Mustang Compact Excavator ME12002 Service Manual_909768 - PDF DOWNLOAD

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ME12002 COMPACT EXCAVATOR

SERVICE MANUAL PART #909768 Revision B - 12/07

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Mustang Manufacturing Company, Inc.

Introduction For your safety and continued proper operation, use only genuine MUSTANG® service parts.

When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number.

The model and serial number decal for this unit is located on the left chassis upright. “Right” and “Left” are determined from a position sitting on the seat and facing forward.

Mustang Company reserves the right to make changes or improvements in the design or construction of any part of the unit without incurring the obligation to install such changes on any previously delivered units.

NOTE: Purchase equivalent, quality tires for your loader. Contact your dealer for replacement tire information.

NOTE: Replacement batteries are not provided by the Mustang Company. For battery specifications see “Engine” chapter. ALL REPLACEMENT BATTERIES MUST BE PURCHASED LOCALLY. Refer to the abbreviations table located on this page for the various fastener descriptions. Standard attaching hardware torque values are also provided on the inside back cover. If a part requires lubrication or a nonstandard torque value, it will be specified behind the part number description in parenthesis.

Items shown in the parts list that do not have part numbers are shown for reference purposes only and are NOT available for purchase.

Dimensions are in inches unless otherwise specified.

NOTE: The following abbreviations and symbols may be used herein: A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ampere AR . . . . . . . . . . . . . . . . . . . . . . . . . . As Required ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly AUX. . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary CCA . . . . . . . . . . . . . . Cold Cranking Amperage CYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder FL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flare FOPS . . . . . . Falling Object Protective Structure GA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hexagon HF . . . . . . . . . . . . . . . . . . . . . . . . . . . High Flow HYD. . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic JIC . . . . . . . . . . . . . . . . . Joint Industrial Council kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt LBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter MM (mm) . . . . . . . . . . . . . . . . . . . . . Millimeter NA . . . . . . . . . . . . . . . . . . . . Naturally Aspirated N/A . . . . . . . . . . . . . . . . . . . . . . .Not Applicable NEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative N•m . . . . . . . . . . . . . . . . . . . . . . . .Newton meter NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number NPT . . . . . . . . . . . . . . . . . . National Pipe Thread PN . . . . . . . . . . . . . . . . . . . . . . . . . .Part Number POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Positive PSI . . . . . . . . . . . . . . . . . Pounds per Square Inch QTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity REF . . . . . . . . . . . . . . . . . . . . . . . . . . . Reference REQ'D.. . . . . . . . . . . . . . . . . . . . . . . . . .Required ROPS . . . . . . . . . .Roll Over Protective Structure RPM. . . . . . . . . . . . . . . . Revolutions Per Minute SAE . . . . . . . . Society of Automotive Engineers SN . . . . . . . . . . . . . . . . . . . . . . . . Serial Number SQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Square ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Straight TURBO . . . . . . . . . . . . . . . . . . . . . Turbocharger V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt

MUSTANG is a registered trademark of the Mustang Manfacturing Company, Inc.

TABLE OF CONTENTS Chapter 1 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bucket Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Maximum Permissible Loads on Dipper Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lift Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 John Deere 4045TF270 and Yanmar 4TNE106T-NS Specifications . . . . . . . . . . . . . . . . . . 9 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Port Codes: Main Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic Joints and Dry Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic Screw Joints and Dry Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 High Quality Screws and MA High Quality Screw Joints . . . . . . . . . . . . . . . . . . . . . . 17 Type Relative for High Quality Screw Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Oil Grades: Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Chapter 2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Check, Clean and Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fluid and Filter Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Lubrication Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Care and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Hydraulic Pump Pressure Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Hydraulic Pump Part Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic Pump Pressure Checklist Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Checking Hydraulic Oil Level: New Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Checking Hydraulic Oil Level: Old Style. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Changing Hydraulic Oil: New Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Changing Hydraulic Oil: Old Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Engine Oil/Filter Change Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Air Cleaner (SN AC02633 and up). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Air Cleaner (SN AB03158 and before) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Checking Coolant Level (SN AC02633 and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Checking Coolant Level (SN AB00473-AB03158) . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Chapter 3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Hydraulic System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Hydraulic System Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Hydraulic System Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Hydraulic System Component Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Hydraulic Pump Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Hydraulic Pump Specifications Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Hydraulic Pump Function Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Hydraulic Pump Port Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hydraulic Pump Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Hydraulic Pump Valve Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Testing Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Hydraulic Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Hydraulic Pump Rotation Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Hydraulic Pump Regulator Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Hydraulic Pump Regulator Performance Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Power or Torque Summation and Negative Displacement Control . . . . . . . . . . . . . . . . . . 72 Function Torque Summation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Negative Control Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Disassembling and Assembling the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Disassembling the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Assembling the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Hydraulic Pump Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Regulator (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Power Shift Proportional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Regulator (rear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Hydraulic Diagram - Main Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Hydraulic Pump Port Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Hydraulic Pump Function Summation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Negative Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Valve Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Fine Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Spool Identification Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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Main Valve Block - Section A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Main Valve Block - Section B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Main Valve Block - Section C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Circuit Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Shock Suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Operating Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Operating Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Boom Cylinders Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Raising the Boom (high speed operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Raising the Boom (low speed operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Lowering the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Regeneration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Dipper Arm Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Dipper Arm Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Retracting the Dipper Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Lowering the Dipper Arm Cylinder (with heavy loads) . . . . . . . . . . . . . . . . . . . . . . . 131 Lowering the Dipper Arm Cylinder (with light loads) . . . . . . . . . . . . . . . . . . . . . . . . 132 Bucket Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Swing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Boom Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Auxiliary Hydraulics Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Auxiliary Hydraulics Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Section Drive Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Section Drive Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Section Drive Counterbalancing System (straight travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Drive Counterbalancing System Function (straight travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Straight Travel Spool (no additional actuation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Straight Travel Spool (with additional actuation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Side Valve Block Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Disassembling and Assembling the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Disassembling the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Inspecting the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Assembling the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 Joystick Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Hydraulic Piloting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Joystick Pilot Valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Disassembling the Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Assembling the Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Printed in U.S.A

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Joystick Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Hydraulic Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Pilot Control Pedals: Control Valve for Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . 167 Connection Ports, Driving Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Pilot Control Pedals - Auxiliary Hydraulics, Dozer Blade . . . . . . . . . . . . . . . . . . . . . 169 Port Connection - Dozer Blade Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Disassembling the Pilot Control Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Assembling the Pilot Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Pilot Oil Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Side Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Shuttle Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Switch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Load Lowering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Driving Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Swing Motor (Swivel Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Hydraulic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Swing Motor Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Disassembling the Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Assembling the Swing Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Chapter 4 John Deere Engine 4045TF270 (SN AC02633 and up). . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 John Deere Engine Model 4045TF270 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Servicing the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Checking Valve Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Servicing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Removing the Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Installing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Servicing the Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Removing the Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Installing the Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Servicing the Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Removing the Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Testing the Fuel Injection Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Disassembling the Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Assembling the Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Checking Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Servicing the Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Inspecting the Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Servicing the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Checking for Water Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

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Chapter 5 Yanmar Engine 4TNE106T-NS (SN AB00473-AB03158) . . . . . . . . . . . . . . . . . . . . . . . . . .229 Yanmar Engine Model 4TNE106T-NS Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Servicing the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234 Checking Valve Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Measuring Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Inspecting the Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Inspecting the Thermoswitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Checking for Cooling System Water Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Checking the V-belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Inspecting the Fuel Injection Valve and Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . . 238 Coolant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Servicing the Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Adjusting the Radiator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Servicing the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245 Disassembling the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Assembling the Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Servicing the Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251 Removing the Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Disassembling the Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 Assembling the Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Installing the Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Servicing the Fuel Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254 Disassembling the Fuel Feed Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Inspecting Fuel Feed Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Assembling the Fuel Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Servicing the Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256 Removing the Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Disassembling the Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Servicing the Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Servicing the Fuel Injection Pump Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 Assembling the Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Installing the Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Servicing the Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 Disassembling the Governor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Assembling the Governor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Disassembling the Governor Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Assembling the Governor Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Servicing the Tappet and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 Disassembling the Tappet and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Inspecting the Tappet and Camshaft Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Assembling the Tappet and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Servicing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265 Disassembling the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Assembling the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Printed in U.S.A

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Servicing the Gear Train and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Disassembling the Gear Train and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Assembling the Gear Train and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Assembling the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Servicing the Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Disassembling the Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Inspecting and Measuring Cylinder Block Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Assembling the Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 Servicing the Trochoid Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Servicing the Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 Turbocharger Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Turbocharger Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Checking Waste Gate Valve Opening Pressure and Lift . . . . . . . . . . . . . . . . . . . . . . . 289 Turbocharger Service Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 Chapter 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 John Deere Engine Model 4045TF270 (SN AC02633 and up) . . . . . . . . . . . . . . . . . . . . 291 Yanmar Engine Model 4TNE106T-NS (SN AB00473-AB03158) . . . . . . . . . . . . . . . . . 293 Troubleshooting the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Troubleshooting the Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Seals and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Traveling Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Bucket, Boom and Dozer Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Inspecting Filter and Drain Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Inspecting for Abnormal Vibration and Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Measuring Pressure of Each Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Chapter 7 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Electric Wiring Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Electric Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Electric Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Right Armrest Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Right and Left Armrest Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Motor Cable Tree and Armrest Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Chassis and Armrest Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Engine RPM Controllers, Buttons, Motors and Pump Regulator Connections . . . . . . 316 Electric Speed Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Setting the Proportional Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Time Ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

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CHAPTER 1 TECHNICAL DATA General Dimensions

Figure 1-1 Primary Dimensions Printed in U.S.A

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Figure 1-2 Primary Dimensions

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ME12002

TECHNICAL DATA

General Specifications Height Width Length Arm Length Slew Angle – Left Slew Angle – Right Front Boom Swing Radius Ground Clearance Undercarriage width Undercarriage Length Rubber Track Width Max. Boom Height Max. Dumping Height Max. Digging Height Max. Digging Radius Max. Vertical Digging Depth Max. Digging Depth Min. Tail Swing Radius Min. Arm Clearance Dozer Blade Width Dozer Blade Height Maximum Lift Above Ground Maximum Depth Below Ground Number of Track Rollers

9’2” (2790 mm) 7’10” (2400 mm) 23’3” (7087 mm) 8’7” (2610 mm) 80° 50° 6’9” (2400 mm) 16.5” (420 mm) 7’10” (2400 mm) 131” (3320 mm) 19.7” (500 mm) 17’4” (5283 mm) 19’4” (5885 mm) 26’1” (7946 mm) 26’2” (7976 mm) 9’2” (2810 mm) 15’8” (4780 mm) 5’5” (1645 mm) 6’11” (2100 mm) 7’10” (2390 mm) 1’9” (550 mm) 24.5” (622 mm) 18.5” (470 mm) 6 per side

Operating Weight with Cab Average Ground Pressure Ground pressure (Rubber Tracks) Ground pressure (Steel Tracks)

25,397 lbs. (11,520 kg) 6.1 psi (0.43 bar) 5.7 psi (0.39 bar) 5.8 psi (0.40 bar)

Gradability Sound Power Sound Pressure Travel Speed - Low Speed Travel Speed - High Speed Bucket Tooth Breakout Force Arm Force Swing Speed

30° (58%) 101 dB(A) 80 dB(A) 2.2 mph (3.6 km/h) 3.9 mph (6.2 km/h) 15,512 lbf (69.6 kN) 11,100 lbf (50.3 kN) 11 rpm

Printed in U.S.A

3

909768/BP1207

TECHNICAL DATA

ME12002

Bucket Geometry E Dry Diameter

2.4" (60 mm)

F Dipper Arm Width

8.7" (220 mm)

Bolt Distance L Bucket Carrier

13.2" (335 mm)

Figure 1-3 Kinematics 909768/BP1207

4

Printed in U.S.A

ME12002

TECHNICAL DATA

Maximum Permissible Loads on Dipper Arm 19’8” (6.0 m)

16’5” (5.0 m)

13’1” (4.0 m)

9’10” (3.0 m)

A B 19’8” 6856* 4894 (6.0 m) (3110*) (2220) 14’9” 6393* 2932 (4.5 m) (2900*) (1330)

-

-

6592* 3715 6834* 5467 (2990*) (1685) (3100*) (2480)

-

-

-

-

6526* 3715 6614* 5390 (2960*) (1685) (3000*) (2445)

-

-

9’10” 6471* 2315 6592* 2612 7231* 3516 8400* 4982 11,684* 8091 (3.0 m) (2935*) (1050) (2990*) (1185) (3280*) (1595) (3810*) (2260) (5300*) (3670) 4’11” 6702* 2127 7231* 2447 8697* 3186 11,398* 4497 18,012* 6647 (1.5 m) (3040*) (965) (3280*) (1110) (3945*) (1445) (5170*) (2040) (8170*) (3015) 0’0” 6989* 2116 7562* 2293 9579* 2535 12,280* 4079 19,665* 6283 (0.0 m) (3170*) (960) (3430*) (1040) (4345*) (1150) (5570*) (1850) (8920*) (2850) -4’11” 7275* 2491 8841* 2491 11,971* 4012 16,854* 6449 (-1.5 m) (3300*) (1130) (4010*) (1130) (5430*) (1820) (7645*) (2925) -9’10” 7088* 4045 7562* 4288 (-3.0 m) (3215*) (1835) (3430*) (1945)

Maximum permissible load on extended dipper arm A Overhang from the center of the turntable.

B Height of load fixing point * Lifting capacity hydraulically limited.

All table values are in lbs. (kg) and for a machine in a horizontal position on firm ground without bucket.

Dozer blade support in drive direction.

Dozer blade support 90° to drive direction

If equipped with a bucket or other implements, lift capacity or tilt load is reduced by bucket or implement weight.

Calculation basis: According to ISO 10567 The excavator's lift capacity is restricted by the settings of the pressure relief valves and the hydraulic system's stabilizing features.

Neither 75% of the static tilt load nor 87% of the hydraulic lift capacity is exceeded.

Printed in U.S.A

5

909768/BP1207

TECHNICAL DATA

ME12002

Lift Capacity Chart

Figure 1-4 Working Range Diagram

909768/BP1207

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Printed in U.S.A

ME12002

TECHNICAL DATA

Hydraulic System Specifications Hydraulic Pump

Description

Type

Double Variable Displacement

System

2 Separately Controlled Variable Displacement Pumps and 1 Gear Pump

1

2

Version A Version B 5 Oil Flow Rate - Version A 6 Oil Flow Rate - Version B 3

K3V63DT

4

Pressure Setting Main Pressure Limiting Valve Pump (2) 7 P1 Main Pressure Limiting Valve Pump P2(2) Main Pressure Limiting Valve Pump (2) 8 P3 Pilot Oil Pressure

31.7 + 31.7 + 5.8 gpm (120 + 120 + 22 L/min) Description 4351±73 psi (300±5 bar) 4641 psi (320 bar) while driving Side Valve Block ( P2 ) 4931±73 psi (340±5 bar)

580±29 psi (40±2 bar)

9

Secondary Pressure Limiting Valve: 10

Main Valve Block (3) Secondary Pressure Limiting Valve:

11

Dozer Blade Valve(3)

5076±73 psi (350±5 bar) 4351±73 psi (300±5 bar)

Swivel Motor (SPLV): (3) 12 Pump - Measuring Points

Turntable Drive Unit Complete 3481±29 psi (240±2 bar)

Swivel Motor (SPLV): 13 Measured at the Motor

Turntable Drive Unit Complete 3336 +0/-73 psi (230 +0/-5 bar)

Drive Motor: Internal Pressure Limiting 14 Valve

350/370±73 psi (350/370±5 bar)

Check Valve: Boom Offset Cylinder

5076±73 psi (350±5 bar)

15

For correct settings : (1) General - Hydraulic oil temperature: 113 - 122°F (45 - 50°C) (2) Settings at maximum engine rpm (See Maintenance chapter) (3) Settings at minimum engine rpm (See Maintenance chapter)

Quantities

Description

16

Hydraulic oil tank

33.8 gal. (128 L)

17

System filling

49.4 gal. (187 L)

Printed in U.S.A

7

909768/BP1207

TECHNICAL DATA

ME12002 Auxiliary Hydraulic

Pressure controlled oil flow - auxiliary hydraulics Pressure psi (bar) Flow gpm (L/min) 435 (30)

34 (129)

653 (45)

33.8 (128)

870 (60)

33.5 (127)

1305 (90)

33.0 (125)

1740 (120)

32.5 (123)

2176 (150)

30.6 (116)

2611 (180) 3046 (210) 3481 (240) 3916 (270) 4134 (285)

28.5 (108) 24.8 (94) 23.5 (89) 20.1 (76) 13.5 (51)

Conditions: 1) Pressure = Pressure setting at the attachment 2) Tolerance of the listed oil flow : +1 / -2 L/min 3) Measuring point for the oil flow = couplers at the dipper arm

Clearance - Hose burst protection valves (inside hose versions)

Part No.

Excavator

Assembled at the

Screw size

Clearance S

*

ME12002

Dozer blade cylinder

1/2"

0.1" (3.4 mm)

* Mustang reserves the right to make changes.

Refer to the parts manual for the part number.

909768/BP1207

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Printed in U.S.A

ME12002

TECHNICAL DATA

John Deere 4045TF270 and Yanmar 4TNE106T-NS Specifications For more information, see “John Deere Engine 4045TF270 (SN AC02633 and up)” on page 203, or “Yanmar Engine 4TNE106T-NS (SN AB00473-AB03158)” on page 229.

Diesel Engine Type Specification: Product 2 Model 1

3

Design

Number of Cylinders Fuel Injection System 6 Aspiration 4 5

Tier II (SN AC02633 and up)

Tier I (SN AB00473AB03158)

John Deere 4045TF270 John Deere 4045TF270 Water-cooled 4-stroke Diesel Engine 4 Direct Fuel Injection Turbocharged Water-cooled/Aspirating Fan

Yanmar 4TNE106T-NS Yanmar 4 TNE106T-NS Water-cooled 4-stroke Diesel Engine 4 Direct Fuel Injection Turbocharged Water-cooled (forced circulation) Force-fed Lubrication with Trochoidal Pump 269 cu. in. (4412 cc) 106 x 125 mm 98 hp (73.4 kW) @ 2100±25 rpm 366.8-400.1 Nm @ 1400 rpm

7

Cooling System

8

Lubrication System

Force-fed Lubrication

9

Displacement

277 cu. in. (4541 cc) 106.7 x 127 mm 99.2 hp (74.0 kW) @ 2200 rpm

10 Nominal Bore and Stroke 11 Horsepower in DIN 12 Maximum Torque 13 14 15 16 17 18 19 20 21 22 23 24

Maximum Engine Speed Without Load Idling Speed Valve Tip Clearance (Intake/Outlet) 1st Cylinder Compression Ratio Compression: Specified Value Compression: Threshold Value Engine Oil Pressure at Rated Speed Pressure Switch for Engine Oil Pump Thermostat Opens At: Thermal Switch Firing Order

25 Direction of Rotation 26 Starting Aid

Max. Inclined Position (engine still supplied with oil): 28 Specific Fuel Consumption 27

29 Exhaust Values According to:

389 Nm @ 1400 rpm 2150*/2000**±15 rpm

2200±25 rpm

850±25 rpm 0.36/0.46 mm Fan Side 17.0:1 348-406 psi (24-28 bar) 348-406 psi (24-28 bar) 50 psi (3.4 bar) 6-11 psi (0.4-0.75 bar) 180°F (82°C) 226±37°F (108±3°C) 1–3–4–2 Counterclockwise (as seen from the flywheel)

1100±25 rpm 0.25~0.35 mm Flywheel Side 17.5:1 508±15 psi (35±1 bar) 406±15 psi (28±1 bar) 64±7.3 psi (4.4±0.5 bar) 7.3±1.5 psi (0.5±0.1 bar) 157-163°F (69.5-72.5°C) 225-235°F (107-113°C) 1–3–4–2 Counterclockwise (as seen from the flywheel) Sheathed-element Heater Plugs 25° Permanently/ 30° Briefly 310 g/hph (231 g/kWh) EPA Tier 1 97/68/EC Stage 1

Heating Flange 35° 315 g/hph (235 g/kWh) EPA Tier 2 97/68/EC Stage 2

* Prior to noise level optimization ** After noise level optimization

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Printed in U.S.A

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909768/BP1207

TECHNICAL DATA

ME12002

...Table continued from previous page

Diesel Engine Type Specification: Model: 30 Design

Tier II (SN AC02633 and up)

Tier I (SN AB00473AB03158)

John Deere 4045TF270 Yanmar 4TNE106T-NS Stanadyne RE519027 Distributor-type Fuel In-line Fuel Injection Pump Injection Pump

35 Injection Pressure

3568 psi (246 bar)

3191 psi (220 bar)

36 Revs Control

Mechanical Governor

Mechanical Governor

37 Injection Time

1±0.5° Before Top Dead Center

11 ~ 13° Force-fed Engine Lubrication with Trochoidal Pump

38 Lubrication System

Capacities 39 Fuel Tank 40 Engine Oil (max./effect.)

41 Coolant (without radiator) 42 Radiator 43 Expansion Tank

909768/BP1207

34 gal. (130 L) 16.9 qts. (16.0 L) 9.0 qts. (8.5 L) 5.8 qts. (5.5 L) 1.6 qts. (1.5 L)

10

34 gal. (130 L) 3.7/2.0 gal. (14.0/7.5 L) 6.3 qts. (6.0 L) 5.6 qts. (5.3 L) 1.2 qts. (1.1 L)

Printed in U.S.A

ME12002

TECHNICAL DATA

Tightening Torques NOTICE:Use these torque values when tight-

and self-tapping, thread forming and sheet metal screws) unless specified otherwise.

ening Mustang hardware (excluding: locknuts

Port Codes: Main Valve Block

Figure 1-5 Port Codes, Main Valve Block Printed in U.S.A

11

909768/BP1207

TECHNICAL DATA Dimension

Tightening Torque

1 5/16 - 12 UNF - 2B

145 ~ 181 lb.-ft.

(196.0 ~ 245.0 Nm)

1 1/16 - 12 UNF - 2B

108 ~ 129 lb.-ft.

(147.0 ~ 175.4 Nm)

9/16 - 18 UNF - 2B

25 ~ 28 lb.-ft.

(34.3 ~ 38.2 Nm)

ME12002 Port Code PR PL AR1 BR1 AR3 BR3 AL1 BL1 AL2 BL2 AR2 BR2 BR4 AL3 BL3 AL4 BL4 X Y R1 (R2) aR1 bR1 aR2 bR2 aR3 bR3 aR4 bR4 aL1 bL1 aL2 bL2 aL3 bL3 aL4 bL4 Pis bL5 PA1 PB1

Port Name Pump Port (Right Side) Pump Port (Left Side) Travel Right Port Travel Right Port Arm Rod Side Port Arm Head Side Port Travel Left Port Travel Left Port Option Port Option Port Swing Motor Port Swing Motor Port Boom Head Port (Confluence) Boom Rod Side Port Boom Head Side Port Bucket Rod Side Port Bucket Head Side Port Arm Confluence Outlet Port Arm Confluence Inlet Port Return Port Return Port Travel Right Pilot Port Travel Right Pilot Port Swing Pilot Port Swing Pilot Port Arm Dump Pilot Port Arm Dig Pilot Port Option Confluence Pilot Port Boom Up Confluence Pilot Port Travel Left Pilot Port Travel Left Pilot Port Option Pilot Port Option Pilot Port Boom Down Pilot Port Boom Up Pilot Port Bucket Dump Pilot Port Bucket Dig Pilot Port Arm Out Confluence Pilot Port Add On Valve Pilot Port Lock Valve Pilot Port (Arm) Lock Valve Pilot Port (Boom)

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Printed in U.S.A

ME12002

TECHNICAL DATA

...Table continued from previous page Dimension

Tightening Torque

7/16 - 20 UNF - 2B

7.2 ~ 9.0 lb.-ft.

(9.8 ~ 12.3 Nm)

PF - 3/4 PF - 1/2 4 - M10

Printed in U.S.A

108 ~ 130 lb.-ft.

(147 ~ 176 Nm) 72 ~ 87 lb.-ft.

(98 ~ 118 Nm) 36 lb.-ft. (49.0 Nm)

Port Code PTA PSW PP HR HL PSP dR4 dL5 dL6 dR7 dR8 dL9 Pe1 (PAT) (dST1) P3 P4 (PB3) T

Port Name Signal Port (Travel) Signal Port (Attachment) Pilot Pressure Inlet Port Negative Control Signal Port (Right Side) Negative Control Signal Port (Left Side) Swing Priority Pilot Port Drain Port Drain Port Drain Port Drain Port Drain Port Drain Port Travel Straight Pilot Port (For Add On Valve) Add On Valve Pilot Port Signal Port Outlet Port (For Option Confluence) Outlet Port (For Add On Valve) Inlet Port (For Add On Valve) Return Port

13

909768/BP1207

TECHNICAL DATA

ME12002

Hydraulic Joints and Dry Assembly Metric Hose Joints for Hydraulic Assembly

Light version (DKOL) DN

RA

Screw

Tool

Torque

05

6L

M12x1.5

SW 14

11 lb.-ft. (15 Nm)

06

8L

M14x1.5

SW 17

15 lb.-ft. (20 Nm)

08

10L

M16x1.5

SW 19

30 lb.-ft. (40 Nm)

10

12L

M18x1.5

SW 22

37 lb.-ft. (50 Nm)

12

15L

M22x1.5

SW 27

55 lb.-ft. (75 Nm)

16

18L

M26x1.5

SW 32

63 lb.-ft. (85 Nm)

20

22L

M30x2

SW 36

74 lb.-ft. (100 Nm)

25

28L

M36x2

SW 41

133 lb.-ft. (180 Nm)

32

35L

M45x2

SW 55

162 lb.-ft. (220 Nm)

Heavy type (DKOS) DN

RA

Screw

Tool

Torque

05

8S

M16x1.5

SW 19

30 lb.-ft. (40 Nm)

06

10S

M18x1.5

SW 22

37 lb.-ft. (50 Nm)

08

12S

M20x1.5

SW 24

44 lb.-ft. (60 Nm)

10

14S

M22x1.5

SW 27

55 lb.-ft. (75 Nm)

12

16S

M24x1.5

SW 30

66 lb.-ft. (90 Nm)

16

20S

M30x2

SW 36

74 lb.-ft. (100 Nm)

20

25S

M36x2

SW 41

133 lb.-ft. (180 Nm)

25

30S

M42x2

SW 50

199 lb.-ft. (270 Nm)

32

38S

M52x2

SW 60

295 lb.-ft. (400 Nm)

Surface galvanic coated and dry (O-ring oiled). Tolerance torque: 10 %

909768/BP1207

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Printed in U.S.A

ME12002

TECHNICAL DATA

Hydraulic Screw Joints and Dry Assembly Screws with Different Seal Types for Hydraulic Use

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE)

Whitworth screw

Metric screw

Thread

Nonreturn valve with elastic seal

Identification aid outside-Ø

Sealing washer

Elastic seal

O-Ring

M10x1.0 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M22x1.5

7 (9) 15 (20) 26 (35) 33 (45) 41 (55) 48 (65)

13 (18) 18 (25) 33 (45) 41 (55) 52 (70) 92 (125)

11 (15) 18 (25) 26 (35) 30 (40) 33 (45) 44 (60)

13 (18) 18 (25) 26 (35) 37 (50) 52 (70) 92 (125)

0.4" (10 mm) 0.5" (12 mm) 0.6" (14 mm) 0.6" (16 mm) 0.7" (18 mm) 0.9" (22 mm)

M27x2.0

66 (90) 133 (180) 74 (100) 107 (145)

1.0" (27 mm)

M33x2.0 111 (150) 229 (310) 118 (160) 155 (210)

1.3" (33 mm)

M42x2.0 177 (240) 332 (450) 155 (210) 266 (360)

1.7" (42 mm)

M48x2.0 214 (290) 398 (540) 192 (260) 398 (540)

1.9" (48 mm)

G 1/8A

7 (9)

13 (18)

11 (15)

13 (18)

0.4" (9.73 mm)

G 1/4A

26 (35)

26 (35)

22 (30)

26 (35) 0.5" (13.16 mm)

G 3/8A

33 (45)

52 (70)

33 (45)

37 (50) 0.7" (16.66 mm)

G 1/2A

48 (65)

66 (90)

41 (55)

48 (65) 0.8" (20.96 mm)

G 3/4A

66 (90) 133 (180) 74 (100) 103 (140) 1.0" (26.44 mm)

G 1A

111 (150) 229 (310) 118 (160) 140 (190) 1.3" (33.25 mm)

G 1 1/4A 177 (240) 332 (450) 155 (210) 266 (360) 1.7" (41.91 mm) G 1 1/2A 214 (290) 398 (540) 192 (260) 398 (540) 1.9" (47.80 mm) Torque Tolerance: - 10%; Steel/Aluminium The indicated values are to be used as appoximate values.

Table continues on next page...

Printed in U.S.A

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TECHNICAL DATA

ME12002

...Table continued from previous page

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE)

Whitworth screw

Metric screw

Thread

Nonreturn valve with elastic seal

Identification aid outside-Ø

Sealing washer

Elastic seal

O-Ring

M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5

15 (20) 26 (35) 33 (45) 41 (55) 41 (55)

26 (35) 41 (55) 52 (70) 66 (90) 92 (125)

26 (35) 33 (45) 41 (55) 52 (70) 59 (80)

26 (35) 33 (45) 41 (55) 52 (70) 74 (100)

0.5" (12 mm) 0.6" (14 mm) 0.6" (16 mm) 0.7" (18 mm) 0.8" (20 mm)

M22x1.5

48 (65) 100 (135) 74 (100) 92 (125)

0.9" (22 mm)

M27x2.0

66 (90) 133 (180) 125 (170) 100 (135)

1.0" (27 mm)

M33x2.0 111 (150) 229 (310) 229 (310) 155 (210)

1.3" (33 mm)

M42x2.0 177 (240) 332 (450) 243 (330) 266 (360)

1.7" (42 mm)

M48x2.0 214 (290) 398 (540) 310 (420) 398 (540)

1.9" (48 mm)

G 1/4A

26 (35)

41 (55)

33 (45)

33 (45) 0.5" (13.16 mm)

G 3/8A

33 (45)

59 (80)

44 (60)

44 (60) 0.7" (16.66 mm)

G 1/2A

48 (65)

85 (115)

55 (75)

74 (100) 0.8" (20.96 mm)

G 3/4A

66 (90) 133 (180) 125 (170) 107 (145) 1.0" (26.44 mm)

G 1A

111 (150) 229 (310) 229 (310) 192 (260) 1.3" (33.25 mm)

G 1 1/4A 177 (240) 332 (450) 243 (330) 266 (360) 1.7" (41.91 mm) G 1 1/2A 214 (290) 398 (540) 310 (420) 398 (540) 1.9" (47.8 mm) Torque Tolerance: - 10%; Steel/Aluminium

The indicated values are to be used as appoximate values.

909768/BP1207

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Printed in U.S.A

ME12002

TECHNICAL DATA

High Quality Screws and MA High Quality Screw Joints

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

Threads according to DIN 912, DIN 931, DIN 933, etc.

Threads according to DIN 7984

8.8 4.1 (5.5) 7 (10) 18 (25) 33 (45) 64 (87) 100 (135) 155 (210) 207 (280) 302 (410) 406 (550) 524 (710)

8.8 4 (5) 6.3 (8.5) 15 (20) 30 (40) 51 (69) 81 (110) 125 (170) 181 (245) 251 (340) 339 (460) 435 (590) 642 (870)

10.9 6 (8) 10 (14) 26 (35) 48 (65) 81 (110) 133 (180) 203 (275) 302 (410) 420 (570) 575 (780)

12.9 7 (10) 13 (17) 31 (42) 59 (80) 108 (147) 170 (230) 258 (350) 354 (480) 509 (690) 686 (930)

738 (1000) 878 (1190) 767 (1040) 1092 (1480) 1305 (1770) 1047 (1420) 1482 (2010) 1770 (2400)

885 (1200)

10.9 5 (7) 9 (12) 22 (30) 44 (59) 74 (100) 118 (160) 184 (250) 254 (345) 361 (490) 487 (660) 620 (840) 922 (1250) 1254 (1700)

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread M8x1.0 M10x1.0 M10x1.25 M12x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2.0 M27x2.0 M30x2.0

Printed in U.S.A

Threads according to DIN 912, DIN Threads according to DIN 931, DIN 933, etc.

7984 8.8 10.9 12.9 8.8 10.9 18 (25) 27 (37) 32 (43) 16 (22) 24 (32) 37 (50) 55 (75) 65 (88) 32 (43) 48 (65) 36 (49) 52 (71) 61 (83) 31 (42) 46 (62) 64 (87) 96 (130) 111 (150) 55 (75) 81 (110) 61 (83) 92 (125) 107 (145) 53 (72) 77 (105) 100 (135) 148 (200) 173 (235) 89 (120) 129 (175) 155 (210) 229 (310) 266 (360) 133 (180) 195 (265) 232 (315) 332 (450) 391 (530) 199 (270) 284 (385) 325 (440) 465 (630) 538 (730) 277 (375) 391 (530) 435 (590) 620 (840) 723 (980) 369 (500) 524 (710) 546 (740) 789 (1070) 922 (1250) 465 (630) 664 (900) 811 (1100) 1143 (1550) 1328 (1800) 679 (920) 959 (1300) 1106 (1500) 1586 (2150) 1844 (2500)

17

959 (1300)

1364 (1850)

909768/BP1207

TECHNICAL DATA

ME12002

Type Relative for High Quality Screw Joints Tightening Torque MA for Screw Joints lb.-ft. (Nm) Turntable*

M18 10.9

291 (395)

Track roller*

M16 12.9

264 (358)

Swivel joint*

M10 10.9

47 (64)

Sprocket*

M16 10.9

203 (275)

Drive unit*

M16 10.9

203 (275)

Swivel unit*

M14 12.9

162 (220)

Cab mounting screws

M10 8.8

33 (45)

M12 8.8

64 (87)

Engine carrier

M10 8.8

33 (45)

M12 10.9

81 (110)

Engine carrier

M10 8.8

33 (45)

Pump carrier

M10 10.9

47 (64)

Pump

M16 10.9

203 (275)

*Must be sealed with Loctite S2420 or equivalent.

909768/BP1207

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Printed in U.S.A

ME12002

TECHNICAL DATA

Fluid Capacities/Lubricants: John Deere 4045TF270 (SN AC02633 and up) Component/ Application

Lubricant

Specification

Diesel Engine

Engine Oilb

API CI-4, API CH-4, ACEA E3-E4

Traveling Drive Gearbox Oil

Gearbox Oilc

Hydraulic Oil Tank

Hydraulic Oild

Q8 T 55, SAE 85W-90 FINA PONTONIC GLS, SAE 85W-90 HVLP46

Biodegradable Oile

Grease

Grease Zerks Battery Terminals Diesel Fuel Tank

Engine and Hydraulic Oil Cooler Air Conditioning

Windshield Washer

Roller and Friction Bearingsf Open Gear (live ring gears)g Multipurpose Greaseh

Season/ Capacitya Temperature 5°F (-15°C) 4.5 gal. (17 L) 113°F (45°C) (with filter change) 4.2 gal. (16 L) (without filter change) Year-round 2.7 qts. (2.6 L)

Year-round

PANOLIN HLP Synth 46 FINA BIOHYDRAN SE 46 BP BIOHYD SE-46 FINA Energrease L21M Year-round

33.8 gal. (128 L)

as required

BP Energrease MP-MG2 FINA Energrease L21 M

Year-round

as required

FINA Marson L2

Year-round

as required

Grade No. 2-D, DIN 51601 Grade No. 1-D, DIN 51601 Water + Antifreeze; SP-C

Over 39°F (4°C) Below 39°F (4°C) Year-round

34 gal. (130 L)

Refrigerating Agent R134ak Compressor Oil Sanden SP10

Year-round

2.2 lbs. (1000 g)

Cleaning Agent

Year-round

8.2 in.3 (135 cm3) 0.3 gal. (1.1 L)

Acid-proof Greasei Diesel Fuel

Coolantj

Water + Antifreeze

3.7 gal. (14 L)

a. Capacities shown are approximate; use only oil level check to determine correct oil level b. Q8 T 660, SAE 10W-40 c. Petroleum-based Hypoid gear oil (SAE 85W-90 acc. To DIN 51502), (API GL-4, GL-5) d. According to DIN 51524 part 3 e. Hydraulic ester oils (HEES) f. KF2K-25 according to DIN 51502 multi-purpose lithium grease with MoS² additive g. KP2N-20 according to DIN 51502 EP multi-purpose calcium sulphonate complex grease h. KF2K-25 according to DIN 51502 multi-purpose lithium grease with MoS² additive i. Standard acid-proof grease j. Ethylene glycol k. According to DIN 8960 Printed in U.S.A

19

909768/BP1207

TECHNICAL DATA

ME12002

Fluid Capacities/Lubricants: Yanmar 4TNE106T-NS (SN AB00473-AB03158) Lubrication Point Motor Oil Hydraulic Oil

Lubricant Fina Kappa 10W-40 CF-4/SG BP Energol SHF 46

Live Ring

Fina Hydran TSX 46 BP Energrease MP-MG2

Gearing

BP Energrease L 21 M

Ball Bearing Travelling Gear Unit Excavator Arm

Fina Potonic GL-5 SAE 85W-90 BP Energrease L 21 M

All Lubrication Points

Gleitmo 800 (for initial lubrication of bolts, slewing bracket and clamping sleeves) BP Energrease L 21 M

Range of Application of Motor Oil: from -13°F to 104°F (-25°C to 40°C).

NOTICE:All specified greases are suitable from -13°F to 104°F (-25°C to 40°C).

Oil Grades: Ambient Temperature Engine Oil Grade F° -4

5

Ambient Temperature F° (C°) 14 23 32 41 50 59 68 77

86

95 104

SAE 10W SAE 20W SAE 10W-30 SAE 10W-40 SAE 15W-40

API CD, CF, CF-4, CI-4 SAE E3, E4, E5

SAE 20 SAE 30 SAE 40 C° -20 -15 -10

909768/BP1207

-5

0

20

5

10

15

20

25

30

35

40

Printed in U.S.A

CHAPTER 2 MAINTENANCE Maintenance Chart Check, Clean and Inspect

Service Activity

Daily

Leakage Check (walk-around excavator)

O

Visual Check (walk-around excavator)

O

Check Hydraulic Oil Level

O

Check Engine Oil Level

O

Check Engine Coolant Level

O

Every Every Every Every 50 250 500 1000 Annual Hours Hours Hours Hours

Check Coolant Thermostat (SN AB00473-AB03158)

O

Check and Clean Air Filter (damage)

O/X

<>

Check Engine Mounting Bolts

O O

Check Engine Coolant Level

O

Check Engine Speed Regulation O

Check Gearbox Oil Level

X

Clean Drain Holes in Cab/Canopy Check Engine/Hydraulic Oil Radiator and Air Conditioning for Contamination.

Clean if Necessary

O/X

Check Cooling and Heating System Hoses for Leaks and Pressure (visual check)

O

Replace Cab Air Filter for Heating and Air Conditioning

<> O

Check Heating Fan Air Filter (damage)

O/X

Inspect Water Separator Prefilter, Drain Water

O/X

<>

O

Check Water Pump

X

Clean

Printed in U.S.A

<>

X

Clean Water Separator

<> Change/Replace

<>

O

Check/Inspect

<> (1)

Change/Replace the first time

21

909768/BP1207

MAINTENANCE

ME12002

Service Activity

Daily

Every Every Every Every 50 250 500 1000 Annual Hours Hours Hours Hours

Clean Radiator Fins

X

Check V-belt Condition and Tension

O

Check Exhaust System for Damage

O

Check Engine Valve Clearance, Set if Necessary

O

Check Fuel Injection Pump, Pressure, Nozzles and Valves

O

Check and Adjust Injection Timing Check Fuel Level

O O

Clean Fuel Tank

X

Engine Oil

O

Oil Filter

<>(1)

<>

<>

<>(1)

<>

<>

Check Radiator Fins

X

Check Engine Valve Clearance, Set if Necessary

O

O

Generator, Starter

O

Clean Fuel Tank

X

Drain Diesel Fuel Tank

X

Check Water Pump

O O

Fuel Filter

<>

<>

Cooling System and Hoses

O

Electrical Connections

O

Pre-heating System

O

Clean Battery

X

Check Battery Fluid

O

Check Alternator, Starter and Electrical Connections

O

Check Bearing Play and Function

O

<> Change/Replace X

Clean

909768/BP1207

O

Check/Inspect

<> (1)

Change/Replace the first time

22

Printed in U.S.A

ME12002

MAINTENANCE

Service Activity

Daily

Every Every Every Every 50 250 500 1000 Annual Hours Hours Hours Hours

Check Hydraulic Cylinder Performance Under Load

O

Check Gear Ring

O

Check Preheating System and Electrical Connections

O

Check Air filter Restriction Gauge

O

Pressure Check for Primary Pressure Limiting Valves

O

Pressure Check for Secondary Pressure Limiting Valves

O

Check Tracks for Cracks or Cuts

O

Check Track Tension, Tighten if Necessary

O

Check Bearing Play on Tread Rollers, Track Carrier Rollers and Front Idlers

O

Check Cylinders, Piston Rods for Damage

O

Check Bolts and Screws for Tightness

O

Check Pin Lock and Line Fastenings (dipper arm and attachment)

O

Check Bucket Teeth for Wear

O

Check Hydraulic Line Clamps

O

Check Hydraulic Pump Bolts

O

Clean Hydraulic Fluid Cooler Fins

X

Check Indicator Lights and Headlights for Correct Function

O

Check Cab Operating Equipment (switches, pedals, levers, joystick, etc.)

O

Check Cab Tilt Lock/Support Components

<> Change/Replace X

Clean

Printed in U.S.A

O

O

Check/Inspect

<> (1)

Change/Replace the first time

23

909768/BP1207

MAINTENANCE

ME12002

Service Activity

Daily

Clean Couplings, Dirt Built up on Hydraulic System Dust Caps

Every Every Every Every 250 500 50 1000 Annual Hours Hours Hours Hours

X

Check and Clean Insulating Mats in the Engine Compartment Grease Central Lubrication System Point

O/X O/X

Check Warning Decals and Operator’s Manual in Place

O

Generator/Starter

O

Check Engine Cover Gas Strut

X

Fluid and Filter Changes

Service Activity

Daily

Every Every Every Every 250 500 50 1000 Annual Hours Hours Hours Hours

Engine Oil

<>(1)

Engine Oil Filter

<>(1)

Fuel Filter (SN AC02633 and up)

<>(1)

Fuel Filter (SN AB00473-AB03158)

<> <> <> <>

Air Filter when Indicator Light Comes on Engine Coolant

<>

Hydraulic Oil Filter Insert

<>(1)

Hydraulic Oil (SN AC02633 and up)

<> <>

Hydraulic Oil (SN AB00473-AB03158)

<>(1)

<>

Breather-hydraulic Oil Tank

<>

Gearbox Oil

<>(1)

Change Final Drive Gear Oil

<> Change/Replace X

Clean

909768/BP1207

<> <>(1)

O

Check/Inspect

<> (1)

Change/Replace the first time

24

<>

Printed in U.S.A

ME12002

MAINTENANCE

Air Conditioning

Service Activity

Daily

Every Every Every Every 50 1000 Annual 250 500 Hours Hours Hours Hours

Test Air Conditioning Function

O

Replace Cab Air Filter

<>

Check Dehumidifier for Corrosion

O

Check Refrigerant

O

Replace Dehumidifier

<>

Replace Compressor Oil

<>

Functional Check Service Activity

Daily

Lights, Signaling System, Audible Warning System

Every Every Every Every 50 250 500 1000 Annual Hours Hours Hours Hours

O

Electrical System Function

O

Electrical Connectors

O

Heating System Function

O

Windshield Wipers

O

Leakage Check Service Activity

Daily

Visual Check for Tightness, Leaking, Chafing of Flexible Lines and Screw Connections

O

Engine and Hydraulic System Components

O

Cooling and Heating Circuit Components

O

Traveling Drive Components

O

<> Change/Replace X

Clean

Printed in U.S.A

O

Check/Inspect

<> (1)

Change/Replace the first time

Every Every Every Every 50 250 500 1000 Annual Hours Hours Hours Hours

25

909768/BP1207

MAINTENANCE

ME12002

Lubrication Check

Service Activity

Daily

Dozer Blade

O

Swiveling Console

O

Boom

O

Dipper Arm

O

Attachments

O

Chassis (front of undercarriage)

O

<> Change/Replace X

Clean

909768/BP1207

O

Check/Inspect

<> (1)

Change/Replace the first time

Every Every Every Every 50 250 500 1000 Annual Hours Hours Hours Hours

26

Printed in U.S.A

ME12002

MAINTENANCE

Lubrication

Figure 2-1 Lubrication Points

Recommended Lubricants

Final Drive Unit An EP grade gear oil that conforms to API GL5, such as Chevron Delo Gear 80W-90 or BP Transgear 80W-90.

Engine Oil A diesel engine oil conforming to an SAE grade, depending on the engine temperature, and classifications API CH-4, CI-4, or ACEA E3, E4 such as BP Vanellus MG 15W-40, BP Vanellus C-Extra 10W-30, or Chevron Delo 400 15W-40. See “Oil Grades: Ambient Temperature” on page 20.

Swing Gear Unit An EP grade gear oil that conforms to API GL5, such as Chevron Delo Gear 80W-90 or BP Transgear 80W-90.

Hydraulic Oil A HVLP 46 (norm) hydraulic oil with anti-wear, anti-foam and anti-oxidation additives that conforms to ISO Viscosity Grade 46, such as, Mobile DTE 15M, Amoco Rykon 46, or BP Energol HLPHD 46.

All Lubrication Points A heavy-duty lithium complex grease with 3% molybendenumdisulfide, such as Chevron RPM Heavy Duty Grease No. 2, Mobilgrease Moly 52 or BP Energrease Moly EP2. See Figure 2-1.

Ranges of Applications From -13°F to +104°F (-25°C to +40°C) outside temperature.

Swing Ring A heavy-duty lithium complex grease with 3% molybendenumdisulfide, such as Chevron RPM Heavy Duty Grease No. 2, Mobilgrease Moly 52 or BP Energrease Moly EP2.

Printed in U.S.A

27

909768/BP1207

MAINTENANCE

ME12002 General Information

Lubricants Lubrication Fillings Used As:

Lubrication Type 10W-40 (Norm)

Engine Oil

BP Vanellus FE

WARNING Instructions are necessary before operating or servicing the machine. Read and understand this entire manual. Follow warnings and instructions for operation and maintenance.

Check for correct function after adjustments or maintenance. Failure to follow instructions can result in injury or death.

APISF-CD + SAE 10W-40 FINA Kappa SE10W-40 Q8 T660-10W-40 Bio Oil HVLP 46 (Norm) Hydraulic Oil

BP Energol SHF 46 FINA Hydran TSX 46

WARNING

Q8 Heller 46 BP Biohyd SE S46 Turntable: Teeth

BP Energrease OG (Farbe weiss)

Ball Bearings

BP Energrease L 21 M

Be sure you are familiar with all safety devices and controls before operating or servicing the machine. Know how to stop before starting.

The machine is designed for use only with approved accessories or referral attachments.

The Mustang Company cannot be responsible for safety if the machine is used with nonapproved modifications or attachments.

RK 15, RK20S Energear Hypo EP 90 API GL 5 Drive Gears

FINA Pontonic MP85W-90 API GL-5 Q8 T55 85W-90

WARNING

SGXP 220 BP Energrease L 21 M Boom, Dipper Arm

The hydraulic reservoir is under pressure.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin and eyes.

Gleitmo 805 (for the first greasing of the bolts )

Track Tension Cylinder Planetary Gear

BP Energrease L 21 M SAE 90 Hypoidöl (GL 5)

Fix and Float Axles

FINA Pontonic MP85W-90 API GL-5

Distribution Gear

Q8 T55 85W-90

Each Lubrication Point

BP Energrease L 21 M

Care and Servicing The care and servicing of the machine has a significant influence on its operational readiness and service life.

Use of lubricants not corresponding to the manufacturer’s recommendations may invalidate warranty claims.

Conditions: Engine Oil:

From -13°F (-25°C) to 104°F (40°C) outside temperature

Grease:

From -13°F (-25°C) to 104°F (40°C) outside temperature

909768/BP1207

More frequent servicing, other than the recommended intervals, may be required under extreme conditions (extremely dusty or hot conditions).

Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws or take to a recycling center for proper disposal.

28

Printed in U.S.A

ME12002

MAINTENANCE

DO NOT pour fluids onto the ground or down a drain.

WARNING

DO NOT power-wash the main hydraulic pumps and controls, throttle solenoids and sealed bearings. High pressure water can be forced through seals and trapped within these components, causing premature failure.

Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized fluid can have enough force to pierce the skin and cause serious injury.

The operating pressure settings of the hydraulic system should only be adjusted by trained, qualified personnel. If malfunctions are caused by unauthorized alteration of operating pressure settings, all warranty responsibilities of the manufacturer are invalidated.

Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands. Obtain immediate medical attention if pressurized fluid pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

Maintenance Safety •

Never fill the fuel tank while the engine is running, while smoking, or when near open flame.

Always lower bucket and dozer blade to the ground before performing any maintenance.

•

Keep your body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust.

•

Use correct procedures to lift and support the machine. Always lift the dozer blade fully before installing jackstands.

•

Wear eye protection while servicing the machine.

•

Keep the engine cover and hydraulic valve covers closed except for service. Close and latch covers before operating the machine.

•

Lead-acid batteries produce flammable and explosive gas. Keep arcs, sparks, flames and lighted tobacco away from batteries.

•

Be sure to have the work area properly ventilated when grinding or welding parts.

Wear a dust mask.

•

Never service the machine without reading the applicable instructions.

•

•

Exhaust fumes can kill. The exhaust system must be tightly sealed. If working in an enclosed area, vent exhaust to outside if the engine must be run for service.

•

Never service or adjust the machine with the engine running unless it is required by the service procedure.

•

Never modify equipment or add attachments not approved by the Mustang Company.

•

Stop the engine and let it cool, then clean any flammable materials from the engine before checking fluid levels.

•

Avoid contact with leaking hydraulic fluid and diesel fuel under pressure.

Printed in U.S.A

WARNING Batteries contain acid which burns eyes and skin on contact. Wear safety goggles and protective clothing to keep acid off body.

In case of acid contact, wash immediately with water for several minutes. In case of eye contact, get medical attention immediately.

29

909768/BP1207

MAINTENANCE

ME12002

Hydraulic System

CAUTION

WARNING

The hydraulic reservoir is pressurized. Release stored hydraulic pressure in lines by cycling the operator’s controls in each direction after the engine is shut down. Release hydraulic reservoir pressure before removing the hydraulic reservoir access cover. Vent the system pressure by rotating the filler cap.

LOOSEN CAP SLOWLY prior to removal.

The hydraulic tank is under pressure. Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands. Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

Fluid leaks from hydraulic hoses and pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands. Obtain immediate medical attention if pressurized oil pierces the skin.

Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

General instructions: •

For maintenance and repair work, open the air bleed filter (depressurize the system).

See “Purging Air from the Fuel System: John Deere Engine Model 4045TF270 (SN AC02633 and up)” on page 46, or “Purging Air from the Fuel System: Yanmar Engine Model 4TNE106T-NS (SN AB00473-AB03158)” on page 46.

•

For pressure setting, see “Hydraulic System Specifications” on page 7.

•

Before each pressure test, the device must be warmed up and hydraulic oil temperature must be at least 122°F (50°C).

•

Primary pressure limiting valves (PPLV) should be set at maximum engine revolutions, see “Hydraulic System Specifications” on page 7.

•

The pressure drop (Delta P between maximum and minimum diesel engine revolution) is tested at unchanged load.

909768/BP1207

Disconnect battery before performing hydraulic service or welding on the machine.

30

Printed in U.S.A

Printed in U.S.A RIGHT

LEFT

DOWN

UP

Motion

Symbol

31

Drive left

Auxiliary hydraulics

Bucket

Boom

Function

(Main valve block)

REARWARD

(Main valve block)

Main pressure limiting valve MR-E1

Pressure Limiting Valve

FORWARD

Symbol

Measuring Point Settings (1) psi (bar)

Fall: 508 (35) Setting: 4641±73 (320±5) Fall: 508 (35)

Settings (1) psi (bar) Setting: 4351±73 (300±5) Fall: 508 (35) Setting: 4351±73 (300±5) Fall: 508 (35) Setting: 4351±73 (300±5) Fall: 508 (35) Setting: 4351±73 (300±5) Fall: 508 (35) Measuring point Setting MP1 (2): 4351±73 (300±5) (Hydraulic pump) Fall: 508 (35) Setting (2): 4351±73 (300±5) Fall: 508 (35) Setting: 4641±73 (320±5)

Measuring Point

Setting: 4931±73 (340±5) Measuring point Fall: 580 (40) MP3 Primary pressure Setting: 4931±73 (340±5) limiting valve (Side valve block) Fall: 580 (40) PPLV 2 Setting: 4931±73 (340±5) (Side valve block) MP1 Fall: 580 (40) (Hydraulic pump) Setting: 4931±73 (340±5) Fall: 580 (40)

Pressure Limiting Valve

Main pressure limiting valve MR-E2

B

A

IN

OUT

DOWN

UP

Motion

Pump 1/Main Valve Block

Boom offset

Dozer blade

Function

Pump 1/Side Valve Block

Checked

Checked

OK?

X

OK?

X

ME12002 MAINTENANCE

Hydraulic Pump Pressure Checklist

909768/BP1207

909768/BP1207

32

LEFT

(Main valve block)

REARWARD

(2) (3)

MR PLV (1)

Joystick

Function PLV-GP (Gear pump)

Setting (1) psi (bar)

Measuring Setting (1) psi (bar) Point Measuring point Setting: 580 (40) MP4 Fall: 73 (5) (Gear pump)

Setting: 4351±73 (300±5) Fall: 508 (35) Setting: 4351±73 (300±5) Fall: 508 (35) Setting (3): 3481±29 (240±2) Measuring point Fall: MP2 (Hydraulic pump) Setting (3): 3481±29 (240±2) Fall: Setting: 4641±73 (320±5) Fall: 508 (35) Setting: 4641±73 (320±5) Fall: 508 (35)

Measuring Point

Checked

Checked

Main pressure limiting valve (main relief valve).

Pressure limiting valve.

Pressure settings correspond with the excavator serial number. Only use the setting figures given in this manual. See the Technical Data chapter.

Notice: Settings only correct without secondary pressure limiting valves.

See the Technical Data chapter for the setting that corresponds with the serial number.

All

Motion

Pressure Limiting Valve

Main pressure limiting valve MR-E2

FORWARD

Symbol

Secondary pressure Limiting valve SPLV 3 (Sw ivel motor)

(Main valve block)

IN

RIGHT

Main pressure limiting valve MR-E1

Symbol

Pressure Limiting Valve

OUT

Motion

Pilot Pressure System

Drive right

Swivel motor

Dipper arm

Function

Pump 2

OK?

X

OK?

X

MAINTENANCE ME12002

Printed in U.S.A

Printed in U.S.A RIGHT

LEFT

DOWN

UP

Motion

Symbol

33

Drive left

Auxiliary hydraulics

Bucket

Boom

Function

(Main valve block)

REARWARD

(Main valve block)

MR-E1

Main pressure limiting valve

Pressure Limiting Valve

Main pressure limiting valve MR-E2

Symbol

Measuring Point Settings (1) psi (bar) Setting: Fall:

Fall: Setting: Fall:

Settings (1) psi (bar) Setting: Fall: Setting: Fall: Setting: Fall: Setting: Fall: Measuring point Setting MP1 (2): (Hydraulic pump) Fall: Setting (2): Fall: Setting:

Measuring Point

Setting: Fall:

Measuring point Setting: Primary pressure MP3 Fall: limiting valve (Side valve block) PPLV 2 Setting: MP1 (Side valve block) (Hydraulic pump) Fall:

Pressure Limiting Valve

FORWARD

B

A

IN

OUT

DOWN

UP

Motion

PUMP 1/Main Valve Block

Boom offset

Dozer blade

Function

PUMP 1/Side Valve Block

Checked

Checked

OK?

X

OK?

X

ME12002 MAINTENANCE

909768/BP1207

MAINTENANCE

ME12002

Hydraulic Pump Part Inspection Part Name

Cylinder

Problem

Corrective Action

Scratches, discoloration, cracks, erosion, wear or seizure Replace rotating group on sliding surface or bores.

Scratches, wear, cracks or seizures on sliding surface.

Piston Replace rotating group Indentation, cracks or dents on neck Scratches, indentation, erosion, wear or scuffing on sliding surface.

Shoe Wear, scuffing or deformation on Replace rotating group shoe surface.

Indentation or crack around caulked area.

Scratches, discoloration, scuffing or seizure at shoe plate location surface.

Swash plate support Replace swash plate support Scratches, wear, scuffing or seizure at pillow bearing sliding surface.

Scratches, erosion, wear, scuffing or seizure at sliding surface.

Shoe plate Replace shoe plate Scratches, discoloration, scuffing or seizure at mounting surface.

Replace with a completely new, Any malfunction that has been Regulator previously tested and set up isolated to the regulator. regulator assembly

909768/BP1207

34

Printed in U.S.A

ME12002

MAINTENANCE

Hydraulic Pump Pressure Checklist Measurements

MP2

Gear pump side

Diesel engine side

B1

MP1

Figure 2-2 Hydraulic Pump Position Measuring Points (MP1-2) (photo taken from underneath)

MP3

Figure 2-3 Side Valve Block Position Measuring Point (MP3)

Printed in U.S.A

35

909768/BP1207

MAINTENANCE

ME12002

Air bleed port for the regulation pump

MP4

Gear pump

Diesel engine side

Figure 2-4 Gear Pump at the Regulation Pump Unit Measuring Point (MP4)

MR

MPLV-1 (MR)

Figure 2-5 Main Pressure Limiting Valve (MR) at the Main Valve Block Position

909768/BP1207

36

Printed in U.S.A

ME12002

MAINTENANCE Adjusting the Main Pressure Limiting Valve (MR)

PPLV-2

1. Remove and retain both nuts from the main pressure limiting valve (MR) and secure the adjustment screw for working hydraulic E1 into the block. See Figure 2-8.

2. Position the driving unit (e.g. drive with the dozer blade against a wall).

3. Set adjustment screw E2 pressure for driving to 4641 psi (320 bar)1. See Figure 2-8.

4. Secure adjustment screw E2 and its nut. See Figure 2-8.

5. Set the pressure for working hydraulic with adjustment screw E1 to 4351 psi (300 bar)1, by extending the boom all the way. See Figure 28.

6. Secure adjustment screw E1. See Figure 2-8.

7. Install nuts removed in step 1. See Figure 2-8.

Adjustment screw for drive

Figure 2-6 Primary-pressure Limiting Valve-2 (Side Valve Block) Position

Nuts

E2 K

E1

Cone Valve

Adjustment screw for working hydraulic

Figure 2-8 Adjusting the Main Pressure Limiting Valve (MR) Main Pressure Limiting Valve (MR) Function

While driving, the pressure automatically increases to 4641 psi (320 bar)1 and moves piston K to the right against the spring (internal hole in the main valve block). This increases main pressure while driving. See Figure 2-8.

PLV-GP

Figure 2-7 Pressure Limiting Valve at the Gear Pump (Pilot Pressure) Position

1. The settings can be changed. See

“Hydraulic System Specifications” on page 7.

Printed in U.S.A

37

909768/BP1207

MAINTENANCE

ME12002

WARNING The hydraulic tank is under pressure. Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands. Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

Figure 2-10 Hydraulic Valve Cover Latch

Checking Hydraulic Oil Level: New Style 1. Position the excavator on a level surface.

2. Fully extend the bucket and boom, retract the arm and position as shown in Figure 2-9.

3. Lower bucket and dozer blade to the ground.

See Figure 2-9. Engage the parking brake.

Shut-off the engine. Remove the ignition key and take it with you.

Figure 2-11 Hydraulic Valve Cover 5. Check the hydraulic oil level sight gauge (1).

See Figure 2-12. Oil level should be between black and red marks on the sight gauge. If hydraulic oil is required, proceed to step 6.

Close the hydraulic valve cover.

Figure 2-9 Excavator Position for Checking and Changing Hydraulic Oil 1

4. Pull the hydraulic valve cover latch. See Figure 2-10. Exit the cab and open the hydraulic valve cover. See Figure 2-11.

Figure 2-12 Oil Level Sight Gauge 909768/BP1207

38

Printed in U.S.A

ME12002

MAINTENANCE 4. Check the hydraulic oil level indicator. Oil level should be between black and red marks on sight gauge. If hydraulic oil is required, proceed to step 5.

6. Slowly open the hydraulic oil filler cap to relieve pressure, then remove cap. See Figure 2-13.

Figure 2-13 Hydraulic Oil Tank Filler Cap 7. Add hydraulic oil until oil level is between red and black marks on sight gauge (1). See Figure 2-12. Open the hydraulic valve cover to check the oil level. See Figure 2-11.

8. Reinstall and securely tighten the filler cap.

9. Close the hydraulic valve cover.

10. Start the engine and let it idle for a few minutes.

Figure 2-15 Hydraulic Reservoir

11. Check hydraulic functions.

5. Slowly open the hydraulic oil filler cap to relieve pressure, then remove cap.

12. Repeat this procedure to recheck the hydraulic oil level.

6. Add hydraulic oil until oil level is between red and black marks on sight gauge.

Checking Hydraulic Oil Level: Old Style

7. Re-install hydraulic oil filler cap and tighten securely.

1. Position the machine on a level surface.

8. Start engine and let idle for a few minutes.

9. Check hydraulic functions. Re-check hydraulic oil level.

Figure 2-14 Checking and changing Hydraulic Oil 2. Fully extend the bucket and boom, and retract arm as shown in Figure 2-14.

3. Lower bucket and dozer blade to the ground.

See Figure 2-14. Turn off the machine.

Printed in U.S.A

39

909768/BP1207

MAINTENANCE

ME12002

Changing Hydraulic Oil: New Style 1. Position the excavator on a level surface.

Figure 2-16 Excavator Position for Checking and Changing Hydraulic Oil

3

2. Fully extend the bucket and boom, and retract arm as shown in Figure 2-16.

Figure 2-18 Rotate the Cab

3. Lower the bucket and dozer blade to the ground. See Figure 2-16. Shut-off the engine.

Remove the ignition key and take it with you.

7. Shut-off the engine. Remove the ignition key and take it with you. Follow the “Mandatory Safety Shutdown Procedure” in the Operator‘s manual.

4. Slowly open the filler cap (1) to relieve pressure. Remove the cap and clean debris out of the strainer. See Figure 2-17.

1

8. Crawl underneath the chassis between the tracks. See Figure 2-18.

9. Open the drain plug (3) and drain oil into a suitable container. Re-install drain plug and tighten securely. See Figure 2-19.

2

3

Figure 2-17 Hydraulic Oil Tank Cover 5. Remove the hydraulic oil tank cover (2). See Figure 2-17.

Figure 2-19 Hydraulic Oil Tank Plug

6. To access the hydraulic oil tank drain plug (3), rotate the cab to an angle of slightly less than 45°, as shown. See Figure 2-18.

IMPORTANT:Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

10. Remove bolts and filter cover (4). Remove and discard old filter (5). Install the new filter (5) into reservoir. See Figure 2-20.

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ME12002

MAINTENANCE

4 5

Figure 2-21 Rotate the cab (bucket shown removed) 17. Cycle all front attachment hydraulic functions and check the hydraulic oil level. See “Checking Hydraulic Oil Level: New Style” on page 38.

3

Figure 2-20 Hydraulic Oil Tank

Changing Hydraulic Oil: Old Style

11. Reinstall filter cover and bolts (4). See Figure 2-20.

1. Position the machine on a level surface.

2. Fully extend the bucket and boom, and retract arm as shown in Figure 2-16. Lower bucket and dozer blade to the ground. Turn off the machine.

12. Reinstall the hydraulic oil tank cover (2). See Figure 2-17.

13. Fill tank with hydraulic oil until oil level is between red and black marks on sight gauge.

14. Re-install hydraulic oil filler cap and tighten securely.

15. Start engine and let it idle for a few minutes.

16. Rotate cab to normal position as shown. See Figure 2-21.

Figure 2-22 Hydraulic Reservoir Printed in U.S.A

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ME12002

3. Slowly open the filler cap to relieve pressure.

Remove cap and clean strainer of any debris.

•

First engine oil/filter change must be performed after 50 hours.

4. Remove the hydraulic reservoir cover as shown. See Figure 2-22.

•

No modifications to the diesel engine or its cooling system.

5. Open the drain plug and drain oil into a suitable container. Re-install drain plug and tighten securely. See Figure 2-22.

•

Mustang OEM filter must be used.

•

Must use API CI-4, API CH-4, ACEA E3E4 rated engine oil.

IMPORTANT: Always dispose of hydraulic fluids according to local regulations or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

•

Applies to units with both Yanmar 4TNE106T-NS engine (SN AB00473AB03158), and John Deere 4045TF270 engines (SN AC02633 and up).

6. Remove bolts and filter cover. Remove and discard old filter. Put clean hydraulic fluid on the filter gasket and install gasket and new filter into reservoir. See Figure 2-22.

Engine Oil/Filter Schedule

7. Reinstall filter cover and bolts.

Standard Schedule

8. Fill reservoir with hydraulic oil until oil level is between red and black marks on sight gauge.

First change after 50 hrs. First change after 50 hrs.

9. Re-install hydraulic oil filler cap and tighten securely.

500 hrs. Schedule

Then every 125 - 250 hrs. Then every 500 hrs.

10. Start engine and let idle for a few minutes.

11. Cycle all front attachment hydraulic functions.

Re-check hydraulic oil level.

Diesel Engine Engine Oil/Filter Change Maintenance Schedules NOTICE:All of the following prerequisites must be fullfilled in order to perform the 500 hrs. maintenance schedule. Perform the standard maintenance schedule (see below) if the following prerequisites are not fullfilled.

500 hrs. Maintenance Schedule Requirements •

If operating in extreme working conditions (high dust concentration, high temperature, using the hydraulic hammer [pile driver]), the standard schedule engine oil/filter maintenance must be performed.

•

The engine oil/filter has to be changed a minimum of once per year.

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ME12002

MAINTENANCE

Fuel System Fuel Circuit John Deere Engine Model 4045TF270 (SN AC02633 and up)

E

B

A

C F

G

D H

I

J

K

L

A

Final Fuel Filter B Primary Fuel Filter/Water Separator C Injection Nozzles D Aneroid Inlet Line

E F G

Fuel Return (Leak-Off ) Line Fuel Supply Pump Fuel Shut-Off Solenoid

Figure 2-23 Fuel Circuit In-Line Fuel Injection Pump Operation

Supply pump (F) draws fuel from the vented fuel tank through primary filter (B). The supply pump pressurizes the fuel so that it flows through the filter and into the injection pump galley. Supply pump output pressure varies depending on load and application.

Printed in U.S.A

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ME12002

Fuel Circuit Yanmar Engine Model 4TNE106T-NS (SN AB00473-AB03158)

Figure 2-24 Fuel Circuit Fuel Filter/Water Separator: John Deere Engine Model 4045TF270 (SN AC02633 and up)

1. Unscrew the plastic ring (2) to change the fuel filter and clean dirt from the housing. See Figure 2-26.

The fuel filter/water separator is located at the rear of the engine as shown (1). See Figure 2-25.

2. Clean around the filter housing. Put fuel on the seal of the new fuel filter.

3. Install the new fuel filter and hand tighten.

4. Remove the plastic bowl (3). See Figure 2-26.

1 2

3

Figure 2-25 Fuel Filter/Water Separator Location

4

Figure 2-26 Fuel Filter/Water Separator 909768/BP1207

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MAINTENANCE

5. The fuel system must be purged of air after changing the fuel filter, or if the fuel tank has been run dry.

6. If water is seen in the plastic bowl, the bowl will need to be drained. If necessary, open the valve (4) to drain the plastic bowl. See Figure 2-26.

7. Clean the new fuel filter element.

8. Clean the fuel filter mount sealing surface.

9. Put oil on the base of the plastic bowl.

10. Install the plastic bowl.

11. Discard fuel/water according to local regulations. DO NOT pour fluids onto the ground or down a drain.

Figure 2-27 Fuel Filter

12. Close the valve opened in step 6.

The fuel system must be purged of air after changing the fuel filter, or if the fuel tank has been run dry.

Fuel Filter/Water Separator: Yanmar Engine Model 4TNE106T-NS (SN AB00473-AB03158)

Water Separator

Fuel Filter

If water is seen in the plastic water separator bowl, the bowl will need to be drained.

1. Unscrew the clear plastic housing. See Figure 2-27.

1. Shut-off fuel using water separator fuel valve.

2. Change the filter element and clean dirt from the housing. See Figure 2-27.

2. Unscrew and remove plastic water separator bowl.

3. Clean around the filter housing. See Figure 227.

3. Discard fuel/water according to local regulations. DO NOT pour fluids onto the ground or down a drain.

4. Put oil on the seal of the new filter element.

See Figure 2-27.

4. Reinstall filter bowl.

5. Install the fuel filter and hand tighten. See Figure 2-27.

Printed in U.S.A

5. Open fuel valve.

6. Purge air from the fuel system.

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Purging Air from the Fuel System: John Deere Engine Model 4045TF270 (SN AC02633 and up)

6. Actuate the fuel pump backing pump lever (3) until there are no more air bubbles in the fuel.

See Figure 2-28.

NOTICE: There should be resistance while

WARNING

performing step 6. If there is no resistance, activate the starter for a few seconds. Do NOT run the engine.

DO NOT bleed air on a hot engine. Spilled fuel can cause a fire.

7. Retighten the vent plug (1) and keep operating the fuel pump backing pump lever (3) until the pumping effect is no longer felt. See Figure 228.

If the fuel tank is run dry, or if the fuel filter, water separator or fuel lines are replaced, trapped air must be removed, or bled, from the fuel system.

8. Press the fuel pump backing pump lever (3) toward the engine as far as possible. See Figure 2-28.

Bleed air from the fuel system according to the following steps:

Purging Air from the Fuel System: Yanmar Engine Model 4TNE106T-NS (SN AB00473-AB03158)

1. Check the fuel filter/water separator for water or dirt, empty it if necessary.

2. Drain and discard water according to local regulations.

If the fuel tank has been run dry, or the fuel filter or fuel lines have been replaced, trapped air will have to be removed, or bled, from the fuel system.

1. Turn the fuel filter valve (Figure 2-29) to the open position (vertical).

1

2. While operating the priming lever on the fuel injector pump, loosen the air bleeding screw (A, Figure 2-29) on the fuel filter. When fuel starts flowing from the bleeder valve (A) without any air or bubbles, tighten the bleeder screw (A).

3

3. Repeat step 2 for bleeder screws B, C, D and E (Figure 2-29).

2

Figure 2-28 Fuel Filter Vent, Drain Plug, Backing Pump Lever 3. Loosen the drain plug (2) at the bottom of the fuel filter/water separator by turning it two or three times. See Figure 2-28.

4. Loosen the vent plug (1) on the fuel filter base by turning it twice. See Figure 2-28.

5. Drain the water from the bottom until fuel starts to run out. As soon as fuel starts to run out, close the drain plug (2) tightly. See Figure 2-28.

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MAINTENANCE A

Figure 2-31 Dust Collector/Dust Cap

IMPORTANT:Always replace the air filter (B), Figure 2-29 Bleeding Air from Fuel System

if the air filter indicator lights up (red), or if the air filter is torn or contaminated at the sides.

See Figure 2-32.

Air Cleaner

3. Move the end of air filter (B) gently to the left and right, and up and down. See Figure 2-32.

Air Cleaner (SN AC02633 and up) IMPORTANT: Do not operate engine without

B

the air cleaner components installed or damage to the engine could occur.

1. Lift the hydraulic tank cover to access the air cleaner. See Figure 2-30.

Figure 2-32 Air Filter 4. Pull air filter (B) out of the outlet pipe and out of the enclosure. See Figure 2-32.

NOTICE:Remove air filter (B) only if replacing it. Do not try to clean, wash, or use it again.

5. Thoroughly clean the inside of the filter housing and the outlet bore.

6. (Optional) To replace safety filter (C), gently pull out the filter element. See Figure 2-33.

Figure 2-30 Air Cleaner Location Access

IMPORTANT:Remove safety filter (C) only if

2. Unlatch and remove dust collector/cap (A) from the air cleaner. See Figure 2-31.

Printed in U.S.A

replacing it. Do not try to clean, wash, or use it again. Usually, the safety filter needs replacement only if there is a hole in air filter (B).

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ME12002 5. Reinstall air cleaner element, wingnut, gasket, and air cleaner cover. Tighten cover bolt.

6. Close and secure engine cover.

C

Figure 2-33 Safety Filter 7. (Optional) Install a new safety filter (C) immediately to prevent the penetration of dust into the air intake system. See Figure 2-33.

IMPORTANT:Do not knock the air or safety filters against a solid object to remove dust.

The filters may become distorted and/or damaged.

Figure 2-34 Air Filter Service

IMPORTANT:Do not knock the element

8. Install a new air filter (B). Exert a little pressure with your hand at the outer edge of the filter. See Figure 2-32.

against a solid object to remove dust. The element may become distorted and damaged.

9. Apply and latch the dust collector/cap (A) to the air cleaner. See Figure 2-31.

Do not operate engine without the air cleaner element installed or damage to the engine could occur.

IMPORTANT:Do not use the latches on the

Coolant System

cap to force the filter into the air cleaner housing. Applying force may damage the filter and/ or housing.

Checking Coolant Level (SN AC02633 and up)

NOTICE:Close the housing so that the dust collector valve points downward and the locking mechanism catches.

WARNING

10. Close and secure the engine cover.

•

Engine must be cold.

Air Cleaner (SN AB03158 and before)

•

1. The air cleaner is located under the engine cover. Pull the engine cover latch handle (located on the left side of the operator’s seat) and raise the engine cover.

Be careful to avoid burns when removing the cap.

•

Keep face away from cap.

•

Cover cap with a cloth, turn cap slowly to release pressure.

2. Turn the air cleaner cover bolt (Figure 2-34) to remove the air cleaner cover and gasket.

1. Lift the hydraulic tank cover to access the expansion reservoir. See Figure 2-35.

3. Remove the wingnut (Figure 2-34) and remove air cleaner element.

4. Clean air cleaner element with 30 psi (200 kPa) compressed air. See Figure 2-34.

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ME12002

MAINTENANCE Checking Coolant Level (SN AB00473AB03158)

WARNING

Figure 2-35 Expansion Reservoir Location Access

•

Engine must be cold.

•

Be careful to avoid burns when removing the cap.

•

Keep face away from cap.

•

Cover cap with a cloth, turn cap slowly to release pressure.

1. Pull the engine cover latch handle (located on the left side of the operator’s seat) and raise the engine cover.

2. Check the coolant level in the expansion reservoir. See Figure 2-36.

2. Check the coolant level in the expansion reservoir (Figure 2-37).

3. If low, slowly loosen cap and allow pressure to escape.

3. If low, slowly loosen cap and allow pressure to escape.

4. Completely remove cap and fill reservoir to MAX line.

5. Check the radiator coolant level.

4. Completely remove cap and fill reservoir to FULL line.

Refer to the engine manual for correct coolant mixture for the engine.

Refer to the engine manual for correct coolant mixture for the engine.

Figure 2-36 Coolant Level Check

Figure 2-37 Coolant Level Check

Printed in U.S.A

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ME12002 NOTES

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CHAPTER 3 HYDRAULIC SYSTEM NOTICE:For hydraulic system maintenance,

24. Hydraulic oil return filter

see “Hydraulic System” on page 30.

25. Leakage oil filter 26. Check valve

Hydraulic System Diagram NOTICE:See Figure 3-1 on page 52 for hydraulic system diagram.

Hydraulic System Diagram Legend 1. Diesel engine 2. Variable + gear pump 3. Pilot oil supply unit 4. Joystick left (dipper arm/swivel motor) 5. Joystick right (bucket/boom) 6. Pilot control valve function drive 7. Pilot control valve function boom offset/auxiliary hydraulics 8. Pilot control valve function dozer blade 9. Switch valve function boom offset/auxiliary hydraulics 10. Main valve block 11. Second valve block 12. Drive unit 13. Swivel unit 14. Boom cylinder 15. Dipper arm cylinder 16. Bucket cylinder 17. Dozer blade cylinder 18. Boom offset cylinder 19. Load lowering valve 20. Load retaining counterbalance valve - load lowering valve boom (option) 21. Load retaining counterbalance valve - load lowering valve dipper arm (option) 22. Shuttle valve block 23. Oil cooler Printed in U.S.A

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ME12002

Hydraulic System Diagram

Figure 3-1 Hydraulic System Diagram

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ME12002

HYDRAULIC SYSTEM

Hydraulic System Component Positions

Air Filter

Hydraulic Pump

Diesel Engine

Air Conditioning Compressor

Water Cooler Sub Tank Water Cooler

Hydraulic Oil Cooler

Figure 3-2 Component Positions

Printed in U.S.A

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ME12002

Fuel Tank, Fuel Level Indicator

Hydraulic Oil Tank Oil Level Indicator

Load Lowering Valve (behind chassis)

Main Valve Block

Figure 3-3 Main Valve Block 909768/BP1207

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Printed in U.S.A

ME12002

HYDRAULIC SYSTEM

Figure 3-4 Battery and Fuel Locations

Printed in U.S.A

55

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HYDRAULIC SYSTEM

ME12002

Selection Valve

Side Valve Block

Pilot Oil Supply Unit

Shuttle Valve Block

Figure 3-5 Valve Locations 909768/BP1207

56

Printed in U.S.A

ME12002

HYDRAULIC SYSTEM

Hydraulic Pump Specifications

Pump Ports

NOTICE:See Figure 3-6 on page 58 for

•

B1

hydraulic pump specifications diagram.

•

B2

•

B3

•

Pm1

•

Pm2

•

Pi1

•

Pi2

Hydraulic Pump Specifications Diagram Legend Variable Pump-1 Main Valve Block Sections

6. Drive right 7. Swivel motor 8. Dipper arm 1 9. Boom 2 10. Drive counter-balancing system Variable Pump-2 Main Valve Block Sections

1. Drive left 2. Auxiliary hydraulics 3. Boom 1 4. Bucket 5. Dipper arm 2 10. Drive counter-balancing system Side Valve Block Sections

11. Boom offset 12. Dozer blade Gear Pump 13. Pilot oil supply unit

Printed in U.S.A

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ME12002

Type: Swash plate-axial piston pump with coupled gear pump for the oil supply unit

Pi2

Position

Pm2

B3

Pm1 B2

Gear pump

Pi1

B1

Variable pump 2

Variable pump 1

Figure 3-6 Hydraulic Pump Specifications Diagram 909768/BP1207

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ME12002

HYDRAULIC SYSTEM

Hydraulic Pump Function Designation Gear pump

Variable pump 2

Variable pump 1

Pressure limiting valve

P2

P3

P1

Regulation start screw

Negative control pilot pressure Minimum displacement (Q min)

Two stage flow control

Two stage flow control

Maximum displacement ( Q max )

Figure 3-7 Hydraulic Pump Function Designation Printed in U.S.A

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ME12002

Hydraulic Pump Port Codes Proportional pressure reduction valve MA4

a4

Pi1/Pg

Pm1

Diesel engine side

Pressure side view

P1/Psv

A3 Dr/Dp Suction side view

Pm2

A1/PL Pi2/Pn

a3

Diesel engine side

Tank

A2/PR

B3

Dr/Dp

B1

Vehicle identification plate

Diesel engine side

Bottom view

a2

a1

Figure 3-8 Hydraulic Pump Port Codes 909768/BP1207

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HYDRAULIC SYSTEM

Hydraulic Pump Section Description

3

1

2

4

5

6

7

8

9

10

11 (MR)

Figure 3-9 Pump Section Description 1. Section boom 2 (summation) 2. Section dipper arm 3. Section swivel motor 4. Section drive right 5. Section drive counterbalancing 6. Section drive left 7. Section auxiliary hydraulics 8. Section boom 9. Section bucket 10. Section dipper arm 2 (summation) 11. Main pressure limiting valve (MR)

Main valve block

Figure 3-10 Main Valve Block Location Printed in U.S.A

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ME12002

Hydraulic Pump Valve Designation 2 4 3 6 7

10

1 5 8 9 15 19

13

20 11 16 12

14 18

17

Figure 3-11 Hydraulic Pump Valve Designation 1 2 3 4 5 6 7 8 9 10

Load check valve section boom 2 (A2) Pilot operated lock valve section dipper arm 1 Check valve for lock valve section dipper arm (AHC) Check valve pump 1 (D5) Check valve for lock valve section boom 1 (BHC) Load check valve section dipper arm 2 (B2) Check valve section dipper arm 1 (A4) Check valve pump 2 (D6) Pilot operated lock valve section boom 1 Load check valve section dipper arm (B1)

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11

Check valve for swing priority (not activated) (A5)

12

Load check valve section swing (A3)

13

Check valve section driving right (D2)

14

Check valve section driving left (D4) Pump port for auxiliary hydraulics (not activated) PB3 Load check valve section dipper arm 1 (A1) Check valve section driving right (D1) Check valve section driving left (D2) Load check valve section boom 1 (B4) Load check valve section bucket (B5)

15 16 17 18 19 20

Printed in U.S.A

ME12002

HYDRAULIC SYSTEM

1

3

2

7

8

4

5

6

10

9

Figure 3-12 Port Relief Valves 1

10

Port relief valve dipper arm rod side (RAR3) Port relief valve dipper arm bottom side (RBR3) Main relief valve (P1+P2) Port relief valve auxiliary hydraulics (option) (RBL2) Port relief valve boom bottom side (RBL3) Port relief valve bucket bottom side (RBL4) Port relief valve bucket rod side (RAL4) Port relief valve boom rod side (RAL3) Port relief valve auxiliary hydraulics (option) (RAL2) Straight travel valve

A B P3 R1 R2 P4

Negative control valve pump 1 Negative control valve pump 2 Plug Tank pipe (suction valve swivel motor) Plug Supply for side valve block

2 3 4 5 6 7 8 9

Printed in U.S.A

P3

A

R2

R1

B

P4

Figure 3-13 Return, Outlet Ports 63

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ME12002

Testing Hydraulic Pressure

Checking the Side Valve Block (PPLV-2) Pressure Setting

Overview: •

One two-step primary-pressure limiting valve for pump P1+P2 (main valve block).

•

The side valve block is supplied by pump P1 through the main valve block.

•

One primary-pressure limiting valve at the side valve block (attach: pressure adjustment).

•

Measuring points at the hydraulic pump (P1, P2) and at side valve block (P3) of the pilot oil supply unit.

MP2

MP1

Figure 3-15 Hydraulic Pump Position Measuring Points (MP1, MP2) (photo taken from underneath) MP3 P3

P2

P1

Figure 3-14 Measuring Points Testing Side Valve Block (P1) Pressure Functions: Dozer blade cylinder and boom offset cylinder.

Figure 3-16 Side Valve Block Position Measuring Point (MP3) 1. Apply pressure gauge at measuring point MP1 and MP3. See Figure 3-15 and Figure 3-16.

2. Full throttle, raise the boom all the way up.

3. Increase the primary pressure limiting valve 1 setting PPLV-1 (MR) up to 5076 psi (350 bar) (main valve block - with adjustment screw e1 at the main relief valve).

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ME12002

HYDRAULIC SYSTEM Pressure Drop Example:

PPLV-2

System pressure at full throttle

= 4351 psi (300 bar)

System pressure at minimum throttle

= 4061 psi (280 bar) => OK (low limit approximately 3844 psi [265 bar])

Pressure Testing Hydraulic Pump P1 (A1) and P2 (A2) Functions: Boom, dipper arm, bucket, drive, auxiliary hydraulics, and swivel.

Checking the Drive Pressure

1. Activating the drive function increases the main pressure limiting valve setting internally to 4641 psi (320 bar) (MR=4351 psi [300 bar]) by using the pilot pressure (port PP).

Checking the Auxiliary Hydraulics Pressure

1. If the secondary pressure limiting valve (shock valve) settings are adjusted lower than the main pressure limiting valve (MR), measuring point MP1 measures auxiliary hydraulics secondary pressure limiting valve (shock valve) settings.

Figure 3-17 Primary-pressure Limiting Valve-2 (Side Valve Block) Position 4. Check the pressure at measuring point (MP3), and if necessary, adjust the primary pressure limiting valve at the side valve block PPLV-2.

See Figure 3-16 and Figure 3-17.

2. With ball valve opened, measuring point MP1 measures auxiliary hydraulics stored system pressure by tracking unpressurized return flow.

5. Adjust the primary-pressure limiting valve PPLV-1 (MR) back to its original setting (main valve block). See “Hydraulic System Specifications” on page 7.

Checking the Swivel Pressure

1. Measuring point MP2 measures swivel motor secondary pressure limiting valve (shock valve) settings because of their lower setting level. See “Hydraulic System Specifications” on page 7.

Checking the Pressure Drop

1. Raise the boom all the way up, at full throttle.

2. Reduce the throttle quickly from maximum to minimum, while holding the boom all the way up.

Checking the Primary-pressure Limiting Valve 1 (MR) Setting

1. Apply gauge at measuring points MP1 and MP2.

3. Check the pressure drop. The pressure drop should not exceed more than 10% of the setting (approximate value only applicable to primary pressure limiting values). An excessive pressure drop might indicate leakage. Refer to the following table: Printed in U.S.A

2. Extend the dipper arm (cylinder bottom side) all the way, at full throttle.

3. Check and write down the pressure.

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ME12002

Checking the Pressure Drop

NOTICE:The pressure drop check procedure only measures main pressure limiting valve functions.

1. The pressure drop for each function should not exceed more than 10% of the setting (approximate value: only applicable to primary pressure limiting values). An excessive pressure drop might indicate leakage.

2. Check the pressure setting and the pressure drop function: dipper arm (rod side), bucket cylinder (rod: bottom side) and boom cylinder (rod: bottom side). For drive left/right (forward/rearward) and auxiliary hydraulics, see “Checking the Primary-pressure Limiting Valve 1 (MR) Setting” on page 65.

3. If any settings deviate from factory settings, set the correct pressure at the primary pressure limiting valve (MR) at the main valve block and check the reason for the pressure drop.

4. Complete the steps in “Checking the Primarypressure Limiting Valve 1 (MR) Setting” on page 65 and steps 1 through 3 of this section.

Checking the Pilot Pressure Pump P3 (A3)

Functions: Hydraulic pilot control system.

Checking the Gear Pump Setting P3 (A3)

1. Apply the pressure gauge at measuring point MP4.

2. Actuate joysticks.

3. Check the pressure level and/or set it at the pressure limiting valve on the gear pump.

NOTICE:Refer to the Pressure Checklist located on the following pages.

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ME12002

HYDRAULIC SYSTEM

Hydraulic Pump Components The components of the axial piston pump can be divided into three sub-groups: Provides the main rotary pumping action Varies the pump`s delivery Swash plate group flow rate Provides the switching of oil Valve cover group between suction and delivery ports.

Rotation group

Hydraulic Schematic

Figure 3-18 Hydraulic Schematic Hydraulic Schematic Legend A1 A2 A3 B1 B3 P1 Dr Pi1 Pi2

Pump output terminal 1 Pump output terminal 2 Gear pump delivery port Suction port for both pumps Suction port for gear pump Proportional valve for variable power shift Drain port Port negative control valve 1 Port negative control valve 2

Printed in U.S.A

Pm1 Pm2 a1 a2 a3 a4

67

Port for two stage flow control system Port for two stage flow control system Measuring point MP1 Measuring point MP2 Gauge port Gauge port

909768/BP1207

HYDRAULIC SYSTEM

ME12002

Hydraulic Pump Rotation Group

Figure 3-19 Rotation Group

NOTICE:The hydraulic pump is symmetrical,

(152) to lightly slide against shoe plate (211). See Figure 3-19.

for illustration purposes each part number is shown in Figure 3-19 only once. However, each part shown is also located on the other side of the hydraulic pump at the parallel location.

Cylinder springs (157) press pistons (151) and shoes (152) against shoe plate (211), and through setting plate (153) and spherical bushing (156).

Cylinder springs (157) then press cylinder block (141) against valve plate (313). See Figure 3-19.

Rotation group consists of the following parts. See Figure 3-19 for identification.

Drive shaft Cylinder block Pistons (9 qty.)

Shoes (9 qty.)

Setting plate Spherical bushing Cylinder springs Bearings

Swash Plate Group

(111) (141) (151) (152) (153) (156) (157) (123 & 124)

Swash plate group consists of the following parts.

See Figure 3-19 for identification.

Shoe plate Swash plate Swash plate bearings Tilt bushing Tilting pin Servo piston

Bearings (123 & 124) support drive shaft (111) at both ends. A splined (grooved) section connects drive shaft (111) to cylinder block (141). See Figure 3-19.

Swash plate (212) is a cylindrical plate located next to shoe plate (211). Swash plate bearings (251) support swash plate (212). See Figure 3-19.

Shoes (152) are shaped over the spherical end of pistons (151), forming a spherical ball joint. The shoe’s hydrostatic pocket counterbalances the pistons’ pressure hydraulic thrust, allowing the shoes

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(211) (212) (251) (214) (531) (532)

Tilt bushing (214) is inserted into swash plate (212). The spherical portion of tilting pin (531), pre-assembled to servo piston (532), is inserted

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HYDRAULIC SYSTEM Coupling (114) within central valve block (312) connects the two pumps and their individual regulators together. Coupling (114) also connects drive shaft (111) on the front pump to the prime mover.

The front and rear pumps share a common oil suction port, but contain independent delivery ports.

into the tilt bushing (214) and swash plate (212) assembly. See Figure 3-19.

Pump regulator pressure applied to either end of servo piston (532) causes linear movement of servo piston (532). See “Hydraulic Pump Regulator Functions” on page 69. This linear movement presses tilting pin (531) into swash plate (212), forcing swash plate (212) to move angularly. This angular movement varies the pump tilting/swash angle. See Figure 3-19.

Hydraulic Pump Regulator Functions Hydraulic pump regulator functions include: •

Summation power control

Use screw adjusters and lock nuts to adjust the maximum (954) and minimum (953) tilting angle settings. See Figure 3-19.

•

Variable power shift (potentiometer controlled)

•

Negative control regulation (NCR)

Valve Cover Group

•

Two stage maximum flow control (two stage switch)

Valve cover group consists of the following parts.

See Figure 3-19 for identification.

Valve cover Valve plate Valve plate pin

Hydraulic Pump Regulator Components

(312) (313) (885)

Valve plate (313) and its two “melon” shaped ports are installed onto valve plate (313). Valve plate (313) is located next to valve plate pin (885). See Figure 3-19.

These ports transport oil to and from cylinder block (141). Valve plate (313) controls the oil passage port used and valve cover (312) connects the ports to the externally piped suction and outlet pressure ports. See Figure 3-19.

When drive shaft (111) rotates, cylinder block (141) also rotates because it is spline-coupled to drive shaft (111). Because shoe (152) is attached to swash plate (212), if swash plate (212) is tilted, pistons (151) arranged in cylinder block (141) rotate when cylinder block (141) rotates. Cylinder block (141) moves forward and rearward once per revolution.

Piston (151) rotates away from valve plate (313) for the first half of the rotation (suction stroke) and rotates toward valve plate (313) for the second half of the rotation (oil delivery stroke).

The larger the swash plate (212) tilt angle, the longer the piston (151) stroke, and the higher the displacement. If the swash plate (212) tilt angle is zero, piston (151) makes no stroke and delivers no oil.

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Figure 3-20 Pump Regulator Components 69

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ME12002 Hydraulic Pump General Description

531 532 611 613 621 625 626 643 646 652

Pivot point Servo pistons Lever linkage system Regulator body Pilot pistons Outer power springs Inner power springs Pilot pistons Control springs Main spools

Pump regulator operation uses a lever linkage system (611) that connects servo pistons (532), main spools (652) and regulator body (613). See Figure 3-20.

Figure 3-21 Pump General Description

Pilot pistons (621 and 643) and control springs (625, 626 and 646) activate the lever linkage system (611). The lever linkage system (611) ensures a highly responsive and accurate control system.

See Figure 3-20.

531 532 874 875 897

Pivot point (531) connects servo piston (532) to pump swash plate (212). See Figure 3-20 for servo piston (532) and pivot point (531), and Figure 3-19 for swash plate (212).

Regulator assembly lever and linkage arrangements are shown in Figure 3-21.

The main feedback lever is shown in the center of the pump where servo pivot (531) connects it to servo piston (532). See Figure 3-21.

Moving servo piston (532) to the left increases pump displacement and moving servo piston (532) to the right decreases pump displacement. See Figure 3-20.

Fixed pivot (874) connects main feedback lever to main spool (652). Feedback pivot (897) connects main feedback lever to displacement lever (right side) and power lever (left side). Fixed pivot pin (875) secures displacement lever (right side) to the regulator body, and fixed pivot (874) secures power lever (left side) to the regulator body. See Figure 3-21.

Servo piston (532) has an area ratio of 4:1. The smaller diameter area on the right side of the servo piston is continuously connected to the pump's outlet pressure. The larger diameter area on the left side of the servo piston (532) is fed from the main regulator spool (652). As the main regulator spool (652) pressurizes the left side of the servo piston, it continuously reduces the pump displacement. See Figure 3-20.

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Pivot point Servo piston Fixed pivot Fixed pivot pin Feedback pivot

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Hydraulic Pump Regulator Performance Diagrams

Figure 3-22 Negative Displacement Control Working area: 174-464 psi (12-32 bar).

Figure 3-23 Total Horsepower Control Regulation start: 1160 psi (80 bar)/pump:

2. Poteniometer changed oil flow.

1. Oil flow change by diesel engine rev. drop.

3. Spring 2 - regulation starts.

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Power or Torque Summation and Negative Displacement Control

Figure 3-24 Power or Torque Summation and Negative Displacement Control The regulator consists of two separate halves: •

Power or Torque Summation Control (left side)

•

Negative Displacement Control (right side) 531 532 611 612 613 621 622 623 625 626 643 646 651 652

Pivot point Servo piston Lever linkage system Power control lever Regulator body NC system Regulator piston - power regulator Housing - power regulator Piston rod - power regulator Outer power springs Inner power springs Piston rod -NC regulation Spring - NC regulation Spool housing Main Spool

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Function Torque Summation Control Variable pump 1 Variable pump 2

Figure 3-26 Variable Pump 2 and 1 Because these two stepped areas are equal, both pumps counter-stroke to the same displacement rate. The inner (626) and outer (625) power springs create a spring preload that balances the force produced. See Figure 3-25.

When return output pressure is low, only outer spring (625) is active. When increased output pressure from both pumps is forced into power control piston (621), outer spring (625) and inner spring (626) are both active. The change in spring rate provides the characteristic curve. See Figure 3-25.

Because of pump(s) pressure forces, power push rod (623) presses against outer power springs (625), and this action moves piston (621). Piston (621) movement presses power control lever (612), located on fixed pivot (875), to the right toward outer power springs (625). Power control lever (612) uses feedback pivot (897) to transmit movement to feedback lever (611). Feedback lever (611) rotates “clockwise” (to the right) around servo pivot (531). See Figure 3-25.

Figure 3-25 Function Torque Summation Control 531 532 611 612 621 623 625 626 652 874 875 897

Servo pivot Servo piston Feedback lever Power control lever Power control piston Power push rod Outer power springs Inner power springs Main spool Fixed pivot Fixed pivot Feedback pivot

Fixed pivot (874) connects feedback lever (611) to main spool (652). Because of this connection, main spool (652) transports pressurized oil to the larger diameter area of servo piston (532). This counterstrokes the pump and rotates main feedback lever (611) “counter-clockwise” (to the left). See Figure 3-25.

Power push rod (623) forces output pressure from variable pump 1 into the larger stepped diameter area of power control piston (621). Power push rod (623) forces return output pressure from variable pump 2 into the smaller stepped diameter area of power control piston (621). See Figure 3-25 and Figure 3-26.

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When servo piston (532) position and pump displacement maintains main spool (652) in a central metering position, a state of equilibrium exists. In this central metering position, pressure forced into the larger diameter area of servo piston (532) maintains equilibrium. See Figure 3-25.

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P1 and P2 Constant, Connected, Loaded

Figure 3-27 P1 and P2 Constant, Connected, and Loaded down the lever and piston positions. See Figure 327.

Balanced condition prerequisites: P1 and P2 are constant, with no regulation function, and are connected and loaded at the same delivery pressure.

P1 is connected to the front pump delivery port and P2 is connected to the rear pump delivery port. See Figure 3-27.

During the balanced condition: •

Power piston force is balanced against the power spring pack force.

•

Main spool (652) metering position is in a null position. See Figure 3-27.

•

Main spool (652) transports enough fluid to the larger stepped diameter area of power control piston (621) to maintain a power piston force balance across the servo piston (532). See Figure 3-27.

•

The larger diameter area on the left side of the servo piston (532) pressure is approximately one-fourth (¼) of the pumps total delivery pressure. See Figure 3-27.

Feedback lever (611) maintains the swash plate (212) position, and moves main spool (652). Write 909768/BP1207

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P1 or P2 Pressure Increase

Figure 3-28 Main Spool and Sleeve Metering While P1 and P2 delivery pressure increases, power control piston (621) compresses power spring pack (inner [626] and outer [625] spring).

Power push rod (623) linear movement causes the power control lever (612) to pivot around fixed pivot 1 toward the left. See Figure 3-28.

Power control lever (612) uses feedback pivot (897) to transmit movement to feedback lever (611). See Figure 3-28.

Feedback lever (611) rotates “clockwise” (to the right) around servo pivot (531), causing main spool (652) to rotate to the right through the spool pivot point. See Figure 3-28.

Main spool (652) metering forces delivery pressure into the larger diameter area on the left side of the servo piston (532) (i.e. Pd to PCL). See Figure 328.

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ME12002

Pump Oil Flow Drops

Figure 3-29 Pump Oil Flow Drops When pump oil flow drops, servo piston (532) moves to the right toward minimum displacement.

As servo piston (532) moves to the right, feedback lever (611) rotates around feedback pivot (897), causing main spool (652) to return to the null position (left of its previous position). See Figure 3-29.

Main spool (652) transports enough fluid to maintain the pressure balance across servo piston (532) and pump swash plate. See Figure 3-29.

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P1 or P2 Decreases, the Oil Flow Increases

Figure 3-30 P1 or P2 Decreases, the Oil Flow Increases While P1 and/or P2 pressure decreases, delivery pressure decreases. This decrease causes power spring pack (inner [626] and outer [625] spring) to shift power push rod (623) to the left while reducing the power piston force. See Figure 3-30.

Feedback pivot (897) and main spool (652) compression spring transmit power lever (left side) movement. Main spool (652) compression spring also eliminates feedback by pulling main spool (652) to the left. Main spool (652) movement to the left meters the larger diameter area on the left side of the servo piston (532) pressure to the tank pressure. Because the small side of the servo piston (532) is connected to the pump delivery pressure, when servo piston (532) moves to the left, pump displacement increases toward maximum. See Figure 3-30.

After servo piston (532) moves to the left and reaches its final position, feedback lever (611) shifts main spool (652) to the null position, restoring equilibrium. See Figure 3-30.

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Variable Horsepower Control

Figure 3-31 Variable Horsepower Control Pump P2 performance can change because of a potentiometer in the cabin.

Power control piston (621) contains an additional piston (898), supplied by a proportional pressure reducing valve. Its pressure (Pf) is applied to the D3 piston diameter with the effect of changing the effective spring preload of the inner (626) and outer (625) power springs. See Figure 3-31.

Apply this pressure (Pf) to shift the torque summation setting. Increasing the applied pressure (Pf) decreases the effective spring preload available and its torque setting.

Power shift control is used so that a machine can operate at lower engine speeds without stalling the engine.

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Negative Control Regulation (611) then rotates slightly “counter-clockwise” (to the left) around servo pivot (531). See Figure 3-32.

After servo piston (532) and pump displacement stabilize, main spool (652) returns to the central metering position. After main spool (652) returns to the central metering position, pressure shifts to the larger diameter area on the left side of the servo piston (532), restoring equilibrium. See Figure 332.

Figure 3-32 Negative Displacement Control and Feedback Mechanisms Negative control pressure presses against the rightend of the displacement piston and push rod (643).

Displacement pilot spring (646) balances the force produced. See Figure 3-32.

Any force imbalance moves displacement control lever against fixed pivot (875). If displacement piston and push rod (643) move to the right, displacement control lever uses feedback pivot (897) to transmit pressure to feedback lever (611). Feedback lever (611) then rotates slightly “clockwise” (to the right) around servo pivot (531). See Figure 3-32.

Fixed pivot (874) connects feedback lever (611) to main spool (652), causing main spool (652) to meter pressurized fluid into the larger diameter area on the left side of the servo piston (532). Fluid entering the larger diameter area of the servo piston (532) counter-strokes the pump. Feedback lever Printed in U.S.A

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P1 Negative Control Pressure Signal

Figure 3-33 Pressure P1 is Connected to Negative Control Pressure Signal When displacement piston force is balanced against displacement spring force, main spool (652) metering is in a null position. Main spool (652) metering also transports enough fluid to the larger diameter area on the left side of the servo piston (532) to maintain a balanced force across the servo piston (532). See Figure 3-33.

During the balanced condition, the larger diameter area on the left side of the servo piston (532) pressure is approximately one fourth (¼) of the pumps total delivery pressure. See Figure 3-33.

Feedback lever (611) maintains the swash plate (212) position, and this moves the main spool (652) which corrects any error. Write down the lever and piston positions. See Figure 3-33.

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NC Valve Pressure Increases, Pump Oil Flow Rate Decreases

Figure 3-34 NC Valve Pressure Increases, Pump Oil Flow Rate Decreases When the negative pressure control signal (Pi) increases, the displacement piston compresses the displacement spring. The linear movement of the displacement piston pivots the displacement lever around fixed pivot 1, toward the left. See Figure 334.

The displacement lever uses feedback pivot (897) to transmit movement to feedback lever (611). See Figure 3-34.

Feedback lever (611) rotates “clockwise” (to the right) around servo pivot (531), causing main spool (652) to rotate to the right through the spool pivot point. See Figure 3-34.

Main spool (652) metering transports delivery pressure to the larger diameter area on the left side of the servo piston (532) (i.e. Pd to PCL). See Figure 3-34.

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Power Regulator in Neutral Position, Lower Flow Rate

Figure 3-35 Power Regulator in Neutral Position, Lower Flow Rate When the power regulator is in neutral position, pump oil flow drops and servo piston (532) moves to the right, toward minimum displacement. As servo piston (532) moves to the right, feedback lever (611) rotates around feedback pivot (897), causing main spool (652) to return to the null position (left of its previous position). See Figure 3-35.

Main spool (652) transports enough fluid to maintain the pressure balance across servo piston (532), and swash plate (212) moves to a new position. See Figure 3-35.

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Negative Control Valve Pressure Decreases, Pump Oil Flow Rate Increases

Figure 3-36 Negative Control Valve Pressure Decreases, Pump Oil Flow Rate Increases Negative control pressure decreases and releases the displacement spring. The piston moves to the left of its previous position and the control pressure decrease reduces piston force displacement. See Figure 3-36.

Feedback pivot (897) and main spool (652) compression spring transmit power lever (left side) movement. Main spool (652) compression spring eliminates feedback by pulling main spool (652) to the left. Main spool (652) movement to the left meters the larger diameter area on the left side of the servo piston (532) pressure to the tank pressure.

Because the small side of the servo piston (532) is connected to pump delivery pressure, when servo piston (532) moves to the left, pump displacement increases toward maximum. See Figure 3-36.

After servo piston (532) moves to the left and reaches its final position, feedback lever (611) shifts main spool (652) to the null position, restoring equilibrium. See Figure 3-36.

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ME12002

Two Stage Maximum Flow Control (Qmax)

Figure 3-37 Two Stage Maximum Flow Control (Qmax) Reduce the displacement piston (643) maximum stroke “clockwise” (to the right) by applying control pressure (PM1) to the piston sleeve arrangement, shown to the left of displacement piston (643). See Figure 3-37.

Applying control pressure (PM1) reduces the pump’s maximum displacement because of the negative control mechanism feedback lever arrangement. See Figure 3-37.

Adjust the external nut to change the maximum displacement. See Figure 3-37.

To adjust the maximum displacement: PM1 pressure measurement > negative control pressure measurement. See Figure 3-37.

Check that: PM1 > 580 psi (40 bar). See Figure 337.

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Disassembling and Assembling the Hydraulic Pump

IMPORTANT:Do not disassemble any component that cannot be tested after re-assembly. Do not disassemble or re-assemble the regulator, gear pump or any other accessory valving attached to the pump unless absolutely necessary.

WARNING Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized fluid can have enough force to pierce the skin and cause serious injury.

10. After re-assembly, test components for relief characteristics, leakage, flow resistance, etc.

Tools

Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands. Obtain immediate medical attention if pressurized fluid pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

Prepare the following tools before disassembling the pump.

Name of tool Quantity Size (mm) Vice mounted on 1 unit bench (soft clamps) Hexagon wrench Each 1 piece 4, 5, 6, 8 and 14 Socket wrench Each 1 piece 19 and 27 Spanner Each 1 piece 19 and 27 Screwdriver 2 pieces Medium Size Plastic-headed 1 piece Hammer Adjustable Angle 1 piece Medium Size Wrench Pliers 1 piece Type TSR-160

General Information 1. Prepare fresh cleaning oil, hydraulic oil, grease, etc.

2. Prepare the hydraulic test equipment and tools (test for the relief characteristics, leakage, flow resistance, etc.). See “Tools” on page 85.

3. All hydraulic pump components are manufactured with precision. Thoroughly clean the work area before disassembling and/or reassembling the pump.

Steel Bar

1 piece

Torque Wrench

1 piece

4. Spread rubber sheet, cloth, paper, or similar material to cover the work area.

Approx. size 10 x 8 x 200 Capable of tightening specified torques

Glue

5. Be sure dust, sand, debris, etc. do not enter the pump.

6. While removing the pump from the excavator, attach caps and masking seals to all ports.

7. Clean the outside of the pump and be sure that the caps and masking seals are attached properly.

8. Carefully support the body section of the casing when lifting the pump.

IMPORTANT:Do not lift the pump by lifting the exposed regulator, third pump, etc.

9. Disassemble the pump on rubber sheet, cloth, paper, or similar material used to cover the work area. See step 4.

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Disassembling the Hydraulic Pump

Figure 3-38 Hydraulic Pump Rotation Group Refer to Figure 3-38 for component identification for all “Disassembling the Hydraulic Pump” steps.

4. Remove the hexagon socket headed bolts from both the front and rear pumps.

5. Remove the regulator from the front pump. See Figure 3-39.

Removing all Plugs, Regulator, and Gear Pump

6. Remove the regulator from the rear pump. See Figure 3-39.

7. Loosen hexagon socket head bolts (401) that tighten the swash plate support (251), pump casing and valve block (312) from both the front and rear pumps. See Figure 3-38.

8. If installed, remove the gear pump before working on the pump unit.

Figure 3-39 Regulator 1. Remove dust, rust and other contaminants from the pump surfaces with cleaning oil.

2. Remove drain port plug and drain hydraulic oil from the pump casing.

3. Remove all plugs from both the front and rear pumps.

Figure 3-40 Pump on Work Area 909768/BP1207

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HYDRAULIC SYSTEM Removing Hexagon Socket Head Bolts and Seal Cover

9. Place pump horizontally onto the work area with the regulator-mounting surface facing downward. See Figure 3-38 and Figure 3-40.

10. Remove the hexagon socket head bolts (401) and separate pump casing from valve block (312) on both the rear and front pumps. See Figure 3-40.

261

Removing Cylinder from Pump Casing

141

Figure 3-43 Hexagon Socket Head Bolts and Seal Cover

Figure 3-41 Cylinder and Pump Casing 1. Remove cylinder (141) out of the pump casing (271), lifting it over drive shaft (111). See Figure 3-41.

Figure 3-44 Seal Cover (rear) 1. Remove the hexagon socket head bolts (406) and remove the seal cover (front) (261). See Figure 3-43 and Figure 3-44.

2. Remove the seal cover by fitting a bolt into the “pulling-out” tapped hole.

IMPORTANT:Do not damage the oil shaft seal installed in the cover.

3. If installed, remove the gear pump before working on the pump unit.

4. Remove the rear pump hexagon socket headed bolts, seal cover (rear) (261), and rear cover.

See Figure 3-44.

Figure 3-42 Pistons 2. Remove pistons (151), set plate (153), spherical bushing (156) and cylinder springs (157).

See Figure 3-42.

IMPORTANT:Do not damage the cylinder, spherical bush, shoes, swash plate (212), etc. sliding surfaces.

3. Complete steps 1 and 2 for both the rear and front pumps.

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ME12002

Removing Swash Plate Support, Drive Shaft

Removing Shoe Plate, Swash Plate and Pump Casing

251

111

Figure 3-46 Shoe Plate, Swash Plate and Pump Casing

Figure 3-45 Swash Plate Support 1. Use plastic-headed hammer to tap lightly on the flange section of the swash plate support (251) at the location where it connects with the pump casing side. See Figure 3-45.

2. Remove swash plate support (251) from pump casing. See Figure 3-45.

3. Remove drive shaft (111) and swash plate support (251). See Figure 3-45.

4. Complete steps 1-3 for both the rear and front pumps.

Figure 3-47 Shoe Plate, Swash Plate and Pump Casing 1. Remove shoe plate (211) and swash plate (212) from pump casing. See Figure 3-38 and Figure 3-46.

2. Complete step 1 for both the rear and front pumps.

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Removing Drive Shafts

Removing Valve Plates from Valve Block

111

Figure 3-48 Drive Shaft

Figure 3-50 Valve Plate, Valve Block

1. Use plastic-headed hammer to tap lightly on the external shaft end of drive shafts (111). See Figure 3-38 and Figure 3-48.

Figure 3-51 Valve Plate, Valve Block 1. Remove valve plates (313, 314) from valve block (312). These may have been removed while completing the steps in “Removing all Plugs, Regulator, and Gear Pump” on page 86.

See Figure 3-50 and Figure 3-51.

Figure 3-49 Drive Shaft 2. Extract each drive shaft (111) from swash plate support (251). If necessary, extract rolling bearing (123), bearing spacer (127), and snap ring (824) from each drive shaft (111). See Figure 3-38 and Figure 3-48.

3. Complete steps 1-2 for both the rear and front pumps.

IMPORTANT:Do not re-use the extracted bearings.

Figure 3-52 Pump Casing 2. Remove stopper (L) (534), stopper (S) (535), servo piston (532), and tilting pin (531) from pump casing. See Figure 3-50 and Figure 3-52.

IMPORTANT:Use a protection shield to prevent the pin head from being damaged when removing tilting pin (531). See Figure 3-52.

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ME12002 flow rate. If loosening both locking screws, it is required to recalibrate both screws.

Removing Needle Bearing and Spline Coupling

2. Remove needle bearing (124) and spline coupling (114) from valve block (312). See Figure 3-53, Figure 3-54, and Figure 3-55.

Figure 3-53 Needle Bearing and Spline Coupling

Figure 3-54 Valve Block

Figure 3-55 Valve Plate 1. Remove needle bearing (124) and spline coupling (114) from valve block (312). See Figure 3-53, Figure 3-54, and Figure 3-55.

IMPORTANT:Do not remove the needle bearing unless it requires replacement. Do not loosen the hexagon stroke adjustment nuts.

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Assembling the Hydraulic Pump

Figure 3-56 Hydraulic Pump Rotation Group Refer to Figure 3-56 for component identification for all “Assembling the Hydraulic Pump” steps.

2. Apply adhesive (medium or equivalent) to the threaded section of tilting pin (531) and servo piston (532). Allow sufficient time for the adhesive to set. See Figure 3-56 and Figure 358.

Installing the Servo Pump

251 271

Figure 3-57 Pump Casing 1. Install servo piston (532), tilting pin (531), stopper (L) (534) and stopper (S) (535) onto pump casing. See Figure 3-56 and Figure 3-58.

Figure 3-58 Swash Plate Support 3. Use plastic-headed hammer to tap lightly onto swash plate support (251), to install it onto pump casing (271). See Figure 3-58.

IMPORTANT:Use a protector to prevent the tilting pin head and feedback pin from being damaged while tightening servo piston (532) and tilting pin (531) onto pump casing.

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4. Complete steps 1-3 for both the rear and front pumps.

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Installing the Swash Plate

5. Apply grease to swash plate (212) and to the sliding sections of swash plate support (251).

See Figure 3-60.

Figure 3-59 Pump Casing Figure 3-61 Swash Plate, Drive Shaft 6. Install drive shaft (111) through swash plate (212) and swash plate support (251). See Figure 3-60 and Figure 3-61.

7. Complete steps 1-6 for both the rear and front pumps.

Figure 3-60 Tilting Pin 1. Place pump casing onto the work area with the regulator-mounting surface facing downward.

2. Install swash plate (212) and tilt bushing (214) onto tilting pin (531). See Figure 3-59 and Figure 3-60.

3. Install swash plate (212) onto swash plate support (251) and install the O-ring. See Figure 359 and Figure 3-60.

4. Confirm that swash plate (212) is installed correctly. Check that it can be removed smoothly.

See Figure 3-59 and Figure 3-60.

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Installing the Drive Shaft If roller bearings are assembled, proceed to “Installing the Oil Seal and Seal Cover” on page 94.

Figure 3-64 Tap Bearing with Plasticheaded Hammer 5. Use plastic-headed hammer to tap lightly on the outer rim of bearing to install drive shaft (111) assembly onto its support. See Figure 364.

Figure 3-62 Install Bearing Spacer

6. Complete steps 1-5 for both the rear and front pumps.

Figure 3-63 Drive Shaft 1. Install bearing spacer (127) onto drive shaft (111). See Figure 3-62 and Figure 3-63.

2. Install roller bearing (123) onto drive shaft (111). See Figure 3-63.

3. Install snap ring (824) onto drive shaft (111).

See Figure 3-63.

4. Install drive shaft assembly (111), complete with bearing (123), bearing spacer (127) and snap ring (824), onto swash plate support (251). See Figure 3-63.

IMPORTANT:Do not use plastic-headed hammer to tap drive shaft (111) because damage may occur.

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Installing the Oil Seal and Seal Cover

Installing the Cylinder Springs

Figure 3-65 Oil Seal and Seal Cover

Figure 3-67 Spherical Bushing

Figure 3-66 Oil Seal 1. Install oil seal (774) into seal cover (F) (261) and seal cover (R). See Figure 3-65 and Figure 3-66.

Figure 3-68 Cylinder 1. Install cylinder springs (157), spacer (158) and spherical bushing (156) onto cylinder (141).

See Figure 3-67 and Figure 3-68.

IMPORTANT:Do not damage oil seal (774) during assembly.

2. Use hexagon socket head bolts (406) to assemble front seal cover (F)(261) into pump casing.

See Figure 3-65 and Figure 3-66.

3. Use hexagon socket head bolts (406) to assemble rear seal cover (R)(261) or rear cover into pump casing. See Figure 3-65 and Figure 3-66.

4. Lightly apply grease to the oil seal.

Figure 3-69 Piston Shoe 2. Install pistons (151) and shoe (152) through set plate (153). See Figure 3-68 and Figure 3-69.

3. Complete steps 1 and 2 for both the rear and front pumps.

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HYDRAULIC SYSTEM Installing Valve Plate onto Valve Block

Figure 3-70 Set Plate Group

Figure 3-72 Needle Bearing

4. Assemble piston (151), shoe (152) and set plate (153) group onto the cylinder bores of the cylinder (141), springs (157), spherical bushing (156) and spacer (158) assembly. See Figure 3-68 and Figure 3-70.

5. Complete step 4 for both the rear and front pumps.

Figure 3-73 Valve Block 1. If the needle bearing is replaced, install needle bearing (124) and splined coupling (114) into valve block (312). See Figure 3-72 and Figure 3-73.

Figure 3-71 Pump Casing 6. Install the splined phases of the retainer and cylinder sub-assembly into the pump casing for both the rear and front pumps. See Figure 3-68 and Figure 3-71.

Figure 3-74 Valve Plate onto Valve Block 2. Use location pin to install valve plate (313) onto valve block (312). See Figure 3-73 and Figure 3-74.

IMPORTANT:Do not change valve plate (313) suction and delivery directions.

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3. Complete steps 1-2 for both the rear and front pumps.

6. Place the feedback pin of tilting pin into the feedback lever of regulator. See Figure 3-76.

7. Install the regulator and tighten the hexagon socket head bolts.

IMPORTANT:Do not accidentally switch the front pump and rear pump regulator.

8. Install drain port plug.

9. Complete steps 6-8 for both the rear and front pumps.

Figure 3-75 Valve Block to P-casing 4. On the rear pump, install valve block (312) onto p-casing, tighten hexagon socket headed bolts (401), and install the O-ring. See Figure 3-73 and Figure 3-75.

For “clock-wise” (to the right) rotation (viewed from input shaft side), install the valve block with the regulator up and with the delivery flange on the left side, when viewed from the shaft end.

For “counter-clockwise” (to the left) rotation (viewed from input shaft side), install the valve block with the regulator up and with the delivery flange on the right side, when viewed from the shaft end.

IMPORTANT:Do not change valve plate (313)/valve block (312) rotation direction. See Figure 3-73.

5. Repeat step 4 for the front pump.

Figure 3-76 Install the Regulator

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Hydraulic Pump Tightening Torques

Figure 3-77 Tightening Torques

No. 401 406 466 467 490 531, 532 808

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Nominal Designation of Screw Thread

Tightening Torque Lb.-Ft. (Nm)

M16 M6 G 1/4 G 1/2 NPTF 1/16 M20 x 1.5 M16

174 (235) 9 (12) 27 (36) 80 (108) 6 (9) 174 (235) 94 (128)

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Regulator (front)

Figure 3-78 Regulator (Front) N o.

405, 436, 438 412, 413 496 630 801

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N ominal D esignation of Screw Thread

Tightening Torque Lb.-Ft. (N m)

M6

9 (12)

M8 NP TF 1/16 M 30 x 1.5 M8

22 (29) 6 (9) 116 (157) 12 (16)

98

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Power Shift Proportional Control

Figure 3-79 Power Shift Proportional Control

No.

Nominal Designation of Screw Thread

312

M14 x 1

351

M3

801 (802)

M22 x 1 M6

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Tightening Torque Lb.-Ft. (Nm) 21±2 (29±3) 0.4±.07 (0.6±0.1) (Apply adhesive Loctite #241 or equivalent) 32±4 (44±5) 5.5±0.4 (7.4±0.5)

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Regulator (rear)

Figure 3-80 Regulator (rear)

No. 436, 438 412, 413 496 630 801

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Nominal Designation of Screw Thread

Tightening Torque Lb.-Ft. (Nm)

M6 M8 NPTF 1/16 M30 x 1.5 M8

9 (12) 22 (29) 6 (9) 116 (157) 12 (16)

100

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Gear Pump

Figure 3-81 Gear Pump

No. 412, 413 436, 438 496 630 801

Printed in U.S.A

Nominal Designation of Screw Thread

Tightening Torque Lb.-Ft. (Nm)

M8 M6 NPTF 1/16 M30 x 1.5 M8

22 (29) 9 (12) 6 (9) 116 (157) 12 (16)

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Hydraulic System

Figure 3-82 Hydraulic System Sections: Main valve block

Sections: Side valve block

1. Drive left

11. Boom offset

2. Auxiliary hydraulics

12. Dozer blade

3. Boom 1 4. Bucket 5. Dipper arm 2 6. Drive right 7. Swivel motor 8. Dipper arm 1 9. Boom 2 10. Drive counter-balancing - straight travel 13. Pump unit (double axial piston pump and gear pump) 14. Tank 15. Pilot control valves

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Hydraulic Diagram - Main Valve Block

Figure 3-83 Main Valve Block Hydraulic Diagram Printed in U.S.A

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Hydraulic Pump Port Codes

Figure 3-84 Hydraulic Pump Port Codes ARM (2) BUCKET BOOM (1) OPTION TRAVEL (LEFT) STRAIGHT TRAVEL TRAVEL (RIGHT) SWING ARM (1) BOOM (2)

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Section dipper arm (2) summation Section bucket Section boom (1) Section auxiliary hydraulics Section drive left Section drive counter-balancing Section drive right Section swivel motor Section dipper arm (1) Section boom (2) summation

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Figure 3-85 Hydraulic Pump Port Codes Printed in U.S.A

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Hydraulic Pump Function Summation

Pilot-operated leakage free valve section dipper arm (1)

Tank Port

Dipper arm summation

Section boom summation 1

2

3

Pilot operated leakage free valve section boom 1

Figure 3-86 Hydraulic Pump Connections Function dipper arm cylinder IN (dipper arm OUT) Function dipper arm cylinder Pilot port 2: OUT (dipper arm IN) Function boom cylinder OUT Pilot port 3: (boom UP) Pilot port 1:

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Negative Control System Functions The negative control system is active during: •

Neutral condition, when no function is being actuated.

•

Fine metering condition, when the pilot control lever is partially actuated.

Figure 3-87 Negative Control System Function 1,2 3,6 4,5 7,9 10 27,28 304 611

pressure to the rear pump regulator. This pressure controls the pump regulator and decreases rear pump (28) discharge. See Figure 3-87.

Center bypass Distribution path Negative control line for Pn (negative control pressure) Opening Tank line Variable piston pump Section bucket Pressure limiting valve

Rear pump (28) hydraulic fluid flows through center bypass (2), path (3), opening (9) (within valve washer [13]), and into return passage (10). See Figure 3-87.

This opening causes a restriction that pressurizes path (3). The negative control signal pressure PN uses the negative control line (4) to transfer this Printed in U.S.A

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Valve Structure

Figure 3-88 Negative Control Valve Components 1 5,6 7 10 611 13 14 15 102

System path Pump regulator canal Opening Tank line Pressure limiting valve Valve washer Spring Valve housing Casing

Stand-by pump: approximately 6 gpm (21 L/min).

Stand-by pressure: approximately 464 psi (32 bar).

Pressure limiting valve (611) consists of valve washer (13), spring (14), valve housing (15), and casing (102). See Figure 3-88 and Figure 3-89.

Center bypass hydraulic fluid pressure increases path (3) pressure PN until the fluid arrives at the pre-set pressure of spring (14). When the fluid arrives at the pre-set pressure of spring (14), hydraulic fluid in path (3) opens valve washer (13) and flows into tank line (10). See Figure 3-88 and Figure 3-89.

Figure 3-89 Negative Control System Function For a larger view of Figure 3-89, see Figure 3-87 on page 107.

In the unloaded state, rear pump (28) hydraulic fluid flows through path (2), opening (9) and tank line (10) to the tank. Opening (9) reduces all discharge, increasing path (3) pressure PN to maximum level and destroking rear pump (28). This minimizes rear pump (28) tilting angle and discharge. See Figure 3-88 and Figure 3-89.

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Fine Metering

Figure 3-90 Fine Metering 1 18 19, 20 304 P

System path Consumer port Pressure path Spool (section bucket) Pilot pressure

When pilot control lever for bucket (excavating) is slightly operated, pilot pressure P shifts the bucket spool (304) partially to the right. Path (19) partially opens and center bypass (2) partially closes. The hydraulic fluid separates: one portion flows through opening (7) and path (1), and the other portion flows through parallel path (20), path (19), and port (18). See Figure 3-90 and Figure 3-91.

Figure 3-91 Negative Control Valve Components For a larger view of Figure 3-91, see Figure 3-88 on page 107.

Flow from path (1) through opening (7) slightly decreases and pressure PN in path (6) slightly decreases. See Figure 3-90 and Figure 3-91.

Pressure PN decreases and front pump (27) discharge increases. When pilot control lever continues to shift, spool (304) also shifts and closes path (2), and center bypass. Path (6) pressure decreases to “zero” and front pump (27) discharge increases to “maximum.” See Figure 3-90, Figure 3-91 and Figure 3-92.

When pilot control lever for bucket (excavating) is slightly operated, it adjusts pump discharge, and this adjustment precisely moves the actuator.

Figure 3-92 Negative Control System Function For a larger view of Figure 3-92, see Figure 3-87 on page 107.

For rear pump (28), the same negative control operating principle occurs using opening (7). See Figure 3-91 and Figure 3-92.

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Spool Identification Codes Main Valve Block - Section A

Main Valve Block - Section B

Figure 3-94 Main Valve Block - Section B Main valve block, section B, spool identification codes: Figure 3-93 Main Valve Block - Section A Section A:

Main valve block, section A, spool identification codes:

Section B: Section C: Section D:

Section G: Swivel us 12 Section H: Dipper arm 1 ua 11 Section I: Boom 2 (summation) ubg11

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Dipper arm 2 (summation) Bucket Boom 1 Auxiliary hydraulics

uag11 uk 11 ub 11 m03b

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Main Valve Block - Section C

Figure 3-95 Main Valve Block - Section C Main valve block, section C, spool identification codes: Section E: Section F:

Drive Drive counter balancing system

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mtr 70 mts-4x

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Valves Load Check Valve

Figure 3-96 Load Check Valve 17 39 511

flow into the tank and lower the boom. See Figure 3-96 and Figure 3-97.

System path Pressure path Load check valve

Load check valve (511) performs the following functions: 1. Load check valve (511) prevents pressurized circuit hydraulic fluid from flowing into the low pressure circuit. The low pressure circuit operates simultaneously with the pressurized circuit. See Figure 3-96.

For example, if the bucket cylinder operates using low pressure while the boom cylinder is hoisting using high pressure, without check valve (511), pressurized fluid from the boom cylinder will flow into the bucket cylinder and lower the boom. See Figure 3-96.

Figure 3-97 Section Boom (1) (spool fully switched) For a larger view of Figure 3-97, see Figure 3-113 on page 120.

2. Load check valve (511) prevents the boom from lowering while it is being slightly operated. See Figure 3-96.

For example, while hoisting using low speed, hydraulic fluid leaks from the center bypass of boom spool (303). Without check valve (511), hydraulic fluid in the boom cylinder could

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Circuit Pressure Protection

Figure 3-98 Main Relief Operation While Traveling The control valve contains relief valves that limit circuit pressure: 1. Main Relief Valve (main pressure limiting valve): limits the pressure of the main hydraulic system.

2. Port Relief Valve (secondary pressure limiting valve): limits the service pressure within a cylinder circuit.

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Main Relief Valve

Figure 3-99 Main Relief Valve Structure Hydraulic fluid from front pump (27) flows through line (23) and into control valve (1), and from rear pump (28) through line (22) and into control valve (1). See Figure 3-87 and Figure 3-98.

Hydraulic fluid flows through check valve (7) or (8) and path (13) to main relief valve (601). Main relief valve (601) limits path (13) pressure to its pre-set amount. See Figure 3-98.

Shock Suction Valve

Figure 3-100 Shock Suction Valve Structure Setting: 5076 psi (350 bar) at 5 gpm (20 L/min).

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Operating Pilot Pressure

Figure 3-101 Pilot Pressure Traveling Hydraulic fluid traveling through pilot path (12) pilot pressure connects to piston chamber (17), inside of main relief valve (601). See Figure 3-101 and Figure 3-103. This connection shifts the piston and increases the pressure setting. The flow from pilot pump (21) (not shown) separates at line (10), one portion flows through path (9) and the other portion flows through path (15) (not shown). See Figure 3-102.

Figure 3-102 Negative Control System Function For a larger view of Figure 3-102, see Figure 3-87 on page 107.

Figure 3-104 Drive Function Figure 3-103 Main Relief Operation (Travel)

Both path (9) and path (15) (not shown) flow into pilot path (12) as follows:

For a larger view of Figure 3-103, see Figure 3-98 on page 113.

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If both travel spools (301R) and (301L) operate simultaneously or if only travel right spool (301R) operates, hydraulic fluid flows into path (15) (not shown), then through path (16) (not shown), shuttle valve (11) (not shown), and into pilot path (12). See Figure 3-101 and Figure 3-104 on page 115.

•

If only travel left spool (301L) operates, hydraulic fluid flows into path (9), then through path (5), path (6), shuttle valve (11) (not shown), and into pilot path (12).

See Figure 3-101, Figure 3-102, and Figure 3-104 on page 115.

If path (13) pressure is less than main relief valve (601) set pressure, valve washer (24) and seat (25) are shut-off and hydraulic fluid in path (13) cannot flow into return path (14). See Figure 3-101 and Figure 3-103 on page 115.

While traveling, path (12) pilot pressure flows through path (25) and into the left end of piston (17). Piston (17) moves to the right and presses against spring (39), increasing the spring force pressure. When path (13) hydraulic fluid is pressurized close to the high pressure setting, valve washer (24) opens against spring (39). Hydraulic fluid in chamber (33) then flows through path (32) and into return path (14), with its pressure decreased. See Figure 3-101 and Figure 3-103 on page 115.

Hydraulic fluid pressure in path (13) moves piston (37) to the left and presses against the right end of plug (40). Simultaneously, path (13) hydraulic fluid flows into path (30), with its pressure decreased by opening (31). Hydraulic fluid pressure in spring chamber (35) decreases because fluid flows through path (36) and into path (30).

The pressure from path (13) presses plunger (38) to the left against spring (34). Plunger (38) opens and path (13) hydraulic fluid flows into return path (14), maintaining the high pressure setting. Adjustment plug (26) adjusts the high pressure setting.

See Figure 3-101 on page 115.

909768/BP1207

ME12002 Operating Main Relief

Figure 3-105 Main Relief Operation While Working While traveling, the force pressing against spring (39) decreases, and the force pressing against valve washer (24) decreases. See Figure 3-105.

When path (13) is pressurized close to the working pressure setting, valve washer (24) opens. Plunger (38) opens and path (13) hydraulic fluid flows into return path (14) to maintain the working pressure setting. Adjustment screw (25) adjusts the working pressure setting. See Figure 3-105.

Port Relief Valve

Figure 3-106 Port Relief Valve Port relief and make-up valves are installed between the cylinders and spools of working components (boom, dipper arm, and bucket). When an external force acts on a cylinder rod, and its spool is in neutral, pressure within the cylinder can become excessive. Port relief valve restricts this pressure to the valve set pressure.

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Port relief valve also functions as a make-up valve.

See “Make-up Function” on page 117. When an external force acts on a cylinder, hydraulic fluid flow may be insufficient for cylinder velocity. If this occurs, a vacuum and cavitation could develop. Port relief valve fills the vacuum by allowing return hydraulic fluid to flow into the cylinder.

Hydraulic fluid between the cylinder and its spool flows into path (6) to pressurize port relief valve.

Hydraulic fluid in path (6) flows through path (4), piston (10), and into spring chamber (3). If spring chamber (3) pressure is lower than the pressure setting, valve washer (2) shuts-off because the force of spring (1) overcomes the pressure. Therefore, path (6) and spring chamber (3) contain the same pressure. See Figure 3-106.

Because spring chamber (3) side pressurized area of seat (8) and plunger (9) is larger than the side pressurized area of path (6), seat (8) and plunger (9) are pressed to the right until they are positioned securely. After seat (8) and plunger (9) are pressed to the right and positioned securely, path (6) hydraulic fluid does not flow into return path (5).

See Figure 3-106.

Path (6) hydraulic fluid flows through path (4), piston (10), spring chamber (3) and into chamber (11).

While hydraulic fluid flows through path (4), its pressure decreases. While hydraulic fluid flows through spring chamber (3), its pressure decreases and the pressure decrease forces plunger (9) to the left. Path (12) opens and hydraulic fluid from path (6) flows into return path (5). See Figure 3-107.

Make-up Function

Figure 3-108 Make-up Function When a vacuum occurs in path (6) side, it also occurs in path (4) and spring chamber (3). The pressure in the side of return path (5) then presses against seat (8). Return pressure shifts seat (8) to the left because the spring chamber (3) sides of seat (8) and plunger (9) are under a vacuum. Hydraulic fluid in return path (5) flows into path (6), filling the vacuum in path (6) side. See Figure 3-108.

Port Relief Function

Figure 3-107 Port Relief Function When path (6) is pressurized to the pressure setting, valve washer (2) is pushed open against spring (1). Hydraulic fluid from chamber (11) flows through path (13) and into return path (5), reducing its pressure. Pressure in path (6) shifts piston (10) to the left until it stops on the end of plug (7). See Figure 3-107.

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ME12002 ering the boom, it supplies return flow from the head side of boom cylinder (1) into the rod side.

This retains hydraulic fluid from front pump (27).

See Figure 3-109.

Boom Cylinders Port Connections

Figure 3-109 Boom Structure Boom functions: •

Summation

•

Piloted leakage-free valve, spool boom (load-holding valve, boom lock valve)

•

Regeneration function rod side

Raising the boom causes hydraulic fluid from front pump (27) and rear pump (28) to combine and flow into boom cylinder (1). During low speed operation, only boom 1 spool (303) functions. Front pump (27) supplies boom 1 spool and boom lock valve (202, 516) with hydraulic fluid. See Figure 3109.

Figure 3-110 Boom Cylinder Port Connections

When control lever is in the neutral position, this position shuts-off the return flow from the head side of boom cylinder (1) and prevents the boom from lowering if boom spool (303) leakage occurs.

See Figure 3-109.

While lowering the boom, only front pump (27) supplies hydraulic fluid to boom cylinder (1).

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Section Boom (1)

Section Boom (2)

Figure 3-111 Section Boom (1) 1 2 3 4 5 6 7 8 9 10 11

Leakage free valve - spool boom Secondary pressure limiting valve with suction function Direct piloted check valve Spool Check valve for regeneration function Check valve for pump regulation (NCsignal) Port - joystick (boom lift/lowering) Port - joystick (boom lowering) Port tank line Port boom cylinder bottom side Port boom cylinder rod side

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Figure 3-112 Section Boom (2), Summation Function 1 2 3 4 5

119

Direct piloted check valve Spool Pilot pressure port - lower boom Pilot pressure port - lift boom Pressure cannel - tank line

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Raising the Boom (high speed operation) During high speed operation, the pilot control lever is fully operated and the spool is fully switched.

Section Boom (1)

Figure 3-113 Section Boom (1) (spool fully switched) Hydraulic fluid from front pump (27) flows through parallel path (17) and into boom 1 spool (303). Hydraulic fluid from rear pump (28) flows through parallel path (18) and into boom 2 spool (306). See Figure 3-114 and Figure 3-115.

While raising the boom, port (5) senses pilot pressure from pilot control valve (25) and shifts boom 1 spool (303) to the right against springs (322) and (328). See Figure 3-113 and Figure 3-114.

Hydraulic fluid from front pump (27) and from parallel path (17) flows through load check valve (511), path (39) and path (35). The hydraulic fluid then forces open boom lock valve (516), and flows into port (3). Hydraulic fluid then flows through line (6) (not shown) and into the head side of boom cylinder (1). See Figure 3-113 and Figure 3-114.

While raising the boom, the path above boom lock valve (516) leads through path (20), sleeve (37) and spool (202) to path (38). Pressure in path (33) opens boom lock valve (516). See Figure 3-113.

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Figure 3-114 Boom Structure 120

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HYDRAULIC SYSTEM

Section Boom (2)

Figure 3-115 Section Boom (2) - Summation Simultaneously in section boom (2), pilot pressure through port (10) shifts boom 2 spool (306) to the right against springs (322) and (323). The hydraulic fluid of rear pump (28) from parallel path (18) flows into port (19) through path (44), path (43) and check valve (511). See Figure 3-115, and for rear pump (28) only, see Figure 3-116.

Hydraulic fluid flows through line (8), combines with hydraulic fluid from front pump (27), flows into line (6) (not shown), and then flows into the head side of boom cylinder (1). See Figure 3-116, and for boom cylinder (1) only, see Figure 3-111 on page 119.

The flow from the rod side of boom cylinder (1) flows through line (7) (not shown) and into boom 1 spool (303). See Figure 3-116, and for boom cylinder (1) only, see Figure 3-111 on page 119.

The flow from the rod side of boom cylinder (1) then flows through return path (15) (not shown) and into the return line. See Figure 3-113 on page 120.

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Figure 3-116 Boom Structure For a larger view of Figure 3-116, see Figure 3-109 on page 118.

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Raising the Boom (low speed operation)

Figure 3-117 Raising the Boom (low speed) During low speed operation, the pilot control lever is partially operated and is not in full-stroke position.

When raising the boom with a low-operating speed, the low pilot pressure presses against both boom 1 spool (303) and boom 2 spool (306). See Figure 3-117 and Figure 3-118.

The pre-load force of spring (322) and spring (328) of boom 1 spool (303) is less than the pre-load force of spring (322) and spring (323) of arm 2 spool (308). When pilot pressure is low, boom 1 spool (303) shifts and boom 2 spool (308) remains in the neutral position. See Figure 3-117, Figure 3118 and Figure 3-125 on page 126.

Only hydraulic fluid from front pump (27) flows into the head side of boom cylinder (1). See Figure 3-116 on page 121.

Figure 3-118 Section Boom (2) - Summation For a larger view of Figure 3-118, see Figure 3-115 on page 121.

During this fine metering operation, boom raising can be controlled properly at slow speed.

Pilot pressure required to move the spool: Section Boom 1: 87-102 psi (6-7 bar) Section Boom 2: 174-189 psi (12-13 bar) 909768/BP1207

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Lowering the Boom

Figure 3-119 Lowering the Boom flows into path (16). This return flow forces open boom lock valve (516). See Figure 3-119 and Figure 3-120.

While lowering the boom, pilot pressure from pilot control valve (25) flows through port (23) and shifts boom 1 spool (303) to the left against springs (322) and (328). See Figure 3-117 on page 122, Figure 3-119, and Figure 3-120.

Return flow lowers the boom cylinder by flowing through path (31), return path (15) and into the tank. See Figure 3-119.

Pilot pressure flows into pilot port (21) of boom lock valve (202, 516) and shifts spool (202). Boom 1 spool (303) center bypass (33) slightly opens.

See Figure 3-119.

Return flow in path (45) decreases, and the boom cylinder lowers at the speed suitable to the front pump discharge. See Figure 3-119.

Front pump (27) hydraulic fluid flows through center bypass (13), center bypass (11) and line (26).

The hydraulic fluid pressurizes the front pump regulator’s negative control pressure, decreasing the discharge from front pump (27). See Figure 3-119 and Figure 3-120.

Front pump (27) hydraulic fluid from parallel path (17) flows through load check valve (511), path (46), and into port (4). Hydraulic fluid then flows through line (7) (not shown) and into the rod side of boom cylinder (1). See Figure 3-119 and Figure 3-120.

Return flow from the head side of boom cylinder (1) flows through line (6) (not shown), port (3), and into boom 1 spool (303). Within boom lock valve (516), pilot pressure from port (21) operates spool (202), and spool (202) forces the return flow through path (20) and into drain port (22). The pressure within the upper side of boom lock valve (516) decreases and the return flow from line (3) Printed in U.S.A

Figure 3-120 Boom Structure 123

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Regeneration Circuit

Figure 3-121 Regeneration Circuit Return flow from the head side of boom cylinder (1) separates at line (44). A portion of this flow opens check valve (14), check valve (47), and then passes through path (34) in boom spool (303). See Figure 3-121, and for boom cylinder (1) only, see Figure 3-111 on page 119.

Path (43) shuts-off, intercepting the flow from path (44) to path (34). See Figure 3-121.

Spring (49) shuts-off check valve (14) and spring (38) presses check valve (47) to the left. See Figure 3-121.

Because boom spool (303) is in the left position, path (48) pressure flows into return path (15), relieving spring chamber (39) pressure. Path (34) hydraulic fluid forces check valve (47) and check valve (14) to the right against spring (38) and spring (49). See Figure 3-121.

Hydraulic fluid flows through path (36) and port (4) into the rod side of boom cylinder (1). See Figure 3-121, and for boom cylinder (1) only, see Figure 3-111 on page 119.

While lowering the boom, the boom 1 spool (303) regenerative circuit function transfers flow from the head side to the rod side. See Figure 3-121.

Figure 3-122 Raising the Boom For a larger view of Figure 3-122, see Figure 3-117 on page 122.

When the control lever returns to the neutral position, pilot pressure through port (23) is cut-off and spring (322) and spring (328) returns boom spool (303) to neutral position. See Figure 3-121 and Figure 3-122.

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Negative Control During the Regeneration Operation

Figure 3-123 Negative Control During the Regeneration Operation The regeneration function saves hydraulic fluid that flows from front pump (27) into the rod side of the boom cylinder (1). While lowering the boom, higher negative control pressure decreases front pump (27) discharge. See Figure 3-124.

path (33) and into center bypass (11). Higher negative control pressure decreases discharge from front pump (27), slowing cylinder movement. See Figure 3-123 and Figure 3-124.

Full Operation Case

Hydraulic fluid in front pump (27) flows from center bypass (13) through the slightly-opened path (33) and into center bypass (11). The hydraulic fluid serves as the negative control signal pressure when, to decrease discharge from front pump (27), it flows through line (26) and into the front pump regulator. See Figure 3-123 and Figure 3-124.

Fine Metering Operation Case

Spool (303) is positioned slightly to the left, path (46) and path (43) are slightly open and path (31) is shut-off. Return flow from path (44) flows through path (43) and path (34), forces open return check valve (41), and flows through path (42) and into return path (15). See Figure 3-123.

Hydraulic fluid from center bypass (13) flows through the partially opened path and into center bypass (11). Hydraulic fluid flows through partial Printed in U.S.A

Figure 3-124 Boom Structure For a larger view of Figure 3-124, see Figure 3-109 on page 118.

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Dipper Arm Section

Figure 3-125 Dipper Arm Section 1

Dipper arm cylinder Pilot pressure hose (cylinder rod 6 side) 10 Bypass 16 Direct piloted check valve 19 Summation line 20 Tank line Pilot pressure hose (cylinder 25 bottom side) 27 Variable axial piston pump 1 28 Variable axial piston pump 2 29 Gear pump 31 Pilot oil supply unit 34 Regeneration function Bypass valve (for regeneration 37, 38 valve) Leakage free valve - spool dipper 204, 516 arm 302 Spool section 1 308 Spool section 2

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•

Summation (bottom and rod side)

•

Direct piloted check valve

•

Regeneration function dipper arm cylinder bottom side

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HYDRAULIC SYSTEM

Dipper Arm Section (1)

Dipper Arm Section (2)

Figure 3-127 Dipper Arm Section (2) Figure 3-126 Dipper Arm Section (1) 1,6 2 3,8 4 5 7 9 10 11

1 2,3 4

Pilot pressure port - dipper arm cylinder rod side Piloted lekage free valve - spool dipper arm Direct piloted check valve Bypass valve Spool Secondary pressure limiting valve with suction function Pilot pressure port - dipper arm cylinder bottom side Dipper arm cylinder bottom side Regeneration valve

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5 6 7 8

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Pilot pressure port for function side valve block Direct piloted check valve Port summation line Pilot pressure line - dipper arm cylinder extending Pilot pressure line - dipper arm cylinder retracting Shuttle valve Spool

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Dipper Arm Control

Figure 3-128 Dipper Arm Control Spool arm 1 (302) and spool arm 2 (308) both operate when extending and/or raising the dipper arm. Hydraulic fluid from front pump (27) and rear pump (28) combine and flow into the arm cylinder.

See Figure 3-128 and Figure 3-129.

Arm lock valve (204, 516) is included with the dipper arm control. When the control lever is in the neutral position, it shuts-off the return flow from the rod side of cylinder (1) and prevents the arm from lowering because of leakage from arm spool (302). See Figure 3-128 and Figure 3-129.

The construction and operation of arm lock valve (204, 516) are the same as those of boom lock valve (202, 516). See “Lowering the Boom” on page 123.

For a larger view of Figure 3-129, see Figure 3-109 on page 118.

Figure 3-129 Boom Structure 909768/BP1207

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Retracting the Dipper Arm Cylinder

Figure 3-130 Dipper Arm Section (1) While extending the dipper arm, pilot pressure from pilot control valve (31) flows through pilot line (29), pilot line (24), and shifts arm 1 spool (302) to the left against spring (322) and spring (328). See Figure 3-130 and Figure 3-131.

Hydraulic fluid from rear pump (28) flows into load check valve (511) and through center bypass (10), into path (15), arm lock valve (516) and path (14). Hydraulic fluid then flows into the rod side of arm cylinder (1) through line (3). See Figure 3-130 and Figure 3-131.

Figure 3-131 Dipper Arm Control For a larger view of Figure 3-131, see Figure 3-128 on page 128.

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Figure 3-132 Dipper Arm Section (2) - Summation Pilot pressure flows through pilot line (29), pilot line (25), and presses arm 2 spool (308) to the right against spring (322) and spring (329). Arm 2 spool (308) shuts-off center bypass (11), preventing fluid from flowing from center bypass (11) and into return path (13). See Figure 3-132 and Figure 3133.

Hydraulic fluid from front pump (27) combines with hydraulic fluid from rear pump (28) to increase cylinder speed. See Figure 3-133.

Hydraulic fluid flows: 1. Through center bypass (11), path (22) and path (26). See Figure 3-132 and Figure 3-133.

2. Through parallel path (21), arm 2 spool (308), path (23) and into the path (26). See Figure 3132 and Figure 3-133.

3. Total flow supplied into path (26) from front pump (27) flows through path (15) and into path (19). The flow then combines with the total flow from rear pump (28). See Figure 3133.

Return flow from the head side of arm cylinder (1) flows into arm 1 spool (302) through path (4).

Return flow then flows through return path (17) and into return line (30). See Figure 3-133.

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Figure 3-133 Dipper Arm Control For a larger view of Figure 3-133, see Figure 3-128 on page 128.

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Lowering the Dipper Arm Cylinder (with heavy loads)

Figure 3-134 Dipper Arm Cylinder Lowering Operation (with heavy loads) While lowering the dipper arm, pilot pressure from pilot control valve (31) flows through path (2) and presses arm 1 spool (302) to the left against spring (322) and spring (328). See Figure 3-135 and Figure 3-130 on page 129.

(28) hydraulic fluid. See Figure 3-134 and Figure 3-135.

Pilot pressure through pilot line (2) and pilot line (6) shifts arm 2 spool (308) to the right against spring (322) and spring (329). See Figure 3-135 and Figure 3-132 on page 130.

While lowering the dipper arm, hydraulic fluid from rear pump (28) flows through center bypass (10) and into arm 1 spool (302). Hydraulic fluid from front pump (27) flows into arm 2 spool (308) and combines with the total flow from rear pump (28). The combined flow proceeds into line (4) and then flows into the head side of arm cylinder (1).

See Figure 3-135.

Arm 1 spool (302) contains the built-in regeneration circuit using check valve (34). Return flow from the rod side of arm cylinder (1) flows through line (3) and into arm lock valve (516). See Figure 3-134 and Figure 3-135.

When pressure on the rod side of arm cylinder (1) is greater than that of the head side of arm cylinder (1), return flow from the rod side of arm cylinder (1) flows into the head side through check valve (34), path (35), and path (36). This saves rear pump Printed in U.S.A

Figure 3-135 Dipper Arm Control For a larger view of Figure 3-135, see Figure 3-128 on page 128.

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Lowering the Dipper Arm Cylinder (with light loads)

Figure 3-136 Lowering the Dipper Arm Cylinder (with light loads) After the dipper arm begins excavating, pressure within the head side of arm cylinder (1) increases and presses piston (37) and sub-spool assembly (38) to the right against spring (41). Path (40) opens and most of the return flow from the rod side of arm cylinder (1) flows through arm 1 spool (302), path (40), return path (17) and return path (27) into the tank (the return flow does not flow into the regeneration circuit). See Figure 3-136 and Figure 3-137.

Figure 3-137 Dipper Arm Control For a larger view of Figure 3-137, see Figure 3-128 on page 128.

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Bucket Section

Figure 3-138 Bucket Structure 1 2 3 4 5 6 7

Pilot pressure port bucket cylinder extending Port bucket cylinder rod side Port bucket cylinder bottom side Pilot pressure port bucket cylinder retracting Secondary pressure limiting valve Spool bucket Direct piloted check valve

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Figure 3-139 Bucket Section While excavating or releasing the bucket, only front pump (27) supplies hydraulic fluid to the bucket cylinder. Bucket spool (304) reduces the return flow from the bucket cylinder and pump discharge controls the bucket operating speed. See Figure 3-139 and Figure 3-140.

When the pilot control lever is in the neutral position, the pilot control valve does not supply any pilot pressure to either pilot port (1) or pilot port (9). Springs (322) and (328) maintain bucket spool (304) in the neutral position. Front pump (27) hydraulic fluid flows through center bypass (7) and into the tank. See Figure 3-139 and Figure 3-140.

When using the pilot control lever for bucket excavating, pilot pressure is supplied into port (1), shifting bucket spool (304) to the right. Center bypass (7) shuts-off and path (16) opens while path (15) flows into return path (5). See Figure 3-139.

Hydraulic fluid from front pump (27) flows into parallel path (13) and then through load check valve (511), path (11), path (16), and into port (6).

See Figure 3-139 and Figure 3-140.

The bucket cylinder extends while the flow from the rod side of the bucket cylinder flows into port (8). Hydraulic fluid then flows through path (15), return path (5), and into the tank. See Figure 3-139.

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Figure 3-140 Dipper Arm Control For a larger view of Figure 3-140, see Figure 3-128 on page 128.

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Swing Section

Figure 3-141 Swing Section 1 2 3 4 5 6

Pilot pressure port Port swing motor Port swing motor Pilot pressure port Spool Direct piloted check valve

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Boom Swing Control

Figure 3-142 Boom Swing Control While swinging the boom right or left, only rear pump (28) supplies hydraulic fluid into the swing motor. See Figure 3-143.

When the pilot control lever is in neutral position, the pilot control valve does not supply any pilot pressure to either pilot port (1) or pilot port (9).

Springs (322) and (328) maintain swing spool (309) in neutral position. Rear pump (28) hydraulic fluid flows through center bypass (7) and into the tank. See Figure 3-142, Figure 3-143 and Figure 3139 on page 134.

When using the pilot control lever for swinging the boom right or left, pilot pressure is supplied into port (9), shifting swing spool (309) to the right or left. Center bypass (7) shuts-off and path (16) opens while path (15) flows into return path (5).

See Figure 3-142.

Hydraulic fluid flows into parallel path (13) and then through load check valve (511), path (11), path (16), and into port (8). See Figure 3-142.

The swing motor turns to the right or left, depending on the swinging direction, and the return flow from the swing motor flows into port (6). Hydraulic fluid then flows through path (15), return path (5), and into the tank. See Figure 3-142.

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Figure 3-143 Dipper Arm Control For a larger view of Figure 3-143, see Figure 3-128 on page 128.

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Swing Left/Right: Swing Priority Mode

Figure 3-144 Swing Left/Right - Swing Priority Mode

NOTICE:Swing priority valve is shown in an

After exiting swing priority mode, the pilot pressure signal deactivates, shifting the swing priority valve spool and opening path (19). Parallel path (13) hydraulic fluid flows through path (19) and into arm 1 spool (302) of the swing priority valve.

See Figure 3-144.

inactive state.

When operating the dipper arm and swing at the same time, swing priority valve (604) operates the swing. See Figure 3-144.

Hydraulic fluid from rear pump (28) flows through parallel path (13) and into swing spool (309) and arm 1 spool (302). Swing spool (309) shifts and shuts-off center bypass (7), causing rear pump (28) to only use parallel path (13) to supply hydraulic fluid into arm 1 spool (302). In swing priority mode, swing priority valve (604) supplies pilot pressure to pilot port (44) and shuts-off path (19).

See Figure 3-144, and for rear pump (28) only, see Figure 3-143 on page 136.

Load check valve (514) and its opening restricts the flow from parallel path (13) to arm 1 spool (302). Rear pump (28) then becomes the primary supplier of hydraulic fluid to swing spool (309).

See Figure 3-144, and for rear pump (28) only, see Figure 3-143 on page 136.

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Auxiliary Hydraulics Section

Figure 3-145 Auxiliary Hydraulics Section 1,5 2,3 4 6 7 8

Pilot pressure hose spool left/right Port consumer Plug Plug/Secondary pressure limiting valve Spool Direct piloted check valve

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Auxiliary Hydraulics Function

Figure 3-146 Auxiliary Hydraulics Section Variable pump 1 supplies oil for auxiliary hydraulics function because the spool design allows a maximum amount of oil to easily flow through the spool.

The two assembled shock valves allow the auxiliary hydraulics section to decrease its working pressure to a level lower than that of the main working hydraulic system.

Example: Hydraulic breaker working pressure, hammer enterprise 2611 psi (180 bar) Excavator system pressure 4351 psi (300 bar)

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ME12002 Section Drive Right

Figure 3-148 Section Drive Right 1,6 2,3

Figure 3-147 Section Drive Left 1,5 2,3 4 6

4

Pilot pressure port Port drive motors Spool Direct piloted check valve

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Pilot pressure port Port drive motors Switch valve (change over valve) Spool Direct piloted check valve

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ME12002

HYDRAULIC SYSTEM

Section Drive Counterbalancing System (straight travel)

Straight travel spool (305) allows the machine to continue to be driven straight while performing other operations, for example, swinging the boom while driving. See Figure 3-150.

If driving and not performing any other operations, hydraulic fluid from front pump (27) flows through straight travel spool (305), travel left spool (301L), and into the left travel motor. Hydraulic fluid from rear pump (28) flows through travel right spool (301R) and into the right travel motor. See Figure 3-150.

Unless there are travel resistance differences between the two drive motors, the excavator continues to drive straight because the left and right drive circuits are isolated from each other.

Performing Other Functions While Driving If operating the excavator using both valves: 1. When driving, only hydraulic fluid from rear pump (28) flows into both travel motors. See Figure 3-150.

Figure 3-149 Section Drive 1 2 3 PL PR

2. When driving and performing other functions, only hydraulic fluid from front pump (27) flows for all other functions. Flow required for all other functions while driving reduces because these functions operate at a reduced speed to maintain the safety and stability of the machine. See Figure 3-150.

Plug Main pressure limiting valve (MR) Spool Port pump 1 Port pump 2

Drive Counterbalancing System Function (straight travel)

Any remaining hydraulic fluid from front pump (27) flows into both travel motors. See Figure 3150.

If the machine does not have the straight travel function, hydraulic fluid flow supplied into each drive motor from one pump differs from that of the other pump. Because of the difference between flow suppliled, the machine cannot travel straight.

Figure 3-150 Drive Function Printed in U.S.A

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Figure 3-151 Performing Other Functions While Driving If raising the boom while driving forward, the boom and travel pilot control valves supply pilot pressure into pilot path (4), pilot path (3) and pilot path (2). See Figure 3-151.

Pilot pressure then operates boom 1 (303), travel left (301L) and travel right (301R) spools. While the pilot pressure is shifting boom 1 spool (303), path (11) shuts-off. Pilot path (18) and pilot path (19) pressurize for operating straight travel spool (305). See Figure 3-151.

Pilot path (25) passes through all spools. If any spool other than boom 1 operates, path (17) and path (16) shut-off pilot path (25). Pilot path (18) and pilot path (19) pressurize and operate straight travel spool (305). See Figure 3-151.

When all other spools are in the neutral position, pilot path (18) leads to the tank through pilot path (25) and drain line (32). Pilot path (18) pressure decreases, deactivating straight travel spool (305).

See Figure 3-151.

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Straight Travel Spool (no additional actuation)

Figure 3-152 Straight Travel Spool (no additional actuation) swing (309), arm1 (302) and boom2 (306).

See Figure 3-118 on page 122 for boom2 (306), Figure 3-151 on page 142 for travel right spool (301R), spools of swing (309), arm1 (302), Figure 3-152 and Figure 3-153.

When only the travel spools are operated, pilot path (18) and spool chamber (13) pressure decreases. Spring (324) and spring (325) then shift straight travel spool (305) to the right. See Figure 3-152.

Front and rear pump hydraulic fluid then flows as follows: 1. Front pump (27) hydraulic fluid flows through line (30), port (10), and then separates into two flows. One flows through center bypass (15) and into travel left spool (301L). The other flows through parallel path (24) and into option spool (310), boom 1 (303), bucket (304), and arm 2 (308).

See Figure 3-143 on page 136 for arm 2 (308), Figure 3-146 on page 139 for spool (310), Figure 3-151 on page 142 for travel left spool (301L), boom 1 (303), bucket (304), Figure 3152 and Figure 3-153.

2. Rear pump (28) hydraulic fluid flows through line (31), port (9), and then separates into two flows. One flows through center bypass (8) and into travel right spool (301R). The other flow opens check valve (7) to the right and flows through path (6), located in straight travel spool (305), and into parallel path (22). From parallel path (22), it flows into the spools of Printed in U.S.A

Figure 3-153 Pump Flow

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Straight Travel Spool (with additional actuation)

Figure 3-154 Straight Travel Spool (with additional actuation) While performing other operations, hydraulic fluid in pilot path (18) and spool chamber (13) pressurize. This shifts straight travel spool (305) to the left against springs (324) and (325). See Figure 3-154.

Front and rear pump hydraulic fluid then flow as follows: 1. Front pump (27) hydraulic fluid flows through port (10) and then separates into two flows.

One flows through parallel path (24) and into the spools of auxiliary hydraulics (310), boom 1 (303), bucket (304), and arm 2 (308). The other flows through path (5), parallel path (22) and into the spools of swing (309), arm 1 (302) and boom 2 (306). Hydraulic fluid in path (5) flows into straight travel spool (305) through path (6), check valve (7) and into center bypass (8) and center bypass (13). Both flows combine with hydraulic fluid from rear pump (28) to increase travel speed.

See Figure 3-118 on page 122 for boom2 (306), Figure 3-143 on page 136 for arm 2 (308), Figure 3-146 for spool (310), Figure 3151 on page 142 for swing spool (309), boom 1 (303), bucket (304), Figure 3-154, and Figure 3-155.

2. Rear pump (28) hydraulic fluid flows through port (9) and then separates into two flows. One flows into center bypass (8) and the other flows into center bypass (15). Each flow supplies supplies hydraulic fluid to the left travel (301L) and right travel (301R) spool.

See Figure 3-151 on page 142 for travel right spool (301R) and travel left spool (301L), Figure 3-154, and Figure 3-155.

Figure 3-155 Pump Flow 909768/BP1207

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Operating an Additional Option While Driving (side valve block)

Figure 3-156 Operation of Additional Option While Driving (side valve block) Option control valve spool operates when controlling additional functions, and straight driving is maintained when pilot pressure from option control valve flows into port (35) of logic valve [e1].

Option control valve pilot pressure flows into port (35) of logic valve [e1]. Piston (301) then presses down while spring (621) and spring (622) force main relief valve (601) onto its seat within casing travel (101) (not shown), and path (34) shuts-off.

Pilot path (18) and pilot path (19) pressurize for operating the straight travel control valve. See Figure 3-156.

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Side Valve Block Regulation

Figure 3-157 Shuttle Valve Block Pump Regulation If any side valve block function activates (dozer blade or arm swing), the pilot signal from the activated spool cap passes through shuttle valve block (22), and then through section arm 2. See Figure 3157.

The spool moves according to the pilot pressure, and the center bypass closes because of the spool movement.

Negative control valve (NR2) pressure decreases, and the decreased pressure signal activates the pump regulator, increasing pump capacity.

Straight Travel Regulation The output pilot pressure from the shuttle valve block activates the logic valve e1 in the main valve block.

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Disassembling and Assembling the Control Valve

Tools Prepare the following tools before disassembling the control valve.

General Information

Name of tool Vice mounted on bench (soft jaws) Hexagon wrench Socket wrench Spanner Adhesive (Loctite #262)

1. Prepare fresh cleaning oil, hydraulic oil, grease, etc.

2. Prepare the hydraulic test equipment and tools (test for the relief characteristics, leakage, flow resistance, etc.). See “Tools” on page 147.

3. All hydraulic pump components are manufactured with precision. Thoroughly clean the work area before disassembling and/or reassembling the pump.

Quantity

Size (mm)

1 unit Each 1 piece Each 1 piece Each 1 piece

8, 10 and 12 27 and 32 27, 32, 41

1 piece

Disassembling the Control Valve

4. Spread rubber sheet, cloth, paper, or similar material to cover the work area.

Place Control Valve in Work Area

5. Be sure dust, sand, debris, etc. do not enter the pump control valve.

in a clean and dry environment and do not damage the sealing flange faces.

IMPORTANT:Disassemble the control valve

6. Remove the control valve from the excavator.

Disassembling of Main Spool (except straight travel)

7. Attach caps and masking seals to all control valve ports.

8. Clean the outside of the control valve and be sure that the caps and masking seals are attached properly.

9. Carefully support the body section of the casing when carrying or transferring the control valve.

IMPORTANT:Do not lift the control valve by lifting the exposed spool, end cover section, etc.

10. Disassemble the pump on rubber sheet, cloth, paper, or similar material used to cover the work area. See step 4.

Figure 3-158 Hexagon Socket Head Bolts 1. Using a 8 mm hexagon wrench, loosen hexagon socket head bolts and remove spring cover, and lock valve selector (for boom1).

11. Do not disassemble any component that cannot be tested after re-assembly.

12. After re-assembly, test components for relief characteristics, leakage, flow resistance, etc.

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ME12002 Disassembling the Straight Travel Spool

Figure 3-159 Remove Spool

IMPORTANT:When extracting each spool

Figure 3-161 Straight Travel Spool

assembly from its casing, use care not to damage the casing.

2. Remove spool, springs, stopper, spring seats and spacer bolt in spool assembly condition from casing. See Figure 3-159.

Figure 3-162 Loosen Plug

Figure 3-160 Hold Spool

1. Using a 32 mm hexagon wrench, loosen plug, remove rod and springs. See Figure 3-161 and Figure 3-162.

3. Secure spool into a vice as shown. See Figure 3-160.

4. Using a 12 mm hexagon wrench, remove spacer bolt, disassemble springs, stopper and spring seats. See Figure 3-160.

Disassembling the Covers

1. Using a 8 mm hexagon wrench, loosen hexagon socket head bolts, remove spool cover, and lock valve selector (for arm1).

Figure 3-163 Straight Travel Spool 2. Remove straight travel spool, as a complete assembly, from casing. See Figure 3-163.

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HYDRAULIC SYSTEM Removing e1 Logic Control Valve Assembly

Removing Main Relief, Port Relief and Swing Priority Valves

Figure 3-166 e1 Logic Control Valve 1. Using a 27 mm spanner wrench, remove e1 logic valve, as a complete assembly, from the travel casing. See Figure 3-166.

Figure 3-164 Main Relief Valve 1. Using a 32 mm spanner wrench, remove main relief valve. See Figure 3-164.

Disassembling the Lock Valve

Figure 3-165 Remove Port Relief Valve 2. Using a 32 mm socket wrench, remove port relief valves. See Figure 3-165.

3. Using a 32 mm socket wrench, remove swing priority valve from casing. See Figure 3-165.

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Figure 3-167 Lock Valve 1. Using a 10 mm hexagon wrench, remove plug, valve washer and springs. See Figure 3-167.

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ME12002 Disassembling the Check Valve

Figure 3-168 Negative Control Relief Valve 1. Using a 27 mm hexagon wrench, remove plug.

See Figure 3-168.

Figure 3-170 Check Valve

Figure 3-169 Damping Rod 2. Remove valve washer, spring and damping rod. See Figure 3-169.

Figure 3-171 Valve Washer 1. Using a 10 mm hexagon wrench and a 41 mm spanner wrench, remove plugs, valve washers, and springs. See Figure 3-171.

Disassembling the Casing

IMPORTANT:Unless instructed, do not disassemble Casing A and B tie bolts. Unless instructed, do not disassemble any plugs not listed in the disassembling procedures. These plugs are blind plugs for sacrifice holes and blind plugs for casting sanitation.

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Inspecting the Control Valve

4. Check if any springs are broken, deformed, and/or worn.

Inspecting the Control Valve and Relief Valve

5. Replace all broken and/or defective springs.

1. Clean all disassembled parts with clean mineral oil.

6. Check if any main valve washer and seat section openings are clogged with foreign materials.

2. Dry all disassembled parts with compressed air.

7. Replace all O-rings with new O-rings.

3. Place all disassembled parts onto a clean surface for inspection.

8. When any broken and/or defective part is found, replace the entire relief valve assembly with a completely new relief valve assembly.

4. Check surfaces of all parts for jagged edges, scratches, notches and other defects.

Assembling the Control Valve

5. Check that seal groove faces of casing and block are smooth and free of dust, dents, rust etc.

Assembling the Check Valve 1. Assemble each valve washer and spring combination as instructed in the table below.

6. Repair all defects.

IMPORTANT:Only use the valve washer and

7. Clean any seat faces within the casing by washing them with a cleaning agent.

spring combinations as shown in the table.

IMPORTANT:Do not leave any cleaning

2. Secure O-rings onto plugs.

agent within the casing.

3. Using a 10 mm hexagon wrench for plugs, tighten each plug to tightening torque 94.0 ~ 108.4 lb.-ft. (127.4 ~ 147.0 Nm).

8. Check that all sliding and fitting parts can be moved manually.

4. Using a 41 mm spanner wrench for plug, tighten the plug to tightening torque 94.0 ~ 108.4 lb.-ft. (127.4 ~ 147.0 Nm).

9. Check that all grooves and paths are free from foreign materials.

10. Check if any springs are broken, deformed, and/or worn.

11. Replace all broken and/or defective springs.

12. If a relief valve is not functioning properly, repair it by following the disassembling and assembling instructions.

13. Replace all seals and O-rings with new ones.

Inspecting the Relief Valve 1. Check that all seat faces on the ends of all valve washers and seats are free from defects and show uniform and consistent contact faces.

2. Confirm manually that the main valve washer and seat can slide lightly and smoothly.

3. Check the outside face of the main valve washer and the inside face of the seat for jagged edges, scratches, notches and other defects.

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HYDRAULIC SYSTEM Assembling the Negative Control Relief Valve 1. Using socket wrench 27 mm, assemble valve washer (2 x 611), springs (2 x 621) and damping rods (2 x 631) together into casing A and casing B. 2. Secure O-ring onto plug.

3. Tighten plug to tightening torque 50.6 ~ 57.8 lb.-ft. (68.6 ~ 78.4 Nm).

Assembling the Lock Valve 1. Assemble valve washers and springs.

2. Secure O-rings onto plugs.

3. Using a 10 mm hexagon wrench, install and tighten the plugs to tightening torque 94.0 ~ 108.4 lb.-ft. (127.4 ~ 147.0 Nm).

Assembling the e1 Logic Control and Logic Valve 1. Using a 27 mm spanner wrench, tighten hexagon socket head bolts to tightening torque 18.1 ~ 21.7 lb.-ft. (24.5 ~ 29.4 Nm).

ME12002 Assembling the Straight Travel Spool 1. Insert the straight travel spool assembly (305) into casing travel (101).

2. Assemble spring (324), spring (325) and rod (337).

3. Using a 32 mm socket wrench, secure O-ring (265) onto plug (252) and tighten plug (252) to tightening torque 50.6 ~ 57.8 lb.-ft. (68.6 ~ 78.4 Nm).

IMPORTANT:Install the spool assembly into casing travel (101) carefully and slowly to avoid damage. Do not under any circumstances force the spool assembly into casing travel (101).

Assembling the Main Spools 1. Hold the middle of each spool (secure into a vice), set spring seats (332), springs and stopper (335).

IMPORTANT:Before tightening the spacer bolt (336), apply adhesive (Loctite #262 or equivalent).

Assembling the Main Relief, Port Relief and Swing Priority Valves

2. Using a 12 mm hexagon wrench, tighten spacer bolt (336) to tightening torque 11.6 ~ 13.0 lb.-ft. (15.7 ~ 17.6 Nm).

1. Install main relief valve, port relief valves and swing priority valve cartridges into the casing and tighten to the specified torque.

3. Assemble the travel, arm 1, boom 1, bucket, boom 2, arm 2, swing and auxiliary hydraulic spools onto the inner and outer springs.

Component Tools

Tightening Torque lb.-ft. (Nm)

4. Carefully insert the previously assembled spool assemblies into their assigned bores within casing A, casing B and casing travel.

Main relief valve

50.6 ~ 57.8 lb.-ft.

(68.6 ~ 78.4 Nm)

IMPORTANT:Install spool assemblies into

Spanner wrench 32mm Port relief Socket valve wrench 32mm Swing Socket priority valve wrench 32mm

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50.6 ~ 57.8 lb.-ft.

(68.6 ~ 78.4 Nm)

casing A, casing B and casing travel carefully and slowly to avoid damage. Do not under any circumstances force the spool assembly into the casings.

50.6 ~ 57.8 lb.-ft.

(68.6 ~ 78.4 Nm)

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Assembling the Covers 1. Assemble spool covers and lock valve selector to the non-spring assembly end of the spool.

2. Using a 8 mm hexagon wrench, tighten the hexagonal socket head bolts to tightening torque 18.0 ~ 21.7 lb.-ft. (24.5 ~ 29.4 Nm).

3. Confirm that O-rings are installed.

4. Assemble spring covers and lock valve selector to the spring end of the spools.

5. Using a 8 mm hexagon wrench, tighten the hexagonal socket head bolts to tightening torque 18.0 ~ 21.7 lb.-ft. (24.5 ~ 29.4 Nm).

6. Confirm that O-rings are installed.

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Joystick Joystick Structure

Figure 3-172 Joystick Structure

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Hydraulic Piloting System

Figure 3-173 Hydraulic Piloting System 1 2 3 4 5 6

Right Joystick Ports

Pilot control valve Variable pump Hydraulic motor Hydraulic cylinder Main valve block Fixed displacment pump

Exit 1 Exit 2 Exit 3 Exit 4

Bucket cylinder extending Boom cylinder retracting Bucket cylinder retracting Boom cylinder extending

Disassembling the Joystick

Joystick Pilot Valve Overview

NOTICE:These steps apply to both the right Exit 2

and left joystick.

Tank

1. Remove the pilot conrol valve.

Exit 3

2. Disconnect all ports.

3. Remove the fixing pin from the joystick base.

See Figure 3-175.

Exit 1 Remove the fixing pin from the joystick base

Exit 4

Pump

Figure 3-174 Joystick Port Positions Left Joystick Ports Exit 1 Exit 2 Exit 3 Exit 4

Swing motor left Dipper arm cylinder retracting Swing motor right Dipper arm cylinder extending

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Figure 3-175 Fixing Pin 155

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4. Remove handle. See Figure 3-175.

8. Rinse the pilot valve in an alkane-based kerosene oil. See Figure 3-178.

501

9. Install blind plugs into all ports.

WARNING ITEMS UNDER TENSION: Return spring (221), plate (151) and push rod (212) are under tension when joint (301) loosens. Be sure that these parts do not launch from the unit, because this may cause damage and/or serious injury. Wear eye protection.

Figure 3-176 Remove Bellow 5. Secure the pilot valve into a vice as shown. See Figure 3-176.

6. Remove the joystick bellow (501). See Figure 3-176.

301

IMPORTANT:Do not damage the bellows.

312

Figure 3-179 Removing the Joint

302

10. Attach socket to universal joint M14 (301). See Figure 3-179.

Figure 3-177 Adjustment Nut and Disc 7. Using a spanner wrench, loosen and remove adjustment nut M14 (312) and disc (302). See Figure 3-177.

Figure 3-180 Rotating the Socket 11. Using a wrench, rotate the socket to remove universal joint M14 (301) as shown. See Figure 3-180.

Figure 3-178 Pilot Valve 909768/BP1207

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151 211

221 212

Figure 3-181 Removing the Plate

Figure 3-183 Removing the Push Rod

12. Remove plate (151). See Figure 3-181.

14. Remove push rods (212), plugs (211), reduction valve assembly and return springs (221) from casing (101). See Figure 3-183.

WARNING ITEMS UNDER TENSION: Return spring (221) releases when removing plug (211). Be sure spring (221) does not launch from the unit, because this may cause damage and/or serious injury. Wear eye protection.

15. Write down the correct order and retain these parts in the correct order for re-installing the parts into casing (101).

125 111

125

Figure 3-184 Removing the Hexagon Bolts 16. If necessary, re-secure the pilot valve into the vice so that port plate (111) is positioned at the top, as shown. See Figure 3-184.

Figure 3-182 Releasing the Friction

17. Using an Allen wrench, loosen hexagon bolts M8 (125) as shown. See Figure 3-184.

13. When return spring (221) is weak, plug (211) is held into casing (101) by O-ring friction.

Release the friction using a screwdriver as shown.

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216

241

201

131 111 101 217

122

Figure 3-185 Removing the Port Plate

Figure 3-187 Spool and Spring Seating

18. Remove port plate (111) and O-ring (122) from casing (101). See Figure 3-185.

22. Disassemble spool (201), spring seating (216), secondary pressure spring (241) and washer #2 (217) as shown. See Figure 3-187.

19. Remove bushing (131) from casing (101). See Figure 3-185.

IMPORTANT:The surface of spool (201) and spring (216) can be damaged because of mishandling. Do not damage the surface of spool (201) while removing spool (201) and do not push spring (216) seating downward more than 0.2” (6 mm).

23. Retain spool (201), spring seating (216), secondary pressure spring (241) and washer #2 (217) in the order of disassembly for reassembly. See Figure 3-187.

212 218

201

246

Figure 3-188 Secondary Spring 241

Figure 3-186 Reduction Valve

24. Remove secondary spring (246) and spring seating (218) from push rod (212). See Figure 3-188.

20. Disassemble the reduction valve by pressing downward on spring seating (216) and flexing secondary pressure spring (241).

21. Slide spring seating (216) sideways, and remove it from spool (201) through the larger opening. See Figure 3-186.

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HYDRAULIC SYSTEM Be sure to carefully monitor the quality of the alkane-based kerosene oil (or similar cleaning fluid).

211 212

IMPORTANT:Dirty alkane-based kerosene oil can damage the parts, and cause a deterioration in performance after reassembly.

6. Place the parts into the “finish wash” container.

7. Rotate the container slowly until even the inner areas of the parts are clean.

8. Remove the parts from the finish wash container.

Figure 3-189 Push Rod 25. Remove push-rod (212) from plug (211). See Figure 3-189.

9. Using a clean cloth, wipe any remaining alkane-based kerosene oil (or similar cleaning fluid) off of the parts.

10. Using the other clean cloth, dry the parts.

211

IMPORTANT:Do not use compressed air for drying the parts because dust and moisture in the compressed air may damage the parts and cause corrosion.

IMPORTANT:Be sure to dry the parts imme-

214

Figure 3-190 O-ring

diately after cleaning and do not leave them un-dried and standing because they may begin to corrode and performance after reassembly will be impaired.

26. Remove O-ring (214) from plug (211). See Figure 3-190.

Preventing Part Corrosion

27. Using a small screwdriver, remove seal (213) from plug (211).

1. Coat the parts with an anti-corrosion spray, according to the manufacturer’s specifications.

Cleaning the Parts 1. Obtain two containers large enough to submerge each individual part and two clean cloths. The “finish wash” container is rotated in step 7.

2. Fill both containers with alkane-based kerosene oil (or similar cleaning fluid).

3. Wash all parts in one of the containers.

4. Reduce the risk of damaging dirty parts covered with dirt and oil by submerging and soaking the individual parts thoroughly until the dirt and oil float to the cleaning fluid surface.

5. Replace the alkane-based kerosene oil (or similar cleaning fluid) if it becomes visibly dirty.

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Assembling the Joystick

3. Write down the fitting position so that spring pin (126) can be inserted into the casing opening.

111

4. Tighten hexagon bolt M8 (125) to tightening torque 15.2±1.1 lb.-ft. (20.6±1.5 Nm). See Figure 3-193.

131

IMPORTANT:The surface of spool (201) and 101

122

Figure 3-191 Casing

spring (216) can be damaged because of mishandling. Do not damage the surface of spool (201) while removing spool (201) and do not push spring (216) seating downward more than 1/4” (6 mm).

1. Install bushing (131) and O-ring (122) into casing (101). See Figure 3-191.

216

217

241

201

125

Figure 3-194 Spool and Spring Seating 111

Figure 3-192 Hexagon Bolt

NOTICE:Steps 5-7 must be installed in order.

5. Install washer #2 (217) onto spool (201). See Figure 3-194.

6. Install secondary spring (241) onto spool (201). See Figure 3-194.

7. Install spring seating (216) onto spool (201).

See Figure 3-194.

111

Figure 3-193 Hexagon Bolt 2. Install port plate (111) onto casing (101) using hexagon bolts M8 (125) and seal washers (121). See Figure 3-192 and Figure 3-193.

IMPORTANT:Replace seal washers (121) with new seal washers (121).

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HYDRAULIC SYSTEM 214

221

Figure 3-195 Spool

Figure 3-197 O-ring

8. Press down spring seating (216) to flex the secondary pressure spring (241). At the same time, slide spring (241) sideways through the larger opening to attach it to spool (201). See Figure 3-195.

10. Install O-ring (214) onto plug (221). See Figure 3-197.

211 213

221

101

Figure 3-198 Seal 11. Insert seal (213) into plug (211) as shown. See Figure 3-198.

Figure 3-196 Return Spring 9. Install return spring (221) into casing (101).

Do not press the spring seating down more than 1/4” (6 mm). See Figure 3-196.

211 212

NOTICE:Follow the installation sequence written down during step 15 of “Disassembling the Joystick” on page 155 when installing the reduction valve assembly, steps 10-16, into casing (101).

Figure 3-199 Push Rod 12. Install push-rod (212) into plug (211). See Figure 3-199.

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212 246

218 101

Figure 3-200 Secondary Spring

Figure 3-202 Plug Assembly

13. Install secondary spring (246) and spring seating (218) into push-rod (212). See Figure 3200.

15. Install the plug assembly into casing (101) as shown. See Figure 3-202.

301

221

151

Figure 3-203 Return Springs Figure 3-201 Push Rod 14. Apply hydraulic oil to the surface of push-rod (212). See Figure 3-201.

WARNING

16. Insert all return spring (221) simultaneously using plate (151) and temporarily secure them using universal joint M14 (301). See Figure 3203.

17. Secure plate (151).

ITEMS UNDER TENSION: Plug assembly and plate (151) must be assembled against spring tension. Be sure spring (221) does not launch from the unit, because this may cause damage and/or serious injury.

301

CAUTION ITEMS UNDER TENSION: The surface of spool (201) and casing (101) can be damaged because of mishandling. Do not damage spool (201) or casing (101) during assembly.

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Figure 3-204 Universal Joint 18. Attach socket to universal joint M14 (301). See Figure 3-204.

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312

302

Figure 3-205 Rotating the Socket 19. Using a wrench, rotate the socket to tighten universal joint M14 (301) onto casing (101) to tightening torque 34.7±2.1 lb.-ft. (47.1±2.9 Nm).

Figure 3-207 Adjustment Nut 22. Install adjustment nut M14 (312). See Figure 3-207.

20. Be sure that all four push-rods (212) are in contact equally.

23. Using a spanner wrench, tighten disc (302).

See Figure 3-207.

IMPORTANT:Excessive tightening or wrong positioning of the disc can cause the valve to malfunction.

301

24. Tighten adjustment nut M14 (312) to tightening torque 50.7±3.6 lb.-ft. (68.8±4.9 Nm). See Figure 3-207.

302

IMPORTANT:Do not allow the position of disc (302) to shift while tightening adjustment nut M14 (312).

Figure 3-206 Disc 21. Install disc (302) onto universal joint M14 (301). See Figure 3-206.

Figure 3-208 Apply Grease 25. Apply grease to the rotating component of universal joint M14 (301) and the end of push-rod (212). See Figure 3-208.

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501

Figure 3-209 Bellows 26. Install bellows (501) as shown. See Figure 3209.

IMPORTANT:Be sure not to damage the bellows.

27. Coat each port with an anti-corrosion spray, according to the manufacturer’s specifications.

28. Insert the blind plugs.

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Joystick Tightening Torque

Figure 3-210 Joystick Tightening Torque No. 125 301 312

Screw Size M8 M14 M14

Tightening Torque 15.2±1.1 Lb.-Ft. (20.6±1.5 Nm) 34.7±2.1 Lb.-Ft. (47.1±2.9 Nm) 50.7±3.6 Lb.-Ft. (68.8±4.9 Nm)

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Hydraulic Pedals

Return spring (335) presses spool (301) against push rod (214).

General Information

Tilting the control handle presses down push rod (214) and spring seat (311), changing the setting of the secondary pressure setting spring (324).

The PVD6P valve is a remote control pressure reduction valve equipped with a shock absorber. A set of four pressure reduction valves, used for controlling the secondary pressure, are installed in a single valve casing.

Port P, oil inlet (primary pressure) and port T outlet (tank) are in casing (101).

Moving the control lever adjusts the output pressure. The control lever valve casing contains a damping component to prevent engine rpm fluctuation.

Specifications Primary pressure Secondary pressure Permissible back pressure Nominal flow Control angles Weight Piping

Maximum pressure 994 psi (69 bar) 0~638 psi (0~44 bar) (maximum control pressure) Maximum 435 psi (30 bar)

3 gpm (10 L/min) ±10°, ±12.4° (single) 9 lbs. (4 kg) Use a supply pipe approximately 8mm internal diameter and a maximum of 10 ft. (3 m) in length. Return oil should flow directly into the tank to avoid back-pressure.

Structure The remote control valve structure is shown in the assembly cross-section. See Figure 3-212. The reduction valves are inserted into the vertical axial hole in the casing.

1 2 3 4 5 6

Spool (301) Secondary pressure setting spring (324) Return spring (335) Spring seating (311) Push rod (214) Plug (202)

Secondary pressure setting spring (324) calculates secondary pressure as 73~145 psi (500~1000 kPa).

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Pilot Control Pedals: Control Valve for Auxiliary Hydraulics

Figure 3-211 Pedal with Damping Function (driving) 520 473 431 472 501 413 214 210 202 224 336 218 311 217 313 251 261

Printed in U.S.A

301 101 420 471 203 201 271 212 102 225 211 324 335 522 414 213 252

Pedal Screw pedal Block Fixing screw Dust cover Shaft Piston rod Packing Bushing Piston Spring Spring washer Washer Washer Washer Plug O-ring

167

Spool Housing Block Ball Lubrication drain Assembling housing Hexagon socket bolt O-ring Casing (shock absorber) Ball O-ring Spring Spring Screw Bushing O-ring Ball

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Figure 3-212 Pedal Assembly 909768/BP1207

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Connection Ports, Driving Pedals 3

4

T

1

2

P

Figure 3-213 Connection Ports 1 2 3 4

Left drive motor rearward Left drive motor forward Right drive motor forward Right drive motor rearward

Pilot Control Pedals - Auxiliary Hydraulics, Dozer Blade

Figure 3-214 Pilot Control Pedal Structure Printed in U.S.A

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Figure 3-215 Pilot Valve Assembly

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Port Connection - Dozer Blade Pedal

Disassembling the Pilot Control Pedal 1. Rinse the remote control valve in an alkanebased kerosene oil (or similar cleaning fluid).

T

2. Place blind plugs into all ports.

3. Secure the remote control valve into a vice.

501 201

P

Lift (1)

Drop (2)

Figure 3-218 Pilot Control Pedal

Figure 3-216 Dozer Blade Pedal - Port Connection

4. Remove bellows (501) from cover (201) as shown. See Figure 3-218.

Port Connection - Auxiliary Hydraulics T 472

Figure 3-219 Hexagon Socket Screw 5. Loosen hexagonal socket screw (472) using an Allen wrench. See Figure 3-219.

P 2

NOTICE:Adhesive (Loctite #241 or equiva-

1

lent) has been applied and the loosening torque is high. The loosening torque varies depending upon how the loctite cleaves.

Figure 3-217 Auxiliary Hydraulics - Port Connection

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413

271

Figure 3-220 Shaft

Figure 3-222 Hexagon Socket Bolt

6. Apply a round rod (0.3” [7 mm] or smaller) to one end of camshaft (413) and tap lightly with a hammer to remove. See Figure 3-220.

9. Loosen hexagon socket bolt (271) using an Allen wrench. See Figure 3-222.

201

420 201

Figure 3-223 Cover Figure 3-221 Block 7. Remove block (420). Only remove block (420) and steel ball (471) assembled (do not disassemble). See Figure 3-221.

10. Remove cover (201). See Figure 3-223.

11. Write down the positions of cover (201) and casing (shock absorber) (102) (O-ring friction retains the plug in the casing).

8. Write down block (420) and cover (201) positions. See Figure 3-221.

WARNING ITEMS UNDER TENSION: Be sure push rod (214) does not launch from the unit, because this may cause damage and/or serious injury.

Figure 3-224 Upper Casing Assembly 12. Remove upper casing assembly and install it into the vice. See Figure 3-224 and Figure 3225.

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HYDRAULIC SYSTEM 17. Write down the plug (202) and casing (102) positions.

13. Write down the positions of casing (shock absorber) (102) and casing (101).

IMPORTANT:The surface of push rod (214) can be damaged because of mishandling. Do not damage the surface of the push rod during removal.

224

214

Figure 3-227 Piston 202

18. Remove piston (224). See Figure 3-227.

19. Write down the positions of piston (224) and casing opening.

Figure 3-225 Push Rod 14. Remove push rod (214) from plug (202). See Figure 3-225.

15. Write down the positions of the plug and push rod. Do not damage the surface of the pushrod.

336

WARNING

102

ITEMS UNDER TENSION: When the plug is removed, be sure piston (224) does not launch from spring (336), because this may cause damage and/or serious injury.

Figure 3-228 Spring 20. Remove spring (336) from casing (102) as shown. See Figure 3-228.

21. Write down the positions of spring (336) and casing opening.

202

Figure 3-226 Plug 16. Remove plug (202) with grease cap (203), packing (210) and O-ring (212) attached.

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ME12002 25. Secure the lower casing assembly into a vice and remove O-rings (211, 213) from casing (101). See Figure 3-231.

218 102

335

Figure 3-229 Spring Washer 22. Remove and retain spring washer (218) from casing (102) using tweezers as shown. See Figure 3-229.

23. Write down the positions of spring washer (218) and casing opening.

101

Figure 3-232 Return Spring 26. Remove pressure reduction valve assembly and return spring (335) from casing (101) as shown. See Figure 3-232.

27. Write down the positions of spring (335) and casing opening.

225

201

Figure 3-230 Steel Ball 24. Remove and retain steel ball (225) from casing (102) using a magnet as shown. See Figure 3230.

IMPORTANT:Do not lose the steel ball.

414

Figure 3-233 Cover 28. Place cover (201) onto a level work surface.

See Figure 3-233.

29. Apply socket onto bushing (414) and tap with a hammer to remove bushing (414) as shown.

See Figure 3-233.

211

213

101

Figure 3-231 O-rings

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HYDRAULIC SYSTEM depending upon the spool assembly. In some cases, no washer is used.

203

311

202

Figure 3-234 Pressure Reduction Valve 30. Complete the following steps to disassemble the pressure reduction valve:

Figure 3-236 Grease Cap and Plug

a. Pressing in spring washer (311). See Figure 3-234.

32. Remove grease cap (203) from plug (202) as shown. See Figure 3-236.

b. Sliding spring washer (311) sideways. See Figure 3-234. c. Bending secondary pressure spring (324).

See Figure 3-234. d. Removing spool (301) from the larger hole of spring washer (311) as shown. See Figure 3-234. e. Retaining parts removed during steps a-d until re-assembly. See Figure 3-234.

Figure 3-237 Plug 217

324

313

33. Using a small, straight screwdriver, remove packing (210) from plug (202). See Figure 3237.

IMPORTANT:Do not damage the inner surface of the plug.

301

Figure 3-235 Spool, Spring, Shim, and Washer 31. Disassemble spool (301), secondary pressure setting spring (324), shim (217) and washer (313) as shown. Retain these parts until reassembly. See Figure 3-235.

NOTICE:Washer (313) sets the secondary pressure spring, and thicknesses vary

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ME12002 spring washer downward more than 0.2” (4 mm).

212

311

212

Figure 3-238 O-ring and plug 34. Remove O-ring (212) from plug (202). See Figure 3-238.

Assembling the Pilot Control Pedal

217

324

313

301

Figure 3-240 Spool and Spring Washer 5. Push spool (301) through the larger hole of spring washer (311). Assemble by sliding the spring washer sideways while bending the secondary pressure setting spring (324). See Figure 3-240.

335 301

Figure 3-239 Spool

NOTICE:Steps 1-4 must be installed in order.

1. Install washer (313) onto spool (301). See Figure 3-239.

2. Install shim (217) onto spool (301). See Figure 3-239.

3. Install secondary pressure setting spring (324) onto spool (301). See Figure 3-239.

101

Figure 3-241 Casing and Return Spring 6. Install casing (101) into a vice. Install return spring (335) into casing (101), in the same order as written down during step 27 of “Disassembling the Pilot Control Pedal” on page 171. See Figure 3-241.

4. Install spring washer onto spool (301). See Figure 3-239.

NOTICE:Washer (313) sets the secondary pressure spring, and thicknesses vary depending upon the spool assembly. In some cases, no washer is used.

IMPORTANT:The surface of spool (301) can be damaged by mishandling. Do not damage the surface of spool (301). Do not push the

101

Figure 3-242 Pressure Reduction Valve 909768/BP1207

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7. Install the pressure reduction valve sub-assembly, assembled during steps 1 through 6, into casing (101), in the same position as written down during step 27 of “Disassembling the Pilot Control Pedal” on page 171. See Figure 3-242.

218

IMPORTANT:Do not damage the lower end

102

of the spool by hitting the lower end of the spool against the casing edge when installing the pressure reduction valve subassembly.

Figure 3-245 Washer 10. Install spring washer (218) into casing (102), using a tweezers as shown, and in the same position as written down during step 23 of “Disassembling the Pilot Control Pedal” on page 171. See Figure 3-245.

213 211

101

336

Figure 3-243 O-rings 8. Install O-rings (211, 213) into casing (101).

See Figure 3-243.

102

Figure 3-246 Spring 225

102

11. Install spring (336) into casing (102) as shown, and in the same position as written down during step 21 of “Disassembling the Pilot Control Pedal” on page 171.

IMPORTANT:Do not damage spring washer (218) during installation.

Figure 3-244 Steel Ball 9. Install upper casing (102) into a vice and install steel ball (225). See Figure 3-244.

224 102

Figure 3-247 Piston Printed in U.S.A

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HYDRAULIC SYSTEM 12. Install piston (224) into casing (102) as shown, and in the same position as written down during step 19 of “Disassembling the Pilot Control Pedal” on page 171.

ME12002 16. Install grease cap (203) into plug (202). See Figure 3-250.

214

202

202

212

Figure 3-248 O-ring

Figure 3-251 Push Rod

13. Install O-ring (212) onto plug (202) as shown.

See Figure 3-248.

17. Install push rod (214) into plug (202). Apply working oil to surfaces before fitting push rod.

There is a risk of damage to the rib part of packing (210); do not use excessive force when fitting. See Figure 3-251.

14. Apply a light coating of grease to packing (210).

210

202 102

Figure 3-249 Packing

Figure 3-252 Push Rod

15. Install packing (210) into plug (202) as shown.

See Figure 3-249.

18. Install the push rod subassembly into casing (102).

NOTICE:Be sure that packing (210) is in the correct orientation prior to installation. See Figure 3-249.

201

414 203

202

Figure 3-250 Grease Cap and Plug 909768/BP1207

Figure 3-253 Bushing 19. Position cover (201) onto a level work surface.

See Figure 3-253.

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20. Position a socket onto bushing (414) and lightly tap it with a hammer until it is installed.

See Figure 3-253.

NOTICE:Be sure that bushing (414) does not dislodge inside cover (201).

271

Figure 3-256 Hexagon Socket Bolt 23. Tighten hexagon socket bolt (271) to the specified torque. See Figure 3-256.

NOTICE:Be sure that damping spring (336) does not lift cover (201).

Figure 3-254 Lower Cover Assembly

420

21. Secure the lower cover assembly into a vice as shown. See Figure 3-254.

201

201

413

Figure 3-257 Block and Cover 24. Assemble block (420) onto cover (201), and in the same position as written down during step 8 of “Disassembling the Pilot Control Pedal” on page 171. See Figure 3-257.

102

Figure 3-255 Cover and Casing

25. Manually press downward onto block (420) and insert camshaft (413) as shown. See Figure 3-257.

22. Assemble cover (201) onto casing (102). See Figure 3-255.

NOTICE:Be sure that the parts are assem-

26. Apply grease to the bearing parts of camshaft (413).

bled in the same position as written down during step 11 of “Disassembling the Pilot Control Pedal” on page 171.

NOTICE:Be sure that damping spring (336) does not lift cover (201).

472

Figure 3-258 Hexagon Socket Screws Printed in U.S.A

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HYDRAULIC SYSTEM 27. Apply adhesive (Loctite #241 or equivalent) to the surfaces of hexagon socket screws (472) as shown. See Figure 3-258.

ME12002 30. Install the top of bellows (501) into block (420). See Figure 3-261.

472

Figure 3-262 Bellows Figure 3-259 Hexagon Socket Screw 28. Tighten hexagon socket screw (472) to the specified torque. See Figure 3-259.

31. Apply anticorrosion oil (WD-40 or equivalent) inside of bellows (501). See Figure 3-262.

32. Install the bottom of bellows (501) into the groove in cover (201). See Figure 3-261.

IMPORTANT:If the bellows are not tightly

420

installed into the groove (and are loose), bellows resistance to dust and water decreases.

No. 125 301 312

Figure 3-260 Push Rod

Screw size Tightening torque 15.2±1.1 Lb.-Ft. M8 (20.6±1.5 Nm) 34.7±2.1 Lb.-Ft. M14 (47.1±2.9 Nm) 50.7±3.6 Lb.-Ft. M14 (68.8±4.9 Nm)

29. Tilt block (420), apply grease to the top of push rod (214) and inject grease into grease cap (203) of plug (202) as shown. See Figure 3-260.

IMPORTANT:Apply and inject grease using a spatula made of soft material. Do not damage the push rod and plug surfaces.

501

201

Figure 3-261 Bellows and Cover 909768/BP1207

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Hydraulic System Components Pilot Oil Supply Unit

T

P

C

P2

B

A

P1

Figure 3-263 Port Connections T P P1 P2 A B C

Tank line Pump supply hose <- gear pump Port drive counter balancing -> main valve block Swing unit - park brake 2nd drive speed - drive unit Microswitch/safety valve/joysticks Oil flow limitation switch P1 u. P2

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ME12002

Hydraulic Diagram

Figure 3-264 Hydraulic Diagram

Side Valve Block Functions: Dozer blade, boom offset.

2 (AP)

P

T1

3

A1

P

T1

1

A1

B1

A2

B2

B1

B2

A1

4

TT

Figure 3-265 Side Valve Block

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ME12002 1 2 3 4 A1 A2 B1 B2 P T1 TT

HYDRAULIC SYSTEM Shuttle Valve Block

Section dozer blade Primary pressure limiting valve 4931 psi (340 bar) Secondary pressure limiting valve dozer blade cylinder bottom side 4351 psi (300 bar) Section boom offset cylinder Port dozer blade cylinder rod side Port boom offset cylinder rod side Port dozer blade cylinder bottom side Port boom offset cylinder bottom side Pressure line from the main valve block Tank line Tightening torque = 13 Lb.-Ft. (18 Nm)

Functions: •

Control signal to regulate the pump (NC) (by the summation segment of section dipper arm/NC Valve).

•

Control signal to valve e1 for function drive counter-balancing.

1

2

3

4

5

Figure 3-266 Pilot Pressure Hose a1 a2 b1 b2

Pilot pressure hose Pilot pressure hose Pilot pressure hose Pilot pressure hose

Figure 3-267 Shuttle Valve Block 1 2 3 4 5

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Control signal (to section dipper arm summation and valve e1).

Pilot pressure hose dozer blade cylinder bottom side.

Pilot pressure hose dozer blade cylinder rod side.

Pilot pressure hose boom offset cylinder rod side.

Pilot pressure hose boom offset cylinder bottom side.

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ME12002

Switch Valve Functions: Switch between function auxiliary hydraulics/boom offset cylinder.

Features: Electric piloting by the left joystick (7/2 way valve).

Not supplied working ports, go to tank.

Electric solenoid (bL2) D

B

F (b2)

A

E (a2)

(aL2) C

Tank

Figure 3-268 Port Positions A B C D E F

Pilot control valve foot pedal Pilot control valve foot pedal (aL2) Main valve block section auxiliary hydraulics (bL2) Main valve block section auxiliary hydraulics (a2) Side valve block section boom offset cylinder (b2) Side valve block section boom offset cylinder

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Load Lowering Valve Function: Counterbalanced valve, preventing pulling forces, moves the boom offset cylinder out of its fixed position.

Features: The pressure limiting valves setting is higher than the system pressure.

Pressure from the opposite valve operates the valves.

C1

Second pressure limiting valve

C2

Second pressure limiting valve

V2

V1

Figure 3-269 Assembling Situation Load Lowering Valve (view from above) C2

C1

V2

V1

Figure 3-270 Load Lowering Valve V1 V2 C1 C2

Port from the side valve block (A2) Port from the side valve block (B2) Port from boom offset cylinder rod side Port from boom offset cylinder bottom side

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Hydraulic Oil Tank Breather Filter The breather filter: •

Forces air in and out of the tank, varying the oil level and pressurizing the hydraulic oil tank.

•

Protects the oil tank against swelling.

•

Pressurizes the oil tank to the defined overpressure value. Write down the overpressure value.

•

Supports variable displacment pump intake, initial pressure: 5.8 psi (0.4 bar).

•

Filters intake air.

Filter cloth

Breathing valve

Figure 3-271 Breathing Filter (Hydraulic Tank)

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HYDRAULIC SYSTEM

Driving Unit

Shock Valves

Leak oil drain

PR (PF) Pilot oil supply unit

Hydraulic brake piston

A

Driving motors ports

B

Figure 3-272 Driving Motors Ports Shock valves

Leak oil drain (always use the top port)

A , B Ports

Port 2nd drive speed

Figure 3-273 Shock Valve Ports Printed in U.S.A

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Swing Motor (Swivel Unit) Hydraulic Diagram

SH

V2 V1

Leak oil drain

PG Anti swing back valve

Shock suction valves Tank line Main valve block B

A

Figure 3-274 Swing Motor (Swivel Unit) Hydraulic Diagram Description Axial-piston motor with integrated mechanical brake-disc.

The brake closes slowly (approximately 4 seconds).

Open Brake Pilot control pressure (signal SH from the main valve bank) opens valve V1; brake opens against the spring force.

Close Brake Signal pressure from the main valve bank is off; Valve V1 is closed and the oil from the brake chamber returns through the throttle valve of the pressure control valve.

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Swing Motor Structure

Figure 3-275 Swing Motor Structure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26

Tapered roller bearing Locking ring Needle bearing Plate Steel disk O-ring O-ring O-ring Control disk Control channel Spring Bushing Teflon ring Brake piston springs Brake piston Cylinder drum Locking ring Piston Piston centering plate Sliding disk Housing Spacing sleeve Shaft seal Screws Bypass valve

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27 28 29 30 31 32 33 34 35 36 37

189

Thrust ring O-ring Screws A - B ports Valve seat Poppet valve Spring Shock valve Housing Housing Release brake valve

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HYDRAULIC SYSTEM Disassembling the Swing Motor

ME12002 Removing the Cover Assembly

Figure 3-276 Swing Motor Removing the Relief Valve, and Time Delay Valve 1. Using a 27 mm wrench, remove bypass valve (26). See Figure 3-276.

2. Using a 5 mm hexagon wrench, loosen the hexagon socket bolt and remove release brake valve (37).

Marking the Swing Motor 1. Before disassembling the swing motor, make a matching mark between A - B ports (30) and housing (22). This assists during reassembly.

See Figure 3-277.

Figure 3-277 Cover Assembly and Balance Plate 1. Using a 10 mm hexagon wrench, loosen hexagon socket bolt (29). See Figure 3-277.

2. Position the motor assembly shaft downward and remove A - B ports (30). See Figure 3-277.

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Removing the Balance Plate 1. Using a steel pointer, remove locking ring (2), remove the inner-race plate of needle bearing (3) and control disk (9). See Figure 3-277.

2. Work carefully to avoid damaging the sliding face of control disk (9). See Figure 3-277.

3. Before removing, write down the location of control disk (9) for correct assembling. See Figure 3-277.

Figure 3-279 Brake Piston 6. Remove brake piston springs (14). See Figure 3-279.

7. Remove brake piston springs (14) from brake piston (15). See Figure 3-279.

8. Write down the position of each spring for correct assembling.

Removing the Brake Piston 1. When removing brake piston (15) from housing (22), there is a sliding resistance against tightening O-rings (6, 7). See Figure 3-279.

Figure 3-278 O-ring and Teflon Ring

2. Use tap holes (M6) to remove brake piston (15) as shown. See Figure 3-279.

4. Remove O-ring (8) from A - B ports (30). See Figure 3-278.

3. Remove O-rings (6, 7) from housing (22) and brake piston (15). See Figure 3-279.

5. Remove bushing (12), Teflon rings (13) and spring (11). See Figure 3-278.

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ME12002 Removing the Cylinder Assembly 1. Remove cylinder drum (16) from housing (22).

See Figure 3-280.

IMPORTANT:The end surface (A) of cylinder drum (16) is a sliding face. Protect the surface when removing cylinder drum (16) by using a soft cloth. See Figure 3-280.

NOTICE:Shaft seal (24) and outer-race plate of tapered roller bearing (1) are left inside of housing (22). See Figure 3-280.

2. Make a matching mark on piston hole of cylinder (16) and piston assembly (18) to fit the piston into the same hole when reassembling. See Figure 3-280.

Figure 3-280 Housing, Brake Piston, Cylinder Assembly 4. Remove plate (4) and steel disk (5) from housing (22). See Figure 3-280.

Figure 3-281 Housing 3. Remove outer-race plate of tapered roller bearing (1) from housing (22). See Figure 3-281.

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4. Using a driver and a hammer, remove shaft seal (24) from housing (22). See Figure 3-281.

5. Remove sliding disk (20) from piston (18). See Figure 3-282.

IMPORTANT:Do not reuse shaft seal (24)

IMPORTANT:Be sure to avoid damaging the

after removing it.

sliding face of sliding disk (20).

Disassembling the Cylinder 1. Remove the inner-race plate from tapered roller bearing (1). See Figure 3-281.

2. Set a gear extractor at two places of the innerrace plate of the tapered roller bearing and the spline end of the cylinder drum (16).

3. Remove the inner-race plate of tapered roller bearing (1). See Figure 3-281.

Figure 3-283 Locking Ring 6. Remove locking ring (17) from cylinder (16).

See Figure 3-283.

Figure 3-282 Piston 4. Remove sliding disk (20), piston (18) and piston centering plate (19) from cylinder drum (16). See Figure 3-282.

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HYDRAULIC SYSTEM Assembling the Swing Motor

ME12002 General Information 1. Check each part for damage caused by either use or disassembly.

2. If parts are scratched, remove scratches by rubbing with sandpaper of “fine” coarseness.

3. Clean each part with fresh cleaning oil and dry with an airjet.

4. Replace all seals.

5. Position piston (18), control disk (9), and sliding disk (20) onto a level work area.

6. Rub the sliding face of piston (18), control disk (9), and sliding disk (20) with sandpaper #2000 grit. See Figure 3-284.

7. When assembling, lubricate the sliding parts with specified clean hydraulic oil.

8. When assembling piston (18) into piston hole of cylinder drum (16), make sure to install each piston into the same hole it occupied before disassembly.

Figure 3-284 Piston

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HYDRAULIC SYSTEM

Assembling the Cylinder

1. Lubricate grease on round area (contacting area with the locking ring [17]) of cylinder drum (16) and assemble locking ring (17). See Figure 3-285.

2. Install piston (18) into piston centering plate (19). See Figure 3-285.

3. Lubricate the inside of each piston cylinder using hydraulic oil. See “Hydraulic System” on page 30. See Figure 3-285.

Figure 3-286 Piston and Cylinder Drum

IMPORTANT:The end surface (A) of cylinder drum (16) is a sliding face. Protect the surface when installing cylinder drum (16) by using a soft cloth. See Figure 3-280.

4. Install piston (18) and return plate (19) onto cylinder drum (16). Assemble cylinder drum (16) and piston (18) according to the marks made in step 2 of “Removing the Cylinder Assembly” on page 192. See Figure 3-285 and Figure 3-286.

5. Lubricate specified hydraulic oil on the shoe sliding face of piston (18) and assemble sliding disk (20).

Figure 3-285 Cylinder Assembly Printed in U.S.A

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Figure 3-287 Cylinder Drum 6. Install inner-race plate of taper roller bearing (1) into cylinder drum (16). See Figure 3-287.

Figure 3-288 Cylinder Drum and Housing 7. Lightly apply adhesive (Loctite 515, 518 or equivalent) to bearing mounting area of the inner-race plate of cylinder drum (16). See Figure 3-288.

8. Install spacing sleeve (23) onto cylinder drum (16). See Figure 3-288.

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HYDRAULIC SYSTEM 1. Secure pads with height 30-50 mm under the bottom of housing (22). When installing cylinder drum (16), the shaft from cylinder drum (16) extends beyond the end of housing (22).

Installing the Oil Seal

1. Apply three bond (kk\1211” - white color) on outer surface of shaft seal (24). See Figure 3288.

2. Lubricate shaft seal (24) with grease. See Figure 3-288.

2. Using seal press insertion socket, secure shaft seal (24) into housing (22). See Figure 3-288.

3. Carefully install cylinder drum (16) into housing (22). See Figure 3-290.

IMPORTANT:Do not damage shaft seal (24) when installing the shaft of cylinder drum (16).

4. Check that locking ring (17) is held in place by the probe portion of piston centering plate (19).

5. Check that the end surface of cylinder drum (16) is about 7.5 mm lower than the top of housing (22). See Figure 3-290.

Figure 3-289 Housing 3. Install outer-race plate of taper roller bearing (1) into housing (22). See Figure 3-289.

Installing the Cylinder Drum

Figure 3-291 Housing 6. Assemble lining plate (5) to friction plate (4).

Apply hydraulic oil to each side. See Figure 3291.

IMPORTANT:Be sure to assemble lining plate (5) to friction plate (4) in the correct sequence.

Figure 3-290 Cylinder Drum

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ME12002 recommended to manually push piston (15) horizontally.

Figure 3-292 Housing 7. Install O-ring (6) into housing (22). Install Oring (7) into piston (15). See Figure 3-292.

8. Lubricate O-ring (6) and O-ring (7) with grease. See Figure 3-292.

Assembling the Brake Piston

Figure 3-294 Springs 2. Install springs (14) into piston (15). See Figure 3-294.

NOTICE:Install springs (14) into position written down during step 8 of “Removing the Balance Plate” on page 191. See Figure 3-294.

Figure 3-293 Piston 1. Lubricate specified hydraulic oil onto the outer silding face of piston (15) and assemble the brake piston onto housing (22). See Figure 3293.

Figure 3-295 Cover

NOTICE:It is too tight to assemble piston (15) because O-rings (6,7) are fitted, therefore it is 909768/BP1207

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HYDRAULIC SYSTEM 6. Assemble O-ring (8) to A - B ports (30). See Figure 3-297.

3. Install spring (11) and bushing (12) with Teflon ring (13) into the bushing hole of A - B ports (30). See Figure 3-295.

7. Lubricate O-ring (8) with grease. See Figure 3297.

4. Install control disk (9) onto A - B ports (30).

See Figure 3-295.

NOTICE:Be sure control disk (9) is assembled in the correct direction. See step 3 of “Removing the Balance Plate” on page 191.

Figure 3-298 Fluid Packing 8. Apply white color fluid packing (kk\1211” white color) as shown. See Figure 3-298.

Figure 3-296 Needle Bearing and Locking Ring 5. Install the inner-race plate of needle bearing (3) and locking ring (2) onto A - B ports (30).

See Figure 3-296.

Figure 3-297 A - B Ports

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HYDRAULIC SYSTEM Assembling the Cover

ME12002 2. Using a 10 mm hexagon wrench, tighten screws (29), A - B ports (30) and housing (22) to tightening torque 76 lb.-ft. (103 Nm). See Figure 3-300.

Assembling the Relief Valve

Figure 3-301 Relief Valve

Figure 3-299 Cover 1. Assemble A - B ports (30) and control disk (9) to housing (22), line-up the matching marks made on housing (22) and A - B ports (30) before disassembling. See step 1 of “Marking the Swing Motor” on page 190.

1. Using a 27 mm wrench, install and tighten bypass valve (26) onto A - B ports (30) to tightening torque 29 lb.-ft. (39 Nm). See Figure 3-301.

NOTICE:Assemble bypass valve (26) to its original state when reassembling.

Checking Relief Valve Assembly

1. Open inlet and outlet port.

2. Load pilot brake release port pressure to 3-5 MPa (435-725 psi).

3. Check that output shaft is rotating smoothly with a torque of approximately 15-21 lb.-ft.

(20-29 Nm).

NOTICE:If output shaft is not rotating, disassemble and check.

4. Open the drain port.

5. Check that relief valves are set to regulation pressure.

Figure 3-300 A - B Ports

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HYDRAULIC SYSTEM NOTES

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ME12002 NOTES

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CHAPTER 4 JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) For specifcations, see “John Deere 4045TF270 and Yanmar 4TNE106T-NS Specifications” on page 9.

John Deere Engine Model 4045TF270 Overview Alternator Cylinder head cover

Fuel filter

Fuel injection pump

Turbocharger

Flywheel

Figure 4-1 John Deere Engine (Overview), Flywheel View Printed in U.S.A

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ME12002

Intake line

Flat belt

Fuel filter

Starter

Engine oil filter Fan wheel

Figure 4-2 John Deere Engine (Overview), Fan View

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP)

Fuel System Fuel filter

Fuel pump including manual pump

Return line

Tank

Water separator

Feed line

Figure 4-3 Fuel System

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) Servicing the Components Checking Valve Tip Clearance

7. Check rocker arms with the following valve tip clearances more thoroughly to detect any damaged parts: •

less than 0.36 mm for intake valve tip clearance, measured from rocker arm to valve tip.

•

less than 0.46 mm for exhaust valve tip clearance, measured from rocker arm to valve tip.

CAUTION Before completing these steps, disconnect the negative terminal battery cable to prevent the engine from accidentally starting while checking the valve tip clearance. Allow the engine to cool down before completing these steps.

ME12002

8. Replace any damaged parts.

NOTICE: Only check the valve clearance after the engine is cold.

1. Remove plug (B) from cylinder head cover (C). See Figure 4-4.

D

2. Remove the hexagon bolts with O-rings (A) from cylinder head cover (C). See Figure 4-4.

E

3. Remove cylinder head cover (C). See Figure 44.

4. Remove the crankcase breather tube.

B A

C

Figure 4-4 Remove Cylinder Head Cover 5. Check the contact surfaces of the valve tips and rocker arm for excessive wear, rupture, or cracks.

6. Replace any damaged parts.

Figure 4-5 Check and Adjust Valve Tip Clearance 9. Remove the plastic plugs/cover plate from the adjustment/rotation opening (D) and the engine adjustment pin opening (E). See Figure 4-5.

10. Use the JDE83 flywheel rotation tool (available directly from John Deere) to turn the flywheel in the direction of rotation (clockwise as seen from the front) until cylinder no. 1 is at the top dead center of the compression stroke.

The engine is at the top dead center of the compression stroke of cylinder no. 1 if the rocker arms of cylinder no. 1 can be moved. If the rocker arms of cylinder no. 1 cannot be moved, rotate the engine one full revolution (360°).

11. Insert the JDG1571 or JDE81-4 adjustment pin (available directly from John Deere) into the flywheel.

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP)

Setting Valve Tip Clearance D

Figure 4-7 Locknut Set Screw Torque to 20 lb.-ft. (27 Nm) 7. Tighten the rocker arm locknut set screw torque to 20 lb.-ft. (27 Nm) (D). See Figure 47.

Figure 4-6 Setting Valve Tip Clearance A

Front side of engine

B

Piston no. 1 at top dead center of compression stroke

Servicing the Cylinder Head

C

Piston no. 4 at top dead center of compression stroke

Removing the Cylinder Head

E

Exhaust valve

Removing the Cylinder Head Cover

I

Intake valve

CAUTION

NOTICE: The cylinder firing order is 1–3–4– 2.

Allow the engine and exhaust system to cool down before completing these steps.

1. Keep piston no. 1 in place at the top dead center of the compression stroke with the adjustment pin (B). See Figure 4-6.

2. Set the valve tip clearance (rocker arm to valve tip) to 0.46 mm on exhaust valves no. 1 and 3.

B

3. Set the valve tip clearance (rocker arm to valve tip) to 0.36 mm on intake valves no. 1 and 2.

C A

D

4. Rotate the crankshaft 360°. Keep piston no. 4 in place at the top dead center of the compression stroke (C). See Figure 4-6.

5. Set the valve tip clearance to 0.46 mm on exhaust valves no. 2 and 4.

Figure 4-8 Exhaust Elbow, Turbocharger and Cylinder Head Cover

6. Set the valve tip clearance to 0.36 mm on intake valves no. 3 and 4.

1. Drain the radiator coolant only after it has cooled down to below the operating temperature.

2. Remove the radiator cap only after it has cooled down so that you can touch it with your bare hands.

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) 3. Turn the radiator cap to the notch to release the pressure.

ME12002 E

4. Remove the radiator cap.

D

5. Remove exhaust elbow (A) at the air intake.

See Figure 4-8.

NOTICE: The cylinder head is removed more easily if you remove the turbocharger without removing the exhaust bracket.

6. Disconnect the oil outlet and intake lines (B) from turbocharger (C). See Figure 4-8.

7. Remove turbocharger (C) and exhaust elbow (A). See Figure 4-8.

Figure 4-10 Fuel Filter/Water Seperator

IMPORTANT:Always replace the cylinder

4. Remove fuel filter/water seperator (E) and the brackets if necessary. See Figure 4-10.

head cover gasket if the cylinder head cover is removed when overhauling the engine or cylinder head.

8. Remove and retain the hexagon nuts and Orings from the cylinder head cover (D).

Replace them if necessary. See Figure 4-8.

9. Remove the cylinder head cover (D). See Figure 4-8.

Removing the Fuel Lines, Fuel Filter/Water Separator A

C

3. Remove the fuel lines.

5. If installed, remove fuel pump (D). Check the front surface of the pump lever for wear.

Replace the fuel pump if the surface is flat or concaved due to wear. See Figure 4-10.

6. (Optional) Remove the alternator to ease the work.

7. Remove the tube that connects the thermostat housing with coolant pump (C). See Figure 49.

8. Remove fuel return line (F) and fuel feed lines (G) as a unit. See Figure 4-11.

9. Remove fuel injection nozzles (H). See Figure 4-11.

F

G

H B

Figure 4-9 Exhaust Bracket, Turbocharger and Oil Intake/Outlet Lines 1. Remove exhaust bracket (A) using the guide pins. See Figure 4-9.

2. Remove the thermostat housing/coolant supplier unit (B). See Figure 4-9.

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Figure 4-11 Fuel Return Lines, Fuel Feed Lines, Injection Nozzle

NOTICE: Loosen all rocker arm set screws before removing the unit.

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Removing the Cylinder Head 1. Remove the rocker arm unit. See Figure 4-12.

Figure 4-14 Remove all Push Rods 4. Clean and check the push rods.

5. Check the cylinder head bolts tightening torques.

Figure 4-12 Remove the Rocker Arm Unit 2. Remove the coolant temperature sensor connector line (A) from the fuel injection pump wiring harness. See Figure 4-13.

If the cylinder head gasket is damaged, check and write down the cylinder head bolts tightening torques.

A B

C

Figure 4-13 Remove the Coolant Temperature Sensor Connector

Figure 4-15 Mark on Spanner and Screw Head

3. Remove all push rods. Write down the position of each push rod and organize them so that they are re-installed into the same position. See Figure 4-14.

6. Mark the surface of screw head (B) and cylinder head (C). See Figure 4-15.

7. Loosen the hexagon bolt by 1/2 rotation. See Figure 4-15.

8. Using a torque wrench, tighten the hexagon bolt until the lines are aligned with each other and write down the torque. See Figure 4-15.

9. Remove and discard all cylinder head bolts.

IMPORTANT:Do not re-use cylinder head bolts.

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) IMPORTANT:NEVER use a screwdriver or a crowbar between the cylinder block and the cylinder head to loosen the cylinder head gasket. The screwdriver or crowbar can damage the sealing surfaces of the cylinder head and the engine block.

ME12002

5. Remove the rockers from the engine block.

Record the position of each rocker and organize them so that they are re-installed into the same position.

6. Wash the rockers with a solvent.

7. Apply clean engine oil to the rockers.

D

8. Re-install the rockers into the same engine block positions.

9. Check the top surface for evenness and usability.

Installing the Cylinder Head

A

Figure 4-16 Cylinder Head 10. Raise cylinder head (D) off of the block. If it is jammed, use a soft hammer to carefully apply soft blows to the cylinder head. See Figure 416.

Cleaning the Cylinder Head 1. Remove sealing materials, rust, carbon deposits, and other foreign materials from the top surface. The sealing surface must be clean.

2. Use a screw tap to clean the threaded bores in the cylinder block.

3. Use compressed air to remove residual material and fluids from the screw bores.

Figure 4-17 Installing the Cylinder Head 1. Dip the ends of fuel pump push rod (A) into clean engine oil. See Figure 4-17.

2. Carefully install fuel pump push rod (A) into the cylinder block. See Figure 4-17.

4. Use compressed air to remove all loose foreign materials from the cylinders and top surface.

B

NOTICE: Remove all residual material from the rockers before re-assembling the engine.

Figure 4-18 Insert Two Parallel Pins 3. If necessary, install two parallel pins (B) into the cylinder block positioning holes. See Figure 4-18.

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NOTICE: Always check the cylinder head

NOTICE: Only use new cylinder head bolts

gasket thoroughly for quality and usability.

with a collared head.

4. Place the new cylinder head gasket onto the cylinder head. Do not use any sealing compound: insert the seal as is (dry).

Tightening the Hexagon Bolts 1. Install and tighten all bolts to the specified tightening torques, follow the tightening order shown in Figure 4-20.

C

First tightening torque 74 lb.-ft. (100 Nm).

Second tightening torque 111 lb.-ft. (150 Nm).

After 5 minutes, check that the tightening torque is 111 lb.-ft. (150 Nm).

Turn Angle Method

1. Final angle of rotation, use JT05993 Torque Angle Gauge to tighten each bolt by a further 60°±10°. See Figure 4-21.

Figure 4-19 Guide Pin 5. Use guide pins (C) to align the cylinder head onto the engine block. See Figure 4-19.

IMPORTANT:If the cylinder head is shifted while positioned on the engine block, the cylinder head gasket can be damaged.

6. Place the cylinder head onto the guide pins and lower it onto the cylinder block. See Figure 419.

D

Figure 4-21 Torque Angle Gauge E C

C

Figure 4-20 Remove the Guide Pins C

Holes (for guide pins)

D

Four-cylinder engine

E

Arrow to front of engine

7. Remove guide pins (C). See Figure 4-19 and Figure 4-20.

8. Obtain new cylinder head bolts with a collared head.

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) Alternate Turn Angle Method

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Installing the Push Rods, Rocker Arm Unit

1. Make two marks (A and B) on the socket spanner that are 1/6 rotation (60° ±10°) apart. See Figure 4-22, 1.

Figure 4-23 Install all Push Rods 1. Install all push rods into the same position from which they were removed. See step 3 of “Removing the Cylinder Head” on page 209.

See Figure 4-23.

Figure 4-22 Alternate Turn Angle Method A

2. Place the socket spanner onto the hexagon bolt.

On cylinder head (C), make a mark aligned with the first mark (A) on the hexagon bolt.

See Figure 4-22, 2.

3. Tighten all hexagon bolts, in the order shown in Figure 4-20 on page 211, until the second mark (B) on the socket spanner is aligned with mark (C) on the cylinder head as shown. See Figure 4-22, 3.

NOTICE: Tightening the cylinder head bolts is not necessary after running the engine if the collar screws have been tightened as specified.

Figure 4-24 Install the Coolant Temperature Sensor Connector 2. Install the coolant temperature sensor connector line (A) to the fuel injection pump wiring harness. See Figure 4-24.

Figure 4-25 Install the Rocker Arm Unit 3. Install the rocker arm unit. See Figure 4-25.

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Installing the Fuel Lines, Fuel Filter/Water Separator A

5. If removed, install fuel pump (G). See Figure 4-28.

6. Install fuel filter/water seperator (H) and brackets if necessary. See Figure 4-28.

B

C

7. Install fuel lines.

8. Install thermostat housing/coolant supplier unit (E). See Figure 4-27.

9. Install exhaust bracket (D) using the guide pins. See Figure 4-27.

Figure 4-26 Fuel Return Lines, Fuel Feed Lines, Injection Nozzle 1. Install fuel injection nozzles (C). See Figure 426.

Installing the Cylinder Head Cover B

2. Install fuel return line (A) and fuel feed lines (B) as a unit. See Figure 4-26.

C A

D

D

F

Figure 4-29 Exhaust Elbow, Turbocharger and Cylinder Head Cover

E

Figure 4-27 Exhaust Bracket, Turbocharger and Oil Intake/Outlet Lines 3. Install the tube that connects the thermostat housing with the coolant pump (F). See Figure 4-27.

1. Install cylinder head cover (D). See Figure 429.

2. Install hexagon nuts and O-rings onto the cylinder head cover (D). See Figure 4-8.

3. Install turbocharger (C) and exhaust elbow (A). See Figure 4-29.

4. (Optional) If the alternator was removed (see step 6 on page 208), install the alternator.

4. Connect oil return and intake lines (B) to turbocharger (C). See Figure 4-29.

5. Install exhaust elbow (A) at the air intake. See Figure 4-29.

H

6. Install the radiator cap.

7. Add radiator coolant.

G

Figure 4-28 Fuel Filter/Water Seperator Printed in U.S.A

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Servicing the Fuel Injection Pump

is running or still warm, damage to the rotating pump components can occur.

Removing the Fuel Injection Pump

2. If installed, remove the cutoff cable and throttle control linkage.

NOTICE: Prior to removing the fuel injection pump, use the flywheel rotation tool to (both rocker arms on this cylinder are movable) turn the engine to the top dead center compression position of cylinder no. 1, and keep the engine in place with the adjustment pin (A), as for setting the valve tip clearance. See Figure 4-30.

3. If installed, remove the electric connection to the stop solenoid or to the throttle position solenoid.

4. If installed, remove the cold-starting switch.

5. Mark the electric cables to ensure correct reassembly.

IMPORTANT:When loosening and tightening fuel feed lines on the fuel injection pump, ALWAYS use a spanner to hold the lock nut and avoid damage to the pump ports. This avoids internal pump damage.

A

6. Remove fuel return line (A) and fuel feed line (C). See Figure 4-31.

7. Use a 17 mm crowfoot wrench with a long socket to remove all fuel feed lines (pressure lines) (B) from the fuel injection pump. See Figure 4-31.

Figure 4-30 Adjustment Pin Opening

IMPORTANT:Make a mark on the drive pin-

All Stanadyne DB2 and DB4 fuel injection pumps have a fixed drive shaft (it remains in the pump if the latter is removed from the engine).

ion and on the pinion of the wheel gear to mark the position of the pinions for re-assembly. The drive pinion of the fuel injection pump fits exactly on the conical drive shaft and is adjusted with a female pin or a Woodruff key.

This secures it against turning it out of position on the pump shaft.

A

B

E

D

C

Figure 4-31 Fuel Injection Pump Fuel Lines 1. Clean the fuel injection pump, lines, and area around the pump with a solvent or steam jet.

See Figure 4-31.

IMPORTANT:If the fuel injection pump is cleaned with a steam jet or cold water while it

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Figure 4-32 End of Pump Shaft 8. Remove the lock nut and washer from the end of the pump shaft. Make sure that the washer does not drop into the control cover.

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) Installing the Fuel Injection Pump

9. Fit drive pinion extractor (E) JDG670A (available direct from John Deere) onto the drive pinion of the fuel injection pump as shown.

See Figure 4-32.

A

B

F

Figure 4-34 Adjustment Marks 1. Apply clean engine oil to a new square sealing ring.

G

Figure 4-33 Adjustment Marks 10. Be sure that adjustment marks (F, G) on the rear side of the front panel (F) and on the injection pump flange (G) are made, clearly visible, and aligned correctly. This ensures that once the pump (or a replacement pump) has been repaired and installed, it can be adjusted correctly on the engine. If the adjustment mark is not clearly visible on the front panel, make a visible mark aligned with the mark on the pump flange. See Figure 4-33.

2. Insert the ring into the groove at the front surface of the pump fastening flange.

3. Slide the fuel injection pump onto the assembly stud bolts and simultaneously insert the pump shaft into the drive pinion.

IMPORTANT:The straight pin of the shaft is easily damaged if assembled incorrectly. Do not move the pump drive pinion when inserting the pump guide pin into the key groove of the drive pinion.

11. Remove the three nuts of the assembly stud bolts (D) from the fuel injection pump. See Figure 4-31.

4. Check the pump shaft and guide pin for correct alignment to the key groove of the pump drive pinion.

12. Remove the fuel injection pump from the assembly stud bolts.

5. Place the fuel injection pump partly on the assembly stud bolts, without engaging the pump guide hub with the engine front panel.

13. Place the pump on a clean, level surface and check the outside of the shaft and drive pinion.

See “Installing the Fuel Injection Pump” below.

6. Place three flat washers, lock washers and hexagon nuts on the assembly stud bolts of the pump.

7. Tighten the nuts only three rotations so that the pump does not fall off of the assembly stud bolts.

IMPORTANT:Do NOT tighten the hexagon nuts more than three full rotations on the assembly stud bolts. The guide pin of the pump drive shaft can be damaged if it is not correctly aligned with the key groove of the drive pinion, and if the nuts are tightened more than three rotations. The pump drive pinion should move forward with the pump (away Printed in U.S.A

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from the front panel of the engine) if the flange is about 3.2 mm away from the front panel.

8. Install the pump fastening flange flush with the front panel of the engine. This makes the drive pinion flush with the front panel front side.

E F D

IMPORTANT:Do NOT use the clamping force of the assembly stud bolts of the pump to pull the pump shaft into the drive pinion.

9. Tighten the nuts of the assembly stud bolts while making sure that the guide pin of the pump shaft is correctly aligned with the key groove of the drive pinion.

Figure 4-36 Fuel Lines

C

14. Connect pressure lines (F) to the fuel injection pump starting with the outlet (lower right) and then counterclockwise around the pump head in the same order as the engine firing order (1– 3–4–2). See Figure 4-36.

15. Using a 17 mm spanner with a long extension, tighten the fuel feed lines (pressure lines) to tightening torque 20 lb.-ft. (27 Nm).

IMPORTANT:When loosening and tighten-

Figure 4-35 End of Shaft 10. Firmly press the pump drive pinion onto the conical shaft. Fit the washer and lock nut (C) onto the end of the shaft. Tighten the lock nut to the following torque: Stanadyne DB4 lock nut: Pump drive pinion: shaft (torque) 150 lb.-ft. (203 Nm).

11. Install the cover plate, use a new O-ring if necessary. Hexagon bolts of front cover plate (torque) 4 lb.-ft. (6 Nm).

ing fuel feed lines on the fuel injection pump, ALWAYS use a spanner to hold the lock nut and avoid damage to the pump ports. This avoids internal pump damage.

16. Connect fuel feed line (D) to fuel return line (E).

17. If installed, connect the fuel cutoff cable to the throttle control linkage.

18. If installed, firmly tighten the electric connections to the stop solenoid and to the throttle position solenoid.

19. If installed, connect the cold-starting switch.

12. Align the adjustment mark on the pump flange to the adjustment mark on the front panel.

13. Tighten the three hexagon nuts to tightening torque 20 lb.-ft. (27 Nm).

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A

Figure 4-37 Fuel Injection Nozzles

Figure 4-38 Pipe Nuts

20. Bleed the fuel system, loosen fuel return line (G) and actuate the fuel pump until there is no more air in the fuel that flows out. See Figure 4-37.

1. Loosen the pipe nuts on each nozzle (A). See Figure 4-38.

2. Remove the fuel return lines and T-elements as a unit. See Figure 4-38.

21. Tighten the line.

22. Start the engine, let it run for a couple of minutes, and then check the entire fuel system for leaks.

Servicing the Fuel Injection Nozzles Removing the Fuel Injection Nozzles IMPORTANT:Thoroughly remove all dirt on the cylinder head in the area around the fuel injection nozzles before you remove them.

Clean with compressed air to avoid dirt entering into the cylinders. Close the hole in the cylinder head after removing each nozzle. Close the openings of the fuel lines immediately after removing them.

B

Figure 4-39 Hexagon Bolt 3. Remove hexagon bolt (B) that secures the nozzle to the cylinder head. See Figure 4-39.

NOTICE: If all fuel injection nozzles have to be removed, remove the fuel leak line and nozzles as a complete unit. In order to remove separate nozzles, only remove the section of the fuel return line required.

C

Figure 4-40 Fuel Injection Nozzle Printed in U.S.A

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) 4. Pull out the injection nozzle using the injection nozzle extractor kit (C), or by using the adapter and the slide grip. See Figure 4-40 on page 217.

5. Clean the injection nozzle hole using the injection nozzle cleaning tool.

6. Remove dirt from the hole with compressed air and cover the hole to keep out foreign materials.

7. Place the nozzle in solvent or clean diesel fuel until the nozzle is clean. Be sure that the carbon stop seal groove is fully immersed.

IMPORTANT:Do not scratch or damage the coating on the nozzle housing above the carbon seal groove.

8. Clean the nozzle tip with a brass wire brush after it has been immersed.

Testing the Fuel Injection Nozzles

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2. Position the nozzle tip below the top of beaker (D) and 30° from the bottom of beaker (D) to contain all spray in beaker (D), as nozzle spray pattern projects at an angle toward the nozzle center line. See Figure 4-41.

NOTICE: Rapidly operating the pump handle causes inaccurate cracking pressure readings and undue wear on the gauge.

3. Pump the handle several times to force air from the lines and determine the correct pump speed for fuel atomization (atomization is the conversion of bulk liquid into a spray or mist).

See Figure 4-41.

4. Fully tighten all connections after forcing the air from the nozzle and line. See Figure 4-41.

Checking the Opening Pressure 1. Actuate the nozzle tester (A) rapidly several times to quickly seal the valve. See Figure 441.

2. Open the gauge valve, actuate the nozzle tester (A), and increase the pressure until the measuring instrument needle drops rapidly. This pressure measurement is the nozzle opening pressure for a new or used nozzle. See Figure 4-41.

C

NOTICE: If the nozzle opening pressure is

A

B

D

Figure 4-41 Checking the Fuel Injection Nozzles

not within the specified range, re-adjust the pressure and the valve stroke BEFORE checking clatter and injection pattern, otherwise these measurements may be affected.

New or overhauled nozzle with new inside parts

1. Connect Y900-3 and Y900-5 Adapters (C) and Y900-2 Fuel Line (B) (included with D01110AA Fuel Injection Nozzle Tester Adapter Set available from a John Deere dealer) to D01109AA OTC Portable Nozzle Tester (A), but do not fully tighten the connections. See Figure 4-41.

NOTICE: When using the JT25510 Bosch Bench Mounted Nozzle Tester, use the KJD10109 Fuel Line and connect line to tester and nozzle.

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Opening pressure for adjustment

3698 – 260 psi (255 – 260 bar)

Opening pressure for check

Minimum 3568 psi (246 bar)

Used nozzle Opening pressure for check

Minimum 3408 psi (235 bar)

NOTICE: The actual nozzle opening pressure is not as important as an identical opening pressure for all nozzles. The opening pressure difference among the cylinders is a maximum 102 psi (7 bar).

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Checking the Clatter

Checking for Leakage

1. Close the measuring instrument valve and actuate the nozzle tester at a speed that causes the nozzle to clatter. The nozzle should clatter softly and the injection pattern should be wide and finely atomized. Fuel injection nozzle tip (injection angle) 144°.

1. Check the nozzle for fuel leakage at the valve seat by placing the nozzle tip, facing downward, onto nozzle tester (A). See Figure 4-41.

2. Write down the speed at which the nozzles began to clatter.

4. Actuate the nozzle tester (A). Slowly increase and maintain the nozzle pressure to about 406508 psi (28-35 bar) below the specified opening pressure. See Figure 4-41. See “Checking the Opening Pressure” on page 218.

2. Actuate the pump handle rapidly.

3. Wipe the nozzle tip with a clean lint-free cloth.

3. If the nozzle does not clatter, dismantle the nozzle and troubleshoot. The nozzle valve is possibly bent or cannot move in its guide because of residue.

5. Check for fuel leakage from the nozzle tip opening.

NOTICE: The fuel ejects in a steady stream (not atomized) before the nozzle clatters.

Actuate the nozzle tester (A) ten times while the pump operates at the correct speed for atomization. The nozzle must atomize during at least eight out of ten actuations (80%). See Figure 4-41.

Printed in U.S.A

6. Wipe the nozzle with a clean lint-free cloth if fuel leaks within five seconds (slight dampness is permissible on used nozzles).

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Disassembling the Fuel Injection Nozzles

B

A

C

P

J

D

E

H I

K

F

N

L M

O

G

Figure 4-42 Fuel Injection Nozzles Diagram A

Nozzle tip

E

Upper sealing washer

I

Upper seal

M

Stroke set screw

B

Carbon seal

F

Prefilter

J

Spring seat

N

Lock nut

C

Nozzle housing

G

Fuel intake

K

Spring screw

O

Pressure setting screw

D

Nozzle valve

H

Upper guide

L

Wave spring washer

P

Lock nut

1. Insert the nozzle into positioning clip (A) and secure positioning clip into a vice. See Figure 4-43.

C B

2. Loosen the pressure setting lock nut (B). See Figure 4-43.

3. Remove lock nut (C) from the stroke set screw and raise the unit. See Figure 4-43.

A

Figure 4-43 Dismantling the Fuel Injection Nozzle

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4. Invert the nozzle. Remove and retain the pressure adjustment spring seat and the stroke adjustment.

NOTICE: Do not bend the stem during removal.

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Assembling the Fuel Injection Nozzles

B

A

D

C

E

G

F

L K

J

I

H

Figure 4-44 Assembling the Fuel Injection Nozzle A

Nozzle housing

E

Spring seat

I

Pressure set screw lock nut

B

Spacer

F

Pressure adjustment spring

J

Stroke set screw

C

Positioning clip

G

Washer

K

Pressure set screw

D

Nozzle valve

H

Stroke set screw lock nut

L

Fastening clips

1. Install spacer (B) onto nozzle housing (A). See Figure 4-44.

12. Adjust the nozzle according to “Testing the Fuel Injection Nozzles” on page 218.

2. Install positioning clip (C) onto nozzle housing (A) so that the flanges face down.

13. Install the stroke set screw lock nut (H) and pressure set screw lock nut (I) onto the set screw unit.

3. Install the three remaining fastening clips (L) onto nozzle housing (A).

4. Dip nozzle valve (D) into clean fuel.

5. Insert nozzle valve (D) into nozzle housing (A).

6. Screw stroke set screw (J) into pressure set screw (K) until the tip barely penetrates into the screw.

7. Invert the set screw unit.

8. Attach spring seat (E), pressure adjustment spring (F), and washer (G) onto the set screw unit.

9. Hold the unit in a slanting position (do not drop the valve).

10. Attach the springs and set screw unit to the fuel injection nozzle unit. Be sure that the spring or valve seat are not shifted during assembly.

11. Screw the pressure set screw (K) by hand as far as possible, usually about 10 full rotations.

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Setting the Opening Pressure

Correcting the Opening Pressure

1. Close the pressure gauge valve of the nozzle tester (A). See Figure 4-45.

NOTICE: Only complete these steps if opening pressure measurements are not within the acceptable range of measurements. See “Setting the Opening Pressure.”

A

B

A

Figure 4-45 Testing Opening Pressure C

2. Rapidly actuate the pump to flush the nozzle.

D

3. Rapidly actuate the pump to increase the pressure until the nozzle opens. The gauge quickly drops after the nozzle opens.

Figure 4-46 Setting Opening Pressure

4. Record the opening pressure measurement.

2. Insert the nozzle into positioning clip and secure positioning clip into a vice. See Figure 4-43.

5. Refer to the following table for acceptable fuel injection nozzle RE48786 opening pressure measurements: New or overhauled nozzle w ith new inside parts 3698 – 260 psi O pening pressure for (255 – 260 bar) adjustm ent O pening pressure for Minim um 3568 psi check (246 bar) Used nozzle O pening pressure for check

Minim um 3408 psi (235 bar)

O pening pressure difference am ong cylinders Maxim um pressure difference = 102 psi (7 bar)

6. If measurements are not acceptable, complete the steps in “Correcting the Opening Pressure.”

1. Remove the nozzle from the tester.

3. Remove lift adjusting lock nut (D). See Figure 4-46.

4. Loosen pressure set screw lock nut (A).

5. Remove the nozzle from the positioning clip and vice.

6. Connect the nozzle to the tester, with the nozzle tip facing downward.

7. Unscrew stroke set screw (B) (two or three rotations) until there is no more contact with stroke set screw (B) when turning pressure set screw (C).

8. Screw pressure set screw (C) clockwise (to the right) to increase opening pressure, or unscrew pressure set screw (C) counter-clockwise (to the left) to decrease opening pressure.

9. Check that the opening pressure is at the high limit of the opening pressure measurement.

See step 5, of “Setting the Opening Pressure.”

10. Write down the opening pressure measurement.

11. If measurements are not acceptable, repeat steps 1 through 10 of this procedure.

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JOHN DEERE ENGINE 4045TF270 (SN AC02633 AND UP) IMPORTANT:Do NOT use excessive manual

12. Remove the nozzle from the tester.

force to hold the valve in place because the valve may bend.

13. Insert the nozzle into positioning clip and secure positioning clip in a vice.

4. Check for valve contact by raising the pressure to 200-500 psi (14-34 bar) above the nozzle opening pressure. See “Setting the Opening Pressure” on page 222.

14. Tighten pressure set screw lock nut to 7 lb.-ft.

(10 Nm). See Figure 4-47.

NOTICE: It is acceptable for a very small amount of fuel to collect at the nozzle tip, it is not acceptable for a rapid dribble of fuel to flow from the nozzle tip.

5. Remove the nozzle from the nozzle tester.

6. Insert the nozzle into positioning clip and secure the positioning clip into a vice. See Figure 4-49.

Figure 4-47 Tighten Pressure Set Screw Lock Nut Adjusting the Nozzle Valve Stroke

1. Connect the nozzle to the nozzle tester (A). See Figure 4-48.

Figure 4-49 Nozzle Valve Stroke Adjustment 7. Screw lift set screw counter-clockwise (to the left) until there is a tolerance of approximately 1/8 rotation.

A

Figure 4-48 Nozzle Connected to Nozzle Tester 2. Actuate the pump to flush fuel through the nozzle. See Figure 4-48.

3. Hold the pressure set screw while slowly turning the lift set screw clockwise (to the right) until the valve does not open.

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Installing the Injection Nozzles

IMPORTANT:Clean the nozzles until they are completely free of oil and grease before installing them.

Figure 4-50 Tighten Pressure Set Screw Lock Nut 8. Hold the pressure set screw while tightening the lock nut of the stroke set screw to 4 lb.-ft.

(5 Nm) torque.

9. Complete all steps in “Checking the Opening Pressure” on page 218.

10. Close the measuring instrument valve and actuate the nozzle tester to the speed at which the nozzles began to clatter. See “Checking the Clatter” on page 219.

11. If the nozzle still clatters, some nozzle valve parts may not be aligned correctly. Screw the pressure set screw repeatedly and reset the valve stroke.

12. Repeat steps 10-11.

13. Clean the nozzle with brass wire brush.

Figure 4-51 Injection Nozzle 1. If installed, remove the nozzle hole plug from the cylinder head.

2. Use compressed air to clean the nozzle hole.

NOTICE: Be sure that the cylinder head sealing surface (where the seal washer will be placed) is smooth, free of damage, and free of dirt. A dirty surface may prevent proper sealing. A rough surface may cause the nozzle to become distorted after tightening the attaching screw, causing the valve to stick.

3. Using spacers and clamps, install the nozzle into the nozzle hole while applying a slight twisting motion. See Figure 4-51.

4. Align the nozzle fastening clips and screw the hexagon bolts, but do not fully tighten the hexagon bolts.

5. Loosely connect the fuel pressure line onto the nozzle.

6. Tighten the nozzle fastening clip hexagon bolts to 30 lb.-ft. (40 Nm).

7. Install the fuel return line unit.

8. Tighten the fuel return line unit hexagon nut to 4 lb.-ft. (5 Nm).

9. Bleed air from fuel pressure line. See “Purging Air from the Fuel System: John Deere Engine Model 4045TF270 (SN AC02633 and up)” on page 46.

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10. Tighten nozzle feed line to 20 lb.-ft. (27 Nm).

See Figure 4-52.

5. Insert adapter (A) into fuel injection nozzle hole with nozzle spacer (B) and two nozzle seals (C) as shown. Use holding plate (D) to secure. See Figure 4-53.

6. Screw the fastening screw into the holding plate (D) and tighten it to 27 lb.-ft. (37 Nm).

E

A

Figure 4-52 Tighten Nozzle Feed Line

Checking Compression NOTICE: Engine starting speed affects com-

Figure 4-54 Test Gauge

pression pressures. Be sure the battery is fully charged, and thoroughly clean the area around the injection nozzles before checking the compression.

7. Install test gauge (E) onto adapter (A). See Figure 4-54.

1. Start the engine. If starting a recently used engine, let it run at its rated speed until it reaches its normal operating temperature. If starting a cold engine, allow the engine to run at idle speed for approximately 10-15 minutes to fully warm up all systems.

9. Use the starter motor to turn the crankshaft for 10-15 seconds. The minimum acceptable cranking speed: 150 rpm cold/200 rpm hot.

8. Reduce the throttle lever to the “STOP” position.

10. Measure the compression pressure in all cylinders and compare the measured values. Compression pressure must be within the following specifications:

2. Shut-off the engine. Remove the ignition key and take it with you. Follow the “Mandatory Safety Shutdown Procedure” in the Operator‘s manual.

3. Shut-off the fuel supply.

4. Remove the fuel injection nozzles.

B

•

Engine compression pressure must be between 348-406 psi (24-28 bar).

•

The maximum acceptable difference between cylinder readings is 51 psi (3.5 bar).

11. If the compression pressure is not within the specifications listed in step 10, complete the steps in “Correcting Low Compression Check Readings” or “Correcting High Compression Check Readings.”

A

C

C

D

Figure 4-53 Compression Test Set Printed in U.S.A

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Correcting Low Compression Check Readings

2. Check the thermostat for corrosion and damage. Replace if necessary.

A low compression check reading is a sign of worn or jammed valves.

3. Place the thermostat and a thermometer in a container with water. Stir the water as you warm it up. Be careful not to break the thermometer. See Figure 4-56.

1. Remove test gauge (E) and adapter (A).

2. Apply oil through the injection nozzle hole and onto the piston ring.

NOTICE: Do not use too much oil and do not apply oil onto the valves.

Thermometer

3. Check the compression pressure. Complete the steps in “Checking Compression” on page 225.

4. If necessary, overhaul the cylinder head. See “Removing the Cylinder Head” on page 207.

Correcting High Compression Check Readings

Water container

A high compression check reading is a sign of worn or jammed piston rings.

Thermostat

1. Replace the piston rings or install a new piston/ sleeve set.

2. Check the compression pressure. Complete the steps in “Checking Compression” on page 225.

3. If necessary, overhaul the cylinders and valves.

See “Removing the Cylinder Head” on page 207.

Servicing the Thermostat

Figure 4-56 Thermostat Inspection 4. Check how the thermostat opens and compare the temperatures with the temperatures in the following table.

Thermostat Inspection Specifications

Inspecting the Thermostat 1. Remove the thermostat housing/coolant supplier unit (F). See Figure 4-55.

Temperature

Start of opening (range)

Complete opening

160°F (71°C) 156-162°F (69-72°C) 171°F (77°C) 165-172°F (74-78°C)

(rated value) 183°F (84°C) 192°F (89°C)

180°F (82°C) 176-183°F (80-84°C) 192°F (89°C) 187-194°F (86-90°C)

201°F (94°C) 214°F (101°C)

194°F (90°C) 192-199°F (89-93°C) 198°F (92°C) 192-199°F (89-93°C)

217°F (103°C) 221°F (105°C)

205°F (96°C) 201-207°F (94-97°C) 212°F (100°C) 210°F (99°C) 205-212°F (96-100°C) 232°F (111°C)

F

Figure 4-55 Thermostat Housing 909768/BP1207

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Servicing the Cooling System

marked on the radiator cap) of pressure to the cooling system with the pressure pump.

Checking for Water Leakage

8. Check all cooling system and radiator hose connections and the entire engine for leaks while the pressure is applied.

CAUTION Be careful to avoid burns when removing the cap. Keep face away from cap. Cover cap with a cloth, turn cap slowly to release pressure.

9. If there are leaks, complete repairs and complete steps 1 through 8. If no leaks are found, but the pressure gauge measures a pressure drop, coolant may be leaking internally in the system or in the area between the cylinder block and cylinder head gasket. Complete repairs and complete steps 1 through 8.

Checking the Radiator Cap

Hand Pump

Figure 4-57 Hand Pump

Radiator Cap

1. Shut-off the engine. Remove the ignition key and take it with you. Follow the “Mandatory Safety Shutdown Procedure” in the Operator‘s manual.

Figure 4-58 Radiator Cap 1. Remove the radiator cap and secure it onto the pressure pump as shown. See Figure 4-58.

2. Let the engine cool down and carefully remove the radiator cap.

2. Using the hand pump, increase the pressure to about 10 psi (0.7 bar). The radiator cap functions correctly if the pressure gauge holds the pressure to about 10 psi (0.7 bar) for 10 seconds.

3. Add coolant to the radiator until it reaches the normal level.

4. Start the engine. If starting a recently used engine, let it run at its rated speed until it reaches its normal operating temperature. If starting a cold engine, allow the engine to run at idle speed for approximately 10-15 minutes to fully warm up all systems.

3. Remove the radiator cap from the pressure gauge, rotate it 180°.

4. Repeat steps 1-2.

5. Radiator cap must open.

5. Turn the key fully counter-clockwise to shutoff the engine.

6. Remove the ignition key and take it with you.

IMPORTANT:Do NOT apply excessive pressure to the cooling system, otherwise the radiator and hoses can be damaged.

7. Connect the pressure gauge and adapter to the radiator filler inlet. Apply 14.5 psi (1.0 bar) (as Printed in U.S.A

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CHAPTER 5 YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) For specifications, see “John Deere 4045TF270 and Yanmar 4TNE106T-NS Specifications” on page 9.

Yanmar Engine Model 4TNE106T-NS Overview

Cylinder head cover

Intake manifold

Alternator Fuel filter

Fan wheel

Oil filter

Figure 5-1 Yanmar 4TNE106T-NS (Overview), Fan View

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Fuel filter

Alternator

Exhaust manifold

Starter

Flywheel

Figure 5-2 Yanmar 4TNE106T-NS (Overview), Flywheel View

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Cooling water pump Alternator

Cylinder head Valve hood Intake manifold

Exhaust manifold

Starting motor

Flywheel housing

Figure 5-3 Engine External View

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Fuel injection valve

Gear case cover

Gear case Fuel injection pump

Stop motor Fuel filter

Oil pan

Dipstick

Cooling water inlet

Cooling water outlet

Alternator

Fuel feed pump

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Radiator fan

Oil filler port

Lubrication filter

Figure 5-4 Engine External View 909768/BP1207

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Fuel System Tank

Return line

Feed line

Water separator

Figure 5-5 Fuel System

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Cylinder head gasket

Checking Valve Tip Clearance

CAUTION Before completing these steps, disconnect the battery cable connected to the negative terminal to prevent the engine from accidentally starting while checking the valve tip clearance.

Cylinder head cover

Valve cover seal

Figure 5-7 Cylinder Head Gasket and Valve Cover Seal 3. Remove the cylinder head gasket and valve cover seal. See Figure 5-7.

4. Manually turn the crankshaft to bring the piston of the No. 1 cylinder (firing order: 1-3-4-2) to its compression top dead center position while watching the rocker arm motion, timing scale and the crankshaft pulley top mark position. At the top mark position, both the intake and exhaust valves are closed.

A

B

C

Figure 5-6 Cylinder Head Cover 1. Shut down the engine. Follow the mandatory safety shutdown procedure in the Operator's manual.

NOTICE: Only check the valve clearance

Figure 5-8 Valve Clearance

after the engine is cold.

5. Insert a 0.2 or 0.3 mm thickness gauge between the rocker arm and valve cap and record the valve clearance (A). See Figure 5-8.

2. Remove the cylinder head cover. See Figure 56.

6. Remove the thickness gauge.

7. Loosen lock nut (C) and adjustment screw (B).

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Cylinder head gasket

Valve Cap Wear Normal

Valve Cap Wear Abnormal Valve cover seal

Figure 5-9 Valve Cap Wear

Figure 5-12 Cylinder Head Gasket and Valve Cover Seal

8. Check the valve cap for any inclination, dirt and wear. See Figure 5-9.

Cylinder head cover

Figure 5-13 Cylinder Head Cover 11. Install the valve cover seal, cylinder head gasket and cylinder head cover. See Figure 5-12 and Figure 5-13.

Figure 5-10 Valve Clearance 9. If necessary, insert a 0.2 or 0.3 mm thickness gauge between the rocker arm and valve cap.

See Figure 5-10.

Figure 5-11 Locknut 10. Adjust the valve clearance to 0.25 ~ 0.35 mm and tighten the lock nut to ~ 11 lb.-ft. (~ 15 Nm). See Figure 5-11.

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Inspecting the Thermostat

Thermostat

Figure 5-14 Measuring Pressure 1. Start the engine. Follow the Engine Start Procedure in the Operator‘s manual.

2. After warming up the engine, remove the fuel injection pipes and valves from the cylinder.

3. Crank the engine with the regulator handle at the stop position (no injection state) before installing the compression gauge adapter.

4. Install the compression gauge and adapter at the cylinder.

5. With the engine set to no injection state, use the starter motor to crank the engine until the compression gauge reading stabilizes.

Figure 5-15 Thermostat Location

6. Be sure the compression gauge reading stabilizes at compression pressure 508 psi (35 bar), 250 rpm. See “John Deere 4045TF270 and Yanmar 4TNE106T-NS Specifications” on page 9.

Housing Cover

Thermostat Sealing Thermoswitch Housing

Figure 5-16 Thermostat Disassembly 1. Disassemble the thermostat. See Figure 5-15 and Figure 5-16.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Checking for Cooling System Water Leakage

Thermometer

Thermostat Hand Pump

Figure 5-19 Hand Pump Checking for Leakage

Water container

Figure 5-17 Thermostat Inspection

1. Add coolant to the radiator until it is completely full.

2. Heat the thermostat in a container filled with water. See Figure 5-17.

2. Attach a hand pump onto the radiator as shown. See Figure 5-19.

3. Check if thermostat opens at the temperature specified on the thermostat. Check by using a thermometer.

3. Operate the hand pump as shown and increase the pressure in the cooling system to about 15 psi (1 bar).

Inspecting the Thermoswitch

4. Check the lines and connections for leaks if the pressure measurement on the pressure gauge drops.

Thermometer

Checking the Radiator Cap

Tester probes Radiator Cap

Figure 5-18 Thermoswitch Inspection Figure 5-20 Radiator Cap

1. Place the thermoswitch in a container filled with antifreeze. See Figure 5-18.

1. Remove the radiator cap and mount it onto the adapter as shown. See Figure 5-20.

2. Heat the antifreeze while measuring the fluid temperature. The switch is normal if the voltameter shows continuity when the fluid temperature reaches 225°-235°F (107°-113°C).

2. Operate the hand pump as shown and increase the pressure to about 15 psi (1 bar) (stamped onto the radiator cap).

3. Check that the radiator cap opens. If the radiator cap does not open, replace the radiator cap.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Checking the V-belt Tension 1. Shut-off the engine. Remove the ignition key and take it with you. Follow the “Mandatory Safety Shutdown Procedure” in the Operator‘s manual.

2. Open the engine cover.

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Inspecting the Fuel Injection Valve and Spray Pattern

WARNING Wear protective glasses when testing injection from the fuel injection valve. Never manually handle the injection nozzle because the oil jetting out from the nozzle is set at high pressure.

Contact may cause loss of sight or injury.

Measuring Fuel Injection Pressure

A

Alternator Water pump

Crankshaft

Figure 5-21 V-belt Tension Check 3. Push the center of the V-belt between the alternator and cooling water pump with a finger.

The tension is normal if the deflection is 0.4 0.6” (10 - 15 mm). See Figure 5-21.

NOTICE: If the V-belt is new, tension is normal if the deflection is 0.3 - 0.4” (7 - 9 mm).

Bar Spanner

Alternator

Figure 5-22 Drive Belt Tightening 4. If not, adjust the V-belt tension by inserting a bar as shown and adjusting the alternator. See Figure 5-22.

B

Figure 5-23 Fuel Injection Valve If necessary, during these steps refer to Figure 5-24 on page 239 to view the fuel injection valve structure.

1. Connect fuel injection valve (B) to high pressure pipe of nozzle tester (A). See Figure 5-23.

2. Operate the nozzle tester lever slowly and read the pressure when fuel injection from the fuel injection valve (B) begins.

3. If the measured injection pressure is below 3191-3336 psi (220-230 bar), replace the pressure adjusting shim with a thicker one.

If the measured injection pressure is above 3191-3336 psi (220-230 bar), replace the pressure adjusting shim with a thinner one.

Approximately: 0.1 mm = 276 psi (19 bar).

4. Check the fuel injection valve (B) for drips after it has ejected fuel.

5. Close the engine cover.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Checking the Nozzle Jet (spray pattern)

5. Operate the nozzle tester lever and create a pressure of about 290 psi (20 bar) below injection pressure. Check if fuel escapes from the fuel injection valve (B).

After adjusting the specified valve opening pressure, check the spray pattern and seat-oil tightness using a nozzle tester.

Upper nozzle screw fitting

Spacers Compression spring Compression spring seat

Pressure spring centering Nozzle needle

Nozzle body

Lower nozzle screw fitting

Figure 5-24 Fuel Injection Valve

Figure 5-25 Nozzle Jet Atomization 1. Remove injection lines and injection nozzles.

2. Connect injection nozzle to the high pressure line of the nozzle tester.

3. Quickly create pressure until the nozzle ejects fuel (ejection 3-4 times).

4. Hold a white sheet of paper about 12” (30 cm) away from the nozzle while the nozzle ejects fuel.

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NOTICE: New nozzles are coated with rustpreventive oil and are pasted with seal peel to shut-off outer air.

Figure 5-26 Nozzle Jet 5. The nozzle jet must create an “optimal” shape on the paper as shown. See Figure 5-26.

6. Replace the fuel injection valve if abnormal atomization occurs. See Figure 5-25.

Nozzle Valve Slide Test

Figure 5-28 Nozzle Punch Mark Injection Timing Check

Figure 5-27 Nozzle Valve Gravity Test 1. Wash the nozzle valve in clean fuel oil.

2. Vertically position the nozzle body as shown.

See Figure 5-27.

3. Insert the nozzle into the body to about 1/3 of its length as shown.

The nozzle valve is normal if it smoothly falls by its own weight into the nozzle body.

If nozzle is new, before using nozzle, remove the seal peel, and immerse it in clean diesel oil or an equivalent solvent to clean the inner and outer surfaces and to remove rust-preventive oil.

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Figure 5-29 Fuel Injection Timing 1. Check that the fuel system is bled. If necessary, complete the steps in “Purging Air from the Fuel System: John Deere Engine Model 4045TF270 (SN AC02633 and up)” on page 46.

2. Check that the matching mark made on the fuel injection pump is aligned to the matching mark made on the control unit.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) 12. Re-install the injection line.

P

0

13. Check the No. 3, No. 4, and No. 2 cylinders, in that order. Repeat steps 1-12 for each cylinder.

I

NOTICE: Turn the crankshaft 180° each time

II

prior to checking the No. 3, No. 4, and No. 2 cylinders.

Correcting the Ignition Timing

III

NOTICE: Only complete these steps if the injection time value is not within 11-13° before the 0° position.

Figure 5-30 Ignition Key Switch (SN AB01968 and up)

1. Loosen the fuel injection pump fastening screws.

3. Turn the ignition key to the “I” position on models SN AB01968 and up. See Figure 5-30.

2. Rotate the fuel injection pump toward or away from the engine. Rotating toward the engine sets an earlier injection time, rotating away from the engine sets a later injection time.

Each line on the check mark = a degree for the injection time.

Turn the ignition key to the RUN position, one position “clockwise” (to the right) from the OFF position, on models SN AB01967 and before.

4. Remove the injection line from the No. 1 cylinder. The No. 1 cylinder is the cylinder furthest from the radiator.

3. Tighten the fuel injection pump fastening screws.

4. Check the injection time value again. Repeat steps 6-10 of “Injection Timing Check” on page 240.

5. Rotate the crankshaft in the direction of rotation: “clockwise” (to the right). Stop turning when the No. 1 cylinder on the fuel injection pump opens and fuel flows from the opening.

6. Check the injection time mark on the Vgrooved pulley. The No. 1 cylinder is positioned near top dead center if this mark is made near the 0° mark. See Figure 5-29.

7. Clean the opening of the fuel injection pump.

8. Rotate the crankshaft approximately 20° against the direction of rotation: “counterclockwise” (to the left).

9. Rotate the crankshaft very slowly in the direction of rotation until the fuel at the opening of the fuel injection pump nearly overflows.

10. Check the injection time using the mark on the timing scale. The injection time value must be 11-13° before the 0° position. See Figure 5-29.

If the injection time value is not 11-13° before the 0° position, complete the steps in “Correcting the Ignition Timing” on page 241.

11. Repeat steps 6 through 10 three times.

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Checking the Oil Pressure Switch 1. Remove the cable connection from the oil pressure switch (in the cutoff solenoid area).

2. Start the engine.

3. Check the engine for correct idling speed.

Figure 5-31 Continuity Test 4. Using an ohmmeter, measure oil pressure switch resistance. See Figure 5-31.

5. Determine if the oil pressure switch is acceptable or defective. Refer to the following table: Oil pressure Infinite resistance switch acceptable Oil pressure If any oil can pass switch defective

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Coolant Circuit

Thermostat

Cylinder head

Bypass Subtank Engine cylinder block

Water pump

L.O. Cooler

Figure 5-32 Coolant Circuit

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Servicing the Water Pump 3 Cylinder head

5

Gear case

4

2

Figure 5-33 Water Pump Disassembling the Water Pump

Assembling the Water Pump

1. Remove the alternator.

1. Install the thermostat (5).

2. Remove the fan, V-belt, and pulley (2). See Figure 5-33.

2. Install the water pump (4).

3. Remove the thermostat cover (3).

4. Remove the water pump (4).

3. Install the thermostat cover (3).

4. Install the fan, V-belt, and pulley (2).

5. Install the alternator.

5. Remove the thermostat (5).

Servicing the Water Pump 1. Check the water pump bearing for abnormal noise, sticking or play, and bearing water leakage.

2. If replacement is necessary, replace the entire water pump assembly.

3. Inspect the thermostat function. See “Inspecting the Thermostat” on page 236.

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Adjusting the Radiator Fan Adjust the air guide plate/air fan according to the following specifications: Fan exhaust: 1/3 of the fan width inside the air guiding box.

Fan intake: 2/3 of the fan width inside the air guiding box.

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Servicing the Starter

Figure 5-36 Starter Disassembly Overview Figure 5-34 Starter Components

Disassembling the Starter

Figure 5-37 Nut M8 1. Using a 12 mm spanner wrench, loosen magnetic switch nut M8 as shown and disconnect the lead (1). See Figure 5-36 and Figure 5-37.

Figure 5-35 Assembled Starter

Figure 5-38 Bolt M6 (during and after removal) 2. Using a 10 mm spanner wrench, remove bolts M6 and magnetic switch (2). See Figure 5-36 and Figure 5-38.

Figure 5-39 Rear Cover (during and after removal) Printed in U.S.A

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3. Using a 8 mm spanner wrench, remove brush holder tightening screws and bolts M5. See Figure 5-39.

4. Remove rear cover (3) from the yoke using a standard-head screwdriver.

Figure 5-40 Brush Holder (during and after removal) 5. For the negative (-) brush, move the brush spring into contact with the brush side and lift the commutator surface. See Figure 5-40.

Figure 5-43 Starter Disassembly Overview 12. Remove the dust cover, shift lever, gear case, and gear shaft.

6. For the negative (+) brush, remove the brush from the brush holder (4). See Figure 5-36 and Figure 5-40.

7. Disassemble the yoke and armature.

Figure 5-44 Gear Case Dust Cover (during and after removal) 13. Using a 4 mm hexagon wrench, remove bolts M5 and remove the dust cover from the gear case. See Figure 5-44.

Figure 5-41 Center Bracket (during and after removal)

14. Remove the gear case dust cover (7). See Figure 5-43 and Figure 5-44.

8. Using a 10 mm spanner wrench, remove three bolts M6 from the gear case. See Figure 5-41.

9. Remove the oil seal 10. Disassemble the gear case and center bracket (5). See Figure 5-36 and Figure 5-41.

Figure 5-45 Pinion (during and after removal) 15. Slide the pinion stopper toward the pinion. See Figure 5-45.

16. Using a standard-head screwdriver, remove the pinion stopper clip.

Figure 5-42 Shift Lever Pin (during and after removal)

17. Remove the pinion (8). See Figure 5-43 and Figure 5-45.

11. Using a 10 mm spanner wrench, remove nut M6 and the shift lever pin (6). See Figure 5-36 and Figure 5-42.

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Inspecting and Maintaining the Armature

4. Complete the following armature coil continuity and ground tests. See Figure 5-48.

Test Type Measurement Normal Abnormal Point (cause) Continuity Across None (open Yes test commutator circuit) Between Ground commutator Yes (shortNone and shaft or test circuiting) armature

5. Replace as necessary according to test results.

Figure 5-46 Armature 1. Place the armature into a vice as shown. See Figure 5-46.

2. Inspect the commutator surface. If the surface is rough, sand the armature using sandpaper as shown.

Figure 5-49 Field Coil Continuity and Insulation Tests 6. Complete the following field coil continuity and ground tests. See Figure 5-49.

Test Type Measurement Normal Abnormal Point (cause) Continuity Across field None (open Yes test coils circuit) Between Yes (shortGround commutator None circuiting) test and yoke

Figure 5-47 Commutator Segments 3. Measure the depth of the insulating material between commutator segments as shown. If the depth is less than 0.2 mm, repair using a lathe.

See Figure 5-47.

Figure 5-50 Brush and Brush Spring Force 7. Check the brush and brush spring force wear.

See Figure 5-50.

8. Check the brush movement, if the brush does not move smoothly, inspect the brush holder for bending, binding, dirt, etc. Clean or replace as necessary.

Figure 5-48 Armature Continuity and Insulation Tests

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10. Complete the following magnetic switch continuity tests. See Figure 5-52 and Figure 5-53.

Continuity Measurement Normal Abnormal Test Point (cause) Between C and None (open Shunt coil Yes ground circuit) Yes (shortSeries coil C and M None circuiting)

11. Replace as necessary according to test results.

12. Check pinion teeth for wear and/or damage.

Replace as necessary.

Figure 5-51 Brush Holder 9. Check the continuity between the insulated brush holder (+) and the brush holder base (-).

The brush holder is grounded, if there is electrical continuity, replace the brush holder. See Figure 5-51.

13. Check that the pinion slides smoothly. Repair or replace pinion if it is damaged, rusted, or fails to slide smoothly.

14. Check springs for damage. Replace as necessary.

15. Check the ball bearing for abnormalities and/or abnormal noises. Replace as necessary.

Assembling the Starter

Figure 5-52 Shunt and Series Coil Continuity Tests

Figure 5-54 Starter Components

Figure 5-53 Magnetic Switch Connection Diagram

Shunt coil Series coil

S13-138 Resistance at 68o F (20o C) 0.6 0.218

Figure 5-55 Starter Assembly Overview 909768/BP1207

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1. While assembling the starter, apply NPCFC6A grease to sliding portions and head of plunger, pinion metal and gear case metal portions, pinion spline portions, shift lever sliding portions.

2. While assembling the starter, apply MAPTEMP SRL grease to the deceleration gear.

Figure 5-58 Shift Lever Pin (during and before installation)

Figure 5-56 Pinion (before installation) 3. Install the pinion (8). See Figure 5-55 and Figure 5-56.

4. Install the pinion stopper clip.

5. Slide the pinion stopper toward the pinion. See Figure 5-56.

Figure 5-59 Starter Assembly Overview 10. Using a 10 mm spanner wrench, install nut M6 and the shift lever pin (6). See Figure 5-58 and Figure 5-59.

Figure 5-57 Gear Case Dust Cover (during and before installation) 6. Install the gear case dust cover (7). See Figure 5-55 and Figure 5-57.

Figure 5-60 Center Bracket (during and before installation)

7. Using a 4 mm hexagon wrench, install bolts M5 and install the dust cover onto the gear case. See Figure 5-57.

11. Assemble the gear case and center bracket (5).

See Figure 5-59 and Figure 5-60.

12. Install the oil seal.

8. Install the dust cover, shift lever, gear case, and gear shaft. Check and replace any worn or damaged gear shaft washers.

13. Using a 10 mm spanner wrench, install three bolts M6 onto the gear case. See Figure 5-60.

9. Check that the gear shaft thrust is between 0.05-0.3 mm. If thrust is greater than 0.3 mm, add a thrust washer so that the thrust is between 0.05-0.3 mm.

Figure 5-61 Brush Holder (during and before installation) Printed in U.S.A

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) 14. Assemble the yoke and armature.

15. For the negative (+) brush, install the brush onto the brush holder (4). See Figure 5-59 and Figure 5-61.

ME12002

21. Using a 12 mm spanner wrench, install magnetic switch nut M8 as shown. See Figure 564.

Measuring the Pinion Projection Length

16. For the negative (-) brush, remove the brush spring from contact with the brush side and install onto the commutator surface. See Figure 5-61.

Figure 5-65 Pinion Projection Length Figure 5-62 Rear Cover (during and before installation) 17. Install the rear cover (3) onto the yoke.

1. When the pinion is protruded by the magnetic switch, measure the pinion moving distance in the thrust direction. The moving distance should be between 0.3-1.5 mm. See Figure 565.

18. Using a 8 mm spanner wrench, install brush holder tightening screws and bolts M5. See Figure 5-62.

Figure 5-63 Bolt M6 (during and after removal) 19. Using a 10 mm spanner wrench, install bolts M6 and install magnetic switch (2). See Figure 5-59 and Figure 5-63.

Figure 5-66 Dust Cover 2. If the moving distance is not between 0.3-1.5 mm, adjust the dust cover. See Figure 5-66.

Figure 5-64 Nut M8 20. Connect the lead (1). See Figure 5-59.

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Servicing the Alternator

Figure 5-67 Alternator Components

Removing the Alternator 3

Disassembling the Alternator 4

2 2 3

4

Figure 5-68 Alternator

Figure 5-69 M5 Through Bolt

1. Disconnect the cable from the negative battery terminal.

1. Remove M5 through bolt (1) as shown. See Figure 5-69.

2. Remove electrical connections (2) from the alternator. See Figure 5-68.

2. Using a dryer, blow hot air onto the rear cover for approximately one minute or until the rear cover temperature rises approximately 122°F (50°C).

3. Loosen the screws and remove the V-belt (3, 4). See Figure 5-68.

4. Remove the screws and alternator (3, 4). See Figure 5-68.

3. Insert two standard-head screwdriver tip into the gap between the front cover and stator core, at two separate places, to separate the front cover and rotor (front side) from the rear cover and stator (rear side).

5. Check the V-belt tension. See “Checking the V-belt Tension” on page 238.

IMPORTANT:Do not damage the stator core with the screwdriver.

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Figure 5-70 Pulley Nut Assembly

Figure 5-72 Rotor Coil

4. Remove pulley nut assembly (2), pulley (3), and rotor (4). See Figure 5-70.

3. Using a circuit tester as shown, check the continuity between slip rings. If there is a disconnection in the rotor coil, replace the rotor. See Figure 5-72.

5. Secure the rotor into a vice.

6. Using a 24 mm spanner wrench, remove pulley nut M16.

Inspecting and Maintaining the Rotor

Figure 5-73 Rotor Coil

Figure 5-71 Slip Ring 1. Measure the outside diameter of the slip ring.

If the slip ring is worn by 1.0 mm or more from the standard 27.0 mm outside diameter, replace the slip ring. See Figure 5-71.

4. Using a circuit tester as shown, check the continuity between the slip ring and rotor core and shaft. If there is a rotor coil short circuit, replace the rotor. See Figure 5-73.

2. Inspect the slip ring surface for smoothness and be sure there is no oil adhesion. If the slip ring surface is too rough, apply a “fine” sandpaper to the surface. If the slip ring surface is stained, clean the surface using alcohol and a cloth.

Figure 5-74 Ball Bearing

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5. Inspect the rear side ball bearing. If abnormal rotation or sound exists, replace the ball bearing. See Figure 5-74.

Assembling the Alternator

Figure 5-77 Brush Holder Pin 5. Insert a pin and force the brush into the brush holder as shown. See Figure 5-77.

Figure 5-75 Pulley Nut Assembly 1. Using a 24 mm spanner wrench, install pulley nut M16. See Figure 5-75.

2. Install pulley nut assembly (2), pulley (3), and rotor (4).

3. Secure the front cover and rotor (front side) onto the rear cover and stator (rear side).

Figure 5-78 Rear Cover 6. Using a dryer, blow hot air onto the rear cover for approximately one minute or until the rear cover temperature rises approximately 122°F (50°C). See Figure 5-78.

Figure 5-76 M5 Through Bolt 4. Install M5 through bolt (1). See Figure 5-76.

Figure 5-79 Pin

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) 7. Extract the pin inserted in step 5. See Figure 579.

Servicing the Fuel Feed Pump Disassembling the Fuel Feed Pump

Installing the Alternator 3

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4

2 2 3

4

Figure 5-80 Alternator 1. Install screws and V-belt (3, 4). See Figure 580.

2. Install screws and alternator (3, 4). See Figure 5-80.

3. Install electrical connections (2) onto the alternator. See Figure 5-80.

4. Re-connect the negative battery cable.

Figure 5-81 Fuel Feed Pump 1. Remove the feed pump assembly from the fuel injection pump.

2. Remove the priming pump and check valve.

See Figure 5-81.

3. Remove the plug and check valve from the fuel outlet side.

4. Remove the plug.

5. Remove the piston.

6. Remove the snap ring.

7. Remove the tappet assembly, spring and push rod.

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Inspecting Fuel Feed Pump Parts

Assembling the Fuel Feed Pump

Check Valve 1. Check for damage and wear.

2. Replace the check valve if there is any damage or wear.

Piston 1. Check for surface defect and wear.

Springs (Piston and Check Valve) 1. Check for surface defect, fatigue.

2. Check valve piston and rust.

Tappet 1. Check for surface defect and wear.

2. Replace the tappet if the push rod outer surface is worn.

Figure 5-82 Fuel Feed Pump 1. Install the tappet assembly, spring and push rod. See Figure 5-81.

2. Install the snap ring.

3. Install the piston.

4. Install the plug.

5. Install the plug and check valve onto the fuel outlet side.

6. Install the priming pump and check valve.

7. Install the feed pump assembly onto the fuel injection pump.

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Servicing the Fuel Injection Pump Removing the Fuel Injection Pump

Figure 5-83 Fuel Injection Pump 1. Remove the fan (1), pulley and V-belt (1) from the engine body. See Figure 5-83.

2. Remove the fuel injection pipe (2), fuel oil piping, fuel return pipe and rear stay.

3. Remove the fuel injection pump drive gear.

4. Remove the fuel injection pump (8).

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Disassembling the Fuel Injection Pump

11. Remove the plunger and barrel.

12. Remove the control rack from the pump housing.

Servicing the Fuel Injection Pump

Figure 5-84 Fuel Injection Pump

NOTICE: Group all parts for re-assembly.

Replace any defective parts.

1. Remove the fuel feed pump. See “Disassembling the Fuel Feed Pump” on page 254.

Figure 5-85 Fuel Pump Driving Gear 1. Make matching marks on the pump drive gear gearing part and the idle gear. See Figure 5-85.

2. Remove the governor cover. See “Disassembling the Governor Cover” on page 260.

3. Remove the governor housing. See “Disassembling the Governor Housing” on page 260.

4. Using a socket wrench handle, remove the bottom screw.

5. Remove the fuel injection pump cover. See “Removing the Fuel Injection Pump” on page 256.

3. Remove fuel pump drive gear nut (5). See Figure 5-83 on page 256.

NOTICE: When removing the drive gear nut, do not drop it into the inside of the gear case.

4. Remove fuel injection pump drive gear (4) from the fuel pump using a gear puller. See Figure 5-83 on page 256.

6. Move the tappet away from the camshaft. See “Disassembling the Tappet and Camshaft” on page 261.

5. Make a mark on the fuel injection pump and use a sticker to record the fuel injection pump installation angle.

7. Remove the bearing holder, camshaft, and tappet. See “Disassembling the Tappet and Camshaft” on page 261.

6. Remove the fuel injection pump (8). See Figure 5-83 on page 256.

8. Remove the plunger spring, plunger spring lower retainer, and plunger spring upper retainer. See Figure 5-84.

Inspecting Fuel Injection Pump Parts 1. Wash all parts before inspection.

9. Remove the control sleeve and pinion.

2. Inspect parts for excessive wear.

10. Remove the lock plate, delivery valve, delivery valve spring, and delivery valve spring holder.

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2. Remove the gear installation nut. See Figure 585.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Adjusting the Spindle Drive Unit Rod Control

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IMPORTANT:Be sure to set the proper clearance. If the clearance is too small, the injection-pump rod can be damaged. If the clearance is too large, the engine maximum speed will be low.

Servicing the Fuel Injection Pump Gears

Figure 5-86 Rod Control

Figure 5-89 Gears Disassembling the Gears Figure 5-87 Spindle Drive Unit 1. Adjust the rod control nut to adjust the spindle motor minimum and maximum movement. See Figure 5-86 and Figure 5-87.

1. Make a matching mark on the pump drive gear and idle gear. See Figure 5-89.

2. Remove the fuel injection pump drive gear.

Reassembling the Gears 1. Assemble the pump drive gear and idle gears by aligning the match marks.

2. Tighten each gear nut to tightening torque 61.4-68.7 lb.-ft. (83.3-93.1 Nm).

Figure 5-88 Spindle Motor 2. Insert a thickness gauge (0.1 mm) between the minimum and maximum adjusting bolts of the injection pump to adjust the rod control in the minimum and maximum position of the spindle motor. See Figure 5-88.

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Assembling the Fuel Injection Pump

Installing the Fuel Injection Pump

Figure 5-91 Fuel Injection Pump

Figure 5-90 Fuel Injection Pump

1. Install the fuel injection pump (8). See Figure 5-91.

NOTICE: Group all parts for re-assembly.

Replace any defective parts.

For a larger view of Figure 5-91, see Figure 583 on page 256.

1. Install the control rack onto the pump housing.

See Figure 5-84.

2. Install the fuel injection pump according to the mark made and sticker applied while completing step 5 in “Removing the Fuel Injection Pump” on page 256.

2. Install the plunger and barrel.

3. Install the lock plate, delivery valve, delivery valve spring, and delivery valve spring holder.

3. Install fuel injection pump drive gear (4) onto the fuel pump.

4. Install the control sleeve and pinion.

5. Install the plunger spring, plunger spring lower retainer, and plunger spring upper retainer.

4. Install fuel pump drive gear nut (5).

5. Install and tighten the gear installation nut to tightening torque 113~123 Nm (83~91 lb.-ft.).

6. Install the bearing holder, camshaft, and tappet.

See “Assembling the Tappet and Camshaft” on page 264.

6. Install the fuel injection pump drive gear cover.

7. Install the fuel injection pump cover. See “Installing the Fuel Injection Pump” on page 259.

7. Install fuel injection pipe (2), fuel oil piping, fuel return pipe and rear stay.

8. Install cooling fan (1), pulley and V-belt (1) onto the engine body.

8. Using a socket wrench handle, install the bottom screw.

9. Install the governor housing. See “Assembling the Governor Housing” on page 260.

10. Install the governor cover. See “Assembling the Governor Cover” on page 260.

11. Install the fuel feed pump. See “Assembling the Fuel Feed Pump” on page 255.

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ME12002

Disassembling the Governor Housing

Disassembling the Governor Cover Governor Housing Extractor

Figure 5-92 Governor Cover 1. Disconnect the link connection by pushing the link leaf spring down with a screwdriver and shifting the governor cover to the left (or right). The link is connected to the control rack and the starting spring is connected to the spring eye.

2. Using a long-nosed pliers, remove the starting spring from the spring eye.

3. Remove the governor cover from the governor housing.

NOTICE: When removing the governor cover from the governor housing, do not bend the governor cover to the left (or right). If the governor cover is bent while the link is connected, a bent link increases the sliding resistance of the control rack after reassembling the governor, causing stiff governor movement.

Assembling the Governor Cover 1. Apply a coat of sealant onto the connecting sides of the governor cover and governor housing.

2. Install the governor cover onto the governor housing.

3. Using a long-nosed pliers, install the starting spring into the spring eye.

4. Connect the link connection by installing the link leaf spring.

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Figure 5-93 Flyweight Removal 1. Using a wrench, remove the camshaft nut and spring washer from the camshaft.

2. Remove the flyweight from the camshaft.

3. Screw the extractor into the flyweight holder threaded portion as shown. See Figure 5-93.

4. Remove the flyweight assembly.

5. Remove the governor housing from the injection pump housing.

6. Disconnect the camshaft and tappet by inserting the tappet holder between the tappet adjusting bolt and nut in the pump housing.

7. Remove and retain seven bolts from the governor housing.

8. Using a wooden or plastic hammer, tap the governor housing to remove it.

Assembling the Governor Housing 1. Install the governor housing by tapping it with a wooden or plastic hammer.

2. Secure the governor housing by installing the seven bolts.

3. Connect the camshaft and tappet by removing the tappet holder from the tappet adjusting bolt and nut in the pump housing.

4. Apply Yanmar sealant No. 977770-01212 or equivalent onto the facing sides of the governor housing and injection pump housing.

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5. Install the governor housing onto the injection pump housing.

4. Wrap oil seal protecting tape around the bearing key groove and thread. See Figure 5-95.

6. Install the flyweight assembly onto the camshaft and tighten the mounting nut tightening torque to 39.8-47.0 lb.-ft. (53.9-63.7 Nm).

5. Using a wooden or plastic hammer, tap the camshaft on the opposite side.

6. Insert a screwdriver into the gap and pry for removal.

7. Using a wrench, install the camshaft nut and spring washer onto the camshaft.

Figure 5-96 Drive Side Camshaft Figure 5-94 Tappet Holder

7. Position the drive side camshaft at top dead center. See Figure 5-96.

Servicing the Tappet and Camshaft

8. Remove the camshaft by pulling it toward the drive side.

Disassembling the Tappet and Camshaft 1. Using a socket wrench handle, remove the bottom screw.

2. Position the camshaft at top dead center and insert the special service tool (tappet holder) into the tappet hole.

Figure 5-97 Tappet Insert 9. Position the tappet insert underneath the tappet holder as shown. See Figure 5-97.

10. Remove the tappet holder by using the tappet insert to elevate the tappet roller.

Figure 5-95 Protective Tape 3. Remove the bearing cover.

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3. Remove and release the plunger. See Figure 599.

The plunger condition is normal if the plunger slides down smoothly because of its own weight.

4. Repeat step 3 several times while turning the plunger to different angles.

Inspecting the Delivery Valve

Figure 5-98 Clamp 11. Remove the tappet from the clamp camshaft hole. See Figure 5-98.

Inspecting the Tappet and Camshaft Parts Inspecting the Pump Housing

Figure 5-100 Delivery Valve

Check for threaded hole cracks, wear and damage.

1. Check the delivery valve at the piston for surface defect, corrosion and wear. See Figure 5100.

Inspecting the Plunger and Delivery Springs Check for surface defects, cracks, uneven wear, corrosion and rust.

Inspecting the Control Rack

Figure 5-101 Rack, Pinion and Sleeve Figure 5-99 Gravity Test Inspecting the Plunger and Barrel 1. Check the barrel at the lead portion for surface defect, uneven corrosion, and wear.

2. After washing, tilt the barrel approximately 60°.

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1. Check the control rack for rack, pinion and sleeve bend. See Figure 5-101.

2. Check the pinion for wear and damage at the gear component.

3. Check the sleeve for wear at the contact face with the plunger collar portion.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Inspecting the Plunger Spring Lower Retainer

Inspecting the Tappet

Figure 5-102 Tappet 1. Check the pin hole, roller, pin and bushing for wear and damage. See Figure 5-102.

Figure 5-104 Plunger Spring Lower Retainer

Inspecting the Camshaft

1. Check the plunger spring lower retainer section that contacts the plunger for deformation and wear.

Figure 5-103 Camshaft 1. Check the camshaft surface for damage and wear. See Figure 5-103.

2. Check the key groove and thread for deformation.

3. Check the shaft for “bend.”

Inspecting the Bearing 1. Check the roller bearing for wear.

2. Check the outer-race plate for surface defect.

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ME12002

4. Position the drive side camshaft at top dead center.

5. Using a wooden or plastic hammer, tap the camshaft to install.

Figure 5-105 Clamp 1. Install the tappet into the clamp camshaft hole.

See Figure 5-105.

Figure 5-108 Bearing Key Groove and Thread 6. Install the bearing key groove and thread. See Figure 5-108.

7. Install the bearing cover.

8. Using a socket wrench handle, install the bottom screw.

Figure 5-106 Tappet 2. Use the tappet insert to elevate the tappet roller and install the tappet holder. See Figure 5-106.

Figure 5-107 Drive Side Camshaft 3. Install the camshaft by pulling it away from the drive side. See Figure 5-107.

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Servicing the Cylinder Head Disassembling the Cylinder Head

Figure 5-109 Cylinder Head Components Disassemble according to the following steps and as shown in Figure 5-109.

9. Remove the exhaust manifold (9) assembly.

10. Remove the hood assembly (10).

1. Remove the oil cooler (1) and alternator assembly. See Figure 5-109.

11. Remove the rocker shaft assembly (11), push rods and valve caps.

2. Remove the fan (2), pulley (2) and V-belt.

12. Remove the cylinder head assembly (12) and head gasket.

3. Remove the thermostat (3) case.

4. Remove the fuel filter (4) and fuel oil piping.

13. Remove the fuel injection valves and fuel return pipe (13).

5. Remove the oil level gauge assembly.

14. Remove the intake/exhaust valves, stem seals and valve springs.

6. Remove the oil filter.

7. Remove the fuel injection pipes (7).

15. Remove the rocker arms from the rocker shaft.

8. Remove the intake manifold (8) assembly.

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ME12002

For a larger view of Figure 5-111, see Figure 5109 on page 265.

2. Install the intake/exhaust valves, stem seals and valve springs.

3. Install the fuel injection valves and fuel return pipe (13).

4. Install the cylinder head assembly (12) and head gasket.

5. Install the rocker shaft assembly (11), push rods and valve caps.

6. Install the hood assembly (10).

7. Install the exhaust manifold (9) assembly.

8. Install the intake manifold (8) assembly.

9. Install the fuel injection pipes (7).

Figure 5-110 Cylinder Head Loosening/Tightening Order 1. Loosen the cylinder head bolts (M13 x 1.5) as shown. See Figure 5-110.

2. Position the cylinder head assembly onto a clean work surface to prevent any damage to the combustion face.

Assembling the Cylinder Head

10. Install the oil filter.

11. Install the oil level gauge assembly.

12. Install the fuel filter (4) and fuel oil piping.

13. Install the thermostat (3) case.

14. Install the fan (2), pulley (2) and V-belt.

15. Install the oil cooler (1) and alternator assembly.

Assembling the Four-Head Cylinder 1. Replace the head gasket with a new head gasket.

2. Apply oil onto cylinder head bolts (M13 x 1.5) threaded and seat portions.

3. Install cylinder head bolts (M13 x 1.5).

4. Tighten cylinder head bolts (M13 x 1.5) to tightening torque 133.8-141.0 lb.-ft. (181.4191.2 Nm) as shown. See Figure 5-110.

Figure 5-111 Cylinder Head Components 1. Install the rocker arms onto the rocker shaft.

See Figure 5-111.

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Servicing the Gear Train and Camshaft

11. Remove the PTO lubrication pipe (8).

Disassembling the Gear Train and Camshaft

13. Remove the flywheel (10).

12. Remove the starting motor (9).

14. Remove the camshaft assembly (11). See “Disassembling the Camshaft” on page 269 and “Inspecting the Camshaft” on page 270.

15. Remove the gear case (12).

16. Remove and discard the oil seal (13) from the gear case cover.

Assembling the Gear Train and Camshaft 1. Apply lithium grease to a new oil seal (13). See Figure 5-112.

2. Install oil seal (13) onto the gear case cover.

3. Apply Yanmar sealant No. 977770-01212 to the gear case.

Figure 5-112 Gear Train and Camshaft Components

4. Install gear case (12) by matching the two dowel pins.

Disassemble the gear train and camshaft according to the following steps and as shown in Figure 5112.

5. Install the oil pan mounting bolts onto the bottom side of the gear case.

1. Complete cylinder head disassembly procedure steps 1 through 12. See “Disassembling the Cylinder Head” on page 265.

6. Install the camshaft assembly (11). See “Assembling the Camshaft” on page 271.

2. Remove the water pump (2). See Figure 5-112.

7. Install the flywheel (10).

8. Install the starting motor (9).

3. Remove the mounting bolt (14).

4. Using a gear puller, remove the crankshaft pulley (3).

9. Install the PTO lubrication pipe (8).

10. Install the PTO drive gear (7).

IMPORTANT:Use a pad and work carefully.

11. Install the idle gear assembly (6).

Do not damage the thread or pulley.

12. Install the fuel injection pump (5).

5. Remove the gear case cover (4).

13. Install the fuel injection pump drive gear (15).

6. Remove the fuel injection pump drive gear mounting nut (16).

14. Install the fuel injection pump drive gear mounting nut (16).

7. Using a gear puller, remove the fuel injection pump drive gear (15).

15. Install the gear case cover (4).

16. Install the crankshaft pulley (3).

IMPORTANT:Use a pad and work carefully.

Do not damage the thread or drive gear.

17. Install the mounting bolt (14).

8. Remove the fuel injection pump (5).

18. Install the cooling water pump (2).

9. Remove the idle gear assembly (6).

10. Remove the PTO drive gear (7).

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19. Complete cylinder head assembly procedure steps 4 through 15. See “Assembling the Cylinder Head” on page 266.

Disassembling the Crankshaft Pulley 1. Remove the mounting bolt.

2. Securely position the gear puller to prevent the crankshaft pulley from being damaged.

3. Using a gear puller, remove the crankshaft pulley.

IMPORTANT:Use a pad and carefully operate when removing the crankshaft pulley so as not to damage the thread.

Assembling the Crankshaft Pulley

Figure 5-113 Gear Train 1. Measure the backlash of each gear (mm). See Figure 5-113 and the following table.

NOTICE: Do not to damage the oil seal while assembling the crankshaft pulley.

Crankshaft gear, Camshaft gear, Fuel injection pump gear, Idle gear, PTO gear, Lubricating oil pump gear

1. Apply lube oil to the mounting bolt. Only apply enough oil to assist with tightening the mounting bolt.

2. Install the crankshaft pulley.

IMPORTANT:Use a pad and carefully oper-

Standard (mm)

Limit (mm)

0.08-0.14

0.16

0.09~0.15

0.17

2. Apply sealant to the gear case cover.

ate when installing the crankshaft pulley so as not to damage the thread.

3. Install the gear case cover by correctly positioning the two dowel pins.

3. Install the mounting bolt.

Disassembling the Fuel Injection Pump

4. Tighten the mounting bolt to tightening torque 79.6-94.0 lb.-ft. (107.9~127.5 Nm).

1. Remove the fuel injection pump drive gear mounting nut.

Assembling the Gear Case Cover

2. Using the gear puller, remove the gear.

NOTICE: Be sure to install the two reinforcing bolts at the center when installing the gear case cover.

IMPORTANT:Use a pad at the shaft and carefully operate when removing the gear. Do not damage the thread.

3. Remove the fuel injection pump.

NOTICE: Be sure to remove the stay on the rear side.

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Assembling the Fuel Injection Pump

Disassembling the Camshaft

1. Install the fuel injection pump.

NOTICE: Be sure to install the stay on the rear side.

2. Install the gear.

IMPORTANT:Use a pad at the shaft and carefully operate when installing the gear. Do not damage the thread.

3. Install the fuel injection pump drive gear mounting nut.

4. Tighten the drive gear nut to tightening torque 61.5-68.7 lb.-ft. (83.4-93.2 Nm).

Assembling the Gear Train Figure 5-115 Camshaft Side Gap 1. Measure the camshaft side gap (mm). See Figure 5-115 and the following table.

Side gap

Standard (mm) Limit (mm) 0.05-0.20 0.30

2. If the measured side gap exceeds the limit, replace the thrust metal.

DANGER After heating crankshaft gear to 356°F~392°F (180°C~200°C), severe burns can occur. Proceed with extreme caution.

Figure 5-114 Gear Train 1. Simultaneously assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C by installing them onto idle gear A, B and C marks. See Figure 5-114.

3. Because the camshaft gear is shrink-fit, heat the camshaft gear to 356°F~392°F (180°C~200°C) before removing.

2. Install the idle gear shaft with the oil hole facing upward.

4. Raise the engine with its mounting flange at the bottom.

3. Install the PTO drive gear with its inner spline side facing the flywheel.

5. Remove the thrust metal mounting bolt from the camshaft gear hole.

Disassembling the Flywheel 1. Install a bolt, to be used as a handle, into the hole at the end face of the flywheel.

6. Rotate the camshaft four turns before removing it to prevent the tappet from being caught by the cam.

2. Carefully remove the flywheel.

7. Remove the camshaft carefully.

NOTICE: Do not damage the ring gear while

NOTICE: Do not to damage the bearing

removing the flywheel.

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bushing.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) 8. Position the engine horizontally and secure it onto the base.

CAUTION

Camshaft Height

ME12002

Standard (mm) Limit (mm) 49.435-49.529 49.185

Measuring the Camshaft Outside Diameter Flywheel Side

Injuries may result when raising the engine vertically or returning it to the horizontal position.

Proceed carefully so as not to lose balance.

Micrometer

Inspecting the Camshaft Checking for Camshaft Bend

1. Check the contact between the tappet and camshaft contact surface, bearing seizure and wear, and gear damage.

Dial Gauge

Camshaft

Figure 5-117 Camshaft Outside Diameter 6. Using a micrometer, measure and write down the camshaft outside diameter. See Figure 5117.

Camshaft

7. Insert the camshaft bushing into the cylinder.

8. Using a cylinder gauge, measure and write down the camshaft bushing inside diameter.

V-Block

Figure 5-116 Camshaft Bend

9. Use the following equation to calculate oil clearance: oil clearance = camshaft bushing inside diameter - camshaft outside diameter

Measuring the Camshaft Bend

1. Support the camshaft with V-blocks. See Figure 5-116.

2. Rotate the camshaft.

3. Using a dial gauge, measure runout at the center of the camshaft and at each plain-bearing shaft. See Figure 5-116.

4. Half (1/2) of the runout measured is the bend.

Compare measurements made to the following table: Bend

Standard (mm) 0-0.02

Limit (mm) 0.05

5. Compare intake-exhaust camshaft height measurements to the following table: 909768/BP1207

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Measuring the Gears

Standard (mm)

Standard Limit (mm) (mm) Bushing inside diameter Camshaft Gear side outside diameter Oil clearance Block inside diameter Intermediate Camshaft position outside diameter Oil clearance Block inside diameter Camshaft Wheel side outside diameter Oil clearance

57.98058.050

58.125

57.91057.940

57.875

0.0400.140

0.250

58.00058.030

58.105

57.89557.925

57.860

0.0750.135

0.245

58.00058.030

58.105

57.91057.940

57.875

0.0500.120

0.230

Shaft outside diameter 45.950-49.975 Bushing inside diameter 46.000-46.025 Clearance 0.025-0.075

Limit (mm)

45.900 46.075 0.175

Inspecting the PTO Drive Gear 1. Check for bearings sticking on both sides.

2. Check for gear damage and looseness.

3. Check for gear shaft damage and wear.

Replacing the Oil Seal 1. Replace the oil seal with a new oil seal when disassembling the gear case.

2. Apply lithium grease.

Assembling the Camshaft

CAUTION Injuries may result when raising the engine vertically or returning it to the horizontal position.

Proceed carefully so as not to lose balance.

Inspecting the Idle Gear 1. Check the bushing seizure, wear, and gear damage.

1. Position the engine horizontally and secure it onto the base.

NOTICE: Do not to damage the bearing bushing.

2. Raise the engine with its mounting flange at the bottom.

3. Install the camshaft carefully.

4. Install the thrust bearing mounting bolt into the camshaft gear hole.

Figure 5-118 Idle Gear 2. Measure and write down the shaft outside diameter and bushing inside diameter. See Figure 5-118.

3. Compare shaft outside diameter and bushing inside diameter measurements to the following table: Printed in U.S.A

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Disassembling the Cylinder Block Removing the Mounting Flange 1. Complete cylinder head disassembly procedure steps 1 through 12. See “Disassembling the Cylinder Head” on page 265.

2. Complete gear train and camshaft disassembly procedure steps 2 through 15. See “Disassembling the Gear Train and Camshaft” on page 267.

3. Remove the oil pan (3). See Figure 5-120.

IMPORTANT:Do not damage the oil pan bonding surface.

4. Remove the lubricating oil suction pipe (4).

Figure 5-119 Camshaft Gear 5. Install the camshaft gear. See Figure 5-119.

Servicing the Cylinder Block

Figure 5-121 Connecting Rod Side Gap 5. Measure the connecting rod side gap. The measurement should be 0.20 ~ 0.40 mm. See Figure 5-121.

6. Wipe-off any carbon deposits on top of the cylinder.

IMPORTANT:Do not damage the inner surFigure 5-120 Cylinder Block Components

face of the cylinder.

CAUTION Injuries may result when raising the engine vertically or returning it to the horizontal position.

Proceed carefully so as not to lose balance.

Figure 5-122 Piston 909768/BP1207

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7. Rotate the piston (5) to the bottom dead center position and remove the connecting rod cap.

See Figure 5-122.

For servicing the piston, see “Servicing the Piston” on page 279.

8. Rotate the piston to the top dead center position and push the connecting rod wide-end with the shaft of a hammer.

NOTICE: Do not allow the cylinder block to collide with the connecting rod wide-end.

Figure 5-124 Bearing Caps

9. Return the rod caps and crank-pin bearings to their correct combinations.

10. Position the engine with the cylinder block upper surface facing downward and secure it onto a base.

11. Remove the mounting flange (6). See Figure 5122.

12. Remove and discard the mounting flange (6) oil seal.

IMPORTANT:Do not damage the combustion surface when removing the mounting flange.

Removing the Crankshaft Figure 5-125 Crankshaft Bearings 2. Remove the bearing caps (7) and cap side bearings. Identify and position upper and lower bearings as pairs. The upper bearing has an oil hole. See Figure 5-123 and Figure 5-124.

3. Remove the thrust bearings. Identify and position each thrust bearing in the direction of removal. See Figure 5-125.

CAUTION

Figure 5-123 Crankshaft Side Gap

Use care when moving the crankshaft, mishandling the crankshaft can cause serious injury, and damage to the crankshaft.

1. Measure the crankshaft side gap. The crankshaft side gap should measure 0.13~0.23 mm.

If the side gap exceeds 0.23 mm, replace the thrust bearing with a thrust bearing exceeding 0.1” (2.605 mm) thickness.

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Inspecting and Measuring Cylinder Block Parts 1. Inspect the cylinder bore for discoloration and/ or cracking. If there is the appearance of cracking, confirm cracking by performing a colorcheck.

2. Wipe-off all carbon deposits and bonding agents.

Figure 5-126 Crankshaft 4. Remove the crankshaft (8). Identify and position each upper bearing with each cap side lower bearing. See Figure 5-120. For servicing the crankshaft, see “Servicing the Crankshaft” on page 277.

3. Clean the cylinder head surface, cylinder bores and oil holes.

4. Check that the oil holes are not clogged.

Removing Piston Pin and Rings

Figure 5-129 Cylinder Bore

Figure 5-127 Piston Ring

5. Check for cylinder bore distortion by measuring at 20 mm below the liner crest and 20 mm above the bottom end of the cylinder. Measure in the center as shown. See Figure 5-129.

1. Remove the piston rings. See Figure 5-127.

2. Remove the circlip and remove the piston pin by pushing it out.

Figure 5-130 Cylinder Bore Measurement 6. Measure in two directions, A and B, at points a, b, and c. See Figure 5-130.

Figure 5-128 Oil Seal

7. Refer to the following table for acceptable measurements:

3. Remove and discard oil seal (11). See Figure 5-120.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Standard (mm)

Cylinder inside diameter Cylinder bore roundness* Cylinder bore cylindricity*

Installing Piston Pin and Rings

Limit (mm)

1. Apply standard lube oil to the sliding contact surfaces of the pistons, rods, and rings.

106.00~106.03 106.13

0.01 or less

0.03

*roundness: Maximum value of the difference between the measured values in the same cross section. *cylindricity: Maximum value of the difference between the measured values in the same direction.

8. If measurements are not acceptable (see step 7 for acceptable measurements), repair or replace as required. When replacing, use an oversized piston and new piston rings as required. Refer to the following table for acceptable measurements: Standard (mm)

Oversized piston (0.25 mm) Cylinder boring dimension

106.25 106.25-106.28

Figure 5-132 Connecting Rod and Piston

Assembling the Cylinder Block

Figure 5-131 Oil Seal 1. Apply lithium grease to and install a new oil seal (11). See Figure 5-131.

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Figure 5-133 Piston 2. Insert each piston (with rod) (5) into the cylinder block as shown. See Figure 5-132 and Figure 5-133.

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Figure 5-136 Crankshaft 1. Install the crankshaft (8). See Figure 5-136.

Figure 5-134 Ring Joints 3. Install the piston ring joints as shown. See Figure 5-134.

NOTICE: Do not position the top ring joint vertical to the piston pin.

Figure 5-137 Bearing Caps

Figure 5-135 Piston Ring 4. Install each piston ring onto the piston with the manufacturer’s mark facing upward. See Figure 5-135.

Installing the Crankshaft

CAUTION Use care when moving the crankshaft, mishandling the crankshaft can cause serious injury, and damage to the crankshaft.

Figure 5-138 Crankshaft Bearings 2. Install the bearing caps (7), cap side bearings, and upper and lower bearings as pairs. The upper bearings have oil holes. See Figure 5137 and Figure 5-138.

3. Install the thrust bearings in the direction of removal. See Figure 5-138.

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Installing the Mounting Flange

7. Install the lubricating oil suction pipe (4).

8. Apply Yanmar sealant No. 977770-01212 to the oil pan and install the oil pan (3).

IMPORTANT:Do not damage the oil pan bonding surface.

9. Complete cylinder head assembly procedure steps 1 through 15. See “Assembling the Cylinder Head” on page 266.

10. Complete gear train and camshaft assembly procedure steps 1 through 18. See “Assembling the Gear Train and Camshaft” on page 267.

Servicing the Crankshaft 1. If necessary, complete all steps in “Removing the Mounting Flange” on page 272 and “Removing the Crankshaft” on page 273.

Figure 5-139 Cylinder Block Components

CAUTION

2. Clean the crankshaft.

Injuries may result when raising the engine vertically or returning it to the horizontal position.

Proceed carefully so as not to lose balance.

NOTICE: Do not damage the combustion surface when installing the mounting flange.

1. If necessary, position the engine with the cylinder block upper surface facing downward and secure it onto a base.

2. Apply lithium grease to and install a new oil seal.

3. Check crankpins/journals for signs of seizure and wear.

DANGER After heating crankshaft gear to 356°F~392°F (180°C~200°C), severe burns can occur. Proceed with extreme caution.

4. Because the crankshaft gear is shrink-fit. Heat the crankshaft gear to 356°F~392°F (180°C~200°C) before removing.

3. Apply Yanmar sealant No. 977770-01212 to and install mounting flange (6). See Figure 5139.

4. Install the rod cap and crank-pin bearing combinations.

IMPORTANT:Do not allow the connecting rod wide-end to collide with the cylinder block.

5. If necessary, rotate the piston (5) to the top dead center position and install the connecting rod wide-end.

Figure 5-140 Color-check

6. If necessary, rotate the piston to the bottom dead center position and install the connecting rod cap.

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5. Color-check the crankshaft as shown. See Figure 5-140.

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6. Replace the crankshaft if it is cracked or heavily damaged. Correct slight crankshaft defects by grinding.

Figure 5-142 Crankpin and Crank Journal Measuring Position Figure 5-141 Crankshaft Bend Measurement 7. Support the crankshaft journals at both ends with V-blocks. See Figure 5-141.

8. While rotating the shaft, use a dial gauge and measure the center journal runout.

9. While rotating the shaft, measure the crankshaft bend. The bend must be 0.02 mm or less.

10. Measure the outside diameter, roundness, and taper at each crankpin and crankshaft journal as shown. See Figure 5-142.

NOTICE: If the oil clearance is excessive and the journal and crankpin metal thicknesses are normal, or if there is partial, uneven wear, re-grind the crankshaft and use oversized bearings.

NOTICE: If rust or surface roughening exists on the rear side of the bearing, coat it with engineer’s blue or equivalent. Then assemble the crankpin metal to the connecting rod and tighten the rod bolt to the specified torque to check the metal for contact. If there is 75% or more surface contact, the metal is normal. If there is less than 75% surface contact, replace the metal.

11. Replace the crankpin and/or crankshaft journal if the roundness exceeds the limit or is below the standard range. Correct uneven wear by grinding. Refer to the table on the following page.

12. Replace the bearing if the oil clearance exceeds the limit or is below the standard range. Refer to the table on the following page.

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13. Replace the crank journal bearing if the diameter exceeds the limit or is below the standard range. Refer to the following table.

Standard (mm) Limit (mm) Pin outside diameter Metal thickness Oil clearance Undersized bearing Pin machining dimension Crankshaft journal outer diameter Crankshaft journal metal thickness Crankshaft journal oil clearance Crankshaft journal undersized bearing Crankshaft journal bearing machining dimension

63.952~63.962 63.902 1.984~1.992 0.054~0.090

0.150

2.109~2.117

3. Remove any debris from the ring and snap ring grooves. If there may be a crack, inspect the ring and snap ring grooves by performing a color-check.

63.702~63.712 75.952~75.962 75.902

2.488~2.503

0.052~0.090

0.150

2.613~2.628

Figure 5-143 Piston Outside Diameter

75.702~75.712

4. Measure the piston length from the bottom end of the piston oval hole to the piston pin hole at the measurement position marked “H” mm in Figure 5-143.

5. Check that measurement position “H” is 30 mm.

Standard (mm) Limit (mm) 2.430~2.480

6. Measure the piston outside diameter. The standard piston outside diameter measurement is 105.930~105.960 mm and the limit is 105.880 mm.

2.35

15. If the side gap is exceeded, use an oversized thrust bearing measuring 2.555~2.605 mm.

7. Measure the clearance between the piston and the cylinder. If the clearance exceeds 0.080 mm, use an oversized piston (0.25 mm). The oversized piston (0.25 mm) diameter should equal 106.250 mm.

16. If necessary, complete all steps in “Installing the Mounting Flange” on page 277 and “Installing the Crankshaft” on page 276.

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1. If necessary, complete all steps in “Removing the Mounting Flange” on page 272 and “Removing Piston Pin and Rings” on page 274.

2. Clean the combustion surface, circumference, ring grooves, piston pin bosses, and wipe-off any carbon deposits.

14. Check the thrust bearings for any damage or wear and for appropriate thickness. Refer to the following table.

Thrust bearing thickness

Servicing the Piston

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Figure 5-144 Piston Pin Outside Diameter 8. Measure the piston pin outside diameter at positions a, b, and c in directions A and B. See Figure 5-144. The piston pin outside diameter measurement should equal 106.250~106.280 mm.

Figure 5-146 Ring Components 10. Measure the top ring, ring groove, and end clearance measurement. See Figure 5-146.

Refer to the following table.

S ta n d a rd (m m ) Ring groove width Ring width Top Ring S ide c learanc e E nd c learanc e

L im it (m m )

2.520~ 2.540 2.440~ 2.460

2.420

0.060~ 0.100 0.300~ 0.450

0.540

Figure 5-145 Piston Pin Hole 9. Measure the piston pin hole diameter at positions a and b in directions A and B. See Figure 5-145. Refer to the following table for acceptable piston pin hole diameter measurements.

Standard (mm) Limit (mm) Pin, inner diameter Pin, outer diameter Clearance

37.000~37.011 37.039

Figure 5-147 Measuring Side Clearance

36.989~37.000 36.959

11. Measure the width of the piston ring. See Figure 5-147.

0.000~0.0220

0.08

12. Insert the piston ring into the ring groove.

13. Measure the side clearance by inserting a thickness gauge between the piston ring and ring groove.

14. Use the following equation to calculate the ring groove width: ring groove width = ring width + measured side clearance

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Inspecting the Connecting Rod

Figure 5-149 Twist Parallelism Measurement 1. Inspect the connecting rod near the chamfered portion and I-beam section of the big and small connecting rod ends. See Figure 5-149.

2. Inspect the connecting rod near the oil hole of the bushing at the small end for cracks, deformation, and discoloration.

Figure 5-148 Ring Joint End Clearance Measurement 15. Using the piston head, push the piston ring into the sleeve to about 30 mm above the bottom end of the cylinder.

16. Measure the end clearance by inserting a thickness gauge into the end clearance. Refer to the following table.

17. Measure the oil ring, ring groove, ring width, side clearance, and end clearance measurement. See Figure 5-148. Refer to the following table.

Standard (mm)

Piston Ring

Ring groove width Ring width Side clearance End clearance

Limit (mm)

Figure 5-150 Connecting Rod Aligner Twist Measurement

2.070~2.085 2.185

3. Using a connecting rod aligner, measure the connecting rod twist and bend. The measurement should be 0.03 mm or less per 100 mm, with a limit of 0.08 mm per 100 mm. See Figure 5-150.

1.970~1.990 1.950 0.080~0.115 0.235 0.450~0.600 0.680 Standard (mm)

Ring groove width Ring width Oil Ring Side clearance End clearance

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Limit (mm)

3.015~3.030 3.130 2.970~2.990 2.950 0.025~0.060 0.180 0.300~0.500 0.600

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Figure 5-151 Connecting Small Rod End 4. Using a cylinder gauge, measure the connecting small rod pin inner and outer diameter. See Figure 5-151, Figure 5-152, and refer to the following table.

Figure 5-153 Tappet Stem Outside Diameter Measurement 3. Measure the tappet stem outside diameter as shown. Refer to the following table.

Standard (mm) Limit (mm)

Tappet hole inner diameter 14.000~14.018 Stem outer diameter 13.966~13.984 Clearance 0.015~0.052

Standard (mm) Limit (mm)

Piston pin inner diameter bushing 37.025~37.038

37.068

Pin outer diameter 36.989~37.000 Clearance 0.025~0.049

36.961 0.107

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14.038 13.946 0.092

5. Measure the outside diameter, roundness, and taper of the connecting big rod end crankpin and bushing.

Inspecting the Tappet

Figure 5-154 Cylinder Bore Correction 4. Prepare the following items for honing: FlexHone, electric drill, and honing fluid. Honing fluid consists of 50% lube oil and 50% diesel oil. See Figure 5-154.

Figure 5-152 Tappet Inspection 1. Inspect the tappet contact surface, this is the surface that contacts the camshaft and push rod. See Figure 5-152.

5. Insert the Flex-Hone into the electric drill.

6. Correct slightly unevenly worn, and otherwise minorly flawed cylinder bores by honing.

For cylinder bores that cannot be repaired only by honing, re-bore the cylinder bore first and then hone the cylinder bore.

2. Using an oilstone, correct any minor tappet contact surface defects as necessary.

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Replace cylinder bores that contain major flaws.

7. Apply the honing fluid to the Flex-Hone and warm-up the electric drill to about 300-1200 rpm.

IMPORTANT:Do not exceed 1200 rpm, otherwise damage may occur.

8. Dip the Flex-Hone, attached to the electric drill, into the honing fluid.

Figure 5-155 Honing Cross Hatch 9. Insert the Flex-Hone into the cylinder bore while rotating the Flex-Hone and moving the electric drill up-and-down for approximately 30 seconds. This process obtains a honing mark with a cross-hatch angle of 30-40°. See Figure 5-155.

IMPORTANT:Do not insert or extract FlexHone into cylinder bore unless the Flex-Hone is rotating, otherwise the cylinder may be damaged.

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Figure 5-156 Cylinder Block Service Life 10. Refer to Figure 5-156 to see if an oversized piston or piston ring is usable.

Lubrication System

Figure 5-157 Lubrication System Diagram 909768/BP1207

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Servicing the Trochoid Pump Removing the Trochoid Pump

Figure 5-160 Trochoid Pump Components 5. Remove the lubricating oil pump assembly (4) from the gear case. See Figure 5-160.

Figure 5-158 Cylinder Head

6. Remove the pressure regulating valve (5) from the lubricating oil pump.

1. Loosen the belt and remove the fan, pulley and V-belt. See Figure 5-158.

7. Wash the pressure regulating valve.

8. Only disassemble the pressure regulating valve if there is any abnormal operation.

For a larger view of Figure 5-158, see Figure 5-109 on page 265.

Inspecting the Trochoid Pump

Figure 5-159 Crankshaft Pulley and Gear Case Cover 2. Using a gear puller, remove the crankshaft pulley (3). See Figure 5-159.

IMPORTANT:Use a pad and work carefully.

Do not damage the thread or pulley.

Figure 5-161 Oil Clearance 1. Measure the oil clearance between the outer rotor and gear case as shown. The oil clearance should measure 0.100~0.165 mm with a limit of 0.25 mm. See Figure 5-161.

3. Remove the gear case cover (4).

4. Check if the pump rotates smoothly and see that there is no play between the shaft, gear, and inner rotor.

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Figure 5-162 Side Clearance 2. Measure the side clearance as shown, the side clearance should measure 0.05~0.10 mm with a limit of 0.15 mm.

ME12002

Figure 5-164 Trochoid Pump Components 2. Install the pressure regulating valve (5) into the lubricating oil pump. See Figure 5-164.

3. Install the lubricating oil pump assembly (4) into the gear case.

NOTICE: If replacing the lubricating oil pump, replace the entire lubricating oil pump assembly.

NOTICE: Always check that the lubricating oil pump rotates smoothly after installation onto the gear case.

Figure 5-163 Lube Oil Pump Bearing 3. Measure the rotor shaft outer diameter, the gear case bearing inner diameter, and the gear case clearance as shown. Refer to the following table.

Standard (mm) Shaft outer diameter 12.955~12.970 Bearing inner diameter 12.980~13.020 Clearance 0.010~0.065

Limit (mm) 12.945 13.050 0.105

Installing the Trochoid Pump 1. If the pressure regulating valve was disassembled (see step 8 of “Removing the Trochoid Pump” on page 285), assemble the pressure regulating valve.

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Figure 5-165 Crankshaft Pulley and Gear Case Cover 4. Install gear case cover (4). See Figure 5-165.

5. Install crankshaft pulley (3).

IMPORTANT:Use a pad and work carefully.

Do not damage the thread or pulley.

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YANMAR ENGINE 4TNE106T-NS (SN AB00473-AB03158) Servicing the Turbocharger

Figure 5-166 Cylinder Head 6. Install the fan, pulley and V-belt and tighten the belt. See Figure 5-166.

For a larger view of Figure 5-166, see Figure 5-109 on page 265.

Figure 5-167 Turbocharger No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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Part Name Turbine shaft Oil thrower Turbine side seal ring Seal plate Journal bearing Thrust bearing Compressor housing M5 hexagon bolt M5 spring washer Compressor side clamp Turbine housing M6 hexagon bolt Turbine side clamp Lockwasher Bearing housing Retaining ring M3 countersunk flat head screw Compressor wheel Shaft end nut Heat protector

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ME12002

Turbocharger Components

Turbine The turbine includes a seal ring and heat insulating plate to protect the bearing. In the turbine, engine exhaust gas accelerates within the turbine housing nozzle portion and blows into the turbine impeller to rotate the turbine shaft.

Compressor The turbine shaft compressor impeller rotates with the shaft to suck and compress air for feeding into the intake manifold.

Compressor Side Sealing Mechanism

Figure 5-168 Turbocharger Components

A seal ring and seal plate are provided to prevent the intake air and oil from leaking and to form a double wall structure on the rear side of the compressor impeller.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Bearings Thrust Bearing

A thrust force constantly pressures the turbine shaft, the thrust bearing prevents the thrust force from moving the turbine shaft.

Radial Bearing

A floating bearing is adopted. Because the bearing moves with the turbine shaft as oil films form both inside and outside of the bearing, the bearing sliding speed is slower than the turbine shaft speed, resulting in higher dynamic stability.

Waste Gate The waste gate consists of a control assembly separated from the turbocharger and a valve assembly installed in the turbine impeller chamber.

When blower side pressure (intake air pressure) exceeds the specified level, turbine inlet exhaust gas partially bypasses to the exhaust discharge side. This controls the turbine rpm which maintains intake pressure at the specified level. The maintained intake pressure improves the response to load variation in the low to medium speed range and minimizes black smoke generation.

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Part Name Turbine shaft Thrust bushing Oil thrower Seal ring Seal ring Seal ring (turbine side) Lock nut lmpeller Seal plate Journal bearing Thrust bearing Compressor housing Flanged bolt Spring washer Clamp Turbine housing Bolt Lock plate Bearing housing Retaining ring Screw Screw Lock washer Heat protector Liquid gasket Waste gate actuator Hose Adapter Clip Retaining ring Waste gate valve Link plate

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Checking Waste Gate Valve Opening Pressure and Lift

Figure 5-169 Waste Gate Valve decreasing manometer control pressure (Pc) near the measuring point. If the 2 mm position is exceeded, restart from the beginning.

1. Prepare the equipment shown in Figure 5-169, described in the following table: Waste gate valve measuring instruments Measures 0 to 10 mm (a flat head Dial gauge type is recommended).

Mercury column or electrical type, Manometer measures 0-29 psi (0-1500 mm Hg).

Pressure Allows gradual adjustment in a regulating range 0-28 psi (0-20 kPa). valve Pressure Suppresses the air supply reducing pressure at 71 psi (490 kPa) or valve less.

Pressure Bourdon tube pressure gauge (0 to gauge 142 psi [980 kPa]).

•

3. Secure the manometer to the waste gate actuator.

4. Set the manometer control pressure (Pc) to 0 and set the dial gauge to 0.

5. Gradually open the pressure regulating valve and measure the Pc value when the actuator rod is operated by 2 mm.

2. Follow these requirements when completing steps 3-6: •

Set the dial gauge on the actuator rod extension line.

•

Check that the piping and joints are leakfree.

•

Secure the turbocharger and dial gauge. If using an electric manometer, be sure it has sufficient precision. When using an electric manometer, also use a mercury column type manometer for calibration and daily check.

•

Do not apply over 71 psi (490 kPa) to the actuator.

6. For the hysteresis, allow the rod to move to 3 mm. This gradually closes the pressure regulating valve. Measure the pressure when the rod moves to 2 mm, and calculate the difference from the pressure measured in step 5 above.

Performing a Waste Gate Actuator Leak Test 1. Apply 17 psi (120 kPa) to the actuator for 1 minute.

2. Check the actuator pressure after 1 minute. The actuator is good if the pressure is 16 psi (110 kPa) or greater. If the pressure is less than 16 psi (110 kPa), replace the actuator.

Use a very slow operating speed for the pressure regulating valve when increasing/

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Turbocharger Service Standards

Figure 5-170 Turbine Shaft Service standards Turbine shaft

Bearing

Thrust bearing Seal ring fixing area Rotor play

Turbine shaft journal outside diameter (A) Turbine shaft seal ring groove width (E) Compressor side seal ring groove width (G) Compressor side seal ring groove width (G) Turbine shaft runout Journal bearing inside diameter (C) Journal bearing outside diameter (D) Bearing housing inside diameter (B) Thrust bearing width (J) Thrust bushing groove dimension (K) Turbine side (bearing housing) (F) Compressor side (seal ring) (H1)

Standard dimension (mm) 7.99 to 8.00 1.25 to 1.28 1.22 to 1.23 1.02 to 1.03 0.002 8.01 to 8.03 12.32 to 12.33 12.40 to 12.41 3.99 to 4.01 4.04 to 4.05 15.00 to 15.02 12.40 to 12.42

7.98 1.29 1.31 1.11 0.011 8.04 12.31 12.42 3.98 4.07 15.05 12.45

Compressor side (seal ring) (H2)

10.00 to 10.02

10.05

Rotor play in axial direction Rotor play in radial direction

0.03 to 0.06 0.08 to 0.13

0.09 0.17

Tightening torque Part Turbine housing set bolt Compressor housing set bolt Thrust bearing set screw Seal plate set screw Blower impeller set nut (left-handed screw)

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Thread diameter M8 M5 M3 M3 M5

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Wear limit (mm)

lb.-ft. (Nm) 21.0±0.7 (28.0±1.0) 3.5±0.4 (4.7±0.5) 1.0±0.1 (1.3±0.1) 1.0±0.1 (1.3±0.1) 1.5±0.1 (2.0±0.2)

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Chapter 6 TROUBLESHOOTING John Deere Engine Model 4045TF270 (SN AC02633 and up) Problem

Possible causes Wrong SAE grade of engine lubrication oil Fuel grade does not comply with specifications Defective or flat battery Loose or oxidized cable connections in starter circuit Defective starter, or pinion does not engage Wrong valve tip clearance Defective fuel injector

Engine does not start or is not easy to start

Defective starting relay Defective glow plug/defective intake-air preheating Defective solenoid switch Cutoff solenoid does not attract Cutoff solenoid without current Clogged filter Air in fuel system Defective cutoff solenoid, timer or relay High pressure created immediately in the hydraulic system Fuel grade does not comply with specifications

Engine starts, but does not run smoothly or evenly

Wrong valve tip clearance Injection line leaks Defective fuel injector Oil level too low Oil level too high Dirty air filter Dirty cooler fins

Engine overheats. Temperature warning system responds

Defective fan, torn or loose V-belt Resistance in cooling system too high, flow capacity too low Damaged seal in radiator Coolant level too low Defective fuel injector

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Problem

Possible causes Oil level too high Fuel grade does not comply with specifications Dirty air filter Defective air filter maintenance switch or gauge

Insufficient engine output

Wrong valve tip clearance Injection line leaks Defective fuel injector Injection line leaks

Engine does not run on all cylinders

Defective fuel injector Oil level too low Machine inclination is too high (see engine specifications)

Insufficient or no engine oil pressure

Dirty oil intake filter Wrong SAE grade of engine lubrication oil Oil level too high

Engine oil consumption too high

Machine inclination is too high (see engine specifications) Oil level too high Blue

Machine inclination is too high (see engine specifications) Engine oil combustion (defective cylinder head gasket) Engine starting temperature too low

White Engine smoke

Fuel grade does not comply with specifications Defective fuel injector Coolant combustion (defective cylinder head gasket) Dirty air filter Defective air filter maintenance switch or gauge

Black

Wrong valve tip clearance Defective fuel injector (drips) Wrong fuel injection pump setting

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Yanmar Engine Model 4TNE106T-NS (SN AB00473-AB03158) Problem

Possible causes Wrong intake/exhaust valve clearance Defective intake/exhaust valve Defective or broken piston ring Worn piston ring, piston and/or cylinder Defective crankpin metal and/or bearing Foreign matter trapped in combustion chamber Wrong intake/exhaust valves open/close timing Wrong lubricating oil properties

Engine does not start

Water in fuel system Clogged fuel filter Air in fuel system Clogged or cracked fuel pipe Insufficient fuel supply to fuel injection pump Priming failure Defective starting motor Defective alternator Open-circuit in wiring Battery voltage drop Wrong intake/exhaust valve clearance Valve seat compression leakage Defective intake/exhaust valve Defective or broken piston ring

Engine starts, but does not run smoothly or evenly

Defective crankpin metal and/or bearing Worn crankpin and/or journal bearing Loosened connecting bolt rod Foreign matter trapped in combustion chamber Excessive gear rearward backlash Wrong intake/exhaust valves open/close timing

Printed in U.S.A

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Problem

Possible causes Wrong intake/exhaust valve clearance Valve seat compression leakage Defective intake/exhaust valve Defective or broken cylinder head gasket Worn crankpin and/or journal bearing Normal

Wrong lubricating oil properties Fuel grade does not comply with specifications Clogged fuel filter Air in fuel system Clogged or cracked fuel pipe Insufficient fuel supply to fuel injection pump Clogged feed pump inlet filter Defective or broken piston ring Worn piston ring, piston and/or cylinder Wrong piston ring joint arrangement Wrong piston ring assembly Worn intake/exhaust valve guide

Insufficient engine output

Exhaust smoke color

White

Wrong intake/exhaust valves open/close timing Worn turbocharger floating bearing Wrong fuel injection pump timing (too late) Fuel grade does not comply with specifications Water in fuel system Uneven fuel injection pump injection volume Wrong fuel injection nozzle spray pattern Valve seat compression leakage Defective intake/exhaust valve Wrong intake/exhaust valves open/close timing Defective turbocharger blower Defective turbocharger waste gate

Black

Insufficient radiator cooling effect Insufficient cooling water level Loose fan belt Defective thermostat Wrong fuel injection pump timing (too late) Fuel grade does not comply with specifications Uneven fuel injection pump injection volume

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Insufficient engine output (continued)

Exhaust smoke color (cont.)

Possible causes Wrong fuel injection nozzle spray pattern Black (continued)

Clogged air filter Excessive use at high operating temperature and/or altitude Clogged exhaust pipe Wrong intake/exhaust valve clearance Defective crankpin metal and/or bearing Wrong piston ring joint arrangement Defective alternator

None

Wrong lubricating oil properties Lubricating oil level too low or too high Clogged fuel filter

Exhaust Engine starts, but stops soon smoke

Air in fuel system Clogged or cracked fuel pipe Insufficient fuel supply to fuel injection pump Defective intake/exhaust valve Defective or broken piston ring High

Worn piston ring, piston and/or cylinder Water in fuel system Clogged air filter

Loud striking sound during combustion

Wrong fuel injection pump timing (too early) Fuel grade does not comply with specifications Water in fuel system

Uneven sounds during combustion

Uneven fuel injection pump injection volume Wrong fuel injection nozzle spray pattern Clogged air filter Clogged exhaust pipe

Printed in U.S.A

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Problem

Possible causes Defective or broken piston ring Defective crankpin metal and/or bearing Worn crankpin and/or journal bearing

While idling

Defective alternator Water in fuel system Uneven fuel injection pump injection volume Wrong fuel injection nozzle spray pattern

Engine rpm fluctuation

Defective intake/exhaust valve Defective crankpin metal and/or bearing Worn crankpin and/or journal bearing While working

Defective alternator Water in fuel system Uneven fuel injection pump injection volume Wrong fuel injection nozzle spray pattern Defective intake/exhaust valve Defective or broken piston ring Defective crankpin metal and/or bearing Worn crankpin and/or journal bearing

Engine vibration

Loosened connecting bolt rod Defective alternator Wrong fuel injection pump timing (too early) Uneven fuel injection pump injection volume Wrong fuel injection nozzle spray pattern

Difficulty returning to low engine speed

Defective alternator Valve seat compression leakage Excessive radiator cooling effect

Excessive fuel consumption

Wrong fuel injection pump timing (too late) Excessive fuel injection volume Wrong fuel injection nozzle spray pattern Excessive use at high operating temperature and/or altitude

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TROUBLESHOOTING Problem

Possible causes Defective or broken cylinder head gasket Defective or broken piston ring Insufficient radiator cooling effect Insufficient cooling water level

Overheat

Cracked regulation container and/or cooler cap Loose fan belt

Cooling water

Defective thermostat Excessive fuel injection volume Excessive use at high operating temperature and/or altitude Low temperature

Excessive radiator cooling effect Defective thermostat Defective or broken piston ring Worn piston ring, piston and/or cylinder Wrong piston ring joint arrangement Wrong piston ring assembly

Excessive consumption

Foreign matter trapped in combustion chamber Worn intake/exhaust valve guide Wrong lubricating oil properties Lubricating oil piping system leakage Excessive fuel injection volume Defective intake/exhaust valve

Fuel oil dilution

Defective or broken piston ring Worn piston ring, piston and/or cylinder

Lubricating Oil Mixture with water

Defective or broken cylinder head gasket Cracked regulation container and/or cooler cap Worn crankpin and/or journal bearing Loosened connecting bolt rod Cracked regulation container and/or cooler cap Wrong lubricating oil properties

Low pressure

Lubricating oil piping system leakage Insufficient trochoid pump delivery capacity Clogged lubricating oil filter Defective pressure regulating valve Wrong lubricating oil level

Printed in U.S.A

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Problem

Possible causes Valve seat compression leakage Defective intake/exhaust valve Defective or broken piston ring Worn piston ring, piston and/or cylinder Defective crankpin metal and/or bearing

Excessive blow-by gas Wrong piston ring joint arrangement (blow-by gas is compressed and burning mixture leaking Wrong piston ring assembly from the piston rings and into the crankcase) Foreign matter trapped in combustion chamber Worn intake/exhaust valve guide Wrong lubricating oil properties Clogged lubricating oil filter Excessive fuel injection volume

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TROUBLESHOOTING Problem

Possible causes Defective or broken piston ring Worn piston ring, piston and/or cylinder Wrong piston ring assembly Wrong intake/exhaust valves open/close timing Worn turbocharger floating bearing Excessive radiator cooling effect White

Defective thermostat Wrong fuel injection pump timing (too early) Wrong fuel injection pump timing (too late) Fuel grade does not comply with specifications Water in fuel system Uneven fuel injection pump injection volume

Discolored engine exhaust while running engine

Wrong fuel injection nozzle spray pattern

Exhaust smoke color

Valve seat compression leakage Defective intake/exhaust valve Wrong intake/exhaust valves open/close timing Defective turbocharger blower Defective turbocharger waste gate Wrong fuel injection pump timing (too early) Black

Wrong fuel injection pump timing (too late) Fuel grade does not comply with specifications Uneven fuel injection volume Excessive fuel injection volume Wrong fuel injection nozzle spray pattern Clogged air filter Excessive use at high operating temperature and/or altitude Clogged exhaust pipe

Printed in U.S.A

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ME12002

Troubleshooting the Starter

Figure 6-1 Yanmar Starter Troubleshooting 909768/BP1207

300

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TROUBLESHOOTING

Troubleshooting the Alternator

Figure 6-2 Yanmar Alternator Troubleshooting Printed in U.S.A

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General Information Indicator Lamps Problem Engine oil pressure indicator light comes on during operation.

Water temperature display light comes on during operation.

Possible Cause

Corrective Action

Engine oil pressure too low.

Stop engine immediately. Check oil level and add oil if necessary. If oil level is correct, oil pump may have failed.

Engine oil level too low.

Add oil.

Oil pump not working.

Replace oil pump. Contact authorized repair center.

Coolant level too low.

Add coolant.

Fan blades rotating too slowly.

Adjust V-belt tension.

Air filter plugged.

Clean air filter.

Engine overheated.

Check cooling system.

Battery voltage light comes on Alternator not charging properly. during operation.

Adjust V-belt tension.

Fuel light comes on.

Add fuel.

Low fuel.

Seals and Hoses Problem

Possible Cause

Corrective Action

Oil, coolant or fuel leakage under engine.

Loose hose connection.

Tighten hose connections.

Seals or hoses damaged.

Change seals or hoses and check engine oil, engine coolant or fuel levels. Add engine oil, coolant or fuel if necessary.

Hydraulic fluid losses from hydraulic system.

Loose hose fittings.

Tighten hose connections.

Seals, hoses or lines damaged.

Change seals, hoses and/or lines.

Possible Cause

Corrective Action

Traveling Gear Problem Machine will not travel in any direction.

Foreign object jammed in track.

Remove object.

Gears not operative.

Repair gears. Contact authorized repair center.

Machine will not travel straight Foreign object jammed in track. forward or backward.

Track tension unequal.

Travel valves damaged.

909768/BP1207

Remove object.

Adjust track tension.

Repair/replace valves. Contact authorized repair center.

302

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Bucket, Boom and Dozer Blade Problem Rotating swing frame is difficult or impossible.

Possible Cause

Corrective Action

Swing brake does not release.

Contact authorized repair center.

Insufficient lubrication.

Lubricate swing gear using remote grease fitting.

Turntable drive unit defective.

Contact authorized repair center.

Front end attachments do not Low hydraulic fluid level. work or work only at a low perHydraulic fluid is not warm. formance level.

Low engine power.

Hydraulic cylinders lower too quickly.

Hydraulic lines overheat.

Add hydraulic fluid.

Warm up the engine.

Contact authorized repair center.

Engine to pump coupling or hydraulic pump damaged.

Contact authorized repair center.

Pressure limiting valves set too low.

Contact authorized repair center.

Hydraulic cylinder damaged.

Contact authorized repair center.

Control valves damaged.

Contact authorized repair center.

Seals contaminated or damaged.

Contact authorized repair center.

Heavy internal leakage at control spools.

Contact authorized repair center.

Secondary cartridge valves damaged.

Contact authorized repair center.

Hydraulic oil filter blocked.

Clean or replace filter.

Low hydraulic fluid in hydraulic fluid reservoir.

Fill hydraulic fluid reservoir.

Secondary cartridges set too low.

Contact authorized repair center.

Hydraulic fluid cooling system not in working order.

Clean hydraulic fluid cooler.

Hydraulic Pump For all abnormal operation, inspect the main pump, main control valve, third pump and circuit. Measure the pilot pressure, pump discharge pressure, load pressure, etc. If checking or partially disassembling the hydraulic pump, see “Disassembling and Assembling the Hydraulic Pump” on page 85.

Dust is very harmful to hydraulic components. If checking or partially disassembling the hydraulic pump, be sure dust, sand, debris, etc. do not enter the pump.

See “Inspecting Filter and Drain Oil” on page 303.

•

See “Inspecting for Abnormal Vibration and Noise” on page 304.

•

See “Measuring Pressure of Each Part” on page 304.

Inspecting Filter and Drain Oil 1. Inspect the hydraulic oil filter.

Handle movable parts carefully. Use an oilstone when performing corrections, even for small damage.

2. Check the hydraulic oil filter for an abnormally large amount of metallic powder. The hydraulic oil filter contains a small amount of metallic powder because of normal shoe and cylinder wear.

While inspecting the hydraulic pump, do not damage the O-rings. Damaging the O-rings causes internal and external oil leakage.

3. Inspect the shoe if the hydraulic oil filter contains an abnormally large amount of metallic powder. An abnormally large amount of metallic powder may indicate abnormal shoe wear.

For all abnormal operation, complete the following sections: Printed in U.S.A

•

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4. Inspect the pump casing drain hydraulic oil.

Inspecting for Abnormal Vibration and Noise 1. Inspect the pump body for any abnormal vibration or noise.

2. Inspect the pump body to determine if the noise is the normal working noise from the regulator or attendant relief valve.

3. For abnormal vibration or sound, inspect for damage or cavitation inside the hydraulic pump.

Measuring Pressure of Each Part 1. If the pump does not control correctly, measure the pressure of each port to find the abnormal port.

2. If all measurements are normal, open each port for inspection.

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TROUBLESHOOTING NOTES

Printed in U.S.A

305

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ME12002 NOTES

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Printed in U.S.A

CHAPTER 7 ELECTRICAL SYSTEM Electric Wiring Diagram Legend Name A1 A2 AB1 B1 B2 B3 G1 H1 H2 H3 H4 H5 H6 H12 H13 H14 H15 H16 H17 H18 H19 H20 H21 H22 K1.1 K1.2 K1.3 K2 K2.1 K4 K5 K6 K7 K8 M1 M2 M3 M4 M5 M6 M7 P1 S1 S2 S4

Name S5 S6 S7 S8 S9 S10 S11

Description Pump regulation Diesel engine idler regulation Stop solenoid Water temperature sensor Horn Fuel level sensor Alternator Right side lamp Right front light Arm light Left front light Left side light Extended lights on arm Control lamp preheating Control lamp load control Control lamp engine temperature Control lamp engine oil pressure Control lamp air filter clogged Control lamp hydraulic oil filter clogged Control lamp overload warning Indoor lighting Cabin roof light front Cabin roof light rear Rotating beacon Climate relay off engine temperature Climate relay on Climate compressor Timer preheating 10 sec.

Preheating relay Starting relay Solenoid engine stop timer Solenoid engine stop Service interval relay Indicator relay Heating van Refueling pump Engine speed regulation Engine speed regulation Starter Windshield wiper Windshield washer Potentiometer pump regulation Alternator speed pick-up Water temperature switch Air filter is clogged

Printed in U.S.A

S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23 S24 S35 S36 S37 S38 S39 R1 X0 X1 X2 X4 X5 X6 X7 X8 X9 X10 X11 X12 X13 X14 X15 X16 X17 X18 X19 X20 X21

307

Description Engine oil pressure 3rd hydraulic circuit button Boom swing/extended hydraulic button 3rd hydraulic circuit button Pump power decrease switch Safety switch right Fast speed switch Pressure switch overload warning device Hydraulic oil level Hydraulic oil filter clogged warning Windshield wiper/washer Heating van switch Fast speed switch Arm light switch Front/side light switch Starting switch Rotating beacon light switch Switch overload warning device Switch roof light Warning indicator Climate temperature Climate switch Climate switch van Climate pressure switch Climate pressure switch Preheating Adaptor Main connector engine cable tree Main connector engine cable tree Engine relays Alternator load control Alternator main plus M3 engine speed set/reset M4 engine speed +/Starter main plus Starter solenoid Heater/climate switches Connector instrument panel left Heater/climate ventilator Connector right to left armrest Connector right to left armrest Connector right to left armrest Main connector armrest cable tree Ground Socket Speed regulator output M3, M4 Speed regulator output +,-,set,reset

909768/BP1207

ELECTRICAL SYSTEM Name X22 X23

Description Connector pump regulator Connector pump regulator

X24

Connector engine speed/pump regulator

X25 X26 X27 X28 X29 X30 X31 X41 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 F1 F2 F3 F4

Switches +/- set reset buttons Connector to horn button Connector anti-theft device Cabin connector Connector instrument panel Motor oil control Buzzer Lights front left Pump regulation valve Boom swing / extended hydraulic valve 3rd hydraulic circuit 3rd hydraulic circuit Safety valve Fast speed valve Pump power decrease valve Full floating axle valve Switch lights, control lamps Anti-theft device, engine relay Lights chassis, arm Heating van, climate, horn Armrest left, engine speed, pump regulation Windshield wiper, cabin Stop solenoid, alternator Valves (Option) cabin Socket, refueling pump Rotating beacon light, cabin, anti-theft device Main fuse

F5 F6 F7 F8 F9 F10 F11 Q1

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ELECTRICAL SYSTEM

Electric Wiring Diagrams

Figure 7-1 Electric Wiring Diagram Printed in U.S.A

309

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Figure 7-2 Electric Wiring Diagram

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ELECTRICAL SYSTEM

Figure 7-3 Electric Wiring Diagram

Printed in U.S.A

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ME12002

Electric Wiring Connections

X17 24 pole 1 Safety valve Boom swing/extended 2 hydraulic valve 3 Fast speed valve 4 Heating van II 5 Heating van I 6 Fast speed switch 7 Fuel level 8 Res. 9 Res. 10 Side lights 11 Front lights 12 Socket/refueling pump 13 Hydraulic oil level 14 Ground 15 Horn 16 Ground 17 Arm light 3rd control hydraulic 18 circuit 19 Pump regulation valve Hydraulic oil filter is 20 clogged Overload warning device 21 switch 22 Res. 23 Res. 24 3rd hydraulic circuit

Right Armrest Connections X1 B D E G A C F H J K L M N P R S T U V W X

21 pole Main plus Ground Main plus Preheating Load control lamp Plus 12V/15 Relay: preheating, starting (+15) Plus 15: stop solenoid Plus 15: stop solenoid Climate pressure switch Climate compressor Start relay Preheating lamp Alternator (+15) Water temperature switch Water temperature sensor Engine speed Engine oil pressure Res. Air filter is clogged Climate temperature

Red Black Red Brown Pink Blue Blue Blue Blue Yellow/red Yellow/blue White/black Grey/red Blue/red Green/black Green/white Blue/black White Grey/blue Yellow

X14, female 13 poles AMP: 3 Display back light 4 Ground 5 Water temperature 11 Speed pick-up signal

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Brown/white Light blue/yellow Brown/black Yellow Red Grey Violet

Green Green/blue Red/black Orange/blue Black Orange Black Green/yellow Red/black/ red Blue/yellow Orange/white Blue/black/ blue

Pink

Green Black Green/white Blue/black

Printed in U.S.A

ME12002

ELECTRICAL SYSTEM

X15, male 13 poles AMP: 1

Pump regulation valve

2 3 4

Potentiometer Potentiometer Potentiometer

5

3rd hydraulic circuit

6 7

3rd hydraulic circuit Safety swich armrest Boom swing/extended hydraulic Climate temperature Climate compressor Climate pressure Water temperature switch

8 9 11 12 13

X16, male 4 pole AMP: 1 Valves supply +15 2 Ground 3 Plus 12 V 4 Plus 12 V X24 1 2 3 4 5 6

6 pole AMP X15, P1 X15, P1 X15, P1 Ground Supply +12 V Res.

X25 1 2 3 4 5 6

6 pole AMP Increase button Set reset button Set reset button Increase button Decrease button Decrease button

Printed in U.S.A

Dark blue/ yellow Light blue Dark blue Green/black Red/black/ red Pink Brown/white Light blue/ yellow Yellow Blue/yellow Yellow/red Green/black

Grey Black Red Red

X27 1 2 3 4 5 6 8 10 11

Starter Valves Stop solenoid Starter Valves Stop solenoid Ground Supply +30 Supply +15

White/black Brown/white Blue White/black Brown/white Blue Black Red Blue

X28 1 2 3 4 5

Windshield wiper rear Rotating beacon Ground Windshield wiper Cabin roof light front

6

Windshield washer

7 8 9

Supply +15 Supply +30 Cabin roof light rear

Blue/red Violet Black White Green White/black/ white Blue Red black Yellow/black

Dark blue Green/black Light blue Black Red

Grey Green Yellow Blue Red Black

313

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ME12002

Right and Left Armrest Connections X14, male 13 poles AMP: 1 Res. lamp 2 Res. lamp 3 Display back light 4 Ground 5 Water temperature 8 Res. lamp 9 Res. lamp 10 Normally closed 11 Speed pick-up signal

X16, female 4 pole AMP: 1 Valves supply +15 2 Ground 3 Plus 12 V 4 Plus 12 V

Brown Brown Green Black Green/white Brown Brown

X11, female 11 pole AMP: 1 Ventilator speed III 2 Ventilator speed II 3 Ventilator speed I 4 Res. Water temperature 5 (switch)

Blue/black

X15, female 13 poles AMP: 1

Pump regulation valve

2 3 4

Potentiometer Potentiometer Potentiometer

5

3rd hydraulic circuit

6 7

3rd hydraulic circuit Safety swich armrest Boom swing/extended hydraulic Climate temperature Climate compressor Climate pressure Water temperature switch

8 9 11 12 13

909768/BP1207

Dark blue/ yellow Light blue Dark blue Green/black Red/black/ red Pink Brown/white Light blue/ yellow Yellow Yellow/blue Yellow/red

6

Pump regulation valve

7 8 9 10 11

Climate compressor To climate thermostat Climate pressure switch Ground Plus 12 V

X13, female 6 pole AMP 1 Thermostat to switch on Thermostet to climate 2 compressor 3 Ground 4 Ventilator speed II 5 Ventilator speed I 6 Ventilator speed III

Green/black

314

Grey Black Red Red

Orange Orange Red Green/black Light blue/ yellow Yellow/blue Yellow Yellow/red Black Red

Yellow Yellow Black Orange Orange Red

Printed in U.S.A

ME12002

ELECTRICAL SYSTEM

Motor Cable Tree and Armrest Connections X1 B D E G A C F H J K L M N P R S T U V W X

21 pole Main plus Ground Main plus Preheating Load control lamp Plus 12V/15 Relay: preheating, starting (+15) Plus 15: stop solenoid Plus 15: stop solenoid Climate pressure Climate compressor Start relay Preheating lamp Alternator (+15) Water temperature switch Water temperature sensor Engine speed Engine oil pressure Res. Air filter is clogged Climate temperature

Printed in U.S.A

Chassis and Armrest Connections X17 24 pole 1 Safety valve Boom swing/extended 2 hydraulic valve 3 Fast speed valve 4 Heating van II 5 Heating van I 6 12V fast speed switch 7 Fuel level 10 Side lights 11 Front lights 12 Socket/refueling pump 13 Hydraulic oil level 14 Ground

Red Black Red Brown Pink Blue Blue Blue Blue Yellow/red Yellow/blue White/black Grey/red Blue/red

15

Horn

16

Ground

Green/black

17

Arm light

Green/white

18

3rd hydraulic circuit

Blue/black White

19

Grey/blue Yellow

21

Pump regulation valve Hydraulic oil filter is clogged Overload warning device switch 3rd hydraulic circuit

20

24

315

Brown/white Light blue/ yellow Brown/black Yellow Red Grey Violet Green Green/blue Red/black Orange/blue Black Orange/ black Black Green/ yellow Red/black/ red Blue/yellow Orange/ white Blue/black/ blue Pink

909768/BP1207

ELECTRICAL SYSTEM

ME12002

Engine RPM Controllers, Buttons, Motors and Pump Regulator Connections X20 female 8 pole AMP 1 Res. 2 Res. 3 Res. 4 Res. Controller output: ->X7, 5 M3 Controller output: ->X7, 6 M3 Controller output: ->X8, 7 M4 Controller output: ->X8, 8 M4

Grey/red Grey/black Grey Brown

X21 male 8 pole AMP 1 Supply +12 V 2 GND 3 Set/reset 4 Set/reset 5 Decrease engine speed 6 Decrease engine speed 7 Increase engine speed 8 Increase engine speed

Red Black Green Yellow Red Black Grey Blue

X22 1 2 3 4 5 6 7

Brown/white Yellow Dark blue Green/black Light blue Black Red

9 pole AMP Proportional valve Y1 Proportional valve Y1 X24, X15, P1 X24, X15, P1 X24, X15, P1 GND Supply +12V

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X24 1 2 3 4 5 6

6 pole AMP X15, P1 X15, P1 X15, P1 GND Supply +12 V Res.

X25 1 2 3 4 5 6

6 pole AMP Increase button Set reset button Set reset button Increase button Decrease button Decrease button

Grey Green Yellow Blue Red Black

X2 1 2 3 4 5 6

6 pole M4, +/- (X8) M4, +/- (X8) M3, set/reset (X7) M3, set/reset (X7) Pump regulation (Y1) Pump regulation (Y1)

Grey Brown Grey/black Grey/red Brown/white Yellow

Dark blue Green/black Light blue Black Red

Printed in U.S.A

ME12002

ELECTRICAL SYSTEM

Electric Speed Control Unit

Figure 7-4 Block Diagram Block Diagram Legend 1 K3 Step relay 2 N1 Speed control box1 3 N2 Speed control box2 4 M6 Spindle drive motor1 5 M7 Spindle drive motor2 6 S31 Joystick right 7 HA2 Horn push-button

Printed in U.S.A

A B C D E F G H I J

Plug 3 pole Plug 8 pole Plug 8 pole Plug 12 pole Plug 6 pole Plug 6 pole Plug 2 pole Plug 2 pole Plug 2 pole Plug 2 pole

317

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ME12002

Setting the Proportional Controller

Figure 7-5 Principle Structure

Function Electric current controls the pump controller valve and regulates pump performance.

The higher the electric current, the lower the pump performance.

Adjust the proportional controller to set the electric current milliamps (mA). 1 amp = 1000 milliamps.

Adjustment Imin = maximum pump performance, potentiometer set to the maximum. See Figure 7-5.

Use adjustment screw R3 to set the current to 0 mA. Imax = minimum pump performance, potentiometer set to the minimum.

Use adjustment screw R2 to set the current to 600 mA.

Time Ramp Use adjustment screw R1 to adjust reaction time.

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INDEX Numerics

Close Brake ............................................. 188 Connection Ports ..................................... 169 Control Rack ................................................... 262 Valve .................................. 108, 147, 151 Coolant System .......................................... 48 Level .............................................. 48, 49 Cooling System ....................................... 227 Water Circuit ..................................... 243 Counterbalancing System ........................ 141 Cover ....................................... 153, 190, 200 Crankshaft ................................ 273, 276, 277 Crankshaft Bearings ................................ 273 Crankshaft Pulley .................................... 268 Cylinder ..................... 87, 131, 132, 193, 195 Assembly ........................................... 192 Block .......................................... 272, 275 Drum .......................................... 195, 197 Four-Head .......................................... 266 Head ........................... 209, 210, 265, 266 Head Cover ........ 206, 207, 213, 234, 235 Head Gasket ............................... 234, 235 Springs ................................................. 94 Cylinder Block ................................. 272, 274

500 hrs. Maintenance Schedule ................. 42

A Air Cleaner .......................................... 47, 48 Service ................................................. 47 Air Conditioning ........................................ 25 Air Filter .................................................... 47 Alternator ................................................. 251 Armrest .................................................... 315 Electrical Connections ............... 314, 315 Left .................................................... 314 Right .......................................... 312, 314 Auxiliary Hydraulics ....... 138, 139, 169, 171

B Backing Pump Lever ................................. 46 Balance Plate ........................................... 190 Barrel ....................................................... 262 Battery ....................................................... 55 Bearing .................................................... 263 Bleeding Air .............................................. 47 Boom ............................... 120, 122, 123, 303 Boom Cylinder Port Connections ......................... 118 Section Boom (1) ....................... 119, 120 Section Boom (2) ............... 119, 121, 122 Structure .... 118, 120, 121, 123, 125, 128 Swing Control .................................... 136 Brake Piston ............................. 191, 192, 198 Breather Filter .......................................... 186 Bucket .............................................. 133, 303 Bucket Geometry ......................................... 4

D Delivery Springs ............................................... 262 Valve .................................................. 262 Diesel Engine ............................................... 9 Dipper Arm ...... 126, 127, 128, 130, 131, 132 Cylinder ............................................. 129 Permissible Loads .................................. 5 Dozer Blade ............................. 169, 171, 303 Drain Plug .................................................. 46 Drive Belt ................................................ 238 Drive Shaft ............................... 88, 89, 92, 93 Driving Pedals ......................................... 169 Dry Assembly ...................................... 14, 15 Dust Cap ....................................................... 47 Collector .............................................. 47

C Camshaft . 261, 262, 263, 264, 267, 269, 270, 271 Bend ................................................... 270 Care and Servicing .................................... 28 Casing .............................................. 150, 172 Chassis ..................................................... 315 Check Valve .................................... 150, 151 Circuit ...................................................... 124 Printed in U.S.A

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INDEX E e1 Logic Control Valve .................... 149, 152 Electrical System ..... 307, 309, 310, 311, 312 Armrest ...................................... 312, 314 Chassis ............................................... 315 Engine John Deere 4045TF270 Compression Check ..................... 225 Cooling System ............................ 227 Cylinder Head .............................. 210 Fuel Circuit .................................... 43 Fuel Injection Nozzles . 217, 220, 221 Fuel Injection Pump ............. 214, 215 Fuel System ............................ 46, 205 Overview ...................................... 203 Thermostat ................................... 226 Troubleshooting ........................... 291 Valve Tip Clearance .................... 206 Oil ........................................................ 27 Oil/Filter Change ................................. 42 Yanmar 3TNV 88 ................................ 20 Yanmar 4TNE106T-NS Alternator ..................................... 251 Camshaft ...... 261, 267, 269, 270, 271 Compression Pressure .................. 236 Cooling System ............................ 237 Cooling Water Circuit .................. 243 Crankshaft Pulley ......................... 268 Cylinder Block ..................... 272, 275 Cylinder Head ...................... 265, 266 External Overview ....................... 231 Flywheel ....................................... 269 Four-Head Cylinder ..................... 266 Fuel Feed Pump ................... 254, 255 Fuel Feed Pump Parts .................. 255 Fuel Filter ....................................... 45 Fuel Injection Pump 256, 257, 259, 268 Fuel Injection Valve ..................... 238 Fuel System ............................ 46, 233 Gear Case Cover .......................... 268 Gear Train .................................... 269 Gears ............................................ 258 Governor Cover ........................... 260 Governor Housing ........................ 260 Idle Gear ...................................... 271 Nozzle Valve Sliding Test ........... 240 Oil Seal ........................................ 271 909768/BP1207

ME12002 Overview ...................................... 229 Starter ................................... 245, 248 Tappet .......................................... 262 Thermostat ................................... 236 Thermoswitch .............................. 237 Troubleshooting ........................... 293 Turbocharger ................................ 287 Valve Tip Clearance .................... 234 V-belt Tension ............................. 238 Waste Gate Valve ........................ 289 Water Pump ................................. 244 Excavator Dimensions ............................................ 1 Exhaust Elbow ......................................... 213

F Final Drive Unit ......................................... 27 Fluid and Filter Changes ............................ 24 Fluid Capacities/Lubricants ................. 19, 20 Flywheel ................................................... 269 Foot Pedals ............................................... 166 Fuel Circuit ............................................ 43, 44 Feed Pump ................................. 254, 255 Filter ............................... 44, 45, 208, 213 Injection Nozzle ......... 217, 218, 220, 221 Injection Pump .... 43, 214, 215, 256, 257, 258, 259, 268 Injection Valve ........................... 238, 239 Location ............................................... 55 Fuel System .................................. 43, 47, 233 Purging Air .......................................... 46 Functional Check ....................................... 25

G Gear .................................................. 258, 271 Case Cover ......................................... 268 Train ........................................... 267, 269 Gear Pump ................................... 57, 86, 101 Setting .................................................. 66 Governor Cover .................................................. 260 Housing .............................................. 260

320

Printed in U.S.A

ME12002

INDEX

H

Injection Nozzle ....................................... 224

Hand Pump .............................................. 227 Horsepower ................................................ 78 Hoses ........................................................ 302 Hydraulic Diagram ............................................... 51 Joints .................................................... 14 Reservoir ........................................ 39, 41 Schematic ............................................. 67 Screw Joints ......................................... 15 System ........................................ 7, 30, 51 Tank Cover .......................................... 48 Valve Cover ......................................... 38 Latch .............................................. 38 Hydraulic Components Positions ............................................... 53 Hydraulic Oil ........................... 27, 38, 40, 41 Level .............................................. 38, 39 Tank ............................................. 41, 186 Tank Cover .......................................... 40 Tank Plug ............................................. 40 Hydraulic Pump Assembling .......................................... 91 Components ......................................... 67 Disassembling ...................................... 86 Disassembling and Assembling ........... 85 Function Summation .......................... 106 Functions .............................................. 59 General Description ............................. 70 Part Inspection ..................................... 34 Port Codes ............................................ 60 Pressure Checklist ................................ 31 Pressure Measurements ........................ 35 Pressure Test ........................................ 65 Regulation ............................................ 69 Regulator Components ........................ 69 Regulator Performance ........................ 71 Rotation Group .................................... 68 Section Descriptions ............................ 61 Specifications ................................. 57, 58 Tightening Torques .............................. 97 Valve Designation ................................ 62

J Joystick ............................................ 154, 165 Bellows .............................. 156, 164, 180 Fixing Pin ........................................... 155 Joystick Pilot Valve ......................... 155, 160 Joystick Ports Left ..................................................... 155 Right ................................................... 155

L Leakage Check ........................................... 25 Lift Capacity Chart ...................................... 6 Load Check Valve ....................................... 112 Load Lowering Valve .............................. 185 Lock Valve ....................................... 149, 152 Logic Control Valve ................................ 149 Lubricants ............................................ 27, 30 Engine Oil ............................................ 27 Hydraulic Oil ....................................... 27 Swing Ring .......................................... 27 Lubrication ................................................. 27 Check ................................................... 26 Points ................................................... 27

M Main Pressure Limiting Valve ...................... 37 Relief Operation ................................. 116 Relief Valve ....................... 113, 149, 152 Spool .............................. 75, 76, 147, 152 Valve Block 11, 12, 54, 57, 61, 102, 103, 110, 111 Maintenance ....................................... 21, 203 Chart ..................................................... 21 General Information ............................. 26 Maximum Flow Control ............................ 84 Metric Hose Joints ..................................... 14 Mounting Flange .............................. 272, 277

I Idle Gear .................................................. 271 Ignition Key Switch ................................. 241 Indicator Lamps ....................................... 302 Printed in U.S.A

321

909768/BP1207

INDEX N NC Valve ................................................... 81 Needle Bearing .......................................... 90 Negative Control ................................................. 80 Control Relief Valve .......................... 152 Displacement Control .................... 72, 79 Nozzle Clatter ................................................. 219 Jet ....................................................... 239 Leakage .............................................. 219 Tester ......................................... 222, 223 Valve Stroke ...................................... 223 Nozzle Jet ................................................. 239

O Oil Grades .................................................. 20 Level .................................................... 38 Pressure Switch .................................. 242 Seal ....................................... 94, 197, 271 Open Brake .............................................. 188 Outlet Ports ................................................ 63

P P-casing ...................................................... 96 Pedal ......................................................... 167 Pilot Control Pedal ............................. 171, 176 Control Pedals .................................... 169 Oil Supply Unit .................................. 181 Pressure .............................................. 115 Pressure Hose ..................................... 183 Pressure Pump ...................................... 66 Valve .................................. 154, 156, 170 Piston ............................................... 193, 279 Shoe ..................................................... 94 Piston Pin ......................................... 274, 275 Piston Ring ....................................... 274, 276 Plate ......................................................... 157 Plugs ........................................................... 86 Plunger ..................................................... 262 Port Codes ..................................... 11, 60, 104 Connection ......................................... 171 Connections ....................................... 181 909768/BP1207

ME12002 Plate ................................................... 158 Positions ............................................. 184 Relief Function .................................. 117 Relief Valve ......... 63, 113, 116, 149, 152 Poteniometer .............................................. 71 Power Regulator ........................................ 82 Power Summation ...................................... 72 Pressure Check Auxiliary Hydraulics ...................... 65 Drive .............................................. 65 Swivel ............................................ 65 Checklist .............................................. 35 Drop ..................................................... 65 Test ................................................. 64, 65 Pressure Drop ............................................. 66 Primary-pressure Limiting Valve .............. 65 Primary-pressure Limiting Valve-2 ..... 37, 65 Proportional Control .................................. 99 PTO Drive Gear ....................................... 271 Pump Casing ................................ 87, 88, 92, 95 Flow ........................................... 143, 144 Housing .............................................. 262 Oil ............................................ 76, 81, 83 Ports ..................................................... 57 Shaft ................................................... 214 Push Rod .................................. 157, 159, 161

R Radiator Cap ............................................. 227, 237 Coolant Level ....................................... 49 Fan ..................................................... 244 Ranges of Applications .............................. 27 Reduction Valve ...................................... 158 Regulator .......................... 71, 86, 96, 98, 100 Relief Valve ..................... 150, 151, 190, 200 Return Ports ............................................... 63 Return Spring ........................................... 161 Rings ................................................ 274, 275 Rocker Arm Unit ............................. 209, 212 Rod Side Gap ........................................... 272 Rotor ........................................................ 252

322

Printed in U.S.A

ME12002

INDEX

S

T

Safety Maintenance ......................................... 29 Safety Filter ................................................ 48 Screw Joints ......................................... 17, 18 Seal Cover ............................................ 87, 94 Seal Types .................................................. 15 Seals ......................................................... 302 Secondary Spring ............................. 158, 162 Section Boom .................................................. 119 Boom (1) ............................................ 120 Boom (2) ............................................ 121 Section Boom (1) ..................................... 119 Section Drive ........................................... 140 Servo Pump ................................................ 91 Set Plate Group .......................................... 95 Shock Suction Valve ................................ 114 Shock Valve Ports .................................... 187 Shoe Plate .................................................. 88 Shuttle Valve Block ................................. 183 Side Valve Block . 57, 64, 102, 145, 146, 182 Sight Gauge ................................................ 38 Sleeve Metering ......................................... 75 Specifications ............................................... 3 Spherical Bushing ...................................... 94 Spline Coupling ......................................... 90 Spool ........................................................ 148 Spray Pattern .................................... 238, 239 Spring Seating .................................. 158, 160 Starter ............................................... 245, 248 Straight Travel Spool ....... 143, 144, 148, 152 Summation ....................................... 121, 122 Summation Control .................................... 73 Swash Plate .......................................... 88, 92 Group ................................................... 68 Swing Gear Unit .............................................. 27 Motor ......................... 188, 189, 190, 194 Priority Mode ..................................... 137 Priority Valve ..................................... 152 Ring ...................................................... 27 Section ............................................... 135 Switch Valve ............................................ 184 Swivel Unit .............................................. 188

Tappet .............................. 261, 262, 263, 264 Holder ................................................ 261 Technical Data ............................................. 1 Primary Dimensions .............................. 1 Test Gauge ............................................... 225 Thermostat ....................................... 226, 236 Thermoswitch .......................................... 237 Tightening Torque ............. 11, 14, 15, 18, 97 Joystick .............................................. 165 Time Delay Valve .................................... 190 Torque ........................................................ 73 Torque Summation .................................... 72 Traveling Gear ......................................... 302 Trochoid Pump ........................................ 285 Troubleshooting ....................................... 291 Boom .................................................. 303 Bucket ................................................ 303 Dozer Blade ....................................... 303 General Information ........................... 302 Hoses .................................................. 302 Indicator Lamps ................................. 302 Seals ................................................... 302 Traveling Gear ................................... 302 Turbine Shaft ........................................... 290 Tightening Torque ............................. 290 Turbocharger ............................ 213, 287, 288 Bearing ............................................... 290 Blower ................................................ 290 Compressor ........................................ 290 Rotor Play .......................................... 290 Seal Plate ............................................ 290 Seal Ring ............................................ 290 Servicing ............................................ 290 Thrust Bearing ................................... 290 Turbine Housing ................................ 290 Turbine Shaft ..................................... 290

Printed in U.S.A

U Universal Joint ......................................... 162

323

909768/BP1207

INDEX

ME12002

V Valve Block .................................................... 89 Cover Group ........................................ 69 Cover Seal .................................. 234, 235 Locations .............................................. 56 Plate ............................................... 89, 95 Tip Clearance ............................. 206, 207 Variable Pump .............................................. 71, 73 Pump-1 ................................................. 57 Pump-2 ................................................. 57 V-belt Tension ......................................... 238

W Waste Gate Valve .................................... 289 Water Leak Check ................................ 227, 237 Pump .................................................. 244 Separator ........................ 44, 45, 208, 213 Wiring ...................... 307, 309, 310, 311, 312 Working Range Diagram ............................. 6

Y Yanmar Engine 4TNE106T-NS ............... 229

909768/BP1207

324

Printed in U.S.A

ME12002

INDEX NOTES

Printed in U.S.A

325

909768/BP1207

®

Mustang Manufacturing Co., Inc. 1880 Austin Road, P.O. Box 547, Owatonna, Minnesota, 55060-0547 USA www.mustangmfg.com

909768/BP1207

© 2007 MUSTANG MANUFACTURING COMPANY, INC. All Rights Reserved.

PRINTED IN USA