Yanmar ViO12-2A Service Manual
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Yanmar ViO12-2A Service Manual

Yanmar ViO12-2A Service Manual

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SERVICE MANUAL
EXCAVATOR
ViO12-2A

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Summary of Contents for Yanmar ViO12-2A

  • Page 1 SERVICE MANUAL EXCAVATOR ViO12-2A...

  • Page 4: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK 1-1 Correct Work ...................................1-1 1-2 Safety Precautions ..................................1-1 1-3 Preparations ....................................1-1 1-4 Cautions for Disassembly and Reassembly..........................1-1 1-5 Cautions for Removal and Installation of Hydraulic Equipment ....................1-2 1-6 Cautions for Removal and Installation of Hydraulic Piping......................1-2 1-7 Cautions for Handling Seals..............................1-3 1-8 Correct Installation of Hydraulic Hose .............................1-3 1-9 Specifications of Hydraulic Hose.............................1-6...
  • Page 5 4-2-6 Adjusting the Maximum (or Minimum) Idling Speed....................4-2-10 4-2-7 Checking the Cooling Water System and Radiator for Water Leakage ..............4-2-10 4-2-8 Checking the Sensors .............................. 4-2-11 4-3 Measurement Procedure, Service Data and Corrective Action................... 4-3-1 4-3-1 Cylinder Head................................4-3-1 4-3-2 Cylinder Block ................................
  • Page 6 6-3-6 Blade ..................................6-3-21 6-3-7 Travel ..................................6-3-25 6-3-8 Track Gauge Change ............................... 6-3-29 6-3-9 Simultaneous Operation of Travel and Blade......................6-3-33 6-3-10 Simultaneous Operation of Boom Up and Bucket....................6-3-37 6-3-11 Hydraulic P.T.O..............................6-3-41 6-4 Pressure Adjustment................................6-4-1 6-4-1 System Relief Valves ..............................
  • Page 7 7-5-2 Removal and Reinstallation of Control Valve ......................7-5-6 7-5-3 Removal and Reinstallation of Swing Motor ......................7-5-9 7-5-4 Removal and Reinstallation of Swivel Joint ......................7-5-11 7-5-5 Disassembly and Reassembly of Swivel Joint ......................7-5-15 7-5-6 Disassembly and Reassembly of Hydraulic Cylinders .................... 7-5-18 7-5-7 Removal and Reinstallation of Boom Swing Cylinder....................
  • Page 8 CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK 1-1 Correct Work....................1-1 1-2 Safety Precautions...................1-1 1-3 Preparations ....................1-1 1-4 Cautions for Disassembly and Reassembly ..........1-1 1-5 Cautions for Removal and Installation of Hydraulic Equipment ....1-2 1-6 Cautions for Removal and Installation of Hydraulic Piping ......1-2 1-7 Cautions for Handling Seals ..............1-3 1-8 Correct Installation of Hydraulic Hose .............1-3 1-9 Specifications of Hydraulic Hose .............1-6...

  • Page 10: General Cautions For Maintenance Work

    1. GENERAL CAUTIONS FOR MAINTENANCE WORK 1. General Cautions for Maintenance Work 1-1 Correct Work Correct work means the quickest possible completion of according to the correct procedures and the specified stan- dards. It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil and grease, etc.

  • Page 11: Cautions For Removal And Installation Of Hydraulic Equipment

    1. GENERAL CAUTIONS FOR MAINTENANCE WORK (6) Keep the parts apt to be damaged by water or oil apart from the oily or wet parts. e.g.: Electrical parts, rubber parts, V-belts, etc. (7) Use the jig for press-fitting the bearings, bushes and oil seals. When Sealing tape using a hammer, use a pad block.

  • Page 12: Cautions For Handling Seals

    1. GENERAL CAUTIONS FOR MAINTENANCE WORK 1-7 Cautions for Handling Seals (1) Clean out grooves of O-rings. Remove burrs or dust if any. Burrs Dust (2) Take care not to twist O-rings. Correct by your finger if it is twisted. (3) Take care not to damage seals when inserting.
  • Page 13 1. GENERAL CAUTIONS FOR MAINTENANCE WORK (3) When the hose is pressurized, the hose length varies slightly at the bend. Allow this change to occur and do not try to fasten the bend. Not pressurized When pressurized (4) It is necessary for the hose to have ample slackness for elongation and contraction, because its length will change by +2 % to -4 % when used at high pressure.
  • Page 14 1. GENERAL CAUTIONS FOR MAINTENANCE WORK (8) The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the hose and prevents sharp bending. Not good Good (9) When a bent hose is attached to two different planes, fix as shown in the diagram to prevent twisting. Not good Good (10) Use the marking on the hose as a guide to prevent twisting during installation.

  • Page 15: Specifications Of Hydraulic Hose

    1-9 Specifications of Hydraulic Hose Two types of hydraulic hoses are used in Yanmar Construction Machinery : the standard parts specified in the Yan- mar Industrial Standards (YIS) and special parts for the respective models. Specifications of the hydraulic hoses can be known by the code number or part descriptions as explained below.
  • Page 16 1. GENERAL CAUTIONS FOR MAINTENANCE WORK 1) Type of Hose (Hose Dia. & Recommended Working Pressure) Working Inner dia. Outer dia. Type of hose Hose dia. pressure (mm) (mm) (MPa) 13.5 17.2 17.5 13.7 (SAE J517, 100R1) 12.7 20.6 10.8 15.1 29.4 19.1...
  • Page 17 1. GENERAL CAUTIONS FOR MAINTENANCE WORK 4) Combination of Fitting Fitting 60 degrees bent type. Code No. R(PT) type Taper pipe thread Straight pipe thread R (PT) G (PF) with male 30 G(PF) degrees seat A·B A·E Straight pipe thread 45 degrees bent type.
  • Page 18 1. GENERAL CAUTIONS FOR MAINTENANCE WORK (2) Special Parts Description ..... Hose 8 Other accessories No accessories...Blank 1 Part name O-ring ....... 1 2 Hose material 6 Total length 7 Hose protector Rubber hose ... G (Unit : cm) Coil spring ....W Wear-resistant high Coil tube ....
  • Page 19 1. GENERAL CAUTIONS FOR MAINTENANCE WORK 5 Combination of fitting Fitting type Code Fitting type Code 90 degrees bent type. R (PT) Taper pipe thread R (PT) UNF thread with female 37 degrees seat Straight pipe thread G 60 degrees bent type. G (PF) (PF) with male 30 UNF thread with female...

  • Page 20: Air Release Of Hydraulic Equipment

    1. GENERAL CAUTIONS FOR MAINTENANCE WORK 1-10 Air Release of Hydraulic Equipment When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic equipment.

  • Page 22: Technical Data

    CHAPTER 2 TECHNICAL DATA 2-1 Specifications..................2-1-1 2-2 Outline Drawing and Working Area ............. 2-2-1 2-3 Weight List of Main Parts ..............2-3-1 2-4 Lifting Capacity List................2-4-1...

  • Page 24: Specifications

    2. TECHNICAL DATA 2. Technical Data 2-1 Specifications Item Unit ViO12-2A Main specifications of machine Dimensions Overall length (Transportation position) 3040 Transportation position Overall height Cabin Traveling position Overall width Full machine width Transportation position 1580 Overall height 2250 Traveling position...
  • Page 25 2. TECHNICAL DATA Item Unit ViO12-2A Main specifications of machine Work performance Swing speed Fuel consumption in practical operation Blade 1000 x 210 / 830 x 210 WidthHeight (Side open/close) Capacity (Side open/close) 0.044 / 0.037 Blade Lift above ground level...
  • Page 26 2. TECHNICAL DATA ViO12-2A Item Unit Hydraulic equipment Control valve Number of connected valves pcs. P1, P2 20.6 System relief set pressure Boom (at rod end) 23.5 Boom (at bottom end) Arm (at rod end) Arm (at bottom end) 23.5...
  • Page 27 2. TECHNICAL DATA ViO12-2A Item Unit Hydraulic equipment Cylinder Stroke Inside diameter Ø50 Track gauge Piston rod diameter Ø25 change Max. track gauge sec. Speed Min. track gauge sec. Swivel joint Swivel joint port diameterNumber inchpcs. 1/49 Motor Type Orbit motor...
  • Page 28 2. TECHNICAL DATA ViO12-2A Item Unit Undercarriage Shoe width Type Grouser Height Steel Shoe and link mounting method crawler Link pitch Number of shoes (One side) pcs. Crawler drive method Shoe width Rubber Lug height crawler Core metal pitch Manner of support...
  • Page 29 2. TECHNICAL DATA ViO12-2A Item Unit Engine Main specifications Compression pressure 3.2 at 250 rpm Cylinder head Open bTDC degrees 7 to 17 Intake valve Close aBDC degrees 35 to 45 Open bBDC degrees 35 to 45 Exhaust valve Close...
  • Page 30 2. TECHNICAL DATA ViO12-2A Item Unit Engine Air cleaner Type Cyclone type Filtration area Fuel injection pump Injection pump type YPES-3ML Injection pump plunger diameter Ø6.0 Injection pump cam lifting height Fuel injection timing (FID) degrees 15 to 17 Firing order 1321...
  • Page 31 2. TECHNICAL DATA ViO12-2A Item Unit Electrical equipment Boom light 12-27 Room lamp (for cabin) Wiper motor (for cabin) Cabin heater (for cabin) 2-1-8...

  • Page 32: Outline Drawing And Working Area

    2. TECHNICAL DATA 2-2 Outline Drawing and Working Area Unité : mm Unité : mm 1440 3040 3270 3350 2050 1000/830 G / G1 R650 / R500 1650 H / swing 1330/1080 1950 2370 2250 3150 1580 820/650 1000/830 2-2-1...

  • Page 33: Weight List Of Main Parts

    2. TECHNICAL DATA 2-3 Weight List of Main Parts Unit : kg Weight Weight Part Part ViO12-2A ViO12-2A 35.2 Boom Ass'y Bucket cylinder Ass'y 22.2 Arm Ass'y Boom cylinder Ass'y 11.5 Bucket Ass'y 20.4 Blade cylinder Ass'y Blade Ass'y 41.1 Swing bearing Ass'y 18.0...

  • Page 34: Lifting Capacity List

    2. TECHNICAL DATA 2-4 Lifting Capacity List ViO12-2A With:   Cabin Canopy) Type  Steel  Rubber) Crawler W/O Bucket Track gauge: Maximum : Reach from swing center line (m) : Load point height (m) : Lifting load (kg)
  • Page 35 2. TECHNICAL DATA Blade above ground Unit : kg 1.5. Max. *185 *185  *185 *190 *185 *185 *205 *205 *265 1775 -0.5 − − − − -1.0 Note : The lifting load with the asterisk (*) mark is limited by hydraulic lifting capacity rather than tipping. The lifting capacity shown in the above list is based on the ISO Standard No.

  • Page 36: Service Standards

    CHAPTER 3 SERVICE STANDARDS 3-1 Machine Performance................3-1-1 3-2 Engine....................3-2-1 3-3 Undercarriage ..................3-3-1 3-3-1 Rubber Crawler Specifications........... 3-3-1 3-4 Controls ....................3-4-1 3-5 Hydraulic Equipment................3-5-1 3-5-1 Hydraulic Cylinders ..............3-5-1 3-6 Implement .................... 3-6-1 3-6-1 Front Attachments..............3-6-1 3-6-2 Blade Moving Device ..............

  • Page 38: Machine Performance

    3. SERVICING STANDARDS 3. Service Standards 3-1 Machine Performance Applicable model ViO12-2A Item Measuring condition Unit Standard Allowance Machine performance Working speed Boom speed Machine position Max. cylinder extension sec. • Engine : rated speed • Hydraulic oil temp. : 50 to 60 °C...
  • Page 39 3. SERVICING STANDARDS Applicable model ViO12-2A Item Measuring condition Unit Standard Allowance Machine performance Machine position High speed 18,4 21,2 sec./ 20 m Travel speed • Engine : rated speed Low speed • Hydraulic oil temp. : 50 to 60 °C •...
  • Page 40 3. SERVICING STANDARDS Applicable model ViO12-2A Item Measuring condition Unit Standard Allowance Machine performance Machine position Traveling drift 15 degrees or less 5 min. • Engine : stopped • Hydraulic oil temp. : 50 to 60 °C • Drift of the machine after 5 min. on a slope with an inclination of 15 degrees.
  • Page 41 3. SERVICING STANDARDS Applicable model ViO12-2A Item Measuring condition Unit Standard Allowance Machine performance Machine position Swing drift at stopping mm or 80 or less, • Engine : rated speed degrees 20 or less • Hydraulic oil temp. : 50 to 60 °C •...

  • Page 42: Engine

    3. SERVICING STANDARDS 3-2 Engine 1) Nominal and Allowable Values ViO12-2A Applicable model 3TNV70-WBVB Item Unit Standard Wear limit Cylinder head Cylinder head distortion 0,05 or less 0,15  Intake degrees Valve seat angle ( ° )  Exhaust ...
  • Page 43 3. SERVICING STANDARDS Applicable model 3TNV70-WBVB Item Unit Standard Wear limit Valve Shaft outside dia. 11,94 11,966 to 11,984 Intake / exhaust Shaft hole inside dia. 12,07 12,000 to 12,020 valve rocker arm Oil clearance 0,13 0,016 to 0,054 Push rod bend 0,03 or less 0.03 Stem outside dia.
  • Page 44 3. SERVICING STANDARDS Applicable model 3TNV70-WBVB Item Unit Standard Wear limit Piston ring 3,010 to 3,030 Ring groove width 3,130 Ring width 2,970 to 2,990 2,950 Oil ring Clearance between groove and ring 0,020 to 0,060 0,180 End gap 0,150 to 0,350 0,440 Connecting rod 37,982 to 38,010...
  • Page 45 3. SERVICING STANDARDS Applicable model 3TNV70-WBVB Item Unit Standard Wear limit 0,111 to 0,250 Crank shaft 0,28 0,05 to 0,15 Cam shaft 0,25 Side gap 0,2 to 0,4 − Connecting rod 0,05 to 0,25 − Idle gear Crank gear, cam gear, idle gear and fuel 0,06 to 0,12 −...

  • Page 46: Undercarriage

    3. SERVICING STANDARDS 3-3 Undercarriage 3-3-1 Rubber Crawler Specifications [Unit : mm] Applicable model ViO12-2A Measuring Part Standard Wear limit position (1) Rubber crawler (2) Idler & shaft Ø30 − Ø249 Ø244 3-3-1...
  • Page 47 3. SERVICING STANDARDS [Unit : mm] Applicable model ViO12-2A Measuring Part Standard Wear limit position (1) Sprocket − 67,5 (2) Track roller & shaft − Ø25 Ø130 Ø124 3-3-2...

  • Page 48: Controls

    3. SERVICING STANDARDS 3-4 Controls Applicable model ViO12-2A Item Measuring conditions Unit Standard Allowable limit Controls Operating force Right control lever • Engine : stopped (Boom) • Hydraulic oil temp. : 50 to 60 °C • Lever operating force : Measure the force by...

  • Page 49: Hydraulic Equipment

    3. SERVICING STANDARDS 3-5 Hydraulic Equipment 3-5-1 Hydraulic Cylinders (Max. retraction length) (Stroke) [Unit : mm] 7-1 / 7-2 6-1 / Tightening torque Standard Allowable limit Nut size N•m Cylinder Ø25 / Ø30 294 to 343 Boom Ø50 Ø30 G1/4 Ø25,5 / Ø30,5 G1/4 / Ø25,5...

  • Page 50: Implement

    3. SERVICING STANDARDS 3-6 Implement 3-6-1 Front Attachments [Unit : mm] Applicable model : ViO12-2A Wear limit Standard Measuring point Bore of bush or hole Boom bracket fulcrum Ø40 Boom fulcrum Ø30 Boom swing cylinder, rod Ø30 Boom swing cylinder, bottom Ø30...

  • Page 51: Blade Moving Device

    3. SERVICING STANDARDS 3-6-2 Blade Moving Device [Unit : mm] Applicable model : ViO12-2A Wear limit Standard Measuring point Bore of bush or hole Blade cylinder, rod Ø25 Blade cylinder, bottom Ø25 -0,5 +0,5 Blade fulcrum Ø25 Track gauge change cylinder Ø33...

  • Page 52: List Of Tightening Torque

    3. SERVICING STANDARDS 3-7 List of Tightening Torque 3-7-1 Machine Unit :N•m Applicable model: ViO12-2A Equipment Thread size Tightening torque Adhesive Remarks Tightening part Engine / Electrical equipment Three Bond 1324 1 Engine bracket Fan side 44,1 to 58,8 or its equivalent...
  • Page 53 3. SERVICING STANDARDS Unit : N•m Applicable model: ViO12-2A Equipment Thread size Tightening torque Adhesive Remarks Tightening part Frame Loctite 262 116 to 138 1 Inner race of swing bearing or its equivalent Loctite 262 116 to 138 2 Outer race of swing bearing...

  • Page 54: Engine

    3. SERVICING STANDARDS 3-7-2 Engine Tightening torque for major bolts and nuts × Item Tightening torque [Unit :N•m] Lubricating oil Thread size Pitch × Cylinder head bolt 1.25 53,9 to 57,9 × Connecting rod bolt 22,6 to 27,5 × Flywheel mounting bolt 1.25 80,4 to 86,4 ×...

  • Page 56: Engine

    CHAPTER 4 ENGINE 4-1 Exploded View (General layouts of major engine components) ..4-1-1 4-2 Measurement, Inspection and Adjustment .......... 4-2-1 4-2-1 Measuring the Compression Pressure........4-2-1 4-2-2 Adjusting the Valve Clearance........... 4-2-2 4-2-3 Checking the V-belt Tension............4-2-3 4-2-4 Checking the Fuel Injection Valve..........4-2-3 4-2-5 Checking and Adjusting Fuel Injection Timing ......

  • Page 58: Exploded View (General Layouts Of Major Engine Components)

    4. ENGINE 4. Engine 4-1 Exploded View (General layouts of major engine components) Lifting fitting Cooling water pump Lifting fitting Fuel filter Suction manifold Fuel injection pump Cooling fan V-belt Regulator handle Crank shaft V-pulley Lube oil filter Oil supply port Dipstick Drain plug Oil supply port...

  • Page 59: Measurement, Inspection And Adjustment

    4. ENGINE 4-2 Measurement, Inspection and Adjustment 4-2-1 Measuring the Compression Pressure 1) Measurement Procedure (1) Warm up the engine. Remove the fuel injection pipe and the fuel injection valve from the cylinder to be measured. Compression gauge (2) Crank the engine before attaching the compression gauge adapter.

  • Page 60: Adjusting The Valve Clearance

    4. ENGINE Causes and countermeasures to be taken when the compression pressure is less than the limit value. Item Causes Countermeasures • Filter element of air cleaner • Clogged filter element • Clean the filter element. • Broken filter element •...

  • Page 61: Checking The V-Belt Tension

    4. ENGINE 4-2-3 Checking the V-belt Tension Push the center of the V-belt between the alternator and the cooling water pump with a finger. If the slack is 10 to 14 mm, the V-belt tension is proper. not, adjust V-belt tension using adjuster at the alternator.
  • Page 62 4. ENGINE [Reference : Structure of fuel injection valve] (Special swirl pre-combustion chamber) Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Valve stop spacer Nozzle valve Nozzle Nozzle body Nozzle case nut 2) Checking the Spray Pattern While pumping the lever of the nozzle tester once or twice per second at the specified fuel injection pressure (Refer to Section "2-1 Specifications".), check the spray pattern.

  • Page 63: Checking And Adjusting Fuel Injection Timing

    Spray angle Identification number Type : Pintle type YANMAR 4-2-5 Checking and Adjusting Fuel Injection Timing Note: The following procedure is performed on the No. 1 cylinder. While checking and adjusting the timing on only No. 1 cylinder is usually sufficient, the same procedure can be performed on any or all cylinders.
  • Page 64 4. ENGINE (3) Loosen two screws (1) to remove the stop solenoid (2) and O-ring (3). (4) Set the throttle to the HIGH-IDLE position. 0002468 (5) Using a wrench on the crankshaft pulley bolt, rotate the crankshaft in a clockwise direction while looking through the flywheel inspection port (1).
  • Page 65 4. ENGINE Note: The TDC (Top Dead Center) mark can be identified by the cylinder numbers stamped near the TDC mark (5) on the flywheel. 0002071A 1 – 15° BTDC (Before Top Dead Center) 2 – 20° BTDC 3 – 25° BTDC 4 –...
  • Page 66 4. ENGINE (8) Highlight 15° of the target timing mark (1) on the fly- wheel timing grid. (9) Turn on all fuel supply valves. Note: As the injection pump injects fuel to a cylinder only once every two engine revolutions, it may be necessary to rotate the crankshaft twice to see fuel being pumped from the timing tool or delivery valve of the cylinder you are using to check injection timing.
  • Page 67 4. ENGINE 2) Adjusting Fuel Injection Timing If the timing marks did not align when performing the Checking Fuel Injection Timing, the following steps must be performed to properly time the engine. (1) Leave the “spill-timing” tool installed in the fuel injec- tion pump.

  • Page 68: Adjusting The Maximum (Or Minimum) Idling Speed

    4. ENGINE 4-2-6 Adjusting the Maximum (or Minimum) Idling Speed (1) First warm up the engine. Then, gradually increase the Maximum idling speed adjusting bolt engine speed up to the maximum idling speed. (Refer to Decrease Increase Section "2-1 Specifications".) (2) If the maximum idling speed differs from the specified one, adjust the maximum idling speed using the maximum idling speed adjusting bolt.

  • Page 69: Checking The Sensors

    4. ENGINE 4-2-8 Checking the Sensors 1) Checking the Thermostat and the Thermoswitch (1) Thermostat Put the thermostat into the water in a container. While To radiator measuring the water temperature, heat the water. Check that the thermostat functions at a temperature of 69.5 to 72.5 °C.

  • Page 70: Measurement Procedure, Service Data And Corrective Action

    4. ENGINE 4-3 Measurement Procedure, Service Data and Corrective Action For the maintenance of all parts, make measurements according to the following measurement procedure. If any part is found to be defective or if any part is not within the allowable value, replace it with a new one. However, if it is expected that any part within the allowable value will exceed the value before the next maintenance based on the record of its use, be sure to replace such a part beforehand.
  • Page 71 4. ENGINE (2) Width and angle of the valve seat Remove carbon deposits from the seat surface. Mea- sure the seat width and angle using vernier calipers and an angle gauge respectively. Standard Wear limit Valve Intake seat Exhaust width Refer to Section "3-2 1) Nominal and Allowable Values".
  • Page 72 4. ENGINE (4) Last, lap the valve using only oil. Notes : 1. After correcting the valve seat, thoroughly clean the valve and the cylinder head using light oil or the like. Thor- oughly remove the valve compound or the grindstone powder. 2.
  • Page 73 4. ENGINE [Valve guide replacement procedure] (1) Extract the valve guide from the cylinder head using a Valve guide insertion tool valve guide extraction tool. (2) Put the valve guide into a container containing liquid Valve guide nitrogen, ether or alcohol together with dry ice. Then, hit projection the sufficiently cooled valve guide to fit it into the cylinder head using a valve guide insertion tool.
  • Page 74 4. ENGINE 5) Checking the Valve Spring (1) Visually check if the valve spring is free from flaws and corrosion. (2) Measure the free length (length of the spring) and inclination (squareness of the side of the coil). Standard Wear limit Free length Inclination Valve...

  • Page 75: Cylinder Block

    4. ENGINE 4-3-2 Cylinder Block Cylinder gauge 1) Checking the Cylinder Block (1) Visually check if the cylinder block is free from water leak, oil leak and cracks. If any portion of the cylin- der block might be cracked, check the portion by color check.
  • Page 76 [1] Items to be prepared Flex-Hone, power drill, and honing liquid Engine oil Light oil Flex-Hone Applicable bore dia. Yanmar code No. 129400-92420 63 to 70 Honing liquid [2] Handling procedure Soak the Flex-Hone in the honing liquid. Insert the Flex-...

  • Page 77: Valve Rocker Arm

    4. ENGINE 4) Overhaul of Cylinder (Reference) Service life of cylinder block (H = 3H Time for boring and honing (H = 1.5H Time for honing (H Increase in L.O.C Increase in L.O.C* Increase in L.O.C Increase in L.O.C and blow-by and blow-by and blow-by and blow-by...
  • Page 78 4. ENGINE 2) Checking the Push Rod Bend, Measuring the Tappet Stem Outside Diameter and Checking the Tappet Con- tact Surface Put the push rod on the surface plate to check that there is no clearance between the push rod and the surface plate. Mea- sure the tappet stem outside diameter with a micrometer.

  • Page 79: Piston And Piston Rings

    4. ENGINE 4-3-4 Piston and Piston Rings 1) Checking the Piston (1) Remove carbon deposits from the head and com- bustion surface of the piston while taking care not to damage the piston. Check if there are any cracks or damage.
  • Page 80 4. ENGINE 4) Measuring the Ring Groove Width, the Ring Width (B), and the End Gap To measure the piston ring groove width, first measure the width (B) of the piston ring. Then, fit the piston ring into the ring groove after cleaning the groove carefully. Insert a thickness gauge between the piston ring and the groove to measure the clearance between them.
  • Page 81 4. ENGINE 5) Installation of Piston Rings (1) Using a piston ring replacer, fit the piston ring into the ring groove, with the manufacturer's mark near the end of the piston ring facing upward (to the com- bustion chamber side). After fitting the piston ring, check that the piston ring moves smoothly.

  • Page 82: Connecting Rod

    4. ENGINE 7) Top Clearance (Reference) Top clearance Refer to Section "3-2 1) Nominal and Allowable Values". 8) Oversized Piston and Piston Ring (0.250S : Oversized by 0.25 mm) Piston assembly code Size classification Piston ring assembly code (including piston ring assembly) 0.250S Unsetting 119717-22950...
  • Page 83 4. ENGINE 3) Measuring the Clearance Between the Crank Pin and Bush To measure the oil clearance between the crank pin and the crank pin metal, measure the inside diameter of the crank pin metal and the outside diameter of the crank pin, and calculate the difference between them.
  • Page 84 4. ENGINE 5) Checking the Contact of the Crank Pin Metal Apply a blue ink or a minium to the inside surface of the crank pin metal. Install the crank pin metal to the crank shaft, and tighten the rod bolts at a specified tightening torque (refer to the above 3 of this section) to check the contact of the metal.

  • Page 85: Cam Shaft

    4. ENGINE 4-3-6 Cam shaft 1) Side Gap Around the Cam Shaft Cam shaft gear Before extracting the cam shaft, contact a dial gauge with the cam shaft gear to measure the side gap around Thrust metal the cam shaft. If the measured value exceeds the wear limit, replace the thrust metal with a new one.

  • Page 86: Crank Shaft

    4. ENGINE 5) Measuring the Outside Diameters of the Cam Shaft Measure the outside diameters of the cam shaft with a Flywheel side micrometer. Calculate the oil clearance from the mea- sured cam shaft outside diameter and the cam shaft Intermediate bush inside diameter measured with a cylinder gauge Gear side...
  • Page 87 4. ENGINE 2) Color Check of Crank Shaft Clean the crank shaft and check it using a color check kit or a magnetic inspector. Replace the crank shaft if it is cracked or badly damaged. If the damage is minor, cor- rect it by re-grinding.
  • Page 88 4. ENGINE Standard Wear limit Crank Crank pin outside dia. Outside dia. Refer to Section "3-2 1) Nominal and Allowable Values". Crank Main metal journal thickness clearance 6) Precautions for Installation of the Metal Caps (1) The lower half of the metal on the cap side has no oil groove. (2) The upper half of the metal on the cylinder block side has an oil groove.

  • Page 89: Gears

    4. ENGINE 4-3-8 Gears 1) Checking the Gears Check the teeth surfaces of each gear and replace the gear if the teeth are damaged, worn, or flaked. 2) Measuring the Backlashes Apply a dial gauge onto the pitch circle of the gear, and measure the backlash. Standard Wear limit Crank gear, cam gear,...

  • Page 90: Trochoid Pump

    4. ENGINE 4-3-9 Trochoid Pump 1) Clearance Between Outer Rotor and Pump Body Insert a thickness gauge between the outer rotor and the Outer rotor pump body to measure the clearance. Pump body Standard Wear limit Clearance between Thickness gauge Refer to Section "3-2 1) Nominal outer rotor and and Allowable Values".

  • Page 91: Precautions For Reassembly

    4. ENGINE 4-4 Precautions for Reassembly Reassemble the engine components in the reverse order of the disassembly procedure. Follow the precautions below particularly before and during the reassembly. 1) Cleaning the Components Clean the cylinder block, the cylinder head, the crank shaft, and the cam shaft carefully so that they are free from chips, dust, sand, and other foreign matter.
  • Page 92 (3) Oil pan mounting surface Notes : 1. Use Three Bond No. 1212 (Yanmar part code : 97777-01212) as the liquid packing. 2. Apply the liquid packing so that there should no break halfway. Otherwise, oil leakage or other trouble may be caused.
  • Page 93 4. ENGINE 8) Applying Lubricating Oil to the Push Rod Adjust Screw Contact Portion Apply lubricating oil to the hatched portion of the push rod as shown in the figure, before reassembly. Apply lubricating oil 9) Installation Direction of the Piston and the Connecting Rod I.D.

  • Page 94: Electrical Equipment

    ; a pinion which transmits the torque to the engine ring gear ; a clutch ; and a magnetic switch which pushes out the pinion and turns on and off the principal current. 1) Specifications Yanmar code 119717-77010 Applicable model...

  • Page 95: Alternator

    The alternator is a revolving-field type three-phase AC generator. The AC electricity generated by the alternator is converted to DC through the full-wave rectification by the diode and is stored in the battery. Specification Regulator specifications Yanmar code 119663-77200 Yanmar code of current limiter 119230-77712 Adjusted voltage (V) 14 to 15 Applicable model 3TNV70-WBVB...
  • Page 96 4. ENGINE Components Adjuster bolt=50 Adjuster Spacer Bolt 8×20 Nut, M10 Dynamo assembly Bolt 10×76 Ball bearing 6201 DDUC3 Screw Clamp Plate assembly Coupler Coil plate Collar Stator assembly Washer Washer Screw Ball bearing 6201 DDUC3 Coupler Collar Flywheel CMP(12P) Pulley Shaft 064682-00EN00...
  • Page 97 4. ENGINE Standard output Standard characteristics (14V) Upper Lower 5×10 Alternator speed (min 064684-00EN00 4-5-4...

  • Page 98: Electric System

    CHAPTER 5 ELECTRIC SYSTEM 5-1 Parts Layout of Electrical Equipment ..........5-1-1 5-1-1 Electrical Equipment and Electric Wiring ......... 5-1-1 5-2 Monitor and Alarm Systems ..............5-2-1 5-2-1 Part Name ................. 5-2-1 5-2-2 Performances of Alarm Sensors..........5-2-1 5-2-3 Operation of Alarm Sensors ............. 5-2-2 5-2-4 Inspection of Electrical Equipment ..........

  • Page 100: Parts Layout Of Electrical Equipment

    5. ELECTRIC SYSTEM 5. Electric System 5-1 Parts Layout of Electrical Equipment 5-1-1 Electrical Equipment and Electric Wiring 5-1-1...
  • Page 101 5. ELECTRIC SYSTEM Part Part Part Battery cable (Negative) Buzzer Stop solenoid Battery cable (Positive) Starter switch Super quick glow Battery Working lamp (Boom light) Engine oil pressure switch Horn switch Water temp. alarm lamp Fuel feed pump Slow blow fuse Battery charge alarm lamp Cut-off valve Timer unit (1 sec)

  • Page 102: Monitor And Alarm Systems

    5. ELECTRIC SYSTEM 5-2 Monitor and Alarm Systems For safer machine operation, the operator needs to have a clear understanding of the machine’s condition. However, it is difficult for the operator to keep an eye on every aspect of the machine he/she is operating. Therefore, alarms and a meter are provided to warn the operator of any trouble of the machine at the early stage.

  • Page 103: Operation Of Alarm Sensors

    5. ELECTRIC SYSTEM 5-2-3 Operation of Alarm Sensors (1) Engine oil pressure monitoring When the engine oil pressure falls to 0,04 to 0,06 MPa or below, the engine oil pressure alarm lamp lights, and the buzzer sounds. Starter SW Engine start Lamp Lamp Engine oil...

  • Page 104: Inspection Of Electrical Equipment

    5. ELECTRIC SYSTEM (3) State of charge monitoring (service hours accumulation) When there occurs a potential difference between the output voltage of the dynamo and the voltage of the battery, the lamp lights. Engine start Starter SW Lamp Lamp Lamp Terminal voltage Voltage ˜...
  • Page 105 5. ELECTRIC SYSTEM (2) Inspection of water temp. switch [1] Check the water temp. switch operation and the insulation/continu- ity resistance. Note : First, check that the continuity resistance R is proper, because the water temp. switch body also serves for grounding. If not, clean the thread part or replace the water temp.
  • Page 106 5. ELECTRIC SYSTEM (3) Inspection of current limiter [1] Measure the electric current when DC 100 V is applied between the point at which all the input/output lead wire terminals have been Current short-circuited together and the body case. (Measure it on the cur- limiter rent limiter only.) Insulation performance...
  • Page 107 5. ELECTRIC SYSTEM (4) Inspection of safety relay and glow relay [1] Measure the insulation resistance R between the coil terminal and the contact terminal. Safety relay Standard value for insulation resistance R Insulation resistance (M) Glow relay [2] Check the continuity between the terminals with a circuit tester. Continuity check Measuring point [Terminal No., Tester (+)]...
  • Page 108 5. ELECTRIC SYSTEM Note : The battery charging circuit is of an electrolytic capacitor type. The operating time t of the timer unit will be about 1.5 to 2 times longer than the specified time after more than 3-consecutive month storage. Therefore, before checking, apply the battery voltage 2 or 3 times at intervals of 10 seconds to temporarily charge the battery.

  • Page 109: Wiring Diagram

    5. ELECTRIC SYSTEM 5-3 Wiring Diagram 5-3-1...

  • Page 110: Circuit Description Of Engine Start And Stop

    5. ELECTRIC SYSTEM 5-4 Circuit Description of Engine Start and Stop 5-4-1 Start Engine Turn the starter switch to ON. ↓ • An electric current is always flowing from the battery positive An electric current flows from the starter terminal through the slow blow fuse (40A) to the starter switch switch terminal ACC to the timer unit terminal Vcc terminal 30.

  • Page 111: Engine Stop

    5. ELECTRIC SYSTEM 5-4-2 Engine Stop Turn the starter switch to OFF. ↓ The flow of electric current from the • When the starter switch is turned to OFF, the electric current starter switch is cut off. Therefore, the flowing from the starter switch terminal AC through the fuse (10A) to excitation of the "HOLD"...

  • Page 112: Battery Charge

    5. ELECTRIC SYSTEM 5-4-3 Battery Charge The electric current produced by the dynamo • An electric current flows from the dynamo terminals G1 and G2 through flows through the current limiter, the starter the both current limiter terminals Sb and then R, and the slow blow switch and the slow blow fuse to the battery fuse to the battery positive terminal, to charge the battery.
  • Page 113 CHAPTER 6 HYDRAULIC SYSTEM 6-1 Outline ....................6-1-1 6-1-1 Control Valve Operation............. 6-1-6 6-2 Hydraulic Circuit Schematic..............6-2-1 6-3 Circuit Operation.................. 6-3-1 6-3-1 Boom..................6-3-1 6-3-2 Arm .................... 6-3-5 6-3-3 Bucket..................6-3-9 6-3-4 Swing ..................6-3-13 6-3-5 Boom Swing................6-3-17 6-3-6 Blade..................

  • Page 115: Outline

    6. HYDRAULIC SYSTEM 6. Hydraulic System 6-1 Outline The hydraulic system consists of an engine, variable displacement piston pumps, a control valve, a boom cylinder, an arm cylinder, a bucket cylinder, a boom swing cylinder, a blade cylinder, a swing motor, a swivel joint, a track gauge change cylinder, two travel motors and a hydraulic oil tank.
  • Page 116 6. HYDRAULIC SYSTEM 1) Hydraulic Pump The variable displacement piston pumps and the pilot pump are linked to the flywheel of the engine through the coupling. The number of revolutions of each hydraulic pump is identical to the engine speed. Discharge volume of each pump / rev Discharge volume...
  • Page 117 6. HYDRAULIC SYSTEM 6-1-3...
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  • Page 120: Control Valve Operation

    6. HYDRAULIC SYSTEM 6-1-1 Control Valve Operation 1) Oil Flow from Hydraulic Pump (1) Oil flow from piston pump P2 The oil from the piston pump P2 flows to the sections through the port P2 of the inlet section and the parallel passage.
  • Page 121 6. HYDRAULIC SYSTEM 6-1-7...
  • Page 122 6. HYDRAULIC SYSTEM 6-1-8...

  • Page 123: Hydraulic Circuit Schematic

    6. HYDRAULIC SYSTEM 6-2 Hydraulic Circuit Schematic 6-2-1...

  • Page 124: Circuit Operation

    6. HYDRAULIC SYSTEM 6-3 Circuit Operation 6-3-1 Boom 1) Boom “Up” (1) Pilot oil flow When the boom control lever is pulled back to raise the boom, the oil from the pilot pump P3 flows through the port A of the cut-off valve and the port 3 of the pilot valve (RH) to the port a3 of the boom section to move its spool.
  • Page 125 6. HYDRAULIC SYSTEM 6-3-2...
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  • Page 128: Arm

    6. HYDRAULIC SYSTEM 6-3-2 Arm 1) Arm “Retract” (1) Pilot oil flow When the arm control lever is pulled back to retract the arm, the oil from the pilot pump P3 flows through the port A of the cut-off valve and the port 3 of the pilot valve (LH) to the port a8 of the arm section to move its spool.
  • Page 129 6. HYDRAULIC SYSTEM 6-3-6...
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  • Page 132: Bucket

    6. HYDRAULIC SYSTEM 6-3-3 Bucket 1) Bucket “Curl” (1) Pilot oil flow When the bucket control lever is moved to the left to curl the bucket, the oil from the pilot pump P3 flows through the port A of the cut-off valve and the port 4 of the pilot valve (RH) to the port a4 of the bucket section to move its spool.
  • Page 133 6. HYDRAULIC SYSTEM 6-3-10...
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  • Page 136: Swing

    6. HYDRAULIC SYSTEM 6-3-4 Swing 1) Right Swing (1) Pilot oil flow When the swing control lever is moved to the right, the oil from the pilot pump P3 flows through the port A of the cut-off valve and the port 2 of the pilot valve (LH) to the port b9 of the swing section to move its spool.
  • Page 137 6. HYDRAULIC SYSTEM 6-3-14...
  • Page 138 6. HYDRAULIC SYSTEM 6-3-15...
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  • Page 140: Boom Swing

    6. HYDRAULIC SYSTEM 6-3-5 Boom Swing The boom swing pedal is linked to the spool of the con- trol valve through L-balls and a rod. 1) Right Boom Swing Oil Flow from Hydraulic Pump When the boom swing pedal is pressed on its near side, the spool is pressed.
  • Page 141 6. HYDRAULIC SYSTEM 6-3-18...
  • Page 142 6. HYDRAULIC SYSTEM Suction filter Hydraulic pump Hydraulic oil tank Return filter Swing cylinder Control valve 6-3-19...
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  • Page 144: Blade

    6. HYDRAULIC SYSTEM 6-3-6 Blade The blade lever is linked to the spool of the control valve through L-balls and a blade cable. 1) Blade "Down" Oil Flow from Hydraulic Pump When the blade lever is pushed forward to lower the blade, the spool is pressed.
  • Page 145 6. HYDRAULIC SYSTEM 6-3-22...
  • Page 146 6. HYDRAULIC SYSTEM Suction filter Hydraulic pump Hydraulic oil tank Return filter Blade cylinder Swivel joint Control valve 6-3-23...
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  • Page 148: Travel

    6. HYDRAULIC SYSTEM 6-3-7 Travel Each travel lever is linked to the spool of the control valve through L-balls and a rod. 1) Forward Travel (Right) Oil Flow from Hydraulic Pump When the right travel lever is pushed forward, the spool of the right travel section is pressed.
  • Page 149 6. HYDRAULIC SYSTEM 6-3-26...
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  • Page 152: Track Gauge Change

    6. HYDRAULIC SYSTEM 6-3-8 Track Gauge Change The track gauge change lever is connected to the spool of the control valve through linkage. 1) Widening When the track gauge change lever is pushed forward to widen the track gauge, the spool of the track gauge change section is pulled.
  • Page 153 6. HYDRAULIC SYSTEM 6-3-30...
  • Page 154 6. HYDRAULIC SYSTEM Suction filter Hydraulic pump Hydraulic oil tank Return filter Track gauge change cylinder Swivel joint Control valve 6-3-31...
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  • Page 156: Simultaneous Operation Of Travel And Blade

    6. HYDRAULIC SYSTEM 6-3-9 Simultaneous Operation of Travel and Blade Oil Flow from Hydraulic Pump When the blade is operated while the machine is travel- ing, the oil from the piston pump P1 and that from the piston pump P2 flow to the control valve, in which they are each divided between the left or right travel section and the blade section.
  • Page 157 6. HYDRAULIC SYSTEM 6-3-34...
  • Page 158 6. HYDRAULIC SYSTEM Blade cylinder Suction filter Hydraulic pump Hydraulic oil tank Return filter Control valve Travel motor (R) B6 A6 B5 A5 Travel motor (L) Swivel joint 6-3-35...
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  • Page 160: Simultaneous Operation Of Boom Up And Bucket

    6. HYDRAULIC SYSTEM 6-3-10 Simultaneous Operation of Boom Up and Bucket Oil Flow from Hydraulic Pump A throttle Ø1.4 mm is installed in the paral-lel passage in the bucket section so that the oil can flow more smoothly to the boom section when the bucket control lever is moved while the boom with a heavy load is being raised.
  • Page 161 6. HYDRAULIC SYSTEM 6-3-38...
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  • Page 164: Hydraulic P.t.o

    6. HYDRAULIC SYSTEM 6-3-11 Hydraulic P.T.O. The P.T.O. pedal is linked to the spool of the P.T.O. section through L-balls and a rod. 1. P.T.O. Combined Flow / Single Acting Actuator Oil Flow from Hydraulic Pump When the P.T.O. pedal is pressed on its far side, the spool of the P.T.O.
  • Page 165 6. HYDRAULIC SYSTEM 6-3-42...
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  • Page 167: Safety Lock

    6. HYDRAULIC SYSTEM 6-3-12 Safety Lock 1) When the lock lever is in the lock position. When one or both of the lock levers are pulled up to the lock position, the cut-off solenoid valve does not operate and the oil passage in the cut-off solenoid valve is closed.
  • Page 168 6. HYDRAULIC SYSTEM 6-3-45...
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  • Page 170: Pressure Adjustment

    6. HYDRAULIC SYSTEM 6-4 Pressure Adjustment 6-4-1 System Relief Valves 1) Conditions (1) Engine : rated speed (2) Hydraulic oil temperature : 50 to 60 °C (3) Pressure gauge capacity : 34.3 MPa 2) Relief Valve Specifications Set pressure Valve Pump L/min No.1...

  • Page 171: Circuit Relief Valves

    6. HYDRAULIC SYSTEM 6-4-2 Circuit Relief Valves 1) Measurement Procedure (1) Arm cylinder bottom 1 Extend the arm cylinder to its stroke end, and holding the control lever in that position, read the pressure gauge. If the relief pressure of the circuit relief valve is lower than the set pressure of the system relief valve, adjust the pressure.

  • Page 172: Swing Brake Valve

    6. HYDRAULIC SYSTEM 6-4-3 Swing Brake Valve 1) Conditions (1) Engine : rated speed (2) Hydraulic oil temperature : 50 to 60 °C (3) Pressure gauge capacity : 19.6 MPa (4) Set pressure : 9.3 MPa 2) Measurement Procedure (1) Remove the step 1. (2) Remove the plugs R (G1/8) 2 from the swing brake valve and install the pressure gauge.

  • Page 173: Cut-Off Valve

    6. HYDRAULIC SYSTEM 6-4-4 Cut-Off Valve 1) Conditions (1) Engine : rated speed (2) Hydraulic oil temperature : 150 to 60 °C (3) Pressure gauge capacity : 9.8 MPa (4) Set pressure : 2.5 to 2.7 MPa 2) Measurement Position (1) Remove the grips 1 of the right and left travel levers, remove the stand cover R 2, and then disconnect the connectors of the wiring.

  • Page 174: Hydraulic Pump

    6. HYDRAULIC SYSTEM 6-5 Hydraulic Pump 1. Outline This piston pump consists of a drive shaft, a swash plate, a rotary group, a control spring, a gear pump, a housing body and so on. It is a variable displacement piston pump that discharges two equivalent volumes by means of a single rotary group.
  • Page 175 6. HYDRAULIC SYSTEM 2. Theory of operation 1) Pump function • The cylinder barrel, which is splined to the drive shaft, revolves with the shaft. • The pistons installed into the cylinder barrel, following the sliding surface of the swash plate, make a reciprocating motion, which causes the volume of the plunger to change, thereby enabling the intake and discharge pumping operations.
  • Page 176 6. HYDRAULIC SYSTEM 2) Control function • The discharge pressures P1 and P2 applied to the pistons which have the same areas cause the swash plate to operate. • Springs are installed to provide force against those discharge pressures. With no load, since the oil pressure applied to the pistons is smaller than the working load of the spring, the swash plate is held at the maximum incli- nation angle.
  • Page 177 6. HYDRAULIC SYSTEM 3) Adjustment procedure a. Loosen the hexagon nut. b. Tighten or loosen the adjust screw to set the horsepower curve. Spring T Spring guide Adjust screw Tighten the adjust screw. Loosen the adjust screw. Seal washer Body H 063267-00EN00 Circuit Pressure P1 + P2 : MPa 6-5-4...
  • Page 178 6. HYDRAULIC SYSTEM 3. Exploded view and component parts 1) Exploded view 063239-00X00 6-5-5...
  • Page 179 6. HYDRAULIC SYSTEM 2) Component parts Part Q'ty Part Q'ty Body S 31 Needle bearing Body H 32 Oil seal Shaft 33 Cone spring 34 Snap ring 42 Cylinder barrel Valve plate 35 Snap ring 28 Piston 39 O-ring 44 Hexagon socket head bolt M10  45 Shoe Shoe holder 51 Plug...
  • Page 180 6. HYDRAULIC SYSTEM 4. Special tools Unit : mm Oil seal installation jig 063145-00EN00 6-5-7...
  • Page 181 6. HYDRAULIC SYSTEM 5. Disassembly and reassembly 1) Precautions for disassembly and reassembly (1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform disassem- bly and reassembly in a clean place that is free from dust. (2) Prepare clean tools and treated oil, and handle the parts carefully.
  • Page 182 6. HYDRAULIC SYSTEM 3) Disassembly Procedure (1) Loosen four hexagon socket head bolts 68 to take gear pump 65 off. Note : Take care not to lose steel ball 67 for gear pump positioning when removing gear pump 65. 063140-00X01 (2) Loosen nut 61.
  • Page 183 6. HYDRAULIC SYSTEM Procedure (5) Remove spring T 15 and spring holder 18 from body S 1. 063043-00X01 (6) Lay body S 1 on its side to remove cylinder barrel kit. Cylinder barrel kit 063042-00EN00 (7) Remove swash plate 10 and pivot pin 12. 063041-00X01 (8) Take off stopper pin A 25 and cone springs 33.
  • Page 184 6. HYDRAULIC SYSTEM Procedure (9) Remove snap ring 42 34. 063038-00X00 (10) Lightly strike shaft 3 with elastic hammer to remove it with ball bearing 30 from body S 1. 063143-00X00 (11) Take off spring guide 19 from body H 2. 063044-00X00 (12) Remove barrel holder 9 and needles 11 as well as shoe holder 8 with assemblies of pistons 6 and shoes 7 from...
  • Page 185 6. HYDRAULIC SYSTEM 4) Reassembly Procedure (1) Install needles 11, barrel holder 9 and shoe holder 8 with piston and shoe assemblies in order in cylinder barrel 4. 063035-00X00 (2) Install oil seal 32 in body S 1. Note : Oil seal New oil seal 32 must be installed.
  • Page 186 6. HYDRAULIC SYSTEM Procedure (5) Install four cone springs 33 and stopper pin A 25. Note : Pay attention to correct direction of cone springs 33. 063039-00X00 063040-00X00 (6) Attach pivot pins 12 in spherical hollows on swash plate 10 and install it on body S 1 after coating grease on pivot pins 12.
  • Page 187 6. HYDRAULIC SYSTEM Procedure (8) Install spring holder 18 on spring T 15 and put spherical tip of spring holder 18 into bore of swash plate 10. 10 18 063237-00X00 063043-00X00 (9) Install spring guide 19 on body H 2. 063044-00X00 (10) Slowly put valve plate 5 on body H 2 in correct position determined by spring pin 56.
  • Page 188 6. HYDRAULIC SYSTEM Procedure (12) Slowly tighten two bolts (M10×65) in upper two positions for temporary installation. Note : When clearance between mating surfaces of body S 1 and body H 2 is 5 to 10 mm, install bolts 44 in remaining two positions.
  • Page 189 6. HYDRAULIC SYSTEM 6. Service standards Clean the parts to be checked and completely dry them. Check the major parts carefully and replace them with new ones if they are excessively worn or damaged and may cause malfunction. Replace any obviously deformed or dam- aged seal with new one.
  • Page 190 6. HYDRAULIC SYSTEM Procedure (4) Valve plate • Check whether there are any flaws in the sliding sur- Discharge port P1 Suction port face. If there are any deep flaws, replace the valve plate with a new one. Discharge port P2 063240-00EN00 (5) Retainer and retainer holder •...
  • Page 191 6. HYDRAULIC SYSTEM 7. Troubleshooting Trouble Cause Inspection Measure 1. Abnormal noise (1) Air sucked in due to low oil Check the hydraulic oil level. Supply hydraulic oil. level. (2) Increased suction pressure Check the filter element. Clean or replace the element. loss due to filter clogging.

  • Page 192: Control Valve

    6. HYDRAULIC SYSTEM 6-6 Control Valve 1. Outline This control valve is a mono-block valve comprising ten-series connected three-position directional control valves which control the operation of the actuators by switching the circuit, system relief valves which control the circuit pressure, circuit relief valves, an anti-cavitation valve, load check valves, throttles and others.
  • Page 193 6. HYDRAULIC SYSTEM 2. Operation of Directional Control Valves (Pilot Controlled Directional Control Valves) 1) Spool in Neutral When the spool is in neutral, the oil fed by the pump flows through the unloaded passage and Actuator ports returns to the tank through the tank passage. Load check valve (Unloaded state) The actuator ports A and B are blocked.
  • Page 194 6. HYDRAULIC SYSTEM 4) Single Operation of Blade When the blade spool is pushed in, the oil from the port P1 is regulated to a specified quantity through the throttle and the specified quantity of oil flows to the port A6 through the load check valve. The return oil from the port B6 returns to the tank through the tank passage.
  • Page 195 6. HYDRAULIC SYSTEM 5) Simultaneous Operation of Blade and Travel When the both travel spools are pulled out and the blade spool is pushed in, the oil from the port P1 and that from the port P2 flow to the travel section ports B5 and B10 respectively, while some of each oil flow is regulated to a specified quantity through the throttle and the specified quantity of oil flows to the blade section.
  • Page 196 6. HYDRAULIC SYSTEM 6) P.T.O. Operation The oil from the port P1 and that from the port P2 are combined and the combined oil flows to the port A7. The port B7 is open to the drain side. When the spool is pushed in, the oil from the port P1 and that from the port P2 are combined and the combined oil flows to the port B7.
  • Page 197 6. HYDRAULIC SYSTEM 3. System Relief Valves These relief valves are of a balance piston type and also of a cartridge type. The relief valves are located between the pump port P in each inlet section, and the tank port T in the P2 side inlet section.
  • Page 198 6. HYDRAULIC SYSTEM 4. Circuit Relief Valves (The circuit relief valves are installed on the cylinder rod side of the boom section and on the cylinder bottom side of the arm section.) These circuit relief valves are of a balance piston type and also of a cartridge type. The circuit relief valves are located between the actuator port P in each section and the tank port T.
  • Page 199 6. HYDRAULIC SYSTEM 2) Suction Operation When the pressure in the tank passage exceeds that in the port P, pressing force is applied to the socket. This creates an opening between the section body seat and the socket and oil flows from the tank passage to the port P, so that the space in the port P is filled with oil.
  • Page 200 6. HYDRAULIC SYSTEM 5. Anti-Cavitation Valve (The anti-cavitation valve is installed on the cylinder rod side of the boom swing section.) This anti-cavitation valve consists of a body, a piston and a spring. The valve is located between the actuator port P in the section and the tank port T.
  • Page 201 6. HYDRAULIC SYSTEM 6. Disassembly and Reassembly 1) Precautions for Disassembly and Reassembly • Precautions for disassembly (1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform disassem- bly and reassembly in a clean area that is free from dust. (2) Prepare clean tools and treated oil, and handle the parts carefully.
  • Page 202 6. HYDRAULIC SYSTEM 3) Exploded View and Component Parts Exploded View Port P1 5 20 18 19 18 19 5 20 18 19 5 18 19 5 5 20 17 12 5 24 16 18 19 5 18 19 5 20 4 36 5 20 18 19...
  • Page 203 6. HYDRAULIC SYSTEM Component Parts Part Q’ty Part Q’ty Nut M8 Plug G3/8 Bolt Anti-cavitation valve P1 inlet section Boom section O-ring 1B P10.0 Circuit relief valve O-ring 1B P11.0 Bucket section Plug G1/4 Travel section (R) O-ring AR P127 Blade section O-ring 1B P10.0 P.T.O.
  • Page 204 6. HYDRAULIC SYSTEM 4) Disassembly Procedure (1) Put the control valve assembly on a clean working table. (2) Remove the spring case 15 of each section. (3) Remove the pilot cases A1 36 and B1 34 of each section. Note : Each spool is installed into the valve body with a specified clearance between them.
  • Page 205 6. HYDRAULIC SYSTEM Procedure (4) Remove the boom spool, the bucket spool, the arm spool and the swing spool. Boom spool Boom spool Swing spool Swing spool Arm spool Arm spool Bucket spool Bucket spool (5) Remove the boom swing spool, the right travel spool, the Left travel Left travel Left travel...
  • Page 206 6. HYDRAULIC SYSTEM Procedure (8) Remove the plug G3 / 8 21 on the side of each section. (9) Remove the check valve holder 20 (with the O-ring 5), the check valve spring 19 and the check valve 18 of each sec- tion.
  • Page 207 6. HYDRAULIC SYSTEM Procedure (12) Remove the O-rings 4 and 7 from the mating face of each section, and remove the O-ring 40. Notes : • Put all the sections in order for reassembly. • Mark the section so that the O-ring 40 can be installed cor- rectly.
  • Page 208 6. HYDRAULIC SYSTEM 5) Reassembly Procedure (1) Install the O-rings 4 and 7 to each section and the O-ring 40 to the blade section. Put the sections in the specified order and insert the bolts 2 into them. Notes : •...
  • Page 209 6. HYDRAULIC SYSTEM Procedure (5) Install the plug G3 / 8 21 (with the O-ring 9) on the side of each section. Tightening torque : 39.2 Note : Apply grease thinly to the O-rings 9. (6) Install the system relief valves 10, the circuit relief valves 24 and the anti-cavitation valve 22.
  • Page 210 6. HYDRAULIC SYSTEM Procedure (9) Install the boom spool, the bucket spool, the arm spool and the swing spool in their original positions. Note : Replace any spool as a spool assembly if necessary. Boom spool Boom spool Swing spool Swing spool Arm spool Arm spool...
  • Page 211 6. HYDRAULIC SYSTEM 6) Troubleshooting Trouble Cause Measure 1. Oil leak from spool (1) Damaged oil seal (1) Replace oil seal. (2) Damaged spool surface (2) Replace spool. (3) Foreign substances on spool surface (3) Remove foreign substances. 2. Spool does not work smoothly or (1) Foreign substances caught inside (1) Clean hydraulic circuit and valves.
  • Page 212 6. HYDRAULIC SYSTEM This manual deals with the instructions relative to servicing and maintenance operations for the hydraulic pilot con- trol unit 4TH5 for the inspections and servicing operations associated with the hydraulic system of the machine to which they are connected. Please consult the maintenance manual supplied by the equipment manufacture. It is recommended that only qualified personnel perform the installation, connection and maintenance of this device, and that all operations shall be carried out in compliance with the technical standards in force and the cleanliness regulations specific to this type of installation.
  • Page 213 6. HYDRAULIC SYSTEM Malfunction Probable case Additional checks Remedy No machine movement (for (1) Leak See <Visual defects> hydraulic signal receivers (2) Control valve seized or Replace pilot unit only) blocked Lack of speed of one or sev- (1) Poor pressure signal Replace pilot unit eral machine movement(s)(for (2) Leak...
  • Page 214 6. HYDRAULIC SYSTEM When removing the pilot control unit, all openings must be plugged immediately to prevent any contamination of the hydraulic system. When replacing the pilot control unit, remove the plastic plugs from the openings and lines just before making the connections.
  • Page 215 6. HYDRAULIC SYSTEM Procedure Remove the pilot control unit from the machine's arm rest of free the unit by unscrewing the 4 screws fixing the plate in order to release the electrical cable. Hold the pilot control unit using a vice or a vice-grip wrench (clamp onto the body above the arm rest, 65 opening).
  • Page 216 6. HYDRAULIC SYSTEM Procedure Clamp the threaded section of the bent lever in a vice fitting with V-shaped vice clamps. Remove the pin (5 mm pin driver) Remove : - pin, - bent lever, - handle. Replace the bent lever onto the new handle and secure it with the pin (5 mm pin driver) Replace the nut on the threaded section and replace the boot.
  • Page 217 6. HYDRAULIC SYSTEM Procedure Remove the pilot control unit from the machine's arm rest. Secure the pilot control unit in a vice (clamp onto the body). Remove the handle. Fit an Allen wrench into the assembly screw and unscrew it (8 mm Allen wrench).
  • Page 218 6. HYDRAULIC SYSTEM Procedure Remove the pilot control unit from the machine's arm rest. Remove the handle. Remove the cardan. Secure the pilot control unit to a vice. Remove the retaining plate. Reassembly : Line up the notches for the grommet in both the plate and the body.
  • Page 219 6. HYDRAULIC SYSTEM Loctite 262 =30Nm =45Nm 6-7-8...
  • Page 220 6. HYDRAULIC SYSTEM Item Description Handle TT Lever kit Rubber boot Retaining plate Cardan kit composed of : 1 cardan + shims Plunger kit composed of : 4 plunger guides 4 plain plungers 4 spring rings Regulating kit Set of 4 return springs Item Description Handle SH1 PRAH + Deutsch connectors 2 &...

  • Page 221: Cut-Off Valve

    6. HYDRAULIC SYSTEM 6-8 Cut-off Valve 1. Outline The cut-off valve consists of body 1, solenoid valve 2 and relief valve 3 and serves to turn on and off pilot pressure supply to the pilot valves 2. Principle of operation When solenoid valve 2 is not energized, the oil passage from port P to port A is blocked and pressurized oil supplied from port P flows through relief valve 3 to port T.
  • Page 222 6. HYDRAULIC SYSTEM 3. Sectional view and list of parts Part name Q’ty Part name Q’ty Body Body Spool Spool Spool Spool Adjust screw Adjust screw Hexagon nut Hexagon nut Shim 6.5x12x0.5 Shim 6.5x12x0.5 Spring 8.6/1x9.5/3.5 Spring 8.6/1x9.5/3.5 6-8-2...
  • Page 223 6. HYDRAULIC SYSTEM 4. Disassembly and reassembly 1) Precautions for disassembly and reassembly (1) Be careful not to damage O-rings or other parts during disassembly and keep the disassembled parts with due care. (2) Replace any damaged O-rings with new ones (3) Be sure to install all parts in the correct orientation.
  • Page 224 6. HYDRAULIC SYSTEM 3) Disassembly and reassembly of the relief valve (1) Remove hexagon nut 5. (Tool: 24 mm wrench) (2) Remove adjust screw 4. (Tool: 14 mm wrench) (3) Remove shim 6, spring 8 and spool 3. (4) To reassemble the relief valve, follow the above steps in reverse order. (5) After reassembly, set the pressure with adjust screw 4.
  • Page 225 6. HYDRAULIC SYSTEM 5. Service standard Procedure (1) Solenoid valve Measure the clearance between the body and the spool. Clearance = φD - φd Standard: Approximately 0.01 mm (2) Relief valve Measure the clearance between the body and the spool. Clearance = φD - φd Standard: Approximately 0.01 mm 6-8-5...
  • Page 226 6. HYDRAULIC SYSTEM 6. Troubleshooting Cause Corrective actions Trouble Spool Spool does not operate due to foreign substances. Remove foreign substances, disassemble and clean malfunction the valve and/or replace the hydraulic oil. Spool damaged or abnormally worn Replace the valve. Solenoid Connector disconnected Firmly insert the connector.

  • Page 227: Swing Motor

    6. HYDRAULIC SYSTEM 6-9 Swing Motor 1. Structure and theory of operation This hydraulic swing motor consists of an orbit motor section and a pinion gear assembly section. Part The hydraulic motor has six holes in the valve 27 and seven holes in the Valve housing valve plate 30, and the displacement per revolution is 11.9 cu.in (195 Valve...
  • Page 228 6. HYDRAULIC SYSTEM Back: Port B (Low pressure) Front: Port A (High pressure) High pressure Drain line Low pressure Drain When hydraulic oil is fed to the port A, the oil flows into the oil holes in the valve 27 corresponding to the port A and runs through the oil holes in the valve plate 30 to rotate the roller 33.
  • Page 229 6. HYDRAULIC SYSTEM 2. Theory of operation for brake valve (Super shockless valve) At starting or stopping, high pressure oil flows through the orifice in the orifice plug 12 into the damper chamber and opens the plunger 7 Then, the high pressure oil flows through the oil hole in the plunger 7, the oil hole in the piston 5 and the orifice in the orifice plug 4, and finally into the other side of the piston 5.
  • Page 230 6. HYDRAULIC SYSTEM 3. Disassembly and reassembly 1) Precautions for disassembly and reassembly (1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform dis- assembly and reassembly in a clean place that is free from dust. (2) Prepare clean tools and treated oil, and handle the parts carefully.
  • Page 231 6. HYDRAULIC SYSTEM 3) Exploded view and component parts Part Q'ty Part Q'ty Part Q'ty Valve body Plug O-ring Plug O-ring Valve drive O-ring Spring Roller Orifice plug Steel ball Drive Piston Hexagon head bolt Wear plate Spring Blind plug Retaining ring Plunger Spring...
  • Page 232 6. HYDRAULIC SYSTEM 4) Disassembly Procedure (1) Remove six hexagon socket head bolts 14 to remove the valve body from the motor. Motor Brake valve (2) Hold the valve body with a vice to remove the cartridge assembly. Brake valve Cartridge assembly (3) Hold the cartridge assembly with a vice to remove plug 2.
  • Page 233 6. HYDRAULIC SYSTEM Procedure (5) Remove plunger 7 from cartridge 8. (6) Disassemble the motor section. Motor (7) Hold the flange with a vice with pinion gear 42 down, and remove four hexagon head bolts 20. (8) Remove valve housing 15. Note : Be careful not to lose springs 22 and pins 23.
  • Page 234 6. HYDRAULIC SYSTEM Procedure (9) Remove balancing plate 26 and valve 27. (10) Remove valve plate 30 and valve drive 32. (11) Remove roller 33 and drive 34. (12) Remove wear plate 35. 6-9-8...
  • Page 235 6. HYDRAULIC SYSTEM Procedure (13) Remove retaining ring 36. (14) Remove pinion gear 42 with a press or a plastic hammer. (15) Remove X-ring 39 from bearing housing 38. (16) Remove ball bearing 40 from bearing housing 38. Notes : a) Remove the bearing by tapping the inner race of it with a punch or the like.
  • Page 236 6. HYDRAULIC SYSTEM Procedure (17) Turn over bearing housing 38 to remove another ball bearing 37. Note : Do not remove the bearing unless required. (18) Remove plug 16, spring 18 and steel ball 19 from valve housing 15. (19) This is the end of disassembly. 6-9-10...
  • Page 237 6. HYDRAULIC SYSTEM 5) Reassembly Procedure Procedure (1) Install ball bearing 37 into bearing housing 38 with a press or a plastic hammer. (2) Turn over bearing housing 38 to install another ball bear- ing 40. (3) Install X-ring 39 into bearing housing 38. (4) Press fit pinion gear 42 into bearing housing 38 with a press.
  • Page 238 6. HYDRAULIC SYSTEM Procedure (5) Hold the flange with a vice to install retaining ring 36 to pinion gear 42. ((6) Install shaft face seal 41 to wear plate 35. Shaft face seal Wear plate (7) Install drive 34, O-ring 31 and then wear plate 35 to bear- ing housing 38.
  • Page 239 6. HYDRAULIC SYSTEM Procedure (9) Install valve drive 32 into roller 33. (10) Install O-rings 29 and 31 to valve plate 30, and then, install valve plate 30 on roller 33. Note : Align the drain holes in the valve plate and the roller. (11) Install valve 27.
  • Page 240 6. HYDRAULIC SYSTEM Procedure (13) Install springs 22 and pins 23 into valve housing 15. (14) Install inner face seal 24 and outer face seal 25 to balanc- ing plate 26. Outer face seal Inner face seal Balancing plate (15) With the notches of balancing plate 26 fitted with pins 23, install balancing plate 26 into valve housing 15.
  • Page 241 6. HYDRAULIC SYSTEM Procedure (17)Install and tighten four hexagon head bolts 20 evenly. Tightening torque : 49 to 54 N·m (18) Install O-ring 11 onto cartridge 8. (19) Install O-ring 10 and two backup rings 9 onto cartridge 8. (20) Install plunger 7 into cartridge 8. 6-9-15...
  • Page 242 6. HYDRAULIC SYSTEM Procedure (21) Install spring 6 and piston 5 into cartridge 8. (22)Install plug 2 into cartridge 8 and tighten it. Tightening torque : 112.8 to 117.7 N·m (23) Install the cartridge assembly into valve body 1 and tighten it.
  • Page 243 6. HYDRAULIC SYSTEM 6) Troubleshooting Trouble Cause Measure 1. Motor does not rotate. (1) Insufficient hydraulic oil quantity in Supply hydraulic oil to a specified level. hydraulic oil tank. (2) Broken pump Replace the pump. (3) Malfunction of relief valve or low set Disassemble and clean the relief valve and pressure of it set the pressure to a specified value.

  • Page 244: Travel Motor

    6. HYDRAULIC SYSTEM 6-10 Travel Motor 1. Structure The travel motor consists of a swash plate type axial piston motor, a hydraulic valve, a two-speed switching mecha- nism, a reduction gear and other parts. The swash plate type axial piston motor has 7 pistons and a high-speed switching mechanism. The hydraulic valve is integrated with the piston motor which is housed in the reduction gear.
  • Page 245 6. HYDRAULIC SYSTEM 2. Theory of Operation 1) Motor When the travel section spool of the control valve is switched for travel, the pressure oil which has flown in through the hydraulic valve flows to the valve plate 5. Then, the pressure oil flows from the valve plate 5 into the cylinder ports, which correspond to the port A, in the cylinder barrel 4 and presses the pistons 6.
  • Page 246 6. HYDRAULIC SYSTEM 2) Hydraulic Valve (Counterbalance Valve) When pressure oil is fed from the port A, it presses and opens the check valve 3 and then flows into the port A' on the inlet side of the hydraulic motor; while the pressure oil flows into the chamber D through the choke C and exceeds the force of the spring 4 to slide the spool valve 2 to the right.
  • Page 247 6. HYDRAULIC SYSTEM 3) Reduction Gear The reduction gear has a planetary double-reduction mechanism. It reduces the speed of the rotational motion transmitted from the hydraulic motor to convert the rotational motion into large low-speed torque, so that the gear case can be rotated.
  • Page 248 6. HYDRAULIC SYSTEM 3. Disassembly and Reassembly 1) Precautions for Disassembly and Reassembly (1) Since the parts of the hydraulic equipment are precision-made for tight clearances, be sure to perform disassem- bly and reassembly in a clean area that is free from dust. (2) Prepare clean tools and treated oil, and handle the parts carefully.
  • Page 249 6. HYDRAULIC SYSTEM 2) Special Tools Press 1. Bearing (for shaft) press-fitting jig 3.0 to 3.9 KN Unit : mm 49.8 to 50 C1.0 2. Oil seal press-fitting jigs Press Jig A Jig B 3.0 to 3.9 KN 30 degrees C0.5 C0.2 19.5 to 19.9...
  • Page 250 6. HYDRAULIC SYSTEM 3) Exploded View and Component Parts (Motor Section and Valve Section) 24 23 Part Q'ty Part Q'ty Body 2 O-ring 1BP18 Control piston Spring V2 Oil seal Ring Bearing 6004 Plug 1 / 16 Shaft Hexagon socket head bolt Ball Plug Swash plate...
  • Page 251 6. HYDRAULIC SYSTEM 4) Disassembly and Reassembly 4)-1 Disassembly of Motor Section Procedure (1) Hold the hydraulic motor with a vice to remove hexagon socket head bolts 28. Note : Put aluminum plates or the like between the hydraulic motor and the vice to prevent damage to the outside surface of the body 2.
  • Page 252 6. HYDRAULIC SYSTEM Procedure (5) Remove the piston shoe assemblies (pistons 9 and shoes 8), shoe holder 10, barrel holder 11 and pins 12 from cyl- inder barrel 13. Note : Each piston shoe assembly cannot be disassembled because the piston and the shoe are caulked. (6) Remove internal snap ring 16 from cylinder barrel 13, and remove retainers 14 and spring 15.
  • Page 253 6. HYDRAULIC SYSTEM Procedure (9) Remove oil seal 3 from body 2 1. 4)-2 Disassembly of Hydraulic Valve Section (10) Loosen plugs 34 (on both sides) to remove shuttle spool 32 and pins 33 (on both sides) from body 1 45. [Width across flats : 5 mm (11) Loosen plugs 38 (on both sides) to remove high-speed spool 35 and spring 36 from body 1 45.
  • Page 254 6. HYDRAULIC SYSTEM 4)-3 Reassembly of Hydraulic Valve Section Procedure (1) Install the spool assembly, rings 26 (on both sides) and springs 25 (on both sides) in this order into body 1 45, and install and tighten plugs 23 with O-rings 24 installed (on both sides).
  • Page 255 6. HYDRAULIC SYSTEM Procedure (5) Install O-rings 17 and 21 to body 1 45. 4)-4 Reassembly of Motor Section (6) Press fit oil seal 3 into body 2 1. Notes : • Fill the space between the lips of the oil seal with grease. •...
  • Page 256 6. HYDRAULIC SYSTEM Procedure (9) Install shaft 5 into body 2 1. Note : Take care not to damage the oil seal with the shaft. (10) Install two balls 6 and swash plate 7 to body 2 1. Notes : •...
  • Page 257 6. HYDRAULIC SYSTEM Procedure (13) Insert three pins 12 into cylinder barrel 13, and then, install barrel holder 11 to the cylinder barrel. (14) Install the shoe holder assembly to cylinder barrel 13. (15) Insert the cylinder barrel assembly into body 2 1 until shoes 8 contact with swash plate 7.
  • Page 258 6. HYDRAULIC SYSTEM Procedure (17) Install valve plate 19 to body 1 45, and combine body 1 45 and body 2 1. Notes : • Install the valve plate with its copper face up (toward the cylinder barrel side). • Apply hydraulic oil to the sliding surface (the copper face) of the valve plate.
  • Page 259 6. HYDRAULIC SYSTEM 4)-5 Exploded View and Component Parts (Reduction Gear Section) Part Q'ty Part Q'ty Plug Gear b1 O-ring 1BP14 Needle bearing O-snap ring Ring Cover Thrust washer O-ring AS568-248-70 or its equivalent Snap ring Angular bearing 90BVV11S2G Snap ring Body Thrust washer Seal ring...
  • Page 260 6. HYDRAULIC SYSTEM 4)-6 Disassembly of Reduction Gear Section Procedure (1) Remove plugs 1 from cover 4 and drain the lubricating oil. Width across flats : 5 mm (2) Put a screwdriver or the like in the notch of body 23 to remove O-snap ring 3.
  • Page 261 6. HYDRAULIC SYSTEM Procedure (5) Remove external snap ring 28 from the top of the shaft, and then remove gear S2 29. Note : Replace external snap ring 28 with a new one in reassembly. (6) Remove the carrier 2 assembly from the body 23. (7) After removing snap ring 7 from carrier 2 14, •...
  • Page 262 6. HYDRAULIC SYSTEM Procedure (9) Remove snap rings 7 from the b1 pin portions of body 2 30, and then, remove thrust plate 16. Note : Replace snap rings 7 with new ones in reassembly. (10) Remove gear b1 17, needle bearing 18, thrust washer 20 and ring 19 from each b1 pin portion of body 2 30.
  • Page 263 6. HYDRAULIC SYSTEM Procedure (13) Remove seal ring 24 from body 23. (14) Remove angular bearing 22 (another set) from body 2 Note : Angular bearing 22 can be disassembled into an inner race and a retainer. (15) Remove floating seat 26 and O-ring 27 together from body 2 30.
  • Page 264 6. HYDRAULIC SYSTEM 4)-7 Reassembly of Reduction Gear Section Procedure (1) Install floating seat 26 and O-ring 27 to body 2 30. Note : 26 27 26 27 Apply grease to the O-ring in advance for easy installation. (2) Install angular bearing 22 (one set) to body 2 30. Note : Since the angular bearing can be Inner race...
  • Page 265 6. HYDRAULIC SYSTEM Procedure (5) Install angular bearing 22 (another set) to body 23. Retainer Inner race Note : Since the angular bearing can be dis- Body assembled into an inner race and a retainer, take care that the retainer is installed in the correct direction.
  • Page 266 6. HYDRAULIC SYSTEM Procedure (9) Insert gear S1 15 into carrier 2 14 and fasten it with exter- nal snap ring 12. Notes : • The snap ring has the front and back sides. Install it with the edge side up (toward the cover side). •...
  • Page 267 6. HYDRAULIC SYSTEM Procedure (13) Install O-ring 5 onto body 23. Note : Apply grease to the O-ring. (14) Put lubricating oil into the body. • Type : Engine oil SAE30 (Class CD or higher) • Quantity : 0.33 L (15) Install cover 4 on body 23.
  • Page 268 6. HYDRAULIC SYSTEM 4. Service Standards (Hydraulic Motor Section) If any of the parts of the hydraulic motor is defective, replace the whole hydraulic motor assembly with a new assem- bly in principle. Part Inspection item Inspection standard Measure Pitting Excessive wear of gear Pitting area rate : and damage to teeth...
  • Page 269 6. HYDRAULIC SYSTEM (Reduction Gear Section) If any of the parts listed below is worn or damaged, replace it with a new one. Part Inspection Item Inspection Standard Measure Rate of pitting area to tooth surface area Pitting Gear body Excessive wear of gear Pitting area rate : 5 % Replace the gear body.
  • Page 270 6. HYDRAULIC SYSTEM 5. Troubleshooting Trouble Cause Measure 1. Motor does not rotate. 1) Malfunction of any hydraulic equipment Check the inlet pressure of the motor. Then, check other than travel motor and repair or replace the other equipment. 2) Malfunction of hydraulic motor (1) Pressure oil leakage due to exces- Replace the excessively worn part.

  • Page 271: Solenoid Valve

    6. HYDRAULIC SYSTEM 6-11 Solenoid Valve 1. Overview The solenoid valve consists of body 1 and solenoid 2. Part Body Solenoid 2. Operating principle When solenoid 2 is not energized, the oil passage is blocked and pressurized oil supplied from port P does not flow to any other ports.
  • Page 272 6. HYDRAULIC SYSTEM 3. Exploded view and parts list Part name Q’ty Body Solenoid Hexagon socket head bolt M4x10 Spool Spring Barrel O-ring 012 (NBR.Hs90) O-ring 011 (NBR.Hs90) O-ring 010 (NBR.Hs90) 10 O-ring 1AP18 6-11-2...
  • Page 273 6. HYDRAULIC SYSTEM 4. Disassembly and Reassembly 1) Precautions for disassembly and reassembly - Be careful not to damage O-rings or other parts during disassembly and keep the disassembled parts with due care. - Replace any damaged O-rings with new ones. - Be sure to install all parts in the correct orientation.
  • Page 274 6. HYDRAULIC SYSTEM 5. Service standard Procedure Measure the clearance between body 1 and barrel 6. Clearance = φD - φd Standard: Approximately 0.04 mm [φD1(2, 3) -φd1(2, 3)] Measure the clearance between barrel 6 and spool 4. Clearance = φD - φd Standard: Approximately 0.01 mm 6-11-4...
  • Page 275 6. HYDRAULIC SYSTEM 6. Troubleshooting Cause Corrective actions Trouble Spool Spool clogged with dirt Remove dirt, disassemble and clean the valve and/ malfunction or replace the hydraulic oil. Spool damaged or worn Replace the valve. Solenoid Connector disconnected Firmly insert the connector. malfunction Coil damaged Replace the solenoid.

  • Page 276: Adjustment And Repair

    CHAPTER 7 ADJUSTMENT AND REPAIR 7-1 Engine of Machine............7-1-1 7-5 Hydraulic Equipment ..........7-5-1 7-1-1 Removal and Reinstallation of Engine....7-1-1 7-5-1 Removal and Reinstallation of 7-1-2 Removal and Reinstallation of Starter Motor..7-1-8 Hydraulic Oil Tank..........7-5-1 7-5-2 Removal and Reinstallation of Control Valve ..7-5-6 7-1-3 Removal and Reinstallation of Fuel Injection Pump ...........

  • Page 277: Engine Of Machine

    7. ADJUSTMENT AND REPAIR 7-1 Engine of machine 7-1-1 Removal and Reinstallation of Engine 1) Preparation Procedure (1) Swing the upperstructure so that the hydraulic oil tank 1 and the engine oil drain block 2 are positioned halfway between the right and left crawlers on the opposite side of the blade.
  • Page 278 7. ADJUSTMENT AND REPAIR 2) Removal of control levers Procedure (1) Remove the bolts 1 retaining the lower covers 2 and the upper covers 3 (L and R) from the engine hood. (2) Disconnect the electric harness from the joystick R. (3) Remove three bolts M6x20 retaining the joystick and pilot valve element on the bracket.
  • Page 279 7. ADJUSTMENT AND REPAIR 3) Removal of engine Procedure (1) Remove the snap pins 1 and the link 2, and then remove the engine hood 3. (2) Loosen the hose clip 4 and disconnect the air cleaner hose A 5 from the engine intake manifold. (3) Disconnect the cover switch 6 from the safety harness and remove the switch bracket.
  • Page 280 7. ADJUSTMENT AND REPAIR Procedure (6) Disconnect the connectors of the current limiter 1, the glow relay 2, the timer unit (1 sec) 3, the safety relay 4 and the fuse box 5 from the harness A. (7) Remove the side cover R 6, and then remove the drain plug 8 from the fuel tank 7 to drain the fuel.
  • Page 281 7. ADJUSTMENT AND REPAIR Procedure (12) Disconnect the hose P1 1 and the hose P2 2 from the connectors. (13) Disconnect the hose P3 3 from the connector. Loosen the hose clips 4 and disconnect the suction hose 5 from the connector. Hydraulic pump 063149-00EN00 (14) Disconnect the connectors of the water temp.
  • Page 282 7. ADJUSTMENT AND REPAIR Procedure (18) Remove the engine using a lifting device. Note: Put a rope to the lifting lugs 1 to lift up the engine. 7-1-6...
  • Page 283 7. ADJUSTMENT AND REPAIR 4) Reinstallation Reinstall the engine in the reverse order of the removal procedure. Adhesive and tightening torque Part Size Adhesive Tightening torque  2,5 to 2,9 N•m Hose clip (CW-T)  35-1 Hose clip (CW-T) 2,2 to 2,5 N•m ...

  • Page 284: Removal And Reinstallation Of Starter Motor

    7. ADJUSTMENT AND REPAIR 7-1-2 Removal and Reinstallation of Starter Motor 1) Removal Procedure (1) Disconnect the battery minus cable 1 from the battery. Note : Place a MAINTENANCE IN PROGRESS label on the machine. (2) Remove the operator’s seat 1 by removing pins 2 and open the engine hood.
  • Page 285 7. ADJUSTMENT AND REPAIR Procedure (6) Disconnect hydraulic hoses from pilot valves. Note: Put a mark on hydraulic hoses to reinstall them to correct positions. A. Pb4 E. Pb9 B. Pb3 F. Pb8 C. Pa4 G. Pa9 D. Pa3 H. Pa8 (7) Remove two bolts M8x20 retaining safety levers brackets and remove the safety levers as an assembly.
  • Page 286 7. ADJUSTMENT AND REPAIR Procedure (13) Cut the band and disconnect the positive battery cable from the battery and the harness connector 1 from the starter motor terminal S 2. (14) Remove the starter motor mounting bolts 3, and then remove the starter motor. Note: Secure the positive battery cable and the harness for the ter- minal S with a band in the place where they were.

  • Page 287: Removal And Reinstallation Of Fuel Injection Pump

    7. ADJUSTMENT AND REPAIR 7-1-3 Removal and Reinstallation of Fuel Injection Pump 1) Removal Procedure (1) Disconnect the battery minus cable 1 from the battery. Note : Place a MAINTENANCE IN PROGRESS label on the machine. (2) Remove the hose connector bolt 2 and disconnect the fuel hose (the fuel filter to the fuel injection pump 3).
  • Page 288 7. ADJUSTMENT AND REPAIR 2) Reinstallation Reinstall the fuel injection pump in the reverse order of the removal procedure. Checking of Fuel Injection Timing Refer to 4-2-5 Checking and adjusting the Fuel Injection Timing in the Chapter 4 for further information. Note : For the proper fuel injection timing, refer to Section "2-1 Specifications".

  • Page 289: Removal And Reinstallation Of Fuel Tank

    7. ADJUSTMENT AND REPAIR 7-1-4 Removal and Reinstallation of Fuel Tank 1) Removal Procedure (1) Disconnect the battery minus cable 1 from the battery. Note : Place a MAINTENANCE IN PROGRESS label on the machine. (2) Remove the battery 2, and then remove the step 3. 7-1-13...
  • Page 290 7. ADJUSTMENT AND REPAIR Procedure (3) Remove the side cover R 4, and then remove the drain plug 6 from the fuel tank 5 to drain the fuel. 12 L Fuel quantity (when the tank is filled up) Warning : Put a container under the fuel drain plug. (4) Disconnect the fuel hose 7 (the fuel filter 8 to the fuel tank 5) and the fuel hose 9 (the fuel tank 5 to the pre-filter 10).

  • Page 291: Removal And Reinstallation Of Radiator

    7. ADJUSTMENT AND REPAIR 7-1-5 Removal and Reinstallation of Radiator 1) Removal Procedure (1) Swing the upperstructure so that the drain plug 2 of the radiator is positioned halfway between the right and left crawlers on the opposite side of the blade. Then, lower the bucket to the ground and stop the engine.
  • Page 292 7. ADJUSTMENT AND REPAIR Procedure (4) Loosen the hose clips 5 and 5-1, and disconnect the radi- ator hose A 3 and hose B 4 from the connectors. (5) Disconnect the rubber hose 6 (the radiator to the sub- tank) from the connector, and remove the fan guard 7, the radiator mount 8 and then the radiator 1.

  • Page 293: Undercarriage

    7. ADJUSTMENT AND REPAIR 7-2 Undercarriage 7-2-1 Outline The undercarriage consists of travel motors, a track frame (crawler frames R and L, and a lower center frame), track rollers, front idlers, rubber crawlers and other parts. Hydraulic oil fed through the control valve and the swivel joint from the hydraulic pump rotates the travel motors, so that the power is transmitted to the crawlers via the sprockets.

  • Page 294: Points Of Reassembly

    7. ADJUSTMENT AND REPAIR 7-2-2 Points of Reassembly Apply heavy-duty grease to moving area of idler. Bolt 10 x 25 (with hexagon socket head). Install rubber crawler so Apply Three Bond 1324 or its equivalent. that lug is set in direction Tightening torque : as shown in top view below.
  • Page 295 7. ADJUSTMENT AND REPAIR Adjustment of Stopper Bolt Set length at the widest track gauge Nut M16 refer to Section “List of Tightening Tightening torque Torque” on page 3-7-1 Apply Three Bond 1324 or its equivalent. Apply Three Bond 1324 or its equivalent. 7-2-3...

  • Page 296: Removal And Reinstallation Of Crawler

    7. ADJUSTMENT AND REPAIR 7-2-3 Removal and Reinstallation of Crawler When raising the machine, support it with safety blocks of sufficient strength. When loosening or removing the nipple valve 1, the high internal pressure could cause grease to eject or the nipple valve to blow.

  • Page 297: Disassembly And Reassembly Of Idler

    7. ADJUSTMENT AND REPAIR 7-2-4 Disassembly and Reassembly of Idler 1) Structure and Component Parts Part Q’ty Part Q’ty Idler Shaft Internal snap ring C62 Spring washer 12 Seal QLN306213.2Y Washer Idler fork Seal QLN306213.2Y Bolt 12x25 Internal snap ring C62 Bearing 6206 Bearing 6206 External snap ring C30...
  • Page 298 7. ADJUSTMENT AND REPAIR 2) Disassembly Procedure (1) Remove the idler assembly from the crawler frame. Crawler frame Idler assembly (2) Remove the idler assembly mounting bolts 5 and remove the idler assembly from the idler fork 4. (3) Remove the seal 3 from the idler 1 and drain the oil. Then, remove the seal 11 on the other side.
  • Page 299 7. ADJUSTMENT AND REPAIR 3) Reassembly Reassemble the idler in the reverse order of the disas- sembly procedure. Notes : [1] Clean all the parts, and check them for damage or defects. [2] Replace the seals with new ones. [3] Apply multipurpose grease to the lips of new seals 3 and 11.

  • Page 300: Disassembly And Reassembly Of Track Roller

    7. ADJUSTMENT AND REPAIR 7-2-5 Disassembly and Reassembly of Track Roller 1) Structure and Component Parts Part Q’ty Part Q’ty Seal TW 25 47 16 Internal snap ring C47 External snap ring C25 Bearing 6005 Bearing 6005 External snap ring C25 Internal snap ring C47 Seal TW 25 47 16 Track roller...
  • Page 301 7. ADJUSTMENT AND REPAIR 2) Disassembly Procedure (1) Remove the track roller mounting bolts and remove the track roller from the crawler frame. Mounting bolt Track roller Crawler frame (2) Remove the seal 1 from the track roller 5 and drain the oil. (3) Remove the seal 9 and the external snap ring C 8, and then take out the roller shaft 10 using a press.
  • Page 302 7. ADJUSTMENT AND REPAIR 3) Reassembly Reassemble the track roller in the reverse order of the disassembly procedure Notes : [1] Clean all the parts, and check them for damage or defects. [2] Replace the seals with new ones. Sleeve [3] Apply multipurpose grease to the lips of new seals 1 and 9.

  • Page 303: Removal And Reinstallation Of Track Gauge Change Cylinder

    7. ADJUSTMENT AND REPAIR 7-2-6 Removal and Reinstallation of Track Gauge Change Cylinder 1) Removal of Track Gauge Change Cylinder Procedure (1) Widen the track frame fully by operating the track gauge change cylinder, and then remove each rubber crawler 1. Note : Refer to Section "7-2-3 Removal and Reinstallation of Crawler".
  • Page 304 7. ADJUSTMENT AND REPAIR Procedure (5) Remove the drain plug 4 from the hydraulic oil tank 5 and drain the hydraulic oil. Hydraulic oil quantity 7,4 L (in tank) Warning : Put a container under the hydraul ic oil drain plug. (6) Remove the motor cover 6, and then remove the hydrau- lic hoses from the travel motor 7.
  • Page 305 7. ADJUSTMENT AND REPAIR Procedure (9) Remove the plates 17 for the pin 18 at the rod end and the pin 19 at the bottom end of the track gauge change cylinder 14, and pull out the pins. (10) Remove the right stopper bolt 20, and then pull out the crawler frame (R) 21 from the lower center frame 2.
  • Page 306 Apply Three Bond 1324 or its equivalent. Tightening torque 44,1 to 58,8 N•m [5] Hydraulic oil to be used : Type YANMAR SUPER HYDRO OIL Set length at the widest track gauge : (VG 46 class) or its equivalent 85 mm...

  • Page 307: Controls

    7. ADJUSTMENT AND REPAIR 7-3 Controls 7-3-1 Control Train Control lever (R) : Boom & Bucket 2) Travel levers 3) Blade lever Control lever (L) : Arm & Swing 5) Pedal (R) : Boom swing 4) Front Lock lever Pedal (L) : P.T.O. 6) Track gauge change lever 7) Lock levers L &...

  • Page 308: Mechanical Control Linkage

    7. ADJUSTMENT AND REPAIR 7-3-2 Mechanical Control Linkage 1) Points of Assembly (1) Use a jig to install the bushing into the link. Bushing installation Press-fit Bushing press-fitting jig Unit : mm Jig No. Bushing Link C0.0394 C0.0394 (C1) (C1) Notes : F-001 : Valve support R0.00787 (R0.2)
  • Page 309 7. ADJUSTMENT AND REPAIR 2) Tightening Torque for Rod Joints Tightening torque Tightening torque N•m Shape of link ball Part Link ball 6 7,8 to 9,8 N•m 4,9 to 6,9 N•m Link ball 8 12,7 to 16,7 N•m 7,8 to 9,8 N•m 7-3-3...

  • Page 310: Adjustment Of Travel And Blade Levers

    7. ADJUSTMENT AND REPAIR 7-3-3 Adjustment of Travel and Blade Levers 1) Adjustment of travel levers (1) Adjust the right and left travel levers with the link balls 1 so that they are flush and in alignment with each other in the position as shown in the figure above.

  • Page 311: Adjustment Of Boom Swing And P.t.o. Pedals And P.t.o. Pedal Lock

    7. ADJUSTMENT AND REPAIR 7-3-4 Adjustment of Boom Swing and P.T.O. Pedals and P.T.O. Pedal Lock 1) Adjustment of pedal R (boom swing pedal) (for right and left boom swing operation) (1) Place the pedal guard 1 in the lock position to cover the pedal R 2, and adjust the pedal R 2 with the rod C 3 so that the clearance between the edge of the pedal guard 1 and that of the pedal R 2 is even around the edges.

  • Page 312: Adjustment Of Lock Lever Switch

    7. ADJUSTMENT AND REPAIR 7-3-5 Adjustment of Lock Lever Switch 1) Lock Lever Switch L&R (1) Remove bolts retaining lower 1 and upper cover 2 (L and R) from the engine hood. (2) Place the lock lever in the unlock position P and loosen the mounting bolt 4 for the safety switch plate to adjust the lock lever switch 3 so that the distance shown in the figure below is within the specified range when the...
  • Page 313 7. ADJUSTMENT AND REPAIR 7-3-6 Adjustment of Travel Lever Lock (1) Confirm that the left and right tracks do not move when the travel lever grips are pushed or pulled with 44 N (4.5 kgf) of power. (2) Adjust the clearance between the lock plate and left travel lever shown in the figure to approximate 2.8 mm when the lock lever is in the unlock position 7-3-7...

  • Page 314: Adjustment Of Accelerator Lever

    7. ADJUSTMENT AND REPAIR 7-3-7 Adjustment of Accelerator Lever 1) Adjustment of Low Idling Speed (1) Loosen the nut 2 to screw in the stopper bolt 1 and move the accelerator lever 4 fully forward. (2) Make sure the low idling speed (1225 to 1275 rpm) when the regulator handle 7 of the fuel injection pump touches the adjust bolt 6.
  • Page 315 7. ADJUSTMENT AND REPAIR 2) Adjustment of High Idling Speed (1) Move the accelerator lever 1 fully rearward to let the regulator handle 2 touch the adjust bolt 3 for low idling speed. (2) Make sure if the high idling speed is within 2135 to 2185 rpm. (3) Adjust the part A of the accelerator cable 4 so as for the accelerator arm to touch the high idling stopper 5 for accelerator lever 1.

  • Page 316: Swing Bearing

    7. ADJUSTMENT AND REPAIR 7-4 Swing Bearing 7-4-1 Removal and Reinstallation of Swing Bearing 1) Removal (1) Remove the implement. Refer to Section "7-6-1 Removal and Reinstallation of Implement". (2) Remove the engine. Refer to Section "7-1-1 Removal and Reinstallation of Engine".
  • Page 317 7. ADJUSTMENT AND REPAIR (2) Service standards Standard Wear limit Axial clearance B Outer race Dial gauge Load 441 lbs. (200 kgf) 0,03 to 0,15 mm 0,4 mm Outer race PCD Radial clearance A 0,03 to 0,25 mm 0,5 mm Load 55 lbs.

  • Page 318: Hydraulic Equipment

    7. ADJUSTMENT AND REPAIR 7-5 Hydraulic Equipment 7-5-1 Removal and Reinstallation of Hydraulic Oil Tank 1) Removal Procedure (1) Swing the upperstructure so that the drain plug 1 of the hydraulic oil tank and the drain plug 2 of the radiator are positioned halfway between the right and left crawlers on the opposite side of the blade.
  • Page 319 7. ADJUSTMENT AND REPAIR Procedure (5) Loose the hose clip 1, disconnect the radiator hose A and hose B from the connectors. (6) Disconnect the rubber hose (the radiator to the sub- tank) from the connector, and remove the fan guard , the radiator mount and the radiator .
  • Page 320 7. ADJUSTMENT AND REPAIR Procedure (10) Remove the mounting bolts 1 and remove the hydraulic oil tank 2 (with the return filter 3) from the turning frame 4. (11) Then disassemble the return filter 3 from the hydraulic oil tank 2. 7-5-3...
  • Page 321 [5] Check the O-ring 6 of the oil level gauge 5 for oil leak. If any oil leak is found, replace the O-ring. [6] Hydraulic oil to be used: Type YANMAR SUPER HYDRO OIL Drain plug (VG 46 class) or its equivalent Oil quantity...
  • Page 322 7. ADJUSTMENT AND REPAIR 3) Oil Level Check (1) Place the machine on firm and flat ground when checking the hydraulic oil level. (2) Check the hydraulic oil level with the oil level gauge when the oil temperature is between 0 °C and 30 °C. (3) The proper oil level is between the upper and lower Upper limit limit marks on the oil level gauge.

  • Page 323: Removal And Reinstallation Of Control Valve

    7. ADJUSTMENT AND REPAIR 7-5-2 Removal and Reinstallation of Control Valve 1) Removal Procedure (1) Lower the bucket to the ground and stop the engine. Note : Before stopping the engine, relieve the residual pressure from the circuit. (2) Disconnect the battery minus cable 1 from the battery. Note : Place a MAINTENANCE IN PROGRESS label on the machine.
  • Page 324 7. ADJUSTMENT AND REPAIR Procedure (7) Remove the mounting bolts 11 from the valve stay 10 and remove the valve stay 10 with the cut-off valve 12 installed. (8) Disconnect the hydraulic hoses from the connectors of the control valve 13. Notes : •...
  • Page 325 • Install the hoses so that each of them is not in contact with any other hoses or parts. • Hydraulic oil to be used : Type YANMAR SUPER HYDRO OIL (VG 46 class) or its equivalent Oil quantity 7.4 L •...

  • Page 326: Removal And Reinstallation Of Swing Motor

    7. ADJUSTMENT AND REPAIR 7-5-3 Removal and Reinstallation of Swing Motor 1) Removal Procedure (1) Lower the bucket to the ground and stop the engine. (2) Disconnect the battery minus cable 1 from the battery. Note : Place a MAINTENANCE IN PROGRESS label on the machine.
  • Page 327 • Install the hoses so that each of them is not in contact with any other hoses or parts. • Hydraulic oil to be used: Type YANMAR SUPER HYDRO OIL (VG 46 class) or its equivalent Oil quantity 7,4 L •...

  • Page 328: Removal And Reinstallation Of Swivel Joint

    7. ADJUSTMENT AND REPAIR 7-5-4 Removal and Reinstallation of Swivel Joint 1) Removal Procedure (1) Operate the front implement and the blade to raise the machine. After raising it, place blocks 1 under the machine. (2) Swing the upperstructure so that the drain plug 1 of the hydraulic oil tank and the engine oil drain block 2 are posi- tioned halfway between the right and left crawlers on the opposite side of the blade.
  • Page 329 7. ADJUSTMENT AND REPAIR Procedure (5) Remove the engine 1. Note: Refer to Section “7-1-1. Removal and Reinstallation of Engine”. (6) Remove the hydraulic oil tank 2. Note: Refer to Section “7-5-1. Removal and Reinstallation of Hydraulic Oil Tank”. (7) Remove the swing motor 3. Note: Refer to Section “7-5-3.
  • Page 330 7. ADJUSTMENT AND REPAIR Procedure Travel motors (11) Disconnect the hydraulic hoses from the hub 1 of the swivel joint 2. Blade cylinder A: For track gauge change cylinder (rod side) B: For track gauge change cylinder (bottom side) I: For travel motor (R) (forward travel) D: For travel motor (R) (reverse travel) E: For blade cylinder (bottom side) F: For blade cylinder (rod side)
  • Page 331 Apply Three Bond 1324 or its equivalent. Tightening torque 22,6 to 28,4 N•m [3] Hydraulic oil to be used : Type YANMAR SUPER HYDRO OIL (VG 46 class) or its equivalent Oil quantity 7,4 L Development of Connector Mounting Angles...
  • Page 332 7. ADJUSTMENT AND REPAIR 7-5-5 Disassembly and Reassembly of Swivel Joint 1) Structure and Component Parts The swivel joint is used to prevent the hydraulic piping from twisting when the upperstructure swings. The swivel joint consists of a shaft, a hub, a seal kit and other parts. The shaft and hub have holes and grooves, and the oil which flows in from the port of the shaft, passing through the hub groove, is fed to the actuators of the undercarriage.
  • Page 333 7. ADJUSTMENT AND REPAIR 2) Disassembly and Reassembly of Swivel Joint • Disassembly (1) Remove the bolts 14. (2) Remove the swivel flange 10 and the O-ring 5. (3) Remove the external snap ring C 12 and the thrust washer 11 from the swivel shaft 7. (4) Pull the swivel shaft 7 out of the swivel hub 6 and remove the O-ring 2.
  • Page 334 7. ADJUSTMENT AND REPAIR 3) Precautions for Handling and Storing Seals (1) Seals are packed in the package that is suitable for storage. (2) Do not leave seals outside the packages. (3) For storing, put seals in the packages and place them in a dark and cool place (in a parts box or cardboard box) under 40°C to avoid direct sunlight.

  • Page 335: Disassembly And Reassembly Of Hydraulic Cylinders

    7. ADJUSTMENT AND REPAIR 7-5-6 Disassembly and Reassembly of Hydraulic Cylinders 1) Sectional View and Component Parts Track gauge Boom Bucket Boom swing Blade Part change cylinder cylinder cylinder cylinder cylinder cylinder Dust seal       Lock washer ...
  • Page 336 7. ADJUSTMENT AND REPAIR 2) Precautions for Disassembly and Reassembly (1) Parts are high precision-made. Be careful not to damage any parts by dropping them or knocking them together when handling them. (2) If there are any burrs on the surface of seal installation parts or O-ring grooves, remove them. (3) Never use the lock washer removed once.
  • Page 337 7. ADJUSTMENT AND REPAIR Procedure (6) Disassembly of bucket, arm, boom swing, blade and track gauge change cylinders Remove the U-nut 1, and then the piston 2 and the head 3 in that order. (7) Remove the O-rings 1, 2 and 3, the dust seal 4, the ISI packing 5, the RGU packing 6 and the PWL bearing 7.
  • Page 338 7. ADJUSTMENT AND REPAIR 4) Reassembly Reassemble the hydraulic cylinder in the reverse order of the disassembly procedure. Notes : • Take care not to install the cushion plunger 1 of the boom cylinder in the wrong direction. • Replace the O-rings, packings and seals with new ones. Head side U-nut Size end Tightening Torque Cylinder...

  • Page 339: Removal And Reinstallation Of Boom Swing Cylinder

    7. ADJUSTMENT AND REPAIR 7-5-7 Removal and Reinstallation of Boom Swing Cylinder 1) Removal Procedure (1) Swing the upperstructure so that the drain plug 2 of the hydraulic oil tank 1 is positioned halfway between the right and left crawlers on the opposite side of the blade. Then, lower the bucket to the ground and stop the engine.
  • Page 340 7. ADJUSTMENT AND REPAIR (7) Disconnect hydraulic hoses from pilot valves. Note: Put a mark on hydraulic hoses to reinstall them to correct positions. A. Pb4 E. Pb9 B. Pb3 F. Pb8 C. Pa4 G. Pa9 D. Pa3 H. Pa8 (8) Remove two bolts M8x20 retaining safety levers brackets and remove the safety levers as an assembly.
  • Page 341 7. ADJUSTMENT AND REPAIR Procedure (14) Disconnect the connectors of the current limiter 1, the glow relay 2, the timer unit (1 sec) 3, the safety relay 4 and the fuse box 5 from the harness A. (15) Remove the side cover R 6, and then remove the drain plug 7 from the fuel tank 8 to drain the fuel.
  • Page 342 7. ADJUSTMENT AND REPAIR 2) Reinstallation Reinstall the boom swing cylinder in the reverse order of the removal procedure. Nut tightening order and tightening torque for fuel tank clamp (1) Tighten the flanged nut 10 B at a tightening torque of 2,45 to 2,94 N·m. (2) Tighten the flanged nut 10 C at a tightening torque of 24.5 to 32,4 N·m.

  • Page 343: Piping Layout

    7. ADJUSTMENT AND REPAIR 7-5-8 Piping Layout 1) Upperstructure (Hydraulic oil tank  Hydraulic pump  Control valve) Control valve Hydraulic pump Track gauge P1port change Boom swing Boom Bucket Travel (R) Blade P.T.O. Swing Travel (L) P2port Viewed from Hydraulic oil tank 063151-00EN00 7-5-26...
  • Page 344 7. ADJUSTMENT AND REPAIR 2) Upperstructure (Control valve  Swing motor) (Control valve  Boom cylinder) Control valve Swing motor Boom cylinder 7-5-27...
  • Page 345 7. ADJUSTMENT AND REPAIR 3) Upperstructure (Control valve  Swivel joint) (Control valve  Boom swing cylinder) 7-5-28...
  • Page 346 7. ADJUSTMENT AND REPAIR 4) Upperstructure (Swing motor  Hydraulic oil tank) (Swing motor  Control valve  Hydraulic oil tank) (Swivel joint  Hydraulic oil tank) 7-5-29...
  • Page 347 7. ADJUSTMENT AND REPAIR 5) Control Levers (Hydraulic pump Cut-off valve Pilot valves) (Pilot valves, Cut-off valve Drain connector Hydraulic oil tank) 7-5-30...
  • Page 348 7. ADJUSTMENT AND REPAIR 6) Control Levers (Pilot valves  Control valve) 7-5-31...
  • Page 349 7. ADJUSTMENT AND REPAIR 7) Upperstructure (Implement) Arm cylinder Bucket cylinder 7-5-32...
  • Page 350 7. ADJUSTMENT AND REPAIR 8) Undercarriage (Swivel joint  Travel motors) (Swivel joint  Blade cylinder) (Swivel joint  Track gauge change cylinder) S/N 22644 and before Travel motors Blade cylinder Track gauge change cylinder Swivel joint 064588-00EN00 7-5-33...
  • Page 351 7. ADJUSTMENT AND REPAIR 9) Undercarriage (High speed travel solenoid valve) 7-5-34...

  • Page 352: Implement

    7. ADJUSTMENT AND REPAIR 7-6 Implement 7-6-1 Removal and Reinstallation of Implement Notes : • When removing a pin, check the number of shims installed and their positions. • When removing a hose, put a plug into the hose connection port to keep the oil from flowing out. 1) Removal of Bucket Procedure (1) Lower the bucket to the ground with its back face down.
  • Page 353 7. ADJUSTMENT AND REPAIR 2) Removal of Arm Procedure (1) Remove the bucket. (2) Remove the nuts 1 (M16) and pull out the pins 2. Then remove the bucket link 3 and the bucket arms 4. (3) Lightly place the top end of the arm 5 on the ground per- pendicularly to the ground.
  • Page 354 7. ADJUSTMENT AND REPAIR 3) Removal of Boom Procedure (1) After raising the boom 1 fully, remove the slide cover 2 from the boom cylinder 3. (2) Place the top end of the boom 1 on the ground. Note : Install an expansion plug to the connector from which the hydraulic hose has been removed and start the engine.
  • Page 355 7. ADJUSTMENT AND REPAIR Procedure (8) Remove the mounting bolts for the bucket L tube 1 and the bucket R tube 2. (9) Remove the plates 3 and remove the tubes. (10) After roping the boom 1, remove the bolt 2 (M10) and Rope pull out the pin 3.
  • Page 356 7. ADJUSTMENT AND REPAIR 4) Removal of Blade Procedure (1) Swing the upperstructure so that the implement is posi- tioned on the opposite side of the blade. Then, lower the bucket and the blade to the ground and stop the engine. (2) Disconnect the battery minus cable 1 from the battery.
  • Page 357 7. ADJUSTMENT AND REPAIR 5) Removal of Boom Bracket Procedure (1) Remove the bucket 1. Refer to Section "7-6-1 1) Removal of Bucket". (2) Remove the arm 2. Refer to Section "7-6-1 2) Removal of Arm". (3) Remove the boom 3. Refer to Section "7-6-1 3) Removal of Boom".
  • Page 358 7. ADJUSTMENT AND REPAIR 6) Reinstallation Reinstall the implement in the reverse order of the removal procedure. Tightening Torque and Adhesive Size Tightening torque Adhesive 1 – 6, 8, 10 and 11 44,1 to 58,8 N·m Apply Three Bond 1324 or its equivalent. 24,5 to 32,3 N·m 7-6-7...

  • Page 360: Periodic Inspection And Servicing

    CHAPTER 8 PERIODIC INSPECTION AND SERVICING 8-1 List of Periodic Inspection and Servicing ..........8-1...

  • Page 362: List Of Periodic Inspection And Servicing

    8. PERIODIC INSPECTION AND SERVICING 8. Periodic Inspection and Servicing 8-1 List of Periodic Inspection and Servicing...
  • Page 363 8. PERIODIC INSPECTION AND SERVICING...

  • Page 364: Fuel, Lube Oil And Grease Recommended

    CHAPTER 9 FUEL, LUBE OIL AND GREASE RECOMMENDED 9. Fuel, Lube Oil and Grease Recommended ..........9-1...
  • Page 366 9. FUEL, LUBE OIL AND GREASE RECOMMENDED 9. Fuel, Lube Oil and Grease Recommended...

  • Page 368: Troubleshooting

    CHAPTER 10 TROUBLESHOOTING 10-1 Non-Breakdowns ................10-1-1 10-1-1 Natural Release of Bucket ............. 10-1-1 10-1-2 Discontinuous Arm Movement ..........10-1-1 10-1-3 Drifting of Upperstructure on Quick Travel Operation.... 10-1-2 10-1-4 Thermal Shock of Travel Motor..........10-1-3 10-1-5 Change of Blade Speed in Loaded Condition......10-1-4 10-1-6 Time Lag on Travel Speed Switching ........

  • Page 370: Non-Breakdowns

    10. TROUBLESHOOTING 10. Troubleshooting 10-1 Non-Breakdowns 10-1-1 Natural Release of Bucket Phenomenon When the arm is extended while scooping with the bucket, the scooping side of the bucket is restricted by the arm and causes back pressure because oil cannot be supplied to the bucket cylinder in time.

  • Page 371: Drifting Of Upperstructure On Quick Travel Operation

    10. TROUBLESHOOTING 10-1-3 Drifting of Upperstructure on Quick Travel Operation Phenomenon The upperstructure drifts on quick travel operation (especially, on spin-or pivot-turning). Drift Reason Inertial force is given to the upperstructure through the quick operation of the undercarriage, and high pressure is applied to the swing motor.

  • Page 372: Thermal Shock Of Travel Motor

    10. TROUBLESHOOTING 10-1-4 Thermal Shock of Travel Motor Phenomenon When the travelling operation is made for pivot turning in cold temperatures after raising the hydraulic oil to more than 140°F (60°C) higher than the ambient temp. through relief valve operation, etc., without travelling after starting the engine, the machine may travel straight instead of making a pivot turn.

  • Page 373: Change Of Blade Speed In Loaded Condition

    10. TROUBLESHOOTING 10-1-5 Change of Blade Speed in Loaded Condition Phenomenon When the blade is being used to raise the machine or do other operations by which the blade is loaded, the blade speed becomes slower than that when the blade is unloaded.

  • Page 374: Time Lag On Travel Speed Switching

    10. TROUBLESHOOTING 10-1-6 Time Lag on Travel Speed Switching Phenomenon In cold temperatures, there is a time lag in switching from the high-travel speed to low-travel speed (with the high- speed pedal released). Reason The shock caused during switching from the high-speed to low-speed is lightened by the throttles of A. In cold tem- peratures, however, the passage resistance of the throttles becomes larger and it takes more time for the swash plate of the travel motor to return to the low speed.

  • Page 375: Fluctuation In Oil Level Of Hydraulic Oil Tank Due To Temperature Change

    10. TROUBLESHOOTING 10-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change Phenomenon The oil level of the hydraulic oil tank varies between before operation (the machine is cool) and after operation (the machine is warm). After operation (machine warm) Upper limit Before operation (machine cool) Midpoint...

  • Page 376: Machine And Engine

    10. TROUBLESHOOTING 10-2 Troubleshooting 10-2-1 Machine and Engine (How to use the charts) Trouble Factors related to the trouble are enumerated in the columns and instructions for corrective procedures are given below. It is recommended that the troubles be inspected and corrected one by one according to the chart.
  • Page 377 10. TROUBLESHOOTING Low output Does the work Hydraulic Set relief pressure implement work power of control valve normally? source Excessive in- Clogging of Clogging of take resistance air cleaner intake pipe Clean Clean Clogging of Excessive Clogging of Clogging of exhaust port of exhaust muffler...
  • Page 378 10. TROUBLESHOOTING Overheating Does the work Hydraulic Set relief pressure implement work power source of control valve normally? Damage or Excessive Cooling water Low cooling Clogging of wear of fan exhaust Loose fan belt system water level radiator resistance belt Supply Adjust Replace...
  • Page 379 10. TROUBLESHOOTING Black smoke emission Does the work Hydraulic Set relief pressure implement work power source of control valve normally? Low output See Low output Fuel Improper fuel Replace Fuel injection Advanced Excessive Uneven injec- pump injection timing injection volume tion volume Adjust Adjust...
  • Page 380 10. TROUBLESHOOTING Starter motor does not turn Except seizure of engine and or output is low. trouble of any work implement Disconnection Connection Disconnection or connection failure of Battery terminal Ground terminal of wire failure coupler Repair Repair Repair Repair Battery Specific gravity Voltage...
  • Page 381 10. TROUBLESHOOTING Battery dies or battery (during operation) cannot be charged Charging failure Discharges Connection Disconnection Discon- Battery Ground Starter or connection nection of failure of terminal terminal switch failure wire coupler Repair Repair Repair Repair Turn off Damaged Battery Wiring Short-circuit battery...
  • Page 382 10. TROUBLESHOOTING Work implement does not move at all or its operation is slow. Hydraulic oil Insufficient Deterioration Viscosity quantity Supply Specified Replace hydraulic oil (Aeration or cavitation) Piping Faulty joint Repair Hydraulic Insufficient dis- Wear of spline of Breakage Inner part Oil leak charge volume...
  • Page 383 10. TROUBLESHOOTING Work Implements Weak digging force Boom, arm and bucket cylinders Do other Hydraulic implements work power source normally? Relief valve˜ Pump P4 pressure Check the pressure and adjust it. Refer to section 5-4 Pres- sure Adjustment Inspect pilot valve by switching Internal leakage or malfunction Pilot valve Lever stroke...
  • Page 384 10. TROUBLESHOOTING Boom, arm and bucket cylinders Slow implement working speed Relief valve˜ Pump P4 pressure Check the pressure and adjust it. Refer to section 4-4 Pres- sure Adjustment Inspect by switching hose Internal leakage or malfunction Pilot valve Lever stroke with hose of other normal of valve spool circuit...
  • Page 385 10. TROUBLESHOOTING Drifting of boom swing Extent of Measure telescopic motion amount of drifting cylinder rod on 15-degrees slope Steering Boom swing Sticking of swing˜ equipment pedal pedal link Adjust neutral Repair pedal link or apply grease position Replace bush Control Circuit relief Dust in circuit...
  • Page 386 10. TROUBLESHOOTING Boom swing cannot be made or is slow Hydraulic Do other work implements source work normally? Sticking of swing Boom swing Wear of Controls pedal link joint pedal link Adjust neutral Repair pedal link or apply grease Replace Replace bush position Circuit relief...
  • Page 387 10. TROUBLESHOOTING Upperstructure cannot swing or swing speed is slow No outside Remove the resistance source resistance? Hydraulic Do other implements work normally? power source Relief valve Operation of Cut-off valve pressure solenoid Replace Check pressure. Refer to section 5-4 Pres- sure Adjustment Movement of [Inspect by switching hose with...
  • Page 388 10. TROUBLESHOOTING Swing only to one side Relief valve Dust in Wear of relief Swing brake valve pressure relief valve valve seat surface Check pressure. Refer Clean or replace to section 5-4 Pres- sure Adjustment Relief valve Cut-off valve pressure Check pressure.
  • Page 389 10. TROUBLESHOOTING [Unintended drifting on slopes] Drifting of swing Measure motion amount of swing bearing Extent of drifting outer race on 15 degrees slope. Refer to 3-1 "Machine Performance" Is valve spool Pilot valve returned to neutral? Repair of replace Defective spool Control valve fitting...
  • Page 390 10. TROUBLESHOOTING Travel Equipment No travelling Crawler tension Before making checks, remove dirt from undercarriage and adjust crawler tension and clogging Hydraulic Do other implements lock lever power source work normally? Release R and L relief Dust in Control valve valves pressure control valve Check the pressure and...
  • Page 391 10. TROUBLESHOOTING Cannot travel straight Crawler tension, Before making checks, remove dirt from clogging undercarriage, and adjust crawler tension. Hydraulic Do other implements work Lift machine body and Check hydraulic power source normally? check R and L revolutions pump Replace hydraulic pump Improper adjustment of lever stopper bolt...
  • Page 392 10. TROUBLESHOOTING Inspection procedures 1. When the hydraulic tester is not used : (1) Reverse the hoses of the hydraulic pumps P1 and P2. Phenomenon : Reversed ....Replace the hydraulic pump. (2) Reverse the hoses between the control valve and the swivel joint. Phenomenon : Reversed ...........Overhaul or replace the control valve.
  • Page 393 10. TROUBLESHOOTING Cannot make spin turning Site condition Dry ground Wet ground Sandy Before making checks, remove dirt from Crawler tension under carriage and adjust crawler tension. and clogging Hydraulic Do other implements power source work normally? R and L relief Wear of relief valve Control valve Dust in control valve...
  • Page 394 10. TROUBLESHOOTING Drift of machine body on slopes Check the drift with machine Extent of drift placed on a 15 degrees slope. Internal Hydraulic Oil leak leakage motor Replace seal or Replace whole assembly Leakage from Dust in check Wear of check Breakage of Brake valve (or counter plunger...
  • Page 395 10. TROUBLESHOOTING No switching to high-speed One side? Both side? Switch Safety switch operation Repair or replace Solenoid Relief valve Cut-off valve operation pressure Check the pressure Replace Oil leak Pipings from joint Repair or replace Internal Swivel joint Oil leak leakage Repair or replace Replace seal...
  • Page 396 10. TROUBLESHOOTING Travelling speed is switched to high-speed naturally˜ or high-speed cannot be cancelled One side? Both side? Switch Safety switch operation Repair or replace Solenoid Spool Cut-off valve operation operation Replace Repair or replace Hydraulic Operation of Internal motor high-speed spool failure of motor Faulty spool...

  • Page 397: Electrical Equipment On Panel

    10. TROUBLESHOOTING 10-2-2 Electrical Equipment on Panel (1) How to read the chart Trouble Inspection/repair instructions Check item Factors in trouble or treatment (2) Refer to the wiring diagram for the number of the connector terminal and lead wire color. (3) Color marks of leads W (White) B(Black)
  • Page 398 10. TROUBLESHOOTING Monitor Lamps Starter switch is turned on, but monitor lamp does not go on Failure of all lamps? Check the power line : Replace fuse Check wire harness Check connector contact Check starter switch Others Only one lamp does not go on Filament blown? Replace bulb Check :...
  • Page 399 10. TROUBLESHOOTING Hourmeter Hourmeter does not work while engine is running Fuse blown? Replace fuse Disconnect the bipole connecter on the back of the instrument panel, and check whether a voltage of 10V or more is applied to the termi- nal No.22B (YB) with the starter switch turned Voltage rises? Replace wire harness B...
  • Page 400 10. TROUBLESHOOTING Water Temp. Alarm Lamp Failure of water temp. alarm lamp Lamp does not go on Lamp goes on even when even on overheating. water temp. is low. Disconnect the wire harness No.14A (Lg) from the water Fuse blown? temp.
  • Page 401 10. TROUBLESHOOTING Battery Charge Alarm Lamp Failure of battery charge alarm lamp Starter switch is turned on, Lamp goes on while running but lamp does not go on the engine Fuse blown? Replace fuse Stop the engine Filament blown? Disconnect the L-terminal of the Replace bulb alternator.
  • Page 402 10. TROUBLESHOOTING Engine Oil Pressure Alarm Lamp Failure of engine oil pressure alarm lamp Starter switch is turned on, Lamp goes on while running but lamp does not go on the engine Fuse blown? Stop the engine Replace fuse Insufficient Filament blown? engine oil? Supply engine oil...
  • Page 403 10. TROUBLESHOOTING Warning Buzzer Buzzer sounds while Starter switch is turned on, running engine but buzzer does not sound Is engine oil Is engine oil pressure alarm pressure alarm lamp on? lamp on? Normal Repair the lamp according to the troubleshooting procedure for engine oil pressure alarm lamp.
  • Page 404 10. TROUBLESHOOTING Fuel Level Gauge Fuel level gauge is faulty Pointer indicates a value Pointer does not work Unstable pointer larger than the real fuel level Check the connection of the Disconnect the terminal No.11A Check if the fuel in the fuel terminal No.10A of the fuel of the fuel level sensor, connect tank is shaking.
  • Page 405 10. TROUBLESHOOTING Water Temperature Water temperature gauge is faulty Pointer indicates a value Pointer does not work larger than the real temperature Check the connection of the Disconnect the terminal No.15A terminal No.15A (LB) of the of the water temp. sensor, water temp.

  • Page 406: Reference Data

    CHAPTER 11 REFERENCE DATA 11-1 Specifications for Attachment ..............11-1...

  • Page 408: Specifications For Attachment

    11-1 Specifications for Attachment Min. J Max. K G’ Unit : mm Model ViO12-2A Item Specifications for bucket installation A (Distance between bucket pins) B (Distance between bucket and bucket arm pivot pins) C (Distance between bucket arm pins) D (Distance between bucket link pins)
  • Page 409 Service Manual MM 58ENMA 0100 1st edition : Dec. 2017 http://www.yanmar. Copyright c 2015 YANMAR CONSTRUCTION EQUIPMENT All Rights Reserved. This manual may not be reproduced or copied in whole or in part, without the written consent of YANMAR CONSTRUCTION EQUIPMENT...

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