parts.

SA-026

PREVENT PARTS FROM FLYING

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTINGS or

VALVE ASSEMBLIES.
• As pieces of parts may fly off, be sure to keep body
and face away from the valve.

• Travel reduction gears are under pressure.

SA-344

• GEAR OIL is hot. Wait for gear oil to cool, then

gradually loosen the air release plug to release
pressure.
• As pieces of parts may fly off, be sure to keep body
and face away from AIR RELEASE PLUG to avoid
injury.

SA-20
SAFETY
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent

falling accidents.
• Keep children and bystanders away from storage
areas.

SA-034

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under pressure.
Hot water or steam is contained in the engine, radiator
and heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.

• To prevent possible injury from hot spraying water,

stop the engine. Begine to work after the engine and
radiator are sufficiently cooled
• DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop. SA-039

Allow all pressure to be release before removing the

cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure by slowly removing the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also becomes hot
during operation.
The engine, hoses, lines and other parts become hot as
well.

• Wait for the oil and components to cool before starting

any maintenance or inspection work.

SA-225

SA-21
SAFETY
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids such as

hydraulic oil or fuel under pressure may break due to
aging, fatigue, and abrasion. It is very difficult to gauge
the extent of deterioration due to aging, fatigue, and
abrasion of rubber hoses by visual inspection alone.

• Periodically replace the rubber hoses.(Refer to the

Periodical Replacement Parts section.)

• Failure to periodically replace rubber hoses may cause a

fire, fluid injection into skin, or the front attachment to fall
SA-019
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines. Make sure that
all connectors are completely connected before
applying pressure.
• Search for leaks with a piece of cardboard; take care
to protect hands and body from high-pressure fluids.
Wear a face shield or goggles for eye protection.
SA-031
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-22
SAFETY
PREVENT FIRES

Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires,
possibly resulting in personal injury or death.

• Check for missing or loose clamps, kinked hoses,

lines or hoses that rub against each other, damage to
the oil-cooler, and loose oil-cooler flange bolts, for oil
leaks.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts. SA-019

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes or hoses.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc.

SA-23
SAFETY
Precautions for Handling Flammables
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.

• Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated
flammables immediately.
• Do not store flammable fluid near open flames.
• Do not burn or crush a pressurerized container.
• Do not store oily cloths. They are liable to catch fire.
• Do not wind easy-to-absorb-oil asbestos or glass wool
around high-temperature parts such as a muffler or
exhaust pipe.

Check Heat Shield Covers around Engine

Compartment
• If the engine compartment heat shield cover becomes
broken or lost, fire may break out.

• If the engine compartment heat shield cover becomes

broken or lost, repair or replace it before operating the
machine.

Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.

• Always check key switch function before operating the

machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to confirm
that the engine hasstopped.
If any abnormalities are found, be sure to repair
them before operating the machine.

SA-24
SAFETY
EVACUATING IN CASE OF FIRE

• If fire breaks out during machine operation, evacuate the

machine in the following way:

• Stop the engine by turning the key switch to the OFF

position.
• Use a fire extinguisher if there is time.
• Exit the machine using handrails and/or steps.

SA-393

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

• If you must operate the machine in a building, be sure

there is adequate ventilation. Either use an exhaust
pipe extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into the
area.

SA-016

SA-25
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create a fire hazard. Store
flammable objects in a safe place before starting
grinding.

• After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the

welded area still smoldering.

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials before engaging in welding, soldering, SA-030

etc.

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Remove flammable fluids thoroughly with
nonflammable solvent before welding or flame cutting
pipes or tubes that contained flammable fluids.

SA-26
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.

• Remove paint before welding or heating.

• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Allow fumes to disperse at least 15 minutes after
SA-029
welding or heating.
• Use attention to the following points when removing
paint.
1. If you sand or grind paint, avoid breathing the dust
which is created.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding.
3. Remove solvent or paint stripper containers and
other flammable material from area.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away from

the top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm
the battery to 16 °C (60 °F) first.
• Do not continue to use or charge the battery when the
electrolyte level is lower than specified. Explosion of
the battery may result. SA-032

• When a terminal become loose, it may induce sparks.

Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness. If electrolyte is splashed
into eyes, flush your eyes continuosly with water for
about 15 minutes. Seek medical attention immediately.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

SA-27
SAFETY
PRECAUTIONS FOR HANDLING
REFRIGERANT

• If refrigerant is splashed into eyes or spilled onto skin,

blindness or a cold contact burn may result.

• Refer to the precautions described on the refrigerant

container for handling refrigerant.
• Use a recovery and recycling system to avoid venting
refrigerant into the atmosphere.
• Never allow the skin to directly come in contact with
refrigerant.
SA-405

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants,
electrolyte, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. Then follow the correct
procedures and use recommended equipment. SA-309

• See your nearest Hitachi dealer for MSDS.

DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items as oil,
fuel, coolant, brake fluid, filters, and batteries.

• When draining fluid, use a leakproof container with a

capacity larger than the drained fluid volume to
receive it.
• Do not pour waste onto the ground, down a drain, or
into any water source.
• Inquire on the proper way to dispose of harmful waste SA-226
such as oil, fuel, coolant, brake fluid, filters, and
batteries from your local environmental or recycling
center.

SA-28
SECTION AND GROUP SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Hydraulic System
TECHNICAL MANUAL Group 2 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SECTION 4 OPERATIONAL PER-
FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
All information, illustrations and speci-
fications in this manual are based on Group 6 Adjustment
the latest product information available
at the time of publication. The right is SECTION 5 TROUBLESHOOTING
reserved to make changes at any time
without notice. Group 1 Diagnosing Procedure
Group 2 Troubleshooting B
Group 3 Troubleshooting C
Group 4 Electrical System Inspection
COPYRIGHT(C)2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
TION Group 1 Swing Bearing
Group 1 Precautions for Disassem- Group 2 Travel Device
bling and Assembling Group 3 Center Joint
Group 2 Tightening Torque Group 4 Track Adjuster
Group 3 Bleeding Air Group 5 Front Idler
Group 4 Painting Group 6 Upper and Lower Roller
SECTION 2 UPPERSTRUCTURE Group 7 Track
Group 1 Pump Device SECTION 4 FRONT ATTACHMENT
Group 2 Control Valve Group 1 Front Attachment
Group 3 Swing Device Group 2 Cylinder
Group 4 Pilot Valve SECTION 5 Engine
Group 5 Solenoid Valve
SECTION 1
GENERAL

CONTENTS
Group 1 Specification
Specifications ........................................... T1-1-1
Working Ranges and Machine
Dimensions for Transportation.................. T1-1-3

Group 2 Component Layout

Main Component Layout .......................... T1-2-1
Electrical Component Layout
(Overview) ............................................. T1-2-2
Electrical System
(Relays) ................................................. T1-2-3
Electrical System
(Lamp Unit, Hour Meter) ........................ T1-2-4
Engine ..................................................... T1-2-5
Control Valve (ZAXIS8-2)......................... T1-2-5
Control Valve (ZAXIS10U-2) .................... T1-2-5
Swing Device........................................... T1-2-6
Travel Device........................................... T1-2-6
2-Spool Solenoid Valve ............................ T1-2-6
Air Bleed Solenoid Valve.......................... T1-2-6

Group 3 Component Specifications

Engine ..................................................... T1-3-1
Engine Accessories ................................. T1-3-4
Hydraulic Component .............................. T1-3-5
Filter ........................................................ T1-3-6
Electrical Component............................... T1-3-6

1MRT-1-1
(Blank)

1MRT-1-2
GENERAL / Specifications
SPECIFICATIONS
ZAXIS8-2

A C

E
D

J I

H G

M1MP-12-005

ZAXIS8-2
Type
Side Frame width Adjustable
Type of Front-End Attachment Boom Swing Type
3 3
Bucket Capacity (Heaped) m (yd ) 0.022 (0.020)
Operating Weight kg (lb) 970 (2140)
Basic Machine Weight kg (lb) 720 (1590)
Yanmar 3TNV70
-1
Engine kW/min 9.5/2100
(PS/rpm) (12.9/2100)
A: Overall Width mm (ft⋅in) 740 (5′1″)
B: Overall Height mm (ft⋅in) 1450 (4′9″)
C: Rear-End Swing Radius mm (ft⋅in) 800 (2′8″)
D: Minimum Ground Clearance mm (ft⋅in) 130 (5′1″)
E: Counterweight Height mm (ft⋅in) 390 (1′3″)
F: Engine Cover Height mm (ft⋅in) 1040 (3′5″)
G: Undercarriage Length mm (ft⋅in) 1220 (4′0″)
H: Undercarriage Width mm (ft⋅in) 720 (2′4″) / 910 (2′12″)
I: Sprocket Center to Idler Center mm (ft⋅in) 900 (2′11″)
180 (7″)
J: Track Shoe Width mm (ft⋅in)
(Rubber Crawler)
kPa 24.0
Ground Pressure 2
(kgf/cm , psi) (0.24, 3.4)
–1
Swing Speed min (rpm) 8.5
Travel Speed (fast/slow) km/h (mph) 4.0/2.0 (2.5/1.2)
Gradeability 30° (tan θ = 0.58)
NOTE: The dimensions do not include the height of the shoe lug.

T1-1-1
GENERAL / Specifications

ZAXIS10U-2 C
A

J D I
H G
M1MP-12-007

ZAXIS10U-2
Type
Side Frame width Adjustable
Type of Front-End Attachment Boom Swing Type
3 3
Bucket Capacity (Heaped) m (yd ) 0.022 (0.020)
Operating Weight kg (lb) 1110 (2450)
Basic Machine Weight kg (lb) 800 (1760)
Yanmar 3TNV70
-1
Engine kW/min 9.5/2100
(PS/rpm) (12.9/2100)
A: Overall Width mm (ft⋅in) 910 (3′0″)
B: Overall Height mm (ft⋅in) 2150 (7′1″)
C: Rear-End Swing Radius mm (ft⋅in) 82.5 (2′9″)
D: Minimum Ground Clearance mm (ft⋅in) 130 (5″)
E: Counterweight Height mm (ft⋅in) 390 (1′3″)
F: Engine Cover Height mm (ft⋅in) 1040 (3′5″)
G: Undercarriage Length mm (ft⋅in) 1360 (4′6″)
H: Undercarriage Width mm (ft⋅in) 760 (2′6″) / 1000 (3′3″)
I: Sprocket Center to Idler Center mm (ft⋅in) 1040 (3′5″)
180 (7″)
J: Track Shoe Width mm (ft⋅in)
(Rubber Crawler)
kPa 23
Ground Pressure 2
(kgf/cm , psi) (0.24, 3.4)
–1
Swing Speed min (rpm) 8.5
Travel Speed (fast/slow) km/h (mph) 4.0/2.0 (2.5/1.2)
Gradeability * 30° (tan θ = 0.58)
NOTE: *Although the machine's gradeability is 58 %(30°),do not attempt to descend/ascend slopes with the
grade of more than 27 %(15°) to ensure safety operation.

T1-1-2
GENERAL / Specifications
WORKING RANGES
ZAXIS8-2
G H K K

F
A
M1MP-12-006

ZAXIS8-2
Side Frame width Adjustable
A: Maximum Digging Reach mm (ft⋅in) 2830 (9′3″) [3000 (9′10″)]
B: Maximum Digging Depth mm (ft⋅in) 1600 (5′3″) [1800 (5′11″)]
C: Maximum Cutting Height mm (ft⋅in) 2840 (9′4″) [2940 (9′8″)]
D: Maximum Dumping Height mm (ft⋅in) 2050 (6′9″) [2150 (7′1″)]
E: Transport Height
1450 (4′9″)
(Rubber Crawler) mm (ft⋅in)
F: Overall Transport Length mm (ft⋅in) 2730 (9′0″) [2790 (9′2″)]
G: Minimum Swing Radius mm (ft⋅in) 1310 (4′4″) [1420 (4′8″)]
H: Boom-Swing Pivot Offset Distance
920 (3′0″) [1060 (3′6″)]
mm (ft⋅in)
I: Blade Bottom Highest Position
185 (7.3″)
(above ground level) mm (ft⋅in)
J: Blade Bottom Lowest Position
175 (6.9″)
(above ground level) mm (ft⋅in)
K: Offset Distance mm (ft⋅in) L420 (L 15″) / R535 (R1′9″)
Maximum Boom-Swing Angle Degree L65° / R55°
NOTE: The dimensions do not include the height of the shoe lug.
The dimensions for the machine equipped with the long arm are shown in brackets [ ].

T1-1-3
GENERAL / Specifications

ZAXIS10U-2
G, H L L

D E

F
A

K K

M1MP-12-008

ZAXIS10U-2
Side Frame width Adjustable
A: Maximum Digging Reach mm (ft⋅in) 3220 (10′7″) [3350 (11′0″)]
B: Maximum Digging Depth mm (ft⋅in) 1780 (5′10″) [1930 (6′4″)]
C: Maximum Cutting Height mm (ft⋅in) 3010 (9′11″) [3050 (10′0″)]
D: Maximum Dumping Height mm (ft⋅in) 2220 (7′3″) [2260 (7′5″)]
E: Transport Height
2150 (7′1″)
(Rubber Crawler) mm (ft⋅in)
F: Overall Transport Length mm (ft⋅in) 2940 (9′8″) [3000 (9′10″)]
G: Minimum Swing Radius mm (ft⋅in) 1310 (4′4″) [1420 (4′8″)]
H: Boom-Swing Pivot Offset Distance
1100 (3′7″)] [1190 (3′11″)]
mm (ft⋅in)
I: Blade Bottom Highest Position
220 (9″)
(above ground level) mm (ft⋅in)
J: Blade Bottom Lowest Position
190 (8″)
(above ground level) mm (ft⋅in)
K: Offset Distance mm (ft⋅in) L420 (L 1′5″) / R535 (R1′9″)
Maximum Boom-Swing Angle Degree L65° / R55°
NOTE: The dimensions do not include the height of the shoe lug.
The dimensions for the machine equipped with the long arm are shown in brackets [ ].

T1-1-4
GENERAL / Component Layout
MAIN COMPONENT

7
6 8
9

5 10
11
4
3
2
12
1
13
14

15
27
26
25
24
23
22
21
20
19
18
17

16 T1MP-01-02-001

1- Main Pump 8 - Air Bleed Solenoid Valve 15 - Arm Cylinder 22 - Track Adjuster
2- Air Cleaner 9 - Pilot Filter 16 - Bucket Cylinder 23 - Side Frame Extend/Retract
Cylinder
3- Return Filter 10 - Front Attachment/ Swing 17 - Boom Cylinder 24 - Center Joint
Pilot Valve (ZAXIS10U-2
only)
4- Reserve Tank 11 - Fuel Tank 18 - Blade Cylinder 25 - Swing Bearing
5- Pilot Pump 12 - Control Valve 19 - Front Idler 26 - Hydraulic Oil Tank
6- Engine 13 - Swing Device 20 - Boom Swing Cylinder 27 - Travel Device
7- Radiator 14 - 2-Spool Solenoid Valve 21 - Lower Roller

NOTE: As for ZAXIS 8-2, swing device (13), swing bearing (25) and center joint (24) are located reversely.

T1-2-1
GENERAL / Component Layout
ELECTRICAL SYSTEM (OVERVIEW)

3
4

5
2
6
7
1

T1MP-01-02-002

1- Battery 4 - Horn Switch 6- Travel Mode Selector 8- Work Light

Switch
2- Slow Blow Fuse 5 - Pilot Shut-Off Switch 7 - Horn 9- 2-Spool Solenoid Valve
3- Air Bleed Solenoid Valve

T1-2-2
GENERAL / Component Layout
ELECTRICAL SYSTEM (RELAYS)
3

2
4

5
6

7
1

T1MP-01-02-012

11 10 9 8

1- Power Relay 4 - Female Plug for Spare 7- Fuse Box 2 10 - Horn Relay
Power Source (Label: ACC)
2- Slow Blow Fuse 5 - Male Plug for Spare Power 8- 1-Second Timer 11 - Unload Relay
3- Battery 6 - Fuse Box 1 9- Safety Start Relay

T1-2-3
GENERAL / Component Layout
ELECTRICAL SYSTEM (LAMP UNIT, HOUR
METER)

1
2 3 4

T1MP-01-02-005

Machine Front

T1MP-01-02-004

T1MP-01-02-006

1- Key Switch 3 - Overheat Indicator 4- Alternator Indicator 5- Hour Meter

2- Engine Oil Pressure
Indicator

T1-2-4
GENERAL / Component Layout
ENGINE
1 6

5
4

2 T1MP-01-02-007

T1MP-01-02-008

CONTROL VALVE (ZAXIS 8-2) CONTROL VALVE (ZAXIS 10U-2)

8 9 8 9
7 7
10 11 10 11

13 13
T1MN-01-02-001 T1MP-01-02-010
12 12

1- Alternator 5 - Governor Lever 8- Overload Relief Valve (Left 11 - Main Relief Valve (P1)
Swing)
2- Starter 6 - Overheat Switch 9 - Overload Relief Valve (Arm 12 - Overload Relief Valve
Roll-In) (Boom Lower)
3- Engine Oil Pressure Switch 7 - Main Relief Valve (P2) 10 - Make-Up Valve (Right 13 - Overload Relief Valve
Boom Swing) (Right Swing)
4- Engine Stop Solenoid

T1-2-5
GENERAL / Component Layout
SWING DEVICE TRAVEL DEVICE

1 2 3

T1MP-01-02-011

T1MP-01-02-009

2-SPOOL SOLENOID VALVE AIR BLEED SOLENOID VALVE

4 5

T1M7-01-02-008

T1M7-01-02-007

1- Make-Up Valve 3 - Travel Mode Selector Valve 5- Auxiliary Solenoid Valve 7- Air Bleed Solenoid Valve
(ZAXIS 8-2), Pilot Shut-Off
Solenoid Valve (ZAXIS
10U-2) (with yellow
identification tape)
2- Counterbalance Valve 4 - Travel Mode Selector 6 - Pilot Relief Valve
Solenoid Valve

T1-2-6
GENERAL / Component Specifications
ENGINE

Manufacturer···················································Yanmar
Model ······························································3TNV70-VHB
Type ································································4-Cycle, Water-Cooled, Overhead Wave, Vertical Inline,
Special Swirl Chamber Type
Cyl. No.-Bore×Stroke ······································3-70 mm×74 mm (2.76 in×2.91 in)
3 3
Piston Displacement ·······································854 cm (52 in )
-1 -1
Rated Output ··················································9.52±0.3 kW / 2100 min (12.9±0.4 PS / 2100 min )
Compression Ratio ·········································23.0
Dry Weight ······················································97 kg (214 lb)
Firing Order·····················································1-3-2
Rotation Direction ···········································Clockwise (View from fan side)

COOLING SYSTEM
Cooling Fan···················································· Dia. 270 mm 5 Blades (F-Type Blade), Draw-In Type
Fan Pulley Ratio············································· Engine rpm×1.33
Thermostat (Atmospheric Pressure)·············· : Full open temp. 71 °C (160 °F)
: Cracking temp. 85 °C (185 °F)
Water Pump··················································· Centrifugal Belt Driven Type

LUBRICATION SYSTEM
Lubrication Pump Type ·································· Trochoid Pump
Oil Filter·························································· Full-Flow Paper Element Type

STARTING SYSYTEM
Motor······························································ Magnetic Pinion Shift Type
Voltage / Output ············································· 12 V / 1.1 kW

T1-3-1
GENERAL / Component Specifications
PREHEAT SYSMTEM
Preheating Method········································· Preheat Position Glow Plug

ENGINE STOP SYSYTEM

Stop Method··················································· Fuel Shut-Off

ALTERNATOR
Type ······························································· Regulator Integrated AC type
Voltage / Output ············································· 12 V / 40 A

FUEL SYSTEM
Injection Pump ··············································· Inline Type
Speed Governor············································· Mechanical All Speed Governor
Fuel Filter ······················································· Full-Flow Filter

PERFORMANCE
IMPORTANT: The values shown here for this product are specification values, and not service standards.

Lubricant Consumption·································· Less than 0.41 mL/hr at Rated Output

Fuel Consumption Ratio ································ Less than 273 g/kW･h (201 g/PS･h) at Rated Output
Injection Timing·············································· before T. D. C from 17°, after T. D. C. until 15°
-1
Intermediate Torque······································· 46.8 to 51.0 N⋅m / 1500 min
-1
(4.8 to 5.2 kgf⋅m / 1500 min )
2 -1
Compression Pressure ·································· 3.24 MPa (33 kgf/cm , 471psi) at 250 min
Valve Clearance (Inlet/Exhaust)····················· 0.15 to 0.25 mm (when cool)
-1 -1
No Load Speed ·············································· Slow: 1300±25 min Fast: 2270±25 min

T1-3-2
GENERAL / Component Specifications
Engine Performance Curve (3TNV70)

Test conditions
1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construction Machinery)
under standard atmospheric pressure.
2. Fan and generator are provided.

Torque
46.8 to 51.0 N⋅m/1500 min-1 N⋅m (kgf⋅m)
(4.8 to 5.2 kgf⋅m/1500 rpm) 60 (6)

Torque
50(5)

40 (4)

30 (3)

20 (2)

9.52±0.3 kW/2100 min-1

(12.9±0.4 PS/2100 rpm)
Output
kW(PS) Fuel
consmption
10 (14) Ratio
Output
g/kW⋅h
8 (11) 360

6 (8) 320

Fuel Consumption
4 (5) Ratio 280

240

1200 1400 1600 1800 2000 2200 2400 T1MP-01-03-001

Engine Speed min-1(rpm)

T1-3-3
GENERAL / Component Specifications
ENGINE ACCESSORIES
RADIATOR
Capacity ......................................................... Approx. 0.95 L (0.25 US gal.)
2
Cap Opening Pressure .................................. 88 kPa (0.9 kgf/cm , 13 psi)

BATTERY
Type ................................................................55B24R
Capacity ..........................................................36 Ah (5-Hour Rate)
Voltage ............................................................12 V

T1-3-4
GENERAL / Component Specifications
HYDRAULIC COMPONENT
MAIN PUMP 1 · 2
Model ............................................................. D05A5R
Type ............................................................... Gear Pump
Maximum Flow (Theoretical Value) ............... 10.6 L/min (2.8 US gpm)

PILOT PUMP
Model ............................................................. PW1-C
Type ............................................................... Gear Pump
Maximum Flow (Theoretical Value) ............... 5.3 L/min (1.4 US gpm)

CONTROL VALVE
Model ............................................................. NSC10-HH (ZAXIS8-2)
NSC10-HG (ZAXIS10U-2)
Type ............................................................... Directly Operated Type (10-Spool) (ZAXIS 8-2)
Pilot Pressure Operated Type+Directly Operated Type
(10-Spool) (ZAXIS 10U-2)
+0.5 +5
Main Relief Set-Pressure (P1, P2)................. 17.7 MPa 0 (180 0 kgf/cm2, 2570 psi)
at 11 L/min (2.9 US gpm)
Overload Relief Set-Pressure
+0.5 +5
(Boom, Arm)................................................... 20.6 0 MPa (210 0 kgf/cm2, 2990 psi)
at 10 L/min (2.6 US gpm)
+0.5 +5
(Swing)........................................................... 7.5 0 MPa (77 0 kgf/cm2, 1090 psi)
at 11 L/min (2.9 US gpm)

SWING MOTOR
Model ............................................................. 104-6407
Type ................................................................Orbit Motor Type

TRAVEL DEVICE
Model ............................................................. PHV-80
Type ............................................................... Two-Stage Planetary Reduction Gear
Reduction Gear Ratio .................................... 25.26

TRAVEL MOTOR
Type ............................................................... Swash Plate Type, Variable Displacement Axial Plunger Motor

TRAVEL BRAKE VALVE

Type ............................................................... Counterbalance Valve Type

CYLINDER
ZAXIS 8-2 Boom Arm Bucket
Rod Diameter................................................. 30 mm (1.18”) 25 mm (0.98”) ←
Cylinder Bore ................................................. 50 mm (1.97”) ← ←
Stroke............................................................. 361 mm (1’2”) 311 mm (1’0”) 243 mm (9.57”)
Fully Retracted Length................................... 621 mm (2’0”) 537 mm (1’9”) 468 mm (1’6”)
Plating Thickness........................................... 30 µm or more ← ←

Boom Swing Blade Side Frame

Extend / Retract
Rod Diameter................................................. 25 mm (0.98”) ← ←
Cylinder Bore ................................................. 50 mm (1.97”) ← ←
Stroke............................................................. 260 mm (10.2”) 83 mm (3.27”) 158 mm (6.22”)
Fully Retracted Length................................... 493 mm (1’7”) 316 mm (1’0”) 363 mm (1’2”)
Plating Thickness........................................... 30 µm or more ← ←

T1-3-5
GENERAL / Component Specifications

ZAXIS 10U-2 Boom Arm Bucket

Rod Diameter................................................. 30 mm (1.18”) ← 25 mm (0.98”)
Cylinder Bore ................................................. 55 mm (2.17”) 50 mm (1.97”) ←
Stroke............................................................. 355 mm (1’2”) 356 mm (1’2”) 282 mm (11.1”)
Fully Retracted Length................................... 623 mm (2’0”) 581 mm (1’11”) 507 mm (1’8”)
Plating Thickness........................................... 30 µm or more ← ←

Boom Swing Blade Side Frame

Extend / Retract
Rod Diameter................................................. 25 mm (0.98”) 30 mm (1.18”) 25 mm (0.98”)
Cylinder Bore ................................................. 50 mm (1.97”) 55 mm (2.17”) 50 mm (1.97”)
Stroke............................................................. 260 mm (10.2”) 87 mm (3.43”) 237 mm (9.33”)
Fully Retracted Length................................... 493 mm (1’7”) 336 mm (1’1”) 413 mm (1’4”)
Plating Thickness........................................... 30 µm or more ← ←

FRONT ATTACHMENT / SWING PILOT VALVE (ZAXIS 10U-2 only)

Model ............................................................. PV48M2074A
Plunger Stroke ............................................... 5.1 mm (0.2 in)

SOLENOID VALVE (2-Spool Solenoid Valve with Pilot Relief Valve)

Model ..............................................................GLV-A
Relief Set-Pressure.........................................2.95 MPa (30 kgf/cm2, 429 psi)
Rated Voltage .................................................DC 12V
Operating Voltage ...........................................DC 10 to 15 V
Solenoid Valve ............................................... A Port Side: Auxiliary (ZAXIS 8-2)
Pilot Shut-Off Valve Solenoid Valve (ZAXIS 10U-2)
B Port Side: Travel Mode Selector Solenoid Valve

FILTER
Filtration
Engine Oil Filter ············································· 20 µm
Fuel Filter ······················································· 8 µm
Return Filter ··················································· 10 µm
Suction Filter ·················································· 105 µm
(150 Mesh)
Pilot Filter ······················································· 10 µm

ELECTRICAL COMPONENT
ENGINE OIL PRESSURE SWITCH
Operating Pressure.........................................49±9.8 kPa (0.5±0.1 kgf/cm2, 7±1 psi)

OVERHEAT SWITCH
Operating Temperature...................................110°C (230°F)

HORN
Voltage / Current ············································ DC 12 V⋅3 A
Sound Pressure ············································· 108 dB (A)

ILLUMINATION
Output ···························································· Work Light: Halogen 12V·23 W

T1-3-6
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
SECTION 2
SYSTEM

CONTENTS
Group 1 Hydraulic System
Outline ..................................................... T2-1-1
Pilot Circuit ............................................... T2-1-2
Main Circuit .............................................. T2-1-8

Group 2 Electrical System

Outline ..................................................... T2-2-1
Main Circuit .............................................. T2-2-2
Electrical Power Circuit
(key Switch : OFF) ................................. T2-2-3
Electrical Power Circuit
(Key Switch: ON) ................................... T2-2-4
Preheating Circuit (Key Switch: HEAT)..... T2-2-6
Starting Circuit (Key Switch: START) ....... T2-2-8
Charging Circuit (Key Switch: ON) ......... T2-2-10
Engine Stop Circuit (Key Switch: OFF)... T2-2-14
Lamp Unit Circuit ................................... T2-2-16

1MRT-2-1
(Blank)

1MRT-2-2
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system mainly consists of main circuit
and pilot circuit.

Main Circuit:

Power Source Controller Actuator

Main Pumps → Control Valves → Motors
Cylinders
Front Attachmens (Optional)

Pilot Circuit:

Power Source Controller Pilot Circuit

Pilot Pumps → 2-Spool Solenoid Valve Unit → Pilot Valve (ZAXIS10U-2 only)
Air Bleed Solenoid Valve Travel Motor

T2-1-1
SYSTEM / Hydraulic System
PILOT CIRCUIT
Overall Circuit
Pressure oil from the pilot pump flows through the pilot
filter and is used in order to operate the operation
control circuit (ZAXIS10U-2 only), travel mode selector
circuit and air bleeding circuit.
Pressure in the pilot circuit is kept specification by the
pilot relief valve.
NOTE: When resistance is big due to the clogged
pilot filter, the relief valve is open and
pressure oil flows to each circuit through
the relief valve.

• Operation Control Circuit (ZAXIS10U-2 only)

Pressure oil flows to each pilot valve through the
pilot shut-off solenoid valve so that pressure oil
according to the pilot valve operation is supplied
to the control valve spool in order to move the
spool.

• Travel Mode Selector Circuit:

Pressure oil flows to the travel motor through the
travel mode selector solenoid valve and shifts the
travel mode selector valve.

• Air Bleeding Circuit:

Pressure oil flows to the air bleed solenoid valve.
When the air bleed solenoid valve is turned ON,
pressure oil in the pilot circuit returns to the
hydraulic oil tank and remaining pressure in the
circuit is released at the same time.

T2-1-2
SYSTEM / Hydraulic System

Right Pilot
Left Pilot Valve
Valve
(ZAXIS10U-2
(ZAXIS10U-2
only)
only)

Control Valve

Each Spool
Operation Control Circuit
(ZAXIS10U-2 only)

Travel Motor

Travel Mode Selector

Circuit

Pilot Shut-Off Travel Mode 2-Spool Solenoid

Solneoid Valve Selector Solenoid Valve
(ZAXIS10U-2 only) Valve

Pilot Relief Valve

Air Bleed Solenoid

Valve

Pilot Relief
Valve Air Bleeding Circuit
Filter

Pilot Pump

Hydraulic
Oil Tank

T1MP-02-01-001

T2-1-3
SYSTEM / Hydraulic System
Operation Control Circuit (ZAXIS10U-2 only)
Controls the operation of control valve.
Consists of the pilot shut-off solenoid valve, the pilot
valve and so on.
Adjusts pressure acting on the control valve spool end
according to the pilot valve operation (control lever
stroke).

NOTE: The boom raise operation is explained

here.

1. When lowering the pilot shut-off lever, the pilot

shut-off switch under the pilot shut-off lever is
turned ON and the pilot shut-off solenoid valve is
shifted.
2. Therefore, pressure oil from the pilot pump flows
to each pilot valve through the pilot shut-off
solenoid valve.
3. When the control lever is turned to boom raise
operation, pressure oil is reduced in the right pilot
valve according to the lever stroke, flows to the
boom spool end and moves the spool according
to the lever stroke.
4. Pressure oil from pump 1 (P1) flows to the boom
cylinder bottom side through the boom spool and
extends the boom cylinder. Therefore, the boom
is raised.

T2-1-4
SYSTEM / Hydraulic System

Pilot Shut-Off
Pump 2 Pump 1 Pilot Pump Solenoid Valve

P2 P1

Control Valve

b c R2
R3

a d R1 R4

Left Pilot Valve

(JIS Lever Pattern) Right Pilot Valve

Boom Cylinder
ｄ c a b R4 R2 R1 R3

T1MP-02-01-002
Boom Raise

a- Left Swing c- Arm Roll-Out R1- Bucket Roll-In R3- Bucket Roll-Out
b- Right Swing d- Arm Roll-In R2- Boom Lower R4- Boom Raise

T2-1-5
SYSTEM / Hydraulic System
Travel Mode Selector Circuit
Shifts the travel mode.
Consists of the travel mode selector switch, travel
mode selector solenoid valve, travel mode selector
valve and so on.
When the travel mode selector switch is turned to
High/Low and the travel mode selector solenoid valve
is shifted, travel mode control pressure is supplied to
the travel motor.
(Refer to the Travel Device group/ COMPONENT
OPERATION.)

Air Bleeding Circuit

Releases remaining pressure in the pilot circuit.
Consists of the air bleed solenoid valve, unload relay
and so on.
When the following conditions exist, the air bleed
solenoid valve is shifted.
• Key switch: ON
• Pilot shut-off switch: OFF (Pilot shut-off lever:
LOCK position)
Therefore, pressure oil in the pilot circuit returns to the
hydraulic oil tank through the air bleed solenoid valve
and remaining pressure in the circuit is released at the
same time.

T2-1-6
SYSTEM / Hydraulic System

Unload Relay Pilot Shut-Off

Switch From Fuse 2-#1

Air Bleed
Solenoid Valve Travel Mode
Selector Switch
Air Bleeding Circuit

Pilot Pump

Travel Mode Selector Travel Mode Selector Circuit

Solenoid Valve

Travel Motor (Left) Travel Motor (Right)

T1MP-02-01-003
Travel Mode Selector Valve

T2-1-7
SYSTEM / Hydraulic System
MAIN CIRCUIT
Overall Circuit
• The main pump (pumps 1 and 2) sucks hydraulic
oil from the hydraulic oil tank and delivers to the
control valve.
• Delivered pressure oil is supplied to the motor
and cylinder according to operation of the spool in
control valve.
• Return oil from the motor or cylinder returns to
the hydraulic oil tank through the control valve
and return filter.
• If oil temperature is low (with high viscosity), and
flow resistance is large in the return filter, the
relief valve opens and hydraulic oil directly returns
to the hydraulic oil tank.

T2-1-8
SYSTEM / Hydraulic System

Swing Motor

Control Valve

Arm Cylinder
Swing Side Frame Extend /
Retract Cylinder
Travel Motor (Left) Arm

Side Frame
Attachments
Extend / Retract

Left Travel

Auxiliary

Blade Cylinder Travel Motor

Blade (Right)

Right Travel

Bucket Cylinder
Bucket

Boom Cylinder
Boom

Boom Swing Cylinder

Boom Swing

P1 P2
Return Filter
Relief Valve

Hydraulic
Oil Tank Main Pump
T1MP-02-01-004

T2-1-9
SYSTEM / Hydraulic System
Neutral Circuit
When the control lever is in neutral, pressure oil from
the main pump (pumps 1 and 2) returns to the
hydraulic oil tank through the control valve.

Single Operation Circuit

• Pressure oil from pump 1 (P1) flows to each
spool of boom swing, boom, bucket, right travel,
blade and auxiliary in the control valve.
• Pressure oil from pump 2 (P2) flows to each
spool of swing, arm, side frame extend/retract,
left travel, auxiliary in the control valve.
• Pressure oil from pumps 1 and 2 are combined in
the auxiliary spool.

T2-1-10
SYSTEM / Hydraulic System

NOTE: The illustration shows ZAXIS10U-2.

Main Pump

P2 P1
Side
Frame Blade Boom
Control Valve Extend / Left Right
Swing Arm Retract Travel Auxiliary Travel Bucket Boom Swing

P2 P1

Boom Swing
Cylinder
Swing Motor Travel Motor Travel Motor
(Left) (Right)

Arm Cylinder Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-005
Extend / Retract Cylinder Cylinder
Cylinder

T2-1-11
SYSTEM / Hydraulic System
Combined Operation Circuit
When each actuator is operated, pressure oil from
pump 1 (P1) is supplied to each spool of boom swing,
boom, bucket, right travel, blade and auxiliary through
the parallel circuit before the boom swing spool.
Pressure oil from pump 2 (P2) is supplied to each
spool of swing, arm, side frame extend/retract, left
travel and auxiliary through the parallel circuit before
the swing spool.

NOTE: The bucket roll-in and boom raise

operations are explained here.

1. When the boom is raised while the bucket is

rolled in, pressure oil from pump 1 (P1) is
supplied to each spool of boom and bucket
through the parallel circuit before the boom swing
spool.
2. Therefore, the boom can be raised while the
bucket is rolled in.

T2-1-12
SYSTEM / Hydraulic System

NOTE: The illustration shows ZAXIS10U-2.

Main Pump

P2 P1
Side
Frame
Extend / Left Right
Control Valve Swing Arm Retract Travel Auxiliary Blade Travel Bucket Boom Boom Swing

P2 P1

Parallel Circuit Parallel Circuit

Boom Swing
Cylinder
Swing Motor Travel Motor Travel Motor
(Left) (Right)

Arm Cylinder Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-006
Extend / Retract Cylinder Cylinder
Cylinder

T2-1-13
SYSTEM / Hydraulic System
(Blank)

T2-1-14
SYSTEM / Electrical System
OUTLINE
The electrical circuit is broadly divided into the main
circuit and lamp unit circuit.

• Main Circuit
The engine and accessory operation related circuit.

• Lamp Unit Circuit

The machine operation condition indicated circuit.
(lamp unit, hourmeter, switch and so on)

T2-2-1
SYSTEM / Electrical System
MAIN CIRCUIT
Here, major functions and construction of the main
circuit will be described.

• Electrical Power Circuit (Key Switch: OFF)

Electrical circuit that is an electric power source
for the electric system on the machine.
(Battery, Slow Blow Fuse, Key Switch, Fuse Box)

• Electrical Power Circuit (Key Switch: ON)

Electrical circuit is actuated when the key switch is
at ON position.

• Preheating Circuit
Preheating circuit that assists the engine in
starting in cold weather. (Key Switch, Glow Plug)

• Starting Circuit
Starting circuit starts the engine.
(Key Switch, Starter, Safety Start Relay)

• Charging Circuit
Charging circuit charges the batteries.
(Alternator, Battery)

• Engine Stop Circuit

The engine stop solenoid stops the engine.
(Engine Stop Solenoid, Alternator)

T2-2-2
SYSTEM / Electrical System
ELECTRICAL POWER CIRCUIT (KEY
SWITCH: OFF)
The battery negative terminal is grounded to the
vehicle frame. Current from the battery positive
terminal flows as shown below when the key switch is
turned OFF.
NOTE: When the key switch is turned OFF, the
horn can ring.

→ Fuse Box → Terminals #1, #3 in Horn Relay

Battery → Slow Blow Fuse
Terminal 1-#1 → Terminal #2 in Power Relay
→ Terminal B in
→ Terminal B in Key Switch
Starter
→ Terminal B in Alternator

Key Switch

Slow Blow Fuse

Fuse Box 1 Fuse Box 2

Battery
Horn Relay

2 1
Starter
Horn Switch 5 3
B

B 2
Alternator
Horn
Power Relay
T1MP-02-02-001

T2-2-3
SYSTEM / Electrical System
ELECTRICAL POWER CIRCUIT (KEY
SWITCH: ON)
1. When the key switch is turned ON, terminal B is
connected to terminals BR, R2 and ACC in the
key switch.
2. Current from terminal BR in the key switch flows
to the lamp unit, hour meter, travel mode selector
switch, pilot shut-off switch and unload relay as a
power source through the fuse box.
3. Current from terminal R2 in the key switch flows
to the work light and auxiliary power source as a
power source through the fuse box.
4. Current from terminal ACC in the key switch flows
to the engine stop solenoid, fuel pump and
1-second timer as a power source through the
fuse box.

T2-2-4
SYSTEM / Electrical System

Key Switch

Slow Blow Fuse

3 1 3

Fuse Box 1 Fuse Box 2

Battery

Working Light
Auxiliary Power Source

Lamp Unit
Hour Meter
Travel Mode Selector Switch
Pilot Shut-Off Switch
Unload Relay

Engine Stop Solenoid

Fuel Pump T1MP-02-02-002
1-Second Timer

T2-2-5
SYSTEM / Electrical System
PREHEATING CIRCUIT (KEY SWITCH:
HEAT)
1. When the key switch is turned to the HEAT
position, terminal B is connected to terminals BR
and R1 in the key switch.
2. Current from terminal R1 in the key switch flows
to the glow plug and preheats the engine.
NOTE: When the key switch is turned to the
START position, current from terminal R1 in
the key switch continues to flow to the glow
plug. Therefore, the starter rotates with the
glow plug operated.

T2-2-6
SYSTEM / Electrical System

Key Switch

Slow Blow Fuse

Battery

Glow Plug
T1MP-02-02-003

T2-2-7
SYSTEM / Electrical System
STARTING CIRCUIT (KEY SWITCH:
START)

1. When the key switch is turned to the START 7. Current from terminal BR in the key switch flows
position, terminal B is connected to terminals BR, to the pilot shut-off switch through the fuse box.
R1, C and ACC in the key switch. The pilot shut-off switch is turned OFF with the
2. Current from terminal ACC in the key switch flows pilot shut-off lever upward and ON with the pilot
to terminal #3 in the 1-second timer, fuel pump, shut-off lever downward respectively. When the
engine stop solenoid holding side as a power engine starts, turn the pilot shut-off switch OFF.
source through the fuse box. 8. When the pilot shut-off switch is turned OFF, the
3. When current from terminal ACC in the key switch safety start relay is turned ON.
flows to terminal #3 in the 1-second timer, current 9. When the safety start relay is turned ON, the
from terminal #2 in the 1-second timer flows to contact of terminals #3 and #1 in the safety start
terminal #1 in the 1-second timer through relay is turned ON. Therefore, current from
terminals #4 and #3 in the power relay so that the terminal C in the key switch flows to terminal #50
power relay is activated for 1 second. in the starter through terminals #3 and #1 in the
4. At this time, current from the battery flows to the safety start relay. Therefore, the contact inside
engine stop solenoid absorbing side for 1 second starter is turned ON.
through terminals #2 and #1 in power relay. 10. Current from the battery flows to the starter motor
5. Therefore, the control rack in engine stop through terminal B in the starter and the contact.
solenoid moves to the START position. Therefore, the starter motor rotates and the
Consequently, fuel is supplied to the engine and engine runs.
the engine can run.
NOTE: Although current to the engine stop NOTE: When the key switch is turned to the
solenoid absorbing side is blocked in 1 START position, current from terminal R1 in
second, current from terminal ACC in the the key switch continues to flow to the glow
key switch flows to the solenoid holding plug. Therefore, the starter rotates with the
side and the engine can run continuously. glow plug operated.
6. Terminal L in the alternator is grounded inside
when the alternator slowly rotates or stops. At this
time, terminal #2 in the lamp unit is grounded
through terminal L in the alternator and the
alternator indicator lights.

T2-2-8
SYSTEM / Electrical System

Glow Plug Key Switch Lamp Unit

Alternator Indicator

Slow Blow Fuse

2
13 1
Fuse Box 1 Fuse Box 2

Battery

Contact

Starter 50 1
2 Safety Start
3 Relay
B 4

B
Alternator
IG
L Pilot Shut-Off
Switch

Engine Stop Solenoid Absorbing Side

Holding

12 34 41 23
Fuel Pump

1-Second
Timer Power Relay T1MP-02-02-004

T2-2-9
SYSTEM / Electrical System
CHARGING CIRCUIT (KEY SWITCH: ON)
1. After the engine starts and the key switch is
released, the key switch returns to the ON
position. When the key switch is in the ON
position, terminal B is connected to terminals BR,
R2 and ACC in the key switch.
2. Current from terminal ACC in the key switch flows
to terminal IG as a power source for the regulator
inside alternator through the fuse box.
3. When the engine runs, the alternator starts
generating and terminal L in the alternator is not
grounded inside. Therefore, terminal #2 in the
lamp unit is not grounded inside the alternator.
Consequently, the alternator indicator goes off.
4. Current from terminal B in the alternator flows to
the battery through each circuit and the slow blow
fuse.
Therefore, the battery is charged.

T2-2-10
SYSTEM / Electrical System

Key Switch Lamp Unit

Alternator
Indicator

Slow Blow Fuse

2
13 1
Fuse Box 1 Fuse Box 2

Battery

B
Alternator
IG
L

T1MP-02-02-004

T2-2-11
SYSTEM / Electrical System
Alternator Operation
The alternator consists of regulator, field coil FC, stator
coil ST, diode D and so on. The regulator consists of IC,
transistors T1, T2 and so on.

1. Current from the battery flows to IC in the 6. First, no current flows to field coil FC. When the
regulator through terminal B in the alternator. rotor in stator coil SC rotates due to the engine
2. When the key switch is in the ON position, current rotation, alternating voltage occurs in stator coil
from the battery flows to IC in the regulator SC according to remaining magnetism in the rotor.
through the key switch and terminal IG in the (Alternating voltage from stator coil SC is
alternator. commutated into direct voltage by diode D.)
3. At this time, current from IC in the regulator flows 7. If current from stator coil SC flows to field coil FC,
to base B in transistors T1 and T2 and collector C the rotor is further magnetized so that the
is routed to emitter E respectively. generating voltage increases. Thereby, current
4. Therefore, terminal L in the alternator is flowing through field coil FC increases. Therefore,
connected to terminal E in the ground through the generating voltage further increases.
transistor T2. 8. When the generating voltage exceeds the battery
5. The ground side in field coil FC is connected to voltage, current from stator coil SC flows to the
terminal E in the ground through terminal F in the battery through terminal B in the alternator and
regulator and transistor T1. the battery starts to be charged.

Alternator Regulator

IG Key Switch

D D D
L

SC F IC
C C
D D D B B
E T1 T2 E Battery
FC

T1MP-02-02-005

T2-2-12
SYSTEM / Electrical System
Regulator Operation

1. When the engine starts and stator coil starts 6. When the generating voltage decreases below
generating, current from IC does not flow to base the set voltage of IC, IC turns transistor T1 ON
B in transistor T2 and transistor T2 is turned OFF. again.
2. Therefore, terminal L in the alternator is not 7. Therefore, current flows through field coil FC and
grounded. the generating voltage of stator coil SC increases.
3. When the generating voltage of stator coil SC 8. The above operation is repeated so that the
exceeds the set voltage of IC, current from IC alternator generating voltage is kept constant.
does not flow to base B in transistor T1 and
transistor T1 is turned OFF.
4. Therefore, the ground side in field coil FC is not
grounded.
5. Consequently, no current flows through filed coil
FC and the generating voltage of stator coil SC
decreases.

Alternator Regulator

IG Key Switch

D D D
L

SC F IC
C C
D D D B B
E T1 T2 E Battery
FC

T1MP-02-02-005

T2-2-13
SYSTEM / Electrical System
ENGINE STOP CIRCUIT (KEY SWITCH:
OFF)
1. When the key switch is turned from ON to OFF
position, terminal B in the key switch is blocked
from terminals BR, R2 and ACC.
Therefore, power source is blocked to each
circuit.
2. No current from terminal ACC in the key switch
flows to the engine stop solenoid holding side
through the fuse box so that the engine stop
solenoid is released.
3. When the engine stop solenoid is released, the
control rack moves to STOP position due to the
spring.
4. Therefore, fuel is not supplied to the engine and
the engine stops.
NOTE: As terminal B in the key switch is directly
connected to the battery, the surge voltage
is absorbed by the battery until the engine
stops.

T2-2-14
SYSTEM / Electrical System

Key Switch

Slow Blow Fuse

13 1
Fuse Box 1 Fuse Box 2

Battery

B
Alternator
IG
L

Engine Stop Absorbing Side

Solenoid Holding

T1MP-02-02-004

T2-2-15
SYSTEM / Electrical System
LAMP UNIT CIRCUIT
1. When the key switch is turned to the HEAT, ON or
START position, terminal B is connected to
terminal BR in the key switch.
2. Current from terminal BR in the key switch flows
to the hour meter through the fuse box and
operates the hour meter.
3. Current from terminal BR in the key switch flows
to the engine oil pressure indicator, overheat
indicator and alternator indicator as a power
source through the fuse box.

Lamp ON Condition:
• Engine Oil Pressure Indicator:
2
Engine oil pressure: 49±10 kPa (0.5±0.1 kgf/cm )
or less
• Overheat Indicator:
Coolant temperature: 110±2 °C or higher
• Alternator Indicator:
Engine stop

T2-2-16
SYSTEM / Electrical System

Engine Oil
Pressure Overheat
Indicator Indicator
Key Switch Alternator
Indicator

Hour Meter
Slow Blow Fuse

13 1
Fuse Box 1 Fuse Box 2

Battery

B
Alternator
IG
L

Overheat Switch

Engine Oil Pressure Switch

T1MP-02-02-006

T2-2-17
SYSTEM / Electrical System
(Blank)

T2-2-18
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
SECTION 3
COMPONENT OPERATION

CONTENTS
Group 1 Pump Device Group 4 Pilot Valve
Outline ..................................................... T3-1-1 Outline (ZAXIS10U-2 Only)........................... T3-4-1
Main Pumps (Pumps1, 2) .......................... T3-1-2 Operation (ZAXIS10U-2 Only) ...................... T3-4-2
Pilot Pump................................................ T3-1-3
Group 5 Travel Device
Group 2 Swing Device Outline........................................................... T3-5-1

Outline ..................................................... T3-2-1 Travel Motor .................................................. T3-5-2

Swing Motor ............................................. T3-2-2 Travel Brake Valve ........................................ T3-5-4

Valve Unit ..................................................... T3-2-6 Travel Reduction Gear.................................. T3-5-8

Group 6 Others (Upperstructure)

Group 3 Control Valve
2-Spool Solenoid Valve ................................. T3-6-1
Outline ..................................................... T3-3-1
Pilot Relief Valve ........................................... T3-6-3
Hydraulic Circuit ..........................................T3-3-12
Air Bleed Solenoid Valve............................... T3-6-4
Main Relief Valve.........................................T3-3-16
Overload Relief Valve ..................................T3-3-17 Group 7 Others (Undercarriage)
Make-Up Valve ............................................T3-3-19 Swing Bearing............................................... T3-7-1
Center Joint................................................... T3-7-2
Track Adjuster ............................................... T3-7-4

1MRT-3-1
(Blank)

1MRT-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of main pumps (pumps 1, 2)
and pilot pump which are installed separately.
Main pumps (pumps 1, 2) are direct-engine-drive type,
2-spool gear pumps and deliver pressure oil to the
main circuit. One suction port and two delivery ports
are equipped for main pumps (pumps 1, 2).
Pilot pump is a direct-engine-drive type, gear pump
and delivers pressure oil to the pilot circuit

Pump 1 Pump 2

T1MP-03-01-001

Pilot Pump

T1MP-03-01-002

T3-1-1
COMPONENT OPERATION / Pump Device
MAIN PUMPS (PUMPS 1, 2)
The drive gears of pumps 1, 2 engage with the driven When the drive gear is rotated, the driven gears of
gears of pumps 1, 2 respectively. The drive gear of pumps 1, 2 are rotated together. Hydraulic oil from the
pump 1 is splied to the driven gear of pump 2. suction port fills the spaces between the gears, flows
The drive gear of pumps 1, 2 is rotated by engine along the inner surfaces of housing and discharges
rotation. through the delivery port.
One suction port and two delivery ports are equipped
for main pumps (pumps 1, 2

Drive Gear of Pump 1 Drive Gear of Pump 2

T1MP-03-01-003
Driven Gear of Pump 1 Driven Gear of Pump 2

Suction Port

Driven Gear Drive Gear

Housing

Delivery Port
T137-02-03-005

T3-1-2
COMPONENT OPERATION / Pump Device
PILOT PUMP
The drive gear is mounted on the shaft. The drive gear
engages the rotation drives the shaft directly and the
drive gear rotated.
When the drive gear is rotated, the driven gear also is
rotated. Hydraulic oil from the suction port fills the
spaces between gears flows along the inner surfaces
of housing and discharges through the delivery port.

Shaft

T1MP-03-01-002

Suction Port
Driven Gear Drive Gear

Shaft

Housing

Delivery Port
T137-02-03-005

T3-1-3
COMPONENT OPERATION / Pump Device
(Blank)

T3-1-4
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit and swing
motor.
The valve unit prevents cavitation in the swing circuit.
The swing motor is an orbit motor and driven by
pressure oil from the pump. The swing motor rotates
the pinion gear and the upperstructure.

Valve Unit

Swing Motor

T522-03-02-001

T3-2-1
COMPONENT OPERATION / Swing Device
SWING MOTOR
The swing motor consists of valve (1), valve drive (2),
valve plate (3), geroller (4), star (5), drive (6) and
pinion gear (7).
Seven internal teeth are equipped for geroller (4). Six
internal teeth are equipped for star (5) and engages
with geroller (4) internally.

T522-03-02-001

1- Valve 3- Valve Plate 5- Star 7- Pinion Gear

2- Valve Drive 4- Geroller 6- Drive

T3-2-2
COMPONENT OPERATION / Swing Device
(Blank)

T3-2-3
COMPONENT OPERATION / Swing Device
Operation
1. High-pressure oil from port B flows to the
chamber in geroller (4) through valve (1) and
valve plate (3), so that the chamber capacity
increases. 1
2. Star (5) rotates in order to increase the chamber
capacity. Star (5) is eccentric to valve drive (2) 2
and drive (6). Therefore, star (5) moves around
the rotating shaft in pinion gear (7) inside geroller
(4). 3
3. Star (5) rotation is transmitted to pinion gear (7)
via drive (6) so that pinion gear (7) rotates. 4
4. At the same time, star (5) rotation is transmitted
to valve (1) via valve drive (2) so that valve (1) 5
rotates.
5. While valve (1) rotates, high-pressure oil and
low-pressure oil alternately flow through twelve
ports in valve (1). Seven ports in valve plate (3) 6
are connected to seven chambers in geroller (4).
6. The port positions in valve (1) and valve plate (3)
change due to valve (1) rotation. Then, the inflow
position for high-pressure oil to the chamber
moves. The swing motor rotates by these
continuous operations.
7

T1MP-03-02-004

T3-2-4
COMPONENT OPERATION / Swing Device

3 Port B

Chamber
Port A

Port Ｂ: Suction Side

（High-Pressure Oil）

7 Port A: Delivery Side

（Low-Pressure Oil）

T502-02-04-002

1- Valve 3- Valve Plate 5- Star 7- Pinion Gear

2- Valve Drive 4- Geroller 6- Drive

T3-2-5
COMPONENT OPERATION / Swing Device
VALVE UNIT
The valve unit consists of the make-up valve.
The make-up valve prevents the cavitation in the
circuit. To Hydraulic
To Control Oil Tank To Control
Valve （Port Ｔ） Valve
Make-Up Valve
When the swing lever is returned to neutral, hydraulic
oil stops supplying to the swing motor. As the swing
motor continues to rotate due to inertial force,
pressure at the hydraulic oil supply side becomes
negative and the cavitation occurs in the circuit.
In order to prevent the cavitation, when pressure in the
circuit becomes lower than pressure at port T T1MP-03-02-002
(hydraulic oil tank), the steel ball moves and the port
opens. Hydraulic oil is drawn into the circuit and Make-Up Valve
makes up for oil.

Make-Up Valve

Steel Ball

Port T

T1MP-03-02-003

T3-2-6
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls the pressure, flow rate and As for ZAXIS 8-2, the spools are operated by direct
flow direction in the hydraulic circuit. operation. As for 10U-2, the spools of side frame
The main components are main relief valve (1), extend/retract, left travel, auxiliary, blade, right travel
overload relief valve (2), make-up valve (3) and and boom swing are operated by direct operation and
spools. those of swing, arm, bucket and boom are by pilot oil
pressure.
ZAXIS8-2 Side Frame
Arm Extend / Left Auxiliary Blade Right Bucket
Retract Travel Travel

1
1
3

Boom Swing

Boom
Swing
T1MN-03-03-001

ZAXIS10U-2 Side Frame Blade

Arm Extend / Left Auxiliary Right Bucket
Retract Travel Travel

1 1

Boom Swing

Swing Boom
T1MP-03-03-019

1- Main Relief Valve 2- Overload Relief Valve 3- Make-Up Valve

T3-3-1
COMPONENT OPERATION / Control Valve

Main Pump

P2 P1

1 2 3 4 5 6 7 8 9 10 11 12

* * * *

P2 P1

16 15 14 13

B A Boom Swing
Cylinder
Swing Motor Travel Travel
Motor Motor
(Left) (Right)
Arm Cylinder Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-005
Extend / Retract Cylinder Cylinder
Cylinder

1- Main Relief Valve (Main 5- Load Check Valve (Arm 9- Overload Relief Valve 13 - Load Check Valve (Boom
Pump P2 Side) Parallel Circuit) (Boom: Rod Side) Swing Parallel Circuit)
2 - Load Check Valve (Swing 6 - Overload Relief Valve 10 - Load Check Valve (Boom 14 - Load Check Valve (Bucket
Parallel Circuit) (Arm: Bottom Side) Parallel Circuit) Parallel Circuit)
3 - Overload Relief Valve 7 - Load Check Valve 11 - Make-Up Valve (Boom 15 - Load Check Valve (Main
(Swing Motor: B Side) (Side Frame Extend / Swing: Bottom Side) Pump P1 Parallel Circuit)
Retract Parallel Circuit)
4- Overload Relief Valve 8 - Load Check Valve (Bucket 12 - Main Relief Valve (Main 16 - Load Check Valve (Main
(Swing Motor: A Side) Parallel Circuit) Pump P1 Side) Pump P2 Parallel Circuit)
NOTE: The illustration shows ZAXIS10U-2.
As for ZAXIS 8-2, the spool with mark * is
operated by direct operation.

T3-3-2
COMPONENT OPERATION / Control Valve
ZAXIS8-2
L K J I H G F E D C B A

T1MN-03-03-002

ZAXIS10U-2
L K’ J’ I H G F E D’ C’ B A

T1MP-03-03-001

T3-3-3
COMPONENT OPERATION / Control Valve

Main Pump

P2 P1

1 2 3 4 5 6 7 8 9 10 11 12

* * * *

P2 P1

16 15 14 13

B A Boom Swing
Cylinder
Swing Motor Travel Travel
Motor Motor
(Left) (Right)
Arm Cylinder Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-005
Extend / Retract Cylinder Cylinder
Cylinder

T3-3-4
COMPONENT OPERATION / Control Valve

Section A Section B (Boom Swing)

12 11

T1MP-03-03-005 T1MP-03-03-006

Section C (Boom) Section C’ (Boom)

10
10

9
9

T1MN-03-03-003
T1MP-03-03-007

T3-3-5
COMPONENT OPERATION / Control Valve

Main Pump

P2 P1

1 2 3 4 5 6 7 8 9 10 11 12

* * * *

P2 P1

16 15 14 13

B A Boom Swing
Cylinder
Swing Motor Travel Travel
Motor Motor
(Left) (Right)
Arm Cylinder Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-005
Extend / Retract Cylinder Cylinder
Cylinder

T3-3-6
COMPONENT OPERATION / Control Valve

Section D (Bucket) Section D’ (Bucket)

14
14

N
N N’
N’

Section N-N
8

Section N’-N’
8

T1MN-03-03-004

T1MP-03-03-020

Section E (Travel (Right)) Section F (Blade)

T1MP-03-03-009
T1MP-03-03-010

T3-3-7
COMPONENT OPERATION / Control Valve

Main Pump

P2 P1

1 2 3 4 5 6 7 8 9 10 11 12

* * * *

P2 P1

16 15 14 13

B A Boom Swing
Cylinder
Swing Motor Travel Travel
Motor Motor
(Left) (Right)
Arm Cylinder Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-005
Extend / Retract Cylinder Cylinder
Cylinder

T3-3-8
COMPONENT OPERATION / Control Valve

Section G (Auxiliary) Section H (Travel (Left))

T1MP-03-03-011 T1MP-03-03-012

Section I (Side Frame Extend/ Retract) Section J (Arm)

T1MP-03-03-013

T1MN-03-03-005

T3-3-9
COMPONENT OPERATION / Control Valve

Main Pump

P2 P1

1 2 3 4 5 6 7 8 9 10 11 12

* * * *

P2 P1

16 15 14 13

B A Boom Swing
Cylinder
Swing Motor Travel Travel
Motor Motor
(Left) (Right)
Arm Cylinder Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-005
Extend / Retract Cylinder Cylinder
Cylinder

T3-3-10
COMPONENT OPERATION / Control Valve

Section J’ (Arm) Section K (Swing)

4
6

T1MP-03-03-014

T1MN-03-03-006

Section K’ (Swing) Section L

4 1

T1MP-03-03-016

T1MP-03-03-015

T3-3-11
COMPONENT OPERATION / Control Valve
HYDRAULIC CIRCUIT
The hydraulic circuit in control valve is divided into
main circuit and pilot operation circuit.

Main circuit
Control Valve
Hydraulic Circuit
Pilot Operation Circuit

NOTE: The pilot operation circuit is not provided for

ZAXIS8-2.

Main circuit
Pressure oil from main pumps (P1, P2) flows into the
control valve respectively.
When the spool is neutral (control levers are in
neutral), pressure oil from the main pump returns to
the hydraulic oil tank through the neutral circuit.
When the spool is operated (control lever is
operated), pressure oil from the main pump flows to
the actuator through the spool.
The main circuit has a parallel circuit. The combined
operation of actuator becomes possible by using this
circuit.

Pressure in the main circuit (between pump and

actuator) is controlled by the main relief valve and
prevents pressure in the main circuit from exceeding
the set pressure when the spool (the control lever) is
operated.
Pressure in the actuator circuit (between control
valve and actuator) is controlled by the overload
relief valve and prevents pressure in the actuator
circuit from exceeding the set pressure due to
external force when the spool (the control lever) is in
neutral.

T3-3-12
COMPONENT OPERATION / Control Valve

Main Pump

P2 P1

Main Relief Overload Relief Overload Relief Main Relief

Valve Valve Valve Valve

* * *

Neutral
* Neutral Circuit
Circuit

Neutral Neutral
Circuit Circuit

Parallel Parallel Parallel Circuit

Parallel Circuit Circuit Circuit
Boom Swing
Cylinder
Swing Motor Travel Travel
Motor Motor
(Left) (Right)
Arm Cylinder
Boom Cylinder

Attachments
Side Frame Blade Bucket T1MP-02-01-005
Extend / Retract Cylinder Cylinder
Cylinder

NOTE: The illustration shows ZAXIS10U-2.

As for ZAXIS 8-2, the spool with mark * is
operated by direct operation.

T3-3-13
COMPONENT OPERATION / Control Valve
Pilot Operation Circuit (ZAXIS10U-2 only)
The swing, arm, bucket and boom are operated by
pilot oil pressure.
Pressure oil from the pilot pump acts on the spool in
control valve and moves the spool.

When the pilot shut-off solenoid valve is turned ON,

pressure oil from the pilot pump flows to the pilot
valve through the pilot shut-off solenoid valve. When
the lever of pilot valve is operated, pressure oil is
reduced according to lever stroke, flows to the spool
end in control valve and moves the spool according
to lever stroke.

NOTE: The spools of side frame extend/retract, left

travel, auxiliary, blade, right travel and
boom swing is operated by direct operation.
The control lever or pedal movement is
transmitted to the spool in control valve
through the link and moves the spool
directly.

T3-3-14
COMPONENT OPERATION / Control Valve

Pilot Shut-Off
Solenoid Valve
Pump 2 Pump 1 Pilot Pump

P2 P1

Control Valve Side Frame Left Travel Blade Right Travel

Extend / Retract
b c R3 R2

a d R1 R4

Swing Arm Auxiliary Bucket Boom Boom Swing

Left Pilot Valve

(JIS Lever Pattern) Right Pilot Valve

ｄ c a b R4 R2 R1 R3

T1MP-03-03-018

a- Left Swing c- Arm Roll-Out R1- Bucket Roll-In R3- Bucket Roll-Out
b- Right Swing d- Arm Roll-In R2- Boom Lower R4- Boom Raise

T3-3-15
COMPONENT OPERATION / Control Valve
MAIN RELIEF VALVE
The main relief valve prevents that pressure in main
circuit exceeds the set pressure.
One main relief valve is provided for the circuits in
Inner
pumps P1 and P2 respectively. Passage 1 2 3 4 5

Operation
1. Pressure oil in port HP acts on pilot poppet (4)
through the inner passage and orifice in piston (3).
2. When pressure in the main circuit increases and HP
exceeds the pressure set by spring (5), pilot
poppet (4) moves to the right and pressure oil LP
flows to port LP through passage A.
3. At this time, pressure difference between port HP Passage B Orifice Spring (2) Passage A
and spring (2) chamber occurs due to the orifice. Chamber
When this pressure difference reaches the T1MP-03-03-002
pressure set by spring (2), main poppet (1) moves
to the right and pressure oil in port HP flows to
port LP through passage B.
1- Main Poppet 4- Pilot Poppet
4. When pressure in port HP decreases, spring (5)
2- Spring 5- Spring
closes pilot poppet (4). Then, pressure in spring 3- Piston
(2) chamber increases. Main poppet (1) is closed
again due to pressure increase in spring (2)
camber and spring (2).

T3-3-16
COMPONENT OPERATION / Control Valve
OVERLOAD RELIEF VALVE
The overload relief valve prevents the actuator circuit
pressure from exceeding the set pressure (relief
operation) and prevents occurrence of cavitation
(make-up operation).
The overload relief valve is provided for the rod circuit
in boom, the bottom circuit in arm and the swing circuit.

Relief Operation
Flows pressure oil to the hydraulic oil tank when
pressure in the actuator increases due to external 1 2 3 4 5
force. Inner Passage
1. Pressure oil in port HP acts on pilot poppet (4)
through the inner passage and orifice in piston (3).
2. When pressure in the main circuit increases and
exceeds the pressure set by spring (5), pilot
poppet (4) moves to the right and pressure oil HP
flows to port LP through passage A.
3. At this time, pressure difference between port HP
and spring (2) chamber occurs due to the orifice. LP
When this pressure difference reaches the
Passage B Orifice Spring (2) Passage A
pressure set by spring (2), main poppet (1) moves Chamber
to the right and pressure oil in port HP flows to T1MP-03-03-003
port LP through passage B.
4. When pressure in port HP decreases, spring (5) 1- Main Poppet 4 - Pilot Poppet
closes pilot poppet (4). Then, pressure in spring 2- Spring 5 - Spring
(2) chamber increases. Main poppet (1) is closed 3- Piston
again due to pressure increase in spring (2)
camber and spring (2).

T3-3-17
COMPONENT OPERATION / Control Valve
Make-Up Operation
When lowering the boom suddenly, the actuator
circuit is lack of pressure oil from the pump. At this
time, oil is supplied to the actuator circuit from the
hydraulic oil tank.
When operating the relief operation due to external 1 2
force, which is explained on the previous page,
pressure in the opposite side circuit decreases. At
this time, oil is supplied to the actuator circuit from
the hydraulic oil tank.

1. When pressure in port HP (actuator circuit) HP

becomes lower than that in port LP (hydraulic oil
tank), spring (2) is compressed and sleeve (1)
moves to the right. LP
2. Hydraulic oil from port LP flows into port HP so
that cavitation is prevented. T1MP-03-03-003

3. When pressure in port HP increases to the fixed

pressure, sleeve (1) is closed by spring (2) force.

1- Sleeve 2- Spring

T3-3-18
COMPONENT OPERATION / Control Valve
MAKE-UP VALVE
The make-up valve prevents cavitation in the main
circuit.
The make-up valve is provided for the bottom circuit in
boom swing. 1 2 3 4

As pressure in port HP acts on spring chamber (4)

through the passage in poppet (2), pressures in port
HP and spring chamber (4) become equal. Accordingly,
when pressure in port HP is higher, the force to close
HP
poppet (2) [Pressure in Spring Chamber (4) ×
Pressurized Area S2 + Spring (3) Force] becomes
larger than the force to open poppet (2) [Pressure in
Port HP × Pressurized Area S1], which closes poppet LP
(2). S1 S2
T574-03-03-010

When pressure in port HP is lower than that in port LP

and the force to open poppet (2) [Pressure in Port LP x
(Pressurized Area S2 - S1)] becomes larger than the 1- Passage 3- Spring
force to close poppet (2) [Spring (3) Force], poppet (2) 2- Poppet 4- Spring Chamber
opens and supplies hydraulic oil from port LP to port
HP. Thereby, cavitation at port HP side is prevented.

T3-3-19
COMPONENT OPERATION / Control Valve
(Blank)

T3-3-20
COMPONENT OPERATION / Pilot Valve
OUTLINE (ZAXIS 10U-2 ONLY)
The pilot valve controls pilot pressure oil to move the
control valve spools. The pilot valve output pressure in
proportion to the control lever stroke and moves the
control valve spools according to PPC (Pressure Pro-
portional Control Valve) function.
The 4-port pilot valve is used for front attachment,
swing and travel operation. Hydraulic Symbol

• Front and Swing Pilot Valve

ISO HITACHI
Port No.
Standard Standard
1 Bucket Roll-Out ← 4 PT 2 1 3 4 PT 2 1 3
2 Boom Lower ←
←
T566-03-05-002
Right 3 Bucket Roll-In
4 Boom Raise ←
1 Left Swing Arm Roll-Out
2 Arm Roll-Out Right Swing
Left
3 Right Swing Arm Roll-In
4 Arm Roll-In Left Swing

View A
2
3

P T

4 1
T1MP-03-04-001

T3-4-1
COMPONENT OPERATION / Pilot Valve
OPERATION (ZAXIS 10U-2 ONLY)

• Spool (6) head comes in contact with spring guide

(3) which is kept raised by return spring (5).

Control Lever-In Neutral (Output Diagram: A to B)

1. When neutral, spool (6) totally blocks pressure oil
in port P (from the pilot pump). The output port is
opened to port T (hydraulic oil tank) through notch
A. Therefore, oil pressure in the output port (to D
the control valve) is equal to that in port T. Pilot Pressure
2. When the control lever is slightly tilted, cam (1) is
tilted and pusher (2) moves downward. Pusher
(2) compress return spring (5) along with spring C
guide (3). At this time, spool (6) moves downward
while keeping the bottom surface of spool (6) A B
head in contact with spring guide (3) due to bal- Lever Stroke T1MJ-03-04-001

ance spring (4) force.

At Beginning of Decompressing (Output Dia-

gram: B to C)
1. When the control lever is further tilted and pusher
D
(2) is moved downward more, notch B on spool
Pilot Pressure
(6) is opened to port P and pressure oil in port P
flows to the output port through notch B.

A B T1MJ-03-04-002
Lever Stroke

T3-4-2
COMPONENT OPERATION / Pilot Valve

1 1

2 2

3
3

Spool (6) Head

4 4

5
5

Port T Port T
6 6
Notch A Notch B

Port P Port P

Output Port T1MP-03-04-002 Output Port T1MP-03-04-005

1 - Cam 3 - Spring Guide 5- Return Spring 7- Hole

2 - Pusher 4 - Balance Spring 6- Spool

T3-4-3
COMPONENT OPERATION / Pilot Valve
During Metering or Decompressing (Output Dia-
gram: C to D)
1. Oil pressure in the output port acts on the notch
on spool (6). As difference in area (S1>S2) on the
notch exists, spool (6) is pushed upward by force.
D
2. When force pushing spool (6) upward (pressure
Pilot Pressure
in the output port×S1) is smaller than force push-
ing spool (6) downward (pressure in the output
port×S2+ balance spring (4) force), balance spring
(4) is not compressed. Therefore, spoo (6) is not C
oushed upward and pressure in the output port
keeps increasing. A B
Lever Stroke T1MJ-03-04-003
3. When pressure in the output port increases fur-
ther, force pushing spool (6) upward (pressure in
the output port×S1) is larger than force pushing
spool (6) downward (pressure in the output
port×S2+ balance spring (4) force), spool (6)
compresses balance spring (4) and is moved
upward.
4. As spool (6) is moved upward, port P is closed so
that pressure oil stops flowing to the output port
and pressure in the output port stops increasing.
5. As spool (6) is moved downward and balance
spring (4) is compressed, pressure acting on
spool (6) increases until pressure balances with
the increasing spring force.

T3-4-4
COMPONENT OPERATION / Pilot Valve

1 1

2 2

3 3

4 4

5 5

Port T Port T

6 6

Port P Port P

Output Port T1MP-03-04-003 Output Port T1MP-03-04-004

S2
T1MP-03-04-006

1 - Cam 3 - Spring Guide 5 - Return Spring 6- Spool

2 - Pusher 4 - Balance Spring

T3-4-5
COMPONENT OPERATION / Pilot Valve
(Blank)

T3-4-6
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of travel motor, travel The travel reduction gear is a two-stage planetary gear
reduction gear and travel brake valve. reduction type, reduces travel motor speed, increases
The travel motor is a variable displacement axial travel motor torque, and rotates the sprocket and track.
plunger swash plate type. The travel brake valve makes starting and stopping of
The motor is operated by pressure oil from the pump travel smoothly, and prevents coasting when
and transmits rotation to the travel reduction gear. descending slope.

Travel Reduction Gear Travel Brake Valve

T1MP-03-05-001
Travel Motor

T3-5-1
COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
The travel motor consists of valve plate, rotor, plungers,
shoes, swash plate and shaft. The rotor is connected
to the shaft by a spline joint and the plungers are
inserted in the rotor.
When pressure oil is supplied from the pump, the
plungers are pushed. The swash plate is tilted and the
shoe slides on the swash plate, so that the rotor
rotates. This rotation is transmitted to the travel
reduction gear via the shaft.

Travel Motor

Swash Plate Rotor Valve Plate

T1MP-03-05-001
Control Piston Shoe Plunger Shaft

Travel Reduction Gear

T3-5-2
COMPONENT OPERATION / Travel Device
Travel Speed Selection

There are two surfaces on the swash plate; surface

(a) and surface (b). Two balls are located off the
center line on the swash plate, so that they can roll
freely. Surface (a) makes contact with the housing at
slow speed and the swash angle becomes large.
Surface (b) makes contact with the housing at fast
speed and the swash angle becomes small.

At Fast Speed: Swash

Plate Rotor Plunger
At Slow Speed: Swash
Surface (b)
Rotor Plunger
Surface (b) Plate

Ball
Ball

Spring From
Control Surface (a) Travel
Piston Mode
Selector
Surface (a) Valve

T571-03-05-004 T571-03-05-005

T3-5-3
COMPONENT OPERATION / Travel Device
TRAVEL BRAKE VALVE
The travel brake valve consists of counterbalance
valve and travel mode selector valve.
The counterbalance valve has two functions; one is to
start and stop the travel smoothly, and the other is to
prevent the machine from running away while
descending slopes.
The travel mode selector valve is switched by pressure
oil from the travel mode selector solenoid valve and
switches the travel mode by the control piston.

Travel Brake Valve

T1MP-03-05-001

Section of Brake Valve Counterbalance Valve

Counterbalance Valve

T1MP-03-05-003
Travel Mode
Selector Valve

Travel Mode T1MP-03-05-002

Selector Valve

T3-5-4
COMPONENT OPERATION / Travel Device
Counterbalance Valve

• Travel Operation • Descending Operation

When pressure oil from the control valve is When the machine travels down a slope, the
supplied to port A, pressure oil opens the check travel motors are forcibly driven by the machine
valve and flows to motor port AM through inside of own weight so that the motor draws oil like a
the spool. On the other hand, return oil from motor pump.
port BM is blocked by check valve B and the Pressure oil in port A is drawn into the travel
spool. motor and pressure at port A decreases.
Thereby, pressure at port A side increases Thereby, the spool returns to the left and return oil
gradually, pressure at port A enters to the spring from port BM to port B is restricted so that the oil
chamber from the orifice, and moves the spool to pressure brake is activated for the travel motor.
the right while acting on the end surface of spool. When return oil from port BM is restricted,
As a result, as the spool notch opens and port BM pressure at port A increases again and moves the
is connected to port B, the travel motor rotates. spool to the right so that the motor rotates.

Control Valve
Spool

Orifice

A B Check Valve B

Spring Chamber

Check Valve A
Notch
AM BM

T1MP-03-05-004

T3-5-5
COMPONENT OPERATION / Travel Device
Travel Mode Selector Valve
• Slow Speed Operation
When the travel is at slow speed, pressure oil
from the travel mode selector solenoid valve is
not supplied to the spool of travel mode selector
valve. As the spool does not move to the right,
pressure oil is not supplied to the control piston.
Surface (a) of the swash plate makes contact with
the housing by pressure oil acting on the plunger
and spring force in the rotor.
As a result, the angle of swash plate increases
and makes the stroke of plunger longer. As a
consequence, the motor capacity becomes larger
and the travel motor rotates at slow speed.

• Fast Speed Operation

When the travel is at fast speed, pressure oil from
the travel mode selector solenoid valve flows
through the inner passage and switches the travel
mode selector valve. Therefore, pressure oil in
travel circuit A or B is supplied to the control
piston through the notch on spool. The swash
plate is pushed by the control piston, which
makes surface (b) contact with the housing.
As a result, the angle of swash plate decreases
and makes the stroke of plunger shorter. As a
consequence, the motor capacity becomes
smaller and the travel motor rotates at fast speed.

• When Engine Stops

When the engine stops, pressure oil acting on the
control piston returns to the hydraulic oil tank
through the travel mode selector valve. As a
consequence, surface (a) of the swash plate
makes contact with the housing by spring force in
rotor.
As a result, the travel motor always rotates at
slow speed whenever the engine is re-started.

T3-5-6
COMPONENT OPERATION / Travel Device
Operation at Slow Speed:
Spool

Travel Mode
Selector Valve

Travel Mode
Selector Solenoid
Valve

Rotor

Swash Plate

T1MP-03-05-005
Control Surface (a) Plunger Spring
Piston
Operation at Fast Speed: Spool

Travel Mode
Selector Valve A B

Travel Mode
Selector
Solenoid Valve

Swash Plate Surface (b)

Surface (a)
Control Plunger Spring T1MP-03-05-006
Piston

T3-5-7
COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEAR
The travel motor rotates the shaft and the rotation is
transmitted to the first stage sun gear. The rotation of
first stage sun gear is reduced by the first stage
planetary gear and first stage carrier, and is
transmitted to the second stage sun gear. The rotation
of second stage sun gear is reduced by second stage
planetary gear and second stage carrier (united with
the travel motor housing).
As the second stage carrier and travel motor is united
into one part, the rotation of second stage planetary
gear is transmitted to the sprocket via the ring gear.

First Stage Planetary Second Stage Sun

Ring Gear Gear Gear Shaft

First Stage Sun

Gear

T1MP-03-05-001

First Stage Carrier Second Stage Carrier Second Stage

Planetary Gear

T3-5-8
COMPONENT OPERATION/Others (Upperstructure)
2-SPOOL SOLENOID VALVE
There are two kinds of 2-spool solenoid valves; one is
the pilot shut-off solenoid valve in order to turn pilot
pressure ON or OFF, the other is the travel mode se-
Pilot Shut-Off Travel Mode Selector
lector solenoid valve in order to shift travel speed. Solenoid Valve Solenoid Valve

NOTE: The structures of pilot shut-off solenoid

valve and travel mode selector solenoid
valve are same. Pilot Relief
Valve

T1M7-03-06-001

T3-6-1
COMPONENT OPERATION/Others (Upperstructure)
Pilot Shut-Off Solenoid Valve
1. When the pilot shut-off lever is turned to the
UNLOCK position, the pilot shut-off switch is
turned ON and the pilot shut-off solenoid valve is
excited by current from the fuse box.
2. Therefore, as the solenoid valve is shifted, pres-
sure oil from the pilot pump supplies pilot pres- LOCK
Position
sure to each pilot valve.
Pilot Shut-Off
Lever
UNLOCK
Position

M1MP-05-015
Travel Mode Selector Solenoid Valve
1. When the travel mode selector switch is turned
ON (fast position), the travel mode selector sole-
noid valve is excited by current from the fuse box.
2. Therefore, as the solenoid valve is shifted, pres- Travel Mode
Selector Switch
sure oil from the pilot pump is supplied to the both
From Fuse Box
right and left travel motors.
3. Consequently, the travel mode selector solenoid
valve in travel motor is shifted and travel motor
rotates at fast speed.
To Travel Motor
Pilot Shut-Off
Switch From Fuse
Box

To Pilot Circuit
Travel Mode
Selector
Solenoid Valve
Pilot Shut-Off
Solenoid Valve

Pilot Pump

T1MP-03-06-001

T3-6-2
COMPONENT OPERATION/Others (Upperstructure)
PILOT RELIEF VALVE
The pilot circuit of 2-spool solenoid valve has a pilot Spring
relief valve which prevents the circuit pressure from
rising more than the set pressure. Pressure oil from
the pilot pump always acts on the relief cap. When this
pressure increases more than the set pressure (by To
spring force), the relief cap is moved and hydraulic oil From Hydraulic
Pilot Pump
flows to the hydraulic oil tank through the hole on relief Oil Tank
cap so that pressure in the pilot circuit is kept the set
pressure.

Hole
T1LA-03-06-002
Relief Cap

T3-6-3
COMPONENT OPERATION/Others (Upperstructure)
AIR BLEED SOLENOID VALVE
The air bleed solenoid valve releases pressure from
the pilot circuit by returning pressure oil from the pilot
pump to the hydraulic oil tank.
B
NOTE: When the key switch is OFF, the air bleed
solenoid valve is not operated.

When the pilot shut-off switch is ON (pilot shut-off

lever: UNLOCK position), the unload relay is excited
and the air bleed solenoid valve is turned OFF. There-
fore, pressure oil from the pilot pump is blocked by
spool (4) in the solenoid valve.
When the pilot shut-off switch is OFF (pilot shut-off
lever: LOCK position), the unload relay is not excited
and the air bleed solenoid valve is turned ON. There-
fore, pressure oil from the pilot pump returns to the
hydraulic oil tank through spool (4) in the solenoid 2
valve and pressure in the pilot circuit is released at the
same time.
1

B
T1M9-03-07-003
Section B-B

4
3

T1M9-03-07-004

1- Port T (To Hydraulic Oil Tank)

2- Port P (From Pilot Pump)
3- Port A (To Hydraulic Oil Tank)
4- Spool

T3-6-4
COMPONENT OPERATION/Others (Upperstructure)

Pilot Shut-Off
Unload Relay
Switch

From Fuse Box

Air Bleed Solenoid

Valve
Air Bleeding Circuit

Pilot Pump

To Pilot Circuit and Travel

Motor
T1MP-03-06-002

T3-6-5
COMPONENT OPERATION / Others (Upperstructure)
(Blank)

T3-6-6
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing sustains self weight of the Outer race (1) is bolted to the upperstructure and inner
upperstructure and makes smooth swing. race (2) is bolted to the undercarriage. The internal
This bearing is a single row type ball bearing and teeth of inner race (2) are enmeshed with the output
consists of outer race (1), inner race (2), ball (5), shaft of swing reduction gear.
support (4) and seal (3).

5
3

T1MG-03-08-001

1- Outer Race 3- Seal 4 - Support 5 - Ball

2- Inner Race

T3-7-1
COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT
H
The center joint is a full 360 °turn joint and delivers
I
pressure oil to the travel motor while preventing hoses
from kinking when the upperstructure slews. G
Body (7) is secured to the undercarriage with the bolts
E J
(4 used). Spindle (8) is secured to the upperstructure
with the stopper. Therefore, during swing operation, C F
body (7) is secure to the undercarriage and spindle (8) A D
rotates together.
Pressure oil flows to both the right and left travel B
motors, side frame extend/retract cylinder and blade
cylinder through the passage in body (7) and spindle J
(8). I H
Seal (13) prevents oil leaks from the clearance
G F
between spindle (8) and body (7).
E D

C B

T1MP-03-07-001

Blade Cylinder Center Joint

2
10

1
11
5
4
9
3
12
7

Side Frame Extend/

Retract Cylinder Travel Motor

T1MP-03-07-008

T3-7-2
COMPONENT OPERATION / Others (Undercarriage)

C
View C

3 4

1 2
6

T1MP-03-07-007
T1MP-03-07-004
A

View A B Section B-B

10 11

9 12

8 2
6 13

1
10
7
11
5

4
13
9

3
12

T1MP-03-07-003
B T1MP-03-07-002

1- Port H (Side Frame Extend) 5- Port E (Blade Raise) 8- Spindle 11 - Port F (Blade Lower)
2- Port J (Drain) 6- Port I (Travel Mode 9- Port C (Left Travel Reverse) 12 - Port A (Left Travel
Selection) Forward)
3- Port B (Right Travel Forward) 7 - Body 10 - Port G (Side Frame Retract) 13 - Seal
4- Port D (Right Travel Reverse)

T3-7-3
COMPONENT OPERATION / Others (Undercarriage)
TRACK ADJUSTER
The track adjuster consists of adjuster cylinder (2) and • Apply grease through the grease fitting. Part A in
so on, and is supported by the side frame. adjuster cylinder (2) is filled with grease and piston
The track adjuster adjusts tension of tracks by using rod (1) is pushed so that the track sag decreases.
adjuster cylinder (2). • If the track sag increases, loosen valve (3) 1 to 1.5
turns and discharge grease.
CAUTION: Pressure in the track adjuster is
high. As valve (3) flies out and grease gushes
out, do not loosen valve (3) too much or 3 Grease Fitting
quickly. Keep faces away from valve (3) and
loosen valve (3) gradually. Do not remove the
grease fitting when discharging grease.

Grease Outlet
T1MP-03-07-005

1 2 A 3

T1MP-03-07-006

1- Piston Rod 2- Adjusting Cylinder 3- Valve

T3-7-4
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
SECTION 4
OPERATIONAL PERFORMANCE TEST

CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Test.................... T4-1-1 Primary Pilot Pressure .................................. T4-5-1
Preparation for Performance Tests ............. T4-1-2 Secondary Pilot Pressure
(ZAXIS10U-2 Only) ..................................... T4-5-3
Group 2 Standard Main Relief Valve Set Pressure .................... T4-5-4
Operational Performance Standard...............T4-2-1 Overload Relief Valve Set Pressure.............. T4-5-6
Main Pump P-Q Diagram ..............................T4-2-4 Swing Motor Drainage .................................. T4-5-8
Travel Motor Drainage ................................ T4-5-10
Group 3 Engine Test
Engine Speed ................................................T4-3-1 Group 6 Adjustment
Engine Compression Pressure......................T4-3-2 Fuel Lever Adjustment .................................. T4-6-1
Valve Clearance ............................................T4-3-4
Nozzle Check ................................................T4-3-6
Injection Timing .............................................T4-3-8

Group 4 Excavator Test

Travel Speed .................................................T4-4-1
Track Revolution Speed ................................T4-4-2
Mistrack Check..............................................T4-4-3
Travel Motor Leakage....................................T4-4-4
Swing Speed..................................................T4-4-5
Swing Function Drift Check ...........................T4-4-6
Swing Motor Leakage....................................T4-4-8
Maximum Swingable Slant Angle ................T4-4-10
Swing Bearing Play...................................... T4-4-11
Hydraulic Cylinder Cycle Time.....................T4-4-12
Dig Function Drift.........................................T4-4-15
Control Lever Operating Force....................T4-4-17
Control Lever Stroke....................................T4-4-18
Combined Boom Raise/Swing
Function Check........................................T4-4-19

1MRT-4-1
(Blank)

1MRT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to quan-
titatively check all system and functions on the ma-
chine.

Purpose of Performance Tests Definition of “Allowable Limit”

1. To comprehensively evaluate each operational 1. Normal machine performance cannot be accom-
function by comparing the performance test data plished after exceeding this limit.
with the standard values.
2. According to the evaluation results, repair, adjust, 2. Repair or adjustment is impossible after exceed-
or replace parts or components as necessary to ing this limit.
restore the machine’s performance to the desired
standard. 3. Therefore, in consideration of operation efficiency
3. To economically operate the machine under op- and maintenance expense, proper maintenance
timal conditions. shall be carried out before reaching the “Allow-
able Limit”.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.

Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.

Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.

The machine performance does not always deteriorate

as the working hours increase. However, the machine
performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
ingly, restoring the machine performance by repair,
adjustment, or replacement shall consider the number
of the machine’s working hours.

Definition of “Performance Standard”

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.

T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.

THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.

TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make
a full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.

PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu- T105-06-01-003

nicate with each other using these signals, and to

follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.

MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use T505-06-01-003

mean values of measurements if necessary.

T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD
Data in ( ) is given for reference.
This Operational Performance Standard values are * The standard measurement condition is as follows;
listed below. Engine Speed Control Lever: Full Stroke
Refer to the correspondence section in T4-3 and after Hydraulic Oil Temperature: 50±5°C (122±41°F)
for the details of measurement method.

Reference
Item ZAXIS8-2 ZAXIS10U-2 Remarks
Page
ENGINE SPEED min-1 T4-3-1
Slow Idle Speed 1240±50 ←
Fast Idle Speed 2240±50 ←
Fast Idle Speed
(2200±50) ←
(one main pump is fully loaded)
Fast Idle Speed
(2150±50) ←
(two main pumps are fully loaded)
ENGINE COMPRESSION 3.24±0.1 After engine warm-up
PRESSURE MPa, (kgf/cm2, psi) (33±1, ← T4-3-2
471±14.5)
VALVE CLEARANCE (IN, EX) mm 0.2±0.05 ← With engine cold T4-3-4
NOZZLE INJECTION 11.8 to 12.8
PRESSURE MPa, (kgf/cm2, psi) (120 to 130, ← T4-3-6
1715 to 1861)
INJECTION TIMING
(Fuel Pump Mounting Standard 15° ← T4-3-8
Angle) deg.

TRAVEL SPEED sec/20 m T4-4-1

Fast Speed Mode 10.3±1.5 ←
Slow Speed Mode 20.0±1.5 ←
TRACK REVOLUTION SPEED
T4-4-2
sec/3 rev.
Fast Speed Mode 8.5±1.5 ←
Slow Speed Mode 17.0±1.5 ←
MISTRACK
200 or less ← T4-4-3
Fast Speed･Slow Speed mm/20 m
TRAVEL MOTOR LEAKAGE
30 ← T4-4-4
mm/3 min
SWING SPEED sec/3 rev. 21.5±1.5 ← T4-4-5
SWING FUNCTION DRIFT mm/90° 50 or less ← T4-4-6
SWING MOTOR LEAKAGE mm/5 min 40 or less ← T4-4-8
MAXIMUM SWINGABLE
20 or more ← T4-4-10
SLANT ANGLE deg.
SWING BEARING PLAY mm 0.3 or less ← T4-4-11

T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard

Reference
Item ZAXIS8-2 ZAXIS10U-2 Remarks
Page
The cylinder stroke ex-
HYDRAULIC CYLINDER CYCLE
cludes the cushion T4-4-12
TIME sec
range.
Boom Raise 2.2±0.5 2.6±0.5
Boom Lower 2.2±0.5 2.5±0.5
Arm Roll-In 3.5±0.3 4.0±0.3
Arm Roll-Out 2.5±0.3 ←
Bucket Roll-In 2.7±0.3 3.1±0.3
Bucket Roll-Out 2.0±0.3 2.4±0.3
Right Boom Swing 4.2±0.5 ←
Left Boom Swing 4.2±0.5 ←
Blade Raise 1.5±0.5 ←
Blade Lower 1.8±0.5 ←
DIG FUNCTION DRIFT mm/5 min T4-4-15
Boom Cylinder 10 or less ←
Arm Cylinder 8 or less ←
Bucket Cylinder 5 or less ←
Bucket Bottom 150 or less ←
Blade Cylinder 3 or less ←
Blade Cylinder (When jacked up) 20 or less ←
Boom Swing Cylinder 5 or less ←
CONTROL LEVER/PEDAL HITACHI Lever Pattern
T4-4-17
OPERATING FORCE N (kgf)
18.0 or less 9.0 or less
Boom Lever
(1.8 or less) (0.9 or less)
Arm Lever (ISO Lever Pattern: 18.0 or less 9.0 or less
Swing) (1.8 or less) (0.9 or less)
18.0 or less 9.0 or less
Bucket Lever
(1.8 or less) (0.9 or less)
Swing Lever (ISO Lever Pattern: 18.0 or less 9.0 or less
Arm) (1.8 or less) (0.9 or less)
10.0 or less
Travel Lever ←
(1.0 or less)
20.0 or less
Blade Lever ←
(2.0 or less)
55.0 or less
Boom Swing Pedal ←
(5.6 or less)

T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard

Reference
Item ZAXIS8-2 ZAXIS10U-2 Remarks
Page
HITACHI Lever
CONTROL LEVER / PEDAL STROKE mm T4-4-18
Pattern
Boom Lever 75±10 85±10
Arm Lever (ISO Lever Pattern: Swing) 75±10 85±10
Bucket Lever 75±10 85±10
Swing Lever (ISO Lever Pattern: Arm) 75±10 85±10
Travel Lever 60±10 ←
Blade Lever 45±10 ←
Boom Swing Pedal 10±5 ←
BOOM RAISE / SWING T4-4-19
Height mm 1400 or more 1600 or more
Time sec 1.9±0.3 1.9±0.3
3.4±0.5
PRIMARY PILOT
(35±5, ← T4-5-1
PRESSURE MPa, (kgf/cm2, psi)
494±73)
2.1±0.5
SECONDARY PILOT
- (22±5, T4-5-3
PRESSURE 2
MPa, (kgf/cm , psi)
305±73)
19.1±1.0 Measure at ma-
MAIN RELIEF VALVE, RELIEF
(195±10, ← chine T4-5-4
SET PRESSURE MPa, (kgf/cm2, psi)
2777±145)
8.8±1.0
Swing (90±10, ← Pump
1279±145)
19.1±1.0
Travel (195±10, ← Pump
2777±145)
OVERLOAD RELIEF VALVE, RELIEF Measure at bench
T4-5-6
SET PRESSURE MPa, (kgf/cm2, psi)
20.6±1.0
Boom, Arm, Bucket (210±10, ←
2995±145)
7.4±1.0 Motor
Swing (75±10, ← (effective pressure
1076±145) + back pressure)
SWING MOTOR DRAINAGE
T4-5-8
L/min, (US gal/min)
0.5 (0.13) or
at constant speed ←
less
TRAVEL MOTOR DRAINAGE
T4-5-10
L/min, (US gal/min)
0.6 (0.16) or Reference value
at constant speed less/
←
Fast / Slow 0.4 (0.11) or
less

T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM

• Hydraulic P-Q Control (Torque Control)

• Rated Pump Speed: 2100 min-1 (rpm)

• Pilot Pump Pressure: 3.4 MPa (35 kgf/cm2, 494
psi)
• Hydraulic Oil Temperature 50±5°C (122±41°F)

• P-Q Point
Delivery Pressure Flow Rate L/min
2
MPa (kgf/cm , psi) (US gal/min)
A 4.9 (50, 712) 10.3 or less
(2.7 or less)
B 9.8 (100, 1425) 10.0 or less
(2.6 or less)
C 17.7 (180, 2573) 9.3 or less
(2.5 or less)

L/min

A
B
C

Flow
Rate

Delivery Pressure MPa (kgf/cm2) T1MP-04-02-001

T4-2-4
OPERATIONAL PERFORMANCE TEST / Standard

• Auxiliary Section P-Q Control (Torque Control)

• Rated Pump Speed: 2100 min-1 (rpm)

• Pilot Pump Pressure: 3.4 MPa (35 kgf/cm2, 494 psi)
• Hydraulic Oil Temperature 50±5°C (122±41°F)

• P-Q Point
Delivery Pressure Flow Rate L/min
2
MPa (kgf/cm , psi) (US gal/min)
A 4.9 (50, 712) 20.6 or less
(5.4 or less)
B 9.8 (100, 1425) 20.0 or less
(5.3 or less)
C 17.7 (180, 2573) 18.6 or less
(4.9 or less)

L/min

A
B
C

Flow
Rate

Delivery Pressure MPa (kgf/cm2) T1MP-04-02-002

T4-2-5
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)

T4-2-6
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Check the engine speed before performing all
other tests as the engine speed always affects
test results.

Preparation:
1. Warm up the machine until the engine coolant
temperature reaches 50 °C (122 °F) or more and
hydraulic oil temperature is 50±5 °C (122±41 °F).
2. Confirm that the governor lever in fuel injection
pump comes into contact with the slow-idle and
fast-idle stopper bolts according to the fuel lever.
Governor
3. Put a special reflection mark on to the crank pulley Lever
side by using an engine tachometer of contact
less. (Reference: Ono HTT-4110)

Measurement:
1. Depending upon the engine speed to be meas-
ured, make measurement as per the following ta-
ble.
Fuel Lever)
Slow Idle
Slow Idle
(No-load)
Fast Idle
Fast Idle
(No-load)

2. Repeat measurement three times and calculate Slow-Idle Fast-Idle T1MP-04-03-001

Stopper Bolt Stopper Bolt
the mean value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
and check for a reduction in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system in-
cluding the air cleaner.

Preparation: Nozzle
1. Warm up the engine.
2. Remove the negative terminal at the battery.
Remove the connector from the engine stop so-
lenoid.
Install the negative terminal to the battery.
3. Remove the high-pressure line and the nozzle
from the cylinder to be measured.
4. Turn the starter and crank the engine.
5. Install a compression gauge kit (YANMAR
TOL-97190080) to the cylinder to be measured.
(Install completely in order not to occur air leak-
age.)
6. Confirm that the batteries are charged. Engine Stop High-Pressure T1MP-04-03-008
Solenoid Line
Measurement:
1. Turn the starter. Record the compression pressure Compression
of each cylinder. Gauge Kit
2. Repeat measurement three times and calculate
the mean value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

T1M9-04-02-001

T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)

T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE
Summary:
1. Perform the measurement when the engine is
cold.
2. Before removing the head cover, clean the area Flywheel Side
around the head cover in order to prevent the en-
try of dust into the engine.

Preparation: Mark
1. Remove the head cover.
IMPORTANT: If no play is felt for both of the locker Crank
arms of inlet and exhaust valves for Pulley
cylinder No. 1 even after aligning the
mark, abnormal wear of the valve
seats is suspected and disassem-
Radiator Side
bled examination is necessary. T1MP-04-03-005
2. Locate the top dead center (TDC) in the com- Mark Groove
pression stroke of piston No.1 (on the flywheel
side).
Turn the crank pulley counterclockwise viewed
from the flywheel and align “mark groove” with
“Mark” of timing gear case cover. At this time, if
both of the locker arms of inlet and exhaust valves
for cylinder No. 1 have play when operated
manually, TDC for cylinder No. 1 is properly lo-
cated.
If not, turn the crank pulley 360 degrees and
check one more time.

NOTE: In order to turn the crank pulley, remove the

fan guard and turn the fan with one hand
while holding the fan belt with the other. If
the glow plug of each cylinder is removed in
advance, the crank pulley can be easily
rotated with no compressive force.

T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement: Valve Head Locker Arm Adjusting Screw
1. Measure the valve clearance between locker arm
and valve.
2. Measure the valve clearances of valves marked
({) in the table below. Lock Nut

Cylinder No. 1 2 3
Remarks
Valve I E I E I E
Cylinder No.1 at top dead First
{ { { {
center T1M9-04-02-003
Cylinder No.1 at overlap × × Second Valve Cap

3. Turn the flywheel 360° and measure the valve

clearances marked (×) in the above table.

Evaluation:
Refer to T4-2 Operational Performance Standard. Normal Abnormal
T1M9-04-02-004

Adjustment
1. Loosen the lock nut and the adjusting screw.
2. Confirm that the valve cap has no tilting, dust in-
gress, or wear.
3. Insert a thickness gauge of 0.2 mm between
locker arm and valve head. Tighten the lock nut
after adjusting the valve clearance by using the
adjusting screw.

T1M9-04-02-005

T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern by using a nozzle tester.
2. Before starting work, clean the mounting part for
nozzle in order to avoid contamination in the en- Nozzle Tester
gine.

Preparation:
1. Remove all nozzles and fuel injection pipings.
2. Clean the carbon at the nozzle injection tip.
3. Install the nozzle, which was removed from the
engine, to the nozzle tester. Nozzle

Measurement:
CAUTION: The fuel spray from the nozzle
may penetrate the skin and results in serious T1M9-04-02-007

injury. If fuel penetrates into the blood stream,

it may cause blood toxication. Do not touch
spray directly. Wear the protection goggle
when measuring.
Nozzle
1. Injection pressure
After installing to the nozzle tester, strongly make
several strokes of the tester to inject fuel. While
operating the tester at approx. 60 time strokes a
minute, measure the fuel injection pressure. Nozzle Holder
Use the shims in the nozzle holder in order to ad-
just the pressure.

NOTE: If the shim is thickened by 0.1 mm, pres- Shim

sure rises by about 0.69 to 0.98 MPa (7 to
2
10 kgf/cm ).

T1MP-04-03-002

T4-3-6
OPERATIONAL PERFORMANCE TEST / Engine Test
2. Spray pattern
After installing to the nozzle tester, strongly make
several strokes of the tester and check the fuel Normal
spray pattern. For this test, do not operate the
pressure gauge in principle.

NOTE: Use clean diesel oil.

3. Oil tight condition

5° to 10°
Keep pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.

Evaluation: T1MP-04-03-003

1. Standard injection pressure:

Refer to T4-2 Operational Performance Standard. Abnormal
2. Spray pattern:
1-1. During injection by using a nozzle tester, in case
an extremely large amount of fuel leakage takes
place out of the overflow connector, confirm by
tightening it again. In case the situation is not
bettered, replace the nozzle assembly.
1-2. Operate the nozzle tester lever at the speed of
one or two strokes a second. Confirm that no
abnormal spray takes place.
1-3. In case spray conditions shown below cannot be
obtained, make readjustment or replacement of
T1MP-04-03-004
the parts.
-No abnormally declining spray pattern.
-Spray direction angles are not too wide or
narrow.
-The whole spray is like fine mist.
-Injection ends with no dripping.
3. Oil tight condition:
After injecting spray two to three times, gradually
raise pressure and hold the pressure for 5 sec-
2
onds at slightly lower than 2 MPa (20 kgf/cm , 290
psi). Confirm that there is no fuel drop coming out
of the nozzle end.

T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Flywheel Side High-Pressure Line
Summary:
1. Measure the injection timing of fuel injection
pump.
2. Clean the part for high-pressure line and take care Delivery
for dust. Holder

Preparation:
1. Release pressure in the fuel system and prepare
for the engine.
2. Check if the matching marks on fuel injection
pump and gear case are aligned.
3. Remove the high-pressure line at flywheel side of
T1MP-04-03-008
cylinder No.1 in the fuel injection pump from the Fuel Injection Pump
fuel injection pump side. (Do not remove the de-
livery holder.) Flywheel Side

Fuel Injection Pump

Measurement:
1. Turn the crank pulley clockwise viewed from the Gear Case
radiator. As oil surface of the delivery holder end
goes up, stop turning at this time.
2. Wipe out fuel around the delivery holder outlet. Crank Pulley
3. Turn the crank pulley counterclockwise viewed
from the radiator and return to the position at 20
degree from the top.
4. Turn the crank pulley clockwise viewed from the
Radiator Side
radiator again. As oil surface of the delivery holder T1MP-04-03-005
end goes up, stop turning at this time.
5. Read the value on timing gauge through the sight
hole on flywheel housing.
6. Repeat measurement three times. Flywheel Housing

T1MP-04-03-006
Sight Hole

Timing Mark

Timing Gauge

T1MP-04-03-007

T4-3-8
OPERATIONAL PERFORMANCE TEST / Engine Test
Adjustment
Explanation is made here about the procedure for
replacing, installing or removing of the fuel injection Fuel Pump
pump.

1. Before removing the fuel pump, put the matching Fuel Pump Drive Gear
marks on fuel injection pump driving gear and idle Matching Mark
gear.

Flange Bolt
(Do not
disassemble)

Gear Mounting Nut

Crank Gear
Idle Gear
T1M9-04-02-013

Injection Angle
2. Before removing the fuel pump, align the center- Adjustment
line of injection angle adjustment sticker with the Sticker
mark-off line on the fuel pump side. Adhere the
injection angle adjustment sticker to the gear
case.

Fuel Pump Gear Case

Mark-Off Line
T1M9-04-02-015

CAUTION: When removing the fuel pump, do

not loosen the four flange bolts fixing pump
Gear Case
flange and fuel pump driving gear. If the four
flange bolts are loosened, adjustment of the
injection timing becomes very difficult.
3. Remove the pump mounting nuts (3 used), the
gear mounting nuts and the spring washer. Re- Fuel Injection
Pump
move the fuel pump from the gear case. Read the Flange Bolt (Do
injection angle marked on the fuel injection pump. not disassemble.)

Pump Flange
Pump
Fuel Injection Pump Drive
Mounting Nut
Gear
Spring Washer Gear Mounting
Nut
T1MP-04-03-009

T4-3-9
OPERATIONAL PERFORMANCE TEST / Engine Test
IMPORTANT: In case the injection angle of fuel Center Line 1° 2°
pump is difficult to read, consult the Injection Angle
Adjustment Sticker
engine manufacturer for it by giving
information on the fuel pump model
and serial number.
4. Read the injection angle marked on the fuel injec-
tion pump to be installed. Figure out the difference
from that of the removed fuel injection pump.
0.5°
NOTE: In case the same fuel injection pump is T1M9-04-02-014

installed again, the angle difference is zero.

Injection angle difference (cam angle) = Injection Angle
Pump Mark-Off Line Adjustment Sticker
(injection angle of installed fuel pump) - (in-
jection angle of removed fuel pump)

5. Install the fuel injection pump temporarily to the

gear case.
Align the matching marks on fuel injection pump
drive gear and idle gear. Install the fuel injection
pump driving gear to the camshaft.
Install the spring washer and the gear mounting
In case of +1° In case of +0.25° T1MJ-04-03-001.TIF
nut temporarily.

Gear Case

Fuel Injection Idle Gear

Pump

Gear
Mounting
Nut

Fuel Injection Pump Drive Gear

Spring Washer
T1MP-04-03-010

T4-3-10
OPERATIONAL PERFORMANCE TEST / Engine Test
6. Read the injection angle difference figured out in
procedure 4 by using the injection angle adjust- Mounting Angle for
ment sticker (minimum 0.5 degrees, cam angle) Fuel Injection Pump
and adjust the mounting angle for fuel injection
pump.

NOTE: For the injection angle difference of +1 de-

Cylinder Block Side
gree, turn the fuel pump 1 degree outward
in relation to the cylinder block, and for – 1
degree, turn the fuel pump 1 degree toward
the cylinder block.

7. Tighten the pump mounting nuts (3 used) and the

gear mounting nut.
: 59 to 69 N⋅m
(6 to 7 kgf⋅m, 44 to 51 lbf⋅ft)

NOTE: For advancing or delaying the injection T1MJ-04-03-002

timing, change the mounting angle of the

fuel injection pump. For example, in case
the injection angle is advanced by 2 de- Gear Case
grees, loosen the nut for fixing the fuel in-
jection pump to the gear case, turn the fuel
pump 1 degree outward in relation to the
cylinder block, and tighten the pump Fuel Injection
mounting nut. Pump
For delaying the injection timing, mount the
pump the other way around.
Gear
Mounting
Nut

Pump
Mounting Nut T1MP-04-03-010

Delay
Advance

Cylinder Block Side

T1M9-04-02-017

Mounting Bolt for Fuel Injection Pump

(Adjustment of Injection Timing)

T4-3-11
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)

T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
1. Measure the time required for the excavator to
travel a test track in order to check overall per-
formance of travel drive system (between main
pump and travel motor).

Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Prepare a level and solid test track 10 m (32 ft 10
in) in length, with an extra length of 3 to 5 m (9.8
to 16 ft) on both ends for machine acceleration
and deceleration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket extended.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

End
Arm Roll-in, Bucket Roll-in
Start

Raise bucket 0.3 to 0.5 m

(1.0 to 1.6 ft) above the
ground.

3 to 5 m (9.8 to 16 ft)
extra length for acceleration /
10 m (32 ft 10 in) deceleration
3 to 5 m (9.8 to 16 ft)
extra length for acceleration / T1MP-04-04-001
deceleration

Measurement:
1. Run the engine to the fast idle speed. Measure at
each mode (slow and fast travel speeds).
2. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
3. Measure the time required to travel 10 m (32 ft 10
in).
4. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
5. Repeat the measurement three times and calcu-
late the mean value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary:
1. Measure the track revolution cycle time in order to
check the total track drive system (between main
pump and travel motor).

Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. Put the mark on one shoe in the track to be
measured by using chalk.
CAUTION: Support the jacked-up machine
securely by using the wooden blocks.
90 to 110°
3. Jack up the track to be measured. Keep the
boom-arm angle between 90 to 110° as shown. Mark

Measurement: T1MP-04-04-002
1. Run the engine to the fast idle speed. Measure at
each mode (slow and fast travel speeds).
2. Operate the travel control lever of the track to be
measured at the full stroke.
3. Measure the time required for 3 revolutions of
shoe in both directions.
4. Jack up the other track and repeat the proce-
dures.
5. Repeat the measurement three times for each
track and calculate the mean value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

NOTE: The measured values may vary widely. The

evaluation based on the results obtained
from the 10 m (32 ft 10 in) travel speed
check is more recommendable.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary:
1. Allow the machine to travel 10 m (32 ft 10 in).
Measure the maximum tread deviation from the
tread chord line drawn between the travel start
and end points in order to check the performance
equilibrium between both sides of the travel de-
vice systems (between main pump and travel
motor).
2. If measured on a concrete surface, the tread de-
viation has a trend to decrease.

Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 10 m (32 ft 10 in) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and de-
celeration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket extended.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

Maximum Distance

10 m (32 ft 10 in)
T1MP-04-04-003

Measurement:
1. Run the engine to the fast idle speed. Measure at
each mode (slow and fast travel speeds).
2. Start traveling the machine in the acceleration
zone with the travel levers at the full stroke.
3. Measure the distance between a straight 10 m (32
ft 10 in) line and the tread made by the machine.
4. After measuring the tracking in forward travel,
swing the upperstructure 180° and measure that
in reverse travel.
5. Repeat the measurement three times in each di-
rection and calculate the mean value.

Evaluation:
Refer to T 4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL MOTOR LEAKAGE
Summary:
1. Measure the amount of travel motor slippage on a
slope, which is due to travel motor inner oil leak.

Preparation:
1. The surface of the test slope must be even, with a
gradient of 20% (11.31 °).
2. Raise the bucket 0.2 to 0.3 m (0.8 to 1.0 ft) above
the ground with the arm and bucket cylinders fully
extended.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

Measurement:
1. Climb the slope and place the travel levers in T1MP-04-04-004
neutral.
2. Stop the engine.
3. After parking the machine, put the matching marks
on the side frame and a track link or shoe.
4. After 3 minutes, measure discrepancy between
the marks.

Evaluation:
Refer to T4-2 Operational Performance Standard.

Amount of slippage after 3 minutes

T1MP-04-04-008

T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
1. Measure the time required to swing three com-
plete turns in order to check the total swing drive
system (between the main pump and swing mo-
tor).

Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Place the machine on level, solid ground with
ample space for swinging. Do not conduct this test Even with
on slopes. the Boom
3. With the arm cylinder fully retracted and the Foot Pin.
bucket cylinder fully extended, hold the bucket so T1MP-04-04-005

that the height of arm top pin is even with the

boom foot pin. The bucket must be empty.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F)

CAUTION: Before starting the measurement,

make sure that there are no person or obsta-
cles within the swing area.

Measurement:
1. Run the engine at fast idle speed. Operate the
swing control lever fully.
2. Measure the time required to swing 3 turns in one
direction.
3. Operate the swing control lever fully in the oppo-
site direction and measure the time required for 3
turns.
4. Repeat the measurement three times each and
calculate the average values.

Evaluation
Refer to T4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
1. Measure the swing drift on the bearing outer cir-
cumference when stopping after a 90° full speed
swing in order to check the valve unit perform-
ance.

Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Place the machine on level, solid ground with Put the matching marks on the
swing bearing outer circumfer-
ample space for swinging. Do not conduct this test ence and track frame.
on slopes. T1MP-04-04-006

3. With the arm cylinder fully retracted and the

bucket cylinder fully extended, hold the bucket so
that the height of bucket pin is even with the boom
foot pin. The bucket must be empty.
4. Put the matching marks on the swing bearing
outer circumference and track frame by using a
tape.
5. Swing the upperstructure 90°.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

CAUTION: Before starting the measurement,

make sure that there are no person or obsta- Swing the upperstructure 90°
cles within the swing area. to the test start position.

T1MP-04-04-007

T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test

Measurement:
1. Run engine at fast idle speed. Operate the swing Measure the arc length along the
circumference of swing bearing.
control lever fully. Swing the upprestructure 90°.
When the marks on swing bearing and track frame
meet, return the swing lever to the neutral posi-
tion.
2. After the swing movement stops, measure the arc
length between two matching marks along the cir-
Mark on the track frame
cumference of swing bearing.
3. Align the marks again, swing 90°. Measure in the
Mark on the swing bearing
opposite direction. T1MP-04-04-009

4. Repeat the measurement three times each direc-

tion and calculate the mean values.

Evaluation:
Refer to T4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
1. Measure the upperstructure drift after parking the
machine on a slope with the upperstructure posi-
tioned 90° to the slope in order to check swing
parking brake performance.

Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Load the bucket with either soil or a weight
equivalent to the weight standard.
Weight: ZAXIS 8-2: 28 kg (62 lb)
ZAXIS 10U-2: 30 kg (66 lb)
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of bucket pin is even with the boom
foot pin.
4. Park the machine on a flat slope with a gradient of
15±1°.
5. Climb the slope and swing the upperstructure
90°toward the slope. Put the matching marks on
swing bearing circumference and track frame.
T1MP-04-04-010
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test

Measurement:
1. Start the engine and maintain engine speed at idle
speed. After 5 minutes, measure the difference Measure the arc length along the
between the marks on swing bearing circumfer- swing bearing circumference.
ence and the track frame.
2. Perform the measurement under the following two
conditions:
⋅ When the brake is applied (with the pilot shut-off
lever in the LOCK position).
Mark on the track frame
⋅ When the brake is released (with the pilot shut-off
lever in the UNLOCK position).
3. Perform the measurement on both right and left Mark on the swing bearing T1MP-04-04-009

swing directions.
4. Perform the measurement three times in each di-
rection and calculate the average values.

Evaluation:
Refer to T4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
1. Measure the maximum slope angle on which the
upperstructure can swing, park the machine on a
slope with the upperstructure positioned 90° to the
slope.

Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Load the bucket with either soil or a weight
equivalent to the weight standard.
Weight: ZAXIS 8-2: 28 kg (62 lb)
ZAXIS 10U-2: 30 kg (66 lb)
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
T1MP-04-04-010
that the height of bucket pin is even with the boom
foot pin.
4. Climb the slope and set the upperstructure 90° to
the slope.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

Measurement:
1. Run the engine at fast idle. Operate the swing
control lever fully and swing the upperstructure to
the uphill side of slope.
2. If swing is possible, measure the slant angle on
the cab floor.
3. Increase the slope angle. Measure on both right
and left swing directions.
4. Perform the measurement three times.

Evaluation:
Refer to T4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
1. Measure the swing play in order to check the wear
of bearing races and balls.

Preparation:
1. Check the swing bearing mounting bolt for loose-
ness.
2. Check the lubrication of swing bearing. Confirm
that bearing rotation is smooth and noiseless.
3. Secure a dial gauge on the track frame by using a
magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the travel
motors. Dial Gauge
5. Position the dial gauge so that its needle point
comes into contact with the bottom surface of
bearing outer race.
6. The bucket should be empty.

NOTE: The measured value may differ depending Round Frame Trunk
on where the magnetic base is located.
Secure the magnetic base directly onto the
round frame trunk or as close to the round
Magnetic Base
frame trunk as possible. T1MP-04-04-019

Measurement:
1. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so Measurement: [h1]
that height of the bucket pin is even with the boom
foot pin. Record dial gauge reading (h1).
2. Lower the bucket to the ground and raise the
machine 0.5 m (20 in) off the ground. Record dial
gauge reading (h2).
3. Calculate bearing play (H) from this data (h1 and Even with the
h2) as follows: Boom Foot Pin.
H = h2 − h1
T1MP-04-04-005

Evaluation:
Refer to T4-2 Operational Performance Standard.
Measurement: [h2]

0.5 m (20 in)

T1MP-04-04-011

T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME Boom Cylinder

Summary:
1. Measure each cylinder cycle time in order to to-
tally check the front attachment function per-
formance (between the main pump and each cyl-
inder).
2. The bucket should be empty.
T1MP-04-04-012

Preparation:
Arm Cylinder
1. Take the following machine position:

1-1. Measure the boom cylinder:

With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
to the ground.
0.5 m
1-2. Measure the arm cylinder: (20 in)
With the bucket cylinder fully extended, adjust
T1MP-04-04-013
the boom so that the bucket bottom clearance
above the ground is approx. 0.5 m (20 in). Bucket Cylinder
Place the arm so that the arm longitudinal
center line perpendicularly points to the
ground.
1-3. Measure the bucket cylinder:
Adjust the boom and arm cylinder strokes so
that when the bucket is moved half the full
stroke, the bucket edge points to the ground
perpendicularly.
T1MP-04-04-020
1-4. Measure the boom swing cylinder: Boom Swing Cylinder
Set the boom swing cylinder in either the right
or left swing stroke end position.

1-5. Measure the blade cylinder:

Jack up the machine by using a front attach-
ment and secure the height space to allow the
blade to move up-and-down full stroke.

T1MP-04-04-014
Blade Cylinder

T1MP-04-04-011

T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
1-6. Measure the side frame extend / retract cylin-
der: Side Frame Extend / Retract Cylinder
Raise the machine off the ground by using the
blade and front attachment. Set the side frame
to the Open or Close condition.

2. Maintain hydraulic oil temperature at 50±5 °C

(122±41 °F).

T1MP-04-04-023

T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Run the engine at fast idle speed.

Operate each cylinder as follows:

(The cylinder stroke excludes the cushion range.)

1-1. Measure the boom cylinder:

Measure the time required to raise or lower the
boom while operating the boom control lever at
full stroke.

1-2. Measure the arm cylinder:

Measure the time required to roll in or out the
arm while operating the arm control lever at full
stroke.

1-3. Measure the bucket cylinder:

Measure the time required to roll in or out the
bucket while operating the bucket control lever
at full stroke.

1-4. Measure the boom swing cylinder:

Measure the time required to swing the front
attachment from right to left or vice versa while
operating the boom swing pedal at full stroke.

1-5. Measure the blade cylinder:

Measure the time required to raise or lower the
blade while operating the blade control lever at
full at stroke.

1-6. Measure the side frame extend / retract cylin-

der:
Measure the time required to open or close the
side frame while operating the side frame ex-
tend / retract control lever at full stroke.

2. Repeat each measurement three times and cal-

culate the average value.

Evaluation:
Refer to T 4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.

T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT

Summary:
1. With the bucket loaded, measure dig function drift
in order to check oil leakage in the control valve
and / or boom, arm, bucket, blade and boom
swing cylinders.

2. When testing the dig function drift just after cylin-

der replacement, slowly operate each cylinder to
its stroke end in order to release air prior to test-
ing. Extension
Retraction

Preparation: Retraction
1. Load the bucket with either soil or a weight
equivalent to the weight standard.
Weight: ZAXIS 8-2: 28 kg (62 lb)
ZAXIS 10U-2: 30 kg (66 lb)
2. With the arm cylinder fully retracted and bucket Arm Top Pin is
Front Drift
even with Boom
cylinder fully extended, had the bucket pin height Foot Pin.
even with the boom foot pin.
T1MP-04-04-015
Fully retract the blade cylinder.
Extension
When measuring the boom swing cylinder, climb
the slope with a gradient of 15±1 ° and set the
upperstructure 90 ° to the slope.
3. Retract the boom cylinder approx. 50 mm (2 in) to
away from the cushion range.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

T1MP-04-04-010

T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test

Boom, Bucket and Blade Cylinder Retraction

Measurement:
Mark Mark
1. Stop the engine.
2. After five minutes, measure the boom and bucket
retraction the arm and blade cylinder extension,
and amount of the bucket drift. When measuring
the swing cylinder, measure the boom swing cyl-
inder retraction and extension in left and right di-
rection to the slope.
3. Repeat the measurement three times and calcu- T1MP-04-04-021

late the mean value.

Evaluation:
Refer to T4-2 Operational Performance Standard.
Arm Cylinder Extension

Remedy:
Refer to T5-2 Troubleshooting B.

Mark

T1MP-04-04-022

Boom Swing Cylinder Extension

T1MP-04-04-016

T4-4-16
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
1. Check the operating function of each control lever
and measure the operating force.
2. Measure the maximum operating force needed to
move the control lever for front attachment.
3. Measure the operating force at the center of each
lever grip.

Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

CAUTION: Before the measurement, make

sure there are no personnel or obstacles
within the swing area.

Measurement: T107-06-03-003

1. Start the engine.

2. In case of boom raise, arm, bucket levers, meas-
ure the maximum operating force with each boom
raise, arm, bucket lever, at full stroke.
3. In case of the boom lower lever, select the place
where the jacked-up machine does not lie sown.
Measure the maximum operating force of boom
lower lever with boom lower relieved.
4. In case of the swing lever, secure the front at-
tachment in order to prevent swinging. Operate
the swing lever and measure the maximum oper-
ating force with swing relieved.
5. In case of the travel lever, jack up the track to be
measured. Operate the travel lever to full stroke T107-06-03-004

and measure the maximum operating force.

6. Repeat the measurement three times and calcu-
late the mean value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

T4-4-17
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Check play and operating function of each control
lever and swing pedal and measure each lever
stroke.
2. Measure the lever stroke at the grip center of each
control lever.
As for the boom swing pedal, measure the stroke
from the center position to stopper.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.

Preparation:
Maintain the hydraulic oil temperature at 50±5 °C T107-06-03-005

(122±41 °F).

Measurement:
1. Stop the engine.
2. Measure the boom, arm, bucket, swing, travel and
blade control lever strokes at the grip top center
from the neutral position to the stroke end.
As for the boom swing pedal, measure the straight
distance between the center and fully depressed
positions at tip of the pedal.
3. Take the measurements by the straight stroke
distances.
4. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to T4-2 Operational Performance Standard.

T4-4-18
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE / SWING FUNC-
TION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions simultane-
ously in order to evaluate combined functions.
2. Confirm that no hesitation is found with the engine
running at maximum speed.
T1MP-04-04-012
Preparation:
1. With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket to
the ground. The bucket should be empty.
2. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

Measurement:
1. Run the engine at fast idle speed. Perform the
followings.
2. Raise the boom and swing simultaneously, both at
full stroke. Measure the time required to swing 90°
and the height (H) of the bucket teeth. T1MP-04-04-017

3. Repeat the measurement three times and calcu-

late the average value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

Remedy:
Refer to T5-2 Troubleshooting B.
H

T1MP-04-04-018

T4-4-19
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)

T4-4-20
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Turn the filling cap on hydraulic oil tank slowly and
Hose
bleed air. (7/16-20UNF)
3. Remove the hose (7/16-20UNF) at the pilot filter
connection. Install tee (ST 6451), nipple (ST
6069) and pressure gauge assembly (ST 6932).
: 19 mm

4. Start the engine and check for oil leakage from

the gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

Measurement: Pilot Filter T1MP-04-05-001

1. Run the engine at fast idle.

2. Measure pressure without load.
3. Repeat the measurement three times and calcu-
late the average value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment:
Adjust the set pressure of relief valve on 2-spool
solenoid valve if necessary.
Adjusting Screw Lock Nut
1. Loosen the lock nut.
: 17 mm

2. Turn the adjusting screw and adjust pressure.

: 6 mm

3. Tighten the lock nut.

: 17 mm
: 15 to 20 N⋅m
(1.5 to 2.0 kgf⋅m, 10.8 to 14.5 lbf⋅ft)
T1LA-03-06-002

4. After the adjustment, check the set pressure.

NOTE: Standard change in pressure.

Adjusting Screw Turns 1/4 1/2 3/4 1

kPa 182 363 545 726
Change in 2
(kgf/cm ) (1.85) (3.7) (5.55) (7.40)
Pressure
(psi) (26.3) (52.6) (78.9) (105.2)

T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE (ZAXIS
10U-2 ONLY)
Preparation:
1. Stop the engine.
2. Turn the filling cap on hydraulic oil tank slowly and
bleed air. Control Valve
3. Remove the pilot line from the circuit to be meas-
ured. Install tee (ST 6451), nipple (ST 6069) and
Pilot Line
pressure gauge (ST 6932) to the pilot port for
spool.
: 19 mm

4. Start the engine and check for oil leakage at the

pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

Measurement: T1MP-04-05-002

CAUTION: Before measuring, check that

there are no obstacles or personnel within
the swing radius. When measuring the boom
lower pilot pressure, raise the machine off
the ground. Pay attention not to allow the
base machine (counterweight) to contact
with the ground. Be careful not to tip-over
due to a loss of balance.

1. Operate the lever to be measured. Measure pilot

pressure at its full stroke by using the pressure
gauge.
2. Repeat the measurement three times and calcu-
late the average valve.

Evaluation:
Refer to T4-2 Operational Performance Standard.

T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE SET PRESSURE
Summary:
Measure the set pressure of main relief valve at the
delivery port in main pump.

Preparation:
1. Stop the engine.
2. Turn the filling cap on hydraulic oil tank slowly and
bleed air.
3. Remove the plugs from hoses of main pumps (P1,
P2).
Install nipple (ST 6066) and pressure gauge as- Main Pump
Port P1
sembly (ST 6933).
: 7 mm, 17 mm

4. Start the engine and check for oil leakage at the

pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

Measurement: Plug
1. Run the engine at fast idle.
2. Slowly operate each control lever or pedal and
fully extend or retract each cylinder in order to re-
lieve the pressure. Measure the relief pressure Main Pump
at this time. Port P2
3. When measuring the swing, secure the machine. T1MP-04-05-003
Operate the swing lever slowly and relieve the
pressure.
NOTE: When measuring main pump P1, operate
the bucket control lever and relieve the
pressure.
When measuring main pump P2, operate
the arm control lever and relieve the pres-
sure.
When measuring main pumps P1 and P2
at the same time, operate the auxiliary con-
trol levers and relieve the pressure.
4. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to T4-2 Operational Performance Standard.

T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment:
Adjust the set pressure of main relief valves if nec-
essary. The main relief valves are installed on the NOTE: The illustration shows ZAXIS 10U-2.
position as illustrated.
Main Relief Main Relief
1. Loosen the lock nut. Valve (P2) Valve (P1)
: 19 mm

IMPORTANT: Adjust the pressure so that the

pressure does not exceed the upper
limit of standard.

2. Turn the adjusting screw and adjust the pressure.

: 4 mm

3. Tighten the lock nut.

: 19 mm
: 20 N⋅m
(2 kgf⋅m, 15 lbf⋅ft)

4. After the adjustment, check the set pressure.

T1MP-05-02-002
NOTE: Standard change in pressure.

Lock Nut
Adjusting Screw 1/4 1/2 3/4 1 Adjusting
Turns Screw
MPa 3.05 6.1 9.15 12.2
Change in 2
(kgf/cm ) (31) (62) (93) (124)
Pressure
(psi) (440) (890) (1330) (1770)

T1MP-03-03-002

Lock Nut Adjusting Screw

Pressure Pressure
Increase Decrease

T505-06-04-007

T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. With the return circuit from the control valve
blocked, the circuit pressure must be increased
by applying an external load. This checking
method is hazardous and the results obtained
with this method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the delivery flow rate of the main re-
lief valve. Accordingly, even if the main relief valve
set pressure can be reset higher than the set
pressure of overload relief valve, the main pump
supplies too much oil to correctly measure the set
pressure of overload relief valve.
The main relief valve has pre-leaking function.
In this case, the set pressure of main relief valve
at pre-leaking function need to be set higher than
that of overload relief valve.
Accordingly, the main relief valve pressure setting
may not be reset higher than the set pressure of
overload relief valve plus the pressure at
pre-leaking.
Therefore, when the set pressure of the overload
relief valve must be checked correctly, remove
the overload relief valve assembly from the ma-
chine and check the overload relief valve unit
performance using the test stand and test block
prepared for this purpose.
If the poppet of overload relief valve seats to the
body of control valve, the test block requires pre-
cise machining.
Use other control valve unit for the measurement
instead of the test block.
3. As an easier method, however, measure the relief
pressure of each cylinders in the same method as
of main relief pressure setting in previous section.
Then, when each relief pressure meets its re-
spective specifications, judge that the set pres-
sure of overload relief valve is correct.
(Refer to “Main Relief Set Pressure Measure-
ment”.)

T4-5-6
OPERATIONAL PERFORMANCE TEST / Component Test
Overload Relief Valve Pressure Adjustment Pro-
cedure NOTE: The illustration shows ZAXIS 10U-2.
Pressure of overload relief valve shall be adjusted by
Overload Relief Overload Relief
using a test device in principle. Valve (Swing) Valve (Arm)
1. Loosen the lock nut.
: 19 mm

2. Turn adjusting screw and adjust the pressure.

: 4 mm

3. Tighten the lock nut.

: 19 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4. After the adjustment, check the set pressure.

NOTE: Standard Change in Pressure.

Adjusting Screw Turns 1/4 1/2 3/4 1
T1MP-05-02-002
MPa 3.05 6.1 9.15 12.2
Change in 2 Overload Relief
(kgf/cm ) (31) (62) (93) (124) Valve (Boom)
Pressure
(psi) (440) (890) (1330) (1770)
Lock Nut

Adjusting Screw

T1MP-03-03-003

Adjusting
Lock Nut Screw

Pressure
Pressure
Increase
Decrease

T505-06-04-007

T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
1. In order to check the performance of swing motor,
measure the amount of oil draining from the
swing motor while swinging the upperstructure.
2. Always secure the test personnel’s safe during
the measurement. Before the measurement,
make sure there are no person or obstacles
within the test track.
3. The amount of drain oil will change depending on
hydraulic oil temperature. Maintain hydraulic oil
temperature at 50±5 °C (122±41 °F).

Preparation:
1. Warm the hydraulic oil temperature to 50±5 °C
(122±41 °F). Rotate the swing motor and warm
up the inside of motor. Drain Port
2. Stop the engine. Turn the filling cap slowly and
bleed air from the hydraulic oil tank.
3. Remove the drain hose from the swing motor at
the motor side. Install plug (7/16-20UNF) to the
removed hose end. Install the hose onto the drain
port of swing motor.
: 19 mm
: 29.5 Nxm (3 kgfxm, 21.5 lbfxft)

Measurement Condition:
1. Set the engine to the fast idle.

T1MP-01-02-009

T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test

CAUTION: Before the measurement, make

sure there are no person or obstacles within
the swing area.
Make sure not to fall off from machine during
the measurement.

Measurement: Even with the

Boom Foot
1. Drain Oil Volume during Swing Operation at Con- Pin.
stant Speed
T1MP-04-04-005
1-1. Start the engine. With the arm cylinder fully re-
tracted and the bucket cylinder fully extended,
hold the bucket so that the height of arm top pin
is even with the boom foot pin. The bucket
should be empty.
1-2. Operate the swing lever to the full stroke. After
swing speed reaches a constant maximum
speed, collect the hydraulic oil from drain hose.
Measure the time at the same time.
1-3. Repeat the measurement more than 3 times in
both clockwise and counterclockwise directions
and calculate the average value.
1-4. The measurement should be at least 45 sec-
onds.

2. Drain Oil Volume at Swing Relief Operation

2-1. Start the engine. Seize the ground by using the
bucket so that the machine does not move.
2-2. Operate the swing lever to the full stroke. Col-
lect the hydraulic oil from the drain hose. Meas-
ure the time at the same time.
2-3. Repeat the measurement more than 3 times in
both clockwise and counterclockwise directions,
and calculate the average value.
2-4. The measurement should be at least 45 sec-
onds.

Evaluation:
Refer to T4-2 Operational Performance Standard.
* Conversion of Measured Value into the
Per-Minute Value
Measure the amount of drain oil by using a cali-
brated container. Convert the measured drain oil
into the per-minute value using the following for-
mula;

∆Q = 60 × q / t

∆Q : Per-Minute Drain Volume (L/min)

t : Time Measured (sec)
q : Measured Drain Oil Volume (L)

T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. In order to check the performance of the travel
motor, measure the amount of oil draining from
the travel motor, while rotating the travel motor
with the measuring side track jacked up.
2. Always secure the test personnel’s safe during
the measurement. Before the measurement,
make sure there are no personnel or obstacles
within the test track.
3. Evaluate the overall performance of the travel
motor taking the test results such as travel speed
and mistrack amount into consideration together
with this test results.
4. The amount of drain oil will change depending on
hydraulic oil temperature. Maintain the hydraulic
oil temperature at 50±5 °C (122±41 °F).

Preparation: Drain Hose

1. Warm the hydraulic oil to 50±5 °C (122±41 °F).
Rotate the travel motor and warm up the inside of
motor.
2. Stop the engine. Turn the filling cap slowly and
bleed air from the hydraulic oil tank.
3. Remove the drain hose from the travel motor at
the motor side. Install plug (7/16-20UNF) to the
removed hose end. Install test hose
(7/16-20UNF) to the drain port of travel motor.
: 19 mm
: 29.5 Nxm (3 kgfxm, 21.5 lbfxft)

T1MP-04-05-004

T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement Condition:
1. Set the engine to the fast idle.

Measurement:
1. Drain Oil Volume During Travel Motor Rotation

CAUTION: When approaching to the rotation

parts, take care that hands, legs or clothes
are not entangled.
Support the jacked-up machine securely by
90 to 110°
using the wooden block.

1-1. Start the engine. Jack-up the track to be meas-

ured. T1MP-04-04-002
1-2. Rotate the track to be measured. Collect the
hydraulic oil from drain hose. Measure the time
at the same time.
1-3. Repeat the measurement more than 3 times in
both forward and reverse directions, and calcu-
late the average value.
1-4. The measurement should be at least 45 sec-
onds.

Evaluation:
Refer to T4-2 Operational Performance Standard.
* Conversion of Measured Value into the
Per-Minute Value T1MP-04-05-005

Measure the amount of drain oil by using a cali-

brated container. Convert the measured drain oil
into the per-minute value using the following for-
mula;

∆Q = 60 × q / t

∆Q : Per-Minute Drain Volume (L/min)

t : Time Measured (sec)
q : Measured Drain Oil Volume (L)

T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-12
OPERATIONAL PERFORMANCE TEST / Adjustment
FUEL LEVER ADJUSTMENT
Fuel Lever Side
IMPORTANT: Do not adjust the slow idle stopper Fuel Lever
bolt and fast idle stopper bolt in
governor lever. These are sealed in
advance by the engine manufacturer.
Machine Cover
Front
1. Remove the cover from the lever stand.
2. Loosen the nuts (2 used). Loosen the slow idle
stopper bolt and fast idle stopper bolt.
3. Adjust the end of slow idle stopper bolt (upper
side) and secure by using the nut.
4. Move the fuel lever until the slow idle stopper bolt
touches the fuel lever. Confirm that the governor T1MP-04-06-002

lever touches the slow idle stopper bolt at this time.

If the governor lever does not touch the stopper
bolt, adjust the length of cable.
5. Move the fuel lever until the governor lever
touches the fast idle stopper bolt (lower side). Fuel Lever
Tighten the fast idle stopper bolt in fuel lever until
the clearance between fuel lever and stopper bolt
becomes 1 to 2 mm and secure the fuel lever by
using the nut. Nut
Slow Idle
Stopper Bolt Standard:
9 mm
Fast Idle
Stopper Bolt

Standard:
Nut 9 mm
T1MP-04-06-001

Governor
Engine Side Lever Cable

Slow Idle Fast Idle T1MP-04-03-001

Stopper Bolt Stopper Bolt

T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)

T4-6-2
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
SECTION 5
TROUBLESHOOTING

CONTENTS
Group 1 Diagnosing Procedure Group 3 Troubleshooting C
Introduction .............................................. T5-1-1 Troubleshooting C Procedure ....................... T5-3-1
Diagnosing Procedure ............................... T5-1-2 Malfunction of Alternator Indicator ................ T5-3-2
Malfunction of Engine Oil Pressure
Group 2 Troubleshooting B Indicator ...................................................... T5-3-3
Troubleshooting B Procedure........................T5-2-1 Malfunction of Overheat Indicator ................. T5-3-4
Engine System Troubleshooting....................T5-2-2 Malfunction of Hour Meter ............................ T5-3-5
Actuator System
Troubleshooting (ZAXIS8-2) ........................T5-2-7 Group 4 Electrical System Inspection
Actuator System Precautions for Inspection and
Troubleshooting (ZAXIS10U-2) ...................T5-2-8 Maintenance................................................ T5-4-1
Front Attachment System Fuse Continuity Test ..................................... T5-4-3
Troubleshooting ......................................... T5-2-11 Battery Voltage Check .................................. T5-4-4
Swing System Troubleshooting ...................T5-2-15 Voltage Check............................................... T5-4-5
Travel System Troubleshooting ...................T5-2-17 Continuity Check ........................................... T5-4-6
Boom Swing System Troubleshooting.........T5-2-20
Blade System Troubleshooting....................T5-2-21
Side Frame Extend / Retract
System Troubleshooting ............................T5-2-22
How to Lower Boom
In Case of Emergency and when
Engine Stops (ZAXIS10U-2 Only)..............T5-2-23
Horn Blowing Prevention Procedure
when Key Switch is OFF............................T5-2-24

1MRT-5-1
(Blank)

1MRT-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Troubleshooting charts shown in this section indicate
the orderly procedures for inspecting and finding out
the cause(s) of problems in the machine.

This section is comprised of three groups: Outline,

Troubleshooting B (diagnosis of machine by system
failure indicator), Troubleshooting C (diagnosis of lamp
unit), and Electric System Inspection.

• Troubleshooting B (diagnosis of machine by

system failure indicator)
This procedure is used for diagnosis of machine
failure.

Example) The starter does not turn.

• Troubleshooting C (diagnosis of lamp unit)

This procedure is used for failures of lamp unit
and hour meter.

Example) The alternator indicator does not light.

• Electric System Inspection

This procedure is used when the information on
precaution for electric system inspection or
inspection method is needed.

Example) Fuse inspection.

T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
Follow the five basic steps shown below for efficient
troubleshooting.

1. Know the system

Study the appropriate technical manuals. Know
what the system is composed of and how it works,
as well as the construction, functions and
specifications of the system components.

2. Ask the operator

T107-07-01-001
Before inspecting, get the full story of
malfunctions from a witness --- the operator.
• How the machine has been used and properly
operated?
• When was the trouble noticed, and what work
was the machine doing at that time?
• What is the character of the trouble? Did the
trouble slowly get worse, or did it appear suddenly
for the first time?
• Did the machine have any trouble previously?
• If so, which parts were repaired or replaced
before?

3. Inspect the machine

Before starting troubleshooting, check the
machine's daily maintenance points, as shown in
the operator's manual.
T107-07-01-002
Check the electrical system, including batteries.
Trouble in the electrical system such as low
battery voltage, loose connections and blown
fuses will result in malfunction of the controllers,
causing total operational failure of the machine.

Note that if the troubleshooting is performed

without noticing that the fuse is blown, it may lead
to the incorrect diagnosis results which causes
significant loss of time. Make sure to check the
fuse before performing the troubleshooting.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.

T107-07-01-003

T5-1-2
TROUBLESHOOTING / Diagnosing Procedure
4. Inspect the actual trouble on the machine
Reproduce the trouble on the machine and make
sure the actual phenomenon.
In case some trouble cannot be actually
confirmed, obtain the details of the malfunction
from the operator.
Also check for any incomplete connections of the
wire harnesses.

5. Check by Each System

CAUTION: Always stop the engine before
disconnecting the harnesses or lines. If they T107-07-01-004

are disconnected while the engine running, it

may cause improper operation of the
machine, or the pressurized oil may spout.

Use "Troubleshooting B, C" in this chapter in

order to confirm the operation condition for each
equipment.

6. Trace causes
Before reaching a conclusion, check the most
suspect causes again. Try to trace what the real
cause of the trouble is.
Make a plan of appropriate repairing procedure,
T107-07-01-007
to avoid consequential malfunctions.

T5-1-3
TROUBLESHOOTING / Diagnosing Procedure
(Blank)

T5-1-4
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
(DIAGNOSIS OF MACHINE BY SYMPTOM)
This procedure is used when operating the diagnosis
by the symptom.

• How to Read the Troubleshooting Flow Charts

YES (OK)
(2)

・ (1) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)

・ As shown to the left, measuring methods or items to be referred to are indicated in the
spaces under the box. Take care to measure or check correctly. Incorrect measuring or
・ Key switch: ON
checking methods may result in making troubleshooting impossible, and may damage
components.

・ The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.

NOTE: The connector drawings show the harness

end connectors seen from the open end
side.

Harness End Harness

Connector

Open End T6L4-05-03-001

Side

T5-2-1
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
Starter does not rotate.
YES
• Check the fuse and wiring connections first.

With key switch

positioned as
YES shown in the table
below, check if
each terminal volt-
age on starter is
normal.
· Pilot shut-off lever: YES
LOCK position
Check if voltage at
terminal B in starter
NO is 12 V.
· Key switch: START

Check if voltage at
Check if battery terminal #1 of
voltage and elec- connector in starter
trolyte density are relay 2 is 12V.
normal.
· Key switch: START
· Voltage: 12 V or more · Pilot shut-off lever:
· Density: 1.25 to 1.28 LOCK position
(at 20 degrees centi-
grade)
NO
Unit: V
Key Switch HEAT
OFF ON START
Terminal
B (M8) 12 12 12 12
#50 0 0 0 12

NO (When the key switch is turned to the START position, if volt-

age at terminal B is lower than 9 volts, battery may be faulty.)

Starter voltage check

Starter Motor
1. Turn the key switch to the ON or START position.
2. Contact minus (−) probe of a circuit tester to the #50
machine (ground to unpainted area like bolt head)
and plus (+) probe to the starter terminal respec-
tively, and check voltages.
(Measure with the harness connected.)
B
T1MS-05-02-001

T5-2-2
TROUBLESHOOTING / Troubleshooting B

Faulty starter.

Open circuit in harness be-

tween battery and starter or
faulty connection.

Open circuit in harness be-

tween starter relay 2 and
starter.

Faulty pilot shut-off switch, or

YES shorted circuit in harness be-
tween pilot shut-off switch and
With safety start
safety relay.
relay disconnected,
check if voltage at
YES terminal #2 of hae-
ness end of con-
Remove connector nector is 12V.
in starter relay 2. · Key switch: ON
Check if voltage at · Pilot shut-off lever: Faulty safety start relay.
terminal #3 of har- LOCK position NO
ness end of con-
nector is 12V.
· Key switch: START Open circuit in harness be-
tween safety start relay and
NO key switch.

Faulty battery.

Connector (Harness end of connector viewed from the

open end side)

Safety Start Relay

2 1
4 3

T5-2-3
TROUBLESHOOTING / Troubleshooting B
Although starter rotates, engine does not start.

• In case of faulty engine, refer to "Engine Shop

Manual".
• Check the wiring connections first.

YES

YES Check if voltage at

terminal #3 in 1-sec-
ond timer is 12V.
Open circuit in har-
· Key switch: ON ness between
YES Check if voltage at NO 1-second timer and
terminal #2 in power fuse box.
relay is 12V.
· Key switch: ON
Open circuit in har-
ness between power
NO relay and fuse box.

Remove fuel line that

goes to engine at fuel
pump.
Check if fuel is deliv-
ered when key switch
is turned ON.
YES Faulty fuel filter.

Check if fuel filter is

clogged. YES
NO

Remove fuel pump

connector. Check if
voltage at terminal #1
NO of harness end of
connector is 12V.
Connector (Harness end of connector viewed from the
· Key switch: ON
open end side)

Power Relay 1-second NO

Timer Fuel Pump
1 2 4
2 1 2 1
3
4 3

Engine Stop Solenoid

R W
B

T1M7-05-03-002

T5-2-4
TROUBLESHOOTING / Troubleshooting B

YES
A
Check for continuity
between terminal B of
YES harness end of con-
nector in engine stop
Remove engine stop solenoid and vehicle Open circuit in har-
solenoid connector. frame. ness between engine
Check if voltage at stop solenoid and
terminal R of harness NO ground.
end of connector is
12V.
· Key switch: ON Open circuit in har-
ness between engine
NO stop solenoid and
fuse box.

YES Faulty fuel pump.

Check for continuity
between terminal #2
of harness end of
connector in fuel
pump and vehicle Open circuit in har-
frame. ness between fuel
NO
pump and ground.

Open circuit in har-

YES ness between fuse
box and fuel pump.
Check if voltage at
fuse 1-#3 (10A) is
12V. Faulty key switch, or
open circuit in har-
· Key switch: ON ness between key
NO
switch and fuse box.

T5-2-5
TROUBLESHOOTING / Troubleshooting B

Faulty power relay,

YES 1-second timer or en-
gine.
Remove engine stop
solenoid from engine
body.
Remove starter motor
A lead wire.
Check if pin on top of
solenoid moves when
key switch is in START
position.
Faulty engine stop so-
· Key switch: START
NO lenoid.

Engine Stop Pin

Solenoid

T1MS-05-02-002

Starter Motor

Lead Wire (Terminal)

T1MS-05-02-001

T5-2-6
TROUBLESHOOTING / Troubleshooting B
ACTUATOR SYSTEM TROUBLESHOOT-
ING (ZAXIS8-2)
All actuators are slow

• In case the trouble occurs only when the hydraulic

oil temperature is low, high viscosity of hydraulic
oil may be the cause.
• As the main circuit consists of 2 systems (2 main
relief valves are located), the possibility of failure
in all main relief valve is small.
• In case more than one actuators are displaying
trouble, the load check valves in the related cir- YES Find out cause of trouble by
cuits may have failed. tracing other trouble symp-
toms.

YES
Check if link mecha-
nism of control lever or
control pedal is normal
Faulty link mechanism of control
lever.
Check if engine speed NO
is normal.
· Refer to "OPERA-
TIONAL PER-
Faulty engine body.
FORMANCE TEST".
NO

T5-2-7
TROUBLESHOOTING / Troubleshooting B
ACTUATOR SYSTEM TROUBLESHOOT-
ING (ZAXIS10U-2)
Actuators are slow.

• In case the trouble occurs only when the hy-

draulic oil temperature is low, high viscosity of hy-
draulic oil may be the cause.
• As the main circuit consists of 2 systems (2
main relief valves are located), the possibility of
failure in all main relief valve is small.
• In case more than one actuators are displaying
trouble, the load check valves in the related cir-
cuits may have failed.
YES Find out cause of trouble by
Actuators of boom, bucket, arm and swing are tracing other trouble symp-
slow. toms.

YES Check if primary pilot

pressure is normal.
· Refer to "OPERA- Check if pilot filter is clogged.
C
TIONAL PER- NO
Check if engine speed FORMANCE TEST".
is normal.
· Refer to "OPERA-
TIONAL PER-
Faulty engine body.
FORMANCE TEST".
NO

YES Clogged pilot filter.

C YES End (faulty pilot relief valve).

Disassemble, clean and

adjust pilot relief valve.
NO Check if symptom disap-
pears.
Faulty pilot pump.
NO

Actuators of boom swing, left travel, right travel,

blade, auxiliary and side frame extend /retract are YES Find out cause of trouble by
slow. tracing other trouble symp-
toms.
Check if link mecha-
YES
nism of control lever or
control pedal is normal.
Faulty link mechanism of control
NO l lever.
Check if engine speed
is normal.
· Refer to "OPERA-
TIONAL PER-
Faulty engine body.
FORMANCE TEST".
NO

T5-2-8
TROUBLESHOOTING / Troubleshooting B
Actuators of boom, arm, bucket and swing do not
work.

• As the main circuit consists of 2 systems (2 main

relief valves are located), the possibility of failure
in all main relief valve is small. YES Faulty pilot shut-off
solenoid valve.
Check for continuity
YES between terminal #2
of harness end of Open circuit in har-
Remove connector of connector and vehi- ness between pilot
pilot shut-off solenoid cle frame. shut-off solenoid
valve. NO
valve and ground.
Check if voltage at
YES
terminal #1 of har-
ness end of connec- Faulty pilot shut-off
tor is 12V. switch, or open circuit
Remove pilot shut-off YES
in harness between
· Key switch: ON switch connector. pilot shut-off switch
· Pilot shut-off lever: Check if voltage at and pilot shut-off so-
UNLOCK position terminal #1 of har- lenoid valve.
NO ness end of connec-
tor is 12V. Open circuit in har-
Check if primary pilot ness between pilot
· Key switch: ON NO
pressure is normal. shut-off switch and
· Refer to “OPERA- fuse box.
TIONAL PERFORM-
ANCE TEST.” YES End. (Faulty pilot re-
lief valve.)
Disassemble, clean
or adjust pilot relief
valve. YES
NO Check if symptom A
Remove connector of
disappears. unload relay. Check if
voltage at terminal #1 Open circuit in har-
NO
of harness end of ness between pilot
connector is 12 V. NO shut-of switch and
unload relay.
· Key switch: ON
· Pilot shut-off lever:
UNLOCK position

YES Faulty unload relay.

Connect connector of
unload relay. Check if
A voltage at terminal #4
of connector is 12 V.
Connector (Harness end of connector viewed from · Key switch: ON Faulty air bleed sole-
the open end) · Pilot shut-off lever: NO noid valve.
UNLOCK position
Pilot Shut-Off Switch Unload Relay
Pilot Shut-Off Solenoid Valve
Air Bleed Solenoid Valve

2 4 1
2 1
5
3

T5-2-9
TROUBLESHOOTING / Troubleshooting B
When control lever is in neutral, actuators of
boom, arm, bucket and swing do not stop.

YES Faulty pilot valve spool.

Check if symptom dis-

appears when pilot
shut-off lever is in LOCK
position.
Faulty control valve spool.
NO

T5-2-10
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
All front attachment functions are weak.

• In case all actuators are weak, refer to “All ac-

tuators are slow or do not work (ZAXIS8-2:
T5-2-7, ZAXIS10U-2: T5-2-8 to 9)

• (ZAXIS10U-2 only)
In case only the front attachment is abnormal,
check the pilot valve and pilot shut-off solenoid
valve.

T5-2-11
TROUBLESHOOTING / Troubleshooting B
Only cylinder(s) in one system does not move, is
slow and weak.

• The main circuit consists of 2 systems (2 main re-

lief valves are located). If one of the main relief
valve is faulty, it may lead to failure in the actuator
operation of the corresponding system.

Pump P1 circuit: Boom swing, boom, bucket,

right travel, blade and auxiliary
Pump P2 circuit: Swing, arm, side frame ex-
tend/retract, left travel and auxiliary

ZAXIS8-2

YES End (Faulty control

Disassemble and valve spool.).
clean control valve
spool corresponding
to cylinder.
Check if problem
disappears Faulty seal in cylin-
NO der.

ZAXIS10U-2
YES End (Faulty control
Disassemble and valve spool.).
clean control valve
YES spool corresponding
to cylinder.
Check if problem dis-
appears. Faulty seal in cylinder.
NO

Check if secondary
pilot pressure corre-
sponding to cylinder
is normal.
· Refer to "OPERA-
TIONAL PER-
FORMANCE TEST".

Faulty pilot valve cor-

responding to cylinder.
NO

T5-2-12
TROUBLESHOOTING / Troubleshooting B
Front attachment cylinders leaking (drift) is large.

ZAXIS8-2

YES
Normal.
Check if each front
attachment cylinder
drift is within specifi- YES
Faulty seal in cylinder.
cations.
Check if oil leaks
· Refer to "OPERA-
NO inside cylinder. Scored spool in control
TIONAL PER-
valve, damaged
FORMANCE TEST".
NO spring, or loosed spool
end.

ZAXIS10U-2

YES Normal.

YES Faulty seal in cylinder.

Check if each front
attachment cylinder
drift is within specifi-
cations. NO Check if oil leaks in-
side cylinder.
· Refer to "OPERA- Scored spool in control
TIONAL PER- valve, damaged spring,
FORMANCE TEST". Check if symptom or loosed spool end.
NO
disappears when pilot
NO shut-off lever is
turned into LOCK
position.
Faulty pilot valve.
YES

Boom cylinder inner leak check

1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tip to the
ground.
2. Remove the hydraulic hose at the rod side of
boom cylinder. Drain oil in the cylinder and hose.
(Install a plug on removed hose end.)
3. Retract the rod of arm cylinder and raise the
bucket from the ground.
If oil comes out from the hose removed line and
T1MP-05-02-001
the rod of boom cylinder is retracted, oil is leaking
in the boom cylinder.
If oil does not come out from the hose removed
line and the rod of boom cylinder is retracted, oil
is leaking in the control valve.

T5-2-13
TROUBLESHOOTING / Troubleshooting B
When control lever is operated (boom raise, arm
roll-out), front attachment drops briefly and
moves.

YES Internal leakage in cylinder.

Check if load check

valve in control valve is
normal.
· Visually check after
disassembling. Faulty load check valve.
NO

NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump
are low. If the load check valve is faulty,
oil in the bottom side of cylinder flows (B)
back into the circuit and the boom cyl-
inder temporarily retracts because of
the load on boom cylinder. When load check
valve is faulty (A)

2. If oil is leaking from bottom side (A) to

rod side (B) due to the faulty piston or
tube of the boom cylinder, the boom
cylinder temporarily retracts as oil
pressure and flow rate from the pump is
low during the initial stage of operation.
Then, the cylinder cannot support the
load and cylinder force is reduced. In
this case, the cylinder drift increases. T105-07-04-012

T5-2-14
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
Upperstructure does not swing, its speed is slow,
or has weak power.
• In case the arm, side frame extend /retract, left
travel and auxiliary cylinders, along with the swing
function move slowly, have no power, or do not
move at all, the main relief valve for pump P2
may be faulty.

ZAXIS8-2 End. (faulty control

YES
valve spool)

Disassemble
YES and clean control
valve spool.
Check if problem
Check if swing disappears.
relief pressure is Faulty swing motor.
normal. NO
· Refer to "OP-
ERATIONAL Faulty overload
PERFORMANCE NO relief valve (swing).
TEST".

ZAXIS10U-2

YES End. (faulty control

valve spool)

Disassemble and
clean control valve
YES
spool.
Check if problem
disappears.
Faulty swing motor.
NO
Check if swing
YES relief pressure is
normal.
· Refer to "OPERA-
TIONAL PER-
Check if secon- FORMANCE
dary pilot pres- Faulty overload
TEST". relief valve (swing).
sure of swing is NO
normal.
· Refer to "OPERA-
TIONAL PER- Faulty pilot valve.
FORMANCE NO
TEST".

T5-2-15
TROUBLESHOOTING / Troubleshooting B
Swing drift is large when swinging is stopped.

• When swing drifts roughly, the swing related valves

may have trouble. When swing drifts smoothly, the
related valve spools may have trouble.

YES Normal.

YES End (faulty control

Check if swing valve spool).
drift is within
specifications. Disassemble and
clean control valve
YES spool.
Check if problem
disappears.

Faulty swing de-

NO vice.
Check if swing
relief pressure is
NO normal.

· Refer to “OPERA-
TIONAL PER-
FORMANCE Faulty swing relief
TEST”. valve (adjust or
replace swing relief
NO
valve).

T5-2-16
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
Machine does not move, moves slowly, or has
weak power.

• Both right and left travel motors and the spools in

control valve seldom become faulty at the same
time.
• In case only one side is faulty, refer to "Machine
mistracks".
• If travel speed does not become fast, refer to
"Travel speed does not change to fast speed".

T5-2-17
TROUBLESHOOTING / Troubleshooting B
Travel speed does not change to fast speed.
Open circuit in har-
YES ness between travel
• Check the wiring connections first. Connect connector of mode selector sole-
travel mode selector noid valve and
solenoid valve. ground.
YES Connect terminal #2
of connector to vehi-
cle frame.
Connect connector of Check if travel speed
travel mode selector becomes fast. Faulty travel mode
switch. selector solenoid
Disconnect connector · Connect connector to NO
YES vehicle frame by us- valve.
of travel mode selec-
tor solenoid valve. ing a clip without dis-
Check if voltage at connecting.
· Travel mode selector Open circuit in har-
terminal #1 of harness between travel
ness end of connec- switch: Fast position
Disconnect connec- mode selector sole-
tor of travel mode tor is 12 V. noid valve and travel
selector switch. NO mode selector switch,
· Key switch: ON
Check if voltage at · Travel mode selector or faulty travel mode
terminal #1 of har- switch: Fast position selector switch.
ness end of con-
nector is 12V.
· Key switch: ON Open circuit in har-
ness between travel
NO
mode selector switch
and key switch.

Travel speed does not change to slow speed.

• Check the wiring connections first.

YES Faulty travel mode
Disconnect connector selector switch.
of travel mode selec-
YES tor switch.
Check if symptom Shorted circuit in
disappears. harness between
Disconnect connec-
travel mode selector
tor of travel mode
solenoid valve and
selector solenoid NO travel mode selector
valve. Check if
switch.
symptom disap-
pears.
Faulty travel mode
selector solenoid
NO valve.

Connector (Harness end of connector viewed from

the open end side)

Travel Mode Selector Solenoid Valve,

Travel Mode Selector Switch

2 1

T5-2-18
TROUBLESHOOTING / Troubleshooting B
Machine mistracks.

• If the machine mistracks to the right (only the

right travel moves slowly, has no power or does
not move), the main relief valve on pump P1 may
be faulty.
If the machine mistracks to the left (only the left
travel moves slowly, has no power or does not
move), the main relief valve on pump P2 may be
faulty.

NOTE: During combined operation of travel and

other actuator except travel, the machine
mistracks.

YES
Faulty center joint.

Switch travel hoses at

YES undercarriage side in
center joint.
Check if problem is YES End (faulty counterbal-
reversed. ance valve).
Check if cycle time of all Disassemble and clean
hydraulic cylinders is counterbalance valve.
normal. NO Check if symptom dis-
appears.
Faulty travel motor.
· Refer to "OPERA- NO
TIONAL PERFORM-
ANCE TEST".
Faulty main pump.
NO
· If boom and bucket move
slowly, main pump 1 is
faulty.
· If arm moves slowly,
main pump 2 is faulty.

T5-2-19
TROUBLESHOOTING / Troubleshooting B
BOOM SWING SYSTEM TROUBLE-
SHOOTING

Boom swing does not move or moves slowly.

• In case each actuator of the boom swing, boom,

bucket, right travel, blade, and auxiliary does not
move or moves slowly, the main relief valve on
pump P1 may be faulty.

Operate boom swing to YES Oil leaks in cylinder.

the left and fully extend
cylinder.
YES Remove line on rod
side.
Check if oil leaks occur
during operation of left Oil leaks in control valve.
boom swing.
NO
Check if link mecha-
nism of boom swing
pedal is normal.

Faulty link mechanism of

boom swing pedal.
NO

T5-2-20
TROUBLESHOOTING / Troubleshooting B
BLADE SYSTEM TROUBLESHOOTING
Blade does not move or moves slowly.
• In case each actuator of the blade, boom swing,
boom, bucket, right travel and auxiliary does not
move or moves slowly, the main relief valve on
pump P1 may be faulty.

Raise blade cylinder. YES Oil leaks in cylinder.

Fully retract cylinder.
Remove only line on
YES bottom side.
Check for oil leaks from
bottom side port of cyl-
inder when blade is Faulty center joint, or oil
raised. leaks in control valve.
NO
Check if link mecha-
nism of blade lever is
normal.

Faulty link mechanism of

NO
blade lever.

T5-2-21
TROUBLESHOOTING / Troubleshooting B
SIDE FRAME EXTEND/RETRACT SYSTEM
TROUBLESHOOTING

Side frame does not move or moves slowly.

• Each actuator of the side frame extend/retract,

swing, arm, left travel and auxiliary does not
move or moves slowly, the main relief valve on
pump P2 may be faulty.

YES Oil leaks in cylinder.

Operate side frame open
and fully extend cylinder.
YES Remove only line on rod
side.
Check for oil leaks from
rod side port during side
frame open operation. Faulty center joint, or oil
NO leaks in control valve.
Check if link mecha-
nism for side frame
extend/retract lever is
normal.

Faulty link mechanism for

side frame extend / retract
NO lever.

T5-2-22
TROUBLESHOOTING / Troubleshooting B
HOW TO LOWER BOOM IN CASE OF
EMERGENCY AND WHEN ENGINE STOPS A
(ZAXIS10U-2 ONLY)

CAUTION: Do not stand under the boom

during operation.

In case the engine stops and the engine cannot

re-start, lower the boom in the following procedures.

1. Raise the pilot shut-off lever and set in the LOCK

position.
2. Remove the elbow and pilot line of the boom
overload relief valve side from the boom section
in control valve.
: 17 mm, 19 mm T1MP-05-02-002

3. Turn and insert special tool (ST 4151) into the Boom Overload Relief Valve
removed line port and move the boom spool di-
rectly. Therefore, boom cylinder bottom pressure
returns to the hydraulic oil tank through the boom
spool and the boom is lowered. Section A (Boom Section)
: 14 mm
4. When the boom is lowered, install the elbow and
pilot line.
: 17 mm, 19 mm Boom Spool
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

ST 4151

Boom Overload
Relief Valve

T1MP-05-02-005

T5-2-23
TROUBLESHOOTING / Troubleshooting B
HOW TO PREVENT HORN BLOWING AT
KEY SWITCH POSITION OF OFF
Normally, the horn can be blown even at OFF position Under the Battery
of the key switch.
In an Immobilizer Version machine (optional), the horn Female Plug
switch needs to be pressed in order to release the lock. (Label: ACC)
At that time, horn blowing can be prevented by
changing connection of the harnesses.
In case such setting is desired that the horn does not
blow on releasing lock (key switch position OFF) of the
immobilizer (optional), follow the following procedures.
1. Remove the plug (label: D) under the battery.
2. Connect the removed male plug (label: D) to the
female plug (label: ACC).

IMPORTANT: After work, confirm that the horn is

blown at the key switch position of
ON.

T1MP-01-02-012
Plug (Label: D)

Electrical Circuit Diagram

Slow Blow Fuse Key Switch

Battery

1 3

Fuse Box 1 Fuse Box 2

Horn Switch
Female Plug (Label: ACC)

Horn
Horn Relay
Plug (Label: D)
T1MP-05-02-004

T5-2-24
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C PROCEDURE
(DIAGNOSIS OF LAMP UNIT)
This procedure is used for failures of lamp unit and
hour meter.

• How to Read the Troubleshooting Flow Charts

YES (OK)
(2)

・ (1) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)

・ The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.

NOTE: The connector drawings show the harness

end connectors seen from the open end
side.

Harness End Harness

Connector

Open End T6L4-05-03-001

Side

T5-3-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDI-
CATOR

• Check the wiring connections first.

NO Open circuit in harness

Disconnect connector
from lamp unit with between alternator and
alternator connector lamp unit.
NO disconnected.
Check for continuity
Disconnect alternator
between terminal #3 of
connector. Connect ter-
harness end of con- Faulty alternator indica-
minal #3 of harness end
When key switch is nector in alternator and YES tor, or open circuit in
of connector to vehicle
turned ON, alternator terminal #2 of harness harness in lamp unit.
frame.
indicator does not light. end of connector in
Check if alternator indi-
lamp unit.
· Key switch: ON cator lights.
· Engine: Stop · Key switch: ON
Faulty alternator (regula-
· Engine: Stop
YES tor).

YES Faulty alternator (regula-

tor).

Disconnect alternator
Even if engine rotates, connector. Check if al-
alternator indicator does ternator indicator goes
not go out. out.
· Key switch: ON · Key switch: ON
· Engine: Running · Engine: Stop
Shorted circuit in harness
between alternator and
NO lamp unit.

Connector (Harness end of connector viewed from the

open end side)

Lamp Unit

3 2 1
6 5 4

Alternator

13 2 1

L IG P
T1MJ-05-04-002

T5-3-2
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR

NOTE: The indicator comes on when engine oil

pressure is below 49± 10 kPa (0.5±0.1
2
kgf/cm , 7.1±1.4 psi). NOTE: 1 kgf/cm2=98.07 kPa

• Check the wiring connections first.

YES Faulty engine oil pressure

switch.

Disconnect engine oil Disconnect connector in

When key switch is pressure switch terminal. lamp unit with engine oil
turned ON, indicator Connect harness end pressure switch terminal Faulty engine oil pressure
does not light. terminal to vehicle frame. disconnected. NO
indicator, or open circuit in
Check if indicator lights. Check for continuity be- harness in lamp unit.
· Key switch: ON tween harness end ter-
· Engine: Stop · Key switch: ON minal in engine oil pres-
· Pressure might not be sure switch and terminal
released for 1 to 2 min- NO #1 of harness end of
utes just after the en- connector. Open circuit in harness
gine stops.
between engine oil pres-
This is normal. YES sure switch and lamp unit.

YES Faulty engine oil pressure

switch.

Disconnect engine oil

After engine is started, pressure switch terminal.
indicator does not go out. Check if indicator goes
out.
· Check if oil filter is · Key switch: ON
clogged or not. · Engine: Stop Shorted circuit in harness
between engine oil pres-
NO sure switch and lamp unit.

Connector (Harness end of connector viewed from the

open end side)

Lamp Unit

3 2 1
6 5 4

T5-3-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICA-
TOR

NOTE: The indicator comes on when coolant tem-

perature is above 110 ± 2 °C (230 ± 36 °F)
and the overheat switch is turned ON.

• Check for loose harness connections beforehand.

YES Faulty overheat switch.

Disconnect overheat
Indicator does not light switch terminal.
when coolant tem- Connect harness end
perature gauge reads terminal to vehicle Disconnect connector in
higher than 110 °C frame. Faulty overheat indicator,
lamp unit with overheat YES
or open circuit in harness
(230 °F) Check if indicator switch terminal discon-
lights. in lamp unit.
· Engine: Running nected.
Check for continuity
· Key switch: ON
NO between harness end
terminal in overheat
switch and terminal #3 Open circuit in harness
of harness end of con- between overheat switch
NO
nector. and lamp unit.

YES Faulty overheat switch.

Indicator keeps lighting Disconnect overheat

without going out. switch terminal. Check
if indicator goes out. YES Shorted circuit in harness
between overheat switch
· Key switch: ON
· Key switch: ON Disconnect connector in and lamp unit.
lamp unit with overheat
NO switch terminal discon-
nected.
Check for continuity Shorted circuit in harness
Connector (Harness end of connector viewed from the between terminal #3 of in lamp unit.
NO
harness end connector
open end side) and vehicle frame.
· Key switch: ON

Lamp Unit

3 2 1
6 5 4

T5-3-4
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER

NOTE: The hour meter operates when the key

switch is turned to the ON, HEAT or START
position.

• Check the wiring connections first.

YES Faulty hour meter.

Disconnect hour me-

Hour meter does not ter terminal (blue line
operate. in red).
Check if terminal
· Key switch: ON voltage is 12 V.
· Key switch: ON Open circuit in harness
between hour meter and
NO
fuse box.

T5-3-5
TROUBLESHOOTING / Troubleshooting C
(Blank)

T5-3-6
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Remove the negative terminals from batteries
first when taking wire harnesses and connectors
off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses and slow blow fuse and, in
some cases, cause fire due to short circuiting. Code Color Code Color
2. Color coding of wire harnesses. R Red W White
The color codes of wire harnesses in the L Blue G Green
electrical system are shown below. O Orange Lg Light Green
In cases on the design sheet where two colors Y Yellow B Black
are indicated for one wire, the left initial stands for Br Brown P Pink
Gr Gray V Violet
the base color, while the right initial stands for the
marking color.

NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Do not
confuse them with color coded wires.

3. Precautions for connecting and disconnecting Right Wrong

terminal connectors.
• When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself.
Release the lock first before attempting to
separate connectors, if a lock is provided. T107-07-06-001

• Water-resistant connectors keep water out so that

if water enters them, water will not easily drain
from them. When checking water resistant
connectors, take extra care not to allow water to Right
enter the connectors. In case water should enter
Rust
the connectors, reconnect only after the
Wrong
connectors are thoroughly dried.
(Deformation)
• Before connecting terminal connectors, check
that no terminals are bent or coming off. In Wrong (Coming Off, Separation)
addition, as, most connectors are made of brass,
check that no terminals are rusting. T107-07-06-002

• When connecting terminal connectors provided

with a lock, insert them together until the lock
"clicks."

T5-4-1
TROUBLESHOOTING / Electrical System Inspection
4. Precaution for using a circuit tester.
Wind a piece of wire Tester Probe
• Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current polarity.
• Before starting the connector test, always check
Sharpen the end of wire
the connector terminal numbers, referring to the T107-07-06-003
circuit diagram.
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or a
pin around the probe to make the test easier.
• When performing the connector test with the
circuit tester, insert the tester probe from the
connector harness side in order not to damage
the terminals in connector.

T5-4-2
TROUBLESHOOTING / Electrical System Inspection
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse,
Fuse Box 1 Fuse Box 2
and such fine cracks are very hard to detect by visual
inspection.
Checking fuse continuity with a tester is far superior to
sight inspection. 1-1 2-1

1. Turn the key switch ON.

When the key switch is turned ON, the power is
supplied to all fuses from key switch terminals BR,
R2 and ACC. (Refer to Circuit Diagram.) 1-3 2-3
2. Remove the fuse box cover and set the correct
voltage measurement range of the tester.
(Measurement range: 0 to 14.5 V)
3. Connect the negative probe to the vehicle ground,
and touch the outside terminal of each fuse with
the positive probe of the tester.
When normal continuity of a fuse is intact, the
tester will indicate 12 volts.

T1MP-05-04-001
Auxiliary

Number Capacity Connected to

1-1 30 A Horn Relay, Power Relay
1-3 10 A 1-second Timer, Fuel Pump, Alternater, Engine Stop Solenoid
2-1 10 A Unload Relay, Pilot Shut-Off Switch, Travel Mode Switch, Hour Meter, Lamp Unit
2-3 10 A Worl Light, Power Source (Auxiliary)

T5-4-3
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF.
Measure voltage between battery positive
terminal and ground (vehicle frame).
Correct Voltage Reading: 12 V

NOTE: If voltage is abnormal, re-charge or replace

the battery.

2. Start the engine. V

Measure voltage between battery positive
terminal and ground (vehicle frame).
Correct Voltage Reading: 14.5 V

NOTE: If voltage is abnormal, check the charging

system. T505-07-01-002

T5-4-4
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE CHECK
Turn switches ON so that the specified voltage is
supplied to the checkpoint. Measure voltage.
Diagnose the circuit between power source and
checking point by checking that specified voltage is
supplied or not.

Check the circuit in either the upstream (from the Evaluation

power source) or downstream (from the accessory) Measured voltage must equal 12 V (battery voltage).
order to locate the failed section in the circuit. If the measured voltage is less than the battery
Set the following check conditions: voltage by 0.5 V or more, some incorrect contacts
• Key switch position: may exist at connectors.
ON (When checking points (4) to (8))
• Relay position:
ON (When checking points (9) or (10))
• Tester black terminal (negative):
Connected to the vehicle frame (ground)
• Tester red terminal (positive):
Connected to the checking point
Power source:
Batteries (12 volts)

Key Switch
Key Switch
B BR R1 R2 C ACC

PREHEAT
OFF
ON
START
1
2
4
Battery 3
5

Tester 6
Relay

Switch
8 7 9

An example of the checking order (Horn Circuit)

1 2 3 4 5 6 7 8 9 10

T5-4-5
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK Harness
A a
Single-line continuity check
Disconnect both end connectors of the harness and
check continuity between ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity Ω

NOTE: When the one end connector is far apart Connect to the
vehicle frame. A a
from the other, connect one end of
connector (A) or the vehicle frame using a
clip. Then, check continuity of the harness
through the vehicle frame as illustrated.
Connect to the
vehicle frame. Ω
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and × Shorted circuit
check continuity between one end connector of the in harness
between the
harness and the vehicle frame: vehicle frame.
If the ohm-meter reading is: Ω
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
Multi-line continuity check First Connected
Disconnect both end connectors of the harness, and
connect two terminals (A) and (B), using a jumper
wire at one end of the connector, as illustrated. Then, A a
check continuity between terminals (a) and (b) at the B b
other connector. If the ohm-meter reading is ∞Ω, C c
either line (A)-(a), or (B)-(b) is in discontinuity. To find
out which line is discontinued, conduct the single line Second Connected
continuity check on both lines individually, or after
changing the connected terminals from (A)-(B) to
(A)-(C). Check continuity once more between Ω
terminals (a) and (c).

NOTE: By Conducting the multi-line continuity T107-07-05-004

check twice, it is possible to find out which

line is discontinued. With terminals (A) and Shorted circuit between harnesses.
(C) short circuited, check continuity
A
× a
between terminals (a) and (c). B b
C c
If the ohm-meter reading is:
0 Ω = Line (B)-(b) has discontinuity.
∞ Ω = Line (A)-(a) has discontinuity.

Multi-lines short circuit check Ω

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C).
T107-07-05-005
If the ohm-meter reading is:
0 Ω = Short circuit exists between the lines.
∞ Ω = No Short circuit exists between the lines.

T5-4-6
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)

DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more re-
FAX: visions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

THE ATTACHED DIAGRAM LIST

(The following diagrams are attached to this manual.)

1 ZAXIS8-2 HYDRAULIC CIRCUIT DIAGRAM ZAXIS10U-2 HYDRAULIC CIRCUIT DIAGRAM

2 ZAXIS8-2/10U-2 ELECTRICAL CIRCUIT DIAGRAM −
3 ZAXIS8-2/10U-2 MAIN HARNESS −
4 ZAXIS8-2/10U-2 STAND HARNESS −
5 ZAXIS8-2/10U-2 LIGHT HARNESS ZAXIS8-2/10U-2 BATTERY CABLE +/−
ZAXIS8-2/10U-2 AIR BLEED SOLENOID VALVE
HARNESS
PART NO. W1MR-E-00

ZAXIS8-2 • 10U-2 HYDRAULIC EXCAVATOR

Workshop Manual

WORKSHOP MANUAL
8-2
10U-2
Hydraulic Excavator

URL:http://www.hitachi-c-m.com

Service Manual consists of the following separate Part No;

Technical Manual : Vol. No.T1MR-E
Workshop Manual : Vol. No.W1MR-E

PRINTED IN JAPAN (E) 2007, 03

INTRODUCTION
TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this manual.
• Be sure to thoroughly read this manual for correct (Note: Do not tear off the form. Copy it for us-
product information and service procedures. age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.

• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance
delivery, operation and activation of all devices and repair of the machine, tools and devices
and systems, operational performance tests, and needed for maintenance and repair, maintenance
troubleshooting procedures. standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-02
SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE
Group 1 Main Frame
Group 2 Pump Device
Group 3 Control Valve
Group 4 Swing Device
Group 5 Pilot Valve
Group 6 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
All information, illustrations and speci-
fications in this manual are based on
SECTION 4 FRONT ATTACHMENT
the latest product information available Group 1 Front Attachment
at the time of publication. The right is
reserved to make changes at any time Group 2 Cylinder
without notice.
SECTION 5 ENGINE

COPYRIGHT(C)2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Control System Group 5 Component Test
Group 2 Hydraulic System Group 6 Adjustment
Group 3 Electrical System SECTION 5 TROUBLESHOOTING
SECTION 3 COMPONENT OPERATION Group 1 Diagnosing Procedure
Group 1 Pump Device Group 2 Troubleshooting A
Group 2 Swing Device Group 3 Troubleshooting B
Group 3 Control Valve Group 4 Troubleshooting C
Group 4 Pilot Valve Group 5 Electrical System Inspection
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SAFETY
RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

this manual, be alert to the potential for personal in-
jury.
• Follow recommended precautions and safe operating
practices.

SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious in-
jury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
SA-1223
• To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.

• NOTE indicates an additional explanation for an

element of information.

SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Keep emergency numbers for doctors, ambulance

service, hospitals, and fire department posted near
your telephone.

SA-2
SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat
Safety belt
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

Respirator or filter mask.

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator.

• Do not wear radio or music headphones while oper-

ating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.

SA-434

INSPECT MACHINE

• If any abnormality is found, be sure to repair it immedi-

ately before operating the machine.

• In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.

SA-435

SA-3
SAFETY
USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

thoroughly remove such material.

FASTEN YOUR SEAT BELT

(ROLL BAR EQUIPPED MACHINES)

• If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.

• Be sure to remain seated with the seat belt securely

least once every 3 years regardless of appearance

SA-4
SAFETY
MOVE AND OPERATE MACHINE SAFELY

• Always be aware that there is a potential danger around

the machine while operating the machine.

• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped).
• Before starting to move or operate the machine, sound
the travel alarm and horn to alert bystanders.
• Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Locate the SA-611
signal person so that the operator can always witness
the signal person.
• Coordinate the meanings of all safety signs, hand
signals and marks before starting the machine. Ap-
point a person who is responsible to make a signal
and/or guidance.
• Never allow any persons or obstacles to enter the
machine operation areas.
• Use appropriate illuminations.

SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury
or death.

• Start the engine only when seated in the operator's

• Before starting the engine, confirm that all control lev-

ers are in neutral.

JUMP STARTING

• Failure to follow correct jump starting procedures could

result in a battery explosion or a runaway machine.

• If the engine must be jump started, be sure to follow

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the
machine.

• Riders also obstruct the operator’s view, resulting in

the machine being operated in an unsafe manner.
• Only allow the operator is allowed on the machine.
Keep riders off.

SA-612

SA-6
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road

shoulder, the machine could tip over due to collapse of
the ground, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of

SA-7
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

• In case more than one machine is operated in the same

job site, accidental collision between machines may
cause serious injury or death.

• For jobs involving multiple numbers of machines, provide

signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s direc-
tions.

SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN

• Incorrect travel pedal/lever operation may result in seri-

ous injury death.

• Before driving the machine, confirm the position of the

SA-614

SA-8
SAFETY
DRIVE MACHINE SAFELY

• Driving the machine in the incorrect direction may result

in serious injury or death and/or severe damage to
property.

• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding di-
rection you wish to travel.

• Avoid passing over any obstructions. Failure to do so

may cause soil, rock fragments and/or metal pieces to
SA-615
be scatter around the machine. Keep bystanders away
from the machine.
• Traveling on a grade may cause the machine to slip or to
overturn, possibly resulting in serious injury or death.

• When traveling up or down a grade, keep the bucket in

• Traveling across the face of slope or steering on a SA-616

slope may cause the machine to skid or to turnover. If

the direction must be changed on a slope, first move
the machine to level ground, then, change the travel-
ing direction to ensure safe operation.

SA-441

SA-442

SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS

• Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.

• Park the machine in compliance with the safe parking

procedures described on page S-16 to prevent the ma-
chine from running away.

• Block both tracks and lower the bucket to the ground,

thrust the bucket teeth into the ground if you must park
on a grade.
• Park a reasonable distance from other machines.

SA-617

SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

• If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

clearly understood by both signalman and operator.

021-E01A-0494-8

SA-11
SAFETY
KEEP PERSONNEL CLEAR FROM WORKING
AREA

• If a person is present near the operating machine, the

person may come in contact with the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Before operating the machine, set up barriers to the

SA-618

NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a

truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

• Never allow the bucket to pass over anyone to avoid

personal injury or death.

SA-619

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if the

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic raise the front attachment with a
panic. Lowering the front attachment may be safer in
most cases.

SA-620

SA-12
SAFETY
AVOID TIPPING

• The danger of tipping is always present when operating

on a grade, possibly resulting in serious injury or death.

To avoid tipping:
• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging
loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E01A-0540-4

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.

SA-622

SA-13
SAFETY
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in
serious injury or death.

• Before digging check the location of cables, gas lines,

OPERATE WITH CAUTION

• If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the

boom or arm.

SA-263

AVOID POWER LINES

• Serious injury or death can result if the machine or front

attachments are not kept a safe distance from electric
lines.

• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
SA-265
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.

SA-14
SAFETY
DO NOT USE FOR CRANING OPERATIONS

• NEVER use the machine for craning operations. If the

SA-014

PROTECT AGAINST FLYING DEBRIS

• If flying debris such as soil, rock fragments or metal

pieces hit eyes or any other part of the body, serious
injury may result.

• Guard against such injuries when working in a job site

SA-15
SAFETY
PARK MACHINE SAFELY

• Unless the machine is not correctly parked, any

• Park the machine on solid level surface to prevent the

HANDLE FLUIDS SAFELY --- AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur, possibly
resulting in serious injury or death.

• Do not refuel the machine while smoking or when near

open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are

flammable. SA-018

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.

SA-019

SA-16
SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting

the machine on public roads.
• Provide an appropriate truck or trailer for transporting SA-624
the machine.
• Be sure to have a signal person.
• Take the following precautions when
loading/unloading the machine.
1. Select firm level ground.
2. Be sure to use a loading dock or ramp strong enough
to support the machine weight.
3. Ramps must be sufficient in width, length, and
strength. Be sure that the incline of the ramp is less
than 15 degrees.
4. Loading docks must be sufficient in width and
strength to support the machine and have a gradient
of less than 15 degrees.
5. Slowly drive the machine.
6. Avoid steering while driving up or down the ramp as it
is extremely dangerous. If steering is unavoidable,
first move back to the ground or flatbed, modify
traveling direction, and begin to drive again.
7. The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it.
8. Wedge the front and rear of tracks. Securely fasten
the machine to the trailer bed with chain or cables.
9. Do not operate any levers besides the travel levers
when driving up or down the ramp.
10.Prevent possible injury from machine tipping while the
upperstructure is rotating.
11.Keep the arm tucked under and rotate the
upperstructure slowly for best stability.

Refer to "transporting" chapter in this manual for details

SA-17
SAFETY
PRACTICE SAFE MAINTENANCE

• Inspection/maintenance work may produce hazardous

situations by contacting and/or accessing a part of body
to a moving, high pressure, and/or high temperature part
of the machine. To avoid serious personal injury or death,
follow the instructions described below.
• Thoroughly coordinate the working procedures to be
taken hereafter with the co-workers before beginning
work such as inspecting/servicing the machine, or
replacing the attachiment .
• Safely park the machine in accordance with the
instructions for “Park Machine Safely.”
• Keep the work area clean and orderly.
• Attach a “DO NOT OPERATE” tag in an easy-to-see
SA-028
location such as on a door or a control lever.
• If moisture permeates into the electrical system,
malfunction and/or erroneous movement of the
machine may result. Do not clean sensors, cable
connectors, and the cab inside using water and/or
steam.
• Wait to begin to work until the engine and hydraulic oil
temperatures have cooled down to the safety range.
• In case inspection/maintenance must be performed 90 to 110°
with the engine runnning, be sure to appoint an
overseer.
• Never lubricate or service the machine while moving it.
• Repair the cracked windowpane before servicing the
machine. Failure to do so may cause personal injury. SA-268

• Whe raising the machine above the ground using the

front attachment function, maintain the angle between
the boom and the arm in the range of 90 to 110°.
Never allow anyone to enter under the machine raised
with the front attachment function.
• In case working under the machine raised above the
ground is unavoidably required, securely hold the
machine with stays or blocks strong enough to support
the machine weight.
• Never work under the raised bucket.
• Keep all parts in good condition and properly installed.
• Always use the specified tools correctly.
• Always use a clean tool.
• Fix any damage found immediately. Replace worn or SA-527
broken parts.
• Remove any buildup of grease, oil, or debris.
• When cleaning parts, use a non-combustible cleaning
solvent. Never use an inflammable fluid such as
dieasel fuel, or gasoline.

SA-037

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

• Before performing any work on the machine, attach a

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing

the machine first.

• Always lower the attachment to the ground before you

SA-527

SA-19
SAFETY
STAY CLEAR OF MOVING PARTS

• Contact with moving parts can cause serious injury or

death due to amputation or entanglement.

• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating
parts.

SA-026

PREVENT PARTS FROM FLYING

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTINGS or

VALVE ASSEMBLIES.
• As pieces of parts may fly off, be sure to keep body
and face away from the valve.

• Travel reduction gears are under pressure.

SA-344

• GEAR OIL is hot. Wait for gear oil to cool, then

gradually loosen the air release plug to release
pressure.
• As pieces of parts may fly off, be sure to keep body
and face away from AIR RELEASE PLUG to avoid
injury.

SA-20
SAFETY
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent

falling accidents.
• Keep children and bystanders away from storage
areas.

SA-034

PREVENT BURNS

Hot spraying fluids:

• To prevent possible injury from hot spraying water,

Allow all pressure to be release before removing the

cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure by slowly removing the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also becomes hot
during operation.
The engine, hoses, lines and other parts become hot as
well.

• Wait for the oil and components to cool before starting

any maintenance or inspection work.

SA-225

SA-21
SAFETY
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids such as

• Periodically replace the rubber hoses.(Refer to the

Periodical Replacement Parts section.)

• Failure to periodically replace rubber hoses may cause a

fire, fluid injection into skin, or the front attachment to fall
SA-019
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.

• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines. Make sure that
all connectors are completely connected before
applying pressure.
• Search for leaks with a piece of cardboard; take care
SA-031

to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-22
SAFETY
PREVENT FIRES

Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires,
possibly resulting in personal injury or death.

• Check for missing or loose clamps, kinked hoses,

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

SA-23
SAFETY
Precautions for Handling Flammables
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.

• Prevent fires by inspecting and cleaning the machine

Check Heat Shield Covers around Engine

Compartment
• If the engine compartment heat shield cover becomes
broken or lost, fire may break out.

• If the engine compartment heat shield cover becomes

broken or lost, repair or replace it before operating the
machine.

Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.

• Always check key switch function before operating the

SA-24
SAFETY
EVACUATING IN CASE OF FIRE

• If fire breaks out during machine operation, evacuate the

machine in the following way:

• Stop the engine by turning the key switch to the OFF

position.
• Use a fire extinguisher if there is time.
• Exit the machine using handrails and/or steps.
SA-393

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

• If you must operate the machine in a building, be sure

there is adequate ventilation. Either use an exhaust
pipe extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into the
area.

SA-016

SA-25
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and

• After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the

welded area still smoldering.

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

• Do not heat by welding, soldering, or using a torch

etc.

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Remove flammable fluids thoroughly with
nonflammable solvent before welding or flame cutting
pipes or tubes that contained flammable fluids.

SA-26
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.

• Remove paint before welding or heating.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away from

• When a terminal become loose, it may induce sparks.

Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

• Be sure to wear eye protection when checking

electrolyte specific gravity.

SA-27
SAFETY
PRECAUTIONS FOR HANDLING
REFRIGERANT

• If refrigerant is splashed into eyes or spilled onto skin,

blindness or a cold contact burn may result.

• Refer to the precautions described on the refrigerant

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants,
electrolyte, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides

• See your nearest Hitachi dealer for MSDS.

DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items as oil,
fuel, coolant, brake fluid, filters, and batteries.

• When draining fluid, use a leakproof container with a

such as oil, fuel, coolant, brake fluid, filters, and

batteries from your local environmental or recycling
center.

SA-28
SECTION 1
GENERAL

 CONTENTS 
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ........................................... W1-1-1

Group 2 Tightening
Tightening Torque Specification .............. W1-2-1
Torque Chart........................................... W1-2-2
Piping Joint............................................. W1-2-5
Periodic Replacement Parts.................. W1-2-10

Group 3 Painting
Painting .................................................. W1-3-1

Group 4 Bleeding Air

Bleed Air from Hydraulic Oil Tank............ W1-4-1

1MRW-1-1
(Blank)

1MRW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling

• Clean the Machine • Precautions for Disassembling

Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.

• Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the

area for disassembling work.

W1-1-1
GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and instal-
replace part. lation of the pump, swing motor, travel motor or cyl-
• Dirt or debris on the contact or sliding surfaces inder is done, bleed air from the hydraulic system in
may shorten the service life of the machine. Take the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic
clean and dry.
motor housing, damage to the motor
• If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, damage
• Be sure to use the designated tools to assemble to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor

• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.

W1-1-2
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
M502-07-055

W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A

1. In general, replace the floating seal with a new

one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W105-03-05-019
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.

(3) Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

Correct
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
Incorrect
compressed air.

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it W105-03-05-020
is installed correctly on the seal ring. Correct D Incorrect

(4) After installing the floating seal, check that seal a a

ring surface (A) is parallel with seal mating C
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.

b b

a=b a≠b

W110-03-05-004

W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of
Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Scoring Separation of W162-01-01-006

Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS

Bolt Dia. Wrench Size Torque

No. Descriptions Q’ty
mm mm N⋅m (kgf⋅m) (lbf⋅ft)
1. Engine rubber vibration insulator mounting nut 10 4 17 49 (5.0) (36)
2. Engine bracket mounting bolt 10 8 17 49 (5.0) (36)
3. Hydraulic oil tank mounting bolt 10 4 17 49 (5.0) (36)
4. Fuel tank mounting bolt 8 5 13 19.5 (2.0) (15)
5. ORS fittings for hydraulic hoses and piping 17 24.5 (2.5) (18)
UNF 7/16-20
19 29.5 (3.0) (22)
19 29.5 (3.0) (22)
UNF 9/16-18
22 39 (4.0) (29)
UNF 3/4-16 27 64 (6.5) (47)
6. Main pump mounting bolt 10 2 17 49 (5.0) (36)
Pump cover mounting bolt 10 5 17 49 (5.0) (36)
7. Control valve mounting bolt 8 4 13 19.5 (2.0) (15)
Stand mounting bolt 10 4 17 49 (5.0) (36)
8. Swing device mounting bolt 10 4 17 49 (5.0) (36)
9. Center joint mounting bolt 10 4 17 49 (5.0) (36)
10. Battery mounting bolt 6 1 10 5 (0.5) (3.5)
11. Swing bearing mounting bolt (Upperstructure) 10 12 17 49 (5.0) (36)
(Track) 10 12 17 49 (5.0) (36)
12. Travel device mounting bolt 10 16 8 (With a 49 (5.0) (36)
hexagon
socket)
Sprocket mounting bolt 10 18 8 (With a 49 (5.0) (36)
hexagon
socket)
13. Lower roller mounting bolt 14 12 22 175 (18.0) (130)
14. Cover mounting bolt 8 13 19.5 (2.0) (15)
10 17 49 (5.0) (36)
15. Pin stopper plate mounting bolt 8 13 19.5 (2.0) (15)
10 17 49 (5.0) (36)
16. Additional counterweight mounting bolt (op- 14 2 22 175 (18.0) (130)
tional)
17. Roll bar mounting bolts (optional) 12 4 19 108 (11.0) (80)
14 2 22 175 (18.0) (130)

NOTE: (1) Apply lubricant (i.e. white zinc B dis-

solved into spindle oil) to reduce their
friction coefficients.
(2) Remove rust, dirt, and dust before in-
stalling fasteners.

W1-2-1
GENERAL INFORMATION / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed. SA-040

Make sure to employ correct bolts and tighten them

correctly when assembling the machine or compo-
nents.

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092

Socket Bolt
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 29.5 (3.0) (22) 19.5 (2.0) (14.5) 9.8 (1.0) (7.2)
M10 17 8 64 (6.5) (47) 49 (5.0) (36) 19.5 (2.0) (14.5)
M12 19 10 108 (11) (80) 88 (9.0) (65) 34 (3.5) (25)
M14 22 12 175 (18) (129) 137 (14) (101) 54 (5.5) (40)
M16 24 14 265 (27) (195) 205 (21) (151) 78 (8.0) (58)
M18 27 14 390 (40) (290) 295 (30) (220) 118 (12) (87)
M20 30 17 540 (55) (400) 390 (40) (290) 167 (17) (123)
M22 32 740 (75) (550) 540 (55) (400) 215 (22) (159)
M24 36 930 (95) (690) 690 (70) (510) 275 (28) (205)
M27 41 1 370 (140) (1010) 1 030 (105) (760) 390 (40) (290)
M30 46 1 910 (195) (1410) 1 420 (145) (1050) 540 (55) (400)
M33 50 2 550 (260) (1880) 1 910 (195) (1410) 740 (75) (550)
M36 55 3 140 (320) (2320) 2 400 (245) (1770) 930 (95) (690)

W1-2-2
GENERAL INFORMATION / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.

Tighten from center and diagonally

Equally tighten upper and lower alternately Tighten diagonally

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W1-2-3
GENERAL INFORMATION / Tightening
Service Recommendations for Split Flange

IMPORTANT: 1. Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent. W105-01-01-015

2. Be sure to use only specified Incorrect

O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to W105-01-01-016
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes W105-01-01-008

tightening of one bolt fully before Correct Incorrect

tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.

Bend along edge sharply Do not bend it round

Nut and Bolt Locking

Correct Correct Incorrect
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while Bend along edge sharply
tightening, not while loosening. W105-01-01-009

Correct Correct Incorrect

• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.

Loosen Incorrect
Correct

Tighten

W105-01-01-010

W1-2-4
GENERAL INFORMATION / Tightening
PIPING JOINT 1 4 3 5 2

IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint

Metal sealing surfaces (4) and (5) of adaptor (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°

30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017

2. Scratches or other damage to

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.

Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5, 18)
19 19 29.5 (3.0, 22)
22 22 39 (4.0, 29)
27 27 64 (6.5, 47)
32 32 137 (14, 101)
36 36 175 (18, 129)
41 41 205 (21, 151)
37°female 17 14 24.5 (2.5, 18)
19 17 29.5 (3.0, 22)
22 19 39 (4.0, 29)
27 22 64 (6.5, 47)
32 27 137 (14, 101)
36 32 175 (18, 129)
41 36 205 (21, 151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.

W1-2-5
GENERAL INFORMATION / Tightening
Piping Joint

Pipe Joint (Metal Joint) 1 4 5 3 2

(Union Nut Wrench size 17 mm)

Metal sealing surfaces (3) (Metal) of pipe (2) and

adapter (1) seal pressure oil.

Take care not damage sealing surfaces when con-

necting / disconnecting pipe. M1M7-07-005

Tightening Torque Chart

Wrench Size (mm) 17
N⋅m 39
Tightening
(kgf⋅m) (4.0)
Torque
(lbf⋅ft) (29)

O-ring Seal Joint

7 6 9
O-ring (6) seats against the end face of adaptor (7) to
seal pressure oil.

IMPORTANT: 1. Be sure to replace O-ring (6) with

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly 8 10 Hose Fittings M104-07-033
in O-ring groove (8). Tightening
nut (9) with O-ring (6) displaced
will damage O-ring (6), resulting
in oil leakage. Wrench Size Tightening Torque
3. Take care not to damage O-ring mm
groove (8) or sealing surface Union Nut N⋅m (kgf⋅m, lbf⋅ft)
(10). 19 44 (4.5, 32.5)
Damage to O-ring (6) will cause 22 74 (7.5, 55)
oil leakage. 24 78 (8.0, 58)
4. If nut (9) is loose and oil is leak- 27 103 (10.5, 76)
ing, do not re-tighten nut (9). Re-
place O-ring (6) with a new one
and check that O-ring (6) is cor-
rectly seated in place, tighten nut
(9).

W1-2-6
GENERAL INFORMATION / Tightening
Quick Coupler

1. Connection Procedure
3 1
• While pulling and fully turning socket ring (1)
counterclockwise, insert socket ring (1) onto plug
(3) until the end face of socket ring (1) comes in
contact with plug (3).
• Release socket ring (1). Check that socket ring
(1) is slightly move backward by the spring force
and the coupler is held in position with balls (2). M1M7-07-006

Be sure to check that socket ring (1) has been 2

moved back fully to the right original position.

2. Disconnection Procedure
• While pulling and fully turning socket ring (1)
counterclockwise, disconnect the coupler. As no
check valve is provided in the coupler, take care
that oil may flow out of the coupler when the cou-
pler is disconnected.
• After the coupler is disconnected, plug the holes
with the exclusively prepared plugs.

CAUTION:

• Take care not to damage the joint surfaces when

disconnecting or connecting the coupler.
• Before disconnecting or connecting the coupler,
clean the coupler and its surroundings with a
cleaning solvent and completely wipe off the
cleaning solvent. Use extra care not to allow for-
eign matter such as dirt to enter the coupler.
• Disconnect or connect the coupler in the correct
procedure. Sufficiently check that no oil leak is
present after connecting the coupler.
• After connecting the coupler, check that that
socket ring (1) has been moved back fully to the
right original position.

W1-2-7
GENERAL INFORMATION / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018

Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5, 10.5) 34 (3.5, 25)
22 29.5 (3.0, 22) 49 (5.0, 36)
27 49 (5.0, 36) 93 (9.5, 69)
36 69 (7.0, 51) 157 (16, 116)
41 108 (11, 80) 205 (21, 151)
50 157 (16, 116) 320 (32.5, 235)
60 195 (20, 144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m (0.4 kgf⋅m, 3.2 lbf⋅ft)
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.4 to 5.1 lbf⋅ft)

M114-07-043 M114-07-042

W1-2-8
GENERAL INFORMATION / Tightening
Connecting Hose
Incorrect Correct

CAUTION: When replacing hoses, be sure to

use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
W105-01-01-011
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose Incorrect Correct
rupture or separation of fitting. Utilize Print
Rubbing Against
marks on hoses when installing to prevent Each Other
hose from being kinked.

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
W105-01-01-012
from rubbing against each other.
Incorrect Correct
Take care so that hoses do not come into Clamp Clamp
contact with moving parts or sharp objects.

Rubbing Against
Each Other

W105-01-01-013

Incorrect Correct

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-9
GENERAL INFORMATION / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace if
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct replace-
ment.

Periodic Replacement Parts Replacement Interval

Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Engine
Engine rubber vibration insulator Every 5 years
Floor mount rubber Every 5 years
Pump coupling Every 5 years
Pump suction hose Every 2 years
Pump delivery hose Every 2 years
Base Machine Swing hose Every 2 years
Auxiliary hose Every 2 years
Hydraulic
Oil cooler hose (C/V to oil cooler) Every 2 years
System
Boom cylinder line hose Every 2 years
Arm cylinder line hose Every 2 years
Front Attachment
Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-10
GENERAL / Painting
PAINTING

Surfaces to Be Painted Painting Color

Main surface of upperstructure 2.5GYO.12/1.0D (SP-424)
(Except the resinated covers) Dark Gray
Boom swing post, Boom swing cylinder
Counterweight
Cab, Canopy (Including the front panel)
Seat base, Floor plate
(Except the resinated covers)

Track, Blade 2.5GYO.12/1.0D (SP-424)

Dark Gray

Front attachment, Upperstructure cover part YR1-01 TAXI Yellow

Lever (Travel, Blade) N-10[N1.0]

Left stay Black

TAXI Yellow TAXI Yellow TAXI Yellow

Black Black
TAXI Yellow

Black

Dark (original)
Black
TAXI Yellow
Black Black Black

Dark Gray
(Swing CYL. included)

Dark Gray Black Dark Gray Dark Gray TAXI Yellow

(Blade CYL. included)
W1MP-01-03-001
TAXI Yellow

W1-3-1
GENERAL / Painting
(Blank)

W1-3-2
GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.
Do not turn the cap on hydraulic oil tank
quickly. The cap may fly off by internal
pressure. Release any remaining pressure
and remove the cap.

Preparation

1. Park the machine on a solid, level surface. Lower

the front attachment onto the ground.

2. Stop the engine. Loosen cap (1) on hydraulic oil

M502-07-055
tank (2) and release any remaining pressure.

3. Remove cap (1) on hydraulic oil tank (2).

4. Install a vacuum pump to the hole without cap (1).

Operate the vacuum pump and maintain negative
pressure in the hydraulic oil tank.
Run the vacuum pump continuously while
working.

2 1 M1MP-07-013

Vacuum Pump

Hose

3
W1MP-01-04-001

W1-4-1
GENERAL / Bleeding Air
(Blank)

W1-4-2
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
SECTION 2
UPPERSTRUCTURE

 CONTENTS 
Group 1 Main Frame Group 5 Pilot Valve
Remove and Install Main Frame ............. W2-1-1 Remove and Install Pilot Valve
(Zaxis10u-2 Only) ................................ W2-5-1
Group 2 Pump Device Disassemble Pilot Valve
Remove and Install Pump Device ........... W2-2-1 (Zaxis10u-2 Only) ................................ W2-5-8
Disassemble Pump Device ................. W2-2-10 Assemble Pilot Valve
Assemble Pump Device ........................ W2-2-14 (Zaxis10u-2 Only) .............................. W2-5-12
Structure of Pilot Pump ......................... W2-2-18
Group 6 Solenoid Valve
Group 3 Control Valve Remove and Install
Remove and Install Control Valve ........... W2-3-1 2-Spool Solenoid Valve ........................ W2-6-1
Disassemble and Assemble Disassemble 2-Spool Solenoid Valve .... W2-6-10
Control Valve..................................... W2-3-10 Assemble 2-Spool Solenoid Valve ......... W2-6-12
Disassemble Body ................................ W2-3-14 Remove and Install
Assemble Body ................................... W2-3-16 Air Bleed Solenoid Valve ................... W2-6-15
Disassemble Spool ............................... W2-3-20 Structure of Air Bleed solenoid Valve..... W2-6-19
Assemble Spool.................................... W2-3-26
Disassemble and Assemble
Check Valve ...................................... W2-3-32

Group 5 Swing Device

Remove and Install Swing Device ........... W2-4-1
Disassemble Swing Device ................... W2-4-10
Assemble Swing Device ....................... W2-4-12

1MRW-2-1
(Blank)

1MRW-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal

CAUTION: The front attachment (1) assembly

weight: 100 kg (220 lb)

1. Remove the front attachment (1) assembly.

(Refer to the Remove and Install Front Attachment
group on W4-1-1.) 1
W178-02-11-072

2. Open engine cover (2).

W1MP-02-04-001

3
CAUTION: The engine cover (2) assembly
weight: 25 kg (55 lb)

3. Hoist and hold the handles (2 places) on engine 4

cover (2). Remove lock pins (5) (2 used) from pins
(4) (2 used). Remove engine cover (2) from
bracket (3) while shifting to the left side. 5

5 4 W1MP-02-02-007

W2-1-1
UPPERSTRUCTURE / Main Frame
4. Remove mat (6) from main frame (7). 6

W1MP-02-04-002

5. Remove bolts (8) (2 used) from cover (9). Remove 8 9

cover (9) from main frame (7).
: 13 mm

6. Remove bolts (10) (2 used) from cover (11).

Remove cover (11) from main frame (7).
: 13 mm

7 11 10 W1MP-02-04-003

7. Remove bolts (12) (2 used) from cover (13).

Remove cover (13) from main frame (7). 12
: 17 mm

W1MP-02-02-008
7

W2-1-2
UPPERSTRUCTURE / Main Frame
8. Remove bolts (16) and (14) (2 used) from bracket 14 14
(15). Remove bolts (18) (2 used) from bracket (17).
Remove bracket (15) from the main frame.
: 10 mm, 13 mm
15

W1MP-02-01-001
18 17
ZAXIS10U-2

9. Remove hoses (21) (10 used) from center joint

19 20
(22). Cap the open ends of hoses and center joint
(22). Remove bolts (19) (2 used) from stopper
(20). Remove stopper (20) from center joint (22).
: 17 mm, 19 mm, 27 mm

W1MP-02-01-007

ZAXIS10U-2

W2-1-3
UPPERSTRUCTURE / Main Frame
10. Remove the caps (2 used) from the counterweight
(optional) mounting bolt (23) hole (2 places) on
main frame (7). Install eyebolts (M14) (2 used) in
the bolt (23) hole (2 places).

W1MP-02-01-003

23 7

11. Install pin (24) to swing post (25) with bolt (26) and
nut (27).
: 17 mm 24

W1MP-02-01-006
26, 27

CAUTION: Main frame (7) weight:

ZAXIS8-2: 695 kg (1532 lb)
ZAXIS10U-2: 830 kg (1830 lb)

12. Attach a nylon sling onto eyebolts (2 used) and pin

(24). Hoist and hold main frame (7) horizontally.

W1MP-02-01-005
7

W2-1-4
UPPERSTRUCTURE / Main Frame
13. Put the matching marks on main frame (7) and 7
outer race (28) of the swing bearing. Remove
bolts (29) (12 used) and washers (30) (12 used) 28
from outer race (28).
: 17 mm

CAUTION: Main frame (7) weight:

ZAXIS8-2: 695 kg (1532 lb)
ZAXIS10U-2: 830 kg (1830 lb)

14. Horizontally hoist and remove main frame (7) from 31 29, 30 W1MP-02-01-004

center frame (31).

W2-1-5
UPPERSTRUCTURE / Main Frame
Installation

1. Remove the caps (2 used) from the counterweight

(optional) mounting bolt (23) holes (2 places) on
main frame (7). Install eyebolts (M14) (2 used) in
the bolt (23) hole (2 places).

W1MP-02-01-003

23 7

2. Install pin (24) to swing post (25) with bolt (26) and
nut (27).
: 17 mm 24

W1MP-02-01-006
26, 27

CAUTION: Main frame (7) weight:

ZAXIS8-2: 695 kg (1532 lb)
ZAXIS10U-2: 830 kg (1830 lb)

3. Attach a nylon sling onto eyebolts (2 used) and pin

(24). Hoist and hold main frame (7) horizontally.

W1MP-02-01-005
7

W2-1-6
UPPERSTRUCTURE / Main Frame
4. Hoist main frame (7) horizontally. Align the
matching marks on main frame (7) and outer race 7
(28) of the swing bearing, and install to track
frame (31).
28

5. Install main frame (7) to outer race (28) of the

swing bearing with washers (30) (12 used) and
bolts (29) (12 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

31 29, 30 W1MP-02-01-004

6. Remove nut (27) from bolt (26). Remove bolt (26)

from swing post (25). Remove pin (24) from swing
post (25). 24
: 17 mm

W1MP-02-01-006
26, 27

W2-1-7
UPPERSTRUCTURE / Main Frame
7. Install the hoses (10 used) to center joint (22).
Install stopper (20) to center joint (22) with bolts 19 20
(18) (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
: 17 mm
21
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

ZAXIS10U-2 W1MP-02-01-007

8. Install bracket (15) to the main frame with bolts 14 14

(16) and (14) (2 used). Install bracket (17) to main
frame (7) with bolts (18) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 15
: 10 mm
: 3.5 N⋅m (0.35 kgf⋅m, 3 lbf⋅ft)
16

W1MP-02-01-001
18 17
ZAXIS10U-2

W2-1-8
UPPERSTRUCTURE / Main Frame
9. Install cover (13) onto main frame (7) with bolts 12
(12) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W1MP-02-02-008
7
10. Install cover (11) onto main frame (7) with bolts
(10) (2 used). 8 9
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

11. Install cover (9) onto main frame (7) with bolts (8)
(2 used).

7 11 10 W1MP-02-04-003

6
12. Install mat (6) to covers (11, 13).

W1MP-02-04-002

W2-1-9
UPPERSTRUCTURE / Main Frame

CAUTION: The engine cover (2) assembly

weight: 25 kg (44 lb) 2

13. Install engine cover (2) to main frame (7). Install

lock pins (5) (2 used) to pins (4) (2 used). Close
engine cover (2).

7
W1MP-02-04-001

5 4 W1MP-02-02-007

CAUTION: The front attachment (1) assembly

weight: 100 kg (220 lb)

14. Install the front attachment (1) assembly to main

frame (7). (Refer to the Remove and Install Front
Attachment group on W4-1-1.)

1
W178-02-11-072

W2-1-10
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

CAUTION: Release any pressure in the

1
hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Remove Main Pump

1. Open engine cover (1).

W1MP-02-04-001

2
2. Remove mat (2) from the main frame.

W1MP-02-04-002

3. Remove bolts (4) (2 used) from cover (3).

: 13 mm

4 3 W1MP-02-04-004

W2-2-1
UPPERSTRUCTURE / Pump Device
4. Remove bolt (5) from cover (6). Remove cover (6)
8 5
from the main frame.
: 13 mm

Main Frame W1MP-02-02-001

7
5. Remove hoses (7) (2 used) from main pump (8).
Loosen band (10). Remove hose (11) from main
pump (8). Cap the open ends.
: 19 mm

6. Remove bolts (9) (2 used) from main pump (8). 8

Remove main pump (8) from the engine.
: 17 mm

W1MP-02-02-002
11

W2-2-2
UPPERSTRUCTURE / Pump Device
Install Main Pump
7
1. Install main pump (8) to the engine with bolts (9)
(2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install hoses (7) (2 used) to main pump (8). Install 8

hose (11) to main pump (8). Tighten band (10) and
secure hose (11).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
9

W1MP-02-02-002
11

Main Pump 5
3. Install cover (6) onto the main frame with bolt (5).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

Main Frame W1MP-02-02-001

4. Install bolts (4) (2 used) to cover (3).

: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W1MP-02-04-004
4 3

W2-2-3
UPPERSTRUCTURE / Pump Device
2
5. Install mat (2) to the main frame.

W1MP-02-04-002

6. Close engine cover (1).

W1MP-02-04-001

W2-2-4
UPPERSTRUCTURE / Pump Device
Remove Pilot Pump

1. Open engine cover (1).

W1MP-02-04-001

CAUTION: The engine cover (1) assembly 2

weight: 25 kg (55 lb)

2. Remove lock pins (4) (2 used) from pins (3)

(2 used). Remove engine cover (1) from bracket 3
(2) while shifting to the left side.

4 3 W1MP-02-02-007

3. Remove bolts (5) (2 used) from bracket (2).

Remove bracket (2) from main frame (6). 2
: 17 mm

6 W1MP-02-02-008

W2-2-5
UPPERSTRUCTURE / Pump Device

W1MP-02-02-009

7, 8
4. Loosen band (8) on hose (7) and remove hose (7)
from pilot pump (9).

5. Remove hose (10) from pilot pump (9).

: 19 mm 9

10 W1MP-02-02-010

6. Remove bolts (12A to 12D) from pilot pump (9). 12A

12D
Remove pilot pump (9) from the engine.
: 12 mm
NOTE: Remove bolts (12B to 12D) from the belt
side of alternator. Remove bolt (12A) from 9
the pilot pump (9) side.

12B
12C

W1MP-02-02-011

W2-2-6
UPPERSTRUCTURE / Pump Device
Install Pilot Pump

W1MP-02-02-009

7, 8

1. Install pilot pump (9) to the engine with bolts (12A

to 12D).
: 12 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
9
NOTE: Install bolts (12B to 12D) from the belt side
of alternator. Install bolt (12A) from the pilot
pump (9) side.

2. Install hose (7) to pilot pump (9). Tighten band (8)

and secure hose (7).

3. Install hose (10) to pilot pump (9).

: 19 mm 10 W1MP-02-02-010
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

12A
12D

12B
12C

W1MP-02-02-011

W2-2-7
UPPERSTRUCTURE / Pump Device
4. Install bracket (2) to main frame (6) with bolts (5)
(2 used).
: 17 mm 2
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

6 W1MP-02-02-008

2
CAUTION: The engine cover (1) assembly
weight: 25 kg (55 lb)

5. Install engine cover (1) to bracket (2). Install lock 3

pins (4) (2 used) to pins (3) (2 used).

4 3 W1MP-02-02-007

6. Close engine cover (1).

W1MP-02-04-001

W2-2-8
UPPERSTRUCTURE / Pump Device
(Blank)

W2-2-9
UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
10

5C
6C
7

6D
5D
4B
3

2
1
8 13

9
4A
5A
6A

11A

11B W1MP-02-02-003

1 - Retaining Ring 5A to 5D - Gasket (4 Used) 9 - Ball (4 Used) 13 - Bolt (4 Used)

2 - Oil Seal 6A to 6D - Side Plate (4 Used) 10 - Body
3 - Front Cover 7 - Drive Gear 11A, 11B - Driven Gear (2 Used)
4A, 4B - Gasket (2 Used) 8 - Driven Gear 12 - Rear Cover

W2-2-10
UPPERSTRUCTURE / Pump Device
Disassemble Pump Device

IMPORTANT: Front cover (3), body (10) and rear Matching Mark
cover (12) are symmetrical. Before
disassembling, put the matching
marks on body (10) and covers (3,
Matching Mark
12).
1. Put the matching marks on each mating position
between front cover (3) and body (10), and
between body (10) and rear cover (12).

IMPORTANT: When removing rear cover (12) from 12

body (10), balls (9) (2 used) are
removed together. Do not lose balls
(9) (2 used). 10
W1MP-02-02-004
2. Remove bolts (13) (4 used) from rear cover (12). 3
Remove rear cover (12) from body (10).
: 13 mm

3. Remove gasket (4A) from rear cover (12).

4. Remove side plate (6A) from the rear cover (12)

side of body (10). Remove gasket (5A) from side
plate (6A).
5A

IMPORTANT: Driven gears (11A, 11B) are in 6A

symmetric position. Put the
matching marks on driving side, 11A
driven side for installation direction
for assembling.
5. Put the matching marks on shaft on the
installation side of rear cover (12) of driven gears
(11A, 11B). Remove driven gears (11A,11B) from Matching Mark
body (10).

6B 11B
W1MP-02-02-005

W2-2-11
UPPERSTRUCTURE / Pump Device

5C
6C
7

6D
5D
4B
3

2
1
8

W1MP-02-02-003

W2-2-12
UPPERSTRUCTURE / Pump Device
6. Remove side plate (6B) from body (10). Remove
gasket (5B) from side plate (6B).

IMPORTANT: When removing front cover (3) from

body (10), balls (9) (2 used) are
removed together. Do not lose balls
(9) (2 used).
7. Remove front cover (3) from body (10). Remove
balls (9) (2 used), gasket (4B), retaining ring (1)
and oil seal (2) from front cover (3).

8. Remove side plate (6D) from body (10). Remove

gasket (5D) from side plate (6D).

IMPORTANT: Driven gears (8) are in symmetric

position. Put the matching marks for
installation direction for assembling.
9. Put the matching marks on shaft of front cover (3)
side of driven gear (8). Remove drive gear (7) and 7
driven gear (8) from body (10).
6D
10. Remove side plate (6C) from body (10). Remove
5D
gasket (5C) from side plate (6C). 5C
6C

8 W1MP-02-02-006
Matching Mark

W2-2-13
UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE

3 7 4B 6D 6C 10 6B 11A 6A

1
13

T1MP-03-01-003

9 5D 8 5C 5B 11B 4A

1 - Retaining Ring 5A to 5D - Gasket (4 Used) 9 - Ball (4 Used) 13 - Bolt (4 Used)

2 - Oil Seal 6A to 6D - Side Plate (4 Used) 10 - Body
3 - Front Cover 7 - Drive Gear 11A, 11B - Driven Gear (2 Used)
4A, 4B - Gasket (2 Used) 8 - Driven Gear 12 - Rear Cover

W2-2-14
UPPERSTRUCTURE / Pump Device
Assemble Pump Device

IMPORTANT: Install side plates (6A to 6D) with the

surface without gaskets (5A to 5D)
groove facing to the gears (7, 8, 11A,
11B) side.
Replace gaskets (5A to 5D), (4A, 4B)
and oil seal (2) with the new ones.
Install gaskets (5A to 5D) with the flat
surface facing to the outer side of
groove, and the open side facing to
the inlet port side of body (10).
1. Apply grease onto new gasket (5C). Install gasket
(5C) to side plate (6C). Install side plate (6C) to
body (10) with the gasket (5C) groove side facing
to the rear cover (12) side. Non-Flat Surface

2. Install drive gear (7) to body (10).

7
IMPORTANT: Install driven gear (8) with the
matching marks facing to the front
cover (3) side. If the installation 6D
direction is opposite, the pump 5D 5C
performance will decreases. 6C
3. Install driven gear (8) to body (10) with the
matching mark on driven gear (8) facing to the
front cover (3) side.
8 W1MP-02-02-006
4. Apply grease onto new gasket (5D). Install gasket Matching Mark
(5D) to side plate (6D). Install side plate (6D) to body Flat Surface
(10) with the gasket (5D) groove side facing to the
front cover (3) side.

W2-2-15
UPPERSTRUCTURE / Pump Device

3 10 6B 11A 6A

1
13

T1MP-03-01-003

9B 5B 11B 4A

W2-2-16
UPPERSTRUCTURE / Pump Device
5. Apply grease onto new gasket (5B). Install gasket
(5B) to side plate (6B). Install side plate (6B) to 5A
body (10) with the gasket (5B) groove side facing
6A
to the front cover (3) side.
11A
6. Install driven gears (11A, 11B) to body (10) with
the matching marks facing to the rear cover (12)
side.

7. Apply grease onto new gasket (5A). Install gasket Matching Mark
(5A) to side plate (6A). Install side plate (6A) to
body (10) with the gasket (5A) groove side facing
to the rear cover (12) side.

6B 11B
8. Apply grease onto new gasket (4B) and balls (9B) W1MP-02-02-005

(2 used). Install gasket (4B) and balls (9) (2 used) 5B

to front cover (3). Install front cover (3) to body
(10).

9. Install front cover (3), body (10) and rear cover

(12) with bolts (13) (4 used).
: 13 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: Do not damage the dust lip and the

main lip parts of oil seal (2) when
installing.
10. Apply grease onto the inside (dust lip and main lip
parts) of new oil seal (2). Install oil seal (2) to front
cover (3).

11. Install retaining ring (1) to front cover (3).

W2-2-17
UPPERSTRUCTURE / Pump Device
STRUCTURE OF PILOT PUMP

1 2

2
12

3
W1MP-02-02-012

2 2 10 9 8

Wrench Size Tightening Torque

Item Part Name Q’ ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Housing 1
2 Bushing 4
3 Bolt 4 13 27.5 (2.8) 20
4 Drive Gear 1
5 Driven Gear 1
6 Plate B 1
7 Ring 1
8 Cover 1
9 Ring 2
10 Plate A 1
11 Retaining Ring 1
12 Oil Seal 1

W2-2-18
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE 1

CAUTION: Release any pressure in the 3

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal
2
1. Remove screws (1) (10 used) from the top, right
and left of covers (2, 3). Remove cover (3) from
the lever stand.

W1MP-02-03-006

2
1

1
W1MP-02-03-007

2. Loosen nuts (5) (2 used) from the travel levers (2

used). Remove grips (4) (2 used) from the travel
levers (2 used) by turning counterclockwise. 4
: 17 mm

W1MP-02-03-008
Travel Lever

W2-3-1
UPPERSTRUCTURE / Control Valve
3. Remove grip (6) from side frame extend/retract
lever (7). Remove cover (2) from the lever stand.

W1MP-02-03-007

4. Remove connector (8) from the cover (3) side.

W1MP-02-03-009
ZAXIS10U-2

5. Remove bolts (11) (2 used) from bracket (10).

Remove cover (9) from bracket (10).
: 13 mm

10 9 W1MP-02-03-010

ZAXIS10U-2

W2-3-2
UPPERSTRUCTURE / Control Valve

6. Remove bolts (13, 17) (2 used for each) from

brackets (14, 16). Remove cover (15) from
brackets (14, 17).
: 13 mm
Hose
7. Remove the hose from the control valve. Attach
an identification tag onto the removed hose for
assembling. Cap the open ends. 13
: 19 mm, 22 mm, 27 mm
NOTE: Number of Hose 17
ZAXIS8-2：24 used
ZAXIS10U-2：32 used

8. Remove lock pin (20) from direct-operated spool 14

(19) in the control valve. Remove the link parts
from spool (19). 16 15 W1MP-02-03-011

ZAXIS10U-2
NOTE: Direct-Operated Spool
ZAXIS8-2：10 used
ZAXIS10U-2：6 used 19, 20 19, 20

19, 20
ZAXIS8-2 W1MN-02-03-006

19, 20

19, 20
ZAXIS10U-2 W1MP-02-03-012

W2-3-3
UPPERSTRUCTURE / Control Valve
9. Remove sems bolts (21) (4 used) from bracket
(22). Remove the control valve from the machine.
: 13 mm

21 22

W1MP-02-03-009
21
ZAXIS10U-2

W2-3-4
UPPERSTRUCTURE / Control Valve
Installation

1. Install the control valve to bracket (22) with sems

bolts (21) (4 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf ft)
21

21 22

2. Install the link parts to direct-operated spool (19)

with lock pin (20). 21 W1MP-02-03-009

NOTE: Direct-Operated Spool ZAXIS10U-2

ZAXIS8-2：10 used
ZAXIS10U-2：6 used
19, 20 19, 20

19, 20
ZAXIS8-2 W1MN-02-03-006

19, 20

19, 20
ZAXIS10U-2 W1MP-02-03-012

W2-3-5
UPPERSTRUCTURE / Control Valve
3. Install the hose to the control valve.
NOTE: Number of Hose
ZAXIS8-2：24 used
ZAXIS10U-2：32 used

: 19 mm Hose
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 13
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft) 17

4. Install cover (15) onto brackets (14, 16) with bolts

(13, 17) (2 used for each).
: 13 mm 14
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
16 15 W1MP-02-03-011

5. Install cover (9) onto bracket (10) with bolts (11)

(2 used). ZAXIS10U-2
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

10 9 W1MP-02-03-010
ZAXIS10U-2

W2-3-6
UPPERSTRUCTURE / Control Valve
6. Install connector (8) to the cover (3) side.

W1MP-02-03-009

ZAXIS10U-2
7. Install covers (2, 3) onto the lever stand with
screws (1) (10 used). 1

W1MP-02-03-006

2
1

1
W1MP-02-03-007

W2-3-7
UPPERSTRUCTURE / Control Valve
8. Install grip (6) to side frame extend/retract lever
(7).

W1MP-02-03-007

9. Install grips (4) (2 used) to the travel levers (2

used) by turning clockwise. Tighten nuts (5) (2
used).
: 17 mm 4

W1MP-02-03-008

W2-3-8
UPPERSTRUCTURE / Control Valve
(Blank)

W2-3-9
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE CONTROL VALVE
ZAXIS8-2
1

4 2
8

5
6

5 P1
10
12
5
6
Boom Swing
5
11 13

5
5 6
6 14
5 Boom
5 Bucket
5
15 6
16
5 Travel (Right)
5
6 13

5 Blade
18 5
5
6 11
Auxiliary
5 19 5

Travel (Left)
6 5
20 5

21 Side Frame
6 5
3
5
22
Arm
6 5

Swing
6 5
21
2
W1MN-02-03-001
P2

W2-3-10
UPPERSTRUCTURE / Control Valve

23
24

25
26
27
28 29

31
27
32

46
33
33
28
34
36 to 41, 43 to 45 35

9, 10, 12 to 14, 16 to 20
W1MN-02-03-004

1- Rod (3 Used) 13 - Body (Travel) (2 Used) 25 - Bolt (10 Used) 36 - Spool (Boom Swing)
2- Nut (6 Used) 14 - Body (Blade) 26 - Spring (10 Used) 37 - Spool (Boom)
3- Main Relief Valve (2 Used) 15 - O-Ring 27 - Spring Seat (20 Used) 38 - Spool (Bucket)
4- Body (P1) 16 - Body (Auxiliary) 28 - Backup Ring (20 Used) 39 - Spool (Travel) (2 Used)
5- O-Ring (22 Used) 18 - Body (Side Frame) 29 - Plug (10 Used) 40 - Spool (Blade)
6- O-Ring (11 Used) 19 - Body (Arm) 30 - O-Ring (10 Used) 41 - Spool (Auxiliary)
8- Make-Up Valve 20 - Body (Swing) 31 - Spring (8 Used) 43 - Spool (Side Frame)
9- Body (Boom Swing) 21 - Overload Relief Valve (2 Used) 32 - Check Valve (8 Used) 44 - Spool (Arm)
10 - Body (Boom) 22 - Body (P2) 33 - O-Ring (20 Used) 45 - Spool (Swing)
11 - Overload Relief Valve (2 Used) 23 - Socket Bolt (20 Used) 34 - Spool Holder (10 Used) 46 - Spool Holder (10 Used)
12 - Body (Bucket) 24 - Cover (10 Used) 35 - Screw (20 Used)

W2-3-11
UPPERSTRUCTURE / Control Valve

ZAXIS10U-2
1

4 2
8

5
6

5 P1
10
12
5
6 Boom Swing
5
11 13

5
5 6
6 14
5 Boom
5 Bucket
5
15 6
16
5
Travel (Right)
5
6 13

5 Blade
18 5
5
6 11
Auxiliary
5 19 5

Travel (Left)
6 5
20 5

21 Side Frame
6 5
3
5
22
Arm
6 5

Swing
6 5
21
2
W1MN-02-03-001
P2

W2-3-12
UPPERSTRUCTURE / Control Valve

23
24

25
26
27
28 29

31
27
32

46
33
33
36, 40 to 43 28
34
35

12 to 14, 16, 18
W1MN-02-03-004

47
48
29

33
37, 38, 44, 45

47
55 54
33
9, 10, 19, 20 53
52
51
50
W1MP-02-03-004
49
1- Rod (3 Used) 15 - O-Ring 29 - Plug (10 Used) 43 - Spool (Side Frame)
2- Nut (6 Used) 16 - Body (Auxiliary) 30 - O-Ring (10 Used) 44 - Spool (Arm)
3- Main Relief Valve (2 Used) 18 - Body (Side Frame) 31 - Spring (8 Used) 45 - Spool (Swing)
4- Body (P1) 19 - Body (Arm) 32 - Check Valve (8 Used) 46 - Spool Holder (6 Used)
5- O-Ring (22 Used) 20 - Body (Swing) 33 - O-Ring (20 Used) 47 - Socket Bolt (16 Used)
6- O-Ring (11 Used) 21 - Overload Relief Valve (2 Used) 34 - Spool Holder (6 Used) 48 - Cover (4 Used)
8- Make-Up Valve 22 - Body (P2) 35 - Screw (12 Used) 49 - Cover (4 Used)
9- Body (Boom Swing) 23 - Socket Bolt (12 Used) 36 - Spool (Boom Swing) 50 - Bolt (4 Used)
10 - Body (Boom) 24 - Cover (6 Used) 37 - Spool (Boom) 51 - Spring Seat (4 Used)
11 - Overload Relief Valve (2 Used) 25 - Bolt (6 Used) 38 - Spool (Bucket) 52 - Spring (4 Used)
12 - Body (Bucket) 26 - Spring (6 Used) 39 - Spool (Travel) (2 Used) 53 - Spring Seat (4 Used)
13 - Body (Travel) (2 Used) 27 - Spring Seat (12 Used) 40 - Spool (Blade) 54 - Check Valve (Bucket
only)
14 - Body (Blade) 28 - Backup Ring (12 Used) 41 - Spool (Auxiliary) 55 - Spring (Bucket only)

W2-3-13
UPPERSTRUCTURE / Control Valve
DISASSEMBLE BODY
ZAXIS8-2
1

4 2
8

5
6

5 P1
10
12
5
6
Boom Swing
5
11 13

5
5 6
6 14
5 Boom
5 Bucket
5
15 6
16
5 Travel (Right)
5
6 13

5 Blade
18 5
5
6 11
Auxiliary
5 19 5

Travel (Left)
6 5
20 5

21 Side Frame
6 5
3
5
22
Arm
6 5

Swing
6 5
21
2
W1MN-02-03-001
P2

W2-3-14
UPPERSTRUCTURE / Control Valve
Disassemble Body
• The body compositions of ZAXIS 8-2 and 10U-2 are IMPORTANT: Put each body (4, 9, 10, 12, 14, 16, 18,
same. Disassembly of ZAXIS 8-2 is explained as an 19, 20, 22) and (13) (2 used) in
example. removed order. Although each body
1. Remove main relief valves (3) (2 used) from look same, the spools are different.
bodies (4, 22). 7. Separate bodies (4, 9, 10, 12, 14, 16, 18, 19, 20,
: 22 mm 22) and (13) (2 used) from the control valve
assembly. Remove O-rings (5) (22 used), (6) (11
2. Remove make-up valve (8) from body (9). used) and (15) between each body.
: 22 mm NOTE: O-ring (15) is installed between bodies (14
and 16).
3. Remove overload relief valves (11) (2 used) from
bodies (10, 19).
: 22 mm

IMPORTANT: Do not confuse overload relief

valves (11, 21). Although overload
relief valves (11, 21) look same, the
set pressures are different.
4. Remove overload relief valves (21) (2 used) from
body (20).
: 22 mm

5. Place the control valve assembly on the

workbench with port holes (A1 to A10, B1 to B10,
P1 and P2) facing upward.

6. Remove nuts (2) (3 used) from rods (1) (3 used) at

the body (4) side. Remove rods (1) (3 used) from
the control valve assembly.
: 13 mm

W2-3-15
UPPERSTRUCTURE / Control Valve
ASSEMBLE BODY
ZAXIS8-2

21 19 18 13 8

3 3

4
22

1
1
2
2

20 21 11 16 14 13 12 11 W1MN-02-03-002

W1MN-02-03-003

1- Rod (3 Used) 6- O-Ring (11 Used) 12 - Body (Bucket) 18 - Body (Side Frame)
2- Nut (6 Used) 8- Make-Up Valve 13 - Body (Travel) (2 Used) 19 - Body (Arm)
3- Main Relief Valve (2 Used) 9- Body (Boom Swing) 14 - Body (Blade) 20 - Body (Swing)
4- Body (P1) 10 - Body (Boom) 15 - O-Ring 21 - Overload Relief Valve (2 Used)
5- O-Ring (22 Used) 11 - Overload Relief Valve (2 Used) 16 - Body (Auxiliary) 22 - Body (P2)

W2-3-16
UPPERSTRUCTURE / Control Valve
ZAXIS10U-2
21 19 18 13 8

3 3

4
22

1
1
2
2

20 21 11 16 14 13 12 11 T1MP-03-03-001

W1MP-02-03-003

W2-3-17
UPPERSTRUCTURE / Control Valve
ZAXIS8-2

21 19 18 13 8

3 3

4
22

9
1
1
2
2

20 21 11 16 14 13 12 11 W1MN-02-03-002

W1MN-02-03-003

W2-3-18
UPPERSTRUCTURE / Control Valve
Assemble Body 7. Install make-up valve (8) to body (9).
• The body compositions of ZAXIS 8-2 and 10U-2 are : 22 mm
same. Disassembly of ZAXIS 8-2 is explained as an : 39.2 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
example.
IMPORTANT: While Checking the installation 8. Install main relief valves (3) (2 used) to bodies (4,
direction and order, arrange each 22).
body (4, 9, 10, 12, 14, 16, 18, 19, 20, : 22 mm
22) and (13) (2 used) on the : 39.2 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
workbench.
1. Apply grease onto O-rings (5) (2 used) and (6).
Install O-rings (5) (2 used) and (6) to body (22).

2. Install body (20) to body (22).

IMPORTANT: Install O-ring (5) besides O-rings (6)

and (5) (2 used) between bodies (14
and 16).
3. Repeat steps 1 and 2, and install all bodies
(20, 19, 18, 13, 16, 14, 13, 12, 10, 9 and 4).

4. Secure the control valve assembly with rods (1) (3

used) and nuts (2) (3 used).
: 13 mm
: 14.7 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

IMPORTANT: Do not confuse overload relief

valves (11, 21). Although overload
relief valves (11, 21) look same, the
set pressures are different.
5. Install overload relief valves (21) (2 used) to body
(20).
: 22 mm
: 39.2 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)

6. Install overload relief valves (11) (2 used) to

bodies (10, 19).
: 22 mm
: 39.2 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)

W2-3-19
UPPERSTRUCTURE / Control Valve
DISASSEMBLE SPOOL
ZAXIS8-2

45 44 43 42 40 39 38 37

W1MN-02-03-003
22 20 19 18 13 41 16 14 13 12 10 36

23
24

25
26
27
28

46
33
33
28
36 to 45 34
35

9, 10, 12 to 14, 16, 18 to 20

W1MN-02-03-004

W2-3-20
UPPERSTRUCTURE / Control Valve

4- Body (P1) 19 - Body (Arm) 28 - Backup Ring (20 Used) 40 - Spool (Blade)
9- Body (Boom Swing) 20 - Body (Swing) 33 - O-Ring (20 Used) 41 - Spool (Auxiliary)
10 - Body (Boom) 22 - Body (P2) 34 - Spool Holder (10 Used) 43 - Spool (Side Frame)
12 - Body (Bucket) 23 - Socket Bolt (20 Used) 35 - Screw (20 Used) 44 - Spool (Arm)
13 - Body (Travel) (2 Used) 24 - Cover (10 Used) 36 - Spool (Boom Swing) 45 - Spool (Swing)
14 - Body (Blade) 25 - Bolt (10 Used) 37 - Spool (Boom) 46 - Spool Holder (10 Used)
16 - Body (Auxiliary) 26 - Spring (10 Used) 38 - Spool (Bucket)
18 - Body (Side Frame) 27 - Spring Seat (20 Used) 39 - Spool (Travel) (2 Used)

W2-3-21
UPPERSTRUCTURE / Control Valve
ZAXIS10U-2

45 44 43 39 40 39 38 37

W1MP-02-03-003
22 20 19 18 13 41 16 14 13 12 10 36

Direct-Operated Spool
23
24

25
26
27
28

46
33
33
28
36, 39 to 41, 43 34
35

9, 13, 14, 16, 18

W1MN-02-03-004

W2-3-22
UPPERSTRUCTURE / Control Valve
Hydraulic Pilot Spool

45
47
48

33
37, 38, 44, 45

47
55 54
33
10, 12, 19, 20 53
52
51
50
W1MP-02-03-004
49

4- Body (P1) 22 - Body (P2) 36 - Spool (Boom Swing) 47 - Socket Bolt (16 Used)
9- Body (Boom Swing) 23 - Socket Bolt (12 Used) 37 - Spool (Boom) 48 - Cover (4 Used)
10 - Body (Boom) 24 - Cover (6 Used) 38 - Spool (Bucket) 49 - Cover (4 Used)
12 - Body (Bucket) 25 - Bolt (6 Used) 39 - Spool (Travel) (2 Used) 50 - Bolt (4 Used)
13 - Body (Travel) (2 Used) 26 - Spring (6 Used) 40 - Spool (Blade) 51 - Spring Seat (4 Used)
14 - Body (Blade) 27 - Spring Seat (12 Used) 41 - Spool (Auxiliary) 52 - Spring (4 Used)
16 - Body (Auxiliary) 28 - Backup Ring (12 Used) 43 - Spool (Side Frame) 53 - Spring Seat (4 Used)
18 - Body (Side Frame) 33 - O-Ring (20 Used) 44 - Spool (Arm) 54 - Check Valve (Bucket only)
19 - Body (Arm) 34 - Spool Holder (6 Used) 45 - Spool (Swing) 55 - Spring (Bucket only)
20 - Body (Swing) 35 - Screw (12 Used) 46 - Spool Holder (6 Used)

W2-3-23
UPPERSTRUCTURE / Control Valve

Direct-Operated Spool

23
24

25
26
27
28

46
33
33
28
36, 39 to 41, 43 34
35

9, 13, 14, 16, 18

W1MN-02-03-004

Hydraulic Pilot Spool

45
47
48

33
37, 38, 44, 45

47
55 54
33
10, 12, 19, 20 53
52
51
50
W1MP-02-03-004
49

W2-3-24
UPPERSTRUCTURE / Control Valve
Disassemble Spool

There are a direct-operated type and a hydraulic pilot

type for the spool. All spools of ZAXIS8-2 are
direct-operated. The spools of ZAXIS10U-2 are both
direct-operated and hydraulic pilot type.
The inner compositions of each body are similar. The
spools of each body are different.

Disassemble Direct-Operated Spool Disassemble Hydraulic Pilot Spool

Disassembly of spool (36) of body (9) is explained as Disassembly of spool (37) of body (10) is explained
an example. here.
1. Remove socket bolts (23) (2 used) from cover 1. Remove socket bolts (47) (2 used) from cover
(24). Remove cover (24) from body (9). (49). Remove O-ring (33) and cover (49) from
: 4 mm body (10).
: 4 mm
2. Remove screws (35) (2 used) from spool holder
(34). Remove spool holder (34), backup ring (28) 2. Remove socket bolts (47) (2 used) from cover
and O-ring (33) from body (9). (48). Remove O-ring (33) and cover (48) from
body (10).
3. Remove the spool assembly from the cover (24) : 4 mm
mounting-side of body (9) by turning. Remove
spool holder (46), backup ring (28) and O-ring 3. Remove the spool assembly from the cover (49)
(33) from body (9). mounting-side of body (10) by turning.

IMPORTANT: Remove bolt (25) while holding IMPORTANT: Remove bolt (50) while holding
spring seat (27). spring seat (51).
4. Clamp the spool assembly by using wooden 4. Clamp the spool assembly by using wooden
pieces. Remove bolt (25) from spool (36). pieces. Remove bolt (50) from the spool assembly.
Remove spring seats (27) (2 used) and spring Remove spring seats (51, 53) and spring (52)
(26) from spool (36). from spool (37).
: 3 mm : 3 mm

W2-3-25
UPPERSTRUCTURE / Control Valve
ASSEMBLE SPOOL
ZAXIS8-2

45 44 43 42 40 39 38 37

W1MN-02-03-003
22 20 19 18 13 41 16 14 13 12 10 36

28 33

W1MN-02-03-005
23 24 27 26 27 46 36 to 43 33 28 34
9, 10, 12 to14, 16, 18, 19, 20

W2-3-26
UPPERSTRUCTURE / Control Valve

4- Body (P1) 19 - Body (Arm) 28 - Backup Ring (20 Used) 40 - Spool (Blade)
9- Body (Boom Swing) 20 - Body (Swing) 33 - O-Ring (20 Used) 41 - Spool (Auxiliary)
10 - Body (Boom) 22 - Body (P2) 34 - Spool Holder (10 Used) 43 - Spool (Side Frame)
12 - Body (Bucket) 23 - Socket Bolt (20 Used) 35 - Screw (20 Used) 44 - Spool (Arm)
13 - Body (Travel) (2 Used) 24 - Cover (10 Used) 36 - Spool (Boom Swing) 45 - Spool (Swing)
14 - Body (Blade) 25 - Bolt (10 Used) 37 - Spool (Boom) 46 - Spool Holder (10 Used)
16 - Body (Auxiliary) 26 - Spring (10 Used) 38 - Spool (Bucket)
17 - Body (Side Frame) 27 - Spring Seat (20 Used) 39 - Spool (Travel) (2 Used)

W2-3-27
UPPERSTRUCTURE / Control Valve
ZAXIS10U-2

45 44 43 39 40 39 38 37

W1MP-02-03-003
22 20 19 18 13 41 16 14 13 12 10 36

Direct-Operated Spool

28 33

W1MN-02-03-005
23 24 27 26 27 46 36, 39 to 41, 33 28 34
43
9, 13, 14, 16, 18

W2-3-28
UPPERSTRUCTURE / Control Valve
Hydraulic Pilot Spool

54, 55 47

W1MP-02-03-005

48 47 33 37, 38, 44, 45 10, 12, 19, 33 53 52 49 51 50

W2-3-29
UPPERSTRUCTURE / Control Valve
Direct-Operated Spool

28 33

W1MN-02-03-005
23 24 27 26 27 46 36, 39 to 41, 33 28 34
43
9, 13, 14, 16, 18

Hydraulic Pilot Spool

54, 55 47

W1MP-02-03-005

48 47 33 37, 38, 44, 45 10, 12, 19, 33 53 52 49 51 50

W2-3-30
UPPERSTRUCTURE / Control Valve
Assemble Direct-Operated Spool Assemble Hydraulic Pilot Spool
Assembly of spool (36) of body (9) is explained as an Assembly of spool (38) of body (12) is explained as
example. an example.

1. Clamp spool (36) by using wooden pieces in a 1. Clamp spool (38) by using wooden pieces in a
vise. Install spring seats (27) (2 used) and spring vise. Install spring seats (51, 53) and spring (52)
(26) to spool (36). Apply LOCTITE #242 onto bolt to spool (38). Apply LOCTITE #242 onto bolt (50).
(25). Install bolt (25) to spool (36). Install bolt (50) to spool (38).
: 3 mm : 3 mm
: 3.92 to 4.9 N⋅m : 3.92 to 4.9 N⋅m
(0.4 to 0.5 kgf⋅m, 3 to 4 lbf⋅ft) (0.4 to 0.5 kgf⋅m, 3 to 4 lbf⋅ft)

2. Install the spool assembly to the cover (24) 2. Install the spool assembly from the cover (49)
mounting side of body (9) by turning. mounting side of body (12) by turning.

3. Install O-ring (33) and backup ring (28) to body (9). 3. Install O-ring (33) to body (12). Install cover (48)
onto body (12) with screws (47) (2 used).
4. Install spool holder (34) to body (9) with screws : 4 mm
(35) (2 used). : 1.96 to 2.94 N⋅m
: 1.96 to 2.94 N⋅m (0.2 to 0.3 kgf⋅m, 1 to 2 lbf⋅ft)
(0.2 to 0.3 kgf⋅m, 1 to 2 lbf⋅ft)
4. Install O-ring (33) to body (12). Install cover (49)
5. Install cover (24) onto body (9) with socket bolts onto body (12) with screws (47) (2 used).
(23) (2 used). : 4 mm
: 4 mm : 5.88 to 6.86 N⋅m
: 5.88 to 6.86 N⋅m (0.5 to 0.7 kgf⋅m, 4 to 5 lbf⋅ft)
(0.6 to 0.7 kgf⋅m, 4 to 5 lbf⋅ft)

W2-3-31
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE CHECK VALVE

55 54

9, 10, 12 to 20

W1MP-02-03-004

31 29 32 30 54, 55

W1MP-02-03-005

9, 10, 12 to 20

9- Body (Boom Swing) 16 - Body (Auxiliary) 29 - Plug (10 Used) 32 - Check Valve (8 Used)
12 - Body (Bucket) 18 - Body (Side Frame) 30 - O-Ring (10 Used) 54 - Check Valve (Bucket only)
13 - Body (Travel) (2 Used) 19 - Body (Arm) 31 - Spring (8 Used) 55 - Spring (Bucket only)
14 - Body (Blade) 20 - Body (Swing)

W2-3-32
UPPERSTRUCTURE / Control Valve
Disassemble and Assemble Check Valve

The check valves are equipped for bodies (9, 10 and

12 to 20). The structures of check valves are identical.
Disassembly and assembly of the check valve in
body (12) are explained as an example.

Disassemble Check Valve Assemble Check Valve

1. Remove plug (29) from body (12). 1. Install spring (55) and check valve (54) to body
: 6 mm (12).
NOTE: Spring (55) and check valve (54) are
2. Remove spring (31) and check valve (32) from equipped for only body (12). They are not
body (12). equipped for the other bodies.

3. Remove spring (55) and check valve (54) from 2. Install spring (31) and check valve (32) to body
body (12). (12).
NOTE: Spring (55) and check valve (54) are
equipped only for body (12). They are not 3. Install O-rings (30) to plug (29). Install plug (29) to
equipped for the other bodies. body (12).
: 6 mm
: 24.5 to 29.4 N⋅m (2.5 to 3.0 kgf⋅m, 18 to
20 lbf⋅ft)

W2-3-33
UPPERSTRUCTURE / Control Valve
(Blank)

W2-3-34
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE 1

CAUTION: Release any pressure in the 3

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal
2
1. Remove screws (1) (10 used) from the top, right
and left of covers (2, 3). Remove cover (3) from
the lever stand.

W1MP-02-03-006

1
W1MP-02-03-007

2. Loosen nuts (5) (2 used) from the travel levers (2

used). Remove grips (4) (2 used) from the travel
levers (2 used) by turning counterclockwise.
: 17 mm 4

Travel Lever W1MP-02-03-008

W2-4-1
UPPERSTRUCTURE / Swing Device
3. Remove grip (6) from side frame extend/retract
lever (7).

W1MP-02-03-007

4. Remove connector (8) from the wiring at cover (3)

side. Remove cover (2) from the lever stand.

W1MP-02-03-009

5. Open engine cover (9).

W1MP-02-04-001

W2-4-2
UPPERSTRUCTURE / Swing Device
6. Remove mat (10) from the main frame. 10

W1MP-02-04-002

7. Remove bolts (11) (2 used) from cover (12). 11 12

Remove cover (12) from the main frame.
: 13 mm

8. Remove bolts (13) (2 used) from cover (14).

Remove cover (14) from the main frame.
: 13 mm

14 13 W1MP-02-04-003

9. Remove bolts (16) (2 used) from cover (15).

Remove cover (15) from the main frame.
: 13 mm

16 15 W1MP-02-04-004

W2-4-3
UPPERSTRUCTURE / Swing Device
10. Remove bolts (19) and (21) (2 used) from bracket 17 18 19 20 21
(20). Push and hold bracket (20) to the lever stand
side with 2-WAY multi-lever (22) attached.
: 13 mm

W1MP-02-04-005
22

22
11. Remove bolts (24) (2 used) from bracket (25).
Remove bolts (17) and (23) (2 used) from bracket
(18). 24
: 10 mm, 13 mm

W1MP-02-04-006

12. Remove hoses (26) (3 used) from swing device

(28). Cap the open ends of hoses (26) and swing
device (28). 26 27
: 19 mm

13. Remove sems bolts (27) (4 used) from swing

26
device (28). Remove swing device (28) from the
main frame.
: 17 mm

28 27 W1MP-02-04-007

W2-4-4
UPPERSTRUCTURE / Swing Device
Installation
26 27
1. Install swing device (28) to the main frame with
sems bolts (27) (4 used).
: 17 mm
26
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install hoses (26) (3 used) to swing device (28).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

28 27 W1MP-02-04-007

22 18
3. Install bracket (18) with bolts (17) and (23) (2
used). Install the left end of bracket (18) to bracket 24
(25) with bolts (24) (2 used).
: 10 mm
: 3.5 N⋅m (0.35 kgf⋅m, 3 lbf⋅ft) 25
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W1MP-02-04-006

4. Install bracket (20) with bolts (19) and (21) (2 17 18 19 20 21

used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

22
W1MP-02-04-005

W2-4-5
UPPERSTRUCTURE / Swing Device
5. Install cover (15) onto the main frame with bolts
(16) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

16 15 W1MP-02-04-004

11 12
6. Install cover (14) onto the main frame with bolts
(13) (2 used). Install cover (12) onto the main
frame with bolts (11) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

14 13 W1MP-02-04-003

10
7. Install mat (10) onto covers (14, 15).

W1MP-02-04-002

W2-4-6
UPPERSTRUCTURE / Swing Device

9. Install cover (2) to the lever stand with screws (1) 1

(5 used).

W1MP-02-03-006

1
W1MP-02-03-007

10. Install connector (8) to the cover (3) side. Install

cover (3) to the lever stand with screws (1) (5
used).

W1MP-02-03-009

W2-4-7
UPPERSTRUCTURE / Swing Device

11. Install grip (6) to side frame extend/retract lever

(7).

W1MP-02-03-007

12. Install grips (4) (2 used) to the travel levers (2

used). Tighten nuts (5) (2 used) and secure grip
(4).
: 17 mm 4

Travel Lever W1MP-02-03-00

13. Close engine cover (9). 9

W1MP-02-04-001

W2-4-8
UPPERSTRUCTURE / Swing Device
(Blank)

W2-4-9
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING DEVICE 3

2
1
4
5
6
7

10
8
11
12 9
13
14
15
16
10
17
18

19
10

20
18
21
22
23
24
25

26
27
28

29
30

W1MP-02-04-008
1- Pin (2 Used) 9- Plug 17 - Valve Drive 25 - Bearing
2- Spring (2 Used) 10 - O-Ring (3 Used) 18 - O-Ring (2 Used) 26 - Bearing Housing
3- Socket Bolt (4 Used) 11 - Outer Face Seal 19 - Geroter 27 - X-Ring
4- Plug (2 Used) 12 - Inner Face Seal 20 - Drive 28 - Bearing
5- O-Ring (2 Used) 13 - Balancing Ring 21 - Wear Plate 29 - Pinion Gear
6- Bolt (2 Used) 14 - Valve 22 - Shaft Face Seal 30 - Plug
7- Valve Housing 15 - O-Ring 23 - O-Ring
8- O-Ring 16 - Valve Plate 24 - Retaining Ring

W2-4-10
UPPERSTRUCTURE / Swing Device

Disassemble Swing Device

1. Put the matching marks between valve housing 8. Remove valve plate (16), O-rings (10, 18) and
(7) and valve plate (16), between valve plate (16) valve drive (17) from gerotor (19).
and gerotor (19), between gerotor (19) and wear
plate (21), and between wear plate (21) and 9. Remove gerotor (19), O-rings (10, 18) and drive
bearing housing (26). (20) from wear plate (21).

2. Secure bearing housing (26) in a vise with the 10. Remove wear plate (21) and O-ring (23) from
pinion gear (29) side facing downward. bearing housing (26). Remove shaft face seal (22)
from wear plate (21).
3. Remove plugs (4) (2 used) from valve housing (7).
Remove balls (6) (2 used) from valve housing (7). 11. Remove retaining ring (24) from pinion gear (29).
Remove pinion gear (29) from bearing housing
4. Remove socket bolts (3) (4 used) from valve (26) by using a plastic hammer or press.
housing (7).
: 14 mm 12. Turn over bearing housing (26). Secure bearing
housing (26) in a vise. Remove X-ring (27) from
5. Remove valve (14) and valve housing (7) from bearing housing (26).
valve plate (16).
NOTE: Spring (2) and pin (1) may be removed IMPORTANT: Remove bearings (25, 28) only when
from housing (7). Do not lose spring (2) and replacing.
pin (1). 13. Tap and remove the inner race of bearing (25)
from bearing housing (26).
6. Remove balancing ring (13), pin (1), spring (2)
and O-ring (15) from valve housing (7). 14. Turn over bearing housing (26). Secure bearing
housing (26) in a vise. Tap and remove the inner
7. Remove inner face seal (12) and outer face seal race of bearing (28) from bearing housing (26).
(11) from balancing ring (13).

W2-4-11
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING DEVICE

2 4

7
5

1
11
13

12 6

10
14
17
15 10

16
19
18

18 21

24 22

25 23

20 26

30 T522-03-02-001

1- Pin (2 Used) 9- Plug 17 - Valve Drive 25 - Bearing

2- Spring (2 Used) 10 - O-Ring (3 Used) 18 - O-Ring (2 Used) 26 - Bearing Housing
3- Socket Bolt (4 Used) 11 - Outer Face Seal 19 - Gerotor 27 - X-Ring
4- Plug (2 Used) 12 - Inner Face Seal 20 - Drive 28 - Bearing
5- O-Ring (2 Used) 13 - Balancing Ring 21 - Wear Plate 29 - Pinion Gear
6- Bolt (2 Used) 14 - Valve 22 - Shaft Face Seal 30 - Plug
7- Valve Housing 15 - O-Ring 23 - O-Ring
8- O-Ring 16 - Valve Plate 24 - Retaining Ring

NOTE: As for 3, 8 and 9, refer to W2-4-10.

W2-4-12
UPPERSTRUCTURE / Swing Device
Assemble Swing Device

1. Install bearing (28) to bearing housing (26) by 7. Apply grease onto O-ring (23). Install O-ring (23)
using a plastic hammer or press. to bearing housing (26). Install drive (20) and
wear plate (21) to bearing housing (26).
2. Turn over bearing housing (26). Install bearing
(25) to bearing housing (26) by using a plastic 8. Apply grease onto O-rings (10, 18). Install O-rings
hammer or press. (10, 18) to wear plate (21). Align the matching
marks of wear plate (21) and gerotor (19). Install
3. Install X-ring (27) to bearing housing (26). gerotor (19) to wear plate (21).

4. Install pinion gear (29) to bearing housing (26) by IMPORTANT: Align matching mark (B) with the
using a press. point of any external teeth (C) of the
rotor.
5. Turn over bearing housing (26). Install retaining 9. Put matching mark (B) on optional teeth (B) at the
ring (24) to the shaft of pinion gear (28). bottom gear part of valve drive (17). Put matching
mark (A) on teeth (A) on the top gear part
6. Apply grease onto shaft face seal (22). Install corresponding to teeth (B) at the bottom gear part
shaft face seal (22) to wear plate (21). of valve drive (17). Install valve drive (17) to the
NOTE: Install shaft face seal (22) with the inner- rotor in geroller (19).
diameter side positioned above the
outer-diameter side as illustrated. 17

A
22 Inner-Diameter Side

B
Matching Mark (A)
W1MP-02-04-010

21 Outer-Diameter Side

Matching Mark (B)

Rotor
External-Teeth Point (C)
W1MP-02-04-011

W2-4-13
UPPERSTRUCTURE / Swing Device

2 4

7
5

1
11
13

12 6

10
14
17

15 10

16
19
18

30 T522-03-02-001

W2-4-14
UPPERSTRUCTURE / Swing Device
10. Apply grease onto O-rings (10, 18). Install O-rings IMPORTANT: Check the direction and install outer
(10, 18) to valve plate (16). Align the matching face seal (11) and inner face seal (12).
marks of gerotor (19) and valve plate (16). Install Face the outer side of outer face seal
valve plate (16) to gerotor (19). (11) and the inner side of inner face
seal (12) facing upward respectively
IMPORTANT: Check the positions to install valve when installing as illustrated.
drive (17) and valve (14). Install valve 13. Install outer face seal (11) to outer side and inner
(14) to valve plate (16). If the face seal (12) to inner side of balancing ring (13).
positions of valve (14) and valve
drive (17) are not correct, the Inner Diameter Side 12 Outer-Diameter
direction of rotation will become Side
reverse.
11. Turn the center of any caves of valve (14) 15
degrees from matching mark (A) on valve drive
W1MP-02-04-013
(17) applied in step 9. Install valve (14) to valve 11 13
drive (17).

IMPORTANT: Align the grooves (2 used) on

balancing ring (13) with pins (1) (2
used). Install balancing ring (13) to
Matching Mark (A)
valve housing (7).
14. Apply grease onto balancing ring (13). Install
balancing ring (13) to valve housing (7).

13 11 13 12
17

14
15° Cave

W1MP-02-04-012

W1MP-02-04-014

12. Apply grease onto springs (2) (2 used) and pins

(1) (2 used). Install springs (2) (2 used) and pins
(1) (2 used) to valve housing (7).

W2-4-15
UPPERSTRUCTURE / Swing Device

7
5

T522-03-02-001

W2-4-16
UPPERSTRUCTURE / Swing Device
15. Apply grease onto O-ring (15). Install O-ring (15)
to valve housing (7).

16. Align the matching marks on valve plate (16) and

valve housing (7). Install valve housing (7) to
valve plate (16). Secure valve housing (7) to
bearing housing (26) with socket bolts (3) (4
used).
: 14 mm
: 50 N⋅m (5.0 kgf⋅m, 37 lbf⋅ft)

17. Apply grease onto O-rings (5) (2 used). Install

O-rings (5) (2 used) to plugs (4) (2 used).

18. Install balls (6) and springs (2 used for each) to

valve housing (7). Install plugs (4) (2 used) to
valve housing (7).

W2-4-17
UPPERSTRUCTURE / Swing Device
(Blank)

W2-4-18
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE 1
(ZAXIS10U-2 ONLY)
3
CAUTION: Release any pressure in the
hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
2
Removal
The pilot valves (2 used) are used. Removal and
installation of one pilot valve is explained here.

1. Remove screws (1) (10 used) from the top, right

and left of covers (2, 3). Remove cover (3) from
the lever stand. W1MP-02-03-006

1
2

1
W1MP-02-03-007

2. Loosen nuts (5) (2 used) from the travel levers (2

used). Remove grips (4) (2 used) from the travel
levers (2 used) by turning counterclockwise. 4
: 17 mm

W1MP-02-03-008
Travel Lever

W2-5-1
UPPERSTRUCTURE / Pilot Valve
3. Remove grip (6) from side frame extend/retract
lever (7).

4. Remove connector (8) from the cover (3) side.

Remove cover (2) from the lever stand.

W1MP-02-03-007

W1MP-02-03-009

5. Raise boot (9) from lever (11). Loosen nut (10).

Remove lever (11) from pilot valve (12).
: 17 mm

9
11

12 12
W1MP-02-06-006

W2-5-2
UPPERSTRUCTURE / Pilot Valve
6. Remove bolts (15) (2 used) from levers (14) (2 12 12
used). Remove levers (14) (2 used) from rod (13).
Remove bolt (18) from link (17). Remove rod (13) 13
from link (17).
: 13 mm 14

7. Remove hoses (16) (6 used) from pilot valve (12).

Cap the open ends of hoses (16) and pilot valve 15 15
(12).
: 19 mm 14 16

W1MP-02-03-009
16 18 17

8. Remove bolts (19) (4 used) from the lever stand.

Remove pilot valve (12) from the lever stand.
: 13 mm 19

W1MP-02-06-007

Lever Stand

W2-5-3
UPPERSTRUCTURE / Pilot Valve
Installation

1. Install pilot valve (12) to the lever stand with bolts

(19) (4 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 19

W1MP-02-06-007

Lever Stand

2. Install hoses (16) (6 used) to pilot valve (12). 12 12

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 13

3. Insert rod (13) into link (17). Install levers (14) (2 14

used) to the both ends of rod (13) with bolts (15)
(2 used). Install link (17) to rod (13) with bolt (18).
15 15
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
14 16

4. Install lever (11) to pilot valve (12) and secure with

nut (10). Install boot (9) to lever (11).
: 17 mm
W1MP-02-03-009
16 18 17

9
11

12 12
W1MP-02-06-006

W2-5-4
UPPERSTRUCTURE / Pilot Valve
5. Install cover (2) to the lever stand. Install
connector (8) to the cover (3) side.

W1MP-02-03-009

6. Install cover (3) to the lever stand. Install covers 1

(2, 3) with screws (1) (10 used).

W1MP-02-03-006

1
2

1
W1MP-02-03-007

W2-5-5
UPPERSTRUCTURE / Pilot Valve
7. Install grip (6) to side frame extend/retract lever
(7).

W1MP-02-03-007

8. Install grips (4) (2 used) to the travel levers (2

used) by turning clockwise. Tighten nuts (5) (2
used). 4
: 17 mm

W1MP-02-03-008
Travel Lever

W2-5-6
UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-5-7
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE PILOT VALVE
(ZAXIS10U-2 ONLY)

10
1

(A)
2

4 14

W1MP-02-06-001

1- Screw Joint 5- Oil Seal (4 Used) 9 - Spring Seat (4 Used) 12 - Spacer (4 Used)
2- Cam 6- Sleeve (4 Used) 10 - Return Spring (4 Used) 13 - Spool (4 Used)
3- Universal Joint 7- O-Ring (4 Used) 11 - Balance Spring (4 Used) 14 - Casing
4- Plate 8- Pusher (4 Used)

W2-5-8
UPPERSTRUCTURE / Pilot Valve
Disassemble Pilot Valve 3. Turn the wrench part of special tool (ST 1515) and
remove universal joint (3) from casing (14).
IMPORTANT: As too strong force may deform or : 24 mm
damage casing (14), handle it with NOTE: Remove universal joint (3) while holding
care. plate (4).
IMPORTANT: Arrange the parts by port number in
order not to confuse. Ports numbers 4. Remove plate (4) from casing (14).
are stamped on the periphery of
casing (14). 5. Remove the sleeve (6) assemblies (4 used) from
1. Wrap casing (14) with cloth and secure in a vise. casing (14). Remove O-rings (7) (4 used),
Attach a spanner onto the wrench part of cam (2). pushers (8) (4 used) and oil seals (5) (4 used)
Hold cam (2) and remove screw joint (1). from the sleeve (6) assemblies (4 used).
: 22 mm, 32 mm

2. Apply grease onto the joint part of universal joint

(3). Install special tools (ST 1516) (2 used) in the
gap of joint part of universal joint (3). Put special
tool (ST 1515) on universal joint (3) while inserting
the protruding part of special tools (ST 1516) (2
used) into the groove (2 places) on special tool
(ST 1515).
3

Wrench
Part

ST 1516

Protruding
Part

ST 1515

Groove

W1MP-02-06-002

W2-5-9
UPPERSTRUCTURE / Pilot Valve

(A)

9
W1MP-02-06-001

W2-5-10
UPPERSTRUCTURE / Pilot Valve
6. Remove the spool (13) assemblies (4 used) from
casing (14).

7. Remove spring seats (9) (4 used) from the spool

(13) assemblies (4 used).
NOTE: Holes (A, C) which have different sizes are
located on spring seats (9) (4 used). Hole
(A) is big and end (B) of sleeve (13) can
pass through it. Hole (C) is small and end
(B) of sleeve (13) cannot pass through it.
Move end (B) of sleeve (13) from hole (C)
to hole (A) and remove spring seats (9) (4
used).

B W1MP-02-06-005

8. Remove balance springs (11) (4 used) and

spacers (12) (4 used) from spools (13) (4 used).

9. Remove return springs (10) (4 used) from casing (14).

W2-5-11
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE PILOT VALVE (ZAXIS10U-2
ONLY)

6 5

14
W1MP-02-06-003

W2-5-12
UPPERSTRUCTURE / Pilot Valve
Assemble Pilot Valve 4. Apply grease onto O-rings (7) (4 used). Install
O-rings (7) (4 used) to sleeves (6) (4 used).
IMPORTANT: As too strong force may deform or
damage casing (14), handle it with 5. Apply hydraulic oil onto pushers (8) (4 used).
care. Install pushers (8) (4 used) to sleeves (6) (4
1. Install spacers (12) (4 used), balance springs (12) used).
(4 used) and spring seats (9) (4 used) to spools
(13) (4 used). 6. Install the pusher (8) assemblies (4 used) to
NOTE: Before installing spring seats (9) (4 used), housing (14).
move end (B) of sleeve (13) into hole (C)
after inserting end (B) of sleeve (13) into 7. Install plate (4) to housing (14) and temporary
hole (A). tighten with universal joint (3).

B W1MP-02-06-005

2. Wrap casing (14) with cloth and secure in a vise.

Install return springs (10) (4 used) to casing (14).
Install the spool (13) assemblies to casing (14).

3. Apply hydraulic oil onto the inner side of sleeves

(6) (4 used) and new oil seals (5) (4 used). Install
oil seals (5) (4 used) to the grooves on inner side
of sleeves (6) (4 used).

5
Lip Part

8
W1MP-02-06-004

NOTE: Install oil seals (5) (4 used) with the lip part
facing downward.

W2-5-13
UPPERSTRUCTURE / Pilot Valve
8. Apply grease onto the joint part of universal joint
(3). Install special tools (ST 1516) (2 used) in the
gap of joint part of universal joint (3). Put special
tool (ST 1515) on universal joint (3) while inserting
the protruding part of special tools (ST 1516) (2
used) into the groove (2 places) on special tool
(ST 1515).

Wrench
Part

ST 1516

ST 1515

Groove

W1MP-02-06-002

9. Turn the wrench part of special tool (ST 1515) and

install plate (4) to housing (14).
: 24 mm
: 44.2 to 50 N⋅m
(4.5 to 5.1 kgf⋅m, 32 to 37 lbf⋅ft)

IMPORTANT: Check the tightness of cam (16).

10. Remove special tools (ST 1515, ST 1516) from
universal joint (3). Install cam (2) to universal joint
(3). Adjust the position of cam (2) so that the
clearance between cam (2) and pushers (8) (4
used) should be 0 to 0.2 mm (0 to 0.008 in).

11. Attach a spanner onto cam (2). Hold cam (2) and
tighten screw joint (1).
: 22 mm, 32 mm
: 68.4 N⋅m (7 kgf⋅m, 50 lbf⋅ft)

W2-5-14
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 2-SPOOL 1
SOLENOID VALVE

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work. 3
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
2
Removal

1. Remove screws (1) (10 used) from the top, right

and left of covers (2, 3). Remove cover (3) from
the lever stand.
W1MP-02-03-006

1
W1MP-02-03-007

2. Loosen nuts (5) (2 used) from the travel levers (2

used). Remove grips (4) (2 used) from the travel
levers (2 used) by turning counterclockwise. 4
: 17 mm

Travel Lever W1MP-02-03-008

W2-6-1
UPPERSTRUCTURE / Solenoid Valve
3. Remove grip (6) from side frame extend/retract
lever (7).

3
6

W1MP-02-03-007

4. Remove connector (8) from the cover (3) side.

Remove cover (2) from the lever stand.

W1MP-02-03-009

5. Open engine cover (9).

W1MP-02-04-001

W2-6-2
UPPERSTRUCTURE / Solenoid Valve
6. Remove mat (10) from the main frame. 10

W1MP-02-04-002

11 12
7. Remove bolts (11) (2 used) from cover (12).
Remove cover (12) from the main frame.
: 13 mm

8. Remove bolts (13) (2 used) from cover (14).

Remove cover (14) from the main frame.
: 13 mm

14 13 W1MP-02-04-003

9. Remove bolts (16) (2 used) from cover (15).

Remove cover (14) from the main frame.
: 13 mm

16 15 W1MP-02-04-004

W2-6-3
UPPERSTRUCTURE / Solenoid Valve
10. Remove bolts (17), (19) (2 used) from bracket (18). 17 18 19
Push and hold bracket (18) to the lever stand side,
with 2-WAY multi-lever (18) attached.
(ZAXIS10U-2 only)
: 10 mm, 13 mm

2-WAY Multi-Lever W1MP-02-04-005

11. Remove hoses (21) (5 used) from 2-spool

solenoid valve (23). Cap the open ends of 2-spool 21 22 21
solenoid valve (23) and hoses (21).
: 19 mm

12. Remove wiring connectors (22) (2 used) from

2-spool solenoid valve (23).

13. Remove bolts (24) (2 used) from bracket (25).

Remove 2-spool solenoid valve (23) from the main
frame. 21
: 17 mm 23
25 21

W1MP-02-06-008

W2-6-4
UPPERSTRUCTURE / Solenoid Valve
Installation

1. Install 2-spool solenoid valve (23) to the main 21 22 21

frame with bolts (24) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install hoses (21) (5 used) to 2-spool solenoid

valve (23).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Install wiring connectors (22) (2 used) to 2-spool 21

23
solenoid valve (23).
25 21

W1MP-02-06-008
4. Install bracket (18) with bolts (17) and (19) (2
used). (ZAXIS10U-2 only)
: 10 mm 17 18 19
: 3.5 N⋅m (0.35 kgf⋅m, 3 lbf⋅ft)
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W1MP-02-04-005
2-WAY Multi-Lever

5. Install cover (15) onto the main frame with bolts

(16) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf ft)

16 15 W1MP-02-04-004

W2-6-5
UPPERSTRUCTURE / Solenoid Valve
6. Install cover (14) onto the main frame with bolts 11 12
(13) (2 used). Install cover (12) onto the main
frame with bolts (11) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

14 13 W1MP-02-04-003

7. Install mat (10) onto covers (12, 14). 10

W1MP-02-04-002

8. Close engine cover (9).

W1MP-02-04-001

W2-6-6
UPPERSTRUCTURE / Solenoid Valve
9. Install cover (2) onto the lever stand. Install the
wiring under cover (3) to connector (8).

W1MP-02-03-009

1
10. Install covers (2, 3) onto the lever stand with
screws (1) (10 used).

W1MP-02-03-006

1
W1MP-02-03-007

W2-6-7
UPPERSTRUCTURE / Solenoid Valve
11. Install grip (6) to side frame extend/retract lever
(7).

12. Install grips (4) (2 used) to the travel levers (2

used). Tighten nuts (5) (2 used) and secure grips W1MP-02-03-007

(4) (2 used).
: 17 mm

Travel Lever W1MP-02-03-008

W2-6-8
UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-6-9
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE 2-SPOOL SOLENOID VALVE

17
5

4 14
7
12
3
8
2 13
9

1
12
10

W1M7-02-07-004

1- Check Valve 6- Solenoid (2 Used) 10 - Spring (2 Used) 14 - Plate (2 Used)

2- Spring 7- Pin (2 Used) 11 - Body 15 - Wave Washer (2 Used)
3- O-Ring 8- O-Ring (2 Used) 12 - O-Ring (4 Used) 16 - Casing (2 Used)
4- Adjuster 9- Spool (2 Used) 13 - Solenoid (2 Used) 17 - Lock Nut (2 Used)
5- Plate (2 Used)

W2-6-10
UPPERSTRUCTURE / Solenoid Valve
Disassemble 2-Spool Solenoid Valve

IMPORTANT: Attach the identification tags onto

solenoid (13) for assembling as the
right and left sides are different.
1. Remove lock nuts (17) (2 used) from casings (16)
(2 used). Remove casings (16) (2 used) from
body (11).

IMPORTANT: When removing solenoids (13) (2

used), pins (7) (2 used) may fall off.
Do not lose pin (7).
2. Remove the solenoid (13) assemblies (2 used)
from body (11).

3. Remove spools (9) (2 used) and springs (10) (2

used) from body (11) by using a magnet.

4. Remove adjuster (4) and O-ring (3) from body (11).

5. Remove spring (2) and check valve (1) from body

(11) by using a magnet.

W2-6-11
UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE 2-SPOOL SOLENOID VALVE
17

12 15 16

14
13

6 11 4 3 2 1

7 12

5
11
8

10
T1LA-03-06-001 T1LA-03-06-002

1- Check Valve 6- Solenoid (2 Used) 10 - Spring (2 Used) 14 - Plate (2 Used)

W2-6-12
UPPERSTRUCTURE / Solenoid Valve
Assemble 2-Spool Solenoid Valve

1. Install check valve (1) and spring (2) to body (11)

and secure with adjuster (4).

2. Install springs (10) (2 used) and spools (9) (2

used) to body (11).

3. Install pins (7) (2 used) to solenoids (6)(2 used).

Install solenoids (6) (2 used) to body (11).

4. Install plates (5) (2 used), O-rings (8) (2 used),

solenoids (13) (2 used), O-rings (12) (2 used),
plates (14) (2 used) and wave washers (15) (2
used) to solenoids (6) (2 used).

5. Install casings (16) (2 used) to the solenoid (6)

assemblies (2 used). Secure casings (16) (2
used) to body (11) with lock nuts (17) (2 used).

W2-6-13
UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-6-14
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL AIR BLEED 1
SOLENOID VALVE
Removal

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

1. Remove mat (1) from the main frame.

W1MP-02-04-002

2 3
2. Remove bolts (2) (2 used) from cover (3).
Remove cover (3) from the main frame.
: 13 mm

3. Remove bolts (4) (2 used) from cover (5).

Remove cover (5) from the main frame.
: 13 mm

5 4 W1MP-02-04-003

4. Remove bolt (6) from cover (7). Remove cover (7)

from the main frame.
: 13 mm
6

7 W1MP-02-06-009

W2-6-15
UPPERSTRUCTURE / Solenoid Valve
5. Remove hoses (9) (4 used) from solenoid valve
(10) under the radiator. Cap the open ends of
9
solenoid valve (10) and hoses (9).
: 19 mm

6. Remove wiring connector (13) from solenoid 9

valve (10). 13

7. Remove bolts (11) (2 used) from solenoid valve (10).

Remove solenoid valve (10) from bracket (12).
12 10
: 13 mm

W1MP-02-06-010
9

W2-6-16
UPPERSTRUCTURE / Solenoid Valve
Installation

1. Install solenoid valve (10) to bracket (12) with

bolts (11) (2 used).
9 9
: 13 mm 13
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

2. Install hoses (9) (4 used) to solenoid valve (10).

: 19 mm 12 10
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Install wiring connector (13) to solenoid valve

(10). 11

W1MP-02-06-010
9

4. Install cover (7) onto the main frame with bolt (6).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
6

7 W1MP-02-06-009

5. Install cover (5) onto the main frame with bolts (4) 2 3
(2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

6. Install cover (3) onto the main frame with bolts (2)
(2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

5 4 W1MP-02-04-003

W2-6-17
UPPERSTRUCTURE / Solenoid Valve
7. Install mat (1) onto cover (5). 1

W1MP-02-04-002

W2-6-18
UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF AIR BLEED SOLENOID
VALVE

A
1 2 3

16 4

15 5

6
14
7

12 10

Section A 11 T1M9-03-07-004

T1M9-03-07-003

Wrench Size Tightening Torque

Item Part Name Q’ ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Main Pipe 1
2 Lock Nut 1
3 Case 1
4 Plunger 1
5 Shim 1
6 Shaft 1
7 Solenoid Coil 1
8 O-Ring 1 (1A-1.9×13.8)
9 Bushing 1
10 Spool 1
11 Spring 1
12 Block 1
13 Case Plate 1
14 O-Ring 2 (1A-1.5×13.5)
15 Plate 1
16 Wave Washer 1

W2-6-19
UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-6-20
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
SECTION 3
UNDERCARRIAGE

 CONTENTS 
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing.......... W3-1-1 Remove and Install Lower Roller............. W3-6-1
Structure of Lower Roller ........................ W3-6-3
Group 2 Travel Device Maintenance Standard ............................ W3-6-4
Remove and Install Travel Device........... W3-2-1
Disassemble Travel Device..................... W3-2-4 Group 7 Track
Assemble Travel Device ......................... W3-2-6 Remove and Install Track ....................... W3-7-1
Disassemble Travel Motor .................... W3-2-10 Maintenance Standard ............................ W3-7-3
Assemble Travel ................................. W3-2-12
Disassemble and Assemble
Brake Valve ....................................... W3-2-14
Maintenance Standard ........................ W3-2-18

Group 3 Center Joint

Remove and Install Center Joint ............. W3-3-1
Disassemble Center Joint ....................... W3-3-4
Assemble Center Joint............................ W3-3-6

Group 4 Track Adjuster

Remove and Install Track Adjuster.......... W3-4-1
Disassemble and Assemble
Track Adjuster ..................................... W3-4-2

Group 5 Front Idler

Remove and Install Front Idler ................ W3-5-1
Disassemble and Assemble
Front Idler ........................................... W3-5-2
Maintenance Standard ............................ W3-5-4

1MRW-3-1
(Blank)

1MRW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Removal

1. Remove the main frame from center frame (2).

Refer to the Remove and Install Main Frame
group on page W2-1-1. Matching Mark 1

2. Put the matching marks on inner race (3) of

swing bearing (1) and center frame (2).

3 2
W105-03-01-001

3. Remove bolts (4) (18 used) from inner race (3) in 1

swing bearing (1).
: 17 mm
3

W1MP-03-01-001

4. Remove swing bearing (1) from center frame (2).

W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation

1. Clean the mounting surfaces of center frame (2)

and swing bearing (1). Machine Front

[S] (Soft Zone)

2. Apply THREEBOND #1102 onto the swing bearing Grease Fitting
Marking Position
Position
(1) mounting surfaces of center frame (2).
Hole for Knock Pin
IMPORTANT: If the matching marks do not align, 10°
the position of soft zone of inner 1
race (3) will be dislocated.
3. Align the matching marks on center frame (2) and
inner race (3) of swing bearing (1).

W1MP-03-01-001
[S] (Soft Zone)
Marking Position

4. Install inner race (3) in swing bearing (1) to center Matching Mark 1
fame (2) with bolts (4) (18 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

5. Install the main frame to center frame (2). Refer

to the Remove and Install Main Frame group on
page W2-1-1.

3 2
W105-03-01-001

W1MP-03-01-001

W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

Removal
1 2
1. Remove the track. Refer to the Remove and In-
stall Track group on page W3-7-1.

2. Remove bolts (2) (3 used) from cover (3). Re-

move cover (3) from side frame (1).
: 13 mm

3 W507-03-02-001

4 5 1
3. Remove hoses (6 to 9) from travel device (4).
Cap the open ends.
6
Attach identification tags onto the removed hoses
for assembling. 7
: 19 mm, 22 mm
8

4. Remove socket bolts (5) (8 used) from side frame 9

(1). Remove travel device (4) from side frame (1).
: 8 mm
W1MP-03-02-008

5. Remove socket bolts (11) (9 used) from sproket

(10). Remove sproket (10) from travel device (4).
: 8 mm
10

W1MP-03-02-009
4 11

W3-2-1
UNDERCARRIAGE / Travel Device
Installation

1. Install sproket (10) onto travel device (4) with

socket bolts (11) (9 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 10

2. Align travel device (4) with side frame (1).

3. Apply LOCTITE #262 on socket bolts (5). Install 4 11

W1MP-03-02-009

travel device (4) onto side frame (1) with socket

bolt (5) (8 used).
: 8 mm 4 5 1
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
6
4. Install hoses (6 to 9) to travel device (4). 7
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 8
: 22 mm 9
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

W1MP-03-02-008

1 2
5. Install cover (3) to side frame (1) with bolts (2)
(3 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

6. Install the track to side frame (1). Refer to the

Remove and Install Track group on page W3-7-1.

7. After completing the work, check the oil level.

Start the engine and check for any oil leaks. 3 W507-03-02-001

8. Perform break-in operation in order to prevent the

travel motor from burning and seizing.
Break-in operation conditions
1-1. Engine speed: Slow idle speed
1-2. Fast speed travel pedal: Slow speed
1-3. Operation duration: Over 2 minutes

W3-2-2
UNDERCARRIAGE / Travel Device
(Blank)

W3-2-3
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL DEVICE
1

4
5 6
16
7

15
12
14
13
12
11

10
28 9
27
23B
26

29
30 24

23A
22
21
20
19
18
Pin 17

11
Shaft

W1MP-03-02-001
31

1 - Sun Gear 9 - Plug (2 Used) 17 - Thrust Washer 25 - Seal Ring

2 - Carrier 10 - O-Ring (2 Used) 18 - Second Stage Planetary 26 - O-Ring
Gear (3 Used)
3- Retaining Ring 11 - Retaining Ring (6 Used) 19 - Needle Bearing (45 Used) 27 - Floating Seal
4- Drive Gear 12 - Thrust Washer (6 Used) 20 - Inner Race (3 Used) 28 - O-Ring
5- Retaining Ring 13 - Needle Bearing (39 Used) 21 - Thrust Washer (3 Used) 29 - Plug
6- O-Ring 14 - First Stage Planetary Gear 22 - Retaining Ring 30 - O-Ring
(3 Used)
7 - Cover 15 - Pin (3 Used) 23A, B - Bearing (2 Used) 31 - Body
8 - Stopper Ring 16 - Spring Pin (3 Used) 24 - Ring Gear

W3-2-4
UNDERCARRIAGE / Travel Device
Disassemble Travel Device 7. Remove retaining rings (11) (3 used) from the
pins (3 used) in body (31). Remove thrust washer
1. Remove plugs (9) (2 used) from cover (7). Drain (17), second stage planetary gears (18) (3 used),
gear oil from the plug (9) mounting hole (DRAIN). needle bearings (19) (45 used), inner races (20)
: 8 mm (3 used) and thrust washers (21) (3 used) from
NOTE: Gear oil : 0.1 L ring gear (24).

2. Remove stopper ring (8) from cover (7). Remove 8. Install the vise to body (31) and ring gear (24).
cover (7) from ring gear (24). Tighten the vise and remove retaining ring (22)
from body (31).
3. Remove O-ring (6) from cover (7).

4. Remove retaining ring (5) and drive gear (4) from 24

the shaft in body (31). Remove retaining ring (3)
from sun gear (1). Remove the carrier (2) as-
sembly from sun gear (1).
Vise
IMPORTANT: Spring pin (16) and pin (15) cannot Vise
be disassembled as they are com-
pressed into carrier (2).
5. Remove retaining rings (11) (3 used), thrust
washers (12) (3 used), first stage planetary gears 31
(14) (3 used), needle bearings (13) (39 used), W571-03-02-006
and thrust washers (12) (3 used) from pins (15)
(3 used) in the carrier (2) assembly.
9. Remove bearing (23A) from body (31).
6. Remove sun gear (1) from the shaft in body (31).
10. Remove the ring gear (24) assembly (23 B, 24 to
26) from body (31). Remove floating seal (25) and
O-ring (26) from ring gear (24).

11. Remove bearing (23B), floating seal (27) and

O-ring (28) from body (31).

W3-2-5
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL DEVICE

31 28 27 23B 23A 21 19 18 20 11 6

W1MP-03-02-002
29, 30 A 25 26 22 1 2 17 16 15 13 14 24

1 - Sun Gear 9 - Plug (2 Used) 17 - Thrust Washer 25 - Seal Ring

W3-2-6
UNDERCARRIAGE / Travel Device
Assemble Travel Device 6. Install thrust washers (21) (3 used), inner races
(20) (3 used), second stage planetary gears (18)
1. Apply grease onto bearing (23B). Install bearing (3 used), needle bearings (19) (45 used) and
(23B) to body (31) with the thick inner race side of thrust washer (17) to the pins (3 used) in body
bearing (23B) facing to the travel motor side. (31). Install retaining rings (11) (3 used) to the
pins (3 used) in body (31).
2. Apply grease to floating seal (27), seal ring (25)
and O-ring (26, 28). Install O-ring (28) and float- 7. Install sun gear (1) and carrier (2) in the shaft in
ing seal (27) to body (31). Install O-ring (26) to body (31), and secure with retaining ring (3).
seal ring (25). Install seal ring (25) to ring gear
(24). 8. Install thrust washers (12) (3 used), first stage
planetary gears (14) (3 used), needle bearings
3. Align ring gear (24) with body (31). Tap around (13) (39 used), thrust washers (12) (3 used) and
ring gear (24) by using a plastic hammer and in- retaining rings (11) (3 used) to pins (15) (3 used)
stall ring gear (24) to body (31). in carrier (2).

4. Secure body (31) and ring gear (24) into the vise. 9. Install drive gear (4) and retaining ring (5) to the
Tighten body (31) and ring gear (24). shaft in body (31).
Install bearing (23A) to body (31) with the thick
inner race side of bearing (23A) facing to the
transmission side. Install retaining ring (22) to
body (31).

5. Remove the vise. Check that ring gear (24) can

turn.
If not or if tight, bearings (23A, 23B) or floating
seal (27) and seal ring (25) are not installed cor-
rectly. Disassemble and assemble the parts
again.

Vise Vise

W571-03-02-006

W3-2-7
UNDERCARRIAGE / Travel Device

W1MP-03-02-002
24

W3-2-8
UNDERCARRIAGE / Travel Device
10. Apply grease on O-ring (6).
Install O-ring (6) to ring gear (24). Add gear oil
(0.1 L).

11. Align the plug (9) hole on cover (7) with the notch
on ring gear (24). Install cover (7) to ring gear (24)
with stopper ring (8).
NOTE: Attach a screwdriver onto the end of stop-
per ring (8). Secure cover (7) while tapping
the end of stopper ring (8) by using a
hammer.

12. Install O-rings (10) (2 used) to plugs (9) (2 used).

13. Install plugs (9) (2 used) to cover (7).

: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 3 to 4 lbf⋅ft)

W3-2-9
UNDERCARRIAGE / Travel Device
DISASSEMBLE TRAVEL MOTOR
1
2

5 7
6

8
20

17
16
14
24 15
14
23 13
22 12
21 11
10
9

W1MP-03-02-003

1- Swash Plate 7- Housing 13 - Rotor 19 - Spring Pin

2- Steel Ball (2 Used) 8- Plug (3 Used) 14 - Washer (2 Used) 20 - Socket Bolt (7 Used)
3- Shaft 9- Plunger (7 Used) 15 - Spring 21 - O-Ring
4- Bearing 10 - Retainer 16 - Retaining Ring 22 - Pin
5- Oil Seal 11 - Holder 17 - Valve Plate 23 - Bearing
6- Piston 12 - Pin (3 Used) 18 - O-Ring 24 - Brake Valve

W3-2-10
UNDERCARRIAGE / Travel Device
Disassemble Travel Motor 6. Place housing (7) horizontally. Tap and remove
shaft (3) and bearing (4) from housing (7) by us-
IMPORTANT: Do not damage the seat surface of ing a bar and plastic hammer.
brake valve (24).
7. Push out oil seal (5) from housing (7) by using a
24 screwdriver.
NOTE: Oil seal (5) has been installed by using
adhesive. Oil seal (5) cannot be used
again.

8. Remove bearing (4) from shaft (3). Attach the in-

W172-03-02-006
ner race of bearing (4) onto the open end of vise.
Remove shaft (3) from bearing (4) by using a
Seat Surface plastic hammer.

1. Place brake valve (24) of the travel motor facing

upward. Remove socket bolts (20) (7 used). Re-
Bar
move the brake valve (24) assembly from hous-
ing (7). 4
: 8 mm
3
2. Remove valve plate (17) and O-ring (21) from
brake valve (24).

3. Remove the rotor (13) assembly, holder (11), pins

(12) (3 used), retainer (10) and plunger assem-
blies (9) (7 used) from housing (7).
W172-03-02-003
4. Remove swash plate (1) from housing (7).

5. Remove steel ball (2) (2 used) and piston (6)

from housing (7) by using a magnet.

NOTE: Do not remove retaining ring (16), washer

(14), spring (15) and washer (14) from ro-
tor (13) unless necessary.

W3-2-11
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL MOTOR

21 18 16 12 2 6 5 8

W1MP-03-02-004

24 23 19 17 7 15 13 9 14 10 1 11 4

1- Swash Plate 7- Housing 13 - Rotor 19 - Spring Pin

NOTE: Refer to page W3-2-10 as for parts 18 and 22.

W3-2-12
UNDERCARRIAGE / Travel Device
Assemble Travel Motor 8. Apply hydraulic oil onto the mounting hole (7
places) for plunger (9) on rotor (13). Install
1. Place housing (7) with the mounting surface for plunger (9) (7 used) to retainer (10). Install the
brake valve (24) facing upward. plunger (9) assembly (9, 10) to rotor (13).

2. Clean the oil seal (5) mounting part of housing (7). 9. Place housing (7) horizontally. Align the splines of
Apply THREEBOND #1104 or #1215 to the outer shaft (3) and cylinder block (13). Install the cylin-
surface of oil seal (5). Install oil seal (5) to hous- der block (13) assembly to housing (7).
ing (7) in order not to deform oil seal (5). Apply
grease to the inner surface on oil seal (5). 10. Add hydraulic oil 0.33 L (0.1 US gal) to housing
NOTE: Use grease OCEAN "7". (7).

IMPORTANT: The lip mounting surface of oil seal IMPORTANT: Install valve plate (17) with the
(5) is located on the mounting side thrust surface in brass facing up-
for bearing (4) in shaft (3). Do not ward.
damage it. 11. Align and install spring pin (19) of brake valve
3. Install bearing (4) to shaft (3). assembly (24) with valve plate (17).

IMPORTANT: Do not damage oil seal (5). 12. Install O-rings (18) and (21) (2 used) to brake valve
4. Tap and install the shaft (3) assembly to housing (24).
(7) by using a plastic hammer.
IMPORTANT: Do not drop valve plate (17) when
IMPORTANT: Insert piston (6) into the piston (6) installing. If so, aligning will become
hole with the step side facing difficult.
downward. 13. Install brake valve (24) to housing (7) while align-
5. Apply grease to ball (2). Install piston (6) and ing the hole for socket bolt (20). Equally tighten
steel balls (2) (2 used) to housing (7). brake valve (24) to housing (7) with socket bolts
(20) (7 used).
6. Align the hollow (2 places) on the back side of : 8 mm
swash plate (1) with steel ball (2). Install swash : 51 to 56.4 N⋅m
plate (1) to housing (7). (5.2 to 6.6 kgf⋅m, 38 to 41 lbf⋅ft)

7. Apply grease onto pins (12) (3 used). Install pins

(12) (3 used) to rotor (13). Install rotor (13) to
holder (11).

W3-2-13
UNDERCARRIAGE / Travel Device
DISASSEMBLE AND ASSEMBLE BRAKE
VALVE

3 4 5 4 3
1

A
B
Section A-A

2 1

21 6

20 7

19
8
18
9
17
10 10
16
11
15
12
14
12
13
15

Section B-B W1MP-03-02-005

W3-2-14
UNDERCARRIAGE / Travel Device

13 22
W1MP-03-02-006

1- Plug (4 Used) 7- Check Valve (2 Used) 13 - Plug (6 Used) 18 - Spring Guide (2 Used)
2- Orifice (2 Used) 8- Spool 14 - Spool 19 - Spring (2 Used)
3- Plug (2 Used) 9- Spring (2 Used) 15 - O-Ring (2 Used) 20 - O-Ring (2 Used)
4- Pin (2 Used) 10 - Plug (2 Used) 16 - O-Ring (2 Used) 21 - Orifice (2 Used)
5- Shuttle 11 - Spring 17 - Ring (2 Used) 22 - Plug (2 Used)
6- Body 12 - Plug (2 Used)

W3-2-15
UNDERCARRIAGE / Travel Device

3 4 5 4 3
1

A
B
Section A-A

2 1

21 6

20 7

19
8
18
9
17
10 10
16
11
15
12
14
12
13
15

Section B-B W1MP-03-02-005

W3-2-16
UNDERCARRIAGE / Travel Device
Disassemble Assemble

IMPORTANT: Do not disassemble counterbalance 1. Apply hydraulic oil onto shuttle (5).
valve assembly (7, 8, 18, 19, 20). Install shuttle (5) and pins (4) (2 used) to body (6).
1. Remove plugs (10) (2 used) from body (6). Re- Install plugs (3) (2 used) to body (6).
move springs (9) (2 used), plates (17) (2 used)
and counterbalance valve assembly (7, 8, 18, 19, 2. Apply hydraulic oil onto spool (14).
20) from body (6). Install spool (14) and spring (11) to body (6). In-
stall O-rings (15) (2 used) to plugs (12) (2 used).
2. Remove plugs (12) (2 used) from body (6). Re- Tighten plugs (12) (2 used).
move spring (11) and spool (14) from body (6).
3. Install counterbalance valve assembly (7, 8, 18,
3. Remove plugs (3) (2 used) from body (6). Re- 19, 20) to body (6). Install plates (17) (2 used)
move pins (4) (2 used) and shuttle (5) from body and springs (9) (2 used) to body (6). Install
(6). O-rings (16) (2 used) to plug (10). Install plugs
(10) (2 used) to body (6).

W3-2-17
UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Travel Motor

1. Clearance between plunger outer diameter and

rotor inner bore

(D-d): 0.023 mm (0.001 in) or less.

D d

W507-02-04-009
Rotor Plunger

2. Clearance between plunger and shoe

δ
Plunger
δ: 0.3 mm (0.012 in) or less.

3. Wear amount of sliding surface against valve

plate of rotor Shoe
Check that there are no damage, wear or seizure.
Damage or wear: 0.02 mm (0.001 in) or less

4. Wear amount of rotor of valve plate against slid-

ing surface
Check that there are no damage, wear or seizure. W107-02-06-141
Damage or wear: 0.02 mm (0.001 in) or less

W3-2-18
UNDERCARRIAGE / Travel Device

Sprocket

D C B

A
W1MP-03-02-007

Unit: mm (in)
Standard Allowable Limit Remedy
A 23.0 (0.9) 18 (0.7)
B 249 (9.8) 244 (9.6)
C 275 (10.8) - Replace
D 291 (11.5) 286 (11.3)
E - -

W3-2-19
UNDERCARRIAGE / Travel Device
(Blank)

W3-2-20
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal

1. Remove the main frame from the center frame.

Refer to the Remove and Install Main Frame
group on page W2-1-1. 1

2. Remove hoses (2) (12 used) from center joint (1).

2
Attach the identification tags onto hoses (2). Cap
the open ends of center joint (1) and hoses (2).
: 19 mm, 22 mm

3. Remove bolts (3) (4 used) and washers (4) (4

used) from flange (5) of center joint (1). Remove 3, 4
center joint (1) from the center frame.
: 17 mm 5

W1MP-02-01-008

W3-3-1
UNDERCARRIAGE / Center Joint
Installation

1. Install flange (5) of center joint (1) to the center

frame with washers (4) (4 used) and bolts (3)
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install hoses (2) (12 used) to center joint (1).

: 19 mm 1
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
2
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

3. Install the main frame to the center frame. Refer to

the Remove and Install Main Frame group on
page W2-1-1.
5
3, 4
IMPORTANT: After completing the work, check the
oil level. Start the engine and check
for any oil leaks.
W1MP-02-01-008

W3-3-2
UNDERCARRIAGE / Center Joint
(Blank)

W3-3-3
UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT

1
11

W1MP-03-03-001

1 - Body 4 - O-Ring 7 - Oil Seal (10 Used) 10 - Dust Seal

2 - Thrust Ring 5 - Flange 8 - O-Ring 11 - Spindle
3 - Retaining Ring 6 - Socket Bolt (4 Used) 9 - Backup Ring

W3-3-4
UNDERCARRIAGE / Center Joint
Disassemble

1. Clamp the center joint in a vise. IMPORTANT: Do not damage the lip surface of oil
seal (7) in spindle (11). Also, avoid
2. Remove socket bolts (6) (4 used) from flange (5). the entry of dust when placing
Remove flange (5) from body (1). spindle (11) horizontally.
: 6 mm IMPORTANT: Do not damage the seal groove by
the pin when removing oil seals (7)
3. Remove O-ring (4), retaining ring (3) and thrust (10 used) by using the pins (2 used).
ring (2) from body (1). 5. Remove oil seals (7) (10 used) from body (1).

IMPORTANT: Put the matching marks on body (1)

and spindle (11).
4. Install special tool (ST 1514) in the socket bolt (6)
hole (2 places) on diagonal with bolts (M6) (2
used). Turn bolt (M16) clockwise and push out
spindle (11) from body (1).

Bolt (M16) Pin

Bolt (M6) ST 1514

W105-03-03-015

6. Remove dust seal (10), backup ring (9) and

O-ring (8) from body (1).

W1MP-03-03-002

W3-3-5
UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT

4
5
T1MP-03-07-003

1 - Body 4 - O-Ring 7 - Oil Seal (10 Used) 10 - Dust Seal

2 - Thrust Ring 5 - Flange 8 - O-Ring 11 - Spindle
3 - Retaining Ring 6 - Socket Bolt (4 Used) 9 - Backup Ring

W3-3-6
UNDERCARRIAGE / Center Joint
Assemble

IMPORTANT: Apply grease or hydraulic oil onto 4. Install O-ring (4) to body (1).
O-ring (8) and seals (7). Install O-ring
(8) and seals (7) into each groove of 5. Install flange (5) to body (1) with socket bolts (6)
body (1). After installing, apply (4 used).
grease onto the lip parts of dust seal : 6 mm
(10) and oil seals (7) (10 used). : 11.8 to 14.7 N⋅m
IMPORTANT: Check the installing direction of dust (1.2 to 1.5 kgf⋅m, 9 to 11 lbf⋅ft)
seal (10) and oil seals (7) (10 used).
1. Install O-ring (8), backup ring (9), dust seal (10)
and oil seals (7) (10 used) to body (1).

IMPORTANT: Slowly rotate and push spindle (11)

into body (1). If spindle (11) is rapidly
pushed in, the seal may be
damaged.
IMPORTANT: Apply grease onto the inside (sliding
part) of spindle (11) and body (1).
2. Clamp spindle (11) in a vise. Align the matching
marks on spindle (11) and body (1). Lightly tap
body (1) by using a hammer and install to spindle
(11).
NOTE: Do not slant body (1).

IMPORTANT: Install retaining ring (3) with the

chamfered surface facing to the
thrust ring (2) side. Check that
retaining ring (3) is in the groove of
body (1) and spindle (11).
3. Install thrust ring (2) and retaining ring (3) to
body (1).

W3-3-7
UNDERCARRIAGE / Center Joint
(Blank)

W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK
ADJUSTER
Removal and installation of track adjuster on both
sides are same. Removal and installation of the left
track adjuster are explained here. Hole (A) A Hole (B) 1

Removal

1. Remove the track (rubber crawler) from side

frame (1). Refer to the Remove and Install Track
group on page W3-7-1.

2. Remove the front idler from side frame (1). Refer

to the Remove and Install Front Idler group on
page W3-5-1.

3. Remove track adjuster (2) from side frame (1).

W1MP-03-04-001

Installation 1 Hole (A) 2 Hole (B)

IMPORTANT: Check that the valve side of track

adjuster (2) is installed in hole (B) on
side frame (1).
1. Insert the track adjuster into hole (A) on side
frame (1). Turn the track adjuster and insert the
valve of track adjuster (2) into hole (B). Detail for Part A 1 Valve

2. Install the front idler to side frame (1). Refer to the W1MP-03-04-002

Remove and Install Front Idler group on page

W3-5-1.

3. Install the track (rubber crawler) to side frame (1).

Refer to the Remove and Install Track group on
page W3-7-1.

W3-4-1
UNDERCARRIAGE / Track Adjuster
DISASSEMBLE AND ASSEMBLE TRACK
ADJUSTER

2
3
4

6
7
5

W1MP-03-04-003

1 2 3, 4 5 6 7

Front Idler (Reference) Track Frame A Track Frame

T1MP-03-07-006

1 - Piston 3- Backup Ring 5- Cylinder Tube 7- Grease Fitting

2 - Dust Seal 4- O-Ring 6- Valve

W3-4-2
UNDERCARRIAGE / Track Adjuster
Disassemble Assemble

1. Remove piston (1) from cylinder tube (5). 1. Apply grease onto O-ring (4) and backup ring (3).
NOTE: If piston (1) cannot be removed from Install backup ring (3) and O-ring (4) in the O-ring
cylinder tube (5), add air from grease fitting (4) groove on cylinder tube (5).
(7).
2. Apply grease onto dust seal (2). Install dust seal
2. Remove valve assembly (6, 7) from cylinder tube (2) to cylinder tube (5).
(5).
: 19 mm IMPORTANT: Release air from cylinder tube (5) in
the followings.
3. Remove dust seal (2) from cylinder tube (5). 3. Fill section A of cylinder tube (5) with grease.

4. Remove backup ring (3) and O-ring (4) from 4. Apply hydraulic oil onto the surface of piston (1).
cylinder tube (5). Place cylinder tube (5) horizontally and insert
piston (1) into cylinder tube (5).

5. Install valve assembly (6, 7) to cylinder tube (5).

: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

6. Insert piston (1) into cylinder tube (5) until grease

stops coming out from valve (6).

7. Tighten valve assembly (6, 7).

: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

W3-4-3
UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-4
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
1
1. Remove the track (rubber crawler). Refer to the
Remove and Install Track group on page W3-7.

2. Insert a pry bar between front idler (1) and side

frame (2). Pry and remove front idler (1) from side
frame (2).

3 2
W1M3-03-05-001

Installation

IMPORTANT: Clean and apply grease to the sliding

part of side frame (2) and the yoke (3)
part of front idler (1).
1. Insert yoke (3) of front idler (1) into the sliding part
of side frame (2). 2

Sliding
Part

W1MP-03-05-001

W3-5-1
UNDERCARRIAGE / Front Idler
DISASSEMBLE AND ASSEMBLE FRONT IDLER

1
2 7
3
6 4

4
3
2

1 9

7
W1MP-03-05-004

8 9

2
5

W1MP-03-05-002

1 - Pin (2 Used) 4- Ball Bearing (2 Used) 7- Yoke (2 Used) 9 - Bolt (4 Used)

2 - Seal (2 Used) 5- Axle 8- Plate 10 - Idler
3 - Retaining Ring (2 Used) 6- Plug

W3-5-2
UNDERCARRIAGE / Front Idler
Disassemble Assemble

1. Remove bolts (9) (4 used) from plate (8). Remove 1. Install axle (5) to ball bearings (4) (2 used).
plate (8) from yokes (7) (2 used).
: 17 mm 2. Install retaining rings (3) (2 used) to axle (5).

2. Remove pins (1) (2 used) from yokes (7) (2 used). 3. Apply grease to the outer side, inner side and
Remove yokes (7) (2 used) from axle (5). inner part of lip of new seal (2).

3. Remove seals (2) (2 used) from idler (10). 4. Install yokes (7) (2 used) to axle (5) with pins (1)
NOTE: Seals (2) (2 used) cannot be reused. (2 used).

4. Remove retaining rings (3) (2 used) from axle (5). IMPORTANT: Apply LOCTITE #262 onto bolts (9)
(4 used).
5. Remove axle (5) from ball bearings (4) (2 used). 5. Install yokes (7) (2 used) to plate (8) with bolts (9)
(4 used).
IMPORTANT: Do not remove ball bearings (4) (2 : 17 mm
used) unless replacing ball bearings : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
(4) (2 used).
6. Remove plug (6) from idler (10). Fill with grease.
Install plug (6) to idler (10).

W3-5-3
UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD

W1MP-03-05-005

B
Unit: mm (in)
Standard Allowable Limit Remedy
A 247 (9.7) 241 (9.5) Cladding by welding
B 20 (0.8) 16 (0.6) and hand finishing
or replace

W3-5-4
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL LOWER ROLLER
There is no upper roller in this machine. Removal and
installation method, and structure of the lower roller
are explained here.

Removal

CAUTION: Support the bottom of center

frame of the raised machine by using the
blocks. 90 to 110º

1. Put a bucket on the ground of the side where the

lower roller is to be removed. Raise the machine.
Place a block under the center frame and support
the machine.
W1MP-03-07-003

CAUTION: Grease pressure in the track ad- Grease Outlet

1 2
juster is high. Do not loosen valve (2) quickly
or too much as valve (2) may fly off or
high-pressure grease in the track adjuster
may gush out.
Do not loosen valve (2) more than one turn.
Keep body parts and face away from valve (2).
Do not loosen grease fitting (1). W1MJ-03-06-001

2. Loosen valve (2) in the track adjuster slowly. 1 2

Drain grease until the clearance from the lower
end of lower roller (4) to track inner side is more
than 70 mm (2.8 in).
: 19 mm
6
3. Tighten valve (2).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

4. Remove bolts (5) (2 used) and washers (6) (2

used) from the inner side and outer side of side
frame (3). Remove lower roller (4) from side
frame (3). 5 4 3 Track
: 22 mm
W1MP-03-07-001

W3-6-1
UNDERCARRIAGE / Upper and Lower Roller
Installation

CAUTION: Support the bottom of center

frame of the raised machine by using the
blocks.

1. Put a bucket on the ground of the side where the 90 to 110º

lower roller is to be installed. Raise the machine.
Place a block under the center frame and support
the machine.

W1MP-03-07-003

1 2
2. Align the bolt (5) hole on lower roller (4) with the
bolt (5) hole (2 places) on side frame (3).

3. Apply LOCTITE #262 onto bolts (5) (2 used). In-

stall lower roller (4) to side frame (3) by washers
6
(6) (2 used) and bolts (5) (2 used).
: 22 mm
: 180 N⋅m (18.4 kgf⋅m, 133 lbf⋅ft)

W1MP-03-07-001
5 4 3

6 3 1
4. Apply grease through grease fitting (1) and adjust
tracks tension.
NOTE: Check clearance (A) from the lower end of
side frame (3) to track (7) inner side below
grease fitting (1).
Track sag specification (A): 60 to 65 mm
(2.4 to 2.6 in)

W1MP-03-07-002
4 5 7

5. Raise the machine by using the front attachment

and remove the blocks under side frame (3).

W3-6-2
UNDERCARRIAGE / Upper and Lower Roller
STRUCTURE OF LOWER ROLLER

W1MP-03-06-001

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Roller 1
2 Ball Bearing 2
3 Retaining Ring 2
4 Axle 1
5 Seal 2

W3-6-3
UNDERCARRIAGE / Upper and Lower Roller
MAINTENANCE STANDARD
Lower Roller

C A C W1MP-03-06-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 68 (2.7) - Cladding by
B 103 (4.0) - welding and
C 15 (0.6) 12 (0.5) hand finishing or
D 130 (5.1) 126 (5.0) replace

W3-6-4
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal

CAUTION: Support the bottom of the center

frame of the raised machine by using the
blocks.

1. Put a bucket on the ground of the side where the

90 to 110°
lower roller is to be removed. Raise the machine.
Place a block under the center frame and support
the machine.

W1MP-03-07-003

CAUTION: Grease pressure in the track 1 2

adjuster is high. Do not loosen valve (2)
quickly or too much as valve (2) may fly off or
high-pressure grease in the track adjuster
may gush out.
Do not loosen valve (2) more than one turn.
Keep body parts and face away from valve (2).
Do not loosen grease fitting (1).

2. Loosen valve (2) in the track adjuster slowly and

drain grease.
: 19 mm
NOTE: If track (3) is turned alternately forward and
backward with valve (2) loosened, grease W1MP-03-07-001

will drain faster.

3
CAUTION: Rubber crawler weight:
ZAXIS8-2: 30 kg (66 lb)
ZAXIS10U-2: 34 kg (75 lb)
4
Reverse
3. Insert a steel pipe in the track (3) inner side under
front idler (5). Turn sprocket (4) backward until the
steel pipe steps on front idler (5). Move track (3) to
the outer side of front idler (5) and remove track
(3).
5 Steel Pipe
M503-07-062

W3-7-1
UNDERCARRIAGE / Track
Installation

CAUTION: Support the bottom of the center

frame of the raised machine by using the
blocks.

1. Put a bucket on the ground of the side where the 90 to 110°

lower roller is to be installed. Raise the machine.
Place a block under the center frame and support
the machine.

W1MP-03-07-003

CAUTION: Rubber crawler weight: 3

ZAXIS8-2: 30 kg (66 lb)
ZAXIS10U-2: 34 kg (75 lb)
4
Reverse
2. Mesh track (3) with sprocket (4). Attach the other
end of track (3) to the lower part of front idler (5).
Rotate sprocket (4) backward and install track (3)
onto front idler (5).

3. Insert the steel pipes in the track (3) inner side 5 Steel Pipe
under front idler (5). Turn sprocket (4) backward W1MP-03-07-005
until the steel pipe steps on front idler (5). Move
track (3) to the center of front idler (5). Remove
the steel pipes from track (3).
1 2
4. Tighten valve (2).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

W1MP-03-07-001

1
5. Add grease through grease fitting (1) and adjust
the track (3) tension.
Check clearance (A) from the lower end of side
frame (6) to track (3) inner side below grease
fitting (1).
Track sag specification (A): 60 to 65 mm (2.4 to 6
2.6 in)

3 W1MP-03-07-002

W3-7-2
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Rubber Crawler Crack 1

1. Outside of Rubber Crawler 2

If there is a crack with depth more than 3 mm
(0.12 in) at lug (1) base, immediately repair the
track.
If there is a crack on lug (1) or on the valley of lug 3
(1) that reaches to steel code (3) or steel core (2)
with length of 30 mm (1.2 in) or more, immediately
repair the track.

W190-03-07-001

2. Inside of Rubber Track (Roller Side)

If there is a crack that reaches to steel code (3) or
steel core (2), immediately repair the track.

3 1 W190-03-07-002

Lower Roller

Lug Wear
Rubber Crawler
1. If lug (1) height (A) is less than 5 mm (0.2 in),
replace the rubber crawler as an assembly.

W190-03-07-003
1

2. When any steel core (3) appeared on the track,

replace the rubber crawler as an assembly.

3
W190-03-07-004

W3-7-3
UNDERCARRIAGE / Track

A A

A-A
W1MP-03-07-004

Unit: mm (in)
Standard Allowable Limit Remedy
1 17 (0.7) 5 (0.2)
2 66 (2.6) 46 (1.8) Replace
3 30 (1.2) 20 (0.8)
4 33 (1.3) 22 (0.9)

W3-7-4
UNDERCARRIAGE / Track

Rubber Crawler and Steel Code Cutting

1. When either of the two rows of steel code (3) has

cut, replace the rubber crawler as an assembly.

3
W190-03-07-005

Steel Core Separation

2. When any steel core (2) has separated, replace

the rubber crawler as an assembly.

2
W190-03-07-006

W3-7-5
UNDERCARRIAGE / Track
(Blank)

W3-7-6
MEMO

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.....................................................................................................................................................................
MEMO

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SECTION 4
FRONT ATTACHMENT

CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment ..... W4-1-1
Maintenance Standard ............................ W4-1-8
Standard Dimensions for Arm and
Bucket Connection ............................ W4-1-11

Group 2 Cylinder
Remove and Install Cylinder ................... W4-2-1
Disassemble Boom Cylinder ................. W4-2-46
Assemble Boom Cylinder...................... W4-2-50
Disassemble Arm Cylinder .................... W4-2-56
Assemble Arm Cylinder......................... W4-2-62
Disassemble Bucket and
Boom Swing Cylinders....................... W4-2-68
Assemble Bucket and
Boom Swing Cylinders....................... W4-2-74
Disassemble Side Frame
Extend/Retract Cylinder..................... W4-2-78
Assemble Side Frame
Extend/Retract Cylinder..................... W4-2-82
Disassemble Blade Cylinder ................. W4-2-86
Assemble Blade Cylinder ...................... W4-2-92
Maintenance Standard .......................... W4-2-98

1MRW-4-1
（Blank）

1MRW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
Removal

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

IMPORTANT: As for handling of the nylon slings,

refer to "Precautions for the Han-
dling of Nylon Slings" on page
W1-1-5.

1. Remove bolt (7) from cover (6). Remove cover 1 2 3

(6) from boom (4) and boom cylinder (5). 4
: 17 mm

2. Attach a nylon sling onto boom cylinder (5) and

hold boom cylinder (5). 5
Remove bolts (3) (2 used) from plate (2). Re- 7
move plate (2) from boom (4). Remove pin (1)
from boom (4) by using a bar and hammer.
: 17 mm
6
3. Operate the control lever and retract the piston
rod. Secure the piston rod to the cylinder tube by W1MP-04-01-001

using a wire.

4. Place the piston rod side of boom cylinder (5) on

the stand.
Piston Rod

Wire

W554-02-03-007
Stand

W4-1-1
FRONT ATTACHMENT / Front Attachment

CAUTION: Front attachment weight: 100 kg Front Attachment

(220 lb) Center of Gravity

5. Attach a nylon sling onto the front attachment 4

center of gravity of boom (4). Take up slack of the
nylon sling. Hold the front attachment.

W1MP-04-01-007
6. Remove plugs (11) (2 used) from the wire to the
work light.

13 14 W1MP-04-01-004

7. Remove bolts (14) (2 used) from clamp (13). 12

Remove clamp (13) from boom (4).
: 13 mm
13
IMPORTANT: Attach an identification tag onto the
removed hoses for assembling.
14
8. Remove hoses (12) (4 used) from the top of
boom (4). Cap the open ends.
: 19 mm

4 W1MP-04-01-005

W4-1-2
FRONT ATTACHMENT / Front Attachment
9. Remove nuts (16) (2 used) from bolt (18). Re-
move bolt (18) from pin (17). Remove pin (17)
from swing post (15) by using a bar and hammer. 4
: 17 mm 18

10. Remove the thrust plates (2 used) between swing 17

post (15) and boom foot (4). Hoist and remove
the front attachment.
16

15
W1MP-04-01-006

W4-1-3
FRONT ATTACHMENT / Front Attachment
Installation
Front Attachment
Center of Gravity
CAUTION: Front attachment weight: 100 kg 4
(220 lb)

1. Hoist the front attachment center of gravity of

boom (4). Align the pin (17) hole on swing post
(15) and boom foot (4).
Insert the thrust plates (2 used) between swing
post (15) and boom foot (4). Check that the
clearance on both sides is within 1 mm respec-
tively. If more than 1 mm, change the thickness or W1MP-04-01-007
the number of thrust plate.

2. Tap and install pin (17) into swing post (15) by

using a plastic hammer. 4
18
IMPORTANT: The clearance between nut (16) and
the boss of swing post (15) should 17
be 3 to 5 mm.
3. Apply LOCTITE #262 onto bolt (18). Insert bolt 16
(18) into the bolt (18) hole on swing post (15) and
install with nuts (16) (2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
15
W1MP-04-01-006

4. Install hoses (12) (4 used) to the pipe on boom

(4).
: 19 mm 12
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

5. Install clamp (13) to boom (4) with bolts (14) 13

(2 used).
: 13 mm 14
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4 W1MP-04-01-005

W4-1-4
FRONT ATTACHMENT / Front Attachment
6. Attach a nylon sling onto boom cylinder (5). Hold
boom cylinder (5).

Piston Rod
CAUTION: If the air in a cylinder is suddenly
compressed, the temperature inside will rise.
As the temperature of hydraulic oil will rise, 5
the seals and rings may be damaged.
Wire
7. Start the engine with the piston rod of boom cyl-
inder (5) retracted fully to the stroke end. Extend
boom cylinder (5) slowly. Align the pin (1) holes
on piston rod of boom (4) and boom cylinder (5).
W554-02-03-007
NOTE: As a result of the work in step 7, the air in Stand
cylinder comes out.

8. Install pin (1) into boom (4) by using a plastic

hammer. Install plate (2) to boom (4) with bolts (3) 1 2 3
(2 used). 4
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

9. Install the lower part of cover (6) onto boom cyl- 5

inder (5). Install cover (6) onto boom (4) with bolt 7
(7).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
6

W1MP-04-01-001

W4-1-5
FRONT ATTACHMENT / Front Attachment
10. Install plug (11) on the wire to the work light.

11. After completing the work, add hydraulic oil to the

11
specified level. Operate every cylinder fully to the
stroke end several times and release the pres-
sure in the circuit. Check for any oil leaks of each
hose.

W1MP-04-01-004

W4-1-6
FRONT ATTACHMENT / Front Attachment
(Blank)

W4-1-7
FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
Pin and Bushing

C Main Frame

B
E D J
I
Side Frame

G K W1MP-04-01-010

Unit: mm (in)
Standard Allowable Limit
Parts Name Remedy
ZX8-2 ZX10U-2 ZX8-2 ZX10U-2
Pin 30 (1.2) ← 29 (1.1) ←
A
Bushing (Boom) 30 (1.2) ← 31.5 (1.2) ←
Pin 25 (1.0) ← 24 (0.9) ←
B
Bushing (Boom Cylinder) 25 (1.0) ← 26.5 (1.0) ←
Pin 25 (1.0) ← 24 (0.9) ←
C
Bushing (Boom Cylinder) 25 (1.0) ← 26.5 (1.0) ←
Pin 30 (1.2) ← 29 (1.1) ← Replace
D
Bushing (Arm) 30 (1.2) ← 31.5 (1.2) ←
Pin 25 (1.0) ← 24 (0.9) ←
E
Bushing (Arm Cylinder) 25 (1.0) ← 26.5 (1.0) ←
Pin 25 (1.0) 30 (1.2) 24 (0.9) 29 (1.1)
F
Bushing (Arm Cylinder) 25 (1.0) 30 (1.2) 26.5 (1.0) 31.5 (1.2)
Pin 25 (1.0) ← 24 (0.9) ←
G
Bushing (Bucket Cylinder) 25 (1.0) ← 26.5 (1.0) ←

W4-1-8
FRONT ATTACHMENT / Front Attachment

P
M

W1MP-04-01-008 N

W1MP-04-01-009
Unit: mm (in)
Standard Allowable Limit
Parts Name Remedy
ZX8-2 ZX10U-2 ZX8-2 ZX10U-2
Pin 25 (1.0) ← 24 (0.9) ←
Bushing (Bucket Cylinder) 25 (1.0) ← 26.5 (1.0) ←
H
Bushing 25 (1.0) ← 24 (0.9) ←
Link B 25 (1.0) ← 26.5 (1.0) ←
Pin 25 (1.0) ← 24 (0.9) ←
I Bushing (Arm) 25 (1.0) ← 26.5 (1.0) ←
Link B 25 (1.0) ← 26.5 (1.0) ←
Pin 25 (1.0) ← 24 (0.9) ←
J
Bushing (Link A) 25 (1.0) ← 26.5 (1.0) ←
Pin 25 (1.0) ← 24 (0.9) ←
K
Bushing (Arm) 25 (1.0) ← 26.5 (1.0) ←
Pin 45 (1.8) ← 44 (1.7) ←
L
Bushing (Main Frame) 45 (1.8) ← 46.5 (1.8) ← Replace
Pin 25 (1.0) ← 24 (0.9) ←
M Bushing ← ←
25 (1.0) 26.5 (1.0)
(Boom Swing Cylinder)
Pin 30 (1.2) ← 29 (112) ←
N Bushing 30 (1.2) ← ←
31.5 (1.2)
(Boom Swing Cylinder)
Pin 25 (1.0) ← 24 (0.9) ←
O
Bushing (Blade) 25 (1.0) ← 26.5 (1.0) ←
Pin 25 (1.0) ← 24 (0.9) ←
P
Bushing (Blade Cylinder) 25 (1.0) ← 26.5 (1.0) ←
Pin 25 (1.0) ← 24 (0.9) ←
Q
Bushing (Blade Cylinder) 25 (1.0) ← 26.5 (1.0) ←

W4-1-9
FRONT ATTACHMENT / Front Attachment
Side Cutter C

B
A

W1MP-04-01-011
Unit: mm (in)
Standard Allowable Limit Remedy
A 39 (1.5) [25 (1.0)]
B 25 (1.0) -
Replace
C 50 (2.0) -
D 60 (2.4) -
NOTE: Values in [ ] are just for reference.

Point 135

E
(23) D

B A
W1MP-04-01-012
Unit: mm (in)
Standard Allowable Limit Remedy
A 75 (2.9) 30 (1.2)
B 60 (2.4) -
C 5 (0.2) - Replace
D 28 (1.1) -
E 18 (0.7) -

W4-1-10
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION

Section A, B W1MP-04-01-014

Unit: mm (in)
ZX10U-2 ZX8-2
a 90 (3.5) 90 (3.5)
b 5 (0.2) 5 (0.2)
c 170 (6.7) 148 (5.8)
d 148 (5.8) 148 (5.8)
e 101 (4.0) 89 (3.5)
f 410 (16.1) 368 (14.5)
g 139 (5.5) 129 (5.0)
i 25 (1.0) 25 (1.0)
j 101 (4.0) 89 (3.5)
k 5 (0.2) 10 (0.4)
l 90° 90°
m 90° 90°
n 100 (4.0) 90 (3.5)

NOTE: Dimensions l and m: 90° means the angle

for the bolt hole.

W4-1-11
FRONT ATTACHMENT / Front Attachment
(Blank)

W4-1-12
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Remove Bucket Cylinder

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

1. Insert a wooden block between bucket cylinder 1

(1) and the arm, and support bucket cylinder (1).

Wooden Arm
Block W571-04-02-001

2 3 4
1

2. Secure link A (5) and link B (4) by using a wire.

6
3. Put the matching marks on the boss of link B (4)
and pin (6). Remove bolts (2) (2 used) from plate
(3). Remove plate (3) from link B (4). Remove pin
(6) from bucket cylinder (1) by using a bar and
hammer. Remove the shims (4 used) between the 5
boss of piston rod and link A (5), and link A (5) and
links B (4) (2 used).
: 17 mm

W1MP-04-02-001

4. Attach a nylon sling onto bucket cylinder (1). Hoist

and hold bucket cylinder (1). Secure the piston
rod to the cylinder tube by using a wire.

W571-04-02-002

W4-2-1
FRONT ATTACHMENT / Cylinder
5. Remove hoses (7) (2 used) from bucket cylinder 7
(1). Cap the open ends.
: 19 mm

6. Remove bolts (10) (2 used) from plate (9). Re-

move plate (9) from arm (11). Remove pin (8)
from bucket cylinder (1) by using a bar and
hammer. Remove the shims (2 used) between the 11
boss of cylinder tube and arm (11).
: 17 mm 10

7. Remove bucket cylinder (1) from arm (11). 9

W1MP-04-02-002
8

W4-2-2
FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder

IMPORTANT: Insert the shims to both sides of

cylinder tube boss. When adding the
shims in order to adjust the clear-
ance, insert the shims to the both
sides respectively. (Clearance: less
than 0.5 mm (0.02 in))
IMPORTANT: Apply grease onto the lip of dust
seal for bucket cylinder (1), boss 7
side and bushing inside (both bot-
tom and rod sides).
1. Align the pin (8) holes on bucket cylinder (1) and
arm (11). Insert the shims (2 used) between the
boss of cylinder tube (1) and arm (11).
11
2. Install pin (8) into arm (11) by using a plastic
hammer. Apply LOCTITE #262 onto bolts (10) (2
10
used). Install plate (9) to arm (11) with bolts (10)
(2 used). 9
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1MP-04-02-002
8 1
3. Install hoses (7) (2 used) to bucket cylinder (1).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 2 3 4

IMPORTANT: If the air in a cylinder is suddenly

compressed, the temperature inside 6
will rise. As the temperature of the
hydraulic oil will rise, the seals and
rings may be damaged.
4. Start the engine with the piston rod of bucket cyl-
5
inder (1) retracted fully to the stroke end. Extend
the piston rod slowly. Align the pin (6) hole on
bucket cylinder (1) with those on link A (5) and
links B (4) (2 used).

W1MP-04-02-001

W4-2-3
FRONT ATTACHMENT / Cylinder
5. Insert the shims (4 used) between the boss of
piston rod (1) and link A (5), and between link A
2 3 4
(5) and links B (4) (2 used). Install pin (6) by using
a plastic hammer.
NOTE: If the clearance is more than 0.5 mm,
change the thickness (0.5 mm (0.02 in), 1.0 6
mm (0.04 in)), or the number of shims.

6. Apply LOCTITE #262 onto bolts (2) (2 used). In-

stall plate (3) to link B (4) with bolts (2) (2 used). 5
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

7. After completing the work, add hydraulic oil to the

specified level. Operate every cylinder fully to the W1MP-04-02-001

stroke end several times and release the pressure

in the circuit. Check for any oil leaks of each hose.

W4-2-4
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer 1
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

1. Insert a wooden block between arm cylinder (1)

and boom (2), and support arm cylinder (1).

Wooden Block 2

W571-04-02-004

2 3 4 1

2. Remove bolts (2) (2 used) from plate (4). Remove

plate (4) from arm (5). Remove pin (3) by using a
bar and hammer. Remove the shims (2 used) 5
between the boss of piston rod and arms (5).
: 17 mm

3. Secure the piston rod to the cylinder tube by using

a wire.

W1MP-04-02-002

1 7 8 9
4. Remove bolt (10) from clamp (11). Remove clamp
(11) from arm cylinder (1).
: 13 mm

IMPORTANT: Attach an identification tag onto the

removed hoses for assembling.
5. Remove hoses (12) (2 used) from arm cylinder (1).
Cap the open ends.
: 19 mm

6. Attach a nylon sling onto arm cylinder (1). Hoist

and hold arm cylinder (1)
12 11 10 2 W1MP-04-02-003

W4-2-5
FRONT ATTACHMENT / Cylinder
7. Remove bolts (9) (2 used) from plate (8). Remove
plate (8) from boom (2). Remove pin (7) from arm 1 7 8 9
cylinder (1) by using a bar and hammer. Remove
the shims (2 used) between the boss of cylinder
tube and boom (2).
: 17 mm

8. Remove arm cylinder (1) from boom (2).

12 11 10 2 W1MP-04-02-003

W4-2-6
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder

IMPORTANT: Insert the shims to both sides of 1 7 8 9

2. Align the pin (7) holes of arm cylinder (1) and

boom (2). Insert the shims (2 used) between the
boss of cylinder tube and arm (2). 12 11 10 2 W1MP-04-02-003

3. Install pin (7) by using a plastic hammer. Apply

LOCTITE #262 onto bolts (9) (2 used). Install
plate (8) to boom (2) with bolts (9) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

4. Install hoses (12) (2 used) to arm cylinder (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

5. Install clamp (11) to arm cylinder (1) with bolt (10).

: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W4-2-7
FRONT ATTACHMENT / Cylinder
IMPORTANT: If the air in a cylinder is suddenly
compressed, the temperature inside
will rise. As the temperature of the
hydraulic oil will rise, the seals and
rings may be damaged. 2 3 4 1
6. Start the engine with the piston rod of arm cylinder
(1) retracted fully to the stroke end. Extend the
piston rod slowly. Align the pin (3) holes on piston
rod and arm (5). 5
NOTE: If it is difficult to align the pin (3) holes, raise
the boom a little and align the holes.

7. Insert the shims (2 used) between the boss of

piston rod and arm (5). Install pin (3) by using a
plastic hammer. Apply LOCTITE #262 onto bolt
(2). Install plate (4) to arm (5) with bolts (2) (2
used).
: 17 mm W1MP-04-02-002

: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

8. After completing the work, add hydraulic oil to the

specified level. Operate every cylinder fully to the
stroke end several times and release the pressure
in the circuit. Check for any oil leaks of each hose.

W4-2-8
FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK 1 2
on W1-4-1.) 3

1. Remove bolt (6) from cover (5). Remove cover (5)

from boom cylinder (4) and boom (7).
: 17 mm 7

2. Attach a nylon sling onto boom cylinder (4). Hoist

and hold boom cylinder (4). Remove bolts (3) (2
used) from plate (2). Remove plate (2) from boom 4
(7). Remove pin (1) by using a bar and hammer.
Remove the shims (2 used) between the boss of
piston rod and boom (7). 6 5 W1MP-04-01-001

: 17 mm

3. Place boom cylinder (4) on a stand. Start the en-

gine. Retract the piston rod to the stroke end.
Secure the piston rod to the cylinder tube by using
a wire. 4

Wire

W554-02-03-007

4. Remove bolt (10) from clamp (9). Remove clamp

(9) from boom cylinder(4). Remove hoses (8) (2
used) from boom cylinder (4). Cap the open ends.
: 19 mm

W1MP-04-02-004
8 4 10 9 8

W4-2-9
FRONT ATTACHMENT / Cylinder
5. Remove nuts (13) (2 used) from bolt (11). Re-
move bolt (11) from swing post (14).
: 17 mm

6. Remove pin (12) from swing post (14) by using a

bar and hammer. Remove the shims (2 used)
from both sides of cylinder tube boss. 4

7. Remove boom cylinder (4). 11

14 W1MP-04-01-006

W4-2-10
FRONT ATTACHMENT / Cylinder
Install Boom Cylinder

IMPORTANT: Insert the shims to both sides of

cylinder tube boss. When adding the
shims in order to adjust the clear-
ance, insert the shims to the both
sides respectively. (Clearance: less
than 0.5 mm (0.02 in))
1. Apply grease onto the lip of dust seal for boom
cylinder (4), boss side and bushing inside (both
bottom and rod sides).
4
2. Apply grease onto the surface of pin (12). Align
the pin (12) holes on boom cylinder (4) and swing 11
post (14). Insert the shims (2 used) between the
12
boss of cylinder tube and swing post (14).
13
3. Install pin (12) by using a plastic hammer.
14 W1MP-04-01-006

IMPORTANT: Install nut (13) so that the clearance

between nut (13) and the boss of
swing post (14) is 3 to 5 mm (0.1 to
0.2 in).
4. Apply LOCTITE #262 onto bolt (11). Insert bolt
(11) into the bolt (11) hole on swing post (14). In-
stall nuts (13) (2 used) to bolt (11).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5. Hoist boom cylinder (4). Install hoses (8) (2 used)

to boom cylinder (4). Install clamp (9) to boom
cylinder (4) with bolt (10).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

W1MP-04-02-004
8 4 10 9 8

W4-2-11
FRONT ATTACHMENT / Cylinder
IMPORTANT: If the air in a cylinder is suddenly
compressed, the temperature inside
will rise. As the temperature of the
hydraulic oil will rise, the seals and
rings may be damaged. 1 2
6. Start the engine with the piston rod of boom cyl-
inder (4) retracted fully to the stroke end. Extend 3
the piston rod slowly. Align the pin (1) holes on
boom cylinder (4) and boom (7).
7
7. Insert the shims (2 used) between the piston rod
boss of boom cylinder (4) and boom (7). Install pin
(1) by using a plastic hammer. Apply LOCTITE
#262 to bolts (3) (2 used). Install plate (2) to boom 4
(7) with bolts (3) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 6 5 W1MP-04-01-001

8. Install cover (5) onto boom cylinder (4). Install

cover (5) onto boom (7) with bolt (6).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9. After completing the work, add hydraulic oil to the

specified level. Operate every cylinder fully to the
stroke end several times and release the pressure
in the circuit. Check for any oil leaks of each hose.

W4-2-12
FRONT ATTACHMENT / Cylinder
Remove Boom Swing Cylinder

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

1. Extend the bucket cylinder. Retract the arm cyl-

inder. Lower the bucket onto the ground. Stop the
engine.

M502-07-055

1 2 3 4 5
2. Remove bolts (2) (2 used) and (3) (5 used) from
undercovers (1, 4). Remove undercovers (1, 4)
from main frame (5).
: 13 mm

W1MP-04-02-032

3. Loosen cap (6) and release any remaining pres-

sure in hydraulic oil tank (7). Remove drain plug
(8) from the cover (4) mounting side. Drain hy-
draulic oil from hydraulic oil tank (7). After draining
hydraulic oil, install drain plug (8) to hydraulic oil
tank (7).
: 12 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

M1MP-07-013
7 6

M1MP-07-015

W4-2-13
FRONT ATTACHMENT / Cylinder
4. Remove screws (9) (10 used) from the top, right 9
and left of covers (10, 11). Remove cover (11)
from the lever stand.
11

W1MP-02-03-006

9
W1MP-02-03-007

5. Loosen nuts (13) (2 used) from travel levers (14)

(2 used). Remove grips (12) (2 used) from travel
levers (14) (2 used) by turning counterclockwise.
: 17 mm 12

14 W1MP-02-03-008

W4-2-14
FRONT ATTACHMENT / Cylinder
6. Remove grip (15) from side frame extend/retract
lever (16).

W1MP-02-03-007

7. Remove cover (10) from the lever stand. Remove

connector (17) from the cover (11) side.

8. Remove bolts (18) (4 used) from the lever stand.

: 17 mm
17

18 18 W1MP-02-03-009

18 W1MP-02-03-010

W4-2-15
FRONT ATTACHMENT / Cylinder
9. Remove bolts (20) (2 used) from bracket (19).
: 13 mm

19 W1MP-02-03-011

10. Open and lock engine cover (21).

W1MP-02-04-001

22
11. Remove mat (22) from main frame (5).

5 W1MP-02-04-002

W4-2-16
FRONT ATTACHMENT / Cylinder
12. Remove bolts (23) (2 used) from cover (24). Re- 23 24
move cover (24) from main frame (5).
: 13 mm

13. Remove bolts (25, 28) (2 used for each) from

covers (26, 27). Remove covers (26, 27) from
main frame (5).
: 13 mm

5 26 25 W1MP-02-04-003

28 27 W1MP-02-04-004

14. Remove bolt (29) from side cover (30). Remove 29

side cover (30) from main frame (5).
: 13 mm

5 W1MP-02-02-001

W4-2-17
FRONT ATTACHMENT / Cylinder
15. Remove bolt (32) from side cover (31). Remove 31 32
side cover (31) from main frame (5).
: 13 mm

5 W1MP-02-06-009

16. Remove connector (33) from horn (32). Remove

bolt (34) from horn (32). Remove horn (32) from
the lever stand.
: 13 mm

W1MP-04-02-033
32, 33, 34

Lever Stand
17. Loosen bands (35) (2 used) from the hose.

W1MP-02-03-009
35 35

W4-2-18
FRONT ATTACHMENT / Cylinder
18. Lean the lever stand in direction of arrow and hold it
until there is enough work space to remove hoses (36)
(2 used) and bolt (37) from hydraulic oil tank (7).
7
19. Remove hoses (36) (2 used) and bolt (37) from
hydraulic oil tank (7). Cap hydraulic oil tank (7)
and hoses (36) (2 used).
: 17 mm, 19 mm

W1MP-04-02-034
37 36

Lever Stand

W1MP-02-03-009

38 7 39 40
20. Remove bolts (39) (2 used), (38) and (42) (2
used) from brackets (40, 41). Remove bracket
(40) from hydraulic oil tank (7) and bracket (41).
: 13 mm

42 W1MP-04-02-035

W4-2-19
FRONT ATTACHMENT / Cylinder
21. Loosen bolt (44) (2 used) and remove wirings (45)
43 44, 45 46 44, 45
(2 used) from battery (48). Loosen nut (43) and
remove battery bracket (46) from battery (48).
Remove battery (48) from bracket (47).
: 10 mm

22. Remove bolts (52), (51) (2 used), (56), (55) (2 W1MP-04-02-036

used) and (69) from brackets (49, 50, 53, 54).

: 13 mm

69 50

55 52

W1MP-04-02-037

54 53

56 47

49
53

50
55

51
54

W1MP-04-02-038

W4-2-20
FRONT ATTACHMENT / Cylinder
23. Lean bracket (47) in direction of arrow and hold it
until there is enough work space to remove bolts
(57) (2 used).

24. Remove bolts (57) (2 used) from hydraulic oil tank (7).
: 17 mm
7

W1MP-04-02-039

W1MP-04-02-040

25. Remove hoses (58) (2 used) from hydraulic oil tank (7).
NOTE: Hoses (58) (2 used) are secured by the
bands (2 used).
7

W1MP-04-02-034
58

W4-2-21
FRONT ATTACHMENT / Cylinder
26. Remove hoses (59) (2 used) from hydraulic oil
tank (7). Remove hose (68) from the return filter.
: 19 mm
7

27. Remove bolt (60) from hydraulic oil tank (7). Re- 68
move hydraulic oil tank (7) from main frame (5).
: 17 mm

W1MP-04-02-034
59
28. Remove bolts (63) (2 used) from plate (62) under
main frame (5). Remove plate (62) from main
frame (5). 61 5 62
: 13 mm 4

29. Remove pin (61) from main frame (5) and boom
swing cylinder (67) by using a bar and hammer.

30. Remove nuts (66) (2 used) from bolt (65). Re- W1MP-04-02-032

move bolt (65) from swing post (64). 63

: 17 mm
63 64
31. Remove pin (63) from swing post (64) and the
piston rod of boom swing cylinder (67) by using a
bar and hammer.

32. Remove the hoses (2 used) of boom swing cyl-

inder (67) from the cover (4) mounting side. Re-
move boom swing cylinder (67) from main frame
(5).
: 19 mm 67

65, 66 W1MP-04-01-006

W4-2-22
FRONT ATTACHMENT / Cylinder
Install Boom Swing Cylinder

1. Align the pin (61) holes on main frame (5) and

boom swing cylinder (67). Install pin (61) into 61 5 62
boom swing cylinder (67) and main frame (5) by
using a plastic hammer.

2. Apply LOCTITE #262 onto bolts (63) (2 used).

Install plate (62) to main frame (5) with bolts (63)
(2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) W1MP-04-02-032

63
3. Align the pin (63) holes on swing post (64) and
the piston rod of boom swing cylinder (67). Install 63 64
pin (63) into swing post (64) by using a plastic
hammer.

IMPORTANT: The clearance between swing post

(64) and nut (66) should be 1 to 5 mm
(0.04 to 0.2 in).
4. Apply LOCTITE #262 onto bolt (65). Install bolt
(65) to swing post (64) and tighten with nuts (66)
(2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 67

65, 66 W1MP-04-01-006

5. Install hoses (69) (2 used) to boom swing cylinder (67).

: 19 mm Pin (63) Hole
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

Pin (61) Hole

W1MP-04-02-041

W4-2-23
FRONT ATTACHMENT / Cylinder
6. Install hydraulic oil tank (7) to the main frame with
bolts (37, 60) and (57) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 7 68

7. Install hoses (36, 59, 58) (2 used for each) and

(68) to hydraulic oil tank (7) and the return filter.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
59

60
W1MP-04-02-034
37 36 58

W1MP-04-02-039

W4-2-24
FRONT ATTACHMENT / Cylinder
8. Install brackets (49, 50) to the hydraulic oil tank
with bolts (52) and (51) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

9. Install bracket (53) to bracket (47) with bolt (56). 47

: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
49
10. Install bracket (55) to bracket (47) with bolts (69) 69 50
and (55) (2 used).
: 13 mm 51
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 55 52

W1MP-04-02-037

54 53

56 47

49
53

50
55

51
54

W1MP-04-02-038
11. Place battery (48) on bracket (47). Install bracket 43 44, 45 46 44, 45
(46) with nuts (43) (2 used).

12. Install wirings (45) (2 used) to the terminals (2

used) of battery (48) with bolts (44) (2 used).
: 10 mm
47

W1MP-04-02-036

W4-2-25
FRONT ATTACHMENT / Cylinder
13. Install bracket (40) to hydraulic oil tank (7) with 38 7 39 40
bolts (39) (2 used). Install bracket (40) to bracket
(41) with bolts (42) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

42 W1MP-04-02-035

14. Install horn (32) to the lever stand with bolt (34).
Install connector (33) of the wiring to horn (32).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W1MP-04-02-033
32, 33, 34

15. Install side cover (31) to main frame (5) with bolt (32). 31 32
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

5 W1MP-02-06-009

W4-2-26
FRONT ATTACHMENT / Cylinder
16. Install side cover (30) to main frame (5) with bolt (29). 29
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

5 W1MP-02-02-001

17. Install covers (26, 27) to main frame (5) with bolts
(25, 28) (2 used for each).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

18. Install cover (24) to main frame (5) with bolts (23)
(2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

28 27 W1MP-02-04-004

23 24

5 26 25 W1MP-02-04-003

W4-2-27
FRONT ATTACHMENT / Cylinder
19. Install mat (22) to main frame (5). 22

5 W1MP-02-04-002

20. Release the lock of engine cover (21) and close it.
21

W1MP-02-04-001

W4-2-28
FRONT ATTACHMENT / Cylinder
21. Install the lever stand with bolts (18) (4 used).
: 17 mm Lever Stand
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

22. Install connector (17).

18 18 W1MP-02-03-009

18 W1MP-02-03-010

23. Install bracket (19) to the lever stand bracket with

bolts (20) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

19 W1MP-02-03-011

Bracket

W4-2-29
FRONT ATTACHMENT / Cylinder
24. Tighten hose bands (35) (2 used) in the lever
stand. Lever Stand

35 35 W1MP-02-03-009

9
25. Install covers (10, 11) to the lever stand with
screws (9) (10 used).
11

W1MP-02-03-006

9
W1MP-02-03-007

W4-2-30
FRONT ATTACHMENT / Cylinder
26. Install grip (15) to side frame extend/retract lever
(16). 14

W1MP-02-03-007

27. Install grips (12) (2 used) to travel levers (14)

(2 used) and tighten with nuts (13) (2 used).
: 17 mm
12

14 W1MP-02-03-008

28. Install covers (1, 4) to main frame (5) with bolts (2)
(2 used) and (3) (5 used). 1 2 3 4 5
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

W1MP-04-02-032

W4-2-31
FRONT ATTACHMENT / Cylinder
29. Remove cap (6) from hydraulic oil tank (7). Add
hydraulic oil to hydraulic oil tank (7) up to level
gauge (70).

M1MP-07-013
7 6

70 M1MP-07-012

W4-2-32
FRONT ATTACHMENT / Cylinder
Remove Blade Cylinder

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer 1 2 3
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

1. Remove bolt (2) from cover (3). Remove cover (3)

from blade cylinder (1).
: 13 mm

W1MP-04-02-005

2. Remove bolts (5) (2 used) from plate (4). Remove

1
plate (4) from the center frame. Remove pin (6)
from the center frame by using a bar and hammer.
: 17 mm

3. Start the engine and retract the piston rod of blade

cylinder (1) to the stroke end. Secure the piston
rod to the cylinder tube by using a wire.

4. Remove hoses (7) (2 used) from blade cylinder 6

W1MP-04-02-006

(1). Cap the open ends.

: 17 mm
7 1 7
5. Remove bolts (9) (2 used) from plate (8). Remove
plate (8) from the blade. Remove pin (10) from the
blade by using a bar and hammer.
: 17 mm

6. Remove blade cylinder (1) from the blade.

10 9 W1MP-04-02-005

W4-2-33
FRONT ATTACHMENT / Cylinder
Install Blade Cylinder

1. Apply grease onto the bushing inside of blade

7 1 7
cylinder (1) and the lip part of dust seal (both
bottom and rod sides).

2. Apply grease onto the surface of pin (10). Align

the pin (10) holes on blade cylinder (1) and the
blade. Install pin (10) into the blade by using a
plastic hammer. Install plate (8) to the blade with
bolts (9) (2 used). 8
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Install hoses (7) (2 used) to blade cylinder (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 10 9 W1MP-04-02-005

IMPORTANT: If the air in a cylinder is suddenly

compressed, the temperature inside 4
will rise. As the temperature of the 5
hydraulic oil will rise, the seals and
rings may be damaged.
4. Retract the piston rod of blade cylinder (1) fully to 1
the stroke end. Start the engine. Extend the piston
rod slowly. Align the pin (6) holes on the piston
rod of blade cylinder (1) and the center frame.

5. Apply grease onto the surface of pin (6). Install

pin (6) by using a plastic hammer.
Install plate (4) to the center frame with bolts (5)
(2 used).
W1MP-04-02-006
: 17 mm 6
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
1 2 3
6. Install cover (3) onto blade cylinder (1) with bolt
(2).

W1MP-04-02-005

W4-2-34
FRONT ATTACHMENT / Cylinder
Remove Side Frame Extend/Retract Cylinder

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

1. Operate side frame extend/retract lever (3) and 1

extend the both side frames fully.

3 W1MP-02-03-006

IMPORTANT: Place the stands (4 used) under 4

track (6) and support the machine.
2. Operate control lever (1) and turn the main frame
to the back side. Operate blade lever (2), lower
blade (5), and raise the front of machine. Operate
control lever (1) and set the angle between boom 90° to 110°
(4) and arm (8) to 90 to 110 degrees. Put the
bottom of bucket (7) on the ground, raise the rear 8 5
of machine, and set the machine in horizontal
position. Place the stands (4 used) under track (6)
and support the machine. W1MP-04-02-007

7 Stand 6

W4-2-35
FRONT ATTACHMENT / Cylinder
3. Remove bolts (16) (2 used) on plate (15) from
side frame extend/retract cylinder (20) mounting 9 10 11
part (A) on left side frame (9). Remove plate (15)
from left side frame (9). Remove pin (14) from left
side frame (9) by using a bar and hammer.
: 17 mm

4. Remove bolts (17) (2 used) on plate (19) from A B

side frame extend/retract cylinder (20) mounting
part (B) on right side frame (11). Remove plate
(19) from right side frame (11). Remove pin (18)
from right side frame (11) by using a bar and
hammer.
: 17 mm 13 12
W1MP-04-02-008

5. Remove bolts (12) (4 used) from cover (13). Re- 14

move cover (13) from center frame (10).
: 13 mm

16
Detail for Part A
W1MP-04-02-009

19
18

W1MP-04-02-010
Detail for Part B

6. Remove hoses (21) (2 used) from side frame ex-

tend/retract cylinder (20). Cap the open ends.
: 19 mm 20

NOTE: Remove hose (21) after turning the cylinder

tube in order to work easily.

21
Pin (14) Hole Pin (18) Hole
W1MP-04-02-011

W4-2-36
FRONT ATTACHMENT / Cylinder
7. Raise the blade and boom, and lower the ma- 11 10 22
chine. Remove bolts (22) (2 used) from center
frame (10).
: 19 mm

W1MP-04-02-012
9

8. Remove bolts (24) (3 used) from cover (25). Re-

23 24
move cover (25) from side frame (23).
: 13 mm

25 W507-03-02-001

NOTE: Travel Device Left Side

9. Remove hoses (27) (4 used) from travel device 26

(26). Cap the open ends. Attach the identification
tags onto the removed hoses for assembling.
: 19 mm, 22 mm
27

W1MP-03-02-008

NOTE: Travel Device Left Side

W4-2-37
FRONT ATTACHMENT / Cylinder
10. Operate control lever (1) and turn the main frame 1
to the right side frame (11) side. Set the angle
between boom and arm to 90 to 110 degrees. Put
the bottom of bucket (7) on the ground and raise
the machine until right side track (6) is off the
ground. Place the stand under center frame (10)
and support the machine.
2

3 W1MP-02-03-006

90° to 110°

SA-268
7 6 Stand 10

W4-2-38
FRONT ATTACHMENT / Cylinder

CAUTION: The right side frame (11) assem-

bly weight: 140 kg (309 lb) 10

9
11. Remove the right side frame (11) assembly from
center frame (10).

W1MP-04-02-014

11
W1MP-04-02-013

10
12. Remove side frame extend/retract cylinder (20)
from center frame (10).

W1MP-04-02-044
20

W4-2-39
FRONT ATTACHMENT / Cylinder
Install Side Frame Extend/Retract Cylinder 1

CAUTION: Release any pressure in the hy-

draulic oil tank before doing any work. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK
on W1-4-1.)

1. Operate control lever (1) and turn the main frame 2

to the right side frame (11) side. Set the angle
between boom (4) and arm (8) to 90 to 110 de-
grees. Put the bottom of bucket (7) on the ground
and raise right side frame (11). Place the stand
under center frame (10) and support the machine.

3 W1MP-02-03-006

90° to 110°

SA-268
7 11 Stand 10

W4-2-40
FRONT ATTACHMENT / Cylinder
2. Insert side frame extend/retract cylinder (20) into
center frame (10) with the piston rod side facing to 9 10
the left side frame (9) side.

Left Side Frame (9) Mounting Side W1MP-04-02-044

W1MP-04-02-011
20

CAUTION: The right side frame (11) assem- Center Frame (10) Inserting Part
bly weight: 140 kg (309 lb)

3. Clean the center frame (10) inserting part of the

right side frame (11) assembly and apply grease.
Insert the right side frame (11) assembly into center
frame (10).

11
W1MP-04-02-013

W1MP-04-02-014

11 10 22

4. Lower right side frame (11). Install bolts (22) (2

used) to center frame (10).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

W1MP-04-02-012
9

W4-2-41
FRONT ATTACHMENT / Cylinder
5. Install hoses (27) (4 used) to travel device (26).
: 19 mm 26
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 27

NOTE: Travel Device Left Side W1MP-03-02-008

6. Install cover (25) onto side frame (23) with bolts
(24) (3 used). 23 24
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

25
W507-03-02-001
IMPORTANT: Place the stands (4 used) under NOTE: Travel Device Left Side
track (6) and support the machine.
1
7. Operate control lever (1) and turn the main frame
to the back side. Operate blade lever (2), lower
the blade, and raise the front of machine. Set the
angle between boom (4) and arm (8) to 90 to 110
degrees. Put the bottom of bucket (7) on the
ground, raise the back of machine, and set the
machine in horizontal position. Place the stands
(4 used) under track (6) and support the machine. 2

3 W1MP-02-03-006

90° to 110°

8 5

W1MP-04-02-007

7 Stand 6

W4-2-42
FRONT ATTACHMENT / Cylinder
8. Install hoses (21) (2 used) to side frame ex-
tend/retract cylinder (20) from the cover (13) 20
mounting side.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

21
Pin (14) Hole Pin (18) Hole
W1MP-04-02-011

9 11
9. Align pin (18) holes on side frame extend/retract
cylinder (20) and right side frame (11) shown on
details for part B. Install pin (18) into right side
frame (11) by using a bar and hammer. Install
plate (19) to right side frame (11) with bolts (17)
(2 used). A B
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W1MP-04-02-008

10. Operate the side frame extend/retract lever and 14

align the pin (14) holes on left side frame (9)
shown on details for part A and the piston rod of
side frame extend/retract cylinder (20). Install pin
(14) into left side frame (9) by using a bar and 15
hammer. Install plate (15) to left side frame (9)
with bolts (16)
(2 used).
: 17 mm Detail for Part A
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) W1MP-04-02-009

19
18

W1MP-04-02-010

Detail for Part B

W4-2-43
FRONT ATTACHMENT / Cylinder
11. Install cover (13) onto center frame (10) with bolts 10
(12) (4 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

A B

12. Raise the blade and boom, and lower the ma- 13 12
W1MP-04-02-008

chine. While operating the side frame ex-

tend/retract lever, fully extend and retract side
frame extend/retract cylinder (20) several times.

W4-2-44
FRONT ATTACHMENT / Cylinder
(Blank)

W4-2-45
FRONT ATTACHMENT / Cylinder
DISASSEMBLE BOOM CYLINDER

13
12
11
10
5
9
8
7
6
5
4

3
2

15
18
19
17

16
15
19A
14
19B

W1MP-04-02-015

1- Piston Rod 6- O-Ring 11 - Cushion Ring 16 - Piston

2- Wiper Ring 7- Backup Ring 12 - Spacer 17 - Steel Ball
3- Cylinder Head 8- U-Ring 13 - Stop Ring 18 - Set Screw
4- O-Ring 9- Bushing 14 - Cushion Bearing 19 - Seal Ring Assembly
5- Backup Ring (2 Used) 10 - O-Ring 15 - Slide Ring (2 Used) 20 - Cylinder Tube

W4-2-46
FRONT ATTACHMENT / Cylinder
Disassemble Boom Cylinder

1. Clamp the pin mounting part (clevis part) of 3. Loosen cylinder head (3) by using a hooked
cylinder tube (20) in a vise horizontally. Extend spanner. Remove the piston rod (1) assembly
piston rod (1) and drain hydraulic oil from the from cylinder tube (20).
cylinder. Cylinder head (3) diameter
ZAXIS8-2 : 63 mm (2.5 in)
IMPORTANT: The lock washer in cylinder head (3) ZAXIS10U-2 : 68 mm (2.7 in)
is provided on cylinder tube (20) and
forms an integral part. Do not
Hooked Spanner
damage cylinder tube (20) and
cylinder head (3) when bending and
extending the lock washer.
2. Pull out piston rod (1) approximately 50 mm (2.0
in). Install a protective cover on piston rod (1). 20
Extend the lock washer in cylinder head (3) by
using a chisel and a hammer.

Lock Washer

1 3 W506-04-02-004

1 3
W506-04-02-003

W4-2-47
FRONT ATTACHMENT / Cylinder

13
12
11
10
5
9
8
7
6
5
4

3
2

15
18
19
17

16
15
19A
14
19B

W1MP-04-02-015

W4-2-48
FRONT ATTACHMENT / Cylinder
IMPORTANT: Cut away the crimped part (2 places) 8. Remove backup rings (5) (2 used) and O-ring (4,
by using a hand drill and loosen set 6, 10) from the outside of cylinder head (3).
screw (18).
4. Secure piston rod (1) horizontally. Remove set 9. Remove stop ring (13), spacer (12) and cushion
screw (18) and steel ball (17) from piston (16). ring (11) from the inside of cylinder head (3).
: 3 mm
10. Remove wiper ring (2), U-ring (8) and backup ring
5. Remove piston (16) and cushion bearing (14) (7) from the inside of cylinder head (3).
from piston rod (1).
: 36 mm
IMPORTANT: Bushing (9) cannot be reused. When
removing bushing (9), replace with
6. Wind a protection tape onto the thread of piston rod the new one.
(1). Remove cylinder head (3) from piston rod (1). 11. Remove bushing (9) from cylinder head (3) by
using special tools (ST 1518, 7375) and a press.
IMPORTANT: Slide rings (15) (2 used) cannot be
reused. When disassembling the
cylinder, replace slide ring (15) with
the new one.
IMPORTANT: Do not damage the seals when
removing.
7. Clamp piston (16) in a vise. Remove slide rings ST 1518
(15) (2 used) from piston (16). Cut and remove
seal ring assembly (19) from piston (16) by using
a screwdriver.
3

16
9
19

ST 7375

W1MP-04-02-016

W506-04-02-007

W4-2-49
FRONT ATTACHMENT / Cylinder
ASSEMBLE BOOM CYLINDER

18 15 19B 15 14 20 5, 10 5, 6 4 3

W1MP-04-02-017

17 19A 16 1 13 12 11 9 8 7 2

1- Piston Rod 6- O-Ring 11 - Cushion Ring 16 - Piston

W4-2-50
FRONT ATTACHMENT / Cylinder
Assemble Boom Cylinder

IMPORTANT: Install U-ring (8) with the groove side 3. Install cushion ring (11), spacer (12) and stop ring
facing to the bushing (9) side. (13) to cylinder head (3).
1. Install backup ring (7) and U-ring (8) to the inside
of cylinder head (3). 4. Install wiper ring (2) to cylinder head (3) by using
special tool (ST 7377).
2. Install bushing (9) into cylinder head (3) by using
special tool (ST 1518) and a press.

ST 7377

2
ST 1518

3 W1MP-04-02-019

W1MP-04-02-018

W4-2-51
FRONT ATTACHMENT / Cylinder

18 15 19B 15 14 20 5, 10 5, 6 4 3

W1MP-04-02-017

17 19A 16 1 13 12 11 9 8 7 2

W4-2-52
FRONT ATTACHMENT / Cylinder
IMPORTANT: Check that O-ring (19A) of seal ring IMPORTANT: If not adjusting seal ring (19B),
assembly (19) is not twisted. piston (16) cannot be installed to
5. Install O-ring (19A) to piston (16). Install seal ring cylinder tube (20).
(19B) to piston (16) by using special tools 1 and 2. 6. Attach piston (16) to special tool and adjust seal
Special tools ring (19B).
Special tool 1: Special tool
ZAXIS8-2 : ST 1519 ZAXIS8-2 : ST 7380
ZAXIS10U-2 : ST 1520 ZAXIS10U-2 : ST 7381
Special tool 2:
ZAXIS8-2 : ST 7378
ZAXIS10U-2 : ST 7379
19A, 19B
Special Tool 2
16
Special Tool
19B
Special Tool 1

19A
W566-04-02-011

16
IMPORTANT: Install slide rings (15) (2 used) with
their slits positioned 180 degrees
facing the opposite of each other.
W566-04-02-010 7. Install slide rings (15) (2 used) to piston (16).

8. Wind a tape in order to protect onto the thread of

piston rod (1). Remove the tape before rotating
the cylinder head (3) assembly. Rotate and install
the cylinder head (3) assembly to piston rod (1).

W4-2-53
FRONT ATTACHMENT / Cylinder

18 15 19B 15 14 20 5, 10 5, 6 4 3

W1MP-04-02-017

17 19A 16 1 13 12 11 9 8 7 2

W4-2-54
FRONT ATTACHMENT / Cylinder
IMPORTANT: Check the direction to install IMPORTANT: Do not drop slide rings (15) (2 used)
cushion bearing (14). from piston (16) when inserting the
9. Install cushion bearing (14) and the piston (16) piston rod (1) assembly into cylinder
assembly to piston rod (1). tube (20).
ZAXIS8-2 11. Apply hydraulic oil onto the seal parts. Secure
: 36 mm cylinder tube (20) in a vise horizontally. Insert the
: 206 N⋅m (21 kgf⋅m, 152 lbf⋅ft) piston rod (1) assembly into cylinder tube (20).
ZAXIS10U-2
: 36 mm 12. Apply hydraulic oil onto the seal parts. Tighten
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft) cylinder head (3) to cylinder tube (20) by using a
hooked spanner. Bend the lock washer in order
10. Insert steel ball (17) into piston (16) and install set not to loosen.
screw (18). Crimp set screw (18) by using a punch ZAXIS8-2
(2 places). Cylinder diameter: 63 mm (2.5 in)
ZAXIS8-2 : 255 N⋅m (26 kgf⋅m, 188 lbf⋅ft)
: 3 mm ZAXIS10U-2
: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft) Cylinder diameter: 68 mm (2.7 in)
ZAXIS10U-2 : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
: 3 mm
: 6.8 N⋅m (1 kgf⋅m, 5 lbf⋅ft)
Hooked Spanner

23 W506-04-02-019

W4-2-55
FRONT ATTACHMENT / Cylinder
DISASSEMBLE ARM CYLINDER
ZAXIS8-2

10
16
13 17
16
12
11
10

8
9
6
5
4

3
2

W1MP-04-02-023

1- Piston Rod 6- O-Ring 10 - Slide Ring (2 Used) 14 - -

2- Wiper Ring 7- - 11 - Piston 15 - Cylinder Tube
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Backup Ring (2 Used)
4- O-Ring 9- Bushing 13 - Set Screw 17 - O-Ring
5- Backup Ring

W4-2-56
FRONT ATTACHMENT / Cylinder
ZAXIS10U-2

10
13
14
12
11
10
14B
9 14A
8
7
6
5
4

3
2

W1MP-04-02-024

1- Piston Rod 5- Backup Ring 9- Bushing 13 - Set Screw

2- Wiper Ring 6- O-Ring 10 - Slide Ring (2 Used) 14 - Seal Ring Assembly
3- Cylinder Head 7- Backup Ring 11 - Piston 15 - Cylinder Tube
4- O-Ring 8- U-Ring 12 - Steel Ball

W4-2-57
FRONT ATTACHMENT / Cylinder
ZAXIS10U-2

10
13
14
12
11
10
14B
9 14A
8
7
6
5
4

3
2

W1MP-04-02-024

W4-2-58
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
• Disassembly of the arm cylinder for ZAXIS10U-2 3. Loosen cylinder head (3) by using a hooked
is explained as an example. spanner. Remove the piston rod (1) assembly
from cylinder tube (15).
1. Clamp the pin mounting part (clevis part) of Cylinder head (3) diameter: 63 mm (2.5 in)
cylinder tube (15) in a vise horizontally. Extend
piston rod (1) and drain hydraulic oil from the
cylinder. Hooked Spanner

IMPORTANT: The lock washer in cylinder head (3)

is provided on cylinder tube (15) and
forms an integral part. Do not 15
damage cylinder tube (15) and
cylinder head (3) when bending and
extending the lock washer.
2. Pull out piston rod (1) approximately 50 mm (2.0
in). Install a protective cover on piston rod (1).
Extend the lock washer in cylinder head (3) by
using a chisel and hammer.
1 3 W506-04-02-004
15

Lock Washer

1 3
W506-04-02-003

W4-2-59
FRONT ATTACHMENT / Cylinder
ZAXIS10U-2

10
13
14
12
11
10
14B
9 14A
8
7
6
5
4

3
2

10
16 W1MP-04-02-024
13 17
16
12
11
10

8
9
6
5
4

3
2

ZAXIS8-2 Cylinder Head and Piston Part Composition

W1MP-04-02-042

W4-2-60
FRONT ATTACHMENT / Cylinder
IMPORTANT: Cut away the crimped part (2 places) 8. Remove backup ring (5) and O-rings (4, 6) from
by using a hand drill and loosen set the outside of cylinder head (3).
screw (13).
4. Secure piston rod (1) horizontally. Remove set 9. ZAXIS10U-2
screw (13) and steel ball (12) from piston (11). Remove wiper ring (2), U-ring (8) and backup ring
: 3 mm (7) from the inside of cylinder head (3).
ZAXIS8-2
5. Remove piston (11) from piston rod (1). Remove wiper ring (2) and U-ring (8) from the
inside of cylinder head (3).
6. Wind a protection tape onto the thread of piston rod
(1). Remove cylinder head (3) from piston rod (1). IMPORTANT: Bushing (9) cannot be reused. When
removing bushing (9), replace it with
IMPORTANT: Slide rings (10) (2 used) cannot be the new one.
reused. When disassembling the 10. Remove bushing (9) from cylinder head (3) by
cylinder, replace slide rings (10) with using special tools (ST 1518, 7375) and a press.
new one.
IMPORTANT: Do not damage the seals when
removing.
7. ZAXIS10U-2
Clamp piston (11) in a vise. Remove slide rings
(10) (2 used) from piston (11). Remove seal ring
ST 1518
assembly (14) from piston (11) by using a
screwdriver.
ZAXIS8-2
Clamp piston (11) in a vise. Remove slide rings 3
(10) (2 used) from piston (11). Remove backup
rings (16) (2 used) and O-ring (17) from piston
(11).
9

14 ST 7375

W1MP-04-02-016

W506-04-02-007

W4-2-61
FRONT ATTACHMENT / Cylinder
ASSEMBLE ARM CYLINDER

ZAXIS8-2

13 10 16, 17 10 15 1 15 5, 6 4 3 1

W1MP-04-02-031

12 11 9 8 2

ZAXIS10U-2

13 10 14B 10 15 1 15 5, 6 4 3 1

W1MP-04-02-025

12 14A 11 9 7, 8 2

1 - Piston Rod 6 - O-Ring 11 - Piston 16 - Backup Ring (2 Used)

(ZAXIS8-2 only)
2 - Wiper Ring 7 - Backup Ring 12 - Steel Ball 17 - O-Ring
(ZAXIS10U-2 only) (ZAXIS8-2 only)
3 - Cylinder Head 8 - U-Ring 13 - Set Screw
4 - O-Ring 9 - Bushing 14 - Seal Ring Assembly
(ZAXIS10U-2 only)
5 - Backup Ring 10 - Slide Ring (2 Used) 15 - Cylinder Tube

W4-2-62
FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder

1. Install bushing (9) into cylinder head (3) by using IMPORTANT: Check the direction to install U-ring
special tool (ST 1518) and a press. (8).
2. ZAXIS10U-2
Install backup ring (7) and U-ring (8) to the inside
of cylinder head (3).
ZAXIS8-2
Install U-ring (8) to the inside of cylinder head (3).
ST 1518

9 8

W1MP-04-02-018

W1LD-04-02-004

3. Install wiper ring (2) to cylinder head (3) by using

special tool (ST 7377).

ST 7377

W1MP-04-02-019

W4-2-63
FRONT ATTACHMENT / Cylinder

ZAXIS8-2

13 10 16, 17 10 15 1 15 5, 6 4 3 1

W1MP-04-02-031

12 11 9 8 2

ZAXIS10U-2

13 10 14B 10 15 1 15 5, 6 4 3 1

W1MP-04-02-025

12 14A 11 9 7, 8 2

W4-2-64
FRONT ATTACHMENT / Cylinder
4. Install O-rings (4, 6) and backup ring (5) to the 6. ZAXIS10U-2
outside of cylinder head (3). IMPORTANT: If not adjusting seal ring (14B),
piston (11) cannot be installed to
IMPORTANT: Check that O-ring (14A) of seal ring cylinder tube (15).
assembly (14) is not twisted. Attach piston (11) to special tool (ST 7380) and
5. ZAXIS10U-2 adjust seal ring (14B).
Install O-ring (14A) to piston (11). Install seal ring
(14B) to piston (11) by using special tools (ST
7378, 1519).

ST 7378 14B

14B 11
ST 7380
ST 1519

14A

W566-04-02-011

11 ZAXIS8-2
Step 6 is unnecessary.

W566-04-02-010 IMPORTANT: Install slide rings (10) (2 used) with

their slits positioned 180 degrees
ZAXIS8-2 facing the opposite of each other.
Install backup rings (16) (2 used) and O-ring (17) 7. Install slide rings (10) (2 used) to piston (11).
to piston (11).
8. Wind a tape in order to protect the thread of
piston rod (1). Remove the tape before rotating
the cylinder head (3) assembly. Rotate and install
the cylinder head (3) assembly to piston rod (1).

W4-2-65
FRONT ATTACHMENT / Cylinder

ZAXIS8-2

13 10 16, 17 10 15 1 15 5, 6 4 3 1

W1MP-04-02-031

12 11 9 8 2

ZAXIS10U-2

13 10 14B 10 15 1 15 5, 6 4 3 1

W1MP-04-02-025

12 14A 11 9 7, 8 2

W4-2-66
FRONT ATTACHMENT / Cylinder
9. Install the piston (11) assembly to piston rod (1). IMPORTANT: Do not drop slide rings (10) (2 used)
ZAXIS8-2 from piston (11) when inserting the
: 36 mm piston rod (1) assembly into cylinder
: 158 N⋅m (16 kgf⋅m, 117 lbf⋅ft) tube (15).
ZAXIS10-2 11. Apply hydraulic oil onto the seal parts. Secure
: 36 mm cylinder tube (15) in a vise horizontally. Insert the
: 206 N⋅m (21 kgf⋅m, 152 lbf⋅ft) piston rod (1) assembly into cylinder tube (15).

10. Insert steel ball (12) into piston (11) and install set 12. Apply hydraulic oil onto the seal parts. Tighten
screw (13). Crimp set screw (13) by using a punch cylinder head (3) to cylinder tube (15) by using a
(2 places). hooked spanner. Bend the lock washer in order
ZAXIS8-2 not to loosen.
: 3 mm Cylinder head diameter: 63 mm (2.5 in)
: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft) : 255 N⋅m (26 kgf⋅m, 188 lbf⋅ft)
ZAXIS10U-2
: 3 mm
: 6.8 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft) Hooked Spanner

15 W506-04-02-019

W4-2-67
FRONT ATTACHMENT / Cylinder
DISASSEMBLE BUCKET AND BOOM
SWING CYLINDERS
Bucket Cylinder

9
13
14
12 13
11
10
9

8
7
6
5
4

3
2

W1MP-04-02-020

1- Piston Rod 5- Backup Ring 9- Slide Ring (2 Used) 13 - Backup Ring (2 Used)
2- Wiper Ring 6- O-Ring 10 - Piston 14 - Seal Ring
3- Cylinder Head 7- Bushing 11 - Steel Ball 15 - Cylinder Tube
4- O-Ring 8- U-Ring 12 - Set Screw

W4-2-68
FRONT ATTACHMENT / Cylinder
Boom Swing Cylinder

9
13

12 14
13
11
10

8
7
6
5
4

3
2

W1MP-04-02-021

W4-2-69
FRONT ATTACHMENT / Cylinder
Bucket Cylinder

9
13
14
12 13
11
10
9

8
7
6
5
4

3
2

W1MP-04-02-020

W4-2-70
FRONT ATTACHMENT / Cylinder
Disassemble Bucket and Boom Swing Cylinders 3. Loosen cylinder head (3) by using a hooked
spanner. Remove the piston rod (1) assembly
• Disassembly of the bucket cylinder is explained from cylinder tube (15).
as an example. Cylinder head (3) diameter: 63 mm (2.5 in)
1. Clamp the pin mounting part (clevis part) of
cylinder tube (15) in a vise horizontally. Extend
piston rod (1) and drain hydraulic oil from the Hooked Spanner
cylinder.

IMPORTANT: The lock washer in cylinder head (3)

is provided on cylinder tube (15) and 15
forms an integral part. Do not
damage cylinder tube (15) and
cylinder head (3) when bending and
extending the lock washer.
2. Pull out piston rod (1) approximately 50 mm (2.0
in). Install a protective cover on piston rod (1).
Extend the lock washer in cylinder head (3) by
using a chisel and hammer. 1 3 W506-04-02-004

Lock Washer

1 3
W506-04-02-003

W4-2-71
FRONT ATTACHMENT / Cylinder

9
13
14
12 13
11
10
9

8
7
6
5
4

3
2

W1MP-04-02-020

W4-2-72
FRONT ATTACHMENT / Cylinder
IMPORTANT: Cut away the crimped part (2 places) 8. Remove backup ring (5) and O-rings (4, 6) from
by using a hand drill and loosen set the outside of cylinder head (3).
screw (12).
4. Secure piston rod (1) horizontally. Remove set 9. Remove wiper ring (2) and U-ring (8) from the
screw (12) and steel ball (11) from piston (10). inside of cylinder head (3).
: 3 mm
IMPORTANT: Bushing (7) cannot be reused. When
5. Remove piston (10) from piston rod (1). removing bushing (7), replace with a
: 36 mm new one.
10. Remove bushing (7) from cylinder head (3) by
6. Wind a protection tape onto the thread of piston using special tools (ST 1517, 7374) and a press.
rod (1). Remove cylinder head (3) from piston rod
(1).

IMPORTANT: Slide rings (9) (2 used) cannot be

reused. When disassembling the
cylinder, replace slide ring (9) with
new one. ST 1517
IMPORTANT: Do not damage the seals when
removing.
7. Clamp piston (10) in a vise. Remove slide rings
(9) (2 used) from piston (10). Remove backup 3
rings (13) (2 used) and O-ring (14) from piston
(10) by using a screwdriver.

13
ST 7374

W1MP-04-02-016

W506-04-02-007

W4-2-73
FRONT ATTACHMENT / Cylinder
ASSEMBLE BUCKET AND BOOM SWING
CYLINDERS

12 9 13, 14 9 10 15 5, 6 4 3 1

W1MP-04-02-022

11 8 7 2

W4-2-74
FRONT ATTACHMENT / Cylinder
Assemble Bucket and Boom Swing Cylinders 3. Install wiper ring (2) to cylinder head (3) by using
special tool (ST 7376).
1. Install bushing (7) into cylinder head (3) by using
special tool (ST 1517) and a press.

ST 7376

ST 1517 2

3 W1MP-04-02-019

4. Install O-rings (4, 6) and backup ring (5) to the

W1MP-04-02-018
outside of cylinder head (3).

IMPORTANT: Check the direction to install U-ring

5. Install backup rings (13) (2 used) and O-ring (14)
(8).
to piston (10).
2. Install U-ring (8) to the inside of cylinder head (3).

IMPORTANT: Install slide rings (9) (2 used) with

3 their slits positioned 180 degrees
facing the opposite of each other.
6. Install slide rings (9) (2 used) to piston (10).
8
7. Wind a tape in order to protect the thread of
piston rod (1). Remove the tape before rotating
the cylinder head (3) assembly. Rotate and install
the cylinder head (3) assembly to piston rod (1).

W1LD-04-02-004

W4-2-75
FRONT ATTACHMENT / Cylinder

12 9 13, 14 9 10 15 5, 6 4 3 1

W1MP-04-02-022

11 8 7 2

W4-2-76
FRONT ATTACHMENT / Cylinder
8. Install the piston (10) assembly to piston rod (1). IMPORTANT: Do not drop slide rings (9) (2 used)
: 36 mm from piston (10) when inserting the
: 158 N⋅m (16 kgf⋅m, 117 lbf⋅ft) piston rod (1) assembly into cylinder
tube (15).
9. Insert steel ball (11) into piston (10) and install set 10. Apply hydraulic oil onto the seal parts. Secure
screw (12). Crimp set screw (12) by using a cylinder tube (15) in a vise horizontally. Insert the
punch (2 places). piston rod (1) assembly into cylinder tube (15).
: 3 mm
: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft) 11. Apply hydraulic oil onto the seal parts. Tighten
cylinder head (3) to cylinder tube (15) by using a
hooked spanner. Bend the lock washer in order
not to loosen.
Cylinder head diameter: 63 mm (2.5 in)
: 255 N⋅m (26 kgf⋅m, 188 lbf⋅ft)

Hooked Spanner

15 W506-04-02-019

W4-2-77
FRONT ATTACHMENT / Cylinder
DISASSEMBLE SIDE FRAME
EXTEND/RETRACT CYLINDER

11
12
11

10
9
8
7
6
5
4

W1MP-04-02-029

1- Piston Rod 5- Backup Ring 9 - O-Ring 12 - O-Ring

2- Wiper Ring 6- O-Ring 10 - Piston 13 - U-Nut
3- Cylinder Head 7- Bushing 11 - Backup Ring (2 Used) 14 - Cylinder Tube
4- O-Ring 8- U-Ring

W4-2-78
FRONT ATTACHMENT / Cylinder
Disassemble Side Frame Extend/Retract Cylinder

1. Clamp the pin mounting part (clevis part) of 3. Loosen cylinder head (3) by using a hooked
cylinder tube (14) in a vise horizontally. Extend spanner. Remove the piston rod (1) assembly
piston rod (1) and drain hydraulic oil from the from cylinder tube (14).
cylinder. Cylinder head (3) diameter: 63 mm (2.5 in)

IMPORTANT: The lock washer in cylinder head (3)

Hooked Spanner
is provided on cylinder tube (14) and
forms an integral part. Do not
damage cylinder tube (14) and
cylinder head (3) when bending and
extending the lock washer. 14
2. Pull out piston rod (1) approximately 50 mm (2.0
in). Install a protective cover on piston rod (1).
Extend the lock washer in cylinder head (3) by
using a chisel and hammer.

Lock Washer 1 3 W506-04-02-004

1 3
W506-04-02-003

W4-2-79
FRONT ATTACHMENT / Cylinder

11
12
11

10
9
8
7
6
5
4

W1MP-04-02-029

W4-2-80
FRONT ATTACHMENT / Cylinder
4. Remove U-nut (13) and piston (10) from piston 7. Remove backup ring (5) and O-rings (4, 6) from
rod (1). the outside of cylinder head (3).
: 24 mm
8. Remove wiper ring (2) and U-ring (8) from the
5. Wind a protection tape onto the thread of piston rod inside of cylinder head (3).
(1) in order to protect the cylinder head (3) seal.
Remove cylinder head (3) from piston rod (1). IMPORTANT: Bushing (7) cannot be reused. When
removing bushing (7), replace with a
IMPORTANT: Do not damage the seals when new one.
removing. 9. Remove bushing (7) from the inside of cylinder
6. Clamp piston (10) in a vise. Remove backup rings head (3) by using special tools (ST 1517, 7374)
(11) (2 used) and O-ring (12) from the outside of and a press.
piston (10). Remove O-ring (9) from the inside of
piston (10).

10
ST 1517
11, 12

W506-04-02-007

ST 7374

W1MP-04-02-016

W4-2-81
FRONT ATTACHMENT / Cylinder
ASSEMBLE SIDE FRAME
EXTEND/RETRACT CYLINDER

13 11, 12 10 14 14 5, 6 4 3 1

W1MP-04-02-030

9 8 7 2

1- Piston Rod 5- Backup Ring 9 - O-Ring 12 - O-Ring

2- Wiper Ring 6- O-Ring 10 - Piston 13 - U-Nut
3- Cylinder Head 7- Bushing 11 - Backup Ring (2 Used) 14 - Cylinder Tube
4- O-Ring 8- U-Ring

W4-2-82
FRONT ATTACHMENT / Cylinder
Assemble Side Frame Extend/Retract Cylinder 3. Install wiper ring (2) to cylinder head (3) by using
special tool (ST 7376).
1. Install bushing (7) into cylinder head (3) by using
special tool (ST 1517) and a press.

ST 7376

ST 1517
2

3 W1MP-04-02-019

4. Install O-rings (4, 6) and backup ring (5) to the

W1MP-04-02-018
outside of cylinder head (3).

IMPORTANT: Check the direction to install U-ring IMPORTANT: Check that O-ring (12) is not twisted.
(8). 5. Install O-ring (12) and backup rings (11) (2 used)
2. Install U-ring (8) to cylinder head (3). to piston (10).

3 6. Install O-ring (9) to the inside of piston (10).

7. Wind a tape in order to protect the thread of

8 piston rod (1). Remove the tape before rotating
the cylinder head (3) assembly. Rotate and install
the cylinder head (3) assembly to piston rod (1).

W1LD-04-02-004

W4-2-83
FRONT ATTACHMENT / Cylinder

13 11, 12 10 14 14 5, 6 4 3 1

W1MP-04-02-030

9 8 7 2

W4-2-84
FRONT ATTACHMENT / Cylinder
8. Install piston (10) assembly to piston rod (1) with
U-nut (13).
: 24 mm
: 159 N⋅m (16 kgf⋅m, 118 lbf⋅ft)

9. Apply hydraulic oil onto the seal parts. Secure

cylinder tube (14) in a vise horizontally. Insert the
piston rod (1) assembly into cylinder tube (14)
straightly in order not to damage.

10. Apply hydraulic oil onto the seal parts. Tighten

cylinder head (3) to cylinder tube (14) by using a
hooked spanner. Bend the lock washer in order
not to loosen.
Cylinder head diameter: 63 mm (2.5 in)
: 255 N⋅m (26 kgf⋅m, 188 lbf⋅ft)

Hooked Spanner

14 W506-04-02-019

W4-2-85
FRONT ATTACHMENT / Cylinder
DISASSEMBLE BLADE CYLINDER
ZAXIS8-2

9
15
16
12
15
11
10
9
8
7
6
5
4

3
2

14
W1MP-04-02-026

1- Piston Rod 5- Backup Ring 9- Slide Ring (2 Used) 13 - -

2- Wiper Ring 6- O-Ring 10 - Piston 14 - Cylinder Tube
3- Cylinder Head 7- Bushing 11 - Steel Ball 15 - Backup Ring (2 Used)
4- O-Ring 8- U-Ring 12 - Set Screw 16 - O-Ring

W4-2-86
FRONT ATTACHMENT / Cylinder
ZAXIS10U-2

12 13
11
10
9
13B
8 13A
7
6
5
4

3
2

14
W1MP-04-02-027

1- Piston Rod 5- Backup Ring 9- Slide Ring (2 Used) 13 - Seal Ring Assembly
2- Wiper Ring 6- O-Ring 10 - Piston 14 - Cylinder Tube
3- Cylinder Head 7- Bushing 11 - Steel Ball
4- O-Ring 8- U-Ring 12 - Set Screw

W4-2-87
FRONT ATTACHMENT / Cylinder
ZAXIS10U-2

12 13
11
10
9
13B
8 13A
7
6
5
4

3
2

14
W1MP-04-02-027

W4-2-88
FRONT ATTACHMENT / Cylinder
Disassemble Blade Cylinder 3. Loosen cylinder head (3) by using a hooked
spanner. Remove the piston rod (1) assembly
• Disassembly of the blade cylinder for from cylinder tube (15).
ZAXIS10U-2 is explained as an example. Cylinder head (3) diameter
1. Clamp the pin mounting part (clevis part) of ZAXIS8-2： 63 mm (2.5 in)
cylinder tube (15) in a vise horizontally. Extend ZAXIS10U-2： 73 mm (2.9 in)
piston rod (1) and drain hydraulic oil from the
cylinder.
Hooked Spanner

IMPORTANT: The lock washer in cylinder head (3)

is provided on cylinder tube (15) and
forms an integral part. Do not
damage cylinder tube (15) and 15
cylinder head (3) when bending and
extending the lock washer.
2. Pull out piston rod (1) approximately 50 mm (2.0
in). Install a protective cover on piston rod (1).
Extend the lock washer in cylinder head (3) by
using a chisel and hammer.

15 1 3 W506-04-02-004

Lock Washer

1 3
W506-04-02-003

W4-2-89
FRONT ATTACHMENT / Cylinder
ZAXIS10U-2

12 13
11
10
9
13B
8 13A
7
6
5
4

3
2

14
W1MP-04-02-027

9
15
16
12
15
11
10

ZAXIS8-2 Piston Part Composition

W1MP-04-02-043

W4-2-90
FRONT ATTACHMENT / Cylinder
IMPORTANT: Cut away the crimped part (2 places) 8. Remove backup ring (5) and O-rings (4, 6) from
by using a hand drill and loosen set the outside of cylinder head (3).
screw (12).
4. Secure piston rod (1) horizontally. Remove set 9. Remove wiper ring (2) and U-ring (8) from the
screw (12) and steel ball (11) from piston (10). inside of cylinder head (3).
: 3 mm
IMPORTANT: Bushing (7) cannot be reused. When
5. Remove piston (10) from piston rod (1). removing bushing (7), replace with a
new one.
6. Wind a protection tape onto the thread of piston rod 10. Remove bushing (7) from the inside of cylinder
(1) in order to protect the cylinder head (3) seal. head (3) by using special tools (ST 1518, 7375)
Remove cylinder head (3) from piston rod (1). and a press.

IMPORTANT: Slide rings (9) (2 used) cannot be

reused. When disassembling the
cylinder, replace slide rings (9) (2
used) with new ones.
IMPORTANT: Do not damage the seals when
removing.
7. ZAXIS10U-2 ST 1518
Clamp piston (10) in a vise. Remove slide rings
(9) (2 used) from piston (10). Cut and remove seal
ring assembly (13) from piston (10) by using a
screwdriver. 3
ZAXIS8-2
Clamp piston (10) in a vise. Remove slide rings
(9) (2 used) from piston (10). Remove backup
rings (15) (2 used) and O-ring (16) from piston 7
(10).

ST 7375
10

13
W1MP-04-02-016

W506-04-02-007

W4-2-91
FRONT ATTACHMENT / Cylinder
ASSEMBLE BLADE CYLINDER

ZAXIS8-2
12 9 15, 16 9 10 14 5, 6 4 3 1

W1MP-04-02-022

11 8 7 2

ZAXIS10U-2
12 9 13B 9 10 14 5, 6 4 3 1

W1MP-04-02-028

11 13A 8 7 2

1- Piston Rod 5- Backup Ring 9- Slide Ring (2 Used) 13 - Seal Ring Assembly (ZAXIS10U-2 only)
2- Wiper Ring 6- O-Ring 10 - Piston 14 - Cylinder Tube
3- Cylinder Head 7- Bushing 11 - Steel Ball 15 - Backup Ring (2 Used) (ZAXIS8-2 only)
4- O-Ring 8- U-Ring 12 - Set Screw 16 - O-Ring (ZAXIS8-2 only)

W4-2-92
FRONT ATTACHMENT / Cylinder
Assemble Blade Cylinder

1. Install bushing (7) into cylinder head (3) by using IMPORTANT: Check the direction to install U-ring
special tool (ST 1518) and a press. (8).
2. Install U-ring (8) to cylinder head (3).

ST 1518 8

3
W1LD-04-02-004

W1MP-04-02-018 3. Install wiper ring (2) to cylinder head (3) by using

special tool (ST 7377).

ST 7377

W1MP-04-02-019

W4-2-93
FRONT ATTACHMENT / Cylinder

ZAXIS8-2
12 9 15, 16 9 10 14 5, 6 4 3 1

W1MP-04-02-022

11 8 7 2

ZAXIS10U-2
12 9 13B 9 10 14 5, 6 4 3 1

W1MP-04-02-028

11 13A 8 7 2

W4-2-94
FRONT ATTACHMENT / Cylinder
4. Install O-rings (4, 6) and backup ring (5) to the 6. ZAXIS10U-2
outside of cylinder head (3). IMPORTANT: If not adjusting seal ring (13B),
piston (10) cannot be installed to
IMPORTANT: Check that O-rings (13A, 16) are not cylinder tube (14).
twisted. Attach piston (10) to special tool (ST 7381) and
5. ZAXIS10U-2 adjust seal ring (13B).
Install O-ring (13A) to piston (10). Install seal ring
(13B) to piston (10) by using special tools (ST
7379, 1520).

13B
ST 7379

13B 10
ST 7381
ST 1520

13A

W566-04-02-011

10 ZAXIS8-2
Step 6 is unnecessary.

W566-04-02-010 IMPORTANT: Install slide rings (9) (2 used) with

their slits positioned 180 degrees
ZAXIS8-2 facing the opposite of each other.
Install backup rings (15) (2 used) and O-ring (16) 7. Install slide rings (9) (2 used) to piston (10).
to piston (10).
8. Wind a tape in order to protect the thread of
piston rod (1). Remove the tape before rotating
the cylinder head (3) assembly. Rotate and install
the cylinder head (3) assembly to piston rod (1).

W4-2-95
FRONT ATTACHMENT / Cylinder

ZAXIS8-2
12 9 15, 16 9 10 14 5, 6 4 3 1

W1MP-04-02-022

11 8 7 2

ZAXIS10U-2
12 9 13B 9 10 14 5, 6 4 3 1

W1MP-04-02-028

11 13A 8 7 2

W4-2-96
FRONT ATTACHMENT / Cylinder
9. Install the piston (10) assembly to piston rod (1). IMPORTANT: Do not drop slide rings (9) (2 used)
ZAXIS8-2 from piston (10) when inserting the
: 36 mm piston rod (1) assembly into cylinder
: 158 N⋅m (16 kgf⋅m, 117 lbf⋅ft) tube (14).
ZAXIS10U-2 11. Apply hydraulic oil onto the seal parts. Secure
: 36 mm cylinder tube (14) in a vise horizontally. Insert the
: 325 N⋅m (33 kgf⋅m, 240 lbf⋅ft) piston rod (1) assembly into cylinder tube (14).

10. Insert steel ball (11) into piston (10) and install set 12. Apply hydraulic oil onto the seal parts. Tighten
screw (12). Crimp set screw (12) by using a punch cylinder head (3) to cylinder tube (14) by using a
(2 places). hooked spanner. Bend the lock washer in order
ZAXIS8-2 not to loosen.
: 3 mm ZAXIS8-2
: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft) Cylinder diameter: 63 mm (2.5 in)
ZAXIS10U-2 : 255 N⋅m (26 kgf⋅m, 188 lbf⋅ft)
: 3 mm ZAXIS10U-2
: 6.8 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft) Cylinder diameter: 73 mm (2.9 in)
: 235 N⋅m (24 kgf⋅m, 173 lbf⋅ft)

Hooked Spanner

14 W506-04-02-019

W4-2-97
FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
Piston Rod Rod Bend and Run Out of Piston Rod
A
Dial Gauge
Cylinder Rod

W105-04-02-094
W166-04-02-022

1m
ZAXIS8-2 Unit: mm (in) V Block
Cylinder Name Recommended Size After
Re-Manufacturing (A) Unit: mm (in)

Boom -0.020 -0.001 Bend Run Out Remedy

30 -0.053 (1.12 -0.002 in)
0.5 (0.020) 1.0 (0.039) Repair
Arm -0.020 -0.001
30 -0.053 (1.12 -0.001 in) 1.0 (0.039) 2.0 (0.079) Replace
Bucket -0.020 -0.001
25 -0.053 (0.98 -0.002 in)
Boom Swing -0.020 -0.001
25 -0.053 (0.98 -0.002 in)
Blade -0.020 -0.001
30 -0.053 (1.12 -0.002 in)
Side Frame -0.020 -0.001
25 -0.053 (0.98 -0.002 in)
Extend/Retract

ZAXIS10U-2 Unit: mm (in)

Cylinder Name Recommended Size After
Re-Manufacturing (A)
Boom -0.020 -0.001
30 -0.053 (1.12 -0.002 in)
Arm -0.020 -0.001
30 -0.053 (1.12 -0.001 in)
Bucket -0.020 -0.001
25 -0.053 (0.98 -0.002 in)
Boom Swing -0.020 -0.001
25 -0.053 (0.98 -0.002 in)
Blade -0.020 -0.001
30 -0.053 (1.12 -0.002 in)
Side Frame -0.020 -0.001
25 -0.053 (0.98 -0.002 in)
Extend/Retract

W4-2-98
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
SECTION 5
ENGINE

 CONTENTS 
Section 1 Introduction Section 5 Periodic Maintenance
Introduction .................................................... 1-1 Introduction .................................................... 5-3
Precautions ................................................ 5-15
Section 2 Yanmar Warranties
Periodic Maintenance Schedule ................... 5-16
Yanmar Limited Warranty............................... 2-3
Periodic Maintenance Procedures .............. 5-18
Emission System Warranty ............................ 2-6
Yanmar Co., Ltd. Limited Emission Section 6 Engine
Control System Warranty - USA Only.......... 2-6 Before You Begin Servicing .......................... 6-3
Introduction .................................................... 6-5
Section 3 Safety
Cylinder Head Specifications ........................ 6-5
Safety Statements ........................................ 3-3
Camshaft and Timing Gear Train
Safety Precautions ....................................... 3-4
Specifications ............................................. 6-7
Section 4 General Service Information Crankshaft and Pistons Specifications .......... 6-8
Component Identification................................ 4-3 Cylinder Block Specifications ...................... 6-13
Location of Labels ........................................ 4-4 Special Torque Chart .................................. 6-14
EPA / ARB Emission Control Special Service Tools ................................... 6-15
Regulations - USA Only .............................. 4-4 Measuring Instruments ................................. 6-17
Emission Control Labels................................. 4-4 Cylinder Head ............................................. 6-20
The 97/68/EC Directive Certified Engines....... 4-5 Cylinder Block ............................................ 6-36
Engine Family ................................................ 4-5
Function of Major Engine Components ......... 4-6
Function of Cooling System Components ..... 4-8
Diesel Fuel ................................................... 4-9
Engine Oil .................................................... 4-13
Engine Coolant............................................. 4-15
Specifications ............................................. 4-18
Principal Engine Specifications ................... 4-20
Engine Service Information ........................ 4-23
Tightening Torques for Standard
Bolts and Nuts ........................................ 4-24
Abbreviations and Symbols .......................... 4-26
Unit Conversions.......................................... 4-27

1MRW-5-1
Section 7 Fuel System Section 11 Alternator
Before You Begin Servicing .......................... 7-3 Before You Begin Servicing ........................ 11-3
Introduction .................................................... 7-5 Introduction .................................................. 11-6
Fuel System Specifications ........................... 7-7 Standard and Optional
Special Service Tools..................................... 7-8 Dynamo Information ................................ 11-6
Measuring Instruments................................... 7-8 Standard and Optional
Fuel System Diagram ..................................... 7-9 Alternator Information ............................... 11-6
Fuel System Components .......................... 7-10 Alternator Specifications............................... 11-6
Fuel Injection Lines .................................... 7-11 Dynamo Specifications ................................. 11-7
Fuel Injection Pump ..................................... 7-13 Alternator Troubleshooting ......................... 11-8
Checking and Adjusting Fuel Alternator Components ............................... 11-9
Injection Timing ...................................... 7-19 Alternator Wiring Diagram .......................... 11-10
Fuel Injectors ............................................... 7-23 Alternator Standard Output ....................... 11-11
Alternator ................................................. 11-12
Section 8 Cooling System
Dynamo Component Location .................... 11-17
Before You Begin Servicing .......................... 8-3
Dynamo Wiring Diagram ............................ 11-18
Introduction .................................................... 8-5
Operation of Dynamo ............................... 11-18
Cooling System Diagram ................................ 8-5
Dynamo Standard Output ......................... 11-19
Engine Coolant Pump Components .............. 8-6
Testing of Dynamo ................................... 11-20
Engine Coolant System Check ....................... 8-7
Dynamo...................................................... 11-20
Engine Coolant Pump ................................... 8-7
Section 12 Electric Wiring
Section 9 Lubrication System
Electric Wiring Precautions ......................... 12-3
Before You Begin Servicing .......................... 9-3
Electric Wire Resistance ............................ 12-4
Introduction .................................................... 9-5
Battery Cable Resistance ............................. 12-5
Oil Pump Service Information......................... 9-5
Electrical Wire Sizes - Voltage Drop ........... 12-6
Lubrication System Diagram ......................... 9-7
Conversion of AWG to
Checking Engine Oil Pressure ...................... 9-8
European Standards ............................... 12-7
Trochoid Oil Pump ......................................... 9-8
Section 13 Troubleshooting
Section 10 Starter Motor
Special Service Tools ................................... 13-3
Before You Begin Servicing ........................ 10-3
Troubleshooting By
Introduction .................................................. 10-5
Measuring Compression Pressure .......... 13-4
Starter Motor Information ........................... 10-5
Quick Reference Table For
Starter Motor Specifications ....................... 10-6
Troubleshooting ...................................... 13-6
Starter Motor Troubleshooting ...................... 10-7
Electric Wiring .......................................... 13-19
Starter Motor Components ......................... 10-8
Starter Motor .............................................. 10-9

1MRW-5-2
TNV IDI Service Manual
Section 1

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

TNV IDI Service Manual 1-1

INTRODUCTION

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1-2 TNV IDI Service Manual

TNV IDI Service Manual
Section 2

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

TNV IDI Service Manual 2-1

YANMAR WARRANTIES

This Page Intentionally Left Blank

2-2 TNV IDI Service Manual

Yanmar Limited Warranty YANMAR WARRANTIES

YANMAR LIMITED WARRANTY

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

How Long is the Warranty Period?

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

What the Engine Owner Must Do:

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

TNV IDI Service Manual 2-3

YANMAR WARRANTIES Yanmar Limited Warranty

Yanmar Limited Warranty - Continued

To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:

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

What Yanmar Will Do:

Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such
repairs and / or replacements at Yanmar’s option, of any parts(s) of the Yanmar product covered by this
Warranty found to be defective in material and / or workmanship. Such repairs and / or replacements will be
made at a location designated by Yanmar at no cost to the purchaser for parts or labor.

What is Not Covered by this Warranty?

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

2-4 TNV IDI Service Manual

Yanmar Limited Warranty YANMAR WARRANTIES
Yanmar Limited Warranty - Continued

Warranty Limitations:
The foregoing is Yanmar's only obligation to you and your exclusive remedy for breach of warranty.
Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all
claims for damages and other relief. In no event shall Yanmar or any authorized industrial engine
dealer or distributor be liable for incidental, special or consequential damages. Such consequential
damages may include, but not be limited to, loss of revenue, loan payments, cost of rental of substitute
equipment, insurance coverage, storage, lodging, transportation, fuel, mileage, and telephone costs. The
limitations in this Warranty apply regardless of whether your claims are based on breach of contract, tort
(including negligence and strict liability) or any other theory. Any action arising hereunder must be brought
within one (1) year after the cause of action accrues or it shall be barred. Some states and countries do not
allow certain limitations on warranties or for breach of warranties. This Warranty gives you specific legal
rights, and you may also have other rights which vary from state to state and country to country.
Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law.

Warranty Modifications:
Except as modified in writing and signed by the parties, this Warranty is and shall remain the complete and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
Yanmar, either orally or in writing.

Questions:
If you have any questions or concerns regarding this Warranty, please call or write to the nearest
authorized Yanmar industrial engine dealer / distributor or other authorized facility.

Retail Purchaser Registration

It is very important for the original retail purchaser to register the Yanmar product. Registration
enables Yanmar to provide the best support for your Yanmar product.
As soon as possible after the purchase of your engine, Yanmar highly recommends that you use the
following website to register your purchase:
http://www.yanmar.co.jp
If it is not possible to access the web site, please contact the nearest Yanmar dealer or distributor.

TNV IDI Service Manual 2-5

YANMAR WARRANTIES Emission System Warranty

EMISSION SYSTEM WARRANTY

YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM

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

Manufacturer’s Warranty Period:

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

Engine Type Warranty Period by Number of Years or Hours of Operation

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

2-6 TNV IDI Service Manual

Emission System Warranty YANMAR WARRANTIES
Limited Emission Control System Warranty - USA Only - Continued

Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair
or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or
distributor.
Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be
warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in
the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, Yanmar is liable for damages to other engine components caused by the failure
of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Add-
on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.

Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• Positive Crankcase Ventilation System
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.

TNV IDI Service Manual 2-7

YANMAR WARRANTIES Emission System Warranty

Limited Emission Control System Warranty - USA Only - Continued

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

Owner’s Warranty Responsibilities:

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

2-8 TNV IDI Service Manual

TNV IDI Service Manual
Section 3

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

TNV IDI Service Manual 3-1

SAFETY

This Page Intentionally Left Blank

3-2 TNV IDI Service Manual

Safety Statements SAFETY

SAFETY STATEMENTS A CAUTION

Yanmar is concerned for your safety and your Caution (the word “CAUTION” is in black
machine’s condition. Safety statements are one of letters with a yellow rectangle behind it)
the primary ways to call your attention to the – indicates a potentially hazardous
potential hazards associated with Yanmar TNV situation which, if not avoided, may
engine operation. Follow the precautions listed result in minor or moderate injury.
throughout the manual before operation, during
0000001en
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the CAUTION
labels from becoming dirty or torn and replace Caution without the safety alert symbol
them if they are lost or damaged. Also, if you need indicates a potentially hazardous
to replace a part that has a label attached to it, situation that can cause damage to the
make sure you order the new part and label at the machine, personal property and / or the
same time. environment or cause the machine to
operate improperly.
This safety alert symbol appears 0000001en

A
with most safety statements. It
means attention, become alert, your
safety is involved! Please read and
abide by the message that follows
the safety alert symbol.

A DANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind
it) - indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en

A WARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en

TNV IDI Service Manual 3-3

SAFETY Safety Precautions

SAFETY PRECAUTIONS A DANGER

A DANGER

FIRE AND EXPLOSION HAZARD!

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

A DANGER A DANGER

EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

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

3-4 TNV IDI Service Manual

Safety Precautions SAFETY

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• NEVER remove the fuel cap with the • Only fill the fuel tank with diesel fuel.
engine running. Filling the fuel tank with gasoline may
• Failure to comply will result in death or result in a fire and will damage the
serious injury. engine.
0000011en • NEVER refuel with the engine running.
• Wipe up all spills immediately.
A DANGER • Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) well away when
refueling.
• NEVER overfill the fuel tank.
FIRE AND EXPLOSION HAZARD!
• Fill the fuel tank. Store any containers
• Diesel fuel is flammable and explosive containing fuel in a well-ventilated
under certain conditions. area, away from any combustibles or
• NEVER use diesel fuel as a cleaning sources of ignition.
agent. • Failure to comply will result in death or
• Failure to comply will result in death or serious injury.
serious injury. 0000005en

0000012en

TNV IDI Service Manual 3-5

SAFETY Safety Precautions

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• If the unit has an electric fuel pump, • Be sure to place the diesel fuel
when you prime the fuel system, turn container on the ground when
the key switch to the ON position for transferring the diesel fuel from the
10 to 15 seconds to allow the electric pump to the container. Hold the hose
fuel pump to prime the system. nozzle firmly against the side of the
• If the unit has a mechanical fuel pump, container while filling it. This prevents
when you prime the fuel system, static electricity buildup which could
operate the fuel priming lever of the cause sparks and ignite fuel vapors.
mechanical fuel pump several times • NEVER place diesel fuel or other
until the fuel filter cup is filled with flammable material such as oil, hay or
fuel. dried grass close to the engine during
• Failure to comply will result in death or engine operation or shortly after
serious injury. shutdown.
0000010en • Failure to comply will result in death or
serious injury.
0000014en

3-6 TNV IDI Service Manual

Safety Precautions SAFETY

A DANGER A WARNING

SEVER HAZARD!
CRUSH HAZARD!
• Keep hands and other body parts
• When you need to transport an engine away from moving / rotating parts
for repair, have a helper assist you to such as the cooling fan, flywheel or
attach it to a hoist and load it on a PTO shaft.
truck.
• Wear tight-fitting clothing and keep
• NEVER stand under a hoisted engine. your hair short or tie it back while the
If the hoist mechanism fails, the engine is running.
engine will fall on you, causing death
or serious injury. • Remove all jewelry before you operate
or service the machine.
• Failure to comply will result in death or
serious injury. • NEVER start the engine in gear.
0000008en
Sudden movement of the engine
and / or machine could cause death or
serious personal injury.
A DANGER • NEVER operate the engine without the
guards in place.
• Before you start the engine make sure
that all bystanders are clear of the
area.
EXPLOSION HAZARD! • Keep children and pets away while the
• NEVER check the remaining battery engine is operating.
charge by shorting out the terminals. • Check before starting the engine that
This will result in a spark and may any tools or shop rags used during
cause an explosion or fire. Use a maintenance have been removed from
hydrometer to check the remaining the area.
battery charge. • Failure to comply could result in death
• If the electrolyte is frozen, slowly warm or serious injury.
the battery before you recharge it. 0000002en

• Failure to comply will result in death or

serious injury.
0000007en

TNV IDI Service Manual 3-7

SAFETY Safety Precautions

A WARNING A WARNING

EXHAUST HAZARD!
• NEVER operate the engine in an EXPOSURE HAZARD!
enclosed area such as a garage,
tunnel, underground room, manhole or • Wear personal protective equipment
ship’s hold without proper ventilation. such as gloves, work shoes, eye and
hearing protection as required by the
• NEVER block windows, vents, or other task at hand.
means of ventilation if the engine is
operating in an enclosed area. All • NEVER wear jewelry, unbuttoned
internal combustion engines create cuffs, ties or loose-fitting clothing
carbon monoxide gas during when you are working near
operation. Accumulation of this gas moving / rotating parts such as the
within an enclosure could cause cooling fan, flywheel or PTO shaft.
illness or even death. • ALWAYS tie back long hair when you
• Make sure that all connections are are working near moving / rotating
tightened to specifications after repair parts such as a cooling fan, flywheel,
is made to the exhaust system. or PTO shaft.

• Failure to comply could result in death • NEVER operate the engine while
or serious injury. wearing a headset to listen to music or
radio because it will be difficult to hear
0000003en
the alert signals.
• Failure to comply could result in death
A WARNING or serious injury.
0000005en

ALCOHOL AND DRUG HAZARD!

• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en

3-8 TNV IDI Service Manual

Safety Precautions SAFETY

A WARNING A WARNING

HIGH-PRESSURE HAZARD!
BURN HAZARD!
• Avoid skin contact with the
• If you must drain the engine oil while it high-pressure diesel fuel spray caused
is still hot, stay clear of the hot engine by a fuel system leak such as a broken
oil to avoid being burned. fuel injection line. High-pressure fuel
• ALWAYS wear eye protection. can penetrate your skin and result in
• Failure to comply could result in death serious injury. If you are exposed to
or serious injury. high-pressure fuel spray, obtain
prompt medical treatment.
0000011en
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
A WARNING or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
BURN HAZARD! 0000008en

• Batteries contain sulfuric acid. NEVER

allow battery fluid to come in contact A WARNING
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area
with a large amount of clean water and SHOCK HAZARD!
obtain prompt medical treatment. • Turn off the battery switch (if
• Failure to comply could result in death equipped) or disconnect the negative
or serious injury. battery cable before servicing the
electrical system.
0000007en
• Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors. ALWAYS keep
the connectors and terminals clean.
• Failure to comply could result in death
or serious injury.
0000009en

TNV IDI Service Manual 3-9

SAFETY Safety Precautions

A WARNING A WARNING

ENTANGLEMENT HAZARD!
• Stop the engine before you begin to To prevent possible eye injury, always
service it. wear SAFETY GLASSES while servicing
the engine.
• NEVER leave the key in the key switch 0000013en
when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are A WARNING
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away BURN HAZARD!
from moving / rotating parts. • Keep your hands and other body parts
• Failure to comply could result in death away from hot engine surfaces such
or serious injury. as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
0000010en
block during operation and shortly
after you shut the engine down. These
A WARNING surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en

3-10 TNV IDI Service Manual

Safety Precautions SAFETY

A WARNING A CAUTION

FUME / BURN HAZARD!

• Always read and follow safety related FLYING OBJECT HAZARD!
precautions found on containers of • ALWAYS wear eye protection when
hazardous substances like parts servicing the engine and when using
cleaners, primers, sealants and compressed air or high-pressure
sealant removers. water. Dust, flying debris, compressed
• Failure to comply could result in death air, pressurized water or steam may
or serious injury. injure your eyes.
0000014en • Failure to comply may result in minor
or moderate injury.
A CAUTION 0000003en

A CAUTION
Be sure to secure the engine solidly to
prevent injury or damage to parts due to
the engine falling during work on the
COOLANT HAZARD! engine.
0000009en
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the A CAUTION
eyes or skin should occur, flush eyes
and wash immediately with clean
water.
• Failure to comply may result in minor
or moderate injury.
0000005en
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the
V-belt. Failure to comply may result in
minor or moderate injury.
0000014en

TNV IDI Service Manual 3-11

SAFETY Safety Precautions

A CAUTION CAUTION
If any oil pump component clearance Make sure the engine is installed on a
exceeds its limit, the oil pump must be level surface. If a continuously running
replaced as an assembly. engine is installed at an angle greater
0000015en than (IDI = 25°, DI = 30°) in any direction
or if an engine runs for short periods of
time (less than three minutes) at an
CAUTION angle greater than (IDI = 30°, DI = 35°) in
• Only use diesel fuels recommended by any direction, engine oil may enter the
Yanmar for the best engine combustion chamber causing excessive
performance, to prevent engine engine speed and white exhaust smoke.
damage and to comply with EPA / ARB This may cause serious engine damage.
warranty requirements. 0000010enTNV

• Only use clean diesel fuel.

• NEVER remove the primary strainer (if CAUTION
equipped) from the fuel tank filler port. Protect the air cleaner, turbocharger (if
If removed, dirt and debris could get equipped) and electric components
into the fuel system causing it to clog. from damage when you use steam or
0000004en high-pressure water to clean the engine.
0000014en

CAUTION
If any problem is noted during the visual CAUTION
check, the necessary corrective action Observe the following environmental
should be taken before you operate the operating conditions to maintain engine
engine. performance and avoid premature
0000021en engine wear:
• Avoid operating in extremely dusty
CAUTION conditions.
NEVER hold the key in the START • Avoid operating in the presence of
position for longer than 15 seconds or chemical gases or fumes.
the starter motor will overheat.
• Avoid operating in a corrosive
0000007en
atmosphere such as salt water spray.
• NEVER install the engine in a
floodplain unless proper precautions
are taken to avoid being subject to a
flood.
• NEVER expose the engine to the rain.
0000003en

3-12 TNV IDI Service Manual

Safety Precautions SAFETY

CAUTION CAUTION
Do not loosen or remove the four bolts If any indicator illuminates during
retaining the fuel injection pump drive engine operation, stop the engine
gear to the fuel injection pump hub. Do immediately. Determine the cause and
not disassemble the fuel injection pump repair the problem before you continue
drive gear from the hub. Correct fuel to operate the engine.
injection timing will be very difficult or 0000029en
impossible to achieve.
0000031en
CAUTION
• Only use the engine oil specified.
CAUTION Other engine oils may affect warranty
If the oil pump must be replaced, replace coverage, cause internal engine
it as an assembly only. Do not replace components to seize and / or shorten
individual components. engine life.
0000030en
• Prevent dirt and debris from
contaminating the engine oil. Carefully
CAUTION clean the oil cap / dipstick and the
surrounding area before you remove
Observe the following environmental
the cap.
operating conditions to maintain engine
performance and avoid premature • NEVER mix different types of engine
engine wear: oil. This may adversely affect the
lubricating properties of the engine oil.
• The standard range of ambient
temperatures for the normal operation • NEVER overfill. Overfilling may result
of Yanmar engines is from +5°F (-15°C) in white exhaust smoke, engine
to +113°F (+45°C). overspeed or internal damage.
0000005en
• If the ambient temperature exceeds
+113°F (+45°C) the engine may
overheat and cause the engine oil to CAUTION
break down. • Only use the engine coolant specified.
• If the ambient temperature is below Other engine coolants may affect
+5°F (-15°C) the engine will be hard to warranty coverage, cause an internal
start and the engine oil may not flow buildup of rust and scale and / or
easily. shorten engine life.
• Contact your authorized Yanmar • Prevent dirt and debris from
industrial engine dealer or distributor contaminating the engine coolant.
if the engine will be operated outside Carefully clean the radiator cap and
of this standard temperature range. the surrounding area before you
0000065en remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en

TNV IDI Service Manual 3-13

SAFETY Safety Precautions

CAUTION CAUTION
• NEVER overfill the engine with engine
oil.
• ALWAYS keep the oil level between the
upper and lower lines on the oil
cap / dipstick.
0000015en
• ALWAYS be environmentally
responsible.

CAUTION • Follow the guidelines of the EPA or

other governmental agencies for the
For maximum engine life, Yanmar proper disposal of hazardous
recommends that when shutting the materials such as engine oil, diesel
engine down, you allow the engine to fuel and engine coolant. Consult the
idle, without load, for five minutes. This local authorities or reclamation facility.
will allow the engine components that
operate at high temperatures, such as • NEVER dispose of hazardous
the turbocharger (if equipped) and materials irresponsibly by dumping
exhaust system, to cool slightly before them into a sewer, on the ground, or
the engine itself is shut down. into ground water or waterways.
0000008en • Failure to follow these procedures may
seriously harm the environment.
CAUTION 0000013en

NEVER use an engine starting aid such

as ether. Engine damage will result.
0000009en

3-14 TNV IDI Service Manual

Safety Precautions SAFETY

CAUTION CAUTION
New Engine Break-in: • NEVER attempt to modify the engine’s
• On the initial engine start-up, allow the design or safety features such as
engine to idle for approximately 15 defeating the engine speed limit
minutes while you check for proper control or the fuel injection quantity
engine oil pressure, diesel fuel leaks, control.
engine oil leaks, coolant leaks, and for • Failure to comply may impair the
proper operation of the indicators engine’s safety and performance
and / or gauges. characteristics and shorten the
• During the first hour of operation, vary engine’s life. Any alterations to this
the engine speed and the load on the engine may affect the warranty
engine. Short periods of maximum coverage of your engine. Yanmar
engine speed and load are desirable. Limited Warranty on page 2-3.
Avoid prolonged operation at 0000044TNVIDISM

minimum or maximum engine speeds

and loads for the next four to five CAUTION
hours.
NEVER use high-pressure water or
• During the break-in period, carefully compressed air at greater than 28 psi
observe the engine oil pressure and (193 kPa; 19 686 mmAq) or a wire brush
engine temperature. to clean the radiator fins. Radiator fins
• During the break-in period, check the damage easily.
engine oil and coolant levels 0000016en

frequently.
0000011en CAUTION
NEVER attempt to adjust the low or high
CAUTION idle speed limit screw. This may impair
NEVER engage the starter motor while the safety and performance of the
the engine is running. This may damage machine and shorten its life. If the idle
the starter motor pinion and / or ring speed limit screws require adjustment,
gear. see your authorized Yanmar industrial
engine dealer or distributor.
0000012en
0000017en

CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en

TNV IDI Service Manual 3-15

SAFETY Safety Precautions

CAUTION CAUTION
The tightening torque in the Standard • When the engine is operated in dusty
Torque Chart in General Service conditions, clean the air cleaner
Information should be applied only to element more frequently.
the bolts with a “7” head. (JIS strength • NEVER operate the engine with the air
classification: 7T) cleaner element(s) removed. This may
allow foreign material to enter the
• Apply 60% torque to bolts engine and damage it.
that are not listed.
0000026en
• Apply 80% torque when
tightened to aluminum alloy.
CAUTION
0000023enTNVIDISM
The maximum air intake restriction, in
terms of differential pressure
CAUTION measurement, must not exceed 0.90 psi
Establish a periodic maintenance plan (6.23 kPa; 635 mmAq). Clean or replace
according to the engine application and the air cleaner element if the air intake
make sure you perform the required restriction exceeds the above
periodic maintenance at intervals mentioned value.
indicated. Failure to follow these 0000046en
guidelines will impair the engine’s safety
and performance characteristics,
shorten the engine’s life and may affect
CAUTION
the warranty coverage on your engine. Do not short-circuit the charging system
See Yanmar Warranties section. between alternator terminals IG and L.
Damage to the alternator will result.
Consult your authorized Yanmar dealer
0000035en
or distributor for assistance when
checking items marked with a z.
0000024enTNVIDISM CAUTION
Do not connect a load between
CAUTION alternator terminals L and E. Damage to
the alternator will result.
If the fuel filter / water separator is
0000036en
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator CAUTION
drain cock is opened. If this happens, Do not remove the positive (+) battery
turn the air vent screw on the top of the cable from alternator terminal B while
fuel filter / water separator 2-3 turns the engine is operating. Damage to the
counterclockwise. alternator will result.
Be sure to tighten the air vent screw 0000037en

after the water has drained out.

0000025en

3-16 TNV IDI Service Manual

Safety Precautions SAFETY

CAUTION CAUTION
Do not turn the battery switch OFF while After marking the position of the pump
the engine is operating. Damage to the drive gear, do not rotate the engine
alternator will result. crankshaft. Rotating the crankshaft will
0000038en cause the fuel injection pump to become
misaligned.
CAUTION 0000048en

Do not operate the engine if the

alternator is producing unusual sounds. CAUTION
Damage to the alternator will result. Do not use a high-pressure wash
0000039en directly on the alternator. Water will
damage the alternator and result in
inadequate charging.
CAUTION
0000049en
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not CAUTION
attempt to repair the engine coolant Do not reverse the positive (+) and
pump or replace individual components. negative (-) ends of the battery cable.
0000041en The alternator diode and stator coil will
be damaged.
CAUTION 0000050en

Use a new special O-ring between the

engine coolant pump and the joint. Be CAUTION
sure to use the special O-ring for each When the battery indicator goes out, it
engine model. Although the O-ring should not come on again. The battery
dimensions are the same as a indicator only comes on during
commercially available O-ring, the operation if the alternator fails. However,
material is different. if an LED is used in the battery indicator,
0000042en the LED will shine faintly during normal
operation.
CAUTION 0000051en

Remove or install the high-pressure fuel

injection lines as an assembly whenever CAUTION
possible. Disassembling the Using a non-specified V-belt will cause
high-pressure fuel injection lines from inadequate charging and shorten the
the retainers or bending any of the fuel belt life. Use the specified belt.
lines will make it difficult to reinstall the 0000052en
fuel lines.
0000047en

TNV IDI Service Manual 3-17

SAFETY Safety Precautions

CAUTION CAUTION
Agricultural or other chemicals, Make sure that the combined total
especially those with a high sulfur resistance of the battery cable in both
content, can adhere to the IC regulator. directions between the starter motor
This will corrode the conductor and and the battery is within the value
result in battery over-charging (boiling) indicated in the Battery Cable
and charging malfunctions. Consult Resistance chart in the Electric Wiring
Yanmar before using the equipment in Section of this manual. The starter
such an environment or the warranty is motor will malfunction and fail if the
voided. resistance is higher than the specified
0000053en value.
0000057en

CAUTION
Make sure that the combined total CAUTION
resistance of the battery cable in both Removing the battery cables or the
directions between the starter motor battery while the engine is operating
and the battery is within the value may cause damage to the current limiter
indicated on the wiring diagram. The depending on the electrical equipment
starter motor will malfunction or break being used. This situation could cause
down if the resistance is higher than the loss of control of output voltage. The
specified value. continuous high voltage of 23-24 volts
0000054en (for 5000 rpm dynamo) will damage the
current limiter and other electrical
equipment.
CAUTION
0000058en
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general CAUTION
cleaning. Do not use high-pressure Reversing the battery cable connections
wash or submerse the starter motor in at the battery or on the engine will
water. destroy the SCR diode in the current
0000055en limiter. This will cause the charging
system to malfunction and may cause
damage to the electrical harnesses.
CAUTION
0000059en
Use a specialized battery charger to
recharge a battery with a voltage of
8 volts or less. Booster starting a battery CAUTION
with a voltage of 8 volts or less will It is important to perform daily checks.
generate an abnormally high voltage Periodic maintenance prevents
and destroy electrical equipment. unexpected downtime, reduces the
0000056en
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en

3-18 TNV IDI Service Manual

Safety Precautions SAFETY

CAUTION CAUTION
• NEVER attempt to modify the engine’s Do not allow the honing tool to operate
design or safety features such as in one position for any length of time.
defeating the engine speed limit Damage to the cylinder wall will occur.
control or the diesel fuel injection Keep the tool in constant up-and-down
quantity control. motion.
• Modifications may impair the engine’s 0000090en

safety and performance

characteristics and shorten the CAUTION
engine’s life. Any alterations to this
Any part which is found defective as a
engine may void its warranty. Be sure
result of inspection or any part whose
to use Yanmar genuine replacement
measured value does not satisfy the
parts.
standard or limit must be replaced.
0000079en
0000119en

CAUTION CAUTION
Identify all parts and their location using
Any part determined to not meet the
an appropriate method. It is important
service standard or limit before the next
that all parts are returned to the same
service, as determined from the state of
position during the reassembly process.
current rate of wear, should be replaced
0000080en
even though the part currently meets the
service standard limit.
CAUTION 0000120en

Do not rotate the crankshaft with the

injection pump removed. CAUTION
0000083en
Never use a steel wire brush to clean
fuel injectors. Damage to the nozzle and
CAUTION other components is likely to result.
Keep the piston pin parts, piston 0000172en

assemblies, and connecting rod

assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en

TNV IDI Service Manual 3-19

SAFETY Safety Precautions

CAUTION
• NEVER remove or attempt to remove
the tamper-proof devices from the
full-load fuel adjusting screw or the
high-speed throttle limit screw on the
fuel injection pump and governor
assembly. These adjustments have
been made at the factory to meet all
applicable emissions regulations and
then sealed.
• NEVER attempt to make any
adjustments to these sealed
adjustment screws. If adjustments are
required, they can be made only by a
qualified fuel injection shop that will
ensure the injection pump continues
to meet all applicable emissions
regulations and then replace the
tamper-proof seals.
• Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.”
0000146en

CAUTION
The fuel return line is a one-piece
assembly. Use care not to bend or twist
the fuel return line.
0000171en

3-20 TNV IDI Service Manual

TNV IDI Service Manual
Section 4

GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-4
EPA / ARB Emission Control Regulations - USA Only.................... 4-4
Emission Control Labels.................................................................. 4-4
EPA / ARB Labels ..................................................................... 4-5
The 97/68/EC Directive Certified Engines ....................................... 4-5
Engine Family.................................................................................. 4-5
Function of Major Engine Components ........................................... 4-6
Function of Cooling System Components ....................................... 4-8
Diesel Fuel ...................................................................................... 4-9
Diesel Fuel Specifications ......................................................... 4-9
Filling the Fuel Tank ................................................................ 4-10
Priming the Fuel System ......................................................... 4-12
Engine Oil...................................................................................... 4-13
Engine Oil Specifications ........................................................ 4-13
Service Categories .................................................................. 4-13
Engine Oil Viscosity................................................................. 4-14
Checking Engine Oil ................................................................ 4-14
Adding Engine Oil.................................................................... 4-14
Engine Oil Capacity (Typical) .................................................. 4-15
Engine Coolant.............................................................................. 4-15
Engine Coolant Specifications................................................. 4-16
Filling Radiator with Engine Coolant........................................ 4-16
Engine Coolant Capacity (Typical) .......................................... 4-17
Specifications ................................................................................ 4-18
Description of Model Number .................................................. 4-18
Engine Speed Specifications................................................... 4-18
Engine General Specifications ................................................ 4-19

TNV IDI Service Manual 4-1

GENERAL SERVICE INFORMATION
Principal Engine Specifications ...................................................... 4-20
2TNV70 .................................................................................... 4-20
3TNV70 .................................................................................... 4-21
3TNV76 .................................................................................... 4-22
Engine Service Information ............................................................ 4-23
Tightening Torques for Standard Bolts and Nuts ........................... 4-24
Abbreviations and Symbols............................................................ 4-26
Abbreviations............................................................................ 4-26
Symbols.................................................................................... 4-26
Unit Conversions ............................................................................ 4-27
Unit Prefixes ............................................................................. 4-27
Units of Length ......................................................................... 4-27
Units of Volume ........................................................................ 4-27
Units of Mass............................................................................ 4-27
Units of Force ........................................................................... 4-27
Units of Torque......................................................................... 4-27
Units of Pressure...................................................................... 4-27
Units of Power .......................................................................... 4-27
Units of Temperature................................................................ 4-27

4-2 TNV IDI Service Manual

Component Identification GENERAL SERVICE INFORMATION

COMPONENT IDENTIFICATION
Figure 4-1 shows where major engine components are located.

(1)
(19) (2) (21)
(20)
(3)
(18)

(17)

(16)

(25)
(15)

(14) (4)

(24)
(13) (5)

(12)
(6) (23)
(11)
(8) (7) (22) 0000583A
(10)
(9)

Figure 4-1

1 – Lifting Eye (Flywheel End) 14 – Governor Lever

2 – Engine Coolant Pump 15 – Fuel Injection Pump
3 – Lifting Eye (Engine Cooling Fan End) 16 – Intake Manifold
4 – Engine Cooling Fan 17 – Air Intake Port (From Air Cleaner)
5 – V-Belt 18 – Fuel Filter
6 – Crankshaft V-Pulley 19 – Fuel Return To Fuel Tank
7 – Side Filler Port (Engine Oil) 20 – Top Filler Port (Engine Oil)
8 – Drain Plug (Engine Oil)* 21 – Rocker Arm Cover
9 – Fuel Inlet 22 – Flywheel
10 – Mechanical Fuel Pump (If Equipped) 23 – Starter Motor
11 – Fuel Priming Lever 24 – Exhaust Manifold
12 – Dipstick (Engine Oil) 25 – Alternator
13 – Engine Oil Filter
* Engine oil drain plug location may vary based on oil pan options.

TNV IDI Service Manual 4-3

GENERAL SERVICE INFORMATION Location of Labels

LOCATION OF LABELS EPA / ARB EMISSION CONTROL

Figure 4-2 shows the location of regulatory and REGULATIONS - USA ONLY
safety labels on Yanmar TNV series engines.
Yanmar TNV engines meet Environmental
Protection Agency (EPA) (U. S. Federal) emission
(2) control standards as well as the California Air
(1)
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA / ARB installation (page
5-16) and maintenance (page 5-16) in the
Periodic Maintenance section of this manual. Also
refer to theYanmar Co., Ltd. Limited Emission
Control System Warranty - USA Only Yanmar Co.,
0000585A Ltd. Limited Emission Control System Warranty -
USA Only on page 2-6.
Figure 4-2
The typical location of the emission control
information label is shown (Figure 4-2, (1)). EMISSION CONTROL LABELS
Typical location of the engine nameplate is shown Since emission control regulations are being issued
(Figure 4-2, (2)). on a global basis, it is necessary to identify which
regulations a particular engine complies with. We
Engine Nameplate (Typical) have listed several different types of labels you
might find on your engine.

0003852

4-4 TNV IDI Service Manual

The 97/68/EC Directive Certified Engines GENERAL SERVICE INFORMATION
EPA / ARB Labels THE 97/68/EC DIRECTIVE
CERTIFIED ENGINES
The engines described in this manual have been
certified by the 97/68/EC Directive.
" "
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
the engines.

97/68/EC DIRECTIVE
(EPA) Less Than 50 HP SAE (37kW)

(97/68/EC)

(EPA & ARB)

ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all
have an Engine Family field. The following is an
explanation of the Engine Family designation:

3 YDX L 1.33 M 3 N
Method of air aspiration

Number of cylinders

Engine speed specifications

Displacement (liter)

Non-road / Off-road engine

Yanmar Diesel

*2005 Model Year

5*: 2005

6 : 2006

7 : 2007

TNV IDI Service Manual 4-5

GENERAL SERVICE INFORMATION Function of Major Engine Components

FUNCTION OF MAJOR ENGINE COMPONENTS

Component Function
The air cleaner prevents airborne contaminants from entering the
engine. Since the air cleaner is application specific, it must be
carefully selected by an application engineer. It is not part of the
Air Cleaner basic engine package as shipped from the Yanmar factory. Periodic
replacement of the air cleaner filter element is necessary. See the
Periodic Maintenance Schedule on page 5-16 for the replacement
frequency.
The dynamo is driven by a V-belt which is powered by the
Dynamo crankshaft V-pulley. The dynamo supplies electricity to the engine
systems and charges the battery while the engine is running.
The engine oil dipstick is used to determine the amount of engine
Dipstick (Engine Oil)
oil in the crankcase.
The electric fuel pump makes sure there is a constant supply of
diesel fuel to the fuel injection pump. The electric fuel pump is
electro-magnetic and runs on 12 VDC. An electric fuel pump may
Electric Fuel Pump
be installed as standard equipment based on engine model and
specification. If an electric fuel pump is installed, turn the key switch
to the ON position for 10 to 15 seconds to prime the fuel system.
The engine oil filter removes contaminants and sediments from the
engine oil. Periodic replacement of the engine oil filter is necessary.
Engine Oil Filter
See the Periodic Maintenance Schedule on page 5-16 for the
replacement frequency.
The fuel filter removes contaminants and sediments from the diesel
fuel. Periodic replacement of the fuel filter is necessary. See the
Fuel Filter Periodic Maintenance Schedule on page 5-16 for the replacement
frequency. Please note that the word “diesel” is implied
throughout this manual when the word “fuel” is used.
The fuel filter / water separator removes contaminants, sediments
and water from diesel fuel going to the fuel filter. This is a required
component of the fuel system. This is standard equipment with
Fuel Filter / Water Separator
every engine. The separator is installed between the fuel tank and
the fuel pump. Periodically drain the water from the fuel filter / water
separator using the drain cock at the bottom of the separator.
If the unit has a mechanical fuel pump, a fuel priming lever on the
mechanical fuel pump primes the fuel system. The fuel system
needs to be primed before you start the engine for the first time, if
Fuel Priming Lever
you run out of fuel, or if fuel system service is performed. To prime
the fuel system, operate the fuel priming lever until the cup in the
fuel filter is full of fuel.

4-6 TNV IDI Service Manual

Function of Major Engine Components GENERAL SERVICE INFORMATION

Component Function
The fuel tank is a reservoir that holds diesel fuel. When fuel leaves
the fuel tank it goes to the fuel filter / water separator. Next, fuel is
pumped to the fuel filter by the fuel pump. Next the fuel goes to the
fuel injection pump. Since fuel is used to keep the fuel injection
Fuel Tank
pump cool and lubricated, more fuel than necessary enters the
injection pump. When the injection pump pressure reaches a preset
value, a relief valve allows excess fuel to be returned back to the
fuel tank. The fuel tank is a required engine component.
The mechanical fuel pump is a diaphragm type of pump and is
installed on the fuel injection pump body. The mechanical fuel
pump is standard equipment on some engine models and is driven
Mechanical Fuel Pump
by a cam on the camshaft of the fuel injection pump. The
mechanical fuel pump is not installed on the fuel injection pump if
the electric fuel pump is installed.
Side and Top Filler Port (Engine You can fill the crankcase with engine oil from either the side or
Oil) top filler port depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key
switch in the operator’s console to the START position, the starter
Starter Motor
motor engages with the ring gear installed on the flywheel and
starts the flywheel in motion.

TNV IDI Service Manual 4-7

GENERAL SERVICE INFORMATION Function of Cooling System Components

FUNCTION OF COOLING SYSTEM COMPONENTS

Component Function
The TNV engine is liquid-cooled by means of a cooling system. The
cooling system consists of a radiator, radiator cap, engine cooling
fan, engine coolant pump, thermostat, and reserve tank. Note that
all cooling system components are required for proper engine
Cooling System
operation. Since some of the components are application
specific, they must be carefully selected by an application
engineer. The application specific items are not part of the
basic engine package as shipped from the Yanmar factory.
The engine cooling fan is driven by a V-belt which is powered by the
Engine Cooling Fan crankshaft V-pulley. The purpose of the engine cooling fan is to
circulate air through the radiator.
The engine coolant pump circulates the engine coolant through the
Engine Coolant Pump cylinder block and cylinder head and returns the engine coolant to
the radiator.
The radiator acts as a heat exchanger. As the engine coolant
circulates through the cylinder block it absorbs heat. The heat in the
Radiator engine coolant is dissipated in the radiator. As the engine cooling
fan circulates air through the radiator, the heat is transferred to the
air.
The radiator cap controls the cooling system pressure. The cooling
system is pressurized to raise the boiling point of the engine
coolant. As the engine coolant temperature rises, the system
pressure and the coolant volume increases. When the pressure
reaches a preset value, the release valve in the radiator cap opens
Radiator Cap
and the excess engine coolant flows into the reserve tank. As the
engine coolant temperature is reduced, the system pressure and
volume is reduced and the vacuum valve in the radiator cap opens
allowing engine coolant to flow from the reserve tank back into the
radiator.
The reserve tank contains the overflow of engine coolant from the
Reserve Tank radiator. If you need to add engine coolant to the system, add it to
the reserve tank, not to the radiator.
A thermostat is placed in the cooling system to prevent engine
coolant from circulating into the radiator until the engine coolant
temperature reaches a preset temperature. When the engine is
Thermostat cold, no engine coolant flows through the radiator. Once the engine
reaches its operating temperature the thermostat opens. By letting
the engine warm up as quickly as possible, the thermostat reduces
engine wear, deposits and emissions.

4-8 TNV IDI Service Manual

Diesel Fuel GENERAL SERVICE INFORMATION

DIESEL FUEL • Total aromatics content should not exceed

35% by volume. Less than 30% is preferred.
Diesel Fuel Specifications • PAH (polycyclic aromatic hydrocarbons)
content should be below 10% by volume.
Diesel fuel should comply with the following
specifications. The table lists several worldwide • Metal content of Na, Mg, Si, and Al should be
specifications for diesel fuels. equal to or lower than 1 mass ppm. (Test
analysis method JPI-5S-44-95)
Diesel Fuel Specification Location • Lubricity: Wear mark of WS1.4 should be Max.
No. 2-D, No. 1-D, 0.018 in. (460 µm) at HFRR test.
USA
ASTM D975-94
Bio-Diesel Fuels
European
EN590:96 In Europe and in the United States, as well as some
Union
other countries, non-mineral oil based fuel
ISO 8217 DMX International resources such as RME (Rapeseed Methyl Ester)
United and SOME (Soybean Methyl Ester), collectively
BS 2869-A1 or A2
Kingdom known as FAME (Fatty Acid Methyl Esters), are
JIS K2204 Grade No. 2 Japan being used as extenders for mineral oil derived
diesel fuels.
KSM-2610 Korea
GB252 China Yanmar approves the use of bio-diesel fuels that do
not exceed a blend of 5% (by volume) of FAME with
Additional Technical Fuel Requirements 95% (by volume) of approved mineral oil derived
diesel fuel. Such bio-diesel fuels are known in the
• The fuel cetane number should be equal to 45 marketplace as B5 diesel fuels.
or higher.
• The sulfur content must not exceed 0.5% by These B5 diesel fuels must meet certain
volume. Less than 0.05% is preferred. requirements.
1. The bio-fuels must meet the minimum
• Bio-Diesel fuels. See Bio-Diesel Fuels on
specifications for the country in which they are
page 4-9.
used.
• NEVER mix kerosene, used engine oil, or
• In Europe, bio-diesel fuels must comply with
residual fuels with the diesel fuel.
the European Standard EN14214.
• Water and sediment in the fuel should not
• In the United States, bio-diesel fuels must
exceed 0.05% by volume.
comply with the American Standard
• Keep the fuel tank and fuel-handling ASTM D-6751.
equipment clean at all times.
2. Bio-fuels should be purchased only from
• Poor quality fuel can reduce engine recognized and authorized diesel fuel suppliers.
performance and / or cause engine damage.
• Fuel additives are not recommended. Some
fuel additives may cause poor engine
performance. Consult your Yanmar
representative for more information.
• Ash content not to exceed 0.01% by volume.
• Carbon residue content not to exceed 0.35%
by volume. Less than 0.1% is preferred.

TNV IDI Service Manual 4-9

GENERAL SERVICE INFORMATION Diesel Fuel

Precautions and concerns regarding the use of Filling the Fuel Tank
bio-fuels:
1. Free methanol in FAME may result in corrosion A DANGER
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures, FIRE AND EXPLOSION HAZARD!
and poor injection nozzle spray atomization.
• Diesel fuel is flammable and explosive
4. FAME may have adverse effects on some under certain conditions.
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine • Only fill the fuel tank with diesel fuel.
lubricating oil. Filling the fuel tank with gasoline may
result in a fire and will damage the
5. Even bio-diesel fuels that comply with a suitable
engine.
standard as delivered, will require additional
care and attention to maintain the quality of the • NEVER refuel with the engine running.
fuel in the equipment or other fuel tanks. It is • Wipe up all spills immediately.
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system, • Keep sparks, open flames or any other
and / or fuel storage containers, may be form of ignition (match, cigarette,
necessary. static electric source) well away when
refueling.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel • NEVER overfill the fuel tank.
engine manufacturers and the diesel fuel • Fill the fuel tank. Store any containers
injection equipment manufacturers, or bio- containing fuel in a well-ventilated
diesel fuels that have degraded as per the area, away from any combustibles or
precautions and concerns above, may affect sources of ignition.
the warranty coverage of your engine. See
• Failure to comply will result in death or
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en

4-10 TNV IDI Service Manual

Diesel Fuel GENERAL SERVICE INFORMATION

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• Be sure to place the diesel fuel • Before you operate the engine, check
container on the ground when for fuel leaks. Replace rubberized fuel
transferring the diesel fuel from the hoses every two years or every 2000
pump to the container. Hold the hose hours of engine operation, whichever
nozzle firmly against the side of the comes first, even if the engine has
container while filling it. This prevents been out of service. Rubberized fuel
static electricity buildup which could lines tend to dry out and become
cause sparks and ignite fuel vapors. brittle after two years or 2000 hours of
engine operation, whichever comes
• NEVER place diesel fuel or other
first.
flammable material such as oil, hay or
dried grass close to the engine during • Failure to comply will result in death or
engine operation or shortly after serious injury.
shutdown. 0000015en

• Failure to comply will result in death or

serious injury. CAUTION
0000014en
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en

TNV IDI Service Manual 4-11

GENERAL SERVICE INFORMATION Diesel Fuel

Note that a typical fuel tank is shown. The fuel tank Priming the Fuel System
on the equipment being serviced may be different.
1. Clean the area around the fuel cap A DANGER
(Figure 4-3, (1)).
2. Remove the fuel cap (Figure 4-3, (1)) from the
fuel tank (Figure 4-3, (2)).
3. Observe the fuel level sight gauge
(Figure 4-3, (3)) and stop fueling when gauge FIRE AND EXPLOSION HAZARD!
shows fuel tank is full. NEVER overfill the fuel • Diesel fuel is flammable and explosive
tank. under certain conditions.
4. Replace the fuel cap and hand-tighten. Over • If the unit has an electric fuel pump,
tightening the fuel cap will damage it. when you prime the fuel system, turn
the key switch to the ON position for
(1) 10 to 15 seconds to allow the electric
fuel pump to prime the system.
• If the unit has a mechanical fuel pump,
(2) when you prime the fuel system,
operate the fuel priming lever of the
mechanical fuel pump several times
until the fuel filter cup is filled with
(3) fuel.
• Failure to comply will result in death or
0000002A
serious injury.
0000010en
Figure 4-3
The fuel system needs to be primed under certain
conditions:
• Before starting the engine for the first time
• After running out of fuel and fuel has been
added to the fuel tank
• After fuel system maintenance such as
changing the fuel filter and draining the fuel
filter / water separator, or replacing a fuel
system component
To prime the fuel system if an electric fuel pump is
installed:
1. Turn the key to the ON position for 10 to 15
seconds. This will allow the electric fuel pump
to prime the fuel system.
2. NEVER use the starter motor to prime the fuel
system. This may cause the starter motor to
overheat and damage the coils, pinion and / or
ring gear.

4-12 TNV IDI Service Manual

Engine Oil GENERAL SERVICE INFORMATION
To prime the fuel system if a mechanical fuel pump ENGINE OIL
is installed:
1. Operate the fuel priming lever (Figure 4-4, (1)) CAUTION
several times until the fuel filter cup • Only use the engine oil specified.
(Figure 4-4, (2)) is filled with fuel. Other engine oils may affect warranty
2. NEVER use the starter motor to prime the fuel coverage, cause internal engine
system. This may cause the starter motor to components to seize and / or shorten
overheat and damage the coils, pinion and / or engine life.
ring gear. • Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
(2) surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
(1) overspeed or internal damage.
0000005en
0000649A

Figure 4-4 Engine Oil Specifications

Use an engine oil that meets or exceeds the
following guidelines and classifications:

Service Categories
• API Service Categories CD or higher
• ACEA Service Categories E-3, E-4, and E-5
• JASO Service Category DH-1

Definitions
• API Classification (American Petroleum
Institute)
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)
• JASO (Japanese Automobile Standards
Organization)
Note:
1. Be sure the engine oil, engine oil storage
containers, and engine oil filling equipment are
free of sediments and water.

TNV IDI Service Manual 4-13

GENERAL SERVICE INFORMATION Engine Oil

2. Change the engine oil after the first 50 hours of

(4)
operation and then every 250 hours thereafter.
3. Select the oil viscosity based on the ambient
temperature where the engine is being
operated. See the SAE Service Grade Viscosity
Chart (Figure 4-5).
(4)
4. Yanmar does not recommend the use of engine
oil “additives.”

Additional Technical Engine oil

Requirements:
(5)
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
(mgKOH/g) test method; JIS K-201-5.2-2 (HCI), (1)
ASTM D4739 (HCI).

Engine Oil Viscosity

Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-5.
(2)
SAE 10W (3)
SAE 20W 0000587C

SAE 10W-30 Figure 4-6

SAE 15W-40
SAE 20 Adding Engine Oil
SAE 30
SAE 40
1. Make sure engine is level.
SAE 20W - 50 2. Remove oil cap (Figure 4-6, (4)).
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F 3. Add indicated amount of engine oil at the top or
(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C) side engine oil filler port (Figure 4-6, (5)).
0000005A
4. Wait three minutes and check oil level.
Figure 4-5
5. Add more oil if necessary.
Checking Engine Oil 6. Replace oil cap (Figure 4-6, (4)) and
hand-tighten. Over-tightening may damage the
1. Make sure engine is level.
cap.
2. Remove dipstick (Figure 4-6, (1)) and wipe with
clean cloth.
3. Fully reinsert dipstick.
4. Remove dipstick. The oil level should be
between upper (Figure 4-6, (2)) and lower
(Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert dipstick.

4-14 TNV IDI Service Manual

Engine Coolant GENERAL SERVICE INFORMATION
Engine Oil Capacity (Typical) ENGINE COOLANT
Note: These are the engine oil capacities
associated with a “deep standard” oil A DANGER
pan. Oil capacity will vary dependant
upon which optional oil pan is used.
Refer to the operation manual provided
by the driven machine manufacturer for
the actual engine oil capacity of your
machine.
SCALD HAZARD!
The following are the engine oil capacities for
various Yanmar TNV engines: • NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
Dipstick Upper
Engine Model burn you. Allow the engine to cool
Limit/ Lower Limit
down before you attempt to remove
2TNV70(VM) 1.9 / 1.3 qt the radiator cap.
2TNV70(VH) (1.8 / 1.2 L)
• Tighten the radiator cap securely after
2.3 / 1.3 qt you check the radiator. Steam can
2TNV70(CH)
(2.2 / 1.2 L) spurt out during engine operation if
3TNV70(CL), the cap is loose.
3.0 / 1.6 qt
3TNV70(VM) • ALWAYS check the level of the engine
(2.8 / 1.5 L)
3TNV70(VH) coolant by observing the reserve tank.
4.0 / 2.2 qt
3TNV70(CH) • Failure to comply will result in death or
(3.8 / 2.1 L)
serious injury.
3TNV76(CL),
3.6 / 1.9 qt 0000002en
3TNV76(VM)
(3.4 / 1.8 L)
3TNV76(VH)
4.7 / 2.4 qt
A WARNING
3TNV76(CH)
(4.4 / 2.3 L)

BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en

TNV IDI Service Manual 4-15

GENERAL SERVICE INFORMATION Engine Coolant

Engine Coolant Specifications

A CAUTION
Use a Long Life Coolant (LLC) or an Extended Life
Coolant (ELC) that meets or exceeds the following
guidelines and specifications:

Additional Technical Coolant

Specifications:
COOLANT HAZARD! • ASTM D6210, D4985 (US)
• Wear eye protection and rubber gloves • JIS K-2234 (Japan)
when you handle long life or extended
• SAE J814C, J1941, J1034 or J2036
life engine coolant. If contact with the
(International)
eyes or skin should occur, flush eyes
and wash immediately with clean Alternative Engine Coolant
water.
If an Extended or Long Life Coolant is not available,
• Failure to comply may result in minor you may use an ethylene glycol or propylene glycol
or moderate injury. based conventional coolant (green).
0000005en
Notes:
CAUTION 1. ALWAYS use a mix of coolant and water.
• Only use the engine coolant specified. NEVER use water only.
Other engine coolants may affect 2. Mix coolant and water per the mixing
warranty coverage, cause an internal instructions on the coolant container.
buildup of rust and scale and / or 3. Water quality is important to coolant
shorten engine life. performance. Yanmar recommends that soft,
• Prevent dirt and debris from distilled, or demineralized water be used to mix
contaminating the engine coolant. with coolants.
Carefully clean the radiator cap and 4. NEVER mix extended or long life coolants and
the surrounding area before you conventional (green) coolants.
remove the cap.
5. NEVER mix different types and / or colors of
• NEVER mix different types of engine extended life coolants.
coolants. This may adversely affect the 6. Replace the coolant every 1000 engine hours
properties of the engine coolant. or once a year.
0000006en

Filling Radiator with Engine Coolant

Fill the radiator and reserve tank as follows. This
procedure is for filling the radiator for the first time
or refilling it after it is flushed. Note that a typical
radiator is illustrated.

4-16 TNV IDI Service Manual

Engine Coolant GENERAL SERVICE INFORMATION
5. Remove the cap of the reserve tank
(2) (Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
(5)
Reinstall the cap.
6. Check the hose (Figure 4-7, (5)) that connects
(3) the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
(6) FULL

LOW there are no cracks or damage. If the hose is

(4) damaged, engine coolant will leak out instead
of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
(1) in the reserve tank. When the engine is running
0000029A
and the engine coolant is at normal
Figure 4-7 temperature, the coolant level in the tank should
be at or near the FULL (HOT) mark
1. Check to be sure the radiator drain plug is
(Figure 4-7, (6)). If the engine coolant is not at
installed and tightened or the drain cock
the FULL (HOT) mark (Figure 4-7, (6)), add
(Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the additional engine coolant to the reserve tank to
bring the level to the FULL (HOT) mark.
cylinder block is closed.
Engine Coolant Capacity (Typical)
Note: Capacities listed are for engine only
OIL
without a radiator. Refer to the operation
manual provided by the driven machine
manufacturer for actual engine coolant
capacity on your machine.
The following are the engine coolant capacities for
various Yanmar TNV engines.

Engine Coolant
Engine Model
Capacity
(1) 0002923
2TNV70 0.6 qt (0.6 L)
Figure 4-8
3TNV70 1.0 qt (0.9 L)
2. Remove the radiator cap (Figure 4-7, (2)) by 3TNV76 1.0 qt (0.9 L)
turning it counterclockwise about 1/3 of a turn.
3. Pour the engine coolant slowly into the radiator
until it is even with the lip of the engine coolant
filler port. Make sure that air bubbles do not
develop as you fill the radiator.
4. Reinstall the radiator cap (Figure 4-7, (2)).
Align the tabs on the back of the radiator cap
with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.

TNV IDI Service Manual 4-17

GENERAL SERVICE INFORMATION Specifications

SPECIFICATIONS
Description of Model Number
3 TNV 76 T - 0 0000
Customer Code
Rated rpm

Turbocharged (No symbol indicates naturally aspirated)

Cylinder Bore (mm)

Engine Series

No. of Cylinders

When ordering parts or making an inquiry about the engine you are working on, be sure to include the
complete model and serial numbers as shown on the engine nameplate. See Location of Labels on
page 4-4.

Engine Speed Specifications

Notation Available Engine Speed Intended Uses

VH 3200 ~ 3600 rpm (min-1) Lawn Mower, Construction, Industrial Machine
VM 2000 ~ 3000 rpm (min-1) Agricultural, Constructive, Industrial Machines
CH 3000 ~ 3600 rpm (min-1) 2-pole Generator Sets, Irrigation Pumps
CL 1500 or 1800 rpm (min-1) 4-pole Generator Sets, Irrigation Pumps
VH: Variable High Speed
VM: Variable Medium Speed
CH: Constant High Speed
CL: Constant Low Speed

4-18 TNV IDI Service Manual

Specifications GENERAL SERVICE INFORMATION
Engine General Specifications
Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Combustion System Swirl Chamber (Ball Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End

Note: The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by
the driven machine manufacturer. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77°F (25°C), Atmospheric pressure 29.53 in Hg (100 kPa,
750 mm Hg), Relative humidity 30%
• Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C)
• With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
• After Engine Break-In Period; Output Allowable Deviation: ± 3%
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW

TNV IDI Service Manual 4-19

GENERAL SERVICE INFORMATION Principal Engine Specifications

PRINCIPAL ENGINE SPECIFICATIONS

2TNV70
Engine Model 2TNV70
Version VM CH VH
Type Vertical In-line Diesel Engine
Combustion System Ball-Type Swirl Chamber
Aspiration Natural
No. of Cylinders 2
Bore × Stroke 2.756 x 2.913 in. (70 × 74 mm)
Displacement 34.777 cu in. (0.570 L)
RPM
3000 3600
(min-1)
Continuous Rated Output hp SAE 10.9 13.1
kW 8.16 9.76
PS 11.1 13.3
RPM
2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
(min-1)
Max. Rated Output (Net) hp SAE 7.99 8.88 9.76 10.55 11.44 12.23 12.03 14.40 12.53 13.12 13.81
kW 5.96 6.62 7.28 7.87 8.53 9.12 8.97 10.7 9.34 9.78 10.3
PS 8.10 9.00 9.90 10.7 11.6 12.4 12.2 14.6 12.7 13.3 14.0
RPM 2160 2375 2570 2780 2995 3210 3165 3800 3400 3600 3815
High Idling
(min-1) ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
182.2 lb (84 kg)
with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at
42 - 64 psi (0.29 -0.44 MPa, 2.96 - 4.49 kgf/cm2)
Rated Engine Speed
Normal Oil Pressure at
8.5 psi (0.06 MPa, 0.6 kgf/cm2) or greater
Low Idle Speed
Electric Starting - Starter Motor: DC12V, 1.3 hp (1.0 kW)**
Starting System Dynamo: DC12V, 20A**
Recommended Battery Capacity: 12V, 36 Amp-Hour (5h rating)**
16.38 x 16.81 x
16.38 x 16.81 x 19.06
16.38 x 16.81 x 19.06 in. 20.24 in.
Dimensions (L × W × H)* in.
(419 × 427 × 484 mm) (416 x 427 x
(416 x 427 x 484 mm)
514 mm)
2.4 / 1.4 qt
(2.3 / 1.3 L) 1.7 / 0.8 qt (1.6 / 0.8 L)
1.7 / 0.9 qt (1.65 / 0.8 L)
Engine Oil Pan Capacity (Dipstick Upper (Dipstick Upper Limit /
(Dipstick Upper Limit / Lower Limit)
Limit / Lower Lower Limit)
Limit)
Engine Coolant Capacity 0.2 gal (0.9 L) Engine Only
Standard Cooling Fan 10.23 in. (260 mm) O.D., 5 Blade Pusher-Type**
* Engine specifications without radiator.
** May vary depending on application.
*** Engine oil capacity for a “Deep Standard” oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.

4-20 TNV IDI Service Manual

Principal Engine Specifications GENERAL SERVICE INFORMATION
3TNV70
Engine Model 3TNV70
Version CL VM CH VH
Type Vertical In-line Diesel Engine
Combustion System Ball-Type Swirl Chamber
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 2.756 x 2.913 in. (70 × 74 mm)
Displacement 52.105 cu in. (0.854 L)
RPM
(min -1) 1500 1800 3000 3600

Continuous Rated Output hp SAE 8.16 9.77 16.27 19.43

kW 6.09 7.29 8.16 9.76
PS 8.27 9.91 16.5 19.7
RPM
(min -1) 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Max. Rated Output (Net) hp SAE 8.98 10.75 12.03 13.32 14.70 15.88 17.16 18.35 17.85 21.40 18.74 19.73 20.71
kW 6.69 8.02 8.97 9.93 11.0 11.8 12.8 13.7 13.3 16.0 14.0 14.7 15.4
PS 9.10 10.9 12.2 13.5 14.9 16.1 17.4 18.6 18.1 21.7 19.0 20.0 21.0
RPM 1600 1895 2160 2375 2570 2780 2995 3210 3165 3800 3400 3600 3815
High Idling
(min -1) ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
with Flywheel Housing 216.1 lb (98 kg)
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
35 - 51psi
Normal Oil Pressure at Rated (0.24-0.35
Engine Speed MPa, 2.44 - 42 - 64 psi (0.29 -0.44 MPa, 2.96 - 4.49 kgf/cm2)
3.57 kgf/cm2)
Normal Oil Pressure at Low
8.5 psi (0.06 MPa, 0.6 kgf/cm 2) or greater
Idle Speed
Electric Starting - Starter Motor: DC12V, 1.3 hp (1.0 kW)**
Starting System Dynamo: DC12V, 20A**
Recommended Battery Capacity: 12V, 36 Amp-Hour (5h rating)**
21.57 x 16.81 19.84 x 16.81 19.84 x 16.81 x
x 19.92 in. 19.84 x 16.81 x 19.92 in. x 21.10 in.
Dimensions (L × W × H)* (548 × 427 × (504 × 427 × 506 mm) (504 x 427 x 19.92 in.
506 mm) 536 mm) (504 x 427 x 506 mm)
4.0 / 2.2 qt
(3.8 / 2.1 L) 3.0 / 1.6 qt
3.0 / 1.6 qt (2.8 / 1.5 L) (2.8 / 1.5 L)
Engine Oil Pan Capacity (Dipstick
(Dipstick Upper Limit / Lower Limit) Upper Limit / (Dipstick Upper Limit /
Lower Limit)
Lower Limit)
Engine Coolant Capacity 0.2 gal (0.9 L) Engine Only
Standard Cooling Fan 12.20 in. (310 mm) O.D., 5 Blade Pusher-Type**

* Engine specifications without radiator

** May vary depending on application.
*** Engine oil capacity for a “Deep Standard” oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.

TNV IDI Service Manual 4-21

GENERAL SERVICE INFORMATION Principal Engine Specifications

3TNV76
Engine Model 3TNV76
Version CL VM CH VH
Type Vertical In-line Diesel Engine
Combustion System Ball-Type Swirl Chamber
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 2.992 x 3.228 in. (76 × 82 mm)
Displacement 68.029 cu in. (1.115 L)
RPM
(min -1) 1500 1800 3000 3600

Continuous Rated Output hp SAE 11.0 13.1 20.2 23.7

kW 8.2 9.8 15.1 17.7
PS 11.1 13.3 20.5 24.1
RPM
(min -1) 1500 1800 2000 2200 2400 2500 2600 2800 3000 3000 3600 3200 3400 3600

Max. Rated Output (Net) hp SAE 12.1 14.3 15.9 17.7 19.2 20.0 20.8 22.4 24.0 22.1 26.1 24.4 25.9 26.1
kW 9 10.7 11.8 13.2 14.3 14.9 15.5 16.7 17.9 16.5 19.5 18.2 19.3 19.5
PS 12.2 14.5 16.1 17.9 19.5 20.3 21.1 22.7 24.3 22.4 26.5 24.7 26.2 26.5
RPM 1600 1900 2160 2375 2570 2675 2780 2995 3210 3200 3800 3400 3600 3815
High Idling (min -1) ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
with Flywheel Housing 247.0 lb (112 kg)
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
35 - 51psi
Normal Oil Pressure at Rated (0.24-0.35
42 - 64 psi (0.29 -0.44 MPa, 2.96 - 4.49 kgf/cm2)
Engine Speed MPa, 2.44 -
3.57 kgf/cm2)
Normal Oil Pressure at Low 8.5 psi (0.06 MPa, 0.6 kgf/cm2) or greater
Idle Speed
Electric Starting - Starter Motor: DC12V, 1.5 hp (1.1 kW)**
Starting System Alternator: DC12V, 40A**
Recommended Battery Capacity: 12V, 36 Amp-Hour (5h rating)**
22.32 x 20.59 x 20.59 x 16.81 x
16.81 x 20.59 x 16.81 x 20.94 in. 16.81 x 20.94 in.
Dimensions (L × W × H)* 20.94 in. (532 × 427 × 532 mm) 22.01 in. (532 × 427 × 532
(567 × 427 × (532 × 427 × mm)
532 mm) 559 mm)
4.7 / 2.4 qt
(4.4 / 2.3 L) 3.6 / 1.9 qt (3.4 / 1.8
Engine Oil Pan Capacity 3.6 / 1.9 qt (3.4 / 1.8 L) (Dipstick Upper Limit / Lower Limit) (Dipstick L) (Dipstick Upper
Upper Limit / Limit / Lower Limit)
Lower Limit)
Engine Coolant Capacity 0.2 gal (0.9 L) Engine Only
Standard Cooling Fan 13.19 in. (335 mm) O.D., 6 Blade Pusher-Type**

* Engine specifications without radiator

4-22 TNV IDI Service Manual

Engine Service Information GENERAL SERVICE INFORMATION

ENGINE SERVICE INFORMATION

Inspection Item Standard Limit
0.006 - 0.010 in
Intake / Exhaust Valve Gap -
(0.15 - 0.25 mm)
Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-19
1711 - 1842 psi
Fuel Injection Pressure (11.8 - 12.8 MPa; -
120 - 130 kgf / cm²)
470 ± 15 psi 370 ± 15 psi
2TNV70
(3.24 ± 0.1MPa; (2.55 ± 0.1 MPa;
3TNV70
Compression Pressure at 33 ± 1 kgf / cm²) 26 ± 1 kgf / cm²)
250 rpm (250 min¯¹) 498 ± 15 psi 399 ± 15 psi
3TNV76 (3.43 ± 0.1MPa, (2.75 ± 0.1 MPa,
35 ± 1 kgf / cm²) 28 ± 1 kgf / cm²)
42 - 64 psi (0.29 - 0.44 MPa;
At rated output -
2.96 - 4.49 kgf/cm2)
Lubricating Oil Pressure
8.5 psi (0.06 MPa;
When idling -
0.6 kgf/cm2) or greater
Full Opening Lift
Valve Opening Temperature
Temperature
Thermostat 0.32 in. (8 mm) or
157 - 163°F
Above
(70 - 73°C)
185°F (85°C)
225 - 235°F
Temperature Coolant Switch -
(107 - 113°C)

TNV IDI Service Manual 4-23

GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts

TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten
fasteners on the machine. Applying excessive CAUTION
torque may damage the fastener or component and The tightening torque in the Standard
not enough torque may cause a leak or component Torque Chart in General Service
failure. Information should be applied only to
the bolts with a “7” head. (JIS strength
classification: 7T)

• Apply 60% torque to bolts

that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
0000023enTNVIDISM

Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
87 - 104 in·lb
M6 x 1.0 mm (9.8 - 11.8 N·m;
1.0 - 1.2 kgf·m)
200 - 251 in·lb
M8 x 1.25 mm (22.6 - 28.4 N·m;
2.3 - 2.9 kgf·m)
33 - 40 ft·lb
M10 x 1.5 mm (44.1 - 53.9 N·m; Use 80% of the value at left
4.5 - 5.5 kgf·m) when the tightening part is
Hexagon Bolt (7T)
aluminum.
and Nut 58 - 72 ft·lb Use 60% of the value at left
M12 x 1.75 mm (78.4 - 98.0 N·m; for 4T bolts and lock nuts.
8.0 - 10 kgf·m)
94 - 108 ft·lb
M14 x 1.5 mm (127.5 - 147.1 N·m;
13 - 15 kgf·m)
159 - 174 ft·lb
M16 x 1.5 mm (215.7 - 235.4 N·m;
22 - 24 kgf·m)
87 in·lb
1/8 mm
(9.8 N·m; 1.0 kgf·m)
173 in·lb
1/4 mm
(19.6 N·m; 2.0 kgf·m)
PT Plug -
22 ft·lb
3/8 mm
(29.4 N·m; 3.0 kgf·m)
43 ft·lb
1/2 mm
(58.8 N·m; 6.0 kgf·m)

4-24 TNV IDI Service Manual

Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION

Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
112 - 148 in·lb
M8 (12.7 - 16.7 N·m;
1.3 - 1.7 kgf·m)
173 - 225 in·lb
M10 (19.6 - 18.734 N·m,;
2.0 - 3.5 kgf·m)
18 - 25 ft·lb
Pipe Joint Bolt M12 (24.5 - 34.3 N·m; -
2.5 - 3.5 kgf·m)
29 - 36 ft·lb
M14 (39.2 - 49.0 N·m;
4.0 - 5.0 kgf·m)
36 - 43 ft·lb
M16 (49.0 - 58.8 N·m;
5.0 - 6.0 kgf·m)

Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

TNV IDI Service Manual 4-25

GENERAL SERVICE INFORMATION Abbreviations and Symbols

ABBREVIATIONS AND SYMBOLS

Abbreviations L liter
L/hr liter per hour
A ampere lb pound
AC alternating current lbf pond force
Association des Constructeurs mL milliliter
ACEA
Européens d’Automobilies mm millimeter
Ah ampere-hour MPa megapascal
approx. approximately mV millivolt
API American Petroleum Institute N newton
ARB Air Resources Board N·m newton meter
ATDC after top dead center No. number
BTDC before top dead center O.D. outside diameter
°C degree Celsius oz ounce
CARB California Air Resources Board PS horsepower (metric)
CCA cold cranking amp psi pound per square inch
cm centimeter qt quart (U.S.)
cm³ cubic centimeter RPM revolutions per minute
cm³/min cubic centimeter per minute SAE Society of Automotive Engineers
cu in cubic inch sec. second
DC direct current t short ton 2000lb
DI direct injection TBN Total Base Number
DVA direct volt adapter TDC top dead center
EPA Environmental Protection Agency V volt
ESG electronic speed governor VAC volt alternating current
°F degree Fahrenheit VDC volt direct current
fl oz fluid ounce (U.S.) W watt
fl oz/min fluid ounce (U.S.) per minute
ft foot Symbols
ft·lb foot pound
ft·lbf/min foot pound force per minute ° angular degree
g gram + plus
gal/hr gallon (U.S.) per hour - minus
gal gallon (U.S.) ± plus or minus
GL gear lubricant Ω ohm
hp horsepower (U.S.) μ micro
hrs hours % percent
I.D. inside diameter ~ approximate
IDI indirect injection
in inch
in·lb inch pound
Japanese Automobile Standards
JASO
Organization
kg kilogram
kilogram force per square
kgf/cm²
centimeter
kgf·m kilogram force meter
km kilometers
kPa kilopascal
kW kilowatt

4-26 TNV IDI Service Manual

Unit Conversions GENERAL SERVICE INFORMATION

UNIT CONVERSIONS Units of Torque

ft·lb x 1.3558 = N·m
Unit Prefixes ft·lb x 0.1383 = kgf·m
Prefix Symbol Power in·lb x 0.1130 = N·m
mega M x 1,000,000 in·lb x 0.0115 = kgf·m
kilo k x 1,000 kgf·m x 7.2330 = ft·lb
centi c x 0.01 kgf·m x 86.8000 = in·lb
milli m x 0.001 kgf·m x 9.8070 = N·m
micro μ x 0.000001 N·m x 0.7376 = ft·lb
N·m x 8.8510 = in·lb
Units of Length N·m x 0.1020 = kgf·m

mile x 1.6090 = km Units of Pressure

ft x 0.3050 =m
in x 2.5400 = cm psi x 0.0689 = bar
in x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm²
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in bar x 100.0000 = kPa
mm x 0.0394 = in = in Hg
bar x 29.5300
(60°F)
Units of Volume kPa x 0.1450 = psi
kPa x 0.0100 = bar
gal (U.S.) x 3.78540 =L kPa x 0.0102 = kg/cm²
qt (U.S.) x 0.94635 =L kg/cm² x 98.0700 = psi
cu in x 0.01639 =L kg/cm² x 0.9807 = bar
cu in x 16.38700 = mL kg/cm² x 14.2200 = kPa
fl oz (U.S.) x 0.02957 =L in Hg (60°) x 0.0333 = bar
fl oz (U.S.) x 29.57000 = mL in Hg (60°) x 3.3770 = kPa
cm³ x 1.00000 = mL in Hg (60°) x 0.0344 = kg/cm²
cm³ x 0.03382 = fl oz (U.S.)
Units of Power
Units of Mass
hp (metric or
x 0.9863201 = hp SAE
lb x 0.45360 = kg PS)
oz x 28.35000 =g hp (metric or
x 0.7354988 = kW
kg x 2.20500 = lb PS)
g x 0.03527 = oz = hp (metric
hp SAE x 1.0138697
or PS)
Units of Force hp SAE x 0.7456999 = kW
= hp (metric
lbf x 4.4480 =N kW x 1.3596216
or PS)
lbf x 0.4536 = kgf kW x 1.3410221 = hp SAE
N x 0.2248 = lbf
N x 0.1020 = kgf Units of Temperature
kgf x 2.2050 = lbf
kgf x 9.8070 =N °F = (1.8 x °C) + 32
°C = 0.556 x (°F - 32)

TNV IDI Service Manual 4-27

GENERAL SERVICE INFORMATION Unit Conversions

This Page Intentionally Left Blank

4-28 TNV IDI Service Manual

TNV IDI Service Manual
Section 5

PERIODIC
MAINTENANCE
Page
Introduction...................................................................................... 5-3
Precautions ................................................................................... 5-15
The Importance of Periodic Maintenance................................ 5-15
Performing Periodic Maintenance ........................................... 5-15
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance - USA Only....................... 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule.................................................... 5-16
Periodic Maintenance Procedures ................................................ 5-18
After Initial 50 Hours of Operation ........................................... 5-18
Every 50 Hours of Operation................................................... 5-21
Every 250 Hours of Operation ................................................. 5-25
Every 500 Hours of Operation ................................................. 5-30
Every 1000 Hours of Operation ............................................... 5-33
Every 1500 Hours of Operation ............................................... 5-36
Every 2000 Hours of Operation ............................................... 5-37

TNV IDI Service Manual 5-1

PERIODIC MAINTENANCE

This Page Intentionally Left Blank

5-2 TNV IDI Service Manual

Introduction PERIODIC MAINTENANCE

INTRODUCTION A DANGER
This section of the Service Manual describes the
procedures for proper care and maintenance of the
engine.

A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
EXPLOSION HAZARD! down before you attempt to remove
• NEVER check the remaining battery the radiator cap.
charge by shorting out the terminals.
• Tighten the radiator cap securely after
This will result in a spark and may
you check the radiator. Steam can
cause an explosion or fire. Use a
spurt out during engine operation if
hydrometer to check the remaining
the cap is loose.
battery charge.
• ALWAYS check the level of the engine
• If the electrolyte is frozen, slowly warm
coolant by observing the reserve tank.
the battery before you recharge it.
• Failure to comply will result in death or
• Failure to comply will result in death or
serious injury.
serious injury.
0000002en
0000007en

A DANGER

FIRE AND EXPLOSION HAZARD!

• Only use the key switch to start the
engine.
• NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en

TNV IDI Service Manual 5-3

PERIODIC MAINTENANCE Introduction

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• Only fill the fuel tank with diesel fuel. • Before you operate the engine, check
Filling the fuel tank with gasoline may for fuel leaks. Replace rubberized fuel
result in a fire and will damage the hoses every two years or every 2000
engine. hours of engine operation, whichever
• NEVER refuel with the engine running. comes first, even if the engine has
been out of service. Rubberized fuel
• Wipe up all spills immediately. lines tend to dry out and become
• Keep sparks, open flames or any other brittle after two years or 2000 hours of
form of ignition (match, cigarette, engine operation, whichever comes
static electric source) well away when first.
refueling. • Failure to comply will result in death or
• NEVER overfill the fuel tank. serious injury.
0000015en
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
• Failure to comply will result in death or
serious injury.
0000005en

5-4 TNV IDI Service Manual

Introduction PERIODIC MAINTENANCE

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• Be sure to place the diesel fuel • NEVER remove the fuel cap with the
container on the ground when engine running.
transferring the diesel fuel from the • Failure to comply will result in death or
pump to the container. Hold the hose serious injury.
nozzle firmly against the side of the 0000011en
container while filling it. This prevents
static electricity buildup which could
cause sparks and ignite fuel vapors. A DANGER
• NEVER place diesel fuel or other
flammable material such as oil, hay or
dried grass close to the engine during
engine operation or shortly after
shutdown.
• Failure to comply will result in death or CRUSH HAZARD!
serious injury. • When you need to transport an engine
0000014en for repair, have a helper assist you to
attach it to a hoist and load it on a
truck.
A DANGER
• NEVER stand under a hoisted engine.
If the hoist mechanism fails, the
engine will fall on you, causing death
or serious injury.

FIRE AND EXPLOSION HAZARD! • Failure to comply will result in death or

serious injury.
• Diesel fuel is flammable and explosive
0000008en
under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
• Failure to comply will result in death or
serious injury.
0000012en

TNV IDI Service Manual 5-5

PERIODIC MAINTENANCE Introduction

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• When you remove any fuel system • Place an approved container under the
component to perform maintenance air bleed port when you prime the fuel
(such as changing the fuel filter) place system. Never use a shop rag to catch
an approved container under the the fuel. Wipe up any spills
opening to catch the fuel. immediately. ALWAYS close the air
• NEVER use a shop rag to catch the bleed port after you complete priming
fuel. Vapors from the rag are the system.
flammable and explosive. • Wear eye protection. The fuel system
• Wipe up any spills immediately. is under pressure and fuel could spray
out when you open the air bleed port.
• Wear eye protection. The fuel system
is under pressure and fuel could spray • If the unit has an electric fuel pump,
out when you remove any fuel system turn the key switch to the ON position
component. for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
• Failure to comply will result in death or of bubbles, to allow the electric fuel
serious injury. pump to prime the system.
0000009en
• If the unit has a mechanical fuel pump,
operate the fuel priming pump several
times until the fuel coming out of the
air bleed port is free of bubbles.
• Failure to comply will result in death or
serious injury.
0000006en

5-6 TNV IDI Service Manual

Introduction PERIODIC MAINTENANCE

A WARNING A WARNING

EXHAUST HAZARD! SEVER HAZARD!

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

TNV IDI Service Manual 5-7

PERIODIC MAINTENANCE Introduction

A WARNING A WARNING

BURN HAZARD!
• Keep your hands and other body parts EXPOSURE HAZARD!
away from hot engine surfaces such
• Wear personal protective equipment
as the muffler, exhaust pipe,
such as gloves, work shoes, eye and
turbocharger (if equipped) and engine
hearing protection as required by the
block during operation and shortly
task at hand.
after you shut the engine down. These
surfaces are extremely hot while the • NEVER wear jewelry, unbuttoned
engine is operating and could cuffs, ties or loose-fitting clothing
seriously burn you. when you are working near
moving / rotating parts such as the
• Failure to comply could result in death
cooling fan, flywheel or PTO shaft.
or serious injury.
0000015en
• ALWAYS tie back long hair when you
are working near moving / rotating
parts such as a cooling fan, flywheel,
A WARNING or PTO shaft.
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
• Failure to comply could result in death
ALCOHOL AND DRUG HAZARD! or serious injury.
• NEVER operate the engine while you 0000005en
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en

5-8 TNV IDI Service Manual

Introduction PERIODIC MAINTENANCE

A WARNING A WARNING

BURN HAZARD!
SHOCK HAZARD!
• Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact • Turn off the battery switch (if
with clothing, skin or eyes. Severe equipped) or disconnect the negative
battery cable before servicing the
burns could result. ALWAYS wear
electrical system.
safety goggles and protective clothing
when servicing the battery. If battery • Check the electrical harnesses for
fluid contacts the eyes and / or skin, cracks, abrasions, and damaged or
immediately flush the affected area corroded connectors. ALWAYS keep
with a large amount of clean water and the connectors and terminals clean.
obtain prompt medical treatment. • Failure to comply could result in death
• Failure to comply could result in death or serious injury.
or serious injury. 0000009en

0000007en

A WARNING
A WARNING

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

TNV IDI Service Manual 5-9

PERIODIC MAINTENANCE Introduction

A WARNING A CAUTION

BURN HAZARD!
COOLANT HAZARD!
• If you must drain the engine oil while it
is still hot, stay clear of the hot engine • Wear eye protection and rubber gloves
oil to avoid being burned. when you handle long life or extended
life engine coolant. If contact with the
• ALWAYS wear eye protection. eyes or skin should occur, flush eyes
• Failure to comply could result in death and wash immediately with clean
or serious injury. water.
0000011en • Failure to comply may result in minor
or moderate injury.
A CAUTION 0000005en

CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
FLYING OBJECT HAZARD! engine life.
• ALWAYS wear eye protection when • Prevent dirt and debris from
servicing the engine and when using contaminating the engine oil. Carefully
compressed air or high-pressure clean the oil cap / dipstick and the
water. Dust, flying debris, compressed surrounding area before you remove
air, pressurized water or steam may the cap.
injure your eyes. • NEVER mix different types of engine
• Failure to comply may result in minor oil. This may adversely affect the
or moderate injury. lubricating properties of the engine oil.
0000003en • NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en

5-10 TNV IDI Service Manual

Introduction PERIODIC MAINTENANCE

CAUTION CAUTION
• Only use diesel fuels recommended by • Only use the engine coolant specified.
Yanmar for the best engine Other engine coolants may affect
performance, to prevent engine warranty coverage, cause an internal
damage and to comply with EPA / ARB buildup of rust and scale and / or
warranty requirements. shorten engine life.
• Only use clean diesel fuel. • Prevent dirt and debris from
• NEVER remove the primary strainer (if contaminating the engine coolant.
equipped) from the fuel tank filler port. Carefully clean the radiator cap and
If removed, dirt and debris could get the surrounding area before you
into the fuel system causing it to clog. remove the cap.
0000004en • NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
CAUTION
0000006en
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine CAUTION
components to seize and / or shorten • NEVER attempt to modify the engine’s
engine life. design or safety features such as
• Prevent dirt and debris from defeating the engine speed limit
contaminating the engine oil. Carefully control or the diesel fuel injection
clean the oil cap / dipstick and the quantity control.
surrounding area before you remove • Modifications may impair the engine’s
the cap. safety and performance
• NEVER mix different types of engine characteristics and shorten the
oil. This may adversely affect the engine’s life. Any alterations to this
lubricating properties of the engine oil. engine may void its warranty. Be sure
to use Yanmar genuine replacement
• NEVER overfill. Overfilling may result parts.
in white exhaust smoke, engine 0000079en
overspeed or internal damage.
0000005en

TNV IDI Service Manual 5-11

PERIODIC MAINTENANCE Introduction

CAUTION CAUTION
Observe the following environmental NEVER hold the key in the START
operating conditions to maintain engine position for longer than 15 seconds or
performance and avoid premature the starter motor will overheat.
engine wear: 0000007en

• Avoid operating in extremely dusty

conditions. CAUTION
• Avoid operating in the presence of For maximum engine life, Yanmar
chemical gases or fumes. recommends that when shutting the
• Avoid operating in a corrosive engine down, you allow the engine to
atmosphere such as salt water spray. idle, without load, for five minutes. This
will allow the engine components that
• NEVER install the engine in a operate at high temperatures, such as
floodplain unless proper precautions the turbocharger (if equipped) and
are taken to avoid being subject to a exhaust system, to cool slightly before
flood. the engine itself is shut down.
• NEVER expose the engine to the rain. 0000008en

0000003en

CAUTION
CAUTION NEVER use an engine starting aid such
Observe the following environmental as ether. Engine damage will result.
operating conditions to maintain engine 0000009en

performance and avoid premature

engine wear:
CAUTION
• The standard range of ambient Make sure the engine is installed on a
temperatures for the normal operation level surface. If a continuously running
of Yanmar engines is from +5°F (-15°C) engine is installed at an angle greater
to +113°F (+45°C). than (IDI = 25°, DI = 30°) in any direction
• If the ambient temperature exceeds or if an engine runs for short periods of
+113°F (+45°C) the engine may time (less than three minutes) at an
overheat and cause the engine oil to angle greater than (IDI = 30°, DI = 35°) in
break down. any direction, engine oil may enter the
• If the ambient temperature is below combustion chamber causing excessive
+5°F (-15°C) the engine will be hard to engine speed and white exhaust smoke.
start and the engine oil may not flow This may cause serious engine damage.
easily. 0000010enTNV

• Contact your authorized Yanmar

industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en

5-12 TNV IDI Service Manual

Introduction PERIODIC MAINTENANCE

CAUTION CAUTION
New Engine Break-in:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for • ALWAYS be environmentally
proper operation of the indicators responsible.
and / or gauges. • Follow the guidelines of the EPA or
• During the first hour of operation, vary other governmental agencies for the
the engine speed and the load on the proper disposal of hazardous
engine. Short periods of maximum materials such as engine oil, diesel
engine speed and load are desirable. fuel and engine coolant. Consult the
Avoid prolonged operation at local authorities or reclamation facility.
minimum or maximum engine speeds • NEVER dispose of hazardous
and loads for the next four to five materials irresponsibly by dumping
hours. them into a sewer, on the ground, or
• During the break-in period, carefully into ground water or waterways.
observe the engine oil pressure and • Failure to follow these procedures may
engine temperature. seriously harm the environment.
• During the break-in period, check the 0000013en

engine oil and coolant levels

frequently. CAUTION
0000011en
Protect the air cleaner, turbocharger (if
equipped) and electric components
CAUTION from damage when you use steam or
NEVER engage the starter motor while high-pressure water to clean the engine.
the engine is running. This may damage 0000014en

the starter motor pinion and / or ring

gear. CAUTION
0000012en
• NEVER overfill the engine with engine
oil.
• ALWAYS keep the oil level between the
upper and lower lines on the oil
cap / dipstick.
0000015en

TNV IDI Service Manual 5-13

PERIODIC MAINTENANCE Introduction

CAUTION CAUTION
NEVER use high-pressure water or If the fuel filter / water separator is
compressed air at greater than 28 psi positioned higher than the fuel level in
(193 kPa; 19 686 mmAq) or a wire brush the fuel tank, water may not drip out
to clean the radiator fins. Radiator fins when the fuel filter / water separator
damage easily. drain cock is opened. If this happens,
0000016en turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
CAUTION
Be sure to tighten the air vent screw
NEVER attempt to adjust the low or high
after the water has drained out.
idle speed limit screw. This may impair
0000025en
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment, CAUTION
see your authorized Yanmar industrial • When the engine is operated in dusty
engine dealer or distributor. conditions, clean the air cleaner
0000017en
element more frequently.
• NEVER operate the engine with the air
CAUTION cleaner element(s) removed. This may
Establish a periodic maintenance plan allow foreign material to enter the
according to the engine application and engine and damage it.
make sure you perform the required 0000026en

periodic maintenance at intervals

indicated. Failure to follow these
guidelines will impair the engine’s safety
CAUTION
and performance characteristics, The maximum air intake restriction, in
shorten the engine’s life and may affect terms of differential pressure
the warranty coverage on your engine. measurement, must not exceed 0.90 psi
See Yanmar Warranties section. (6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
Consult your authorized Yanmar dealer restriction exceeds the above
or distributor for assistance when mentioned value.
checking items marked with a z.
0000046en
0000024enTNVIDISM

5-14 TNV IDI Service Manual

Precautions PERIODIC MAINTENANCE

CAUTION PRECAUTIONS
The tightening torque in the Standard The Importance of Periodic
Torque Chart in General Service
Information should be applied only to
Maintenance
the bolts with a “7” head. (JIS strength Engine deterioration and wear occurs in proportion
classification: 7T) to length of time the engine has been in service and
the conditions the engine is subject to during
• Apply 60% torque to bolts operation. Periodic maintenance prevents
that are not listed. unexpected downtime, reduces the number of
• Apply 80% torque when accidents due to poor machine performance and
tightened to aluminum alloy. helps extend the life of the engine.
0000023enTNVIDISM
Performing Periodic Maintenance
CAUTION A WARNING
It is important to perform daily checks.
Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
EXHAUST HAZARD!
the life of the engine.
0000060en
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
• NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause
illness or even death.
• Make sure that all connections are
tightened to specifications after repair
is made to the exhaust system.
• Failure to comply could result in death
or serious injury.
0000003en

Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind, or
snow, from damaging the machine.

TNV IDI Service Manual 5-15

PERIODIC MAINTENANCE Periodic Maintenance Schedule

Yanmar Replacement Parts PERIODIC MAINTENANCE

Yanmar recommends that you use genuine Yanmar SCHEDULE
parts when replacement parts are needed.
Genuine replacement parts help ensure long Daily and periodic maintenance is important to
engine life. keep the engine in good operating condition. The
following is a summary of maintenance items by
Required EPA / ARB Maintenance - periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
USA Only application, loads, diesel fuel and engine oil used
To maintain optimum engine performance and and are hard to establish definitively. The following
compliance with the Environmental Protection should be treated only as a general guideline.
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB, CAUTION
California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-16 and Establish a periodic maintenance plan
Periodic Maintenance Procedures on page 5-18. according to the engine application and
make sure you perform the required
EPA / ARB Installation Requirements periodic maintenance at intervals
indicated. Failure to follow these
- USA Only
guidelines will impair the engine’s safety
The following are the installation requirements for and performance characteristics,
the EPA / ARB. Unless these requirements are met, shorten the engine’s life and may affect
the exhaust gas emissions will not be within the the warranty coverage on your engine.
limits specified by the EPA and ARB. See Yanmar Warranties section.
Maximum Exhaust Gas Restriction shall be: Consult your authorized Yanmar dealer
or distributor for assistance when
• 2TNV70: 0.85 psi (5.88 kPa; 600 mm Aq) or checking items marked with a z.
less 0000024enTNVIDISM

• 3TNV70 and 3TNV76: 1.70 psi (11.76 kPa;

1200 mm Aq) or less
Maximum air intake restriction shall be 0.90 psi
(6.23kPa; 635mm Aq) or less. Clean or replace the
air cleaner element if the air intake restriction
exceeds the above mentioned value.

5-16 TNV IDI Service Manual

Periodic Maintenance Schedule PERIODIC MAINTENANCE

c:Check :Replace z: Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval

System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Check and Refill Engine Coolant c
Check and Clean Radiator Fins c
Check and Adjust Cooling Fan V- c1st c 2nd
Belt time and after
Cooling
or
System
every 1
Drain, Flush and Refill Cooling yr. which-
System with New Coolant ever
comes
first
Adjust Intake / Exhaust Valve
Cylinder z
Clearance
Head
Lap Intake / Exhaust Valve Seats z
Electrical Check Indicators c
Equipment Check Battery c
Check Engine Oil Level c

Engine Oil Drain and Fill Engine Oil 2nd

1st
and
Replace Engine Oil Filter time
after
Engine
Check and Adjust Governor Lever
Speed c c
and Engine Speed Control
Control
Emission Inspect, Clean and Test Fuel
z
Control Injectors
Warranty Inspect Crankcase Breather System z
Check and Refill Fuel Tank Level c
Drain Fuel Tank c
Drain Fuel Filter / Water Separator c
Fuel
Check Fuel Filter / Water Separator c
Clean Fuel Filter / Water Separator c
Replace Fuel Filter
z or
Replace Fuel System and Cooling
Hoses every 2
System Hoses
yrs.
Intake and Clean or Replace Air Cleaner
c
Exhaust Element
Complete
Overall Visual Check Daily c
Engine

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

TNV IDI Service Manual 5-17

PERIODIC MAINTENANCE Periodic Maintenance Procedures

PERIODIC MAINTENANCE CAUTION

PROCEDURES • Only use the engine oil specified.
Other engine oils may affect warranty
After Initial 50 Hours of Operation coverage, cause internal engine
components to seize and / or shorten
Perform the following maintenance after the initial engine life.
50 hours of operation. • Prevent dirt and debris from
• Replace Engine Oil and Engine Oil Filter contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
• Check and Adjust Cooling Fan V-Belt surrounding area before you remove
the cap.
Replace Engine Oil and Engine Oil Filter
• NEVER mix different types of engine
A WARNING oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en

BURN HAZARD!
• If you must drain the engine oil while it CAUTION
is still hot, stay clear of the hot engine
oil to avoid being burned.
• ALWAYS wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en

5-18 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
The engine oil on a new engine becomes Remove the engine oil filter as follows:
contaminated from the initial break-in of internal
parts. It is very important that the initial oil and filter 1. Turn the engine oil filter (Figure 5-2, (2))
change is performed as scheduled. counterclockwise (Figure 5-2, (4)) using a filter
wrench.
Note: The oil drain plug may be in another
location if an optional oil pan is used.
Drain the engine oil as follows:
1. Make sure the engine is level.
2. Start the engine and bring it up to operating (3)
temperature. (4)
3. Stop the engine.
4. Remove the oil filler cap (Figure 5-1, (1)) to
vent the engine crankcase and allow the engine
oil to drain more easily. (2)
5. Position a container under the engine to collect
waste oil.
(1)
(1) 0000651B

Figure 5-2
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
(1) clean engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (3)) until it contacts the mounting
surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m,
2.0 - 2.4 kgf·m or one additional turn using the
filter wrench.

Applicable Engine Oil Filter Part No.

2TNV70
0000587B
3TNV70 119305-35150
Figure 5-1 3TNV76
6. Remove the oil drain plug (Figure 5-2, (1)).
4. Add new engine oil to the engine as specified in
Allow oil to drain.
Adding Engine Oil on page 4-14.
7. After all oil has been drained from the engine,
reinstall the oil drain plug (Figure 5-2, (1)) and Check and Adjust Cooling Fan V-Belt
tighten to 39.8 - 47.0 ft·lb (53.9 - 63.7 N·m, 5.5 - The V-belt will slip if it does not have the proper
6.5 kgf·m). tension. This will prevent the alternator from
8. Dispose of used oil properly. generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping.

TNV IDI Service Manual 5-19

PERIODIC MAINTENANCE Periodic Maintenance Procedures

Check and adjust the V-belt tension (deflection) as

follows: B
1. Press the V-belt down with your thumb with a
force of approximately 22 ft·lb (98 N·m,
10 kgf·m) to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-4, (A), (B) and (C)). You can A
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is: C

(4) 0000652B

Figure 5-4

Used V-Belt Tension

(4) A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)

2. If necessary, adjust the V-belt tension. Loosen

(5) the adjusting bolt (Figure 5-5, (1)) and move
the alternator (Figure 5-5, (2)) with a pry bar
(Figure 5-5, (3)) to tighten the V-belt to the
(1) desired tension. Then tighten the adjusting bolt.

(3)

(2)
(3) (1)
0000587C
(2)
Figure 5-3
0000653B

Figure 5-5

5-20 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
3. Tighten the V-belt to the proper tension. There
must be clearance (Figure 5-6, (1)) between Every 50 Hours of Operation
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between After you complete the initial 50 hour maintenance
the V-belt and the bottom of the pulley groove, procedures, perform the following procedures every
replace the V-belt. 50 hours thereafter.
• Drain Fuel Filter / Water Separator
• Check Battery

Drain Fuel Filter / Water Separator

(2)
(1)
A DANGER
0000584

Figure 5-6
4. Check the V-belt for cracks, oil or wear. If any of FIRE AND EXPLOSION HAZARD!
these conditions exist, replace the V-belt.
• Diesel fuel is flammable and explosive
• “New V-belt” refers to a V-belt which has been under certain conditions.
used less than 5 minutes on a running engine.
• When you remove any fuel system
• “Used V-belt” refers to a V-belt which has been component to perform maintenance
used on a running engine for 5 minutes or (such as changing the fuel filter) place
more. an approved container under the
5. Inspect the condition of the used V-belt. There opening to catch the fuel.
must be clearance (Figure 5-6, (1)) between • NEVER use a shop rag to catch the
the V-belt and the bottom of the pulley groove. If fuel. Vapors from the rag are
there is no clearance (Figure 5-6, (2)) between flammable and explosive.
the V-belt and the bottom of the pulley groove,
replace the V-belt. • Wipe up any spills immediately.
6. Install the new V-belt. Refer to the table for • Wear eye protection. The fuel system
proper tension. is under pressure and fuel could spray
out when you remove any fuel system
New V-Belt Tension component.
A B C • Failure to comply will result in death or
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in. serious injury.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm) 0000009en

7. After adjusting, run the engine for 5 minutes or

more. Check the tension again using the
specifications for a used V-belt.

Used V-Belt Tension

A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)

TNV IDI Service Manual 5-21

PERIODIC MAINTENANCE Periodic Maintenance Procedures

The cup of the separator is made from

CAUTION semi-transparent material. In the cup is a
If the fuel filter / water separator is red-colored float ring. The float ring will rise to the
positioned higher than the fuel level in surface of the water to show how much needs to be
the fuel tank, water may not drip out drained. Also, some optional fuel filter / water
when the fuel filter / water separator separators are equipped with a sensor to detect the
drain cock is opened. If this happens, amount of contaminants. This sensor sends a
turn the air vent screw on the top of the signal to an indicator to alert the operator.
fuel filter / water separator 2-3 turns
Drain the fuel filter / water separator as follows:
counterclockwise.
Be sure to tighten the air vent screw 1. Position an approved container under the fuel
after the water has drained out. filter / water separator (Figure 5-7, (1)) to
0000025en
collect the contaminants.

CAUTION (8)

(5) (11)
(9) (4) (6)
• ALWAYS be environmentally (3) (10)
responsible. (1)
(7)
• Follow the guidelines of the EPA or (2)
other governmental agencies for the 0000590A

proper disposal of hazardous Figure 5-7

materials such as engine oil, diesel
fuel and engine coolant. Consult the 2. Close (Figure 5-7, (2)) the fuel cock
local authorities or reclamation facility. (Figure 5-7, (3)).

• NEVER dispose of hazardous 3. Turn the retaining ring (Figure 5-7, (4)) to the
materials irresponsibly by dumping left (Figure 5-7, (9)).
them into a sewer, on the ground, or 4. Carefully remove the cup (Figure 5-7, (1)).
into ground water or waterways. Remove the retaining spring (Figure 5-7, (6))
and float (Figure 5-7, (7)) from the cup. Pour
• Failure to follow these procedures may
the fuel into an approved container and dispose
seriously harm the environment.
properly. Hold the bottom of the cup with a shop
0000013en
towel to prevent the fuel from dripping. Wipe up
Drain the fuel filter / water separator whenever any spills immediately.
there are contaminants, such as water, collected in 5. Clean the inside of the cup.
the bottom of the cup. NEVER wait until the 6. Inspect the condition of the mesh filter
scheduled periodic maintenance if contaminants (Figure 5-7, (10)). Clean the mesh filter if
are discovered. necessary.
7. Inspect the condition of the O-ring
(Figure 5-7, (11)). Replace the O-ring if
necessary.

5-22 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
8. Put the float (Figure 5-7, (7)) and retaining
spring (Figure 5-7, (6)) inside the cup. A WARNING
9. Reinstall the cup to the mounting flange
(Figure 5-7, (8)) and turn the retaining ring
(Figure 5-7, (4)) to the right (Figure 5-7, (5)).
Hand-tighten only.
10. Open the fuel cock (Figure 5-7, (3)). BURN HAZARD!
11. Be sure to prime the fuel system. See Priming • Batteries contain sulfuric acid. NEVER
the Fuel System on page 4-12. allow battery fluid to come in contact
12. Check for fuel leaks. with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
CAUTION safety goggles and protective clothing
If the fuel filter / water separator is when servicing the battery. If battery
positioned higher than the fuel level in fluid contacts the eyes and / or skin,
the fuel tank, water may not drip out immediately flush the affected area
when the fuel filter / water separator with a large amount of clean water and
drain cock is opened. If this happens, obtain prompt medical treatment.
turn the air vent screw on the top of the • Failure to comply could result in death
fuel filter / water separator 2-3 turns or serious injury.
counterclockwise. 0000007en

Be sure to tighten the air vent screw

after the water has drained out. CAUTION
0000025en

Check Battery

A DANGER
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
EXPLOSION HAZARD! proper disposal of hazardous
materials such as engine oil, diesel
• NEVER check the remaining battery fuel and engine coolant. Consult the
charge by shorting out the terminals. local authorities or reclamation facility.
This will result in a spark and may
cause an explosion or fire. Use a • NEVER dispose of hazardous
hydrometer to check the remaining materials irresponsibly by dumping
battery charge. them into a sewer, on the ground, or
into ground water or waterways.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it. • Failure to follow these procedures may
seriously harm the environment.
• Failure to comply will result in death or
0000013en
serious injury.
0000007en

TNV IDI Service Manual 5-23

PERIODIC MAINTENANCE Periodic Maintenance Procedures

• When the amount of fluid nears the lower limit

(Figure 5-8, (1)), fill with distilled water Every 250 Hours of Operation
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with Perform the following maintenance every 250 hours
insufficient battery fluid, the battery life is of operation.
shortened, and the battery may overheat and
explode. During the summer, check the fluid • Drain Fuel Tank
level more often than specified. • Replace Engine Oil and Engine Oil Filter
• Check and Clean Radiator Fins
(3) • Check and Adjust Cooling Fan V-Belt
(2) • Check and Adjust the Governor Lever and
Engine Speed Control
• Clean Air Cleaner Element
(1)
Drain Fuel Tank

A DANGER
0000067A

Figure 5-8
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery. FIRE AND EXPLOSION HAZARD!
• If the engine still will not start after charging, • Diesel fuel is flammable and explosive
have your authorized Yanmar industrial engine under certain conditions.
dealer or distributor check the battery and the • When you remove any fuel system
engine’s starting system. component to perform maintenance
• If operating the machine where the ambient (such as changing the fuel filter) place
temperature could drop to 5°F (-15°C) or less, an approved container under the
remove the battery from the machine at the end opening to catch the fuel.
of the day. Store the battery in a warm place • NEVER use a shop rag to catch the
until the next use. This will help start the engine fuel. Vapors from the rag are
easily at low ambient temperatures. flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en

5-24 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
4. Drain the tank until clean diesel fuel with no
CAUTION water or dirt flows out. Reinstall and tighten the
drain plug firmly.
5. Reinstall the fuel cap.
6. Check for fuel leaks.

Replace Engine Oil and Engine Oil Filter

• ALWAYS be environmentally
responsible. CAUTION
• Follow the guidelines of the EPA or • Only use the engine oil specified.
other governmental agencies for the Other engine oils may affect warranty
proper disposal of hazardous coverage, cause internal engine
materials such as engine oil, diesel components to seize and / or shorten
fuel and engine coolant. Consult the engine life.
local authorities or reclamation facility.
• Prevent dirt and debris from
• NEVER dispose of hazardous contaminating the engine oil. Carefully
materials irresponsibly by dumping clean the oil cap / dipstick and the
them into a sewer, on the ground, or surrounding area before you remove
into ground water or waterways. the cap.
• Failure to follow these procedures may • NEVER mix different types of engine
seriously harm the environment. oil. This may adversely affect the
0000013en lubricating properties of the engine oil.
Note that a typical fuel tank is illustrated. • NEVER overfill. Overfilling may result
in white exhaust smoke, engine
1. Position an approved container under the diesel overspeed or internal damage.
fuel tank (Figure 5-9, (1)) to collect the 0000005en
contaminates.

(3)

(1)

(2)
0000065A

Figure 5-9
2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.

TNV IDI Service Manual 5-25

PERIODIC MAINTENANCE Periodic Maintenance Procedures

Check and Clean Radiator Fins

CAUTION
A CAUTION

• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or FLYING OBJECT HAZARD!
other governmental agencies for the
• ALWAYS wear eye protection when
proper disposal of hazardous
servicing the engine and when using
materials such as engine oil, diesel
compressed air or high-pressure
fuel and engine coolant. Consult the
water. Dust, flying debris, compressed
local authorities or reclamation facility.
air, pressurized water or steam may
• NEVER dispose of hazardous injure your eyes.
materials irresponsibly by dumping
• Failure to comply may result in minor
them into a sewer, on the ground, or
or moderate injury.
into ground water or waterways.
0000003en
• Failure to follow these procedures may
seriously harm the environment. Dirt and dust adhering to the radiator fins reduce
0000013en
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
Change the engine oil every 250 hours of operation clean as needed.
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace Note that a typical radiator is shown in Figure 5-10
Engine Oil and Engine Oil Filter on page 5-18. for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa; 2 kgf/cm2) or less of
compressed air (Figure 5-10, (1)). Be careful
not to damage the fins with the compressed air.
• If there is a large amount of contamination on
the fins, apply detergent, thoroughly clean and
rinse with tap water.

CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en

5-26 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
2. If the governor lever does not make proper
contact with the high idle stop or the low idle
speed limit screw, adjust the throttle cable or
linkage as necessary.
(1) Note: DO NOT FORCE the throttle cable or
FULL

LOW linkage to move. This may damage the

the governor lever, the throttle cable or
linkage and cause irregular operation of
the engine speed control.
IMPORTANT
0000085A
The engine speed control (throttle lever,
accelerator pedal etc.), should be equipped
Figure 5-10 with stops to prevent the application of
excessive pressure by the governor lever to
Check and Adjust Cooling Fan V-Belt
either the high idle stop or low idle speed
Check and adjust the cooling fan V-belt every 250 limit screw.
hours of operation after the initial 50 hour V-belt
maintenance. See Check and Adjust Cooling Fan (2)
V-Belt on page 5-19.

Check and Adjust the Governor Lever and (3)

Engine Speed Control
The governor lever and engine speed control
(throttle lever, accelerator pedal etc.), are
connected together by a cable or linkage. If the
cable becomes stretched, or the linkage wears or (1)
loosens, the governor lever may not respond to a
change in the position of the engine speed control. Figure 5-11

CAUTION
NEVER attempt to adjust the low or high
idle speed limit screw. This may impair
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en

1. Check that the governor lever (Figure 5-11, (1))

makes firm contact with the high idle stop
(Figure 5-11, (2)) and the low idle speed limit
screw (Figure 5-11, (3)) when the engine
speed control is in the full speed or low idle
speed positions.

TNV IDI Service Manual 5-27

PERIODIC MAINTENANCE Periodic Maintenance Procedures

Clean Air Cleaner Element

Note that a typical air cleaner is shown in
Figure 5-12 and Figure 5-13 for illustrative
purposes only.
The engine performance is adversely affected
when the air cleaner element is clogged with dust.
(1)
Be sure to clean the air filter element periodically.

CAUTION
0000071A
• When the engine is operated in dusty
conditions, clean the air cleaner Figure 5-13
element more frequently.
• NEVER operate the engine with the air A CAUTION
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en

1. Unlatch and remove the air cleaner cover

(Figure 5-12, (1)).
2. Remove the element (Figure 5-12, (2)) (outer FLYING OBJECT HAZARD!
element if equipped with two elements). • ALWAYS wear eye protection when
servicing the engine and when using
(6) compressed air or high-pressure
(4)
(2) water. Dust, flying debris, compressed
(5) air, pressurized water or steam may
(3)
injure your eyes.
(1) • Failure to comply may result in minor
or moderate injury.
0000003en

3. Blow air (Figure 5-12, (3)) through the element

0000070A from the inside out using 42 - 71 psi
Figure 5-12 (0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2)
compressed air to remove the particulates. Use
the lowest possible air pressure to remove the
dust without damaging the element.
If the air cleaner is equipped with a double
element, only remove and replace the inner
element (Figure 5-13, (1)) if the engine lacks
power or the dust indicator actuates (if
equipped).

5-28 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
The inner element should not be removed when
cleaning or replacing the outer element. The Every 500 Hours of Operation
inner element is used to prevent dust from
entering the engine while servicing the outer Perform the following maintenance every 500 hours
element. of operation.
4. Replace the element with a new one if the • Replace Air Cleaner Element
element is damaged, excessively dirty or oily. • Replace Fuel Filter
5. Clean inside of the air cleaner cover. • Clean Fuel Filter / Water Separator
6. Install the element into the air cleaner case
(Figure 5-12, (4)). Replace Air Cleaner Element
7. Install the air cleaner cover making sure you
match the arrow (Figure 5-12, (5)) on the cover CAUTION
with the arrow on the case (Figure 5-12, (6)). The maximum air intake restriction, in
8. Latch the air cleaner cover to the case. terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
restriction exceeds the above
mentioned value.
0000046en

Replace the air cleaner element (Figure 5-12, (2))

every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the
air cleaner case (Figure 5-12, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-13, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.

TNV IDI Service Manual 5-29

PERIODIC MAINTENANCE Periodic Maintenance Procedures

Replace Fuel Filter

CAUTION
A DANGER

FIRE AND EXPLOSION HAZARD! • ALWAYS be environmentally

responsible.
• Diesel fuel is flammable and explosive
under certain conditions. • Follow the guidelines of the EPA or
other governmental agencies for the
• When you remove any fuel system proper disposal of hazardous
component to perform maintenance materials such as engine oil, diesel
(such as changing the fuel filter) place fuel and engine coolant. Consult the
an approved container under the local authorities or reclamation facility.
opening to catch the fuel.
• NEVER dispose of hazardous
• NEVER use a shop rag to catch the materials irresponsibly by dumping
fuel. Vapors from the rag are them into a sewer, on the ground, or
flammable and explosive. into ground water or waterways.
• Wipe up any spills immediately. • Failure to follow these procedures may
• Wear eye protection. The fuel system seriously harm the environment.
is under pressure and fuel could spray 0000013en

out when you remove any fuel system

component. Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
• Failure to comply will result in death or diesel fuel flow.
serious injury.
0000009en
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
CAUTION separator.
For maximum engine life, Yanmar 3. Turn the retaining ring (Figure 5-14, (1)) to the
recommends that when shutting the left (Figure 5-14, (2)).
engine down, you allow the engine to
idle, without load, for five minutes. This
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before (6)
the engine itself is shut down. (2)
(5) (4)
0000008en (1)
(3)

0000589A

Figure 5-14

5-30 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
4. Carefully remove the cup (Figure 5-14, (3)) and Clean Fuel Filter / Water Separator
pour the fuel into an approved container and
dispose of waste properly. Hold the bottom of A DANGER
the cup with a shop towel to prevent the fuel
from dripping. Wipe up any spills immediately.
5. Remove the element (Figure 5-14, (4)) by
pulling it down.
6. Replace the element with a new one. FIRE AND EXPLOSION HAZARD!
Applicable Fuel Filter Part No. • Diesel fuel is flammable and explosive
under certain conditions.
2TNV70
3TNV70 119810-55650 • NEVER use diesel fuel as a cleaning
3TNV76 agent.
• Failure to comply will result in death or
7. Wash the inside of the cup with clean fuel. serious injury.
8. Check the condition of the cup O-ring 0000012en

(Figure 5-14, (6)). Replace if necessary.

9. Reinstall the cup to the mounting flange and A DANGER
turn the retaining ring (Figure 5-14, (1)) to the
right (Figure 5-14, (2)). Hand-tighten only.
10. Open the fuel cock of the fuel filter / water
separator.
11. Prime the fuel system. See Priming the Fuel FIRE AND EXPLOSION HAZARD!
System on page 4-12. • Diesel fuel is flammable and explosive
12. Check for fuel leaks. under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en

TNV IDI Service Manual 5-31

PERIODIC MAINTENANCE Periodic Maintenance Procedures

3. Turn the retaining ring (Figure 5-15, (4)) to the

CAUTION left (Figure 5-15, (10)).
4. Carefully remove the cup (Figure 5-15, (1)) and
pour the fuel into an approved container and
dispose of properly. Hold the bottom of the cup
with a shop towel to prevent the fuel from
dripping. Wipe up any spills immediately.
• ALWAYS be environmentally 5. Keep the retaining spring (Figure 5-15, (6)) and
responsible. float (Figure 5-15, (7)) handy for reassembly.
• Follow the guidelines of the EPA or 6. Remove the element (Figure 5-15, (8)) by
other governmental agencies for the pulling it down.
proper disposal of hazardous
7. Replace the element with a new one.
materials such as engine oil, diesel
fuel and engine coolant. Consult the Applicable Mesh Filter Part No.
local authorities or reclamation facility.
2TNV70
• NEVER dispose of hazardous 3TNV70 171081-55910
materials irresponsibly by dumping 3TNV76
them into a sewer, on the ground, or
into ground water or waterways. 8. Wash the inside of the cup with clean diesel
• Failure to follow these procedures may fuel.
seriously harm the environment. 9. Check the condition of the cup O-ring. Replace
0000013en if necessary.
Periodically clean the fuel filter / water separator 10. Put the float (Figure 5-15, (7)) and retaining
element and inside the cup. spring (Figure 5-15, (6)) inside the cup.
11. Reinstall the cup to the mounting flange
1. Position an approved container under the cup (Figure 5-15, (9)) and turn the retaining ring
(Figure 5-15, (1)) of the fuel filter / water (Figure 5-15, (4)) to the right (Figure 5-15, (5)).
separator to collect the contaminants. Hand-tighten only.
(2) 12. Open the fuel cock (Figure 5-15, (3)).
(9) 13. Prime the fuel system. See Priming the Fuel
System on page 4-12.
c

o 14. Check for fuel leaks.

(5)
(10) (4) (6)
(3) (8)
(1)
(7)

0000590B

Figure 5-15
2. Close (Figure 5-15, (2)) the fuel cock
(Figure 5-15, (3)).

5-32 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE

Every 1000 Hours of Operation A WARNING

Perform the following maintenance every 1000
hours of operation.
• Drain, Flush and Refill Cooling System with
New Coolant BURN HAZARD!
• Adjust Intake / Exhaust Valve Clearance • Wait until the engine cools before you
drain the engine coolant. Hot engine
Drain, Flush and Refill Cooling System with
coolant may splash and burn you.
New Coolant
• Failure to comply could result in death
A DANGER or serious injury.
0000016en

A CAUTION

SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously COOLANT HAZARD!
burn you. Allow the engine to cool • Wear eye protection and rubber gloves
down before you attempt to remove when you handle long life or extended
the radiator cap. life engine coolant. If contact with the
• Tighten the radiator cap securely after eyes or skin should occur, flush eyes
you check the radiator. Steam can and wash immediately with clean
spurt out during engine operation if water.
the cap is loose. • Failure to comply may result in minor
• ALWAYS check the level of the engine or moderate injury.
coolant by observing the reserve tank. 0000005en

• Failure to comply will result in death or

serious injury.
0000002en

TNV IDI Service Manual 5-33

PERIODIC MAINTENANCE Periodic Maintenance Procedures

CAUTION
(1)

FULL

LOW

• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel (2) 0000074A
fuel and engine coolant. Consult the
local authorities or reclamation facility. Figure 5-16
• NEVER dispose of hazardous 4. Drain the coolant from the engine block.
materials irresponsibly by dumping Remove the coolant drain plug
them into a sewer, on the ground, or (Figure 5-17, (1)) from the engine block.
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment. OIL

0000013en

Engine coolant contaminated with rust or scale

reduces the cooling effect. Even when extended life
engine coolant is properly mixed, the engine
coolant gets contaminated as its ingredients
deteriorate. Drain, flush and refill the cooling
system with new coolant every 1000 hours or once
a year, whichever comes first.
(1)
1. Allow engine and coolant to cool. 0002923A

2. Remove the radiator cap (Figure 5-16, (1)). Figure 5-17

3. Remove the drain plug or open the drain cock 5. After draining the engine coolant, flush the
(Figure 5-16, (2)) at the lower position of the radiator and engine block to remove any rust,
radiator and drain the engine coolant. scale and contaminants.
6. Reinstall and tighten the drain plug or close the
drain cock at the radiator. Reinstall and tighten
the engine block drain plug.
7. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-16.

5-34 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE
Adjust Intake / Exhaust Valve Clearance
Every 1500 Hours of Operation
Proper adjustment is necessary to maintain the
correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run Perform the following maintenance every 1500
noisily, resulting in poor engine performance and hours of operation.
engine damage. See Measuring and Adjusting • Inspect, Clean and Test Fuel Injectors
Valve Clearance on page 6-34.
• Inspect Crankcase Breather System

Inspect, Clean and Test Fuel Injectors

A WARNING

HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
0000008en

Proper operation of the fuel injectors is required to

obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on
page 7-24.
This procedure is considered normal maintenance
and is performed at the owner’s expense. This
procedure is not covered by the Yanmar Limited
Warranty.

TNV IDI Service Manual 5-35

PERIODIC MAINTENANCE Periodic Maintenance Procedures

Inspect Crankcase Breather System 2. Remove the diaphragm cover, spring,

Proper operation of the crankcase breather system diaphragm plate (Figure 5-18, (5)) and
is required to maintain the emission requirements diaphragm.
of the engine. The EPA / ARB requires that the 3. Inspect the diaphragm for tears. Inspect the
crankcase breather system is inspected every 1500 spring for distortion. Replace components if
hours. necessary.

There are three different crankcase breather 4. Reinstall the diaphragm, diaphragm plate,
systems used on the TNV engines. Only the spring and diaphragm cover. Tighten the
non-turbo TNV engines crankcase breather system diaphragm bolts to the specified torque. See
requires periodic maintenance. Tightening Torques for Standard Bolts and Nuts
on page 4-25.
The non-turbo TNV engines use a crankcase Failure of the diaphragm and / or spring will cause
breather system that has a spring-backed the loss of pressure control and allow an excessive
diaphragm (Figure 5-18, (1)) in the valve cover amount of crankcase fumes to be routed to the
(Figure 5-18, (2)). When the crankcase pressure intake manifold. This could result in excessive
reaches a predetermined value, the diaphragm deposits in the intake system, high engine exhaust
opens a passage that allows crankcase fumes to smoke levels, excessive engine oil consumption,
be routed to the intake manifold. and / or engine run-on due to the burning of the
engine oil.
(4)
(3)

(5)

(1)

(2)

0004055

Figure 5-18
To inspect the diaphragm and spring
(Figure 5-18, (3)):
1. Remove the bolts retaining the diaphragm cover
(Figure 5-18, (4)).

5-36 TNV IDI Service Manual

Periodic Maintenance Procedures PERIODIC MAINTENANCE

Every 2000 Hours of Operation

Perform the following maintenance every 2000

hours of operation.
• Check and Replace Fuel Hoses and Engine
Coolant Hoses
• Lap the Intake and Exhaust Valves

Check and Replace Fuel Hoses and Engine

Coolant Hoses

CAUTION

• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en

Regularly check the fuel system and engine coolant

system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years. See Check and Replace Fuel Hoses and
Engine Coolant Hoses on page 5-37.

Lap the Intake and Exhaust Valves

Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
and Exhaust Valves on page 6-27.

TNV IDI Service Manual 5-37

PERIODIC MAINTENANCE Periodic Maintenance Procedures

This Page Intentionally Left Blank

5-38 TNV IDI Service Manual

TNV IDI Service Manual
Section 6

ENGINE
Page
Before You Begin Servicing ............................................................ 6-3
Introduction...................................................................................... 6-5
Cylinder Head Specifications .......................................................... 6-5
Adjustment Specifications ......................................................... 6-5
Cylinder Head............................................................................ 6-5
Intake / Exhaust Valve and Guide ............................................. 6-6
Push Rod................................................................................... 6-6
Valve Spring .............................................................................. 6-6
Rocker Arm and Shaft ............................................................... 6-7
Camshaft and Timing Gear Train Specifications ............................. 6-7
Camshaft ................................................................................... 6-7
Idler Gear Shaft and Bushing .................................................... 6-8
Timing Gear Backlash ............................................................... 6-8
Crankshaft and Pistons Specifications ............................................ 6-8
Crankshaft ................................................................................. 6-8
Crankshaft Reconditioning ........................................................ 6-9
Thrust Bearing ........................................................................... 6-9
Piston....................................................................................... 6-10
Piston Ring .............................................................................. 6-11
Connecting Rod....................................................................... 6-12
Tappet ..................................................................................... 6-13
Cylinder Block Specifications ........................................................ 6-13
Cylinder Block.......................................................................... 6-13
Special Torque Chart .................................................................... 6-14
Torque for Bolts and Nuts........................................................ 6-14
Special Service Tools .................................................................... 6-15
Measuring Instruments .................................................................. 6-17

TNV IDI Service Manual 6-1

ENGINE
Cylinder Head ................................................................................ 6-20
Cylinder Head Components ..................................................... 6-20
Disassembly of Cylinder Head ................................................. 6-21
Cleaning of Cylinder Head Components .................................. 6-25
Inspection of Cylinder Head Components................................ 6-25
Reassembly of Cylinder Head.................................................. 6-29
Measuring and Adjusting Valve Clearance .............................. 6-34
Cylinder Block ................................................................................ 6-36
Crankshaft and Camshaft Components ................................... 6-36
Disassembly of Cylinder Block Components............................ 6-37
Disassembly of Camshaft and Timing Components ................ 6-38
Disassembly of Crankshaft and Piston Components ............... 6-42
Inspection of Crankshaft and Camshaft Components.............. 6-46
Reconditioning the Crankshaft ................................................. 6-51
Honing and Boring.................................................................... 6-53
Reassembly of Crankshaft and Piston Components................ 6-54
Reassembly of Camshaft and Timing Components ................. 6-60

6-2 TNV IDI Service Manual

Before You Begin Servicing ENGINE

BEFORE YOU BEGIN A WARNING

SERVICING
A WARNING

FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
To prevent possible eye injury, always cleaners, primers, sealants and
wear SAFETY GLASSES while servicing sealant removers.
the engine.
0000013en
• Failure to comply could result in death
or serious injury.

A WARNING
0000014en

A CAUTION

ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch FLYING OBJECT HAZARD!
when you are servicing the engine. • ALWAYS wear eye protection when
Someone may accidentally start the servicing the engine and when using
engine and not realize you are compressed air or high-pressure
servicing it. This could result in a water. Dust, flying debris, compressed
serious injury. air, pressurized water or steam may
• If you must service the engine while it injure your eyes.
is operating, remove all jewelry, tie • Failure to comply may result in minor
back long hair, and keep your hands, or moderate injury.
other body parts and clothing away 0000003en
from moving / rotating parts.
• Failure to comply could result in death CAUTION
or serious injury.
NEVER use an engine starting aid such
0000010en
as ether. Engine damage will result.
0000009en

TNV IDI Service Manual 6-3

ENGINE Before You Begin Servicing

CAUTION CAUTION
• Only use the engine oil specified. Do not loosen or remove the four bolts
Other engine oils may affect warranty retaining the fuel injection pump drive
coverage, cause internal engine gear to the fuel injection pump hub. Do
components to seize and / or shorten not disassemble the fuel injection pump
engine life. drive gear from the hub. Correct fuel
• Prevent dirt and debris from injection timing will be very difficult or
contaminating the engine oil. Carefully impossible to achieve.
clean the oil cap / dipstick and the 0000031en

surrounding area before you remove

the cap. CAUTION
• NEVER mix different types of engine Identify all parts and their location using
oil. This may adversely affect the an appropriate method. It is important
lubricating properties of the engine oil. that all parts are returned to the same
• NEVER overfill. Overfilling may result position during the reassembly process.
in white exhaust smoke, engine 0000080en

overspeed or internal damage.

0000005en CAUTION
Keep the piston pin parts, piston
CAUTION assemblies, and connecting rod
Any part which is found defective as a assemblies together to be returned to
result of inspection or any part whose the same position during the
measured value does not satisfy the reassembly process. Label the parts
standard or limit must be replaced. using an appropriate method.
0000088en
0000119en

CAUTION CAUTION
• Only use the engine coolant specified. Do not allow the honing tool to operate
Other engine coolants may affect in one position for any length of time.
warranty coverage, cause an internal Damage to the cylinder wall will occur.
buildup of rust and scale and / or Keep the tool in constant up-and-down
shorten engine life. motion.
0000090en
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and CAUTION
the surrounding area before you Any part determined to not meet the
remove the cap. service standard or limit before the next
• NEVER mix different types of engine service, as determined from the state of
coolants. This may adversely affect the current rate of wear, should be replaced
properties of the engine coolant. even though the part currently meets the
0000006en
service standard limit.
0000120en

6-4 TNV IDI Service Manual

Introduction ENGINE

INTRODUCTION
This section of the Service Manual describes servicing of the engine.

CYLINDER HEAD SPECIFICATIONS

Adjustment Specifications
Model Valve Clearance
0.006 - 0.010 in.
All
(0.15 - 0.25 mm)

Cylinder Head
Reference
Inspection Item Standard Limit
Page
0.0020 in. (0.05 mm) or 0.0059 in.
Combustion Surface Distortion (Flatness)
less (0.15 mm)
See Valve
0.0157 - 0.0236 in. 0.0354 in.
Intake Recession on
(0.4 - 0.6 mm) (0.9 mm)
Valve Recession page 6-27
0.0157 - 0.0236 in. 0.0315 in.
Exhaust
(0.4 - 0.6 mm) (0.8 mm)
Intake 120° - See Valve Face
Seat Angle
Valve Seat Exhaust 90° - and Valve Seat
Seat Correction Angle 40°, 150° - on page 6-28

TNV IDI Service Manual 6-5

ENGINE Cylinder Head Specifications

Intake / Exhaust Valve and Guide

Reference
Inspection Item Standard Limit
Page
0.2362 - 0.2367 in. 0.2394 in.
Guide Inside Diameter
(6.000 - 6.012 mm) (6.08 mm)
Valve Stem Outside 0.2346 - 0.2352 in. 0.2323 in.
Diameter (5.960 - 5.975 mm) (5.90 mm)
Intake
0.0010 - 0.0020 in. 0.0063 in.
Oil Clearance
(0.025 - 0.052 mm) (0.15 mm)
0.0004 in. See
Valve Stem Bend - Inspection of
(0.010 mm)
Valve
0.2362 - 0.2367 in. 0.2394 in. Springs on
Guide Inside Diameter
(6.000 - 6.012 mm) (6.08 mm) page 6-28
Valve Stem Outside 0.2341 - 0.2346 in. 0.2323 in.
Diameter (5.945 - 5.960 mm) (5.90 mm)
Exhaust
0.0016 - 0.0026 in. 0.0067 in.
Oil Clearance
(0.040 - 0.067 mm) (0.17 mm)
0.0004 in.
Valve Stem Bend -
(0.010 mm)
0.3858 - 0.3937 in. See
Valve Guide Projection From Cylinder Head -
(9.8 - 10.0 mm) Reassembly
0.429 - 0.441 in. of Valve
Valve Stem Seal Projection From Cylinder Head
(10.9 - 11.2 mm) Guides on
Valve Guide Installation Method Cold-fitted - page 6-29

Push Rod
Reference
Inspection Item Standard Limit
Page
See Push
Less than 0.0012 in. 0.0012 in.
Push Rod Bend Rod Bend on
(0.03 mm) (0.03 mm)
page 6-25

Valve Spring
Reference
Inspection Item Standard Limit
Page
1.4882 in. See
Free Length -
(37.8 mm) Inspection of
Valve
0.0512 in. Springs on
Squareness -
(1.3 mm) page 6-28

6-6 TNV IDI Service Manual

Camshaft and Timing Gear Train Specifications ENGINE
Rocker Arm and Shaft
Reference
Inspection Item Standard Limit
Page
0.4724 - 0.4732 in. 0.4752 in.
Arm Shaft Hole Diameter See
(12.000 - 12.020 mm) (12.07 mm)
Inspection of
0.4711 - 0.4718 in. 0.4701 in.
Shaft Outside Diameter Rocker Arm
(11.966 - 11.984 mm) (11.94 mm)
Assembly on
Oil Clearance
0.0006 - 0.0021 in. 0.0051 in. page 6-26
(0.016 - 0.054 mm) (0.13 mm)

CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Inspection Item Standard Limit
Page
See Removal
0.0020 - 0.0059 in. 0.0098 in.
End Play of Camshaft
(0.05 - 0.15 mm) (0.25 mm)
on page 6-41
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
1.3439 - 1.3490 in. 1.3343 in.
Cam Lobe Height
(34.135 - 34.265 mm) (33.89 mm)
1.5748 - 1.5778 in. 1.5807 in.
Bushing Inside Diameter
(40.000 - 40.075 mm) (40.150 mm)
1.5724 - 1.5732 in. 1.5711 in.
Gear End Camshaft Outside Diameter
(39.940 - 39.960 mm) (39.905 mm)
0.0016 - 0.0053 in. 0.0096 in.
Oil Clearance
(0.040 - 0.135 mm) (0.245 mm) See
1.5748 - 1.5758 in. 1.5787 in. Inspection of
Bushing Inside Diameter
Shaft Outside (40.000 - 40.025 mm) (40.100 mm) Camshaft on
Diameter /
1.5713 - 1.5722 in. 1.5699 in. page 6-52
Bearing Intermediate Camshaft Outside Diameter
(39.910 - 39.935 mm) (39.875 mm)
Inside
Diameter 0.0026 - 0.0045 in. 0.0089 in.
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.5748 - 1.5758 in. 1.5787 in.
Bushing Inside Diameter
(40.000 - 40.100 mm) (40.100 mm)
1.5724 - 1.5732 in. 1.5711 in.
Flywheel End Camshaft Outside Diameter
(39.940 - 39.960 mm) (39.905 mm)
0.0016 - 0.0033 in. 0.0077 in.
Oil Clearance
(0.040 - 0.085 mm) (0.195 mm)

TNV IDI Service Manual 6-7

ENGINE Crankshaft and Pistons Specifications

Idler Gear Shaft and Bushing

Reference
Inspection Item Standard Limit
Page
1.4547 - 1.4557 in. 1.4528 in.
Shaft Outside Diameter See
(36.950 - 36.975 mm) (36.900 mm)
Inspection of
1.4567 - 1.4577 in. 1.4596 in.
Bushing Inside Diameter Idler Gear
(37.000 - 37.025 mm) (37.075 mm)
and Shaft on
Oil Clearance
0.0010 - 0.0030 in. 0.0069 in. page 6-53
(0.025 - 0.075 mm) (0.175 mm)

Timing Gear Backlash

Reference
Inspection Item Standard Limit
Page
See
Checking
Crank Gear, Cam Gear, Idler Gear, Fuel Injection Pump Gear 0.0024 - 0.0047 in. 0.0055 in.
Timing Gear
and PTO Gear (0.06 - 0.12 mm) (0.14 mm)
Backlash on
page 6-38

CRANKSHAFT AND PISTONS SPECIFICATIONS

Crankshaft
Note: Check appropriate parts catalog for undersized replacement main bearing inserts.

Reference
Inspection Item Standard Limit
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
0.0004 in.(0.01 mm) 0.0008 in.
Roundness
or less (0.02 mm)
Journal Outside 1.6517 - 1.6520 in. 1.6497 in. See
Diameter (41.952 - 41.962 mm) (42.902 mm) Inspection of
Bearing Inside 1.6528 - 1.6536 in. Crankshaft
- on page 6-51
Diameter (41.982 - 42.002 mm)
Connecting Rod Journals
Bearing Insert 0.0592 - 0.0594 in.
-
Thickness (1.503 - 1.509 mm)
0.0008 - 0.0020 in. 0.0043 in.
Oil Clearance
(0.020 - 0.050 mm) (0.110 mm)

6-8 TNV IDI Service Manual

Crankshaft and Pistons Specifications ENGINE
(Crankshaft Cont.)
Reference
Inspection Item Standard Limit
Page
Journal Outside 1.8485 - 1.8489 in. 1.8465 in.
Diameter (46.952 - 46.962 mm) (46.902 mm)
Bearing Inside 1.8497 - 1.8505 in. See
-
Diameter (46.982 - 47.002 mm) Inspection of
Main Bearing Journal
Bearing Insert 0.0791 - 0.0793 in. Crankshaft
- on page 6-51
Thickness (2.009 - 2.014 mm)
0.0008 - 0.0020 in. 0.0047 in.
Oil Clearance
(0.020 - 0.050 mm) (0.120 mm)

Crankshaft Reconditioning
Reference
Item Finishing Precision
Page
1.6418 - 1.6422 in.
Connecting Rod Journal Undersize Finished Size
(41.702 - 41.712 mm)
1.8387 - 1.8391 in. See
Main Bearing Journal Undersize Finished Size
(46.702 - 46.712 mm) Reconditioning
0.138 - 0.150 in. the Crankshaft
Journal Radius
(3.5 - 3.8 mm) on page 6-51
Journal Face Finish 0.8S (Super Polish)
Thrust Face Finish 1.6

Thrust Bearing
Reference
Inspection Item Standard Limit
Page
0.0044 - 0.0098 in. 0.0110 in.
Crankshaft End Play - All Models See Removal
(0.111 - 0.250 mm) (0.28 mm)
of Crankshaft
0.0760 - 0.0780 in. 0.0728 in. on page 6-44
Bearing Thickness
(1.930 - 1.980 mm) (1.850 mm)

TNV IDI Service Manual 6-9

ENGINE Crankshaft and Pistons Specifications

Piston
Reference
Inspection Item Standard Limit
Page
2.7543 - 2.7555 in. 2.7526 in.
2/3TNV70
Piston Outside Diameter (69.960 - 69.990 mm) (69.915 mm)
(Measure at 90° to the Piston Pin.) 2.9904 - 2.9915 in. 2.9886 in.
3TNV76
(75.955 - 75.985 mm) (75.910 mm)
Piston Diameter Measurement Location 0.8661 - 0.9843 in.
-
(Upward From the Bottom of the Piston) (22.0 - 25.0 mm)
See
0.0012 - 0.0020 in. Inspection of
2/3TNV70 -
(0.030 - 0.050 mm) Pistons,
Piston-to-Cylinder Clearance
0.0014 - 0.0022 in. Piston Rings
3TNV76 - and Wrist Pin
(0.035 - 0.055 mm)
on page 6-48
0.8661 - 0.8665 in. 0.8677 in.
Hole Inside Diameter
(22.000 - 22.009 mm) (220.039 mm)
0.8659 - 0.8661 in. 0.8648 in.
Wrist Pin Pin Outside Diameter
(21.995 - 22.000 mm) (21.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil Clearance
(0.000 - 0.014 mm) (0.074 mm)

6-10 TNV IDI Service Manual

Crankshaft and Pistons Specifications ENGINE
Piston Ring
Reference
Model Inspection Item Standard Limit
Page
0.0610 - 0.0618 in.
Ring Groove Width -
(1.550 - 1.570 mm)
0.0579 - 0.0587 in. 0.0571 in.
Ring Width
(1.470 - 1.490 mm) (1.450 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0059 - 0.0118 in. 0.0154 in.
End Clearance
(0.150 - 0.300 mm) (0.390 mm)
0.0606 - 0.0614 in. 0.0654 in.
Ring Groove Width
(1.540 - 1.560 mm) (1.660 mm)
0.0579 - 0.0587 in. 0.0571 in. See Inspection
Ring Width of Pistons,
2TNV70 (1.470 - 1.490 mm) (1.950 mm)
Second Ring Piston Rings
3TNV70 0.0020 - 0.0035 in. 0.0083 in.
Side Clearance and Wrist Pin on
(0.050 - 0.090 mm) (0.210 mm) page 6-48
0.0071 - 0.0130 in. 0.0165 in.
End Clearance
(0.180 - 0.33 mm) (0.42 mm)
0.1185 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.010 - 3.030 mm) (3.130 mm)
0.1170 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0008 - 0.0024 in. 0.0071 in.
Side Clearance
(0.020 - 0.060 mm) (0.180 mm)
0.0059 - 0.0138 in. 0.0173 in.
End Clearance
(0.150 - 0.350 mm) (0.440 mm)

TNV IDI Service Manual 6-11

ENGINE Crankshaft and Pistons Specifications

(Piston Ring Cont.)

Reference
Model Inspection Item Standard Limit
Page
0.0610 - 0.0618 in.
Ring Groove Width -
(1.550 - 1.570 mm)
0.0579 - 0.0587 in. 0.0571 in.
Ring Width
(1.470 - 1.490 mm) (1.450 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0059 - 0.0118 in. 0.0154 in.
End Clearance
(0.150 - 0.300 mm) (0.390 mm)
0.0622 - 0.0628 in. 0.0667 in.
Ring Groove Width
(1.580 - 1.595 mm) (1.695 mm)
0.0563 - 0.0571 in. 0.0555 in. See Inspection
Ring Width of Pistons,
(1.430 - 1.450 mm) (1.410 mm)
3TNV76 Second Ring Piston Rings
0.0005 - 0.0065 in. 0.0112 in. and Wrist Pin on
Side Clearance
(0.013 - 0.165 mm) (0.285 mm) page 6-48
0.0071 - 0.0130 in. 0.0165 in.
End Clearance
(0.180 - 0.33 mm) (0.42 mm)
0.1185 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.010 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0008 - 0.0024 in. 0.0071 in.
Side Clearance
(0.020 - 0.060 mm) (0.180 mm)
0.0079 - 0.0177 in. 0.0213 in.
End Clearance
(0.200 - 0.450 mm) (0.540 mm)

Connecting Rod
Connecting Rod Small End
Reference
Inspection Item Standard Limit
Page
0.8671 - 0.8676 in. 0.8688 in.
Wrist Pin Bushing Inside Diameter See
(22.025 - 22.038 mm) (22.068 mm)
Inspection of
0.8658 - 0.8661 in. 0.8647 in.
Wrist Pin Outside Diameter Connecting
(21.991 - 22.000 mm) (21.963 mm)
Rod on
Oil Clearance
0.0010 - 0.0019 in. 0.0041 in. page 6-49
(0.025 - 0.047 mm) (0.105 mm)

6-12 TNV IDI Service Manual

Cylinder Block Specifications ENGINE
Connecting Rod Big End
Reference
Inspection Item Standard Limit
Page
0.0079 - 0.0157 in. See
Side Clearance -
(0.20 - 0.40 mm) Inspection of
Connecting
Bearing Inside Diameter and Oil Clearance See Crankshaft on page 6-8 Rod on
page 6-49

Connecting Rod Distortion

Reference
Model Inspection Item Standard Limit
Page
See
Less than Inspection of
Twist and Bend per 0.003 in.
All Models 0.001 in. Connecting
3.937 in.(100 mm) (0.08 mm)
(0.03 mm) Rod on
page 6-49

Tappet
Reference
Inspection Item Standard Limit
Page
0.8268 - 0.8276 in. 0.8284 in.
Tappet Bore (Block) Inside Diameter
(21.000 - 21.021 mm) (21.041 mm) See
0.8239 - 0.8252 in. 0.8231 in. Inspection of
Tappet Stem Outside Diameter
(20.927 - 20.960 mm) (20.907 mm) Tappets on
0.0016 - 0.0037 in. 0.0053 in. page 6-50
Oil Clearance
(0.040 - 0.094 mm) (0.134 mm)

CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection Item Model Standard Limit
Page
2TNV70 2.7563 - 2.7567 in. 2.7638 in.
3TNV70 (70.010 - 70.020 mm) (70.200 mm) See
Cylinder Inside Diameter Inspection of
2.9925 - 2.9929 in. 3.0000 in.
3TNV76 Cylinder
(76.010 - 76.020 mm) (76.200 mm)
Block on
Roundness 0.0004 in. (0.01 mm) 0.0012 in. page 6-47
Cylinder Bore
Taper or less (0.03 mm)

TNV IDI Service Manual 6-13

ENGINE
SPECIAL TORQUE CHART
Torque for Bolts and Nuts
Lubricating Oil
Thread Diameter and Application (Thread
Component Tightening Torque Reference Page
Pitch Portion and Seat
Surface)
40 - 43 ft·lb See Reassembly of
Cylinder Head Bolts M9 x 1.25 mm (53.9 - 57.9 N·m; Applied Cylinder Head on
5.5 - 5.9 kgf·m) page 6-31
17 - 20 ft·lb
See Installation of
Connecting Rod Bolts M7 x 1.0 mm (22.6 - 27.5 N·m; Applied
Pistons on page 6-58
2.3 - 2.8 kgf·m)
59 - 64 ft·lb See Installation of
Flywheel Bolts M10 x 1.25 mm (80.4 - 86.4 N·m; Applied Crankshaft on
8.2 - 8.8 kgf·m) page 6-57
56 - 60 ft·lb See Installation of
Main Bearing Cap Bolts M10 x 1.25 mm (75.5 - 81.5 N·m; Applied Crankshaft on
7.7 - 8.3 kgf·m) page 6-57
61 - 69 ft·lb
Cast
(83.4 - 93.1 N·m;
FC250 See Installation of
Crankshaft 8.5 - 9.5 kgf·m)
M12 x 1.25 mm Applied Crankshaft on
Pulley Bolts 83 - 90 ft·lb
Forged page 6-57
(113 - 123 N·m;
PS48C
11.5 - 12.5 kgf·m)
11 - 15 ft·lb See Reassembly of
Glow Plug M10 x 1.25 (14.7 - 19.6 N·m; Not Applied Intake Manifold / Valve
1.5 - 2.0 kgf·m) Cover on page 6-33

See Tightening Torques for Standard Bolts and Nuts on page 4-25 for standard hardware torque values.

6-14 TNV IDI Service Manual

Special Service Tools ENGINE

SPECIAL SERVICE TOOLS

Note: Tools not having Yanmar part numbers must be acquired locally.

No Tool Name Applicable Model and Tool Size Illustration

L1 L2 d1 d2
Valve Guide Tool
1 (For Removing 0.787 in. 2.953 in. 0.217 in. 0.374 in.
Valve Guides) (20 mm) (75 mm) (5.5 mm) (9.5 mm)

Locally Manufactured 0000827

L1 L2 d1 d2

Valve Guide Tool 0.394 in. 2.362 in. 0.433 in. 0.669 in.
2 (For Installing (10 mm) (60 mm) (11 mm) (17 mm)
Valve Guides) Allowance L1:
0 to -0.0118 in.
Locally Manufactured
(0 to -0.3 mm) 0000828

L1 L2 d1 d2
Wrist Pin Bushing 0.984 in. 3.346 in. 0.866 in. 0.984 in.
Tool (25 mm) (85 mm) (22 mm) (25 mm)
3 (For Removing /
Allowance d1: Allowance d2:
Installing of Wrist 0000829
-0.0118 to -0.0118 to
Pin Bushings)
Locally Manufactured -0.0236 in. -0.0236 in.
(-0.3 to -0.6 (-0.3 to -0.6
mm) mm)

Valve Spring
Compressor
Yanmar Part No.
4 (For Removing /
129100-92630
Installing Valve 0000830

Springs)

TNV IDI Service Manual 6-15

ENGINE Special Service Tools

No Tool Name Applicable Model and Tool Size Illustration

d1 d2 d3 L1 L2 L3
0.157 in.
0.591 in. 0.827 in. 0.472 in. 0.433 in. 2.559 in.
(4 mm) or
(15 mm) (21 mm) (12 mm) (11 mm) (65 mm)
more

Stem Seal Tool

5 (for Installing
Stem Seals)
Allowance:
d1: ±0.00787 in. (±0.2 mm)
L1: ±0.00393 in. (±0.1 mm)
Locally Manufactured

0000820

L1 L2 d1 d2
Camshaft 0.709 in. 2.756 in. 1.772 in. 1.890 in.
Bushing Tool (18 mm) (70 mm) (45 mm) (48 mm)
6 (For Removing
Allowance d1: Allowance d2:
Camshaft
-0.0118 to -0.0118 to
Bushing)
Locally Manufactured -0.0236 in. -0.0236 in. 0000822
(-0.3 to -0.6 (-0.3 to -0.6
mm) mm)

Yanmar Part No. Cylinder Bore

Flex-Hone 2.756 - 2.992 in.

129400-92410
7 (For Preparing (70 - 76 mm)
Cylinder Walls)

0000823

Piston Ring
Yanmar Part No. 955500-02476
Compressor
8 The Piston Insertion Tool is Applicable for
(For Installing
2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons
Pistons)
0000824

Piston Ring Tool

(For Removing/
9 Available Locally
Installing of
Piston Rings)
0000825

6-16 TNV IDI Service Manual

Measuring Instruments ENGINE

MEASURING INSTRUMENTS
No. Instrument Name Application Illustration

1 Dial Indicator (Available Locally) Measure shaft bend and end play

0000831

Measurements of narrow or deep portions that

2 Test Indicator (Available Locally)
cannot be measured by dial gauge

0000832

3 Magnetic Stand (Available Locally) For holding the dial gauge when measuring.

0000833

For measuring the outside diameters of

4 Micrometer (Available Locally)
crankshaft, pistons, piston pins, etc.

0000834

For measuring the inside diameters of cylinder

5 Cylinder Bore Gauge (Available Locally)
liners, bearing bores, etc.
0000835

For measuring outside diameters, depth,

6 Calipers (Available Locally)
thickness and width
0000836

7 Depth Micrometer (Available Locally) For measuring of valve recession

0000837

For measuring valve spring inclination and

8 Square (Available Locally)
straightness of parts

0000838

TNV IDI Service Manual 6-17

ENGINE Measuring Instruments

(Measuring instruments Cont.)

No. Instrument Name Application Illustration

9 V-Block (Available Locally) For measuring shaft bend

0000839

For tightening nuts and bolts to the specified

10 Torque Wrench (Available Locally)
torque

0000840

For measuring piston ring gaps, piston ring

11 Feeler Gauge (Available Locally)
clearance, and valve adjustment clearance

0000841

6-18 TNV IDI Service Manual

Measuring Instruments ENGINE

This Page Intentionally Left Blank

TNV IDI Service Manual 6-19

ENGINE Cylinder Head

CYLINDER HEAD
Cylinder Head Components

(1)

(30)
(2)
(29)
(28)
(27) (3)

(4)

(26)
(5)

(6) (7)
(24) (8)
(25)
(23)
(9)
(11)
(22) (10)
(12)
(13)
(14)
(21) (15)
(16)

(17)

(18)
(20)
(19)

0002130

Figure 6-1

6-20 TNV IDI Service Manual

Cylinder Head ENGINE
1 – Baffle Plate Disassembly of Cylinder Head
2 – Oil Fill Cap
3 – Valve Cover / Intake Manifold Prepare a clean, flat working surface on a
4 – Gasket workbench large enough to accommodate the
5 – Rocker Arm Shaft cylinder head assembly. Discard all gaskets,
6 – Rocker Arm Shaft Support O-rings and seals. Use new gaskets, O-rings and
7 – Adjuster Lock Nut seals on reassembly of cylinder head.
8 – Valve Adjuster Screw
9 – Rocker Arm IMPORTANT
10 – Circlip Mark all valve train components so they can
11 – Valve Cap be installed in their original locations.
12 – Keeper
13 – Valve Spring Retainer Note: Record all measurements taken during
14 – Valve Spring disassembly.
15 – Valve Stem Seal
1. Drain coolant from engine into a suitable
16 – Valve Guide
17 – Cylinder Head
container. See Drain, Flush and Refill Cooling
18 – Exhaust Valve System with New Coolant on page 5-33.
19 – Intake Valve
20 – Cylinder Head Gasket CAUTION
21 – Push Rod (2 per cylinder) Identify all parts and their location using
22 – Glow Plug
an appropriate method. It is important
23 – Glow Plug Wiring Harness
that all parts are returned to the same
24 – Cylinder Head Bolt
position during the reassembly process.
0000080en

2. Remove the coolant pump. See Disassembly of

Engine Coolant Pump on page 8-7.
3. Remove the high-pressure fuel lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 7-23.

TNV IDI Service Manual 6-21

ENGINE Cylinder Head

Removal of Intake Manifold / Valve Cover

1. Remove the intake manifold bolts (2)
(Figure 6-2, (1)) and valve cover bolts
(Figure 6-2, (2)).
2. Remove the valve cover / intake manifold (1)
(Figure 6-2, (3)). Discard gasket
(Figure 6-2, (4)).

(1)

(2)

Figure 6-3
(3)
(4) Removal of Rocker Arm Assembly
1. Remove the bolts (Figure 6-4, (1)) and nuts
(Figure 6-4, (2)) that retain the rocker arm shaft
supports.
(5) 2. Remove the rocker arm shaft assembly from
the cylinder head.
(6)
(7) Note: Identify the push rods so they can be
reinstalled in their original locations.
(8)
3. Remove the push rods and identify for
reinstallation.
0002131

(2)
Figure 6-2
3. Remove the exhaust manifold bolts
(Figure 6-2, (5)) and nuts (Figure 6-2, (6)).
Remove the exhaust manifold (Figure 6-2, (7))
and the exhaust manifold gasket
(Figure 6-2, (8)). (1) (2)
Removal of Glow Plugs
1. Disconnect the glow plug harness
(Figure 6-3, (2)) from the glow plugs
(Figure 6-3, (1)).
2. Remove the glow plugs from the cylinder head.

0002147

Figure 6-4

6-22 TNV IDI Service Manual

Cylinder Head ENGINE
Disassembly of Rocker Arm Assembly Removal of Cylinder Head
1. Remove the rocker arm shaft alignment set 1. Loosen the cylinder head bolts following the
screw (Figure 6-5, (6)) from support sequence shown in Figure 6-6.
(Figure 6-5, (5)).
(2)
(8)
(2) 2
8
12
14
9
5
3
(1) (1)
(3)
4 10 11 1
(4) (7) 6 13 7
(6)
(5)

(2)
(9) 8 5
4 10 1

(1)
2 9 3
6 7

0002148

1 – Cooling Fan End

(8) 2 – Camshaft Side
0002160

Figure 6-5 Figure 6-6

Note: On 3-cylinder models, the set screw is 2. Remove the cylinder head bolts
located in the center support. On (Figure 6-7, (1)).
2-cylinder models, the set screw is 3. Lift the cylinder head away from the cylinder
located in the front (cooling fan) end block. Discard the cylinder head gasket
support. (Figure 6-7, (2)). Position the cylinder head on
the work bench to prevent damage to the
2. Remove two circlips (Figure 6-5, (8)). combustion surface.
Note: The rocker arm shaft fits tightly in the
rocker arm supports. Clamp the support
in a padded vise. Twist and pull out on (1)
the rocker arm shaft to remove. Reverse
this process when installing the rocker
arm shaft into the supports.
3. Slide the rocker arm shaft (Figure 6-5, (7)) out
of the rocker arm supports (Figure 6-5, (5)),
springs (Figure 6-5, (4)), and rocker arms
(Figure 6-5, (1)).
(2)
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.
4. Remove the valve adjusting screw
(Figure 6-5, (3)) and lock nut (Figure 6-5, (2))
from the rocker arms. Mark parts so they can
0002150
be reinstalled on the same rocker arm.
Figure 6-7

TNV IDI Service Manual 6-23

ENGINE Cylinder Head

Removal of Intake / Exhaust Valves 8. Turn the cylinder head so the exhaust port side
1. Put the cylinder head on the work bench with faces down. Remove the intake and exhaust
the combustion side down (Figure 6-8). valves (Figure 6-9, (6)) from the cylinder head.
9. Remove the valve stem seals (Figure 6-9, (5)).

Removal of Valve Guides

Note: Removal of valve guides should be
postponed until inspection and
measurement procedures have been
performed. See Inspection of Valve
Guides on page 6-26.
0000191
If the valve guides are not within specifications, use
Figure 6-8
a drift pin and hammer to drive the valve guides
2. Remove the valve stem cap (Figure 6-9, (1)) (Figure 6-10, (1)) out of the cylinder head.
and keep with the valve it was installed on.
3. Using the valve spring compressor tool, (1)
compress one of the valve springs (Figure 6-8).
4. Remove the valve keepers (Figure 6-9, (2)).
5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 6-9, (3))
and valve spring (Figure 6-9, (4)).

(1)
(2)
(3) 0002152

(4)
Figure 6-10
(5)

(6)

0002151

Figure 6-9
7. Repeat procedure with all remaining valves.
Note: If the valves are to be reused, identify
them so they can be reinstalled in their
original location.

6-24 TNV IDI Service Manual

Cylinder Head ENGINE
Cleaning of Cylinder Head
CAUTION
Components
Any part determined to not meet the
service standard or limit before the next
A WARNING service, as determined from the state of
current rate of wear, should be replaced
even though the part currently meets the
service standard limit.
0000120en

FUME / BURN HAZARD! IMPORTANT

Mark all valve train components so they can
• Always read and follow safety related
be installed in their original locations.
precautions found on containers of
hazardous substances like parts Note: Record all measurements taken during
cleaners, primers, sealants and inspection.
sealant removers.
Inspection of Push Rods
• Failure to comply could result in death
or serious injury. Push Rod Bend
0000014en
Determine if the bend of the push rods is within the
Thoroughly clean all components using a specified limit.
non-metallic brush and an appropriate solvent. 1. Place the push rods on a flat inspection block or
Each part must be free of carbon, metal filings and layout bed.
other debris.
2. Roll the push rods until a gap can be observed
Inspection of Cylinder Head between a portion of the push rod and the
surface of the block or layout bed.
Components
3. Use a feeler gauge to measure the gap
Visually inspect the parts. Replace any parts that (Figure 6-11). See Push Rod on page 6-6 for
are obviously discolored, heavily pitted or otherwise the service limit.
damaged. Discard any parts that do not meet its
specified limits.

CAUTION
Any part which is found defective as a
result of inspection or any part whose
measured value does not satisfy the
standard or limit must be replaced.
0000119en

0000204

Figure 6-11

TNV IDI Service Manual 6-25

ENGINE Cylinder Head

Inspection of Rocker Arm Assembly Inspection of Valve Guides

Rocker Arm Shaft Hole Diameter Visually inspect the valve guides for distortions,
scoring or other damage.
Use a telescoping gauge and micrometer to
measure the inside diameter of all the rocker arm Note: Measure valve guides while they are
support brackets and the rocker arms installed in cylinder head.
(Figure 6-12). Record the measurements. See
Use a telescoping gauge and micrometer to
Rocker Arm and Shaft on page 6-7 for the service
measure the inside diameter of the valve guide.
limit.
Measure in three places and 90° apart
Inspect contact areas (Figure 6-12, (1)) for (Figure 6-14). Record the measurements. See
excessive wear or damage. Intake / Exhaust Valve and Guide on page 6-6 for
the service limit. Replace valve guides if not within
specification.

0001869
(1)
(1) Figure 6-14

Inspection of Cylinder Head

0001916
Cylinder Head Distortion
Figure 6-12 Put the cylinder head flat and inverted (combustion
side up) on the bench. Use a straightedge and
Rocker Arm Shaft Outside Diameter feeler gauge to measure cylinder head distortion
Use a micrometer to measure rocker arm shaft (Figure 6-15). Measure diagonally and along each
diameter. Measure at each rocker arm location in side. Record the measurements. See Cylinder
two directions 90° apart (Figure 6-13). Record the Head on page 6-5 for the service limit.
measurements. See Rocker Arm and Shaft on
page 6-7 for the service limit.

0000192

Figure 6-15

0001952

Figure 6-13

6-26 TNV IDI Service Manual

Cylinder Head ENGINE
If distortion exceeds the service limit, resurface or Valve Recession
replace the cylinder head. Remove only enough Note: The valve guides must be installed to
material to make the cylinder head flat, but do not perform this check.
remove more than 0.008 in. (0.20 mm).
Insert the valves into their original locations and
Inspection of Intake and Exhaust Valves press them down until they are fully seated. Use a
Visually inspect the intake and exhaust valves. depth micrometer (Figure 6-18) to measure the
Replace any valves that are obviously discolored, difference between the cylinder head gasket
heavily pitted or otherwise damaged. surface and the combustion surface of each
exhaust and intake valve (Figure 6-19). Record the
Valve Stem Diameter measurements. See Cylinder Head on page 6-5 for
Use a micrometer to measure the valve stem the service limit.
diameter. Measure the valve stem near the
combustion end and near the opposite end
(Figure 6-16, (1)). Record the measurements. See
Intake / Exhaust Valve and Guide on page 6-6 for
the service limit.

(1)

0000193
0000197
Figure 6-18
Figure 6-16
Valve Stem Bend
Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 6-17). Record the
measurements. See Intake / Exhaust Valve and
Guide on page 6-6 for the service limit.

0001755

Figure 6-19

Figure 6-17

TNV IDI Service Manual 6-27

ENGINE Cylinder Head

Valve Face and Valve Seat

Always check the clearance between the valve and (1)
150° 40°
valve guide before grinding or lapping the valve
seats. See Intake / Exhaust Valve and Guide on
page 6-6 for the service limit. If the clearance (3)
(2)
exceeds the limit, replace the valve and / or valve
guide to bring the clearance within the limit.
0001862
Roughness or burrs will cause poor seating of a
valve. Visually inspect the seating surfaces of each Figure 6-21
valve and valve seat to determine if lapping or Valve seat diameter can be adjusted by
grinding is needed. top-grinding with a 150° stone to make the seat
Visually inspect all valve faces and valve seats for diameter smaller, and bottom-grinding using a 40°
pitting, distortion, cracking, or evidence of stone to make the seat diameter larger. Once the
overheating. Usually the valves and valve seats can seat location has been corrected, grind and lap the
be lapped or ground to return them to serviceable seat angle (Figure 6-21, (1)) to specification. See
condition. Severely worn or damaged components Cylinder Head on page 6-5 for the service limit.
will require replacement. Grind the valve face and / or valve seat only
Coat the valve seat with a thin coat of bluing enough to return them to serviceable condition.
compound. Install valve and rotate to distribute Grinding is needed if the valve and the valve seat
bluing onto the valve face. The contact pattern do not contact correctly. Check the valve recession
should be approximately centered on the valve face after grinding.
(Figure 6-20, (1)) and even in width. If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.

Inspection of Valve Springs

Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
(1)
limits, replace the springs. Record the
measurements.

0001691B
Fractures
Check for fractures on the inside and outside
Figure 6-20 portions of the springs. If the valve spring is
fractured, replace the valve spring.
Also visually inspect the valve seat for even
contact. Corrosion
Light cutting can be performed by the use of a Check for corrosion of spring material caused by
hand-operated cutter (Figure 6-21, (3)). oxidation.

6-28 TNV IDI Service Manual

Cylinder Head ENGINE
Squareness Reassembly of Cylinder Head
Use a flat surface and a square to check each Use new gaskets, O-rings and seals on reassembly
spring for squareness (Figure 6-22). See Valve of cylinder head.
Spring on page 6-6 for the service limit.
IMPORTANT
Liberally oil all components during
assembly to prevent premature wear or
damage.

Reassembly of Valve Guides

1. The valve guides are installed into the cylinder
head with an extremely tight press-fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes.
This will cause the valve guides to contract,
0000201
making it easier to install the valve guides in
Figure 6-22 place.
2. Immediately after removing the valve guides
Free Length
from the freezer, insert the valve guides
Use a caliper to measure the length of the spring (Figure 6-24, (1)) in their proper positions.
(Figure 6-23). See Valve Spring on page 6-6 for
the service limit. (1)
2
3
1

4
0

5
9

6
8
7

0002152

Figure 6-24
0000200

Figure 6-23

TNV IDI Service Manual 6-29

ENGINE Cylinder Head

3. Finish installing the valve guides

(Figure 6-25, (1)) to the proper height
(Figure 6-25, (3)) using the valve guide
installation tool (Figure 6-25, (2)). See valve (1)
guide projection specification on page 6-6.
(4)
(2)
(2)

(3)

(1) 0001873B

0001756A
Figure 6-26
Figure 6-25 2. Measure the distance (Figure 6-27, (1)) from
the cylinder head to valve stem seal to ensure
Reassembly of Intake and Exhaust Valves
proper clearance (Figure 6-27, (2)) between
IMPORTANT the valve guide and seal. See valve stem seal
Always install new valve stem seals. projection specification on page 6-6.

The exhaust valve stem seals are different

than the intake valve stem seals and can be
identified by the color the seal spring
(Figure 6-26, (4)). Ensure they are installed
in the correct locations. (2)
(1)
Marking
Engine Model
Intake Exhaust
2TNV70, 3TNV70, White (Seal Black (Seal
3TNV76 Spring) Spring)
0001874

1. Oil the lip of the valve stem seal Figure 6-27

(Figure 6-26, (2)). Using the valve stem seal
3. Put the cylinder head assembly on its exhaust
installation tool (Figure 6-26, (1)), install a new
port side.
valve stem seal on each of the valve guides
(Figure 6-26, (3)). 4. Install all the valves (Figure 6-28, (6)) in their
proper location in the cylinder head.

6-30 TNV IDI Service Manual

Cylinder Head ENGINE

(1)
(2) (1)

(3)
(4)
(5)

(2)

(6)

0002151

Figure 6-28 0002150

5. Put the cylinder head on the workbench with Figure 6-29

the combustion side down to install the valve 3. Lightly oil the threads of the cylinder head bolts
springs. Reinstall the valve spring (Figure 6-29, (1)). Tighten the bolts to the
(Figure 6-28, (4)) and spring retainer specified torque shown in the chart below.
(Figure 6-28, (5)). Tighten in the sequence shown in Figure 6-30.
6. Using a valve spring compressor tool, See Torque for Bolts and Nuts on page 6-14.
compress the valve spring.
First Step 1/2 of final torque
7. Insert the valve keeper (Figure 6-28, (2)) and
slowly release the tension in the valve spring. Second Step Final torque
Reinstall the valve cap (Figure 6-28, (1)).
Repeat steps on all remaining valves. (2)

Reassembly of Cylinder Head 13

7
3
1
6
10
12

1. Carefully clean both the combustion surface of (1)

11 5 4 14
the cylinder head and the top surface of the 9 2 8

cylinder block. Install a new cylinder head

gasket (Figure 6-29, (2)) on the cylinder block.
(2)
2. Position the cylinder head on the cylinder head
gasket. 7
3
1
6
10

(1)
9 2 8
5 4

0002149

1 – Cooling Fan End

2 – Camshaft Side
Figure 6-30

TNV IDI Service Manual 6-31

ENGINE Cylinder Head

4. Insert the push rods in their respective Note: On 3-cylinder models, the set screw is
positions. located in the center support. On
2-cylinder models, the set screw is
Reassembly of Rocker Arm Assembly located in the front (cooling fan) end
support.
(2)
2. Align the hole in the rocker arm shaft
(Figure 6-32, (7)) and the hole in the rocker
(1) arm support (Figure 6-32, (5)). Reinstall the
alignment set screw (Figure 6-32, (6)).
3. Place the rocker arm shaft assembly onto the
cylinder head.
4. If removed, reinstall the valve adjusting screws
(Figure 6-32, (3)) and lock nuts
(1) 0001914 (Figure 6-32, (2)).
Figure 6-31 5. Align the push rods with their respective rocker
arms.
IMPORTANT
Ensure the lubrication holes in the rocker 6. Reinstall and tighten the rocker arm shaft
arm shaft (Figure 6-31, (1)) are oriented retaining bolts to the specified torque.
correctly with respect to the rocker arms 7. Tighten the rocker arm shaft alignment screw.
(Figure 6-31, (2)). 8. Adjust the valve clearance. See Measuring and
1. Lubricate the rocker arm shaft. Slide the rocker Adjusting Valve Clearance on page 6-34.
arm supports (Figure 6-32, (5)), springs
(Figure 6-32, (4)) and rocker arms
(Figure 6-32, (1)) onto the shaft.

(8)
(2)
(1)
(3)
(4) (7)
(6)
(5)

(9)

(8)
0002160

Figure 6-32
Note: The rocker arm shaft fits tightly in the
rocker arm supports. Clamp the support
in a padded vise. Twist and push on the
rocker arm shaft to reinstall.

6-32 TNV IDI Service Manual

Cylinder Head ENGINE
Reassembly of Intake Manifold / Valve
(1)
Cover
1. Reinstall the glow plugs (Figure 6-33, (1)) and
tighten to specification. Reinstall the electrical
harness (Figure 6-33, (2)). (2)

(3)
(2)
(4)

(1)

(5)
(6)
(7)

(8)

0002131

Figure 6-34
0002146
5. Reinstall the exhaust manifold using a new
Figure 6-33 gasket. Tighten the bolts and nuts
(Figure 6-34, (5 and 6)) securely.
2. Lightly grease a new valve cover gasket
(Figure 6-34, (4)). Place the gasket in the 6. Reinstall the fuel injectors. See Installation of
groove of the intake manifold / valve cover the Fuel Injectors on page 7-29.
(Figure 6-34, (3)). 7. Reinstall the high pressure and return fuel
3. Place the valve cover on the cylinder head. injection lines. See Installation of the Fuel
Injectors on page 7-29.
4. Reinstall and tighten bolts
(Figure 6-34, (1 and 2)) securely. 8. Reinstall the coolant pump. See Reassembly of
Engine Coolant Pump on page 8-9.
9. Reinstall the alternator. See Installation of
Alternator on page 11-16.

TNV IDI Service Manual 6-33

ENGINE Cylinder Head

Measuring and Adjusting Valve • If there is no valve clearance, and the piston is
at TDC of the compression stroke, extreme
Clearance
wear or damage to the cylinder head or valves
Measure and adjust while the engine is cold. may be possible.
Notes: • If adjusting each cylinder individually, the
cylinder to be adjusted first does not have to be
• The No. 1 piston position is on the flywheel end the No. 1 cylinder. Select and adjust the
of the engine, opposite end of the radiator. The cylinder where the piston is nearest to the top
firing order is 1-3-2 for 3-cylinder engines and dead center after turning. Adjust the remaining
1-2 for 2-cylinder engines. cylinders in the order of firing by turning the
• 3-cylinder engines fire every 240° of crankshaft crankshaft each time.
rotation. • To decrease the number of rotations required
• 2-cylinder engines are an uneven firing engine. to check all cylinders of a 3-cylinder engine,
No. 2 cylinder fires 180° after No. 1. The other cylinders can also be checked as
crankshaft then rotates 540° before No. 1 indicated in the chart below. 2-cylinder engines
cylinder fires again. must have each cylinder adjusted when the
• Valve clearance of both the intake and exhaust piston is at TDC.
valves can be checked with the piston for that Example: On a 3-cylinder engine, with the No. 1
cylinder at top dead center (TDC) of the piston at TDC on the compression stroke (both
compression stroke. When a piston is at TDC valves closed), the valves indicated on the top line
of the compression stroke, both rocker arms of the chart can be adjusted without rotating the
will be loose and the cylinder TDC mark on the crankshaft. To adjust the remaining two valves,
flywheel will be visible in the timing port of the rotate the crankshaft until the No. 1 piston is at TDC
flywheel housing. on the exhaust stroke (exhaust valve only open).

3-Cylinder Engines
Cylinder No. 1 2 3
Valve Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 Cylinder at TDC
• • • •
Compression
No. 1 Cylinder at TDC Exhaust • •

1. Remove the intake manifold / valve cover. See

Removal of Intake Manifold / Valve Cover on
page 6-22.
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to
TDC of the compression stroke while watching
the rocker arm motion and timing grid on the
flywheel. (Position so both the intake and
exhaust valves are closed.)
3. Insert a feeler gauge (Figure 6-35, (1))
between rocker arm and valve cap and record
the measured valve clearance. (Use the data
for estimating wear.)

6-34 TNV IDI Service Manual

Cylinder Head ENGINE
6. Insert a feeler gauge of the correct thickness
(1)
(Figure 6-37, (1)) between rocker arm and
valve cap. Turn the valve adjustment screw to
adjust the valve clearance so there is a slight
“drag” on the feeler gauge when sliding it
between the rocker arm and valve cap. Hold the
adjusting screw while tightening the valve
adjusting screw lock nut (Figure 6-36, (1)).
Recheck the clearance (see Adjustment
Specifications on page 6-5).
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that the initial
0001782A
clearance adjustment be made slightly
Figure 6-35 on the “loose” side before tightening the
lock nut.
4. If adjustment is required, proceed to the next
step. (1)
5. Loosen the valve adjusting screw lock nut
(Figure 6-36, (1)) and valve adjusting screw
(Figure 6-36, (2)) on the rocker arm. Check the
valve for inclination of the valve cap, entrance of
dirt, or wear.

(2)

0001782A

Figure 6-37
7. Apply oil to the contact surface between
adjusting screw and push rod.
8. Rotate the crankshaft and measure the next
(1) cylinder. Continue until all valves are adjusted.
0001783A

Figure 6-36

TNV IDI Service Manual 6-35

ENGINE Cylinder Block

CYLINDER BLOCK
Crankshaft and Camshaft Components

(1)
(3)

(5)
(2) (6)
(39) (4)
(9) (5)
(41) (40)
(10)
(11)
(12) (7)
(13) (8)

(16)
(38) (15)
(37) (14)
(36) (34)
(35) (33)

(31) (32)
(30) (17)
(29) (18)
(28)
(19) (20)
(21)
(22)
(27)

(23)

(24)

(25)

(26)

0002180

Figure 6-38

6-36 TNV IDI Service Manual

Cylinder Block ENGINE
1 – Cylinder Block Disassembly of Cylinder Block
2 – Camshaft Bushing
3 – Gear Case Components
4 – Dowel (2 used) Prepare a clean, flat working surface on a
5 – O-Ring workbench large enough to accommodate the
6 – Gear Case Cover engine components. Discard all used gaskets,
7 – Front Crankshaft Seal
O-rings and seals. Use new gaskets, O-rings and
8 – Fuel Injection Pump Gear Cover
seals for reassembly of engine.
9 – Tappets
10 – Camshaft
11 – Camshaft Gear Key CAUTION
12 – Camshaft End Plate
Identify all parts and their location using
13 – Camshaft Gear
14 – Idler Gear Shaft
an appropriate method. It is important
15 – Idler Gear Bushing that all parts are returned to the same
16 – Idler Gear position during the reassembly process.
17 – Oil Pickup O-Ring 0000080en

18 – Oil Pickup
19 – Crankshaft IMPORTANT
20 – Crankshaft Gear Key Mark all valve train components so they can
21 – Crankshaft Gear be installed in their original locations.
22 – Crankshaft Pulley
23 – Main Bearing Inserts Note: Record all measurements taken during
24 – Main Bearing Cap disassembly.
25 – Crankcase Extension
If the engine will be completely disassembled, the
26 – Oil Pan
following preliminary steps should be performed:
27 – Thrust Bearings
28 – Flywheel 1. Disconnect the battery cables at the battery.
29 – Connecting Rod Cap Always disconnect the negative (-) cable first.
30 – Connecting Rod Bearing Inserts
31 – Connecting Rod 2. Remove the throttle cable, electrical
32 – Wrist Pin Bushing connections, intake and exhaust system
33 – Circlip connections, and fuel supply lines from the
34 – Wrist Pin engine.
35 – Piston
3. Remove the alternator. See Removal of
36 – Oil Ring
Alternator on page 11-12.
37 – Second Compression Ring
38 – Top Compression Ring 4. Drain the engine coolant from the radiator and
39 – Dowel (2 used) cylinder block. See Drain, Flush and Refill
40 – Crankshaft Rear Seal Cooling System with New Coolant on
41 – Flywheel Housing page 5-33. Remove the cooling system
components from the engine.

A CAUTION
Be sure to secure the engine solidly to
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en

TNV IDI Service Manual 6-37

ENGINE Cylinder Block

5. Remove the engine from the machine. Mount

the engine to a suitable engine repair stand
having adequate weight capacity.
6. Clean the engine by washing with solvent, air or
steam cleaning. Carefully operate to prevent (3)
(1)
any foreign matter or fluids from entering the (2)
engine, fuel system, or electrical components
remaining on the engine.
7. Drain the engine oil into a suitable container.
Remove oil filter.
8. Remove the cylinder head. See Disassembly of
Cylinder Head on page 6-21.
0002181
9. Remove the fuel injection pump from the gear
case only if it must be sent out for repair, or will Figure 6-39
interfere with other procedures such as “hot
tank” cleaning. See Removal of Fuel Injection
Checking Timing Gear Backlash
Pump on page 7-13. Prior to removing the timing gears, measure the
10. Remove the starter motor. See Removal of gear backlash and determine the gear wear.
Starter Motor on page 10-10. Note: Check the backlash between each pair of
mating gears. If not within specification,
Disassembly of Camshaft and Timing replace both mating gears. Do not allow
Components the gear being checked to move axially
Discard all gaskets, O-rings and seals. Use new as excess end play could cause a false
gaskets, O-rings and seals on reassembly of reading. See Timing Gear Backlash on
camshaft and timing components. page 6-8 for service limits.

Removal of Timing Gear Case Cover (1)

(2)
1. Remove the bolt and washer retaining the
crankshaft pulley. (3)
B
B
IMPORTANT C C

Use care not to damage the threads in the A

end of the crankshaft when removing the (5) A

crankshaft pulley.
(4)
2. Remove the crankshaft pulley with a gear puller. 0002190

3. Remove the bolts that retain the gear case 1 – Fuel Injection Pump Drive Gear
cover to the cylinder block and oil pan. 2 – Camshaft Drive Gear
4. Remove the gear case cover (Figure 6-39, (1)). 3 – Auxiliary Drive Gear (Optional)
4 – Crankshaft Drive Gear
5. Remove the dowel pins (Figure 6-39, (3)) and 5 – Idler Gear
O-ring (Figure 6-39, (2)).
Figure 6-40

6-38 TNV IDI Service Manual

Cylinder Block ENGINE
Measuring Idler Gear-to-Crankshaft Gear Removal of Timing Gears
Backlash 1. Remove the bolts from the idler gear shaft
1. Install a dial indicator as shown in Figure 6-41. (Figure 6-42, (1)). Remove the idler gear shaft,
idler gear (Figure 6-42, (3)) and bushing
(Figure 6-42, (2)).

(3)
(2)
(1)

00021
0002192

Figure 6-41 Figure 6-42

2. Rotate the idler gear back and forth to check 2. Do not remove the crankshaft gear unless it is
idler gear-to-crankshaft gear backlash. Total damaged and requires replacement. If the gear
indicator reading is backlash. Record the must be removed, remove it with a gear puller.
measurement.
3. Removal of the camshaft gear requires the
Measuring Idler Gear-to-Camshaft Gear camshaft be removed with a press. Do not
remove the camshaft gear unless it or the
Backlash
camshaft is damaged and requires
1. Drive a small wooden wedge between the replacement. See Removal of Camshaft on
crankshaft gear and idler gear to prevent the page 6-41.
idler gear from rotating.
2. Install a dial indicator to read camshaft gear CAUTION
backlash. Rotate camshaft drive gear against Do not loosen or remove the four bolts
idler gear to measure backlash. Record the retaining the fuel injection pump drive
measurement. gear to the fuel injection pump hub. Do
3. Check the idler gear-to-fuel injection pump not disassemble the fuel injection pump
drive gear backlash in the same manner as the drive gear from the hub. Correct fuel
camshaft drive gear. Record the measurement. injection timing will be very difficult or
impossible to achieve.
0000031en

TNV IDI Service Manual 6-39

ENGINE Cylinder Block

4. Do not remove the fuel injection pump drive Removal of Oil Pan
gear unless absolutely necessary due to 1. Invert the engine (oil pan up) on the engine
damage to the gear or pump. Do not loosen or stand.
remove the four bolts (Figure 6-43, (3))
retaining pump drive gear to the hub. Only 2. Remove the oil pan (Figure 6-44, (2)).
remove the nut (Figure 6-43, (1)) and washer 3. Remove the crankcase extension
(Figure 6-43, (2)), leaving the hub attached to (Figure 6-44, (1)) if equipped.
the gear. Remove the pump drive gear and hub
as an assembly using a gear puller.

(3)
(1)

(1)

(2) (2)

0002183

Figure 6-43
0002184
CAUTION
Do not loosen or remove the four bolts Figure 6-44
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do 4. Remove the oil pickup tube (Figure 6-45, (1))
not disassemble the fuel injection pump and O-ring (Figure 6-45, (2)).
drive gear from the hub. Correct fuel
injection timing will be very difficult or
impossible to achieve.
0000031en

(2)
(1)

0002185

Figure 6-45

6-40 TNV IDI Service Manual

Cylinder Block ENGINE
Removal of Camshaft 2. Remove two bolts (Figure 6-48, (3)) retaining
1. Before removing the camshaft, check the the camshaft thrust plate (Figure 6-48, (1)).
camshaft end play.
• Method A: Install a dial indicator (5)
(Figure 6-46, (1)) on the cylinder block. Move
the camshaft and gear (Figure 6-46, (2)) in
and out to measure the end play. Record the
measurement. See Camshaft on page 6-7 for
the service limit.

(2)
(2)

(1)
(3)
(4)
0002186

Figure 6-48
3. Extract the tappets (Figure 6-48, (5)) through
(1) the top of the cylinder block. Mark the tappets
so they can be reinstalled in the same location.
4. Slowly pull the camshaft (Figure 6-48, (2))
assembly out of the engine being careful not to
0002191
damage the front camshaft bushing.
Figure 6-46 5. Remove the camshaft gear (Figure 6-48, (4))
• Method B: Use a feeler gauge to measure the only if the gear or camshaft require
clearance between the thrust plate replacement. Use a knife-edge puller and a
(Figure 6-47, (1)) and front camshaft bearing press to remove the gear. The gear is a
(Figure 6-47, (2)). Record the measurement. shrink-fit and will need to be heated to
See Thrust Bearing on page 6-9 for the service 356° - 392°F (180° - 200°C) to remove.
limit.

(1)

(2)

0001710B

Figure 6-47

TNV IDI Service Manual 6-41

ENGINE Cylinder Block

Removal of Gear Case Disassembly of Crankshaft and

Note: The camshaft must be removed before Piston Components
the gear case can be removed. See
Removal of Camshaft on page 6-41. Removal of Pistons
1. Remove bolts (Figure 6-49, (4)).
CAUTION
Note: It is not necessary to remove the fuel
injection pump from the gear case to Keep the piston pin parts, piston
remove the gear case. If the fuel injection assemblies, and connecting rod
pump does not need to be repaired, assemblies together to be returned to
leave it mounted to the timing gear case. the same position during the
See Removal of Fuel Injection Pump on reassembly process. Label the parts
page 7-13. using an appropriate method.
0000088en
2. Remove the gear case (Figure 6-49, (1)) from
the cylinder block. IMPORTANT
3. Inspect and measure the camshaft bushing. Engines with high operating hours may
See Camshaft on page 6-7 for service limits. If have a ridge near the top of the cylinders
damaged or worn beyond service limits, remove that will catch the piston rings and make it
the camshaft bushing (Figure 6-49, (3)). impossible to remove the pistons. Use a
suitable ridge reamer to remove ridges and
4. Remove O-rings (Figure 6-49, (2)). carbon prior to removing pistons.
Note: Pistons can fall from cylinder block if
engine is inverted. Rotate the engine so
(3) the connecting rods are horizontal before
(1) removing the connecting rod caps.

(4)

(2)

0002187

Figure 6-49

6-42 TNV IDI Service Manual

Cylinder Block ENGINE
1. Using a feeler gauge, measure the connecting IMPORTANT
rod side clearance (Figure 6-50). See Do not rotate crankshaft when using
Connecting Rod on page 6-12 for the standard PLASTIGAGE. A false reading may result.
limit. If the measurement is out of specification,
replace the crankshaft, connecting rod, or both. 5. Reinstall the bearing cap and tighten to
specification. See Special Torque Chart on
page 6-14.
6. Remove the bearing cap.

(1)

0001899

Figure 6-52
7. Compare the width of the flattened
0000219 PLASTIGAGE (Figure 6-52, (1)) to the
Figure 6-50 graduation marks on the package. The mark
that most closely matches the width of the
IMPORTANT flattened PLASTIGAGE will indicate the bearing
Mark the connecting rod caps and oil clearance. Record the measurements. See
connecting rods so the caps and connecting Crankshaft on page 6-8.
rods stay together.
8. Repeat with the remaining connecting rods.
2. Remove the bearing cap. Do not remove the
bearing inserts at this time.
IMPORTANT
Do not allow the connecting rod to contact
3. Wipe oil from the bearing insert and crankshaft the crankshaft journal during piston
journal surfaces. removal. Damage to the bearing journal
4. Place a piece of PLASTIGAGE® may result.
(Figure 6-51, (1)) along the full width of the
9. Use a wooden dowel against the connecting
bearing insert.
rod and tap the piston / connecting rod
assembly out of the cylinder.
(1) 10. Mark the cylinder number on the piston and
connecting rod.

0001898

Figure 6-51

TNV IDI Service Manual 6-43

ENGINE Cylinder Block

11. Remove the bearing inserts (Figure 6-53, (2)).

(2)
12. Remove the compression rings
(Figure 6-53, (3)) from the piston using a piston
ring expander.
(3)
13. Remove the oil ring (Figure 6-53, (4)) from the
piston using a piston ring expander. (1)

(3)
(4)
(4)
(5)

(9) (6)
(5) 0002188

Figure 6-54
(8) 3. Before removing the main bearing caps,
(7) measure the crankshaft end play. Use either of
the following two methods:
(2)
• Method A: Install a dial gauge
(1) (Figure 6-55, (1)) on the cylinder block. Move
the crankshaft (Figure 6-55, (2)) in and out to
measure the end play. Record the
measurement.
0001705A

Figure 6-53
14. Remove the circlips (Figure 6-53, (5)) from the
wrist pin.
15. Remove the wrist pin (Figure 6-53, (6)) and
connecting rod (Figure 6-53, (8)) from the
piston (Figure 6-53, (9)).
16. Repeat steps until all pistons are removed and (1)
dissembled.

Removal of Crankshaft (2)

0001961
1. Remove the flywheel (Figure 6-54, (1)) from
the crankshaft. Figure 6-55
2. Remove the bolts (Figure 6-54, (2)) from the
flywheel housing assembly. Remove the
flywheel housing from the engine.

6-44 TNV IDI Service Manual

Cylinder Block ENGINE
• Method B: Use a feeler gauge to measure the
clearance (Figure 6-56, (3)) between the
thrust bearing (Figure 6-56, (1)) and
crankshaft (Figure 6-56, (2)). Record the (1)
measurement. See Thrust Bearing on
page 6-9 for the service limit.

0001899

Figure 6-58
9. Compare the width of the flattened
PLASTIGAGE (Figure 6-58, (1)) to the
(1)
graduation marks on the package. The mark
(2) that most closely matches the width of the
flattened PLASTIGAGE will indicate the bearing
oil clearance. Record the measurement. See
Crankshaft on page 6-8 for clearance
specifications.
(3) 0001962
10. Repeat with the remaining main bearings.
Figure 6-56
Note: Be sure to note the markings on the main
4. Remove the bearing cap. Do not remove the bearing caps, or make marks so they can
bearing inserts at this time. be reinstalled in the same order as they
5. Wipe oil from the bearing insert and crankshaft were removed. The “arrows” on the main
journal surfaces. bearing caps point to the flywheel end of
the engine.
6. Place a piece of PLASTIGAGE®
(Figure 6-57, (1)) along the full width of the
bearing insert.

(1)

0001898

Figure 6-57
IMPORTANT
Do not rotate crankshaft when using
PLASTIGAGE. A false reading may result.
7. Reinstall the bearing cap and tighten to
specification. See on page 6-14.
8. Remove the bearing cap.

TNV IDI Service Manual 6-45

ENGINE Cylinder Block

11. Remove the crankshaft from the engine. Inspection of Crankshaft and
12. Remove the bearing inserts (Figure 6-59, (1)) Camshaft Components
and thrust bearings (Figure 6-59, (2)).
Note: Do not remove the crankshaft gear A WARNING
unless the gear or crankshaft are
damaged and require replacement.

FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
cleaners, primers, sealants and
sealant removers.
(1) • Failure to comply could result in death
or serious injury.
(2) 0000014en

Thoroughly clean all components using a brush

0002189 and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
Figure 6-59 debris.
13. If necessary, remove the crankshaft gear Note: Record all measurements taken during
(Figure 6-60, (1)) and key (Figure 6-60, (2)). If inspection.
using a gear puller, be careful not to damage
the threads in the end of the crankshaft. Replacement of Crankshaft Oil Seals
1. Remove the seal (Figure 6-61, (2)) from the
(2) gear case cover (Figure 6-61, (1)).
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212, Yanmar Part No.
977770-01212 to the outside diameter of a new
(1) oil seal (Figure 6-61, (2)).
3. Install a new seal in the gear case cover with
the lip facing in away from the crankshaft pulley.
Apply lithium grease to the lip of the seal.
0002193

Figure 6-60

6-46 TNV IDI Service Manual

Cylinder Block ENGINE

(1) Inspection of Cylinder Block

1. Ensure that oil passages are clear and
unobstructed.
2. Check for discoloration or evidence of cracks. If
(2) a fracture is suspected, use the color check
method or the MAGNAFLUX® method to
determine if the cylinder block is fractured.
0002181A 3. Measure cylinders for roundness, taper, and
Figure 6-61 inspect for evidence of scoring. Consider
honing, re-boring or replacing the cylinder block
4. Remove the rear oil seal (Figure 6-62, (1)) from if the measurements are not within
the flywheel housing (Figure 6-62, (2)). specification.
(2) • Take measurements at three places
(Figure 6-63) (a, b, and c), and in two
directions (d and e) in each cylinder. Collect
and record the measurements. See Cylinder
Block on page 6-13 for specifications.

a 20 mm
(0.75 in.)
d
e
b
(1)

c
20 mm
Figure 6-62 (0.75 in.) 0000230B

5. Apply a continuous bead of ThreeBond Liquid Figure 6-63

Gasket No. 1212, Yanmar Part No.
977770-01212 to the outside diameter of a new Roundness
oil seal (Figure 6-62, (1)). Roundness can be calculated by subtracting the
6. Install a new seal in the flywheel housing smaller measured value from the larger measured
(Figure 6-62, (2)) with the lip facing in away value of (d or e) at each measuring location (a, b,
from the flywheel. Apply lithium grease to the lip and c).
of the seal.
Taper
Crankshaft Bearing Oil Clearance Taper can be calculated by subtracting the
Oil clearance should be checked during minimum measured value from the maximum
disassembly to determine the extent of wear, and measured value of locations (a, b, and c).
during assembly to ensure long engine life. The Calculate along both the (d) axis and (e) axis and
same procedure is done for both connecting rods use the larger of the two calculations as the value
and main bearings. See Removal of Pistons on to compare to the specifications.
page 6-42 or Removal of Crankshaft on page 6-44
for specific information.

TNV IDI Service Manual 6-47

ENGINE Cylinder Block

Inspection of Pistons, Piston Rings and 5. Subtract the piston measurement from the
Wrist Pin greatest measurement acquired during cylinder
inspection (see Inspection of Cylinder Block on
Notes:
page 6-47) to obtain piston-to-cylinder
• On an engine with low hours, the pistons, clearance. Record the measurements. See
piston rings may be reused if they are found to Piston on page 6-10 for specifications.
be within specifications. The pistons and piston 6. Measure the diameter of the wrist pin bore on
rings must be reinstalled in the same cylinders both sides of the piston (Figure 6-65). See
from which they were originally removed. Piston on page 6-10 for specifications. Record
• On an engine with high hours, the pistons rings the measurements.
should be replaced and the cylinder honed
(See Honing and Boring on page 6-53) or
replaced. The piston should be replaced as
necessary.
1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s
instructions for correct operation.
2. Wash the pistons in an appropriate solvent
using a soft brush.
0000237
3. Visually inspect each piston for cracks. Pay
particular attention to the ring lands between Figure 6-65
the piston ring grooves.
7. Measure the outside diameter of the wrist pin in
4. Measure the diameter of the piston skirt at 90° three places and at 90° (Figure 6-66). See
to the wrist pin bore as shown (Figure 6-64). Piston on page 6-10 for specifications. Record
Measurements must be taken at a specified the measurements.
distance (Figure 6-64, (1)) from the bottom of
the piston, based on engine model. Record the
measurements. See Piston on page 6-10 for
specifications.

0001889

Figure 6-66
8. Using a micrometer, measure the thickness of
each piston ring. See Piston Ring on page 6-11
(1) for specifications. Record the measurements.
Notes:
• On an engine with low hours, the pistons,
piston rings and cylinders may be reused if they
0000235
are found to be within specifications.
Figure 6-64

6-48 TNV IDI Service Manual

Cylinder Block ENGINE
• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed
(See Honing and Boring on page 6-53) or
replaced. The piston should be replaced as
necessary.
9. Place each compression piston ring in the
groove as shown (Figure 6-67). Use a feeler
gauge to measure the clearance between the
piston ring and the piston ring land. Record the (1)
measurements. See Piston Ring on page 6-11 (2)
for specifications. Replace the piston if not
within specification.

(3)
0001964

Figure 6-68
Note: Always check the piston ring end gap
when installing new piston rings. See
Piston Ring on page 6-11 for
specifications. Use a piston ring end gap
filing tool to adjust the piston ring end
gap on new piston rings.
0001892
11. Repeat the above steps for each cylinder and
Figure 6-67 piston assembly.

10. To measure piston ring end gap, insert each Inspection of Connecting Rod
compression piston ring (Figure 6-68, (1)), one 1. Measure the wrist pin bushing bore using a
at a time, into the cylinder. Use a piston with the bore gauge (Figure 6-69, (1)). Replace the
piston rings removed to slide the ring into the bushing if not within specifications. If the
cylinder bore until it is approximately 1.18 in. bushing has been removed, measure the inside
(30 mm) (Figure 6-68, (2)) from the bottom of diameter of the connecting rod small end
the bore. Remove the piston. Measure the end (Figure 6-69, (2)). Record the measurements.
gap (Figure 6-68, (3)) of each piston ring. See Connecting Rod on page 6-12 for
Record the measurements. See Piston Ring on specifications.
page 6-11 for specifications.

TNV IDI Service Manual 6-49

ENGINE Cylinder Block

3. Place the connecting rod bearing inserts into

the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
specified torque.
4. Measure the inside diameter. Record the
measurements. See Crankshaft on page 6-8 for
specifications.

Inspection of Tappets
(1)
1. Inspect the tappet contact surfaces for
abnormal wear (Figure 6-72, (1)). Normal wear
(2) will be even as shown in (Figure 6-72, (2)).
0001724A
Slight surface defects can be corrected using
an oilstone.
Figure 6-69
2. Measure the connecting rod twist
(Figure 6-70, (1)) and bend (Figure 6-70, (2))
using a connecting rod alignment tool
(Figure 6-71). Record the measurements. See
Connecting Rod on page 6-12 for
specifications.

(1) (2) 0002194

Figure 6-72
(2)
2. Measure the outside diameter of the tappet
stem (Figure 6-73, (1)). Record the
measurements. See Tappet on page 6-13 for
the service limit.
(1)

0001896

Figure 6-70

0002195

Figure 6-73
3. Measure the tappet bores in the cylinder block.
Record the measurements. See Tappet on
page 6-13 for the service limit.
0000242

Figure 6-71

6-50 TNV IDI Service Manual

Cylinder Block ENGINE
Inspection of Crankshaft
1. Put the crankshaft end journals
(Figure 6-74, (4)) on V-blocks.
2. Place a dial indicator (Figure 6-74, (3)) on a
center main bearing surface.

(2)
(1)

(3)

(1)
(2) 0001733A

Figure 6-75

Reconditioning the Crankshaft

(4) (4) 0000232A If any of the crankshaft journals do not meet the
specifications, it may be possible to grind any or all
Figure 6-74
of them to an undersize. The connecting rod
3. Rotate the crankshaft and observe runout. bearings, main bearings, and thrust bearing inserts
Record the measurements. See Crankshaft on are available as 0.010 in. (0.25 mm) undersize. If
page 6-8 for specifications. the journals are ground undersize, the following
4. Use the color check method or MAGNAFLUX to finishing standards (Figure 6-76) must be adhered
inspect the crankshaft for cracks. Replace the to:
crankshaft if evidence of fractures is found.
5. Measure the outside diameter of each crankpin
(Figure 6-75, (2)) and main bearing journal
(Figure 6-75, (1)). See Crankshaft on page 6-8
for specifications. Take measurements at
several places around each bearing surface. If
not within specification, grind the journals and
install undersize bearings, or replace the
crankshaft. Record the measurements.

TNV IDI Service Manual 6-51

ENGINE Cylinder Block

(1)
Ry (1)

R
R

R
0001712A

0000234A Figure 6-78

Figure 6-76 4. Measure the diameter of the gear end
(Figure 6-79, (1)), intermediate
Item Finishing Precision (Figure 6-79, (2)), and flywheel end
Connecting Rod Journal 1.6418 - 1.6422 in. (Figure 6-79, (3)) bearing journals. Record the
Undersize Finished Size (41.702 - 41.712 mm) measurements. See Camshaft on page 6-7 for
Main Bearing Journal 1.8387 - 1.8391 in. specifications.
Undersize Finished Size (46.702 - 46.712 mm)
0.138 - 0.150 in. (3)
Journal Radius (R)
(3.5 - 3.8 mm)
Journal Face Finish (Ry) 0.8S (Super Polish)
(2)
Thrust Face Finish (1) 1.6
(1)
Inspection of Camshaft
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 6-77). Place the
indicator on the center bearing journal. 0001713A

Figure 6-79

0002196

Figure 6-77
2. Rotate the camshaft and observe the runout.
Record the measurements. See Camshaft on
page 6-7 for specifications.
3. Measure the height of each lobe
(Figure 6-78, (1)). Record the measurements.
See Camshaft on page 6-7 for specifications.

6-52 TNV IDI Service Manual

Cylinder Block ENGINE
Inspection of Camshaft Bushing and Bores Honing and Boring
1. Measure the I.D. of the front bushing and the Pistons must move freely in the cylinders while
remaining bores in the cylinder block. Record maintaining adequate compression and oil sealing.
the measurements. See Camshaft on page 6-7 If the cylinder walls are scuffed, scored,
for specifications. out-of-round, or tapered beyond specifications,
If the camshaft bushing is not within specification, rebore and hone to restore cylinders to usable
replace using the appropriate service tool. If the condition. Slight imperfections can be corrected by
remaining bores are not within specification, the honing alone.
cylinder block will require replacement as there are
1. Boring - Significant cylinder damage may be
no bearing inserts used.
corrected by boring the cylinder to an oversize
Inspection of Idler Gear and Shaft dimension. Refer to the appropriate parts
catalog for available oversize pistons and piston
1. Measure the outside diameter rings.
(Figure 6-80, (1)) of the idler gear shaft
(Figure 6-80, (2)). Record the measurements. • Boring a cylinder should always be done in a
See Idler Gear Shaft and Bushing on page 6-8 properly equipped machine shop.
for specifications. • A bored cylinder should always be finished with
2. Measure the inside diameter (Figure 6-80, (3)) a hone to properly prepare the cylinder surface
of the idler gear bushing (Figure 6-80, (4)). so the new piston rings will seat properly.
Record the measurements. See Idler Gear • After the cylinder has been bored and honed,
Shaft and Bushing on page 6-8 for install the appropriate oversize pistons and
specifications. piston rings.
2. Honing - Minor cylinder imperfections may be
(4)
corrected by using a rigid cylinder hone
(Figure 6-82, (1)). Be sure not to exceed the
maximum cylinder bore specification.
(1) (3) Deglazing - A used cylinder that did not require
boring or honing, should always be deglazed with
(2) a ball hone (Figure 6-82, (2)) before installing
new piston rings. This will properly prepare the
Figure 6-80 cylinder surface to allow new piston rings to seat
properly.
Note: When honing a cylinder, with either a
ridged hone or a ball hone
(Figure 6-81, (1)), move the rotating
hone up and down in the cylinder bore to
accomplish a 30° to 40° crosshatch
pattern (Figure 6-81). This will provide
the ideal surface for the proper seating of
new piston rings.

TNV IDI Service Manual 6-53

ENGINE Cylinder Block

• When honing is completed, wash the cylinder

CAUTION block with hot water and soap. The cylinder wall
Do not allow the honing tool to operate is adequately cleaned when a white rag wiped
in one position for any length of time. in cylinder comes out clean. Use brushes to
Damage to the cylinder wall will occur. clean all passages and crevices. Rinse with hot
Keep the tool in constant up-and-down water and dry with compressed air. Apply clean
motion. engine oil to all steel surfaces to prevent
0000090en rusting.

(1)
Reassembly of Crankshaft and
Piston Components
Notes:
• Proceed slowly. Make no forced assemblies
unless a pressing operation is called for. All
parts must be perfectly clean and lightly
lubricated when assembled.
• Use new gaskets, seals and O-rings during
assembly.
• Liberally apply clean engine oil to all internal
0000248A
parts during assembly.
Figure 6-81
• All fasteners should be tightened to a given
• Use a 50:50 mixture of diesel fuel and engine torque. If a special torque is not provided in the
oil as a honing fluid. Special Torque Chart on page 6-14, tighten to
• Use a 300-grit hone at 300 - 1200 rpm standard torque specifications. See Tightening
(Figure 6-82). Torques for Standard Bolts and Nuts on
page 4-25.
(1)

(2)

0000249B

Figure 6-82
IMPORTANT
Solvents will not adequately remove honing
residue, resulting in premature piston and
ring wear. Always wash cylinders using hot,
soapy water.

6-54 TNV IDI Service Manual

Cylinder Block ENGINE
Reassembly of Pistons Note: The actual appearance of the match
1. Select the parts needed to assemble the piston marks will vary but they will always be in
and connecting rod for one cylinder. the same locations.

2. If removed, install a new wrist pin bushing

(Figure 6-83, (7)) using a press and the
appropriate service tool. Be sure to align the oil
holes.
(3)

C H MS
(4)

(5)

(9) (6)
(5)

(8)
(7) (1) 0002464

(2) (2)

(1)
E106 R

0001705A 0002090

Figure 6-83
(3)
3. Reinstall one circlip (Figure 6-83, (5)) into the
piston. Ensure the circlip is securely seated in
the groove. 80 80
IMPORTANT
The piston and connecting rod must be 0002089

assembled with the correct orientation. Figure 6-84

When correctly assembled, the piston
identification mark (Figure 6-84, (1)) 4. Place the connecting rod into the piston. The
stamped into the top of the piston will be on match marks (Figure 6-85, (4)) on the
the opposite side of the connecting rod as connecting rod and cap must be on the
the match marks (Figure 6-84, (3)) opposite side as the piston identification mark
stamped into the connecting rod and (Figure 6-85, (2)) on the top of the piston.
connecting rod cap. When reinstalled in the
cylinder, the embossed mark
(Figure 6-84, (2)) cast into the beam of
connecting rod will face the flywheel end of
the engine.

TNV IDI Service Manual 6-55

ENGINE Cylinder Block

(1) (3)
(6)
(4)

(5)

(9) (6)
(5)

(2) (5)
(8)
(7)

(3) (2)

(1)

(4)

0001705A
0000227A
Figure 6-86
1 – Fuel Injection Pump Side of Engine
2 – Piston Identification Mark Note: Reinstall the top and second piston rings
3 – Embossed Mark on Connecting Rod with the stamped “makers mark”
4 – Connecting Rod and Cap Match Marks (Figure 6-87, (1)) facing the top of the
5 – Flywheel End of Engine piston. The “makers mark” may vary in
6 – Camshaft Side of Engine appearance but will always be located on
Figure 6-85 the top surface of the piston ring
adjacent to the piston ring gap. The oil
5. Lubricate and install the wrist pin ring and oil ring expander can be
(Figure 6-86, (6)) through the piston and installed either side up.
connecting rod.
6. Reinstall the second circlip (Figure 6-86, (5)) (1)
and ensure it is securely seated in the groove.
Note: If installing new piston rings the end gap
must be checked and adjusted as
necessary. See Inspection of Pistons, 0000225A
Piston Rings and Wrist Pin on
Figure 6-87
page 6-48. Use a piston ring end gap
filing tool to adjust the piston ring end IMPORTANT
gap on new piston rings. Always use a piston ring expander when
installing piston rings. Never attempt to
install piston rings by hand.

6-56 TNV IDI Service Manual

Cylinder Block ENGINE
7. Reinstall the oil ring expander
(1)
(Figure 6-88, (4)). Install the oil ring
(Figure 6-88, (3)) with the end gap at 180° from
the expander end gap.
8. Reinstall the second compression ring (2)
(Figure 6-88, (2)). This ring is identified by its
dark color and tapered face profile. (3)
9. Reinstall the top compression ring
(Figure 6-88, (1)). This ring is identified by its
silver color and barrel-shaped face profile.
IMPORTANT
The oil ring expander (Figure 6-88, (4)) end
gap must be located 180° from the oil ring
(Figure 6-88, (3)) end gap.

1 – Top Compression Ring End Gap

(1)
2 – Second Compression Ring End Gap
3 – Oil Ring End Gap
Figure 6-89
(2)
Installation of Crankshaft
(3) 1. If removed, reinstall the key and timing gear on
crankshaft.
2. Install new bearing inserts (Figure 6-90, (1))
(4) and thrust bearing (Figure 6-90, (2)) in the
0001722B cylinder block and main bearing caps. Be sure
Figure 6-88 the oil holes in the upper bearing shells align
with the oil ports in the cylinder block. Apply a
10. Stagger the piston ring end gaps at 120° liberal coat of clean engine oil to the bearings
intervals (Figure 6-89, (1, 2, and 3)). Do not and crankshaft journals.
position the top piston ring end gap in line with
the wrist pin.

TNV IDI Service Manual 6-57

ENGINE Cylinder Block

(2)

(3)

(1)

(1)
(4)
(2)

0002188
0002189

Figure 6-90 Figure 6-91

3. Install the crankshaft in the engine. Installation of Pistons

IMPORTANT IMPORTANT
The main bearing caps are numbered and Do not allow the connecting rod to contact
have arrows for proper positioning. The the crankshaft journal during piston
No. 1 cap is at the flywheel end. The arrows installation. Damage to the crankshaft
point toward the flywheel end of the engine. bearing journal may result.

4. Reinstall the main bearing caps. 1. Lubricate piston, piston rings, and cylinder with
clean engine oil or assembly lubricant.
5. Apply a light coat of clean engine oil to the
bearing cap bolts and tighten the bolts to the 2. Rotate the crankshaft so the crankpin for the
specified torque in two stages (1/2 then full piston being installed is near bottom dead
torque). See Special Torque Chart on center.
page 6-14.
6. Rotate the crankshaft to ensure it turns freely.
7. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212 to the mounting
flange of the flywheel housing
(Figure 6-91, (2)).
8. Align the flywheel housing with the two dowel
pins (Figure 6-91, (3)).
9. Reinstall flywheel housing and seal assembly.
10. Reinstall the flywheel (Figure 6-91, (1)) and
tighten the bolts to the specified torque. See
Special Torque Chart on page 6-14.

6-58 TNV IDI Service Manual

Cylinder Block ENGINE
4. Carefully reinstall the piston and rod assembly.
(1)
Be sure the match marks (Figure 6-93, (4))
stamped into the connecting rod and cap are
facing the fuel injection pump side of the
(2) cylinder block, and the piston identification
mark (Figure 6-93, (2)) stamped into the piston
(3) top is facing the camshaft side
(Figure 6-93, (6)). The embossed mark cast
into the connecting rod beam (Figure 6-93, (3))
will be facing the flywheel end of the engine
(Figure 6-93, (5)).

(6) (1)

0000226A

1 – Top Compression Ring End Gap (2) (5)

2 – Second Compression Ring End Gap
3 – Oil Ring End Gap
Figure 6-92
(3)
IMPORTANT
Ensure piston ring gaps are located
correctly (Figure 6-92).
(4)
3. Using a piston ring compressor, compress the
piston rings.
0000227A
IMPORTANT
1 – Fuel Injection Pump Side of Engine
The piston and connecting rod must be
2 – Piston Identification Mark
reinstalled with the correct orientation.
3 – Embossed Mark on Connecting Rod
When installed correctly, the identification 4 – Rod and Cap Match Marks
mark (Figure 6-93, (2)) stamped into the 5 – Flywheel End of Engine
top of the piston will be on the same side of 6 – Camshaft Side of Engine
the engine as the fuel injection pump
(Figure 6-93, (1)) and the embossed mark Figure 6-93
(Figure 6-93, (3)) cast into the connecting 5. Reinstall the bearing inserts (Figure 6-94, (1))
rod beam will face the flywheel end of the in the connecting rod and cap.
engine (Figure 6-93, (5)).
6. Apply a liberal coat of clean engine oil to the
bearing inserts and crankshaft journal.

TNV IDI Service Manual 6-59

ENGINE Cylinder Block

7. Apply a light coat of clean engine oil to the rod

cap bolts. Reinstall the connecting rod cap
(3)
(Figure 6-94, (2)). Tighten the connecting rod
(1)
bolts to the specified torque in two stages (1/2
then full torque). See Special Torque Chart on (4)
page 6-14.

(2)

0002187
(1)
Figure 6-95
(2) 4. Reinstall the gear case (Figure 6-95, (1)).
Tighten the bolts (Figure 6-95, (4)) to the
specified torque.

Installation of Camshaft
0001965
Note: The gear housing must be installed prior
Figure 6-94 to reinstalling the camshaft. See
Installation of Gear Case on page 6-60.
8. Reinstall the remaining pistons in their
respective cylinders. 1. If removed, reinstall the camshaft end plate
(Figure 6-96, (1)), key, and camshaft gear
Reassembly of Camshaft and Timing (Figure 6-96, (4)) onto the camshaft using a
Components press.
• Heat the gear to 356 - 392°F (180 - 200°C) and
Installation of Gear Case press onto the end of the camshaft.
1. If removed, install a new camshaft bushing 2. Lubricate the camshaft (Figure 6-96, (2)) with
(Figure 6-95, (3)) using the appropriate service clean engine oil or assembly lube. Slowly insert
tool. the camshaft through the front of the engine.
2. Apply a continuous bead of ThreeBond Liquid 3. Reinstall and tighten the cap screws
Gasket No. 1212, Yanmar Part No. (Figure 6-96, (3)).
977770-01212 to the mounting area of the gear
case. Be sure to circle each bolt hole.
3. Reinstall dowels and new O-rings
(Figure 6-95, (2)).

(2)

(1)
(3)
(4)
0002186

Figure 6-96

6-60 TNV IDI Service Manual

Cylinder Block ENGINE
4. Lubricate the camshaft lobes and tappets with
(1)
clean oil or assembly lube. Reinstall the tappets (2)
in their respective locations in the cylinder
block. Push the tappets fully into the tappet (3)
bores until they make solid contact with the B
B
C C
camshaft.
A
5. If removed, reinstall the fuel injection pump. (5) A

Adjust the fuel injection timing after installation.

See Checking and Adjusting Fuel Injection (4)
Timing on page 7-19. 0002190

1 – Fuel Injection Pump Gear

Installation of Timing Gears 2 – Camshaft Gear
1. Set No. 1 piston to top dead center. 3 – Optional Accessory Drive Gear
4 – Crankshaft Gear
2. Rotate the camshaft until mark
5 – Idler Gear
(Figure 6-98, (C)) is approximately at the
9 o’clock position. Figure 6-98
3. Lubricate the idler gear (Figure 6-97, (3)), 7. When all gears are properly aligned, tighten the
bushing (Figure 6-97, (2)) and idler gear shaft idler gear retaining bolts to specified torque.
(Figure 6-97, (1)) with clean engine oil or See Special Torque Chart on page 6-14 for
assembly lube. specifications.

Installation of Gear Case Cover

1. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212, Yanmar Part No.
977770-01212 to the mounting area of the gear
(3) case cover (Figure 6-99, (1)). Be sure to circle
(2) the bolt holes.
(1)

0002182

(3)
Figure 6-97 (1)
(2)
4. Align the timing gears as shown in Figure 6-98.
5. Reinstall the idler gear and idler gear shaft. Be
sure the oil hole in the bushing is facing toward
the top of the engine.
6. Ensure all three timing marks
(Figure 6-98, (A, B, and C)) are aligned.
0002181

Figure 6-99
2. Reinstall the dowels (Figure 6-99, (3)) and a
new O-ring (Figure 6-99, (2)).

TNV IDI Service Manual 6-61

ENGINE Cylinder Block

IMPORTANT
Be sure to align the flats on the oil pump
with the flats on the crankshaft gear.
3. Reinstall the timing gear case cover. (1)
4. Reinstall and tighten the gear case cover bolts.
5. Reinstall the crankshaft pulley.
6. Reinstall the washer and bolt. Tighten to the
specified torque. See Special Torque Chart on
(2)
page 6-14 for specifications.

Installation of Oil Pan

1. Reinstall the oil pickup tube (Figure 6-100, (1))
and a new O-ring (Figure 6-100, (2)).
0002184

Figure 6-101

Final Assembly of Engine

1. Reinstall the starter motor.
2. Reinstall the cylinder head. See Reassembly of
Cylinder Head on page 6-31.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
(2) 5. Reinstall the alternator.
(1) 6. Reconnect and adjust the throttle cable.
7. Reconnect all electrical connections.
0002185
8. Fill the engine with oil and coolant.
Figure 6-100 9. Reconnect the battery cables, negative (-) cable
2. Apply a continuous bead of ThreeBond Liquid last.
Gasket No. 1212, Yanmar Part No.
977770-01212 to the mounting surface of the oil
pan (Figure 6-101, (2)) and crankcase
extension (if equipped) (Figure 6-101, (1)). Be
sure to circle each bolt hole.
3. If equipped, reinstall the crankcase extension
(Figure 6-101, (1)). Reinstall the oil pan and
tighten the bolts securely.

6-62 TNV IDI Service Manual

TNV IDI Service Manual
Section 7

FUEL SYSTEM
Page
Before You Begin Servicing ............................................................ 7-3
Introduction...................................................................................... 7-5
Fuel Injection Pump................................................................... 7-5
Stop Solenoid ............................................................................ 7-6
Fuel System Specifications ............................................................. 7-7
Special Torque Chart................................................................. 7-7
Test and Adjustment Specifications .......................................... 7-7
Special Service Tools ...................................................................... 7-8
Measuring Instruments .................................................................... 7-8
Fuel System Diagram ...................................................................... 7-9
Fuel System Components ............................................................. 7-10
Fuel Injection Lines ....................................................................... 7-11
Removal of High-Pressure Fuel Injection Lines ...................... 7-11
Installation of High-Pressure Fuel Injection Lines ................... 7-12
Removal of Fuel Return Line................................................... 7-12
Installation of Fuel Return Line................................................ 7-13
Fuel Injection Pump....................................................................... 7-13
Removal of Fuel Injection Pump.............................................. 7-13
Installation of Fuel Injection Pump........................................... 7-16
Checking and Adjusting Fuel Injection Timing .............................. 7-19
Checking Fuel Injection Timing ............................................... 7-19
Adjusting Fuel Injection Timing................................................ 7-23
Fuel Injectors................................................................................. 7-23
Removal of Fuel Injectors........................................................ 7-23
Testing of Fuel Injectors .......................................................... 7-24

TNV IDI Service Manual 7-1

FUEL SYSTEM
Disassembly and Inspection of Fuel Injectors .......................... 7-27
Adjusting Fuel Injector Pressure .............................................. 7-28
Reassembly of Fuel Injectors ................................................... 7-29
Installation of the Fuel Injectors................................................ 7-29

7-2 TNV IDI Service Manual

Before You Begin Servicing FUEL SYSTEM

BEFORE YOU BEGIN A WARNING

SERVICING
A WARNING

To prevent possible eye injury, always

wear SAFETY GLASSES while servicing
ENTANGLEMENT HAZARD! the engine.
0000013en
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch A CAUTION
when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie FLYING OBJECT HAZARD!
back long hair, and keep your hands, • ALWAYS wear eye protection when
other body parts and clothing away servicing the engine and when using
from moving / rotating parts. compressed air or high-pressure
• Failure to comply could result in death water. Dust, flying debris, compressed
or serious injury. air, pressurized water or steam may
0000010en
injure your eyes.
• Failure to comply may result in minor
A WARNING or moderate injury.
0000003en

A CAUTION

FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
cleaners, primers, sealants and PINCH HAZARD!
sealant removers. Carefully rotate the alternator toward the
cylinder block while loosening the
• Failure to comply could result in death
V-belt. Failure to comply may result in
or serious injury.
minor or moderate injury.
0000014en
0000014en

TNV IDI Service Manual 7-3

FUEL SYSTEM Before You Begin Servicing

CAUTION CAUTION
• NEVER remove or attempt to remove Remove or install the high-pressure fuel
the tamper-proof devices from the injection lines as an assembly whenever
full-load fuel adjusting screw or the possible. Disassembling the
high-speed throttle limit screw on the high-pressure fuel injection lines from
fuel injection pump and governor the retainers or bending any of the fuel
assembly. These adjustments have lines will make it difficult to reinstall the
been made at the factory to meet all fuel lines.
applicable emissions regulations and 0000047en
then sealed.
• NEVER attempt to make any CAUTION
adjustments to these sealed
After marking the position of the pump
adjustment screws. If adjustments are
drive gear, do not rotate the engine
required, they can be made only by a
crankshaft. Rotating the crankshaft will
qualified fuel injection shop that will
cause the fuel injection pump to become
ensure the injection pump continues
misaligned.
to meet all applicable emissions
0000048en
regulations and then replace the
tamper-proof seals.
• Tampering with or removing these CAUTION
devices may void the “Yanmar Limited Do not rotate the crankshaft with the
Warranty.” injection pump removed.
0000146en 0000083en

CAUTION CAUTION
Never use a steel wire brush to clean The fuel return line is a one-piece
fuel injectors. Damage to the nozzle and assembly. Use care not to bend or twist
other components is likely to result. the fuel return line.
0000172en 0000171en

CAUTION
Do not loosen or remove the four bolts
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
drive gear from the hub. Correct fuel
injection timing will be very difficult or
impossible to achieve.
0000031en

7-4 TNV IDI Service Manual

Introduction FUEL SYSTEM

INTRODUCTION

(4)
(3)
(1)

(2)

0002238
(5) (6)

Figure 7-1

This section of the Service Manual describes the The Yanmar ML Fuel Injection Pump is an in-line
procedures necessary to remove, install, and time type pump which consists of a fuel supply plunger
the ML fuel injection pump and its associated (Figure 7-1, (1)) for each cylinder, a camshaft
system components. This fuel injection pump is (Figure 7-1, (2)), and a pump housing
representative of the fuel injection pumps used on (Figure 7-1, (3)). A delivery valve (Figure 7-1, (4))
other TNV IDI model engines. connects to a high-pressure fuel line for each
cylinder. The fuel injection pump housing contains
Fuel Injection Pump a governor (Figure 7-1, (5)).
Note: If the ML fuel injection pump itself Fuel from the fuel tank to the fuel injection pump is
requires servicing, it must be taken to an delivered by a low-pressure electric fuel pump. On
authorized Yanmar FIE (Fuel Injection a few special models, a mechanical fuel pump is
Equipment) repair facility. used instead of an electric pump. The mechanical
The following describes the features of the ML fuel fuel pump is mounted to the fuel injection pump
injection pump, manufactured by Yanmar. housing in place of the cover plate
(Figure 7-1, (6)).
The fuel injection pump is a very important
component of the engine. It is capable of making Fuel to be injected into the cylinders is pressurized
very precise fuel delivery adjustments according to by the up and down motion of each
the varied loads applied to the engine. camshaft-driven plunger, and is then supplied by
the high-pressure fuel lines to the respective fuel
All of the fuel injection pump components are very injector.
precisely machined. It is extremely important to
follow good service practices and maintain
cleanliness when servicing the fuel injection pump.

TNV IDI Service Manual 7-5

FUEL SYSTEM Introduction

Stop Solenoid
CAUTION
The ML fuel injection pumps are equipped with a
• NEVER remove or attempt to remove
stop solenoid that controls the fuel flow inside the
the tamper-proof devices from the
fuel injection pump.
full-load fuel adjusting screw or the
high-speed throttle limit screw on the With the starter switch in the OFF position, no
fuel injection pump and governor current flows to the stop solenoid and the solenoid
assembly. These adjustments have plunger is extended holding the fuel injection pump
been made at the factory to meet all fuel rack in the “closed” position and not allowing
applicable emissions regulations and fuel to flow through the injection pump and to the
then sealed. engine.
• NEVER attempt to make any When the starter switch is turned to the start
adjustments to these sealed position, the “pull coil” (36.5 Amp draw / white wire)
adjustment screws. If adjustments are inside the solenoid is activated and pulls the
required, they can be made only by a solenoid plunger into the solenoid. This releases
qualified fuel injection shop that will the fuel injection pump fuel rack, allowing fuel to
ensure the injection pump continues flow through the injection pump and allowing the
to meet all applicable emissions engine to start and run.
regulations and then replace the
tamper-proof seals. When the starter switch is returned to the ON or
• Tampering with or removing these RUN position, the “pull coil” no longer receives
devices may void the “Yanmar Limited current and the “hold coil” (0.5 Amp draw / red wire)
Warranty.” inside the solenoid is activated. The “hold coil”
holds the solenoid plunger in the RUN position,
0000146en
allowing fuel to continue flowing and the engine to
The fuel injector is essentially a spring-loaded continue running.
valve. When fuel pressure from the fuel injection
To stop the engine, the key switch is turned to the
pump reaches a pre-determined level, the pintle
OFF position. Current no longer flows to the stop
(valve) is forced off its seat and fuel is atomized as
solenoid “hold coil,” and the solenoid plunger
it passes between the pintle and seat. The timing
extends and moves the injection pump fuel rack to
and quantity of the fuel injected into the cylinder is
the “closed” position, and shutting off the fuel flow
controlled by the fuel injection pump and governor
and stopping the engine.
assembly.
Failure of the stop solenoid could result in the
engine not starting, the engine stopping suddenly
or the engine continuing to run with the key switch
returned to the ON or RUN position, or the engine
failing to stop when the key switch is turned to the
OFF position. Use a VOA multimeter or continuity
light to check for a good ground and 12V at the stop
solenoid in the correct sequence.

7-6 TNV IDI Service Manual

Fuel System Specifications FUEL SYSTEM

FUEL SYSTEM SPECIFICATIONS

Special Torque Chart
Lubricating Oil Application
Component Tightening Torque
(Thread Portion and Seat Surface)
36.1 - 43.5 ft·lb
Fuel Injector (49 - 59 N·m, Not Applied
5.0 - 60 kgf·m)
44 - 51 ft·lb
Fuel Pump Drive Gear Nut (59 - 69 N·m; Not Applied
6 - 7 kgf·m)
22 - 25 ft·lb
High -Pressure Fuel Injection Line Nuts (29 - 34 N·m; Not Applied
3.0 - 3.5 kgf·m)
18 - 24 ft·lb
Fuel Return Line Nuts (24 - 33 N·m; Not Applied
2.5 - 3.3 kgf·m)
17 - 21 ft·lb
Fuel Injection Pump Mounting Nuts (23 - 28 N·m; Not Applied
2.3 - 2.9 kgf·m)
21.4 - 36.1 ft·lb
Fuel Injector Nozzle Case Nut (29 - 49 N·m; Not Applied
3.0 - 5.0 kgf·m)

Test and Adjustment Specifications

Fuel Injector Pressure Fuel Injection Timing
1784 - 1929 psi
See Checking and Adjusting Fuel Injection Timing on
(12.3 - 13.3 MPa;
page 7-19
125 - 136 kgf/cm2)

Note: Fuel injector pressures given are for used parts. New injectors (5 hours operation or less) will read
approximately 72.5 psi (0.5 MPa; 5 kgf/cm2) higher.

TNV IDI Service Manual 7-7

FUEL SYSTEM Special Service Tools

SPECIAL SERVICE TOOLS

Note: Tools not having Yanmar part numbers must be acquired locally.

No. Tool Name Application Illustration

For tightening nuts and bolts to the specified

1 Torque Wrench (Locally Available)
torque

0000840

MEASURING INSTRUMENTS
No. Instrument Name Application Illustration

For observing injection spray pattern of fuel

1 Fuel Injector Tester (Locally Available) injection nozzle and measuring injection
OFF
P-

OFF
E-
ON AG
-G

pressure

2 “Spill-Timing” Tool (Shop Fabricated)* Used to set fuel injection timing

* Make from a short piece of the end of a high-pressure fuel line, a high-pressure fuel line nut, and a short piece of
clear plastic tubing (a thin nozzle from an aerosol spray can works well). Drill out the end of the fuel line to accept
the nozzle. Use a small amount of silicone sealant to seal the nozzle into the fuel line.

7-8 TNV IDI Service Manual

Fuel System Diagram FUEL SYSTEM

FUEL SYSTEM DIAGRAM

(9)

(8)

(10)

(12)
(7)
(11)

(1)

(3)
(6)

(5) (2)
(4)
0001058A

Figure 7-2

1 – Diesel Fuel Supply 6 – Fuel Filter

2 – Fuel Filter / Water Separator 7 – Fuel Injection Pump
3 – Mechanical Fuel Pump (Used in place of the 8 – High-Pressure Fuel Injection Lines
electric fuel pump on some models) 9 – Fuel Injectors
4 – Electric Fuel Pump (Used on models 10 – Fuel Return from Fuel Injectors
without mechanical fuel pump) 11 – Air Bleed Orifice
5 – Low-Pressure Fuel Supply Lines 12 – Fuel Return to Tank

TNV IDI Service Manual 7-9

FUEL SYSTEM Fuel System Components

FUEL SYSTEM COMPONENTS

(19)

(18) (1)

(17) (2)

(3)

(16)
(7)
(15) (4)

(6)
(7)
(5)
(11)

(14)

(10)

(9)
(8)

(13)
(12)
0002208

Figure 7-3

7-10 TNV IDI Service Manual

Fuel Injection Lines FUEL SYSTEM
1 – High-Pressure Fuel Injection Lines FUEL INJECTION LINES
2 – Fuel Return Line Nut
3 – Fuel Return Line
4 – Fuel Injector
Removal of High-Pressure Fuel
5 – Gasket Injection Lines
6 – Protector
7 – Fuel Return Hose CAUTION
8 – Fuel Injection Pump Drive Gear Nut
9 – Lock Washer Remove or install the high-pressure fuel
10 – Fuel Injection Pump Drive Gear Assembly injection lines as an assembly whenever
(DO NOT remove or loosen the four bolts possible. Disassembling the
that fasten the injection pump drive gear to high-pressure fuel injection lines from
the injection pump drive gear hub!) the retainers or bending any of the fuel
11 – Fuel Injection Pump lines will make it difficult to reinstall the
12 – Lube Oil Line fuel lines.
13 – Mechanical Fuel Supply Pump (Optional on
0000047en
some models)
14 – Fuel Return Fitting Note: To prevent “rounding” the fuel line nuts
15 – Low Pressure Fuel Inlet Fitting always use a “line” or “flare nut” wrench.
16 – Fuel / Water Separator
17 – Electric Fuel Supply Pump 1. Close any fuel valves in the fuel supply line.
18 – Fuel Filter
2. Clean the area to keep contaminants from
19 – Fuel Filter Mount
entering the fuel system.
3. Place a drain pan under the fuel injection pump
to catch any spillage.
4. Loosen the fuel line nuts at the fuel injection
pump.
5. Next, loosen the fuel line nuts at the fuel
injectors. Use one wrench to hold the fuel return
line nut and fuel return line from rotating. Use a
second wrench to loosen the fuel line nut
(Figure 7-4). Repeat with the remaining fuel
injectors.

0002237

Figure 7-4

TNV IDI Service Manual 7-11

FUEL SYSTEM Fuel Injection Lines

6. Finish loosening all the fuel line nuts and

remove the high-pressure fuel lines as an
assembly being careful not to bend any of the
fuel lines. Be sure to protect the fuel system
from contamination by plugging or covering all
open connections.
7. Plug or cap all openings to minimize leakage
and prevent contamination. 0002237

Installation of High-Pressure Fuel

Figure 7-5
Injection Lines
Removal of Fuel Return Line
CAUTION 1. Clean the area to keep contaminants from
Remove or install the high-pressure fuel entering the fuel system.
injection lines as an assembly whenever 2. Remove the high-pressure fuel injection lines
possible. Disassembling the as an assembly. See Removal of High-Pressure
high-pressure fuel injection lines from Fuel Injection Lines on page 7-11.
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
CAUTION
fuel lines.
0000047en
The fuel return line is a one-piece
assembly. Use care not to bend or twist
Note: To prevent “rounding” the fuel line nuts the fuel return line.
always use a “line” or “flare nut” wrench. 0000171en

1. Start all the fuel line nuts by hand. Then use a

wrench to just “snug” all the fuel line nuts.
(1)
2. Tighten the fuel line nuts on the fuel injection
pump to the specified torque. See Special (2)
Torque Chart on page 7-7.
3. When tightening the fuel line nuts on the fuel
injectors, use one wrench to hold the fuel return (3)
line nut and fuel return line from rotating. Use a
second wrench to tighten the fuel line nuts
(Figure 7-5). See Special Torque Chart on (4)
page 7-7.

Figure 7-6
3. Remove all fuel return line nuts
(Figure 7-6, (2)) from the injectors
(Figure 7-6, (4)).

7-12 TNV IDI Service Manual

Fuel Injection Pump FUEL SYSTEM
4. Remove the fuel return hose from the fuel
return fitting on the fuel injection pump.
5. Carefully remove the fuel return line assembly
(Figure 7-6, (3)).
6. Remove and discard the copper gasket
(3) (2)
(Figure 7-6, (1)) from each fuel injector.
7. Plug or cap all openings to minimize leakage
and prevent contamination.

Installation of Fuel Return Line (1)

1. Install a new copper gasket on each fuel
injector.

CAUTION (4) 0000163A

The fuel return line is a one-piece
assembly. Use care not to bend or twist Figure 7-7
the fuel return line.
3. Close any fuel valves in the fuel supply line.
0000171en
4. Place a drain pan under the fuel injection pump
2. Carefully reinstall the fuel return line assembly. to catch any spillage.
3. Reinstall and hand-tighten the fuel return line 5. Clean the area to keep contaminants from
nuts. entering the fuel system.
4. Tighten the fuel return line nuts to the specified 6. Remove the high-pressure fuel injection lines
torque. See Special Torque Chart on page 7-7. as an assembly. See Removal of High-Pressure
5. Reinstall the fuel return hose. Fuel Injection Lines on page 7-11.
6. Reinstall the high-pressure fuel injection line 7. Disconnect the fuel return lines from the fitting
assembly. See Installation of High-Pressure on the fuel injection pump (Figure 7-8, (1)).
Fuel Injection Lines on page 7-12. Plug the open ends of the lines to minimize
leakage and prevent contamination.

FUEL INJECTION PUMP

Removal of Fuel Injection Pump
1. Loosen the cooling fan V-belt.
2. Remove the engine cooling fan guard (if
equipped), engine cooling fan (Figure 7-7, (2)),
spacer (Figure 7-7, (3)) if equipped, V-pulley
(Figure 7-7, (4)) and cooling fan V-belt
(Figure 7-7, (1)).

TNV IDI Service Manual 7-13

FUEL SYSTEM Fuel Injection Pump

12. Remove the lube oil line (Figure 7-9, (1)) from
the fuel injection pump and cylinder block.
IMPORTANT
Take care to not damage or bend the lube
oil line.

(2)

(1)

(3)

0002239

Figure 7-9
0002210

13. Remove the fuel injection pump drive gear

Figure 7-8
access cover (Figure 7-10, (1)) from the gear
8. Remove the fuel supply line (Figure 7-8, (2)) case cover (Figure 7-10, (2)).
from the fitting on the fuel injection pump. Note: The cover is secured with an adhesive
9. Plug or cap all openings to minimize leakage sealant. Use a gasket scraper to
and prevent contamination. separate the cover from the gear case
cover.
10. Remove the throttle cable from the fuel injection
pump.
11. Separate the stop solenoid wiring connector
(Figure 7-8, (3)). (2)

(1)
0002211

Figure 7-10
14. To aid in reassembly, make reference marks
(Figure 7-11, (1)) on the drive gear and idler
gear.

7-14 TNV IDI Service Manual

Fuel Injection Pump FUEL SYSTEM

CAUTION
After marking the position of the pump
drive gear, do not rotate the engine
crankshaft. Rotating the crankshaft will
cause the fuel injection pump to become
misaligned. (3)
0000048en

(1)

(2)
Figure 7-12

(1) 16. Hold the gear train stationary using a large

socket wrench on the crankshaft pulley bolt.
Loosen the fuel injection pump drive gear
retaining nut (Figure 7-12, (1)) and turn it out to
the end of the fuel injection pump shaft.
0002096
17. Remove the injection pump drive gear and hub
Figure 7-11
from the injection pump drive shaft as an
assembly using an appropriate gear puller
CAUTION (Figure 7-13).
Do not loosen or remove the four bolts
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
drive gear from the hub. Correct fuel
injection timing will be very difficult or
impossible to achieve.
0000031en

15. Do not loosen or remove the four bolts

(Figure 7-12, (3)) holding the pump drive gear
to the hub. Only remove the single drive gear
nut (Figure 7-12, (1)) and washer
(Figure 7-12, (2)), leaving the hub attached to
the gear. 0002209

Figure 7-13
Note: The injection pump drive gear can be
removed from the gear case; however, it
is best to let it remain in the gear case.

TNV IDI Service Manual 7-15

FUEL SYSTEM Fuel Injection Pump

18. Once the fuel injection pump drive gear and 20. Remove the three nuts fastening the fuel
hub assembly have “popped” loose from the injection pump to the gear case. Remove the
tapered fuel injection pump drive shaft, carefully fuel injection pump. Leave the fuel injection
remove the drive gear nut (Figure 7-14, (1)) pump drive gear in the gear case and meshed
and lock washer (Figure 7-14, (2)). with the idler gear.

CAUTION
Do not rotate the crankshaft with the
injection pump removed.
0000083en

21. If the fuel injection pump requires servicing, it

must be sent to an authorized Yanmar FIE
repair facility for repair and calibration, or
replaced with a new fuel injection pump.
(1)

CAUTION
• NEVER remove or attempt to remove
(2) the tamper-proof devices from the
full-load fuel adjusting screw or the
0002183A
high-speed throttle limit screw on the
Figure 7-14 fuel injection pump and governor
assembly. These adjustments have
19. Locate the mark (Figure 7-15, (1)) stamped
been made at the factory to meet all
into the upper outside mounting boss of the fuel
applicable emissions regulations and
injection pump. Highlight this mark and make a
then sealed.
corresponding mark on the gear case or front
plate. • NEVER attempt to make any
adjustments to these sealed
adjustment screws. If adjustments are
required, they can be made only by a
qualified fuel injection shop that will
ensure the injection pump continues
to meet all applicable emissions
regulations and then replace the
tamper-proof seals.
• Tampering with or removing these
(1) devices may void the “Yanmar Limited
Warranty.”
0000146en

0002416
Installation of Fuel Injection Pump
Figure 7-15 1. Ensure the fuel injection pump drive gear is
aligned with the idler gear using the reference
marks made earlier (Figure 7-16, (1)).

7-16 TNV IDI Service Manual

Fuel Injection Pump FUEL SYSTEM
4. Align the key on the fuel injection pump shaft
with the keyway in the fuel injection pump drive
gear hub. Reinstall the fuel injection pump into
the fuel injection pump drive gear and gear
housing. Install the pump retaining nuts
finger-tight.
5. Reinstall the fuel injection pump drive gear lock
washer (Figure 7-18, (2)) and nut
(Figure 7-18, (1)). Do not lubricate threads of
(1)
the nut or shaft. Hold the crankshaft pulley bolt
with a socket wrench and tighten the drive gear
nut to the specified torque. See Special Torque
Chart on page 7-7.
0002096

Figure 7-16
2. If installing the fuel injection pump on an engine
with the front gear case cover removed, the fuel
injection pump drive gear can be aligned with
the idler gear by aligning the stamped marks
(Figure 7-17, (A, B, C)) on the fuel injection
pump drive gear, idler gear, and crankshaft
drive gear. Ensure all three timing marks
(A, B, C) are aligned.
(1)
(1)
(2)
(2)
(3)
B
B
C C 0002183A

A
A Figure 7-18
(5)
6. Align the reference marks (Figure 7-19, (1))
(4)
made during disassembly on both the fuel
0002190
injection pump mounting flange and gear case.
1 – Fuel Injection Pump Drive Gear
2 – Camshaft Drive Gear If installing a replacement fuel injection pump,
3 – Optional Accessory Drive Gear align the manufacturer-applied mark on the
4 – Crankshaft Drive Gear pump mounting flange with the mark made on
5 – Idler Gear the timing gear cover.
Figure 7-17
3. Install a new O-ring on the fuel injection pump
mounting flange. Apply some grease to the
O-ring to hold it in place during the installation
of the fuel injection pump.
Note: Ensure the tapered surface of the fuel
injection pump shaft is clean and dry.

TNV IDI Service Manual 7-17

FUEL SYSTEM Fuel Injection Pump

11. Reinstall the lube oil line (Figure 7-20, (1)).

(1)

0002416

Figure 7-19
7. Tighten the fuel injection pump retaining nuts to 0002239

specification. See Special Torque Chart on Figure 7-20

page 7-7.
8. Reconnect the fuel supply and return lines to 12. Apply ThreeBond Liquid Gasket No. 1212,
Yanmar Part No. 977770-01212, or equivalent
the fuel injection pump.
sealant to the sealing surface of the fuel
9. Reconnect the throttle linkage and stop injection pump drive gear access cover.
solenoid connector. Reinstall the cover on the front of the gear case
10. If installing a new or recalibrated fuel injection and tighten the bolts.
pump, check the fuel injection timing before 13. Reinstall the fuel injection high-pressure lines.
completing the installation of the fuel injection See Installation of High-Pressure Fuel Injection
pump. See Checking and Adjusting Fuel Lines on page 7-12.
Injection Timing on page 7-19.
Note: While it is not required to check the IMPORTANT
injection timing when reinstalling the When installing a new or repaired fuel
original fuel injection pump, it is injection pump, add 5 - 7 oz (150 - 200 cc)
recommended that it be done. of new, clean engine oil to the fuel injection
pump at the fill plug located in the upper
outside section of the governor housing.
14. Reinstall the coolant pump V-pulley
(Figure 7-21, (4)), spacer (Figure 7-21, (3)) (if
equipped) and engine cooling fan
(Figure 7-21, (2)).

7-18 TNV IDI Service Manual

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
2. Clean the area around the fuel injection pump.
Note: The stop solenoid must be removed to
allow fuel to flow through the fuel
(3)
injection pump.
(2)
3. Remove two screws (Figure 7-22, (1)).
Remove the stop solenoid (Figure 7-22, (2))
and O-ring (Figure 7-22, (3)).

(1)

(4) 0000163A (2)

Figure 7-21 (3)
(1)
15. Reinstall the cooling fan V-belt
(Figure 7-21, (1)). Adjust as described in
Check and Adjust Cooling Fan V-Belt on
page 5-27.
16. Reinstall the cooling fan guard (if equipped).
17. Prime the fuel system. See Priming the Fuel
System on page 4-12.
18. Operate the engine and check for fuel and lube
oil leaks. 0002468

Figure 7-22
CHECKING AND ADJUSTING 4. Set the throttle to the HIGH-IDLE position.
FUEL INJECTION TIMING 5. Using a wrench on the crankshaft pulley bolt,
rotate the crankshaft in a clockwise direction
Note: The following procedure is performed on while looking through the flywheel inspection
the No. 1 cylinder. While checking and port (Figure 7-23, (1)). Rotate the crankshaft
adjusting the timing on only No. 1 until the injection timing marks on the flywheel
cylinder is usually sufficient, the same are visible for No. 1 cylinder.
procedure can be performed on any or
all cylinders.

Checking Fuel Injection Timing

Note: Some fuel may drain from the fuel
injection pump during this process. Make
provisions to contain and dispose of any
such spillage.
1. Ensure the fuel injection pump is primed with
fuel. See Priming the Fuel System on
page 4-12.

TNV IDI Service Manual 7-19

FUEL SYSTEM Checking and Adjusting Fuel Injection Timing

(3)
(2)
(4)
(1)

1
(5)

00020
(1)
0002071A

Figure 7-23
1 – 15° BTDC (Before Top Dead Center)
6. Typical flywheel markings are as shown in 2 – 20° BTDC
(Figure 7-24). 3 – 25° BTDC
Note: A typical flywheel will have multiple 4 – Direction of Rotation
timing grids depending on the number of 5 – TDC (Top Dead Center)
cylinders. Any grid and its corresponding Figure 7-24
cylinder can be used to check the fuel
injection timing. 7. The flywheel shown in (Figure 7-24) is for a
Yanmar “Standard Specification” IDI engine.
Flywheels used on some “OEM Specific” IDI
engines may be marked differently. You should
contact that specific OEM for information on the
identification of the timing marks.
Note: The TDC (Top Dead Center) mark can
be identified by the cylinder numbers
stamped near the TDC mark
(Figure 7-24, (5)) on the flywheel.
8. If you are uncertain as to the timing degree
designation of the timing marks on the flywheel
timing grid, you can determine the timing
degree designation by measuring the timing
grid.
• First measure the distance between two of the
“longer” marks on the timing grid. (They are 5°
apart.) Then measure the distance from the
TDC mark to the first “longer” mark on the
timing grid. Divide that measurement by the
distance between the two “longer” marks. The
resulting answer will tell you how many
degrees there are between the TDC mark and
the first “longer” mark.

7-20 TNV IDI Service Manual

Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
• EXAMPLE: If the distance between the two
“longer” marks is approximately 2.0 cm and the (2)
distance from the TDC mark is approximately (1)
4.0 cm, the answer is approximately 2. This
indicates there is 10° (2 x 5°) between the TDC
mark and the first “longer” mark on the timing
grid. That means the first “longer” mark on the
timing grid indicates 10° BTDC, the second
“longer” mark indicates 15° BTDC and the third
timing mark indicates 20°. If the answer is 3,
that indicates there is 15° (3 x 15°) between
0002142
the TDC mark and the first “longer” mark and Figure 7-26
that the first “longer” mark indicates 15° BTDC
with the second and third “longer” marks 10. Highlight the target timing mark
indicating 20° BTDC and 25° BTDC (Figure 7-26, (1)), (Figure 7-27, (1)) on the
respectively. flywheel timing grid as determined in the Fuel
9. Highlight the timing reference mark on the Injection Timing Chart below.
flywheel housing (Figure 7-25, (2)) or engine
back plate (Figure 7-26, (2)). Highlight the TDC
(Top Dead Center) mark (Figure 7-25, (1)),
(1)
(Figure 7-26, (1)) on the flywheel.
(2)

(1)
(2)
1

0002066

Figure 7-27
0002065A

Figure 7-25
Fuel Injection Timing Chart
Model VM CH VH
Engine Speed (rpm) 2000-2100 2200 2300-2600 2700-3000 3000-3600 3100-3400 3500-3600
2TNV70 Injection 15° 16° 18° - - -
3TNV70 Timing BTDC 15° 16° 18° 21° 20° 21°
3TNV76 ±1° 15° 16° 18° 21° 20° 21°

11. Remove all high-pressure fuel injection lines.

See Removal of High-Pressure Fuel Injection
Lines on page 7-11.
12. Turn on all fuel supply valves.

TNV IDI Service Manual 7-21

FUEL SYSTEM Checking and Adjusting Fuel Injection Timing

Note: As the injection pump injects fuel to a Note: The fuel injection pump injects fuel to a
cylinder only once every two engine cylinder only once every two engine
revolutions, it may be necessary to rotate revolutions.
the crankshaft twice to see fuel being
16. “Flick” the nozzle of the timing tool with a finger
pumped from the timing tool or delivery
to remove bubbles and establish a fuel level of
valve of the cylinder you are using to
approximately 1/2 the height of the nozzle.
check injection timing.
17. Very slowly rotate the crankshaft clockwise until
13. Install the “spill-timing” tool (Figure 7-28, (1)) the fuel level in the nozzle of the “spill timing”
onto the delivery valve for the cylinder being tool, or in the delivery valve, just begins to
checked. See Measuring Instruments on move. Immediately stop rotating the crankshaft.
page 7-8.
18. Check the position of the flywheel target timing
Note: If a timing tool is not available, timing can mark (Figure 7-27, (1)) on the flywheel grid in
be checked by watching the fuel in the relation to the timing reference mark
delivery valve itself. (Figure 7-27, (2)) on the flywheel housing or
back plate. If the two marks are aligned, the fuel
(1) injection timing is correct. If the marks do not
align, the fuel injection timing must be adjusted.
See Adjusting Fuel Injection Timing on
page 7-23.
19. Repeat Steps 13-17 two or three times to verify
timing.
20. Remove the “spill-timing” tool.
21. Reinstall the shut-off solenoid.
22. Reinstall the high-pressure fuel injection lines.
See Installation of High-Pressure Fuel Injection
Lines on page 7-12.
23. Replace the flywheel inspection port cover.
0000592A 24. Prime the fuel system. Operate the engine and
Figure 7-28 check for leaks.

Note: The following references to the direction

of rotation are made facing the cooling
fan end of the engine and are adjusted
by turning the crankshaft.
14. Slowly rotate the crankshaft clockwise using a
wrench on the crankshaft pulley bolt until fuel is
pumped from the nozzle of the “spill-timing” tool
or delivery valve.
15. Slowly rotate the crankshaft clockwise
approximately two more revolutions until the
timing grid on the flywheel (for the cylinder
being checked) is at approximately 30° BTDC.

7-22 TNV IDI Service Manual

Fuel Injectors FUEL SYSTEM
Adjusting Fuel Injection Timing 5. Adjust the position of the fuel injection pump
and tighten the fuel injection pump mounting
If the timing marks did not align when performing nuts.
the Checking Fuel Injection Timing on page 7-19,
the following steps must be performed to properly 6. Recheck the fuel injection timing. Repeat the
time the engine. fuel injection timing and adjustment procedures
until the timing is correct. See Checking Fuel
1. Leave the “spill-timing” tool installed in the fuel Injection Timing on page 7-19 and repeat steps
injection pump. 3 - 6.
2. Determine if the timing is “advanced” or 7. Remove the “spill-timing” tool.
“retarded” by comparing the position of the 8. Reinstall the shut-off solenoid.
target timing mark on the flywheel grid
(Figure 7-29, (1)) with the timing mark on the 9. Reinstall the high-pressure fuel injection lines.
flywheel housing or back plate See Installation of High-Pressure Fuel Injection
(Figure 7-29, (2)). Lines on page 7-12.
10. Replace the flywheel inspection port cover.
11. Prime the fuel system. Operate the engine and
check for leaks.
(2) (1)

FUEL INJECTORS
Removal of Fuel Injectors
1. Close any fuel valves in the fuel supply line.
2. Clean the area around the fuel injection pump
and fuel injectors to keep contaminants from
0002469 entering the engine or fuel system.
Figure 7-29 3. Remove the high-pressure fuel injection lines
as an assembly. See Removal of High-Pressure
3. Loosen the nuts fastening the fuel injection Fuel Injection Lines on page 7-11.
pump to the gear case.
4. Remove nut (Figure 7-30, (1)). Remove the
4. If the injection timing was less than the target fuel return line (Figure 7-30, (2)) and copper
timing, the injection timing is “retarded” and will washer (Figure 7-30, (3)) from the fuel
need to be “advanced.” injectors. See Removal of Fuel Return Line on
To “advance” the injection timing: Rotate the page 7-12.
top of the fuel injection pump away from the Note: The fuel injectors used on IDI engines
engine. screw into the cylinder head.
If the injection timing was greater than the target 5. Remove the fuel injectors (Figure 7-30, (4)).
timing, the injection timing is “advanced” and will
need to be “retarded.”
To “retard” the injection timing: Rotate the top
of the fuel injection pump toward the engine.

TNV IDI Service Manual 7-23

FUEL SYSTEM Fuel Injectors

(1) Testing of Fuel Injectors

(2) CAUTION
Never use a steel wire brush to clean
(3) fuel injectors. Damage to the nozzle and
other components is likely to result.
(4)
0000172en

(6) 1. Thoroughly clean the fuel injector nozzle using

clean diesel fuel and a brass wire brush.
(5) 2. Visually inspect the fuel injectors and nozzle
protectors for deposits or damage. Clean, repair
or replace as necessary.
Note: Test the fuel injector using an injection
nozzle tester. Operate the tester
0002213
following the information provided by the
tester manufacturer. Use clean, filtered
Figure 7-30 fuel or FIE calibration fluid for the test.
6. Remove the injector nozzle gaskets 3. Using the correct adapter, connect a fuel
(Figure 7-30, (5)) and protector injector to a nozzle tester. Aim the fuel injector
(Figure 7-30, (6)) from the cylinder head. into a suitable container to catch the fuel spray
(Figure 7-31).

OFF
P-

OFF
E -
ON AG
-G

Figure 7-31

7-24 TNV IDI Service Manual

Fuel Injectors FUEL SYSTEM
5. Pump the operating lever slowly to hold the
A WARNING pressure steady at a point just below the
opening pressure and hold that pressure for five
seconds. Observe the injector to see that it is
sealing properly and is not “dripping.” If fuel
leaks from the return line fitting, check that the
nozzle case nut is tight. Service or replace the
HIGH-PRESSURE HAZARD!
injector if fuel continues to leak from either the
• Avoid skin contact with the return line fitting or nozzle.
high-pressure diesel fuel spray caused
6. Pump the operating lever more rapidly to
by a fuel system leak such as a broken
repeatedly “pop” the injector and observe the
fuel injection line. High-pressure fuel
spray pattern. The pattern should be a very fine
can penetrate your skin and result in
uniform spray. If dripping or an uneven pattern
serious injury. If you are exposed to
is seen, service or replace the injector. See
high-pressure fuel spray, obtain
Fuel Injector Test Results on page 7-26.
prompt medical treatment.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
0000008en

A WARNING

To prevent possible eye injury, always

wear SAFETY GLASSES while servicing
the engine.
0000013en

4. Pump the operating lever of the tester slowly,

observing the pressure reading at the point
where the fuel injector begins spraying fuel.
See Test and Adjustment Specifications on
page 7-7 for correct pressure readings.
Note: Opening pressure of a new fuel injector
will be approximately 72.5 psi (0.5 MPa;
5 kgf/cm2) higher than one that has been
operated for five hours or longer.

TNV IDI Service Manual 7-25

FUEL SYSTEM Fuel Injectors

Fuel Injector Test Results

A B C D E

Injection Pattern

0001742
0001743 0001744

120 120 120 120 120

0 0 0 0 0

Pressure Gauge 0001748

0001747 0001749 0001750 0001751
Reading Gauge needle Gauge needle Gauge needle Although the Pressure does not
fluctuates around fluctuates around stays at a position gauge needle increase even
the valve opening the valve opening near the valve reaches the valve when the tester
pressure. pressure. opening pressure. opening pressure, lever is operated.
the pressure drop
is large.
Although atomized
Atomization is Bar shape with
Atomization 5°-10° cone and (burner like
excessively excessive after Drops.
Pattern roughly uniform. shape), the needle
one-sided. drops.
does not pulsate.
Sticking of needle.
Excessively
Normally caused
Caused by Damage to the damaged or worn
by carbon
excessive carbon seat. seat.
contamination of
contamination of Contamination of Contamination of
(Normal, injector is the nozzle tip.
Possible Cause the nozzle tip. seat by fine foreign seat by foreign
good) Sometimes caused
Sometimes caused particles. matter.
by flaws in or
by internal Excessively worn Damaged or
damage to the
contamination. seat. broken internal
needle tip.
parts or nozzle
case nut.

Note: If the fuel injector fails any tests, it should be serviced or replaced as necessary. If the pressure is
outside specified limits, adjust the pressure. See Adjusting Fuel Injector Pressure on page 7-28.

7-26 TNV IDI Service Manual

Fuel Injectors FUEL SYSTEM
Disassembly and Inspection of Fuel 3. Remove the nozzle case nut.
Injectors 4. Carefully remove the injector from the vise.
5. Turn the injector over and remove the nozzle
CAUTION body, nozzle valve, valve stop spacer, nozzle
Never use a steel wire brush to clean spring seat, nozzle spring, and shims.
fuel injectors. Damage to the nozzle and 6. Inspect the sealing surfaces (Figure 7-33, (2))
other components is likely to result. between the valve stop spacer and nozzle body
0000172en for nicks or scratches. Check the contact area
between the valve stop spacer and the nozzle
1. Clean carbon from used injectors using clean valve (Figure 7-33, (1)) for scoring or pitting.
diesel fuel. Hardened deposits or varnish can Use a magnifying glass to inspect.
be cleaned using a brass wire brush.
(1)

(1)
(2)
(2)

(3)

(4)

(5)
(6)
0001333A
(7)
Figure 7-33
(8)

(9)

(10)
0002214

1 – Return Fuel Fitting Nut

2 – Return Fuel Fitting
3 – Injector Body
4 – Pressure Adjusting Shims
5 – Spring
6 – Spring Seat
7 – Valve Stop Spacer
8 – Nozzle Valve
9 – Nozzle Body
10 – Nozzle Case Nut
Figure 7-32
2. Place the fuel injector in a soft-jawed vise with
the nozzle pointing up.

TNV IDI Service Manual 7-27

FUEL SYSTEM Fuel Injectors

7. Perform a nozzle valve slide test:

(a) Wash nozzle body and valve in clean diesel (1)
fuel. (2)
(b) While holding the nozzle body vertical, pull
the nozzle valve about 2/3 of the way out
(3)
(Figure 7-34).
(c) Release the valve. It should fall smoothly to
its seat by its own weight. (4)

(5)
(6)
0002093
(7)

(8)

(9)

(10)
0001332A
0002214
Figure 7-34 1 – Return Fuel Fitting Nut
2 – Fuel Return Fitting
Replace the fuel injector assembly if it fails any
3 – Injector Body
inspection. 4 – Pressure Adjusting Shims
5 – Spring
Adjusting Fuel Injector Pressure 6 – Spring Seat
The fuel injectors open when pressure reaches a 7 – Valve Stop Spacer
predetermined pressure threshold. They close 8 – Nozzle Valve
when the pressure is reduced below that threshold. 9 – Nozzle Body
The pressure threshold can be adjusted by adding 10 – Nozzle Case Nut
or removing shims (Figure 7-35, (4)). Figure 7-35

Fuel Injector Shim Kit The injection pressure will change by

approximately 100 - 142 psi (0.69 - 0.98 MPa;
Yanmar Part No. 129901-53800
7 - 10 kgf/cm2) for every 0.004 in. (0.1 mm) shim
(Includes one each of the following shims)
thickness.
129901-53810 0.0039 in. (0.10 mm)
129901-53820 0.0079 in. (0.20 mm) See the parts catalog for available shims.
129901-53830 0.0118 in. (0.30 mm) 1. Disassemble the fuel injector assembly. See
129901-53840 0.0157 in. (0.40 mm) Disassembly and Inspection of Fuel Injectors
129901-53850 0.0197 in. (0.50 mm) on page 7-27.
129901-53860 0.0205 in. (0.52 mm) 2. Remove or add adjusting shims as needed.
129901-53870 0.0213 in. (0.54 mm) 3. Reassemble the fuel injector assembly. See
129901-53880 0.0220 in. (0.56 mm) Reassembly of Fuel Injectors on page 7-29.
129901-53890 0.0228 in. (0.58 mm)
129901-53900 0.0315 in. (0.80 mm)

7-28 TNV IDI Service Manual

Fuel Injectors FUEL SYSTEM
4. Retest the fuel injector. See Testing of Fuel (1)
Injectors on page 7-24. If the injector cannot be
adjusted to the appropriate pressure, discard
(2)
the fuel injector.

Reassembly of Fuel Injectors (3)

1. Secure the injector in a soft-jawed vise with the (4)

nozzle end up.
2. Reinstall the shims, nozzle spring, nozzle (6)
spring seat, valve stop spacer, nozzle valve,
and nozzle body.
(5)
3. Reinstall the nozzle case nut. Tighten it to
specification.

Installation of the Fuel Injectors

1. Insert the nozzle gaskets (Figure 7-36, (5)) and 0002213

nozzle protector (Figure 7-36, (6)) in the

Figure 7-36
cylinder head.
2. Reinstall the fuel injector (Figure 7-36, (4)) in
the cylinder head and tighten to specification.
3. Reinstall new copper washers
(Figure 7-36, (3)), high-pressure and return
fuel lines (Figure 7-36, (2)). See Installation of
High-Pressure Fuel Injection Lines on
page 7-12 and Installation of Fuel Return Line
on page 7-13. Tighten fuel line nuts
(Figure 7-36, (1)) to specifications.
4. Prime the fuel system. See Priming the Fuel
System on page 4-12.
5. Operate the engine and check for fuel leaks.

TNV IDI Service Manual 7-29

FUEL SYSTEM Fuel Injectors

This Page Intentionally Left Blank

7-30 TNV IDI Service Manual

TNV IDI Service Manual
Section 8

COOLING SYSTEM
Page
Before You Begin Servicing ............................................................ 8-3
Introduction...................................................................................... 8-5
Cooling System Diagram................................................................. 8-5
Engine Coolant Pump Components ................................................ 8-6
Engine Coolant System Check........................................................ 8-7
Engine Coolant Pump ..................................................................... 8-7
Disassembly of Engine Coolant Pump ...................................... 8-7
Cleaning and Inspection ............................................................ 8-8
Reassembly of Engine Coolant Pump....................................... 8-9

TNV IDI Service Manual 8-1

COOLING SYSTEM

This Page Intentionally Left Blank

8-2 TNV IDI Service Manual

Before You Begin Servicing COOLING SYSTEM

BEFORE YOU BEGIN A WARNING

SERVICING
A DANGER

ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.

SCALD HAZARD! • NEVER leave the key in the key switch

when you are servicing the engine.
• NEVER remove the radiator cap if the Someone may accidentally start the
engine is hot. Steam and hot engine engine and not realize you are
coolant will spurt out and seriously servicing it. This could result in a
burn you. Allow the engine to cool serious injury.
down before you attempt to remove
the radiator cap. • If you must service the engine while it
is operating, remove all jewelry, tie
• Tighten the radiator cap securely after back long hair, and keep your hands,
you check the radiator. Steam can other body parts and clothing away
spurt out during engine operation if from moving / rotating parts.
the cap is loose.
• Failure to comply could result in death
• ALWAYS check the level of the engine or serious injury.
coolant by observing the reserve tank. 0000010en

• Failure to comply will result in death or

serious injury.
0000002en
A WARNING

A WARNING

FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
BURN HAZARD! hazardous substances like parts
• Wait until the engine cools before you cleaners, primers, sealants and
drain the engine coolant. Hot engine sealant removers.
coolant may splash and burn you.
• Failure to comply could result in death
• Failure to comply could result in death or serious injury.
or serious injury. 0000014en
0000016en

TNV IDI Service Manual 8-3

COOLING SYSTEM Before You Begin Servicing

A WARNING A CAUTION

BURN HAZARD!
• If you must drain the engine oil while it
PINCH HAZARD!
is still hot, stay clear of the hot engine Carefully rotate the alternator toward the
oil to avoid being burned. cylinder block while loosening the
V-belt. Failure to comply may result in
• ALWAYS wear eye protection. minor or moderate injury.
• Failure to comply could result in death 0000014en
or serious injury.
0000011en
CAUTION
• Only use the engine coolant specified.
A CAUTION Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and
FLYING OBJECT HAZARD! the surrounding area before you
• ALWAYS wear eye protection when remove the cap.
servicing the engine and when using • NEVER mix different types of engine
compressed air or high-pressure coolants. This may adversely affect the
water. Dust, flying debris, compressed properties of the engine coolant.
air, pressurized water or steam may 0000006en
injure your eyes.
• Failure to comply may result in minor CAUTION
or moderate injury.
Use a new special O-ring between the
0000003en
engine coolant pump and the joint. Be
sure to use the special O-ring for each
CAUTION engine model. Although the O-ring
If the engine coolant pump must be dimensions are the same as a
replaced, replace the engine coolant commercially available O-ring, the
pump as an assembly only. Do not material is different.
attempt to repair the engine coolant 0000042en

pump or replace individual components.

0000041en

8-4 TNV IDI Service Manual

Introduction COOLING SYSTEM

INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70
and 3TNV76 engine coolant pump.

COOLING SYSTEM DIAGRAM

(1)

(2)

(3)
(4)
(6)

(5)
0002046

Figure 8-1

1 – Cylinder Head 4 – Radiator

2 – Thermostat 5 – Coolant Recovery Tank
3 – Engine Coolant Pump 6 – Cylinder Block

TNV IDI Service Manual 8-5

COOLING SYSTEM Engine Coolant Pump Components

ENGINE COOLANT PUMP

COMPONENTS
1
7 2

3 4

9
11

6
5
8
10

0001959

Figure 8-2

1 – Thermostat Cover 7 – Engine Coolant Pump Gasket

2 – Thermostat 8 – V-Belt
3 – Special O-Ring 9 – Engine Coolant Pump V-Pulley
4 – Engine Coolant Pump 10 – Spacer
5 – Temperature Switch 11 – Engine Coolant Fan
6 – Gasket

8-6 TNV IDI Service Manual

Engine Coolant System Check COOLING SYSTEM

ENGINE COOLANT SYSTEM 2. Before removing the engine coolant pump or

thermostat, it will be necessary to drain the
CHECK engine coolant. Drain the coolant into a clean
Check the engine coolant system for leakage. container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
1. With the radiator properly filled, install a cooling
• Drain the coolant from the radiator. See steps
system tester (Figure 8-3, (1)).
1 - 4 in Drain, Flush and Refill Cooling System
with New Coolant on page 5-33.
3. Loosen the alternator mounting bolts. Loosen
and remove the V-belt and rotate the alternator
away from the engine and out of the way.

A CAUTION
(1)
0000577A

Figure 8-3
2. Apply 10.8 - 14.8 psi (75 - 105 kPa;
0.75 - 1.05 kgf/cm²) to the cooling system. If the
pressure reading drops, the engine coolant PINCH HAZARD!
system is leaking. Identify the source of the leak Carefully rotate the alternator toward the
and repair. cylinder block while loosening the
V-belt. Failure to comply may result in
minor or moderate injury.
ENGINE COOLANT PUMP 0000014en

4. Remove the engine coolant fan guard (if

Disassembly of Engine Coolant equipped), engine coolant fan (Figure 8-4, (1)),
Pump spacer (Figure 8-4, (2)) and engine coolant
pump V-pulley (Figure 8-4, (3)).
Verify the condition of the engine coolant pump
before disassembling it from the engine. Check the (4)
engine coolant pump shaft bearing for abnormal
noise, sticking, excessive play and water leakage.
(3)
Replace the coolant pump if any of these conditions
are present. (2)
(1)

CAUTION
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant 0001959B

pump or replace individual components. Figure 8-4

0000041en
5. Disconnect the coolant hoses and the
1. Make sure the engine and engine coolant are temperature switch lead wire from the engine
not hot. coolant pump.

TNV IDI Service Manual 8-7

COOLING SYSTEM Engine Coolant Pump

6. Remove the engine coolant pump 2. Place the temperature switch and an accurate
(Figure 8-4, (4)). Discard the gasket. thermometer (Figure 8-6, (3)) in engine
7. Remove the thermostat cover (Figure 8-5, (1)). coolant.
3. Slowly increase temperature of the fluid using
an external heat source.
(1)
4. The temperature switch is normal if the
continuity light or ohmmeter indicates continuity
(2) when the fluid temperature reaches
225°F - 235°F (107°C - 113°C).

Thermostat
1. Check for proper operation of the thermostat.
(4)
(3) Place the thermostat (Figure 8-7, (1)) and an
accurate thermometer (Figure 8-7, (2)) in warm
water.

0001959A (2)
Figure 8-5
8. Remove the thermostat (Figure 8-5, (2)).
Remove the temperature switch
(Figure 8-5, (3)) and gasket (Figure 8-5, (4)). (1)
Discard the gasket.

Cleaning and Inspection

Temperature Switch
0000577A
1. Check for proper operation of the temperature
switch. Connect a continuity light or ohmmeter Figure 8-7
to the temperature switch. Connect one lead to 2. Slowly increase temperature of the water using
the terminal of the switch (Figure 8-6, (1)) and an external heat source.
the other lead to the metal portion of the switch
(Figure 8-6, (2)). 3. The thermostat is normal if it starts to open at
the temperature value stamped on the flange of
(3) the thermostat, and fully opens as the
(1)
temperature of the water is increased.

Radiator Cap
(2)
1. Check for proper operation of the radiator cap.
Install the radiator cap (Figure 8-8, (1)) on a
cooling system tester.

0000577A

Figure 8-6

8-8 TNV IDI Service Manual

Engine Coolant Pump COOLING SYSTEM

CAUTION
Use a new special O-ring between the
engine coolant pump and the joint. Be
sure to use the special O-ring for each
engine model. Although the O-ring
(1) dimensions are the same as a
commercially available O-ring, the
0000577A
material is different.
Figure 8-8 0000042en

2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 5. Reinstall the engine coolant pump bolts.
0.75 - 1.05 kgf/cm²) to the radiator cap. The Tighten the bolts.
radiator cap relief valve must open within the 6. Inspect and reinstall the coolant hoses and the
specified range. temperature switch lead wire.
Reassembly of Engine Coolant Pump 7. Reinstall the engine coolant pump V-pulley
(Figure 8-10, (3)), spacer (Figure 8-10, (2))
1. Reinstall the thermostat (Figure 8-9, (1)). engine coolant fan (Figure 8-10, (1)) and
engine coolant fan guard (if equipped).

(4)

(2)
(6) (3)
(1) (2)
(1)

(5)

0001959B

(4)
0001959C Figure 8-10
(3)
Figure 8-9 8. Inspect the condition of the V-belt. There must
be clearance (Figure 8-11, (1)) between the
2. Reinstall the thermostat cover (Figure 8-9, (2)). V-belt and the bottom of the pulley groove. If
Tighten the thermostat cover bolts. there is no clearance (Figure 8-11, (2))
3. Reinstall the temperature switch between the V-belt and the bottom of the pulley
(Figure 8-9, (3)) and a new gasket groove, replace the V-belt.
(Figure 8-9, (4)).
4. Position the engine coolant pump on the engine
and install a new gasket (Figure 8-9, (6)). Use
a new special O-ring (Figure 8-9, (5)) on
assembly between the engine coolant pump
and the joint.

TNV IDI Service Manual 8-9

COOLING SYSTEM Engine Coolant Pump

(2)
(1)

0000584

Figure 8-11
9. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and Adjust Cooling
Fan V-Belt on page 5-27.
10. Reinstall and tighten the drain plug or close the
drain cock in the radiator. Reinstall and tighten
the engine block drain plug or reconnect the
coolant hose at the oil cooler.
11. Fill radiator and engine with engine coolant.
See Drain, Flush and Refill Cooling System
with New Coolant on page 5-33.

CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en

8-10 TNV IDI Service Manual

TNV IDI Service Manual
Section 9

LUBRICATION
SYSTEM
Page
Before You Begin Servicing ............................................................ 9-3
Introduction...................................................................................... 9-5
Oil Pump Service Information.......................................................... 9-5
Engine Oil Pressure................................................................... 9-5
Outer Rotor Outside Clearance ................................................. 9-5
Outer Rotor Side Clearance ...................................................... 9-5
Outer Rotor to Inner Rotor Tip Clearance ................................. 9-5
Inner Rotor and Gear Boss Clearance ...................................... 9-6
Lubrication System Diagram ........................................................... 9-7
Checking Engine Oil Pressure ........................................................ 9-8
Trochoid Oil Pump........................................................................... 9-8
Oil Pump Components .............................................................. 9-8
Disassembly of Oil Pump .......................................................... 9-9
Cleaning and Inspection .......................................................... 9-10
Reassembly of Oil Pump ......................................................... 9-11

TNV IDI Service Manual 9-1

LUBRICATION SYSTEM

This Page Intentionally Left Blank

9-2 TNV IDI Service Manual

Before You Begin Servicing LUBRICATION SYSTEM

BEFORE YOU BEGIN A WARNING

SERVICING
CAUTION

ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
NEVER permit anyone to operate the • NEVER leave the key in the key switch
engine or driven machine without proper when you are servicing the engine.
training. Someone may accidentally start the
engine and not realize you are
• Read and understand this Operation
servicing it. This could result in a
Manual before you operate or service
serious injury.
the machine to ensure that you follow
safe operating practices and • If you must service the engine while it
maintenance procedures. is operating, remove all jewelry, tie
back long hair, and keep your hands,
• Machine safety signs and labels are
other body parts and clothing away
additional reminders for safe operating
from moving / rotating parts.
and maintenance techniques.
• Failure to comply could result in death
• See your authorized Yanmar industrial
or serious injury.
engine dealer or distributor for
0000010en
additional training.
0000002en

A WARNING

BURN HAZARD!
• Keep your hands and other body parts
away from hot engine surfaces such
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en

TNV IDI Service Manual 9-3

LUBRICATION SYSTEM Before You Begin Servicing

A WARNING CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
FUME / BURN HAZARD! • Prevent dirt and debris from
• Always read and follow safety related contaminating the engine oil. Carefully
precautions found on containers of clean the oil cap / dipstick and the
hazardous substances like parts surrounding area before you remove
cleaners, primers, sealants and the cap.
sealant removers. • NEVER mix different types of engine
• Failure to comply could result in death oil. This may adversely affect the
or serious injury. lubricating properties of the engine oil.
0000014en
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
A CAUTION overspeed or internal damage.
0000005en

CAUTION
If the oil pump must be replaced, replace
it as an assembly only. Do not replace
individual components.
FLYING OBJECT HAZARD! 0000030en

• ALWAYS wear eye protection when

servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en

9-4 TNV IDI Service Manual

Introduction LUBRICATION SYSTEM

INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70
and 3TNV76 trochoid oil pumps.
Note: See Replace Engine Oil and Engine Oil Filter on page 5-25 for engine oil and engine oil filter
replacement procedures.

OIL PUMP SERVICE INFORMATION

Engine Oil Pressure
Model at Rated Engine rpm at Low Idle Speed
2TNV70 - VM
42 - 64 psi (0.29 - 0.44 MPa 2.96 - 4.49
3TNV70 - VH
kgf/cm2)
3TNV76 - CH 8.8 psi (0.06 MPa; 0.6 kfg/cm2) or greater
3TNV70 - CL 35 - 51 psi (0.24 - 0.35 MPa 2.44 - 3.57
3TNV76 - CL kgf/cm2)

Outer Rotor Outside Clearance

Reference
Model Standard Limit
Page
Check Outer
2TNV70
0.0047 - 0.0083 in. 0.0118 in. Rotor Outside
3TNV70
(0.12 - 0.21 mm) (0.30 mm) Clearance on
3TNV76
page 9-10

Outer Rotor Side Clearance

Reference
Model Standard Limit
Page
Check Outer
2TNV70
0.0008 - 0.0028 in. 0.0047 in. Rotor Side
3TNV70
(0.02 - 0.07 mm) (0.12 mm) Clearance on
3TNV76
page 9-10

Outer Rotor to Inner Rotor Tip

Clearance
Reference
Model Standard Limit
Page
Outer Rotor to
2TNV70
0.0063 in. Inner Rotor Tip
3TNV70 -
(0.16 mm) Clearance on
3TNV76
page 9-10

TNV IDI Service Manual 9-5

LUBRICATION SYSTEM Oil Pump Service Information

Inner Rotor and Gear Boss Clearance

Standard
Standard Standard Reference
Item Parts Clearance
Dimension Clearance Page
Limit
2.0886 - 2.0925 in.
Gear Boss Diameter
Inside Clearance of (53.05 - 53.15 mm) 0.012 - 0.020 in. 0.024 in.
Inner Rotor 2.1043 - 2.1083 in. (0.3 - 0.5 mm) (0.6 mm) Check Inner
Rotor Diameter Rotor and
(53.45 - 53.55 mm)
Gear Boss
Width Across Flat of 1.9468 - 1.9587 in. Clearance on
Inner Rotor Width Gear Boss (49.45 - 49.75 mm)
Across Flat
0.008 - 0.024 in. 0.028 in. page 9-11
Width Across Flat of 1.9665 - 1.9705 in. (0.2 - 0.6 mm) (0.7 mm)
Clearance
Rotor (49.95 - 50.05 mm)

9-6 TNV IDI Service Manual

Lubrication System Diagram LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

Oil Filter

Bypass Valve

Fuel
Injection Pump

Oil Pressure
Switch

Cylinder Body - Main Gallery

Pressure
Regulator Valve
Idle Gear Camshaft Crank
Oil Pump Shaft Bearing Journal

Rocker Arm Crank Pin

Oil Suction Pipe Bearing
Strainer

Rocker Arm

Tappet
Cam Face

Oil Pan
0001624

Figure 9-1

TNV IDI Service Manual 9-7

LUBRICATION SYSTEM Checking Engine Oil Pressure

CHECKING ENGINE OIL TROCHOID OIL PUMP

PRESSURE Oil Pump Components
Perform an engine oil pressure check if there is any
indication of low oil pressure such as the oil
pressure indicator is on or the oil pressure gauge (1)
indicates low oil pressure. See Engine Oil Pressure (2)
on page 9-5 for the engine oil pressure (5)
specification. (6)

1. Disconnect the wire lead from the oil pressure

switch or sending unit (Figure 9-2, (1)).
(3)

(4)
(1) 0001955A

1 – Crankshaft
2 – Oil Pump Cover
3 – Oil Pressure Regulator
4 – Gear Case Cover
5 – Outer Rotor
6 – Inner Rotor
Figure 9-3

0000020A

Figure 9-2
2. Remove the oil pressure switch.
3. Install a mechanical oil pressure gauge in the
oil pressure switch port.
4. Start the engine:
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty
oil pressure switch or sending unit or faulty
machine oil pressure gauge in instrument
panel.
• If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the
lubrication system to locate the cause of the
low oil pressure. See Troubleshooting Charts
on page 13-7. Repair as necessary.

9-8 TNV IDI Service Manual

Trochoid Oil Pump LUBRICATION SYSTEM
Disassembly of Oil Pump (2)
(1)
CAUTION (3)
If the oil pump must be replaced, replace (4)
it as an assembly only. Do not replace
individual components.
0000030en

1. Remove the engine cooling fan guard (if

equipped), engine cooling fan (Figure 9-4, (1)),
spacer (Figure 9-4, (2)), engine coolant pump
V-pulley (Figure 9-4, (3)) and V-belt.

(4) 0001955B

Figure 9-5
(3)
4. Remove the oil pump cover (Figure 9-5, (1))
(2) from the gear case.
(1)
5. Remove the outer rotor (Figure 9-5, (3)) and
inner rotor (Figure 9-5, (4)) from the gear case
cover.
6. Remove the oil pressure regulator valve
(Figure 9-6, (1)) from the oil pump cover
0001959B (Figure 9-6, (2)).
Figure 9-4
(2)
2. Remove the front crankshaft pulley and gear
case cover. See Removal of Timing Gear Case
Cover on page 6-38.
3. Remove the seven oil pump cover screws
(Figure 9-5, (2)).
Note: The oil pump cover screws are installed (1)
using a liquid thread lock. It may be 0001958A
necessary to used “localized heat” (small
propane torch) and an impact-type Figure 9-6
screwdriver to remove these screws.

TNV IDI Service Manual 9-9

LUBRICATION SYSTEM Trochoid Oil Pump

Cleaning and Inspection Outer Rotor to Inner Rotor Tip Clearance

Wash the oil pump cover, the oil pressure regulator Determine the outer rotor to inner rotor tip
valve, the oil pump cavity and the inner and outer clearance. Insert a feeler gauge between the top of
rotors. Inspect the parts for wear or damage. an inner rotor tooth (Figure 9-8, (1)) and the top of
Replace as necessary. an outer rotor tooth (Figure 9-8, (2)) and measure
the clearance.
Note: If the oil pump cavity is damaged, the
gear case cover must be replaced.

A CAUTION
If any oil pump component clearance
exceeds its limit, the oil pump must be
replaced as an assembly.
0000015en

Check Outer Rotor Outside Clearance

1. Reinstall the outer and inner rotors. The dots on
the rotor faces must face “up.” Make sure that
the pilot on the back of the inner rotor fits into
(1) (2)
the bore of the oil pump cavity and the top 0001150B
surface of the inner rotor is flush with the top
Figure 9-8
surface of the outer rotor.
2. Determine the outside clearance of the outer Record the measurement. See Outer Rotor to Inner
rotor. Insert a feeler gauge between the outer Rotor Tip Clearance on page 9-5 for the service
rotor (Figure 9-7, (1)) and the gear case oil limit.
pump cavity (Figure 9-7, (2)).
Check Outer Rotor Side Clearance
(1) Determine the side clearance of the outer rotor
across the pump cavity. While pressing down on
the outer rotor, measure the depression using a
depth micrometer (Figure 9-9).
(2)

0001151A

Figure 9-7
Record the measurement. See Outer Rotor Outside
Clearance on page 9-5 for the service limit.

Figure 9-9
Record the measurement. See Outer Rotor Side
Clearance on page 9-5 for the service limit.

9-10 TNV IDI Service Manual

Trochoid Oil Pump LUBRICATION SYSTEM
Check Inner Rotor and Gear Boss 2. Reinstall the outer rotor in the gear case. The
Clearance dot mark on the face of the outer rotor must
face up toward the oil pump cover.
(5)
3. Reinstall the inner rotor into the gear case cover
with the dot mark also facing up. Make sure that
(3) the pilot on the back side of the inner rotor fits
into the bore in the gear case cover and the top
surface of the inner rotor is flush with the top
surface of the outer rotor.
4. Reinstall the oil pressure regulator valve
(1) (6)
(Figure 9-11, (4)) into the oil pump cover
(4) (Figure 9-11, (5)). Apply LOCTITE® 242 (red) to
(2) the valve plug, following the manufacturer’s
1 – Crank Gear instructions.
2 – Inner Rotor
5. Reinstall the oil pump cover (Figure 9-11, (5)).
3 – Inside Width Across Flats of Inner Rotor
4 – Overall Inside Diameter of Inner Rotor
Apply LOCTITE 290 (green) or LOCTITE 262
5 – Overall Inside Diameter of Gear Boss (red) to the oil pump cover screws. Tighten the
6 – Outside Width Across Flats of Gear Boss pump cover screws to 52 - 70 in·lb
(5.9 - 7.9 N·m, 0.6 - 7.9 kgf·m).
Figure 9-10
6. Reinstall the crankshaft pulley and gear case
Record the measurement. See Inner Rotor and cover. See Removal of Timing Gear Case
Gear Boss Clearance on page 9-6 for service Cover on page 6-38.
limits. 7. Reinstall the engine coolant pump V-pulley
(Figure 9-12, (3)), spacer (Figure 9-12, (2)),
Reassembly of Oil Pump engine cooling fan (Figure 9-12, (1)) and
engine cooling fan guard (if equipped).
(5)
(1) (4)
(2)
(3)
(2)
(1)
(4)

(3) 0001959B
0001976A

Figure 9-11 Figure 9-12

1. Lubricate the outer rotor (Figure 9-11, (1)), 8. Reinstall the V-belt. Tighten the V-belt to the
inner rotor (Figure 9-11, (2)) and pump bore in proper tension. See Check and Adjust Cooling
the gear case cover (Figure 9-11, (3)) with Fan V-Belt on page 5-27.
clean engine oil.

TNV IDI Service Manual 9-11

LUBRICATION SYSTEM Trochoid Oil Pump

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9-12 TNV IDI Service Manual

TNV IDI Service Manual
Section 10

STARTER MOTOR
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-5
Starter Motor Information .............................................................. 10-5
Starter Motor Specifications .......................................................... 10-6
Starter Motor Troubleshooting....................................................... 10-7
Starter Motor Components ............................................................ 10-8
Starter Motor ................................................................................. 10-9
Removal of Starter Motor ...................................................... 10-10
Disassembly of Starter Motor ................................................ 10-10
Cleaning and Inspection ........................................................ 10-12
Reassembly of Starter Motor................................................. 10-17
Check Pinion Projection Length ............................................ 10-19
No-Load Test......................................................................... 10-19
Installation of Starter Motor ................................................... 10-20

TNV IDI Service Manual 10-1

STARTER MOTOR

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10-2 TNV IDI Service Manual

Before You Begin Servicing STARTER MOTOR

BEFORE YOU BEGIN A WARNING

SERVICING
A WARNING

SHOCK HAZARD!
• Turn off the battery switch (if
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
battery cable before servicing the
• Stop the engine before you begin to
electrical system.
service it.
• Check the electrical harnesses for
• NEVER leave the key in the key switch
cracks, abrasions, and damaged or
when you are servicing the engine.
corroded connectors. ALWAYS keep
Someone may accidentally start the
the connectors and terminals clean.
engine and not realize you are
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000009en
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands, A WARNING
other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury.
0000010en
FUME / BURN HAZARD!
• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
cleaners, primers, sealants and
sealant removers.
• Failure to comply could result in death
or serious injury.
0000014en

TNV IDI Service Manual 10-3

STARTER MOTOR Before You Begin Servicing

A CAUTION CAUTION
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general
cleaning. Do not use high-pressure
wash or submerse the starter motor in
water.
FLYING OBJECT HAZARD! 0000055en

• ALWAYS wear eye protection when

servicing the engine and when using CAUTION
compressed air or high-pressure Use a specialized battery charger to
water. Dust, flying debris, compressed recharge a battery with a voltage of
air, pressurized water or steam may 8 volts or less. Booster starting a battery
injure your eyes. with a voltage of 8 volts or less will
• Failure to comply may result in minor generate an abnormally high voltage
or moderate injury. and destroy electrical equipment.
0000056en
0000003en

CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en

CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated on the wiring diagram. The
starter motor will malfunction or break
down if the resistance is higher than the
specified value.
0000054en

10-4 TNV IDI Service Manual

Introduction STARTER MOTOR

INTRODUCTION
This section of the Service Manual covers the servicing of starter motor. Yanmar Part No. 119717-77010 is
standard equipment on 3TNV76 model engines and is used in this section to show the service procedures
for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the engine
being serviced.

STARTER MOTOR INFORMATION

YANMAR Mfg. No Load Loaded
Part Mfg. Model Specification Terminal Amperage Terminal Amperage
Number Number RPM Torque RPM
Voltage Draw Voltage Draw
42 in.-lb
119515- 428000- DC12V -1.3 hp 3000 1240
Denso 11.5 90A (Max) 8.0 200 (Max) (4.7 N·m;
77010 2190 (1.0 kW) (Min) 0.48 kgf·m) (Min)

119717- 428000- DC12V -1.5 hp 3000 61 in.-lb 1130

77010 Denso 1590 (1.1 kW) 11.5 90A (Max) (Min) 8.7 230 (Max) (6.9 N·m; (Min)
0.70 kgf·m)

119740- 428000- DC12V -1.9 hp 3000 119 in.-lb 1000

Denso 11.5 90A (Max) 8.5 350 (Max) (13.5 N·m;
77010 3310 (1.4 kW) (Min) (Min)
1.38 kgf·m)

TNV IDI Service Manual 10-5

STARTER MOTOR Starter Motor Specifications

STARTER MOTOR SPECIFICATIONS

Yanmar Part Number 119717-77010 119515-77010
Nominal Output 1.5 hp (1.1 kW) 1.34 hp (1.0 kW)
6.6 lb 6.3 lb
Weight
(3.0 kg) (2.85 kg)
Revolution Direction (As Viewed From Pinion) Clockwise Clockwise
Engagement System Magnetic Shift Magnetic Shift
Terminal Voltage/Current 11.5 V / 90 A max 11.5 V / 90 A max
No-load
Revolution 3000 rpm (min-1) 3000 rpm (min-1)
Terminal Voltage/Current 8.7 V / 230 A 8.0 V / 230 A
Loaded Torque 61 in·lb (6.9 N·m; 0.70 kgf·m) 41.7 in·lb (4.7 N·m; 0.48 kgf·m)
Revolution 1130 rpm (min) 1240 rpm (min)
Terminal Voltage/Current 2.5 V / 325 A max 2.5 V / 260 A max
Stalled 73 in.-lb 43.5 in.-lb
Torque
(8.24 N·m; 0.84 kgf·m) minimum (4.9 N·m; 0.5 kgf·m) minimum
Clutch System Overrunning Overrunning
Pinion Projection Voltage at 212°F (100 °C) 8.0 V max 8.0 V max
Pinion DP or Module/Number of Teeth M2.54/9 M2.54/9
Application Standard Standard
3.1 - 4.0 lbf 3.1 - 4.0 lbf
Spring Force
(13.7 - 17.6 N; 1.4 - 1.8 kgf) (13.7 - 17.6 N; 1.4 - 1.8 kgf)
Brush
Standard 0.55 in. (14 mm) 0.55 in. (14 mm)
Length
Service Limit 0.44 in. (11.1 mm) 0.44 in. (11.1 mm)
Solenoid Pull-In Coil Resistance 0.484 W at 68°F (20°C) 0.484 W at 68°F (20°C)
Switch Hold-In Coil Resistance 1.055 W at 68°F (20°C) 1.055 W at 68°F (20°C)
Outside Standard 1.102 in. (28.0 mm) 1.102 in. (28.0 mm)
Diameter Service Limit 1.063 in. (27.0 mm) 1.063 in. (27.0 mm)
Standard 0.001 in. (0.02 mm) 0.001 in. (0.02 mm)
Commutator Run-Out
Service Limit 0.002 in. (0.05 mm) 0.002 in. (0.05 mm)
Insulation Standard 0.024 in. (0.6 mm) 0.024 in. (0.6 mm)
Depth Service Limit 0.008 in. (0.2 mm) 0.008 in. (0.2 mm)

10-6 TNV IDI Service Manual

Is the shift lever at NO Move shift lever to Is battery fully charged NO • Charge or replace battery.
NEUTRAL position? NEUTRAL position. and terminals clean? • Clean terminals.

YES
Engine does not start? Inspect wiring up to solenoid switch
Is starter motor solenoid and repair if necessary.
NO • Key switch
switch actuating sound
YES heard? • Safety relay
• Solenoid switch assembly
NO NO • Electrical connections
Does engine crank? Is starter motor operating? YES

YES
• Adjust / pinion projection length.
Starter Motor Troubleshooting

• Inspect shift lever for deformation,

Pinion and ring gear NO return spring for fatigue and pinion

TNV IDI Service Manual

meshing normal? for sliding.
YES • Repair meshing between pinion and
ring gear or replace as needed.
YES
Connect M terminal of starter NO • Inspect brush and replace if worn.
Pinion roller clutch or motor directly to battery. • If brushes are not worn, replace armature
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.

YES

Solenoid switch assembly If starter motor becomes wet, replace solenoid switch
contact defective. Repair assembly even if function is normal.
NO or replace.
(slow revolution) NO
STARTER MOTOR TROUBLESHOOTING

Is revolution normal? Is battery fully charged • Charge or replace battery. If a problem occurs:
and terminals clean? • Clean terminals. Immediately disconnect battery negative terminal.

YES YES

Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES

Does engine turn when YES Repair or replace Repair or replace key switch, starting
starter motor is replaced? starter motor. motor relay or magnetic switch assembly.

Slow Revolution

Inspect condition of engine.

0000102
STARTER MOTOR

10-7
STARTER MOTOR Starter Motor Components

STARTER MOTOR COMPONENTS

(8)

(14)

(13)

(11) (12)
(3) (10)
(9) (15)
(2) (7) (17)
(1) (6)
(5)
(4)

(16)
(19)

(21)
(20) (18)
(22)
(23)

(24)

0002486

Figure 10-1

10-8 TNV IDI Service Manual

Starter Motor STARTER MOTOR
1 – Nut STARTER MOTOR
2 – Needle Bearing
3 – Pinion Housing
4 – Pinion Retaining Ring A WARNING
5 – Pinion Stop
6 – Pinion
7 – Shift Lever
8 – Solenoid Switch Assembly
9 – Snap Ring
10 – Washer
11 – Bushing SHOCK HAZARD!
12 – Intermediate Housing
13 – Reduction Gear
• Turn off the battery switch (if
14 – Washer equipped) or disconnect the negative
15 – Through Bolt battery cable before servicing the
16 – End Housing electrical system.
17 – Brush Plate and Holder • Check the electrical harnesses for
18 – Field Assembly cracks, abrasions, and damaged or
19 – Armature
corroded connectors. ALWAYS keep
20 – Bushing
21 – Plate
the connectors and terminals clean.
22 – Planetary Gear (3 used) • Failure to comply could result in death
23 – Washer (3 used) or serious injury.
24 – Pinion Shaft 0000009en

Note: While starter motor design varies

between models, the basic repair
procedures are the same. The following
procedures are typical and may differ
from the starter being serviced.

TNV IDI Service Manual 10-9

STARTER MOTOR Starter Motor

Removal of Starter Motor 3. Remove the two bolts or nuts retaining the
solenoid switch assembly (Figure 10-4, (1)) to
1. Disconnect the battery cables at the battery, the pinion housing. Remove the solenoid switch
negative (-) cable first. assembly and dust covers (Figure 10-4, (2)).
2. Remove the electrical wires from the solenoid Remove the plunger (Figure 10-4, (4)) and
switch assembly. torsion spring (Figure 10-4, (3)) from the pinion
3. Remove the starter mounting bolts housing.
(Figure 10-2, (1)). Remove the starter motor
from the flywheel housing.
(1)

(4)

(3)
(2) (1)

0000140A
0002126
Figure 10-4
Figure 10-2
4. Remove the two bolts (Figure 10-5, (1))
Disassembly of Starter Motor securing the rear cover (Figure 10-5, (2)) to the
brush holder assembly (Figure 10-5, (3)).
1. Make alignment marks across all mating joints.
2. Disconnect the field wire from the solenoid
switch (Figure 10-3). (2)

(3)
(1)

0000142A

Figure 10-5
5. Remove the two through bolts. Remove the rear
cover (Figure 10-5, (2)).

0000138

Figure 10-3

10-10 TNV IDI Service Manual

Starter Motor STARTER MOTOR
6. Pull the brush springs up using a brush spring 11. Remove the shift lever (Figure 10-8, (2)), pin,
puller. On the negative (-) side, bring the brush and spacer (Figure 10-8, (1)).
spring into contact with the side of the brushes
to hold the brushes clear of the commutator (1)
(2)
surface. On the positive (+) side, remove the (3)
brushes from the brush holder assembly
(Figure 10-6).

(4)
0000148A

Figure 10-8
12. Pull the pinion stop (Figure 10-9, (1)) down to
expose the retaining ring. Using a flat-blade
screwdriver, remove the retaining ring
0000143
(Figure 10-9, (2)) from the pinion shaft.
Figure 10-6
7. Remove the brush plate and holder
(Figure 10-7, (1)).

(2) (1)

(3)
(2) (1)
0000151A

Figure 10-9
0000144A

Figure 10-7
8. Pull the field assembly (Figure 10-7, (3)) off
from the armature assembly (Figure 10-7, (2)).
9. Remove the armature from the intermediate
housing.
10. Remove the intermediate housing, gear and
pinion shaft assembly (Figure 10-8, (4)) from
the pinion housing (Figure 10-8, (3)).
Disengage from the shift lever as it is removed.

TNV IDI Service Manual 10-11

STARTER MOTOR Starter Motor

13. Remove the pinion stop (Figure 10-10, (3)), 15. Inspect the intermediate bushing
return spring (if equipped), and pinion clutch (Figure 10-11, (2)) and replace if worn or
assembly (Figure 10-10, (2)), from the pinion damaged.
shaft (Figure 10-10, (1)). 16. Inspect armature bushing (Figure 10-11, (7))
and replace if worn or damaged.
(2)
Cleaning and Inspection
Armature
Commutator Surface Inspection
If the commutator surface is rough, polish the
surface with a #500 to #600 emery cloth.

(1)

(4) (3) 0000152B

Figure 10-10
14. Remove the snap ring (Figure 10-11, (1)).
Remove the pinion shaft (Figure 10-11, (5)),
planetary gears (Figure 10-11, (6)), washers,
and reduction gear (Figure 10-11, (4)) from the
intermediate housing (Figure 10-11, (3)).
0000117
(4)
Figure 10-12

(3) Measure Commutator Outside Diameter

Measure the commutator outside diameter.
Replace the armature if the measurement is less
than the limit. See Starter Motor Specifications on
(2) page 10-6.
(1)

(7)

(6)

0000113

(5) 0002487 Figure 10-13

Figure 10-11

10-12 TNV IDI Service Manual

Starter Motor STARTER MOTOR
Measure Commutator Insulation Depth
Measure the depth of the insulating material
(Figure 10-14, (1)) between commutator segments
(Figure 10-14, (2)). If the depth measures less
than the limit, use a hacksaw blade
(Figure 10-14, (3)) to remove the insulating
material until the depth is within the limit. See
Starter Motor Specifications on page 10-6 for
service limit.
0000114
A normal commutator condition is indicated in
(Figure 10-14, (4)). An abnormal commutator Figure 10-15
condition is indicated in (Figure 10-14, (5)). Armature Coil Insulation Test
Check for continuity between a commutator
(3) segment and the shaft or armature using a
multimeter (Figure 10-16). The multimeter should
not indicate continuity.
If the multimeter indicates continuity, replace the
armature.
(2)
(1)

(5) (4)
0000118

Figure 10-14
Armature Coil Continuity Test 0000115

Check for continuity between the commutator Figure 10-16

segments using a multimeter (Figure 10-15). The
multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the armature.

TNV IDI Service Manual 10-13

STARTER MOTOR Starter Motor

Measure Armature and Commutator Run-Out Field Coil Insulation Test

Measure the armature core run-out and the Check for continuity between either field coil
commutator run-out using a dial indicator terminal and the yoke using a multimeter
(Figure 10-17). Replace the armature if either of (Figure 10-19). The multimeter should not indicate
the measurements is not within specifications. See continuity.
Starter Motor Specifications on page 10-6 for
service limit. If the multimeter indicates continuity, replace the
field coil assembly.

0000116

Figure 10-17
0000120
Field Coil
Figure 10-19
Field Coil Continuity Test
Measure Brush Length
Check for continuity between the field coil terminals
using a multimeter (Figure 10-18). The multimeter Measure the length of the brush (Figure 10-20).
should indicate continuity. Replace the brush if the length is less than the limit.
See Starter Motor Specifications on page 10-6 for
If the multimeter does not indicate continuity, service limit.
replace the field coil assembly.

0000121
0000119
Figure 10-20
Figure 10-18

10-14 TNV IDI Service Manual

Starter Motor STARTER MOTOR
Brush Holder Solenoid Switch
Brush Holder Insulation Test If the starter motor becomes wet, replace the
solenoid switch even if the solenoid switch
Check for continuity between each brush holder assembly function is normal.
and the base using a multimeter (Figure 10-21).
The multimeter should not indicate continuity. Shunt Coil Continuity Test
If the multimeter indicates continuity, replace the Check for continuity between the “S” terminal and
brush holder. the switch body using a multimeter (Figure 10-23).
The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the solenoid switch.

0000122

Figure 10-21
0000124
Brush Spring Test
Test the spring force for each brush spring Figure 10-23
(Figure 10-22). Replace the brush spring if the Series Coil Continuity Test
force is not within the range. See Starter Motor
Specifications on page 10-6 for the service limit. Check for continuity between the “S” and “M”
terminals using a multimeter (Figure 10-24). The
multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the solenoid switch.

0000123

Figure 10-22

0000125

Figure 10-24

TNV IDI Service Manual 10-15

STARTER MOTOR Starter Motor

Coil Resistance Test

See Starter Motor Specifications on page 10-6 for
service limit.

Contact Continuity Test

Depress the plunger at the bottom of the solenoid
switch. Check for continuity between the “B” and
“M” terminals using a multimeter (Figure 10-25).
The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the solenoid switch. 0000127

Figure 10-26
Slide the pinion clutch assembly on the shaft
(Figure 10-27). It should slide smoothly on the
shaft. Rust, too much grease, or damage could
prevent the pinion clutch from sliding smoothly. If
the pinion clutch assembly does not slide smoothly,
clean the shaft and pinion clutch assembly or
replace the damaged component.

0000126

Figure 10-25

Pinion Clutch Assembly

Pinion Clutch Assembly Inspection
Manually rotate the pinion clutch assembly in the
0000128
drive direction. It should rotate freely in the drive
direction and is locked by turning it in the opposite Figure 10-27
direction (Figure 10-26). Replace the pinion clutch
assembly if the results are different.

10-16 TNV IDI Service Manual

Starter Motor STARTER MOTOR
Reassembly of Starter Motor (2)
1. Apply a appropriate starter bendix grease
(obtain locally) to the pinion shaft.
2. Reassemble the reduction gear
(Figure 10-28, (4)), pinion shaft
(Figure 10-28, (5)), planetary gears
(Figure 10-28, (6)), and washers into the
intermediate housing (Figure 10-28, (3)).
Reinstall snap ring (Figure 10-28, (1)).
(1)
(4)
(4) (3) 0000152B

(3) Figure 10-29

4. Apply a small amount of high temperature
lithium grease (obtain locally) to the contact
(2)
surfaces of the shift lever. Reassemble the shift
lever (Figure 10-30, (2)), spacer (if equipped)
(1) (Figure 10-30, (1)), and pin.
5. Reinstall the pinion shaft assembly
(Figure 10-30, (4)) in the pinion housing
(Figure 10-30, (3)). Be sure the shift lever
properly engages the pinion.
(7)
(1)
(2)
(6) (3)

(5) 0002487

Figure 10-28
3. Reinstall the pinion clutch assembly
(Figure 10-29, (2)), return spring (if equipped)
and pinion stop (Figure 10-29, (3)) onto the (4)
pinion shaft (Figure 10-29, (1)). Reinstall the 0000148A

retaining ring (Figure 10-29, (4)) in the groove

Figure 10-30
in the pinion shaft. Slide the pinion stop over the
retaining ring. 6. Apply a small amount of high temperature
lithium grease (obtain locally) to the surface of
the plunger and the hole that engages the shift
lever.
7. Attach the plunger to the shift lever.

TNV IDI Service Manual 10-17

STARTER MOTOR Starter Motor

8. Reinstall the plate onto the intermediate 13. Reinstall the two through bolts and tighten
housing and carefully reinstall the armature securely.
assembly (Figure 10-31, (2)) into the pinion 14. Reinstall the return spring (if equipped)
shaft assembly. (Figure 10-33, (3)) on the solenoid plunger
(Figure 10-33, (4)). Reinstall the solenoid
(2) (1)
switch coil (Figure 10-33, (1)) and dust covers
(Figure 10-33, (2)). Secure with nuts or bolts.

(3) (4)

0000144A
(3)
Figure 10-31 (2) (1)
9. Reinstall the field assembly (Figure 10-31, (3))
0000140A
over the armature assembly and align to the
pinion housing. Figure 10-33
10. Position the brush springs in brush holders. 15. Reconnect the wire to the solenoid switch
Reinstall the brushes in the brush holders. assembly. Tighten the nut. Reinstall the cover
Reversing the brushes will cause the starter over the connection.
motor to turn backwards.
11. Carefully reinstall the brush holder
(Figure 10-32, (3)) assembly.
12. Reinstall the rear cover (Figure 10-32, (2)) and
secure with two bolts (Figure 10-32, (1)).

(2)

(3)
(1)
0000138
0000142A
Figure 10-34
Figure 10-32

10-18 TNV IDI Service Manual

Starter Motor STARTER MOTOR
Check Pinion Projection Length No-Load Test
1. Connect the positive (+) lead from a battery to Test the characteristics of the starter motor by
the “S” terminal. performing a no load test.
2. Connect the negative (-) lead to the “M”
terminal. CAUTION
3. Lightly pull the pinion away from the gear The starter motor can be damaged if
housing. operated continuously longer than
4. Turn the switch ON and measure the pinion 10 seconds while performing the
moving distance L in the thrust direction no-load test.
(Figure 10-35). Perform this test within 10 0000034en

seconds.
1. Secure the starting motor in a vise or other
suitable fixture.
2. Connect an ammeter (Figure 10-37, (1)) in
series between the battery positive (+) terminal
(Figure 10-37, (2)) and the main positive (+)
terminal (Figure 10-37, (3)) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to or
0000132
greater than the amperage draw
specification for the starter motor being
Figure 10-35 tested.
See Starter Motor Specifications on page 10-6 for
service limit.
(3)
5. If the measured L dimension is outside the
standard range, adjust the dust covers to obtain (6) (1)
the standard range. Dust covers M (8)
(Figure 10-36, (1)) are available in 0.020 in. (2)
(0.5 mm) and 0.031 in. (0.8 mm) thicknesses. (7)

(5)
(1) (4)
0002127A

Figure 10-37
3. Connect a wire lead between the mounting
base of the starter motor (Figure 10-37, (4))
and the battery negative terminal
(Figure 10-37, (5)).
4. Connect a voltmeter (Figure 10-37, (7)) to the
0000133
battery negative (-) terminal (Figure 10-37, (5))
and the main positive (+) battery terminal
Figure 10-36 (Figure 10-37, (3)) on the starter motor.

TNV IDI Service Manual 10-19

STARTER MOTOR Starter Motor

5. Install a switch (Figure 10-37, (6)) in a circuit Installation of Starter Motor

between the battery positive (+) terminal
(Figure 10-37, (2)) and the starter solenoid 1. Reinstall the starter motor to the flywheel
switch terminal (Figure 10-37, (8)) on the housing.
starter motor. 2. Reinstall the starter mounting bolts
6. Use a suitable tachometer to monitor the rpm of (Figure 10-38, (1)). Tighten the bolts to
the starter. specification. See Tightening Torques for
Standard Bolts and Nuts on page 4-25.
7. Turn the switch to the ON position to energize
the solenoid and operate the starter. Monitor (1)
the rpm, amperage draw and voltage. For test
specifications, see Starter Motor Information on
page 10-5 for the appropriate starter motor.

0002126

Figure 10-38
3. Reconnect the electrical wires to the solenoid
switch assembly. Be sure to place the cover
over the battery positive (+) cable connection.
4. Reconnect the battery, negative (-) cable last.

10-20 TNV IDI Service Manual

TNV IDI Service Manual
Section 11

ALTERNATOR
Page
Before You Begin Servicing .......................................................... 11-3
Introduction.................................................................................... 11-6
Standard and Optional Dynamo Information ................................. 11-6
Standard and Optional Alternator Information............................... 11-6
Alternator Specifications................................................................ 11-6
Dynamo Specifications .................................................................. 11-7
Alternator Troubleshooting ............................................................ 11-8
Alternator Components ................................................................. 11-9
Alternator Wiring Diagram ........................................................... 11-10
Alternator Standard Output ........................................................ 11-11
Alternator .................................................................................... 11-12
Removal of Alternator............................................................ 11-12
Disassembly of Alternator...................................................... 11-12
Reassembly of Alternator ...................................................... 11-14
Installation of Alternator......................................................... 11-16
Dynamo Component Location..................................................... 11-17
Dynamo Wiring Diagram ............................................................. 11-18
Operation of Dynamo .................................................................. 11-18
Dynamo Standard Output ........................................................... 11-19
Testing of Dynamo ...................................................................... 11-20
Testing Stator Coil Continuity ................................................ 11-20
Testing Stator Coil Short-to-Ground ...................................... 11-20
Testing Dynamo Regulated Output ....................................... 11-20

TNV IDI Service Manual 11-1

ALTERNATOR
Dynamo ........................................................................................ 11-20
Removal of Dynamo............................................................... 11-20
Disassembly of Dynamo......................................................... 11-21
Reassembly of Dynamo ......................................................... 11-21
Installation of Dynamo............................................................ 11-22

11-2 TNV IDI Service Manual

Before You Begin Servicing ALTERNATOR

BEFORE YOU BEGIN A WARNING

SERVICING
A WARNING

SHOCK HAZARD!
• Turn off the battery switch (if
ENTANGLEMENT HAZARD! equipped) or disconnect the negative
battery cable before servicing the
• Stop the engine before you begin to
electrical system.
service it.
• Check the electrical harnesses for
• NEVER leave the key in the key switch
cracks, abrasions, and damaged or
when you are servicing the engine.
corroded connectors. ALWAYS keep
Someone may accidentally start the
the connectors and terminals clean.
engine and not realize you are
servicing it. This could result in a • Failure to comply could result in death
serious injury. or serious injury.
0000009en
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands, A WARNING
other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury.
0000010en
BURN HAZARD!
• Keep your hands and other body parts
away from hot engine surfaces such
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en

TNV IDI Service Manual 11-3

ALTERNATOR Before You Begin Servicing

A WARNING A CAUTION

FUME / BURN HAZARD!

PINCH HAZARD!
• Always read and follow safety related
precautions found on containers of Carefully rotate the alternator toward the
hazardous substances like parts cylinder block while loosening the
cleaners, primers, sealants and V-belt. Failure to comply may result in
sealant removers. minor or moderate injury.
0000014en
• Failure to comply could result in death
or serious injury.
0000014en
CAUTION

A CAUTION

NEVER permit anyone to operate the

engine or driven machine without proper
training.

FLYING OBJECT HAZARD! • Read and understand this Operation

Manual before you operate or service
• ALWAYS wear eye protection when the machine to ensure that you follow
servicing the engine and when using safe operating practices and
compressed air or high-pressure maintenance procedures.
water. Dust, flying debris, compressed
air, pressurized water or steam may • Machine safety signs and labels are
injure your eyes. additional reminders for safe operating
and maintenance techniques.
• Failure to comply may result in minor
or moderate injury. • See your authorized Yanmar industrial
engine dealer or distributor for
0000003en
additional training.
0000002en

CAUTION
Do not short-circuit the charging system
between alternator terminals IG and L.
Damage to the alternator will result.
0000035en

11-4 TNV IDI Service Manual

Before You Begin Servicing ALTERNATOR

CAUTION CAUTION
Do not connect a load between Using a non-specified V-belt will cause
alternator terminals L and E. Damage to inadequate charging and shorten the
the alternator will result. belt life. Use the specified belt.
0000036en 0000052en

CAUTION CAUTION
Do not operate the engine if the Agricultural or other chemicals,
alternator is producing unusual sounds. especially those with a high sulfur
Damage to the alternator will result. content, can adhere to the IC regulator.
0000039en This will corrode the conductor and
result in battery over-charging (boiling)
and charging malfunctions. Consult
CAUTION Yanmar before using the equipment in
Do not remove the positive (+) battery such an environment or the warranty is
cable from alternator terminal B while voided.
the engine is operating. Damage to the 0000053en
alternator will result.
0000037en
CAUTION
Do not use a high-pressure wash
CAUTION directly on the alternator. Water will
Do not turn the battery switch OFF while damage the alternator and result in
the engine is operating. Damage to the inadequate charging.
alternator will result. 0000049en
0000038en

CAUTION
Do not reverse the positive (+) and
negative (-) ends of the battery cable.
The alternator diode and stator coil will
be damaged.
0000050en

CAUTION
When the battery indicator goes out, it
should not come on again. The battery
indicator only comes on during
operation if the alternator fails. However,
if an LED is used in the battery indicator,
the LED will shine faintly during normal
operation.
0000051en

TNV IDI Service Manual 11-5

ALTERNATOR Introduction

INTRODUCTION
This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part
No. 129423-77200 alternator is used in this section to show the service procedures for the representative
alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures
for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working
on.

STANDARD AND OPTIONAL DYNAMO INFORMATION

YANMAR Part Number Mfg. Mfg. Part Number Specification
171301-77201 Kokusan GP8138 DC12V-15A
119910-77200 Kokusan GP9191 DC12V-20A

STANDARD AND OPTIONAL ALTERNATOR INFORMATION

YANMAR Part Number Mfg. Mfg. Part Number Specification
119620-77201 Denso 100211-4531 DC12V-40A
129423-77200 Denso 101211-1170 DC12V-40A with Pulse
129961-77200 Denso 101211-2591 DC12V-55A
119626-77210 Denso 101211-2951 DC12V-55A with Pulse

ALTERNATOR SPECIFICATIONS
Yanmar Part Number 129423-77200
Nominal Output (13.5 Volts Heat) 40 Amps
Weight 6.17 lb (2.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 5000 rpm (min-1)
Operating Range 1350 - 18000 rpm (min-1)
Grounding Characteristics Negative (-) Side of Circuit
Integrated Regulator IC Regulator
Outside Diameter of Pulley 2.724 in. (69.2 mm)
Belt Shape Type A

11-6 TNV IDI Service Manual

Dynamo Specifications ALTERNATOR

DYNAMO SPECIFICATIONS
Yanmar Part Number 119910-77200
Nominal Output 20 Amps
Weight 3.97 lb (1.8 kg)
Revolution Direction (As Viewed From Pulley) Clockwise
Rating Continuous
Battery Voltage 12 Volts
Rated Revolution 3500 rpm
Operating Range 1400 - 6600 rpm
Grounding Characteristics Negative (-) Side of Circuit
Regulator Current Limiter (Part No. 119653-77710)
A-Belt 2.56 in. (65 mm)
Outside Diameter of Pulley
Special M-Belt 2.28 in. (58 mm)
Belt Shape Type A or Type Special M

TNV IDI Service Manual 11-7

11-8
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF Replace the battery indicator.
Does battery indicator and IG terminal at alternator L terminal. Does battery Battery indicator is available from
turn ON? indicator turn on? driven machine manufacturer.
ALTERNATOR

ON ON Inspect rotor assembly and

brushes.
Start Engine.

Inspect or replace V-belt.

Battery indicator ON. Inspect alternator.

At idle, does battery Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?

Battery indicator
OFF is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.

Battery voltage minus

L terminal voltage is Excessive voltage drop between
BAT and batt ( + side) terminal.
ALTERNATOR TROUBLESHOOTING

greater than 0.5 volt.

Does battery indicator Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.

Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?

OFF
Notes: Not abnormal.
1) Use a fully charged battery

TNV IDI Service Manual

2) DC voltmeter: 0 to 30 V, 0.5 class
3) The check method is also applicable to the bench test
Alternator Troubleshooting
Alternator Components ALTERNATOR

ALTERNATOR COMPONENTS
Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.

14
12 13
10 11

8 9
6
5
29
4

3 7 19
2
16 18
1 17
25
15 28
27
26
24
23
22 0000255
21
20
Figure 11-1

1 – Nut 20 – Rear Frame Housing

2 – Pulley 21 – Bolt (2 used)
3 – Collar 22 – Holder
4 – Front Frame Housing 23 – IC Regulator Assembly
5 – Stator Assembly 24 – Bolt (2 used)
6 – Stud (2 used) 25 – Bolt
7 – Front Frame Housing Bearing 26 – Brush (2 used)
8 – Bearing Cover 27 – Bolt
9 – Bearing Cover Bolt (4 used) 28 – Rear Cover
10 – Rotor Assembly 29 – Bolt (3 used)
11 – Rear Frame Housing Bearing
12 – Bearing Cover
13 – Thrust Washer
14 – Thrust Washer
15 – Nut (2 used)
16 – Nut
17 – Insulation Bushing
18 – Spring (2 used)
19 – Brush Holder

TNV IDI Service Manual 11-9

ALTERNATOR Alternator Wiring Diagram

ALTERNATOR WIRING DIAGRAM

IG 1
IG P
B

PI P L
2
F
IC
L
3 3

0.5μF
B
4A
E T

5 6

1 – Key Switch 4 – Battery

2 – Charge Lamp (3.4 Watts Max.) 5 – Alternator Assembly
3 – Load 6 – IC Regulator Assembly
Figure 11-2

CAUTION CAUTION
Do not short-circuit the charging system Do not remove the positive (+) battery
between alternator terminals IG and L. cable from alternator terminal B while
Damage to the alternator will result. the engine is operating. Damage to the
0000035en alternator will result.
0000037en

CAUTION
Do not connect a load between
alternator terminals L and E. Damage to
the alternator will result.
0000036en

11-10 TNV IDI Service Manual

Alternator Standard Output ALTERNATOR

ALTERNATOR STANDARD OUTPUT

Output Current
60

Cold
50

13.5 Volts, Constant Ambient

Temperature at 77˚F (25˚C)
Hot
40

0 1 2 3 4 5 6 7 8
Alternator RPM (x10³ min¯¹)

Figure 11-3

TNV IDI Service Manual 11-11

ALTERNATOR Alternator

ALTERNATOR
A WARNING

SHOCK HAZARD! 2 1
• Turn off the battery switch (if 0000264

equipped) or disconnect the negative Figure 11-4

battery cable before servicing the
electrical system. Disassembly of Alternator
• Check the electrical harnesses for 1. Remove the nut (Figure 11-5, (1)) from the
cracks, abrasions, and damaged or shaft of the rotor assembly. Remove the pulley
corroded connectors. ALWAYS keep (Figure 11-5, (2)).
the connectors and terminals clean.
• Failure to comply could result in death
or serious injury.
0000009en

Removal of Alternator
1. Disconnect the electrical wires from the
alternator.
2. Loosen the V-belt.

A CAUTION

2
1 0000256

PINCH HAZARD! Figure 11-5

Carefully rotate the alternator toward the
cylinder block while loosening the
V-belt. Failure to comply may result in
minor or moderate injury.
0000014en

3. Remove the V-belt adjuster from the alternator

bolt (Figure 11-4, (1)).
4. Remove the nut (Figure 11-4, (2)) from the
gear case stud. Remove the alternator.

11-12 TNV IDI Service Manual

Alternator ALTERNATOR
2. Remove the three bolts (Figure 11-6, (1)) 5. Remove the bolts retaining the holder
retaining the rear cover (Figure 11-6, (2)) to the (Figure 11-7, (2)) to the rear frame housing.
rear frame assembly. Remove the holder.
6. Remove the nut (Figure 11-7, (3)) retaining the
insulation bushing (Figure 11-7, (4)). Remove
the insulation bushing.
7. Remove the two bolts (Figure 11-8, (1)) and
3 1 two nuts (Figure 11-8, (2)) securing the rear
frame housing to the front frame housing.

4 2
5
1

0000257A

Figure 11-6
3. Remove the brush holder (Figure 11-6, (3)).
0000265A
Remove the brush springs (Figure 11-6, (4))
and brushes (Figure 11-6, (5)). Figure 11-8
4. Remove the bolt retaining the regulator 8. Using a press, remove the rotor assembly
assembly (Figure 11-7, (1)) to the holder (Figure 11-9, (1)) from the front frame housing
(Figure 11-7, (2)). (Figure 11-9, (2)) and rear frame housing
(Figure 11-10, (1)).
3 3
1
4
1

2
100266A

Figure 11-9
0000258A

Figure 11-7

TNV IDI Service Manual 11-13

ALTERNATOR Alternator

9. Remove the stator assembly Reassembly of Alternator

(Figure 11-10, (1)) from the front frame
housing. 1. If removed, reinstall the two thrust washers
(Figure 11-12, (3)) and bearing cover
4 (Figure 11-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new bearing
(Figure 11-12, (1)). Press the bearing into the
3 rear frame housing.

3
1 2
1

0000259A

Figure 11-10
10. If it is necessary to replace the bearing
0000260A
(Figure 11-10, (2)) in the front frame housing,
remove the four bolts (Figure 11-10, (3)) Figure 11-12
securing the plate (Figure 11-10, (4)) to the
2. If removed, lubricate the outside diameter of a
front frame housing. Remove the plate. Use a
new front frame housing bearing. Press the
puller to remove the bearing. Discard the
bearing (Figure 11-13, (2)) into the front frame
bearing.
housing. Reinstall the plate (Figure 11-13, (4))
11. If it is necessary to replace the bearing to the front housing. Tighten the four bolts
(Figure 11-11, (1)) in the rear frame housing, (Figure 11-13, (3)).
use a puller to remove. Discard the bearing.
Remove the bearing cover (Figure 11-11, (2))
and two thrust washers (Figure 11-11, (3)). 4

2
3
2
1

0000259A

0000260A

Figure 11-11 Figure 11-13

11-14 TNV IDI Service Manual

Alternator ALTERNATOR
3. Position the stator assembly (Figure 11-13, (1))
on the front frame housing studs.
4. Lubricate the shaft of the rotor assembly
(Figure 11-14, (1)). Press the rotor assembly 3
into the front frame housing (Figure 11-14, (2)) 1
4
and rear frame housing (Figure 11-14, (3)).

0000258A

100266A Figure 11-16

Figure 11-14 7. Reassemble the regulator assembly

(Figure 11-16, (1)) to the holder
5. Align the front frame housing with the rear (Figure 11-16, (2)).
frame housing. Reinstall the two bolts 8. Reinstall the brush holder (Figure 11-17, (3)),
(Figure 11-15, (1)) and two nuts springs (Figure 11-17, (4)) and brushes
(Figure 11-15, (2)). (Figure 11-17, (5)).
2 9. Reattach the regulator assembly and holder to
the rear frame housing.

1 1
3

4 2
0000265A 5
Figure 11-15
6. Reinstall the insulation bushing
0000257A
(Figure 11-16, (4)) and nut (Figure 11-16, (3)).
Figure 11-17
10. Reinstall the rear cover (Figure 11-17, (2)) to
the rear frame housing with three bolts
(Figure 11-17, (1)).

TNV IDI Service Manual 11-15

ALTERNATOR Alternator

4. Start the engine. Listen for any unusual sounds

from the alternator.

CAUTION
Do not operate the engine if the
alternator is producing unusual sounds.
Damage to the alternator will result.
0000039en

5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.

2
1 0000256

Figure 11-18
11. Reassemble the pulley (Figure 11-18, (2)) and
nut (Figure 11-18, (1)) to the shaft of the rotor
assembly. Tighten the nut.

Installation of Alternator
1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 11-19, (2)) on
the gear case stud and the V-belt adjuster bolt
(Figure 11-19, (1)).

2 1
0000264

Figure 11-19
2. Reconnect the electrical wires to the alternator.
Tighten the nuts to 15 - 20 in.-lb (1.7-2.3 N·m;
17-23 kgf·m).
3. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and Adjust Cooling
Fan V-Belt on page 5-27.

11-16 TNV IDI Service Manual

Dynamo Component Location ALTERNATOR

DYNAMO COMPONENT LOCATION

Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on.

(1)

(2)
(3)
(4)
(7)

(5)
(8) (9)
0002140

(6) (10)

(11) (12)

(13)

(14)

0002140

Figure 11-20

1 – Rear Cover 8 – Spacer

2 – Nut 9 – Stator Assembly
3 – Lock Washer 10 – Front Bearing (2 used)
4 – Flat Washer 11 – Flat Washer
5 – Rear Bearing 12 – Flywheel Assembly
6 – Output Wire and Connector 13 – Pulley Half
7 – Plate 14 – Through Bolt

TNV IDI Service Manual 11-17

ALTERNATOR Dynamo Wiring Diagram

DYNAMO WIRING DIAGRAM

(3)

(5) (6)

(2) (4)

(1)

0002137

Figure 11-21

1 – Dynamo 4 – Charge Lamp (3.4 Watts Max.)

2 – Current Limiter Assembly 5 – Battery
3 – Key Switch 6 – Load

OPERATION OF DYNAMO
The dynamo consists of a series of permanent
magnets that rotate around a stationary stator coil.
The magnets are attached to the flywheel which is
rotated via the engine cooling fan drive belt. The
resultant output is an AC (alternating current)
signal. The AC is converted to DC (direct current)
by the current limiter. The current limiter outputs
charging DC current to the battery.

11-18 TNV IDI Service Manual

Dynamo Standard Output ALTERNATOR

DYNAMO STANDARD OUTPUT

0002138

Figure 11-22

TNV IDI Service Manual 11-19

ALTERNATOR Testing of Dynamo

TESTING OF DYNAMO DYNAMO

Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo
1. Disconnect the output wire connector from the
Testing Stator Coil Continuity dynamo.
1. Disconnect the dynamo output wire connector. 2. Loosen the V-belt.
2. Connect one meter lead to each of the stator
wire terminals and read the meter. A CAUTION
Results: The meter reading should indicate
continuity. If continuity is not indicated, the windings
are open and the stator must be replaced.

Testing Stator Coil Short-to-Ground

1. Disconnect the dynamo output wire connector. PINCH HAZARD!
2. Test continuity between each stator wire Carefully rotate the alternator toward the
terminal and engine ground. cylinder block while loosening the
Results: The meter reading should indicate infinity. V-belt. Failure to comply may result in
If the meter reading indicates continuity, the minor or moderate injury.
windings are shorted to ground and the stator must 0000014en

be replaced.
3. Remove the V-belt adjuster from the dynamo
Testing Dynamo Regulated Output bolt (Figure 11-23, (1)).

1. Test and record the battery voltage with the 4. Remove the nut (Figure 11-23, (2)) from the
engine OFF. gear case stud. Remove the dynamo.

2. Start the engine and operate it at normal

operating rpm.
3. Check the battery voltage with the engine
running.
Results: The meter reading with the engine
running must be higher than with the engine not
running.
(1) 0002141
• If results are not correct, test the stator for (2)
continuity and shorts to the ground.
Figure 11-23
• Check the charging system wiring.
• If no problems are found in previous checks,
replace the IC regulator.

11-20 TNV IDI Service Manual

Dynamo ALTERNATOR
Disassembly of Dynamo
(3)
1. Remove the rear cover (Figure 11-24, (1)).
2. Remove the nut (Figure 11-23, (2)), lock
washer (Figure 11-24, (3)), and flat washer
(Figure 11-24, (4)).
(2)
(1)
(2) (1)
(3)
(4)

0002145

Figure 11-26

Reassembly of Dynamo
1. Reinstall the rear bearing (Figure 11-26, (3)).
0002143
2. Reinstall the stator (Figure 11-26, (1)).
Figure 11-24 3. Reinstall screws (Figure 11-26, (1)).
3. Remove the through bolt (Figure 11-25, (1)), 4. Reinstall the front bearings (Figure 11-27, (5))
pulley half (Figure 11-25, (2)), flywheel and spacer (Figure 11-27, (6)).
(Figure 11-25, (3)), flat washer 5. Reinstall the flat washer (Figure 11-27, (4)),
(Figure 11-25, (4)), bearings flywheel (Figure 11-27, (3)), pulley half
(Figure 11-25, (5)), and spacer (Figure 11-27, (2), and through bolt
(Figure 11-25, (6)). (Figure 11-27, (1)).

(6) (6)
(5) (5)
(4) (4)
(3) (3)
(2) (2)
(1) (1)

0002144 0002144

Figure 11-25 Figure 11-27

4. Remove the screws (Figure 11-26, (1)) and the
stator assembly (Figure 11-26, (2)).
5. Remove the rear bearing (Figure 11-26, (3)).

TNV IDI Service Manual 11-21

ALTERNATOR Dynamo

6. Reinstall the flat washer (Figure 11-28, (4)), Installation of Dynamo

lock washer (Figure 11-28, (3)), and nut
(Figure 11-28, (2)). Tighten the nut to the 1. Position the dynamo on the gear case. Loosely
specified torque. reinstall the nut (Figure 11-29, (2)) on the gear
case stud and the V-belt adjuster bolt
7. Reinstall the rear cap (Figure 11-28, (1)). (Figure 11-29, (1)).
(1)
(2)
(3)
(4)

(1) 0002141
(2)

Figure 11-29

0002143 2. Reconnect the dynamo output wire connector.

Figure 11-28 3. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and Adjust Cooling
Fan V-Belt on page 5-27.
4. Start the engine. Listen for any unusual sounds
from the alternator.

CAUTION
Do not operate the engine if the
alternator is producing unusual sounds.
Damage to the alternator will result.
0000039en

5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.

11-22 TNV IDI Service Manual

TNV IDI Service Manual
Section 12

ELECTRIC WIRING
Page
Electric Wiring Precautions .......................................................... 12-3
Electric Wire Resistance ............................................................... 12-4
Battery Cable Resistance.............................................................. 12-5
Electrical Wire Sizes - Voltage Drop ............................................. 12-6
Conversion of AWG to European Standards................................. 12-7

TNV IDI Service Manual 12-1

ELECTRIC WIRING

This Page Intentionally Left Blank

12-2 TNV IDI Service Manual

Electric Wiring Precautions ELECTRIC WIRING

ELECTRIC WIRING CAUTION

PRECAUTIONS Removing the battery cables or the
Failure to follow these precautions may result in the battery while the engine is operating
failure of an electrical component and the loss of may cause damage to the current limiter
warranty coverage on that item as well as related depending on the electrical equipment
items. Make sure that all users read and being used. This situation could cause
understand these precautions. loss of control of output voltage. The
continuous high voltage of 23-24 volts
(for 5000 rpm dynamo) will damage the
CAUTION current limiter and other electrical
Do not reverse the positive (+) and equipment.
negative (-) ends of the battery cable. 0000058en
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
Reversing the battery cable connections
at the battery or on the engine will
CAUTION destroy the SCR diode in the current
When the battery indicator goes out, it limiter. This will cause the charging
should not come on again. The battery system to malfunction and may cause
indicator only comes on during damage to the electrical harnesses.
operation if the alternator fails. However, 0000059en
if an LED is used in the battery indicator,
the LED will shine faintly during normal
operation.
0000051en

CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated in the Battery Cable
Resistance chart in the Electric Wiring
Section of this manual. The starter
motor will malfunction and fail if the
resistance is higher than the specified
value.
0000057en

TNV IDI Service Manual 12-3

ELECTRIC WIRING Electric Wire Resistance

ELECTRIC WIRE RESISTANCE

Metric
AWG Ohms / Foot
Nominal mm²
20 0.5 0.009967
18 0.8 0.006340
16 1.25 0.004359
14 2 0.002685
12 3 0.001704
10 5 0.001073
8 8 0.000707
6 15 0.000421
4 20 0.000270
2 30 0.000158
1 40 0.000130
0 (1/0) 50 0.000103
00 (2/0) 60 0.000087
000 (3/0) 85 0.000066
0000 (4/0) 100 0.000051

Wiring voltage drop should not exceed 5% [0.05] x 12 Volts = 0.6 Volts.
Voltage Drop = Current [Amps] x Length of Wire [Feet] x Resistance per Foot [Ohms]
Example:
Current draw of 100 Amps x 3 feet of 4 AWG wire
100 Amps x 3 Feet x 0.000270 = 0.08 Volts [Voltage Drop]

12-4 TNV IDI Service Manual

Battery Cable Resistance ELECTRIC WIRING

BATTERY CABLE RESISTANCE

Maximum Total Battery Cable Length
(Positive Cable + Negative Cable + a*)
AWG mm² 12V Starter Motor Output
Less Than 2.68 hp (2 kW) Greater Than 2.68 hp (2 kW)
m ft m ft
6 15 1.5 4.75 N/A N/A
4 20 2.3 7.4 N/A N/A
2 30 3.8 12.6 2.3 7.5
1 40 4.6 15.3 2.8 9.2
0 (1/0) 50 5.9 19.5 3.5 11.6
00 (2/0) 60 7.0 22.8 4.2 13.7
000(3/0) 85 9.3 30.5 5.6 18.3
0000 (4/0) 100 11.9 39.0 7.1 23.4
00000 (5/0) 125 N/A N/A 8.3 27.3
000000 (6/0) 150 N/A N/A 10.1 33.3

Note: Total allowable resistance of the complete battery cable circuit (positive cable + negative cable + a*)
(a*: Resistance (:) of a battery switch or other electrical equipment having high resistance)
Note: For starter motors of less than 2.68 HP (2 kW): the total resistance must be less than 0.002 Ω. For
starter motors of greater than 2.68 HP (2 kW): the total resistance must be less than 0.0012 Ω.

TNV IDI Service Manual 12-5

ELECTRIC WIRING Electrical Wire Sizes - Voltage Drop

ELECTRICAL WIRE SIZES - VOLTAGE DROP

Total Length of conductor from source of current to device and back to source (in feet)
current on
circuit in 10 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
amps.
12 Volts Wire Size (AWG)
5 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
10 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
15 12 10 10 8 8 6 6 6 4 4 2 2 2 2 2 1 1 1 1
20 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
25 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
30 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
40 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
50 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0
60 6 4 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0 4/0
70 6 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0
80 6 4 2 2 1 0 3/0 3/0 4/0 4/0
90 4 2 2 1 0 2/0 3/0 4/0 4/0
100 4 2 2 1 0 2/0 3/0 4/0
24 Volts
5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8
10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2
20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
25 12 12 10 10 8 6 6 6 4 4 4 4 2 2 2 2 2 2 1
30 12 10 10 8 8 6 6 4 4 4 2 2 2 2 2 1 1 1 1
40 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
50 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
60 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
70 8 6 6 4 4 2 2 1 1 0 0 2/0 2/0 3/0 3/0 3/0 3/0 4/0 4/0
80 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
90 8 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 4/0
100 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0

12-6 TNV IDI Service Manual

Conversion of AWG to European Standards ELECTRIC WIRING

CONVERSION OF AWG TO EUROPEAN STANDARDS

Conductor Size Conductor Diameter Conductor Cross-sectional Area
(AWG) (mm) (mm2)
25 0.455 0.163
24 0.511 0.205
23 0.573 0.259
22 0.644 0.325
21 0.723 0.412
20 0.812 0.519
19 0.992 0.653
18 1.024 0.823
17 1.15 1.04
16 1.29 1.31
15 1.45 1.65
14 1.63 2.08
13 1.83 2.63
12 2.05 3.31
11 2.30 4.15
10 2.59 5.27
9 2.91 6.62
8 3.26 8.35
7 3.67 10.6
6 4.11 13.3
5 4.62 16.8
4 5.19 21.2
3 5.83 26.7
2 6.54 33.6
1 7.35 42.4
0 (1/0) 8.25 53.4
00 (2/0) 9.27 67.5
000(3/0) 10.40 85.0
0000 (4/0) 11.68 107.2
00000 (5/0) 13.12 135.1
000000 (6/0) 14.73 170.3
1.1 circular mil (CM) ≅ 0.0005067 mm
2

TNV IDI Service Manual 12-7

ELECTRIC WIRING Conversion of AWG to European Standards

This Page Intentionally Left Blank

12-8 TNV IDI Service Manual

TNV IDI Service Manual
Section 13

TROUBLESHOOTING
Page
Special Service Tools .................................................................... 13-3
Troubleshooting By Measuring Compression Pressure ................ 13-4
Compression Pressure Measurement Method ........................ 13-4
Standard Compression Pressure ............................................ 13-5
Engine Speed and Compression Pressure
(Use for Reference) ................................................................. 13-5
Measured Value and Troubleshooting..................................... 13-6
Quick Reference Table For Troubleshooting ................................ 13-6
Troubleshooting Charts ................................................................. 13-7
Electric Wiring ............................................................................. 13-19

TNV IDI Service Manual 13-1

TROUBLESHOOTING

This Page Intentionally Left Blank

13-2 TNV IDI Service Manual

Special Service Tools TROUBLESHOOTING

SPECIAL SERVICE TOOLS

For measuring compression pressure

Compression Gauge Kit
Yanmar Part No. TOL-97190080

0000849

TNV IDI Service Manual 13-3

TROUBLESHOOTING Troubleshooting By Measuring Compression Pressure

TROUBLESHOOTING BY 3. Turn off the fuel supply valve in the fuel supply
line. Disconnect the fuel injection stop solenoid
MEASURING COMPRESSION at the connector. Crank the engine for a few
PRESSURE seconds with the stop solenoid disconnected
(no injection state) before installing the
Compression pressure drop is one of major causes compression gauge adapter (Figure 13-1, (1)),
of increasing blow-by gas (engine oil contamination this will expel any residual fuel from the
or increased engine oil consumption as a resultant cylinder.
phenomenon) or starting failure. The compression
pressure is affected by the following factors: 4. Install one injector gasket at the tip end of the
compression gauge adapter. Install the
1. Degree of clearance between piston and compression gauge and the compression
cylinder gauge adapter at the cylinder to be measured.
2. Degree of clearance at intake / exhaust valve 5. Crank the engine until the compression gauge
seat reading is stabilized.
3. Gas leak from nozzle gasket or cylinder head
gasket
The pressure will drop due to increased parts wear.
Pressure drop reduces the durability of the engine.
1
A pressure drop may also be caused by scratched
cylinder or piston by dust entrance from the dirty air
cleaner element or worn or broken piston ring.
Measure the compression pressure to determine
the condition of the engine.

Compression Pressure Measurement

Method
Figure 13-1
1. Warm up the engine.
6. After performing the compression check,
2. Stop the engine. Remove the high-pressure fuel
remove the compression gauge and
injection lines as an assembly from the engine.
compression gauge adapter from the cylinder.
See Removal of High-Pressure Fuel Injection
Reinstall the fuel injector, high-pressure fuel
Lines on page 7-11. Remove the fuel injector
injection lines and reconnect the stop solenoid.
from the cylinder to be measured. See Removal
See Installation of the Fuel Injectors on
of Fuel Injectors on page 7-23.
page 7-29 and Installation of High-Pressure
Fuel Injection Lines on page 7-12.
CAUTION
7. Turn on the fuel supply valve and reconnect the
Remove or install the high-pressure fuel
injection pump stop solenoid.
injection lines as an assembly whenever
possible. Disassembling the 8. Prime the fuel system. Check for leaks. Test the
high-pressure fuel injection lines from engine.
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
fuel lines.
0000047en

13-4 TNV IDI Service Manual

Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING
Standard Compression Pressure
Engine compression pressure list (reference value)
Compression Pressure at 250 rpm (250 min-1)
Engine Model Deviation Between Cylinders
Standard Limit
2TNV70 470 ± 15 psi 370 ± 15 psi
3TNV70 (3.24 ± 0.1 MPa; 33 ± 1 kgf/cm²) (2.55 ± 0.1 MPa; 26 ± 1 kgf/cm²) 29 to 43 psi
498 ± 15 psi 399 ± 15 psi (0.2 to 0.3 MPa; 2 to 3 kgf/cm²)
3TNV76
(3.43 ± 0.1 MPa; 35 ± 1 kgf/cm²) (2.75 ± 0.1 MPa; 28 ± 1 kgf/cm²)

Engine Speed and Compression Pressure (Use for Reference)

569 psi
3.92 MPa
(40 kgf/cm2)
Compression Pressure

498 psi
3.43 MPa
(35 kgf/cm2)
427 psi
2.94 MPa
(30 kgf/cm2)
356 psi
2.45 MPa
(25 kgf/cm2)

285 psi
1.96 MPa
(20 kgf/cm2)

200 250 300 350 400

Engine Speed (min-1)
0001915

Figure 13-2

TNV IDI Service Manual 13-5

TROUBLESHOOTING Quick Reference Table For Troubleshooting

Measured Value and Troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.

No. Item Cause Corrective Action

Clogged element Clean the element.
1 Air Cleaner Element Broken element
Replace the element.
Defect at element seal portion
2 Valve Clearance Excessive or no clearance Adjust the valve clearance.
3 Valve Timing Incorrect valve clearance Adjust the valve clearance.
Replace the gasket.
4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake / Exhaust Valve Sticking valve Replace the intake / exhaust valve.

5 Gas leak due to worn valve seat

Valve Seat or foreign matter trapped in Lap the valve seat.
valve
Piston
Gas leak due to scratching or
6 Piston Ring Perform honing and use an oversized part.
wear
Cylinder

QUICK REFERENCE TABLE

FOR TROUBLESHOOTING
The following table summarizes the general trouble
symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a
serious problem so as not to shorten the engine
service life.

13-6 TNV IDI Service Manual

Troubleshooting Charts TNV IDI Service Manual TROUBLESHOOTING
Troubleshooting Charts
Insufficient Poor
Engine Engine Air
Trouble Symptom Starting Problem Engine Exhaus Engine Oil
Surging Coolant Intake
Output t Color
Engine
Exhaust During
Starts But
Color Work
Stops Soon.
Exhaust
Smoke Corrective Action Reference Page

Cause

Engine Does Not Start

None
Little
Much
Ordinary
White
Black
White
Black
High Knocking Sound During Combustion
Abnormal Engine Sound
Uneven Combustion Sound
During Idling
During Work Operation
Excessive Engine Vibration
Difficulty in Returning to Low Speed
Excessive Fuel Consumption
Excessive Oil Consumption
Dilution by Diesel Fuel
Oil with Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Low Water Temperature
Pressure Drop
Pressure Rise
Exhaust Temperature Rise
Improper Intake/Exhaust Valve See “Measuring and Adjusting
O O O O O O Adjust the Valve Clearance.
Clearance Valve Clearance” on page 6-34.
See “Valve Face and Valve Seat”
Compression Leakage from Valve Seat O O O O O O O O Lap the Valve Seat.
on page 6-28.
Correct or Replace Intake/ See “Inspection of Intake and
Intake/Exhaust Valve Seizure O O O O O O O O O O O
Exhaust Valve. Exhaust Valves” on page 6-27.
See “Disassembly of Cylinder
Cylinder Head Gasket Blowout O O O Replace the Gasket.
Head” on page 6-21.
See “Reassembly of Cylinder
Seized or Broken Piston Ring O O O O O O O O O O O O Replace the Piston Ring.
Head” on page 6-31.

Engine System
Perform Honing and Use Oversize See “Honing and Boring” on
Worn Piston Ring, Piston or Cylinder O O O O O O O
Parts. page 6-53.
See “Inspection of Crankshaft and
Seized Crankpin Metal or Bearing O O O O O O O Repair or Replace. Camshaft Components” on
page 6-46.
Improper Arrangement of Piston Ring See “Reassembly of Pistons” on
O O O O Correct the Ring Joint Positions.
Gaps page 6-55.

TNV IDI Service Manual 13-7

TROUBLESHOOTING Troubleshooting Charts

This Page Intentionally Left Blank

13-8 TNV IDI Service Manual

Troubleshooting Charts TROUBLESHOOTING

Insufficient Poor
Engine Engine Air
Trouble Symptom Starting Problem Engine Exhaus Engine Oil
Surging Coolant Intake
Output t Color
Engine
Exhaust During
Starts But
Color Work
Stops Soon.
Exhaust
Smoke Corrective Action Reference Page

Cause

Engine Does Not Start.

None
Little
Much
Ordinary
White
Black
White
Black
High Knocking Sound During Combustion
Abnormal Engine Sound
Uneven Combustion Sound
During Idling
During Work Operation
Excessive Engine Vibration
Difficulty in Returning to Low Speed
Excessive Fuel Consumption
Excessive Oil Consumption
Dilution by Diesel Fuel
Oil with Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Low Water Temperature
Pressure Drop
Pressure Rise
Exhaust Temperature Rise
See “Reassembly of Pistons” on
Reverse Assembly of Piston Rings O O O O Reassemble Correctly.
page 6-55.
See “Inspection of Crankshaft and
Worn Crankpin and Journal Bearing O O O O O O Measure and Replace. Camshaft Components” on
page 6-46.
Loose Connecting Rod Bolt O O O Tighten to the Specified Torque. See “” on page 6-14.
Foreign Matter Trapped in Combustion See “Disassembly of Cylinder
O O O O Disassemble and Repair.
Chamber Block Components” on page 6-37.
See “Checking Timing Gear
Excessive Gear Backlash O Adjust Gear Meshing.
Backlash” on page 6-38.
See “Inspection of Valve Guides”
Worn Intake/Exhaust Valve Guide O O O Measure and Replace.
on page 6-26.

Engine System - Continued

See “Check and Adjust the
Governor Adjusted Incorrectly O O O O O Make Adjustment. Governor Lever and Engine
Speed Control” on page 5-27.
Improper Open/Close Timing of Intake/ See “Measuring and Adjusting
O O O O O O Adjust the Valve Clearance.
Exhaust Valves Valve Clearance” on page 6-34.

TNV IDI Service Manual 13-9

TROUBLESHOOTING Troubleshooting Charts

This Page Intentionally Left Blank

13-10 TNV IDI Service Manual

Troubleshooting Charts TROUBLESHOOTING

Poor
Insufficient
Exhaus Engine Engine Air
Trouble Symptom Starting Problem Engine Engine Oil
t Surging Coolant Intake
Output
Color
Engine
Starts Exhaust During
but Stops Color Work
Soon. Corrective Action Reference Page
Exhaust
Smoke

Cause

Engine Does Not Start.

None
Little
Much
Ordinary
White
Black
White
Black
High Knocking Sound During Combustion
Abnormal Engine Sound
Uneven Combustion Sound
During Idling
During Work Operation
Excessive Engine Vibration
Difficulty in Returning to Low Speed
Excessive Fuel Consumption
Excessive Oil Consumption
Dilution by Diesel Fuel
Oil with Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Low Water Temperature
Pressure Drop
Pressure Rise
Exhaust Temperature Rise
See “Disassembly of Engine
Excessive Radiator Cooling O O O Replace Thermostat.
Coolant Pump” on page 8-7.
See “Disassembly of Engine
Replace Thermostat or Check for Coolant Pump” on page 8-7. or
Insufficient Radiator Cooling O O O
Loose Fan Belt. Check and Adjust Cooling Fan V-
Belt on page 5-27
Check Water Leakage from See “Engine Coolant System
Insufficient Engine Coolant Level O O O
Engine Coolant System. Check” on page 8-7.
See “Disassembly of Engine
Cracked Water Jacket O O O Repair or Replace.
Coolant Pump” on page 8-7.

Engine Coolant System

See “Check and Adjust Cooling
Stretched Fan Belt O O O Adjust the Belt Tension.
Fan V-Belt” on page 5-19.
See “Disassembly of Engine
Defective Thermostat O O O O Check or Replace.
Coolant Pump” on page 8-7.
See “Engine Oil Specifications” on
Incorrect Engine Oil O O O O O O Use Correct Engine Oil.
page 4-13.
See “Disassembly of Oil Pump” on
Engine Oil System Leakage O O Repair.
page 9-9.
Insufficient Delivery Capacity of See “Disassembly of Oil Pump” on
O Check and Repair.
Trochoid Pump page 9-9.
See “Replace Engine Oil and
Clogged Engine Oil Filter O O Clean or Replace.
Engine Oil Filter” on page 5-25.
See “Disassembly of Oil Pump” on
Defective Pressure Regulating Valve O Clean, Adjust or Replace.
page 9-9.

Engine Oil System

See “Adding Engine Oil” on
Insufficient Engine Oil Level O O Add Correct Engine Oil.
page 4-14.
See “Checking Engine Oil” on
Overfilled Engine Crankcase O Check Engine Oil
page 4-14.

TNV IDI Service Manual 13-11

TROUBLESHOOTING Troubleshooting Charts

This Page Intentionally Left Blank

13-12 TNV IDI Service Manual

Troubleshooting Charts TROUBLESHOOTING

Cause

Engine Does Not Start.

None
Little
Much
Ordinary
White
Black
White
Black
High Knocking Sound During Combustion
Abnormal Engine Sound
Uneven Combustion Sound
During Idling
During Work Operation
Excessive Engine Vibration
Difficulty in Returning to Low Speed
Excessive Fuel Consumption
Excessive Oil Consumption
Dilution by Diesel Fuel
Oil with Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Low Water Temperature
Pressure Drop
Pressure Rise
Exhaust Temperature Rise
See “Checking and Adjusting Fuel
Too Early Timing of Fuel Injection Pump O O O Check and Adjust.
Injection Timing” on page 7-19.
See “Checking and Adjusting Fuel
Too Late Timing of Fuel Injection Pump O O O O Check and Adjust.
Injection Timing” on page 7-19.
See “Diesel Fuel Specifications”
Incorrect Diesel Fuel O O O O O O Use Correct Fuel Oil.
on page 4-9.
See “Drain Fuel Filter / Water
Water in Fuel System O O O O O O O Draining the Fuel Filter.
Separator” on page 5-21.
See “Drain Fuel Filter / Water
Clogged Fuel Filter O O O Clean or Replace.

Fuel System
Separator” on page 5-21.

TNV IDI Service Manual 13-13

TROUBLESHOOTING Troubleshooting Charts

This Page Intentionally Left Blank

13-14 TNV IDI Service Manual

Troubleshooting Charts TROUBLESHOOTING

Cause

Engine Does Not Start.

None
Little
Much
Ordinary
White
Black
White
Black
High Knocking Sound During Combustion
Abnormal Engine Sound
Uneven Combustion Sound
During Idling
During Work Operation
Excessive Engine Vibration
Difficulty in Returning to Low Speed
Excessive Fuel Consumption
Excessive Oil Consumption
Dilution by Diesel Fuel
Oil with Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Low Water Temperature
Pressure Drop
Pressure Rise
Exhaust Temperature Rise
See “Priming the Fuel System” on
Air in Fuel System O O O Bleed the Air.
page 4-12.
See “Check and Replace Fuel
Clogged or Cracked Fuel Line O O O Clean or Replace. Hoses and Engine Coolant
Hoses” on page 5-37.
Check the Fuel Tank Cock, Fuel
Insufficient Fuel Supply to Fuel Injection See the appropriate procedure in
O O O Filter, Fuel Line, and Fuel Feed
Pump Periodic Maintenance on page 5-1
Pump.
Uneven Injection Volume from Fuel See “Testing of Fuel Injectors” on
O O O O O O O O O Check and Adjust.
Injection Pump page 7-24.
See “Testing of Fuel Injectors” on
Excessive Fuel Injection Volume O O O O O O O Check and Adjust.

Fuel System
page 7-24.
Poor Spray Pattern from Fuel Injection See “Testing of Fuel Injectors” on
O O O O O O O O O Check and Adjust.
Nozzle page 7-24.
Foreign Matter Trapped in the
See “Fuel System Components”
Priming Failure O Valve Inside the Priming Pump
on page 7-10.
(Disassemble and Clean).
See “Drain Fuel Tank” on
Clogged Strainer at Feed Pump Inlet O Clean the Strainer.
page 5-24.

TNV IDI Service Manual 13-15

TROUBLESHOOTING Troubleshooting Charts

This Page Intentionally Left Blank

13-16 TNV IDI Service Manual

Troubleshooting Charts TROUBLESHOOTING

Cause

Engine Does Not Start.

Clogged Exhaust Pipe O O O O Clean Exhaust Pipe.

Air/Exhaust Gas System

Starting Motor Defect O Repair or Replace Stater Motor. See “Starter Motor” on page 10-9.
See “Removal of Alternator” on
Alternator Defect O Repair or Replace Alternator. page 11-12. or Removal of
Dynamo on page 11-20
Open-Circuit in Wiring O Repair Open Circuit.
See “Check Battery” on

Electrical System
Battery Voltage Drop O Inspect and Change the Battery.
page 5-23.

TNV IDI Service Manual 13-17

TROUBLESHOOTING Troubleshooting Charts

This Page Intentionally Left Blank

13-18 TNV IDI Service Manual

Electric Wiring TNV IDI Service Manual WIRING DIAGRAM

ELECTRIC WIRING
Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine
manufacturer for specific information.

KEY SWITCH* 30A

FUSE*

EMERGENCY
STOP
SWITCH*

YAZAKI NO.
LA206 7122 - 3016

Items marked with * are

YAZAKI NO.
7123 - 3010 not provided by Yanmar.
GLOW PLUG
11V-9 ±1.0 A/PER ONE 0002427A
119717 - 77800
PRE-HEAT TIME 3 sec

TNV IDI Service Manual 13-19

WIRING DIAGRAM Electric Wiring

This Page Intentionally Left Blank

13-20 TNV IDI Service Manual

MEMO

.....................................................................................................................................................................

.....................................................................................................................................................................
MEMO

.....................................................................................................................................................................

SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)

DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more re-
FAX: visions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

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