Yanmar V7 Wheel Loader Service Manual - PDF DOWNLOAD

SERVICE MANUAL

WHEEL LOADER V7

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1-1 Correct Work ...........................................................................................................................................................................1-1 1-2 Safety Precautions ..................................................................................................................................................................1-1 1-3 Preparations ............................................................................................................................................................................1-1 1-4 Cautions for Disassembly and Reassembly............................................................................................................................1-1 1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............................................................................................1-2 1-6 Cautions for Removal and Installation of Hydraulic Piping......................................................................................................1-2 1-7 Cautions for Handling Seals....................................................................................................................................................1-3 1-8 Correct Installation of Hydraulic Hose .....................................................................................................................................1-3 1-9 Specifications of Hydraulic Hose.............................................................................................................................................1-6 1-10 Air Release of Hydraulic Equipment......................................................................................................................................1-8

&+$37(5 7(&+1,&$/ '$7$ 2-1 Specifications ...................................................................................................................................................................... 2-1-1 2-2 Outline Drawing and Working Area ..................................................................................................................................... 2-2-1 2-3 Lifting Capacity List ............................................................................................................................................................. 2-3-1 2-4 Periodic Inspection and Servicing ....................................................................................................................................... 2-4-1 2-5 Fuel, Lube Oil and Grease Recommended......................................................................................................................... 2-5-1 2-6 Hydraulic Circuit Schematic ................................................................................................................................................ 2-6-1 2-7 Electrical Diagram................................................................................................................................................................ 2-7-1

&+$37(5 6(59,&( 67$1'$5'6 3-1 Machine Performance ......................................................................................................................................................... 3-1-1

&+$37(5 (1*,1( 4-1 Safety .................................................................................................................................................................................. 4-1-1 4-1-1 Safety Statements ...................................................................................................................................................... 4-1-1 4-1-2 Safety Precautions ..................................................................................................................................................... 4-1-2 4-2 Engine ................................................................................................................................................................................. 4-2-1 4-2-1 Before You Begin Servicing ....................................................................................................................................... 4-2-1 4-2-2 Special Service Tools................................................................................................................................................. 4-2-2 4-2-3 Measuring Instruments............................................................................................................................................... 4-2-4 4-2-4 Cylinder Head............................................................................................................................................................. 4-2-6 4-2-5 Measuring and Adjusting Valve Clearance .............................................................................................................. 4-2-20 4-2-6 Crankshaft and Camshaft Components ................................................................................................................... 4-2-23 4-3 Fuel System ........................................................................................................................................................................ 4-3-1 4-3-1 Before You Begin Servicing ....................................................................................................................................... 4-3-1 4-3-2 Introduction................................................................................................................................................................. 4-3-2 4-3-3 Special Service Tools................................................................................................................................................. 4-3-

4-3-4 Measuring Instruments............................................................................................................................................... 4-3- 4-3-5 Fuel System Diagram................................................................................................................................................. 4-3- 4-3-6 Fuel System Components .......................................................................................................................................... 4-3- 4-3- Fuel Injection Pump............................................................................................................................................... .. 4-3- 4-3- Checking and Adjusting Fuel Injection Timing ......................................................................................................... 4-3- 4-3- Fuel Injectors................................................................................................................................................ ......... 4-3- 4-4 Cooling System ................................................................................................................................................................... 4-4-1 4-4-1 Before You Begin Servicing ....................................................................................................................................... 4-4-1 4-4-2 Introduction................................................................................................................................................................. 4-4-2 4-4-3 Cooling System Diagram............................................................................................................................................ 4-4-2 4-4-4 Engine Coolant Pump Components ........................................................................................................................... 4-4-3 4-4-5 Engine Coolant System Check................................................................................................................................... 4-4-4 4-4-6 Engine Coolant Pump ................................................................................................................................................ 4-4-4 4-5 Lubrication System.............................................................................................................................................................. 4-5-1 4-5-1 Before You Begin Servicing ....................................................................................................................................... 4-5-1 4-5-2 Introduction................................................................................................................................................................. 4-5-2 4-5-3 Lubrication System Diagram ..................................................................................................................................... 4-5- 4-5-4 Checking Engine Oil Pressure ........................................................................................................................ ......... 4-5- 4-5-5 Trochoid Oil Pump..................................................................................................................................................... 4-5- 4-6 Starter Motor ....................................................................................................................................................................... 4-6-1 4-6-1 Before You Begin Servicing ....................................................................................................................................... 4-6-1 4-6-2 Introduction................................................................................................................................................................. 4-6-2 4-6-3 Starter Motor Information ........................................................................................................................................... 4-6-2 4-6-4 Starter Motor Troubleshooting.................................................................................................................................... 4-6-3 4-6-5 Starter Motor Components ......................................................................................................................................... 4-6-4 4-7 Alternator............................................................................................................................................................................. 4-7-1 4-7-1 Before You Begin Servicing ....................................................................................................................................... 4-7-1 4-7-2 Introduction................................................................................................................................................................. 4-7-2 4-7-3 Alternator Specifications............................................................................................................................................. 4-7-2 4-7-4 Alternator Troubleshooting ......................................................................................................................................... 4-7-3 4-7-5 Alternator Components .............................................................................................................................................. 4-7-4 4-7-6 Alternator Wiring Diagram .......................................................................................................................................... 4-7-5 4-7-7 Alternator Standard Output ........................................................................................................................................ 4-7-6 4-7-8 Alternator.................................................................................................................................................................... 4-7-7 4-8 Electric Wiring .................................................................................................................................................................... 4-8-1 4-8-1 Electric Wiring Precautions ....................................................................................................................................... 4-8-1 4-9 Troubleshooting .................................................................................................................................................................. 4-9-1 4-9-1 Special Service Tools................................................................................................................................................. 4-9-1 4-9-2 Troubleshooting By Measuring Compression Pressure ............................................................................................. 4-9-2 4-9-3 Quick Reference Table For Troubleshooting ............................................................................................................. 4-9-4

&+$37(5 (/(&75,& 6<67(0 5-1 Electric Equipment of Machine............................................................................................................................................ 5-1-1 5-1-1 Localisation of fuse and relays ................................................................................................................................... 5-1-1 5-1-2 Identification of fuses ................................................................................................................................................. 5-1-2 5-1-3 Identification of relays ................................................................................................................................................. 5-1-3 5-1-4 Identification of connectors ........................................................................................................................................ 5-1-4 5-2 Electric diagram ................................................................................................................................................................... 5-2-1 5-2-1 Steering column ......................................................................................................................................................... 5-2-1 5-2-2 Engine line ................................................................................................................................................................. 5-2-1 5-2-3 Cabine line ................................................................................................................................................................. 5-2-3 5-2-4 Electric system description......................................................................................................................................... 5-2-4

&+$37(5 +<'5$8/,& 6<67(0 6-1 Hydraulic Circuit .................................................................................................................................................................. 6-1-1 6-1-1 Valve setting chart ..................................................................................................................................................... 6-1-1 6-1-2 Pressure outlets ......................................................................................................................................................... 6-1-1 6-2 Circuit Operation ................................................................................................................................................................. 6-2-1 6-2-1 Loader ........................................................................................................................................................................ 6-2-1 6-2-2 Steering ..................................................................................................................................................................... 6-2-2 6-2-3 6-2-3 Loader quick-coupling (optional)...................................................................................................................... 6-2-3 6-3 Hydrostatic Transmission................................................................................................................................................... 6-3-1 6-3-1 Valve setting chart .................................................................................................................................................... 6-3-1 6-3-2 Description of operation.................................................................................................................................... ...... 6-3-2 6-3-3 Hydrostatic balancing ................................................................................................................................................ 6-3-3 6-3-4 Hydrostatic pump ...................................................................................................................................................... 6-3-4 6-3-5 Working pressure control .......................................................................................................................................... 6-3-5 6-3-6 Pressure relief control valves .................................................................................................................................... 6-3-6 6-3-7 Towing procedure with hydrostatic moto .................................................................................................................. 6-3-7 6-3-8 Overfeeding pressure control ................................................................................................................................... 6-3-8 6-3-9 Idling adjustment ....................................................................................................................................................... 6-3-8 6-3-10 Control valve operation and start point setting ....................................................................................................... 6-3-9 6-3-11 Control valve diagram ........................................................................................................................................... 6-3-10 6-3-12 Hydrostatic motor .................................................................................................................................................. 6-3-11 6-3-13 Checking the hydrostatic motor displacement change ......................................................................................... 6-3-12 6-4 Troubleshooting .................................................................................................................................................................. 6-4-1 6-4-1 Pump / Motor ............................................................................................................................................................ 6-4-1 6-4-2 Equipment ................................................................................................................................................................. 6-4-2

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1-1 Correct Work...........................................................................................1-1 1-2 Safety Precautions..................................................................................1-1 1-3 Preparations ...........................................................................................1-1 1-4 Cautions for Disassembly and Reassembly ...........................................1-1 1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............1-2 1-6 Cautions for Removal and Installation of Hydraulic Piping .....................1-2 1-7 Cautions for Handling Seals ...................................................................1-3 1-8 Correct Installation of Hydraulic Hose ....................................................1-3 1-9 Specifications of Hydraulic Hose ............................................................1-6 1-10 Air Release of Hydraulic Equipment .....................................................1-8

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

*HQHUDO &DXWLRQV IRU 0DLQWHQDQFH :RUN &RUUHFW :RUN Correct work means the quickest possible completion of according to the correct procedures and the specified standards.

It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions to watch out for.

6DIHW\ 3UHFDXWLRQV (1) Never attempt servicing while engine is running or immediately after stopping operation.

(2) Wear work cloths, safety shoes and helmet.

(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.

(4) When working together with other persons, allocate everyone's share of job, arrange the signals and act in concert with the other persons.

(5) The operation of the crane and slinging work must be performed by qualified persons.

(6) Do not enter or pass under the raised load.

(7) Lift and support the massive parts by crane before removing the installation bolts.

(8) Disconnect cables from battery before repairing the electric system.

(9) Remove the battery when welding the machine.

3UHSDUDWLRQV (1) Check the service record of the machine. (That is, check how many months or hours the machine has been used since the preceding overhaul, what was the trouble then and what parts were replaced.)

(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), containers, oil & grease, etc.

(3) Have the service literature (operation manual, parts catalog, etc.) ready.

&DXWLRQV IRU 'LVDVVHPEO\ DQG 5HDVVHPEO\ (1) Clean the machine before disassembly.

(2) Check and record the condition of the machine before disassembly : • Model, machine number, operation hours • Reasons for repair, history of repair • Contamination of filters • Fuel and oil condition • Damage to parts, etc.

(3) Place alignment marks on the necessary parts to facilitate reassembly.

(4) Clean all the removed parts and new replacement parts and put them in order.

(5) Use new seals, split pins, etc. for reassembly.

1-1

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

(6) Keep the parts apt to be damaged by water or oil apart from the oily or wet parts. e.g.: Electrical parts, rubber parts, V-belts, etc.

(7) Use the jig for press-fitting the bearings, bushes and oil seals. When

Sealing tape

using a hammer, use a pad block.

(8) Clean the joint surface of all parts and keep them free from dust.

(9) Wind the sealing tape securely, leaving a space of one or two threads from the tip of the male screw. The tape should have an overlap of about 10 mm.

One and a half threads

&DXWLRQV IRU 5HPRYDO DQG ,QVWDOODWLRQ RI +\GUDXOLF (TXLSPHQW (1) Check that the hydraulic oil temperature is low enough.

(2) Release air from the hydraulic tank to prevent the hydraulic oil from flowing out.

(3) Be sure to plug open the ends of hydraulic components to prevent dust from entering.

(4) Be sure to wipe hydraulic oil from the hydraulic components so that it will not be mistaken for an oil leak.

(5) Take care not to damage the plating on the cylinder rod.

(6) Remove or install cylinders with rods fully retracted.

(7) Be sure to release air after installing the hydraulic cylinders.

• Run the engine at a low speed. Extend and retract the cylinders 4 to 5 times up to 50 to 100 mm from the end of the stroke. Then, fully extend and retract.

(8) Be sure to pressurize the hydraulic tank after installing the hydraulic components (in the case of the sealed hydraulic tank). Otherwise, hydraulic pumps might suffer cavitation and their life will be shortened.

• To pressurize the hydraulic tank, fully extend each cylinder and tighten the oil filter port plugs.

&DXWLRQV IRU 5HPRYDO DQG ,QVWDOODWLRQ RI +\GUDXOLF 3LSLQJ (1) Installation of hydraulic hose Take care not to twist the hoses. (Judge whether or not the hose is twisted by

Metal fitting

the hose mark.) For hoses with a metal fitting, use two wrenches to prevent twisting.

Use one to fix the hose, and the other to tighten the fitting to the specified tightening torque. Carefully check that the hoses do not come in contact after

Hose

Pipe or connector

Fixed side

tightening. If any contact is found, correct it or use tubes.

(2) When installing hoses, first tighten to the specified torque and then loosen them a little. Then retighten to the specified torque.

• Break in the installed parts before tightening (except those using seal tapes).

(3) When installing pipes, turn the nuts more 1/4 to 1/2 turn after they reach the sharp torque rise point.

(4) When installing or removing hoses, use two wrenches, one to fasten the hose and the other to tighten or loosen the hose to prevent twisting.

(5) Check for oil leakage by applying max. pressure 5 to 6 times after attaching hydraulic hoses or pipes.

1-2

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

&DXWLRQV IRU +DQGOLQJ 6HDOV (1) Clean out grooves of O-rings. Remove burrs or dust if any.

Burrs

Dust

(2) Take care not to twist O-rings. Correct by your finger if it is twisted.

(3) Take care not to damage seals when inserting.

(4) Handling of floating seals : • Completely wipe off all the oil from the O-ring and housing after detaching the floating seals.

• Before installing, apply a little gear oil to the matching face of the housing.

• Turn the seals two or three times after installation to break them in.

(5) Apply grease to the lip of the oil seals to prevent wear.

Grease

&RUUHFW ,QVWDOODWLRQ RI +\GUDXOLF +RVH In order to mount the hydraulic hose most effectively and economically, observe the following cautions.

(1) When a hose is used at the minimum bending radius, use elbows to avoid sharp bending.

Not good

Good

(2) To prevent twisting, the hose should be bent in the same direction as it moves.

Not good

Good

1-3

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

(3) When the hose is pressurized, the hose length varies slightly at the bend. Allow this change to occur and do not try to fasten the bend.

Not pressurized

When pressurized

(4) It is necessary for the hose to have ample slackness for elongation and contraction, because its length will change by +2 % to -4 % when used at high pressure.

Not good

Good

(5) Use the proper adapters, not pipes, in order to reduce the number and length of joints and improve the external appearance.

Not good

Good

(6) Use an elbow to prevent excessive twisting or bending of the hose.

Not good

Good

(7) Use adapters to make the hose as straight as possible. The outside appearance can be improved by avoiding the use of hoses that are too long.

Not good

Good

1-4

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

(8) The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the hose and prevents sharp bending.

Not good

Good

(9) When a bent hose is attached to two different planes, fix as shown in the diagram to prevent twisting.

Not good

Good

(10) Use the marking on the hose as a guide to prevent twisting during installation.

Twisting of metal fitting with union nuts should be with a wrench on the hexagonal parts.

Hose mark Not good

Hose mark Good

1-5

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

6SHFLILFDWLRQV RI +\GUDXOLF +RVH Specifications of the hydraulic hoses can be known by the part descriptions as explained below. (For the parts number, please refer to our Parts Catalog.)

Description ..................... Hose 1

P 2

06

AB

075

W

2

4

5

6

7

3

8 8 Other accessories No accessories...Blank O-ring ....................... 1

1 Part name 2 Hose material Rubber hose ........... G Wear-resistant high pressure rubber hose ....................... H Plastic hose ............ P Wear-resistant plastic hose ............ F

6 Total length (Unit : cm) 5 Combination of fitting Fitting type R(PT)

Taper pipe thread R (PT)

3 Recommended working pressure psi(Mpa) Over 2986 (20.6) ..................... 1 2489 to 2986 (17.2 to 20.6) ..... 2 1991 to 2489 (13.7 to 17.2) ..... 3 1564 to 1991 (10.8 to 13.7) ..... 4 995 to 1564 (6.9 to 10.8) ......... 5 427 to 995 (2.9 to 6.9) ............. 6 213 to 427 (1.5 to 2.9) ............. 7 Below 213 (1.5) ....................... 8

G(PF) 30°

90°

G(PF)

4 Nominal dia. (inch) 1 / 8" ......................... 02 3 / 16" ....................... 03 1 / 4" ......................... 04 3 / 8" ......................... 06 1 / 2" ......................... 08 5 / 8" ......................... 10 3 / 4" ......................... 12 1" .............................. 16

The example hose,

Code

30°

Straight pipe thread G (PF) with male 30 degrees seat 90 degrees bent type.

Straight pipe thread G (PF) with male 30 degrees seat

Without fitting

A

B

C

Y

*For the combination of fitting, refer to the list on the following page.

P

2

06

AB

075

W

2

3

4

5

6

7

7 Hose protector Coil spring ............... W Coil tube .................. S Wire braid ................ B Tube (Rubber) ......... R Tube (Vinyl) ............. V Sponge rubber ......... P Hose cover ............... K No protection ..... Blank

List of pipe threads Symbol Name G (PF) Straight pipe thread R (PT) Male taper pipe thread Rc (PT) Female taper pipe thread

stands for :

2 Material : Plastic 3 Working pressure : 2489 to 2986 psi (17.2 to 20.6 MPa) 4 Nominal dia. : 3 / 8" 5 Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat.

6 Length : 29.5 in. (75 cm) 7 Hose protector : Coil spring

1-6

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

5 Combination of fitting Fitting type

Code

Fitting type 90°

R (PT)

Taper pipe thread R (PT)

A UNF

Code

90 degrees bent type.

UNF thread with female 37 degrees seat

P

60 degrees bent type.

UNF thread with female 37 degrees seat

Q

45 degrees bent type.

UNF thread with female 37 degrees seat

R

37° G (PF) 30°

Straight pipe thread G (PF) with male 30 degrees seat

60°

B UNF

90 degrees bent type.

Straight pipe thread G (PF) with male 30 degrees seat

90°

G (PF)

45°

C UNF

30°

60°

G (PF) 45° G (PF) G (PF) 30°

60 degrees bent type.

Straight pipe thread G (PF) with male 30 degrees seat 45 degrees bent type.

Straight pipe thread G (PF) with male 30 degrees seat Straight pipe thread G (PF) with male 30 degrees seat

O-ring flange type

UNF, thread with O-ring groove

UNF

D

S

O-ring O-ring One-touch fitting (male)

E

F

T

90°

G

90 degrees elbow straight pipe thread male 30 degrees seat

V

Eyejoint with O-ring groove

W

G (PF) 30°

90°

90 degrees bent O-ring flange type 45 degrees bent O-ring flange type

45°

G (PF) 30°

30° G (PF) NPTF

H O-ring groove

J

Straight pipe thread, female 30 degrees seat with O-ring groove

K

30 degrees bent type.

Straight pipe thread G (PF) with male 30 degrees seat

L

Taper pipe thread NPTF

M

PF nut 30°

Straight pipe thread with jam nut female 30 degrees seat

X

G (PF) 90°

Gauge port G (PF)

90 degrees elbow straight pipe thread with gauge port plug male 30 degrees seat

Z

30° UNF 37°

Without fitting UNF, thread with female 37 degrees seat

Y

Note : According to the combination of bending or elbow fittings, some hoses require drawings or original hoses to locally manufacture.

N

1-7

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

$LU 5HOHDVH RI +\GUDXOLF (TXLSPHQW When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic equipment. If the air is left in the hydraulic system, the air is compressed or expanded depending on the load, having an adverse effect on the smooth operation of the hydraulic equipment and shortening the service life. $LU 5HOHDVH RI 9DULDEOH 'LVSODFHPHQW 3LVWRQ 3XPSV 1) Make sure that all joints and fitting are not loosened.

2) Put a specified quantity of hydraulic oil into the hydraulic oil tank.

Note : 1. Set the machine at the oil level check position.

2. Keep the oil supply cap of the hydraulic oil tank removed.

3) Run the engine at low idling speed for 5 to 10 minutes.

4) Check the oil level in the hydraulic oil tank. If the oil level is lower than the specified level, supply the hydraulic oil to the tank after stopping the engine.

5) Run the engine again at low idling speed for a few minutes.

6) Check the oil level and supply the hydraulic oil to the specified level. Then install the oil supply cap. $LU 5HOHDVH RI (DFK +\GUDXOLF &RPSRQHQW Run the engine at medium speed and activate the respective circuits for about 10 to 15 minutes.

1-8

1. GENERAL CAUTIONS FOR MAINTENANCE WORK

$LU 5HOHDVH RI +\GUDXOLF &\OLQGHUV 1) Set the Engine Speed at Low Idling Range.

2) Extend and Retract the Cylinder Up to 1.97 to 3.9 in. (50 to 100 mm) from Each Stroke End Slowly 4 or 5 Times.

1.97 to 3.9 in.

(50 to 100 mm)

1.97 to 3.9 in.

(50 to 100 mm) Retraction stroke end

Retraction stroke end

Note : The extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end for the blade cylinder.

3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times.

$LU 5HOHDVH RI +\GUDXOLF 2LO WDQN Replace the oil supply cap of the hydraulic tank with the vacuuming cap.

Connect the vacuuming cap to the vacuum compressor, vacuum the air in the hydraulic oil tank. ø8

(Unit: mm)

ø6

25

16

R2

7

R1

G(PF)1

Note: " " dimensions * be changed can

*11

R0.7

*35

3.5

*55

HEX41 can be used

ø4 29±0.1

O-ring: P29

ø41 and over Material: SS or Aluminum

Vacuuming Cap 044068-00EN01

1-9

&+$37(5

7(&+1,&$/ '$7$ 2-1 Specifications...................................................................................... 2-1-1 2-2 Outline Drawing and Working Area .................................................... 2-2-1 2-3 Lifting Capacity ................................................................................... 2-3-1 2-4 Periodic Inspection and Servicing....................................................... 2-4-1 2-5 Fuel, Lube Oil and Grease Recommended ........................................ 2-5-1 2-6 Hydraulic Circuit Schematic................................................................ 2-6-1 2-7 Electrical Diagram .............................................................................. 2-7-1

2. TECHNICAL DATA

7HFKQLFDO 'DWD 6SHFLILFDWLRQV Unit

V7

Standard bucket capacity

m3

0,7

Operating mass (cabin)

kg

4100

Overall height

mm

2460

Overall lenght (with bucket on ground)

mm

4820

Overall width (with bucket)

mm

1700

Overall width (w/o bucket)

mm

1640

Overall operating height (bucket raised)

mm

3800

Height to hinge pin

mm

3100

Dump angle fully raised

Deg

43

Dumping clearence Dumping reach Dumping depth

mm mm mm

2450 650 65

Wheelbase

mm

1950

Ground clearance

mm

370

Min. turning radius with bucket in carry position (outside)

mm

4210

Angle of articulation

Deg

-/+ 36

Oscillation angle (total)

Deg

-/+ 9

-

12.0/75 R18

Item Main specifications of machine Dimensions

Standard tires Traveling performance Working speed

Forward

km/hr

Reverse

0–7

km/hr

0–7

Forward

km/hr

0–20

Reverse

km/hr

0–20

Max traction force

kg

2300

Tractivion force ratio / weight

%

56

Operating temperature range

°C

+48° ~ –15°

Tipping load straight (with bucket)

kg

3000

Tipping load fully turned (with bucket)

kg

2700

Tipping load fully turned (with pallet forks)

kg

2200

Rated operating load (with bucket)

kg

1350

Rated operating load (with with pallet forks EN 474/3 at 80%)

kg

1800

Lifting capacity with forks (at max. hight)

kg

1980

Travel speed Travel speed

Work performance

Max. auxiliary hydraulic flow (std machine)

lmin / MPa

2-1-1

63 / 20

2. TECHNICAL DATA

Item

Unit

97

Main specifications of machine Transmission Type

-

HYDROMATIK Closed circuit hydraulic transmissione)

Pump

-

With variable displacement

-

With double displacement

Hydrostatic motor Axle Front

-

Rigid

Rear

-

Oscillating

Deg

20

Total reduction

-

16,91 : 1

Differential reducers

-

Conventional (automatic proportional limited-slip differential)

Final gears

-

Epicyclic reducers

Service

-

Drum - type on the front axle working on all the wheels

Parking

-

Manual lever on the drum type of the front axle

Engine model

-

4TN9 8 %DSA2

Type

-

Vertical type series watercooled 4cycle diesel engine

Combustion system

-

Direct injection

SFV PP x mm

4 - ¡ 8 [ 90

FP

2190

N: USP

35 30

Oscillating

Brake

Engine Main specifications

Number of cylinders - Bore × Stroke

Total displacement Rated output / engine speed (GROSS) Compression pressure at 250 rpm

Mpa

3.33 - 3.53

Specific fuel consumption

/ K

-

Maximum idling speed

rpm

3235

Minimum idling speed

rpm

3185

Ng

170

-

Forced lubrication with trochoid pump

g/kW•h

Engine dry mass (excluding air cleaner and silencer) Lubricating method Specific lubricating oil consumption

2-1-2

2. TECHNICAL DATA

Item

Unit

V7

Engine Cylinder head Intake valve Exhaust valve

Open

bTDC

degrees

10 to 20

Close

aBDC

degrees

40 to 50

Open

bBDC

degrees

51 to 61

Close

aTDC

degrees

13 to 23

Intake valve clearance (Cold engine) Exhaust valve clearance (Cold engine)

mm

0.15 to 0.25

mm

0.15 to 0.25

Intake valve seat angle

degrees

120

Exhaust valve seat angle

degrees

90

Piston First compression ring Second compression ring Oil-ring

Ring shape

Barrel face (chrome-plated)

Ring quantity

pcs.

Ring shape

4 Taper face (inner cut)

Ring quantity

pcs.

Ring shape

4 Bevel cutter (with coil expander)

Ring quantity

pcs.

4

Governor Name

Mechanical all speed type

Type

Centrifugal type

Fuel feed system -

Filter paper with automatic air release device

FPð

Oil/water separator

-

Feed pump

-

6FUHHQ W\SH PHVKHV

0HFKDQLFDO GLDSKUDJP W\SH

-

Trochoid pump

MPa

to 0.

-

Full flow filter

LO filter filtration area

FPð

Filter valve opening pressure

MPa

0.08 to 0.12

Operating pressure of alarm switch

MPa

.04 to 0.06

Fuel filter Fuel filter filtration area

Lubrication system Lubrication pump LO pressure regulating valve opening pressure LO filter

2-1-3

2. TECHNICAL DATA

Item

Unit

97

Engine Cooling device Cooling system

-

/LTXLG FRROHG (Radiator)

Fan belt size

-

-

Thermostat opening temperature Thermostat full-open temperature Radiator cap pressure Radiator fan Operating temperature of water temperature alarm switch

C

1

C

73

NJI FPð

-

Blade pcs.×Ømm

7×Ø380

ºC

107 to 113

Air cleaner Type

-

Cyclone type

Filtration type

-

Double

Pump type

-

Electrical

Injection pump type

-

Rotating

(mm)

-

degrees

17,6

-

1 - 3 - 4 2

Fuel injection pump

Injection pump cam lifting height Fuel injection timing (FIT) Firing order Nozzle

Hall valve

Type Ømm ×pcs.

Nozzle hole diameter × Number of holes Spray angle

degrees

Ø0.18 x 4 159

psi (MPa)

19.6 to 20.6

-

-

rpm

-

mmHg

-

-

Quick glow plug

Starting aids capacity

V - NW

12-

Battery voltage - 5 hrs rate capacity

V - Ah

80

Fuel injection pressure Turbocharger Type Revolution speed Boost pressure Starting device Cold starting aids

2-1-4

2. TECHNICAL DATA

Item

Unit

V7

Electrical equipment Type Alternator

Regulator

Magnet

Nominal output

V-A

12 - 40

Rated speed

rpm

5000

Type

IC regulator

Regulation voltage

V

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Type Starter motor

Stop motor

14.2 to 14.8

Nominal output

V - kW

12 - 1.

Engagement

-

Magnet shift

Type

-

-

V-A

-

Liquid Crystal Display (LCD) Monitor light

Nominal output

V-W

-

Hour meter

V-W

-

V-W

-

Battery charge alarm light Engine oil pressure alarm light

V-W

-

Water temperature alarm light

V-W

-

Preheat pilot light

V-W

-

V

-

Water temperature meter

V-W

-

Fuel gauge

V-W

-

Horn

V-W

-

Monitor lamps

Engine trouble monitor light (LED)

Fuse

Blade fuse

A × pcs.

2 × 1, 15 × 5, 10 × 5, 7.5 × 3 [ 3 [ 2

Slow blow fuse

A × pcs.

40 [ 2 30 [ 3

Boom light

V-W

12 -

Room lamp (for cabin)

V-W

Wiper motor (for cabin)

V-W

Cabin heater (for cabin)

V-W

-

Cigarette lighter (for cabin)

V-W

-

2-1-5

2. TECHNICAL DATA

Item

Unit

V7

Hydraulic equipment Pump Type

High pressure

-

Displacement

l/min / rpm

58 / 2800

Max. pressure

MPa

35,0

Type

Low pressure

Axial piston pump

-

Gear pump

l/min / rpm

60 / 2800

Main relief valve set pressure for power steering

MPa

20,5 - 21,5

Overloadrelief valve set pressure for power steering

MPa

26,0

Displacement

Control valve Type

-

Modular

pcs

2

Main relief valve set pressure

Mpa

17,0

Overload relief valve set pressure for lifting section

Mpa

25,0

Overload relief valve set pressure for bucket section rod side

Mpa

26,0

Overload relief valve set pressure for bucket section bottom side

Mpa

30,0

L

60

Quantity of section for std version

Hydraulic oil tank Hydraulic oil amount (Tank capacity / Others)

-

%\SDVV

cm2

-

Option

-

Electrical indicator

By-pass valve opening pressure

-

Type

-

Type Return filter

Filtration area

Yes

Hydraulic cylinder

Lifting

pcs

Quantity

mm

70

Stroke

mm

589

-

Double action

pcs

1

Bore

mm

80

Stroke

mm

395

-

Double action

Quantity

Type Steering

2

Bore Type

Bucket

Double action

Quantity

pcs

1

Bore

mm

65

Stroke

mm

255

2-1-6

2. TECHNICAL DATA

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A

4820

B

1670

C

1950

D

1205

E

2495

F

mm

2680

Ground clearance

370

AA

Track width

1280

AB

Maximum width without accessory

1640

AC

Bucket blade width

1700

Maximum dumping height

650

G

2-2-1

2. TECHNICAL DATA

3 /LIWLQJ &DSDFLW\ • The machine can be equipped with universal forks, which are installed on the lifting arm.

• Machines equipped with forks have a smaller lifting capacity. The position of the load affects the machine's centre of gravity, which increases the risk of tipping.

WARNING The load's centre of gravity must not be more than 500 mm from the tip of the fork.

Do not lift a load higher than 500 mm from the ground.

WARNING A machine carrying a load must not travel faster than 15 km/h.

• The lifting capacities indicated below comply with EN 474 recommendations and are determined under the most unfavourable conditions for the machine, with the front articulated part turned to 40°: – The lifting capacity of the machine on a flat, stable surface corresponds to 80% of the static tipping load.

– The lifting capacity of the machine on uneven ground corresponds to 60% of the static tipping load.

60%

80%

1400

1800

2-3-1

2. TECHNICAL DATA

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Parts & Operations

General.

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Daily

Missing or broken parts

○

Tightening of nuts and bolts

○ ○ □ ○

Motor state Machine Tire pressure

Differential reducers Splitter

Hydraulic circuit

Hydraulic oil

Greasing

Electrical equipment

○ ○ ○

● ● ●

■

Lubrication of universal joint gaskets

■

Headlights, horn, travel alarm, Direction lights

○

Dashboard and indicators

○ ○ ○ 1st time

Battery electrolyte

○ ●

GO filter

□

○ □

Air filter

● ●

Secondary filter Engine oil Engine

○

Oil filter Cooling fluid Belt Radiator vents

Every 2000h / Every two years

●

● 1st time ■

Fuel tank

Every 1000h / Every year

●

Lubricating the central hinge

System state

Every 500h

○

Hydraulic oil return filter Greasing points

Every 250h

● 1st time ● 1st time ● 1st time

Epicyclic reducers Transmissions

Every 50h

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○ ○ ○

● 1st time ● 1st time

● ● ● ● □ ●

Fuel hose, coolant hose

○

Intake and exhaust valves

○

Injectors and injection pressure

○

Heating

2-4-1

2. TECHNICAL DATA

5 )XHO /XEH 2LO DQG *UHDVH 5HFRPPHQGHG • Select a fuel and an oil according to the machine's operating temperature.

• Always use a Yanmar long-life cooling fluid.

IMPORTANT Do not mix different types of oils.If you need to top up the oil with a different make or type from the oil left in the tank, remove the remaining oil completely.

Temperatures °C Components

Fluid -

Thermal engine

Engine oil

Axles, limited slip differential type

Hydraulic oil

-20

-10

0

10

20

30

YANMAR GOLDEN DIESEL HP/A 10W–30

8

YANMAR UNIVERSAL GEAR EP LS 85W-90

4 4,1

Axles Splitter

YANMAR UTTO SPECIAL FLUID 10W-30

Hydraulic oil Epicyclic reducers

0,6 0,9 57

Hydraulic circuit Service brakes

+

Quantity prescribed (L)

YANMAR SPECIAL HYDRAULIC ISO15 (SP15)

Brake fluids

1,1

N° 2-D Fuel tank

N° 3-D

Diesel

70

N° 3-D (S) Cooling system

Long-life cooling fluid

YANMAR POWER COOLANT B–36

10

Greasing

Greases

YANMAR CONTACT GREASE EP

-

2-5-1

2-6-

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HYDRAULIC PUMP

STEERING UNIT

25 MPa

26 MPa

30 MPa

RESTRICTOR VALVE

RESTRICTOR VALVE

17 MPa

4+ 6(&7,21 237,21

RADIATOR

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CHECK VALVE

HYDROSTATIC MOTOR

48,&. +,7&+ &</,1'(5 237,21

HYDROSTATIC PUMP

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HYDRAULIC OIL FILTER

2. TECHNICAL DATA

6 +\GUDXOLF &LUFXLW 6FKHPDWLF

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2. TECHNICAL DATA

7 Electrical 'LDJUDP To consult the electrical diagrams, refer to the specific chapter "5-2 Elecrical diagram" on page 5-2-1.

2-7-

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6(59,&( 67$1'$5'6 3-1 Machine Performance......................................................................... 3-1-1

3. SERVICE STANDARDS

6HUYLFH 6WDQGDUGV 0DFKLQH 3HUIRUPDQFH Applicable model Item

97

Measuring condition

Unit

Standard

Machine performance Working speed

Bucket speed

Machine position

Lifting

Up Max. cylinder stroke

1,7

Lowering

sec.

Min. cylinder stroke

Down

1,7

Up

3,9

 Engine: Max. rpm  Hydraulic fluid temperature: 50-60°C  Bucket: unladen  Parking brake: blocked  Lifting points arm: highest position

Arm lifting speed

Machine position

Lifting

Max. cylinder stroke

sec. on the ground Bucket teeth resting

Down    

Engine: Max. rpm Hydraulic fluid temperature: 50-60°C Bucket: unladen Parking brake: blocked

3-1-1

Lowering

2,5

3. SERVICE STANDARDS

Applicable model Item

97

Measuring condition

Standard

Machine performance

Parking brake performance

Status Machine position

Stationary vehicle 30 cm 18%

   

Engine: Stop Gear position: Neutral Gradient: 18% Parking brake lever position: 6/7 clicks

3-1-2

&+$37(5 (1*,1( 4-1 Safety ........................................................................ 4-1-1

4-6 Starter Motor ............................................................. 4-6-1

4-1-1 Safety Statements ............................................ 4-1-1 4-1-2 Safety Precautions ........................................... 4-1-2 4-2 Engine ....................................................................... 4-2-1

4-6-1 Before You Begin Servicing ............................. 4-6-1 4-6-2 Introduction....................................................... 4-6-2 4-6-3 Starter Motor Information ................................. 4-6-2 4-6-4 Starter Motor Troubleshooting.......................... 4-6-3 4-6-5 Starter Motor Components ............................... 4-6-4 4-6-6 Starter Motor .................................................... 4-6-5 4-7 Alternator................................................................... 4-7-1

4-2-1 Before You Begin Servicing ............................. 4-2-1 4-2-2 Special Service Tools....................................... 4-2-2 4-2-3 Measuring Instruments..................................... 4-2-4 4-2-4 Cylinder Head................................................... 4-2-6 4-2-5 Measuring and Adjusting Valve Clearance .... 4-2-20 4-2-6 Crankshaft and Camshaft Components ......... 4-2-23 4-3 Fuel System .............................................................. 4-3-1 4-3-1 4-3-2 4-3-3 4-3-4 4-3-5 4-3-6

Before You Begin Servicing ............................. 4-3-1 Introduction....................................................... 4-3-2 Special Service Tools....................................... 4-3- Measuring Instruments..................................... 4-3- Fuel System Diagram....................................... 4-3- Fuel System Components ................................ 4-3-

4-7-1 Before You Begin Servicing ............................. 4-7-1 4-7-2 Introduction....................................................... 4-7-2 4-7-3 Alternator Specifications................................... 4-7-2 4-7-4 Alternator Troubleshooting ............................... 4-7-3 4-7-5 Alternator Components .................................... 4-7-4 4-7-6 Alternator Wiring Diagram ................................ 4-7-5 4-7-7 Alternator Standard Output .............................. 4-7-6 4-7-8 Alternator .......................................................... 4-7-7 4-8 Electric Wiring .......................................................... 4-8-1

4-8-1 Electric Wiring Precautions ............................. 4-8-1 4-3- Fuel Injection Pump.......................................... 4-3- 4-9 Troubleshooting......................................................... 4-9-1 4-3- Checking and $GMXVWLQJ )XHO ,QMHFWLRQ 7LPLQJ 4-9-1 Special Service Tools ....................................... 4-9-1 4-3- Fuel Injectors............................................ .. 4-3- 4-9-2 Troubleshooting By 4-4 Cooling System ......................................................... 4-4-1 Measuring Compression Pressure................... 4-9-2 4-9-3 Quick Reference Table 4-4-1 Before You Begin Servicing ............................. 4-4-1 For Troubleshooting ......................................... 4-9-4 4-4-2 Introduction....................................................... 4-4-2 4-4-3 Cooling System Diagram.................................. 4-4-2 4-4-4 Engine Coolant Pump Components ................. 4-4-3 4-4-5 Engine Coolant System Check......................... 4-4-4 4-4-6 Engine Coolant Pump ...................................... 4-4-4 4-5 Lubrication System.................................................... 4-5-1 4-5-1 4-5-2 4-5-3 4-5-4 4-5-5

Before You Begin Servicing ............................. 4-5-1 Introduction....................................................... 4-5-2 Lubrication System Diagram ............................ 4-5- Checking Engine Oil Pressure ......................... 4-5- Trochoid Oil Pump............................................ 4-5-

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4-2-20



4. ENGINE

The 4-valve cylinder head operates two valves with a single rocker arm by employing a valve bridge (Figure 4-2-35, (1) between the two valves (Figure 4-2-35, (2)). Clearance (Figure 4-2-35, (4)) between the valve bridge and valves must be set before adjusting the clearance (Figure 4-2-35, (5)) between the rocker arm (Figure 4-2-35, (3)) and valve bridge.

(5)

(3)

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NOTICE Do not loosen or tighten the valve adjusting screw lock nut without holding the valve bridge.

Always hold the valve bridge using a wrench to prevent bending of the valve stems.

4. Loosen the valve bridge adjusting screw lock nut (Figure 4-2-36, (1)) while holding the bridge (Figure 4-2-36, (3)) with a wrench (Figure 4-2-36, (2)).

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Figure 4-2-36

Note: If adjusting each cylinder individually, the cylinder to be adjusted first does not have to be the No. 1 cylinder. Select and adjust the cylinder where the piston is nearest to the top dead center after turning, and make adjustment for other cylinders in the order of firing by turning the crankshaft 180° each time.

5. To assure the valve bridge contacts the rear valve, apply light, downward (Figure 4-2-37, (4)) finger pressure on the valve bridge (Figure 4-2-37, (3), and loosen the valve bridge adjusting screw (Figure 4-2-37, (1)), until there is visible clearance (Figure 4-2-38, (2)) between the adjusting screw and the front valve.

6. To assure the valve bridge has equal contact with the front and rear valves, apply light downward (Figure 4-2-37, (4)) pressure on the valve bridge (Figure 4-2-37, (3), adjust the valve bridge adjusting screw ((Figure 4-2-37, (1)), (Figure 4-2-38, (1))) so there is zero “0” clearance (Figure 4-2-39, (2)) between the 3. Make sure there is clearance (Figure 4-2-35, (5)) adjusting screw and the front valve. between the valve bridge (Figure 4-2-35, (1)) and the rocker arm (Figure 4-2-35, (3)).

2. Rotate the crankshaft clockwise as seen from the coolant pump end, to bring No. 1 piston to TDC on the compression stroke while watching the rocker arm motion and the timing grid on the flywheel. (Position where both the intake and exhaust valves are closed.)

(1)

(4)

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Figure 4-2-37

4-2-21

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4. ENGINE

7. Tighten the lock nut (Figure 4-2-38, (1)), while holding the valve bridge (Figure 4-2-38, (3)) with a wrench (Figure 4-2-38, (2)). Verify that the valve clearance (Figure 4-2-38, (4) is zero “0”.

(1)

(3) (2)

9. If adjustment is required, proceed to the next step.

10. Loosen the valve adjusting screw lock nut (Figure 4-2-40, (5)) and valve adjusting screw (Figure 4-2-40, (4)) on the rocker arm (Figure 4-2-40, (3)) and check the clearance gap (Figure 4-2-40, (2)) for evidence of dirt or wear.

Note: There is a tendency for the clearance to decrease slightly when the lock nut is tightened. It is suggested that you make the clearance adjustment is made slightly on the “loose” side before tightening the lock nut.

(1)

(4)

11. Adjust the valve clearance (Figure 4-2-40, (2)) by turning the adjusting screw (Figure 4-2-40, (4)) until there is a slight “drag” on the feeler gauge when sliding it between the rocker arm and the valve bridge.

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Figure 4-2-38

(3)

Note: There is a tendency for the clearance to decrease slightly when the lock nut is tightened. It is suggested that you make the initial clearance adjustment is made slightly on the “loose” side before tightening the lock nut.

(1)

(2)

(4) (5)

8. To adjust the actual valve clearance between the rocker arm and the valve bridge, insert a feeler gauge (Figure 4-2-39, (1)) of the correct K0001918 thickness (See Adjustment Specifications on page 6-4) between the rocker arm Figure 4-2-40 (Figure 4-2-38, (2)) and valve bridge (Figure 4-2-38, (3)). Record the results and use 12. Hold the adjusting screw (Figure 4-2-40, (4)) while tightening the valve adjusting screw lock this value as an indication of wear. nut (Figure 4-2-40, (5)). Recheck the clearance.

(2)

13. Apply oil to the contact surface between the adjusting screw and push rod.

14. Rotate the crankshaft to measure and adjust the set of valves. Continue until all valves are measured and adjusted.

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4-2-23

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Figure 4-2-91

Figure 4-2-90

4-2-43

4. ENGINE

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3LVWRQ LQVWDOODWLRQ

NOTICE

When correctly assembled, the piston identification mark )LJXUH

stamped into the top of the piston will be on the same side of the connecting rod as the match marks )LJXUH

stamped into the connecting rod and connecting rod cap.

Do not allow the connecting rod to contact the crankshaft journal during piston installation.

Damage to the crankshaft bearing journal may result. /XEULFDWH SLVWRQ SLVWRQ ULQJV DQG F\OLQGHU ZLWK FOHDQ HQJLQH RLO RU DVVHPEO\ OXEULFDQW

When installed in the cylinder, the piston identification mark )LJXUH

stamped on the top of the piston must face the fuel injection pump side )LJXUH

of the engine and the embossed mark on the connecting rod )LJXUH

must face the flywheel end )LJXUH

of the engine.

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NOTICE Ensure the piston ring gaps are located correctly )LJXUH .

± 7RS &RPSUHVVLRQ 5LQJ (QG *DS ± 6HFRQG &RPSUHVVLRQ 5LQJ (QG *DS ± 2LO 5LQJ (QG *DS

K0001967

1 2 3 4 5 6

Figure 4-2-92 8VLQJ D SLVWRQ ULQJ FRPSUHVVRU FRPSUHVV WKH SLVWRQ ULQJV

NOTICE The piston and connecting rod must be installed in the correct orientation. The orientation of the piston to the cylinder is different depending on engine model.

– Fuel injection pump side of engine – Piston identification mark – Embossed mark on connecting rod – Rod and cap match marks – Flywheel end of engine – Camshaft side of engine

Figure 4-2-93 5HLQVWDOO WKH EHDULQJ LQVHUWV )LJXUH

LQ WKH FRQQHFWLQJ URG DQG FDS

4-2-44

4. ENGINE

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Figure 4-2-94 5HLQVWDOO WKH UHPDLQLQJ SLVWRQV LQ WKHLU UHVSHFWLYH F\OLQGHUV

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RQWR WKH FDPVKDIW XVLQJ D SUHVV +HDW WKH JHDU WR ) & DQG SUHVV RQWR WKH HQG RI WKH FDPVKDIW Rotate the cylinder block so that gravity will keep the tappets )LJXUH

in place and out of the way of the camshaft lobes when the camshaft is being reinstalled.

1RWH

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4-2-45

4. ENGINE

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Figure 4-2-96

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B

C C A A

K0001709A

– Fuel injection pump gear – Camshaft gear – Optional accessory drive gear – Crankshaft gear – Direction of rotation – Oil pump gear – Idler gear

Figure 4-2-98 :KHQ DOO JHDUV DUH SURSHUO\ DOLJQHG WLJKWHQ WKH LGOHU JHDU UHWDLQLQJ EROWV WR VSHFLILHG WRUTXH 6HH (QJLQH 7LJKWHQLQJ 7RUTXH VHFWLRQ IRU WLJKWHQLQJ WRUTXH

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Figure 4-2-97 $OLJQ WKH WLPLQJ JHDUV DV VKRZQ LQ )LJXUH

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4. ENGINE

5HLQVWDOO WKH FUDQNVKDIW SXOOH\

NOTICE 8VH WKH FUDQNVKDIW SXOOH\ installation tool )LJXUH

when reinstalling the pulley )LJXUH

. The tool will guide the pulley hub and protect the front

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seal )LJXUH

from damage.

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Figure 4-2-101

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Figure 4-2-100

4-2-47

4. ENGINE

)XHO 6\VWHP %HIRUH <RX %HJLQ 6HUYLFLQJ %HIRUH SHUIRUPLQJ DQ\ VHUYLFH SURFHGXUHV ZLWKLQ WKLV VHFWLRQ UHDG WKH IROORZLQJ VDIHW\ LQIRUPDWLRQ DQG UHYLHZ WKH 6DIHW\ VHFWLRQ RQ SDJH

3ULPLQJ WKH )XHO 6\VWHP The fuel system needs to be primed under certain conditions: • Before starting the engine for the first time.

• After running out of fuel and fuel has been added to the fuel tank.

• After fuel system maintenance such as changing the fuel filter and draining the fuel filter/water separator, or replacing a fuel system component.

To prime the fuel system: 1. Turn the key to the ON position for 10 - 15 seconds. This will allow the electric fuel pump to prime the fuel system.

2. Never use the starter motor to crank the engine in order to prime the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and/or ring gear. %HIRUH <RX %HJLQ 6HUYLFLQJ %HIRUH SHUIRUPLQJ DQ\ VHUYLFH SURFHGXUHV ZLWKLQ WKLV VHFWLRQ UHDG WKH IROORZLQJ VDIHW\ LQIRUPDWLRQ DQG UHYLHZ WKH 6DIHW\ VHFWLRQ RQ SDJH

4-3-1

4. ENGINE

,QWURGXFWLRQ This section of the 6HUYLFH 0DQXDO describes the procedures necessary to remove, install, and time the MP fuel injection pump and its associated system components. This fuel injection pump is representative of the fuel injection pumps used on other TNV DI model engines. The descriptions given in this section basically apply also to fuel injection pumps used for electronically controlled engines unless otherwise described herein.

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K0000038

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UHSDLU IDFLOLW\

NOTICE • Never remove or attempt to remove the tamperproof devices from the full-load fuel adjusting screw or the high-speed throttle limit screw on the fuel injection pump and governor assembly.

These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed.

Figure -1 The following describes the features of the MP fuel injection pump, manufactured by YANMAR. The fuel injection pump is a very important component of the engine. It is capable of making very precise fuel delivery adjustments according to the varied loads applied to the engine.

All of the fuel injection pump components are very precisely machined. It is extremely important to follow good service practices and maintain cleanliness when servicing the fuel injection pump.

• Never attempt to make any adjustments to these sealed adjustment screws. If adjustments are required, they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper-proof seals.

The YANMAR MP “Mono-Plunger” fuel injection pump is a distributor type pump which consists of a single fuel supply plunger, a distributor shaft, a hydraulic head and a pump housing. The hydraulic head has a delivery valve for each cylinder. The fuel injection pump housing contains a governor and an internal camshaft.

• Tampering with or removing these devices may void the “YANMAR Limited Warranty”.

The fuel is pressurized by the up and down motion of the camshaft-driven single plunger. It is then distributed to the proper fuel injector by the rotating distributor shaft.

There are two versions and sizes of the MP fuel injection pump. The smaller of the two pumps, the MP2 pump, is used on the 3TNV82A - 4TNV88 model engines.

4-3-2

4. ENGINE

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The MP fuel injection pumps are equipped with a stop solenoid that controls the fuel flow inside the fuel injection pump.

The YANMAR TNV model engines are equipped with a cold start device (CSD).

With the starter switch in the OFF position, no current flows to the stop solenoid and the solenoid plunger is extended holding the fuel injection pump fuel rack in the “closed” position and not allowing fuel to flow through the injection pump and to the engine.

When the starter switch is turned to the start position, the “pull coil” (36.5 Amp draw/white wire) inside the solenoid is activated and pulls the solenoid plunger into the solenoid. This releases the fuel injection pump fuel rack, allowing fuel to flow through the injection pump and allowing the engine to start and run.

The cold start device is located in the upper section of the fuel injection pump and is connected to the engine’s cooling system.

• The cold start device improves engine starting at lower temperatures. At engine cooling system temperatures below 5 °C, the cold start device advances the fuel injection timing and slightly increases the fuel injection volume.

• For approximately the first 5 minutes of operation, the idle speed of the engine will be slightly elevated.

NOTICE

When the starter switch is returned to the ON or RUN position, the “pull coil” no longer receives current and the “hold coil” (0.5 Amp draw/red wire) inside the solenoid is activated. The “hold coil” holds the solenoid plunger in the RUN position, allowing fuel to continue flowing and he engine to continue running.

Allow the engine to warm-up for at least five minutes and the idle speed of the engine to return to normal before engaging the transmission or any PTOs. Engaging the transmission or PTO at an elevated engine speed could result in an unexpected movement of the equipment.

To stop the engine, the key switch is turned to the OFF position. Current no longer flows to the stop solenoid “hold coil”, and the solenoid plunger extends and moves the injection pump fuel rack to the “closed” position, shutting off the fuel flow and stopping the engine.

• When the cold start device is activated, you may notice a slight increase in the exhaust smoke of the engine during engine warm-up.

Failure of the stop solenoid could result in the engine not starting, the engine stopping suddenly, the engine not continuing to run with the key switch returned to the ON or RUN position, or the engine failing to stop when the key switch is turned to the OFF position. Use a multimeter or continuity light to check for 12 V at the stop solenoid connector in the correct sequence.

4-3-3

4. ENGINE

Figure • When the engine is started with the cooling water sensor detecting a low water temperature of 10 °C or lower and the E-ECU receives the corresponding signal, then the E-ECU causes the CSD’s solenoid valve to increase the injection rate and advance the injection timing.

• Because of this, the engine speed increases by approximately 75 min-1 while the CSD is operating. When the water temperature becomes 10 °C or higher, the CSD is turned off and the engine returns to the normal speed.

7URFKRLG )XHO 3XPS 1RWH 7KH WURFKRLG IXHO SXPS ORFDWHG RQ WKH VLGH RI WKH 03 IXHO LQMHFWLRQ SXPS LV QRW D ³IXHO VXSSO\´ SXPS 7KH IXQFWLRQ RI WKLV SXPS LV WR UDLVH WKH SUHVVXUH RI WKH IXHO VXSSOLHG E\ WKH HOHFWULF IXHO VXSSO\ SXPS WR WKH LQWHUQDO IXHO SUHVVXUH UHTXLUHG E\ WKH 03 IXHO LQMHFWLRQ SXPS The use of an electric fuel supply pump is required on all TNV model engines with the MP fuel injection pump.

4-3-4

4. ENGINE

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/XEULFDWLQJ RLO DSSOLFDWLRQ 7KUHDG SRUWLRQ DQG VHDW VXUIDFH

Fuel injector retainer bolt

39.2 N·m

Not applied

Fuel pump drive gear nut

78 - 88 N·m

Not applied

High-pressure fuel injection line nuts

29 - 34 N·m

Not applied

Fuel return line bolts

7.8 - 9.8 N·m

Not applied

Fuel injection pump mounting nuts

23 - 28 N·m

Not applied

&RPSRQHQW

Fuel injector nozzle case nut

Fuel injection pump plunger plug

39.2 - 44.1 N·m

30 - 35 N·m

4-3-5

Not applied

Not applied

4. ENGINE

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19.6 - 20.6 MPa

V

21.6 - 22.6 MPa

S

18.6 - 19.6 MPa

R

21.1 - 22.1 MPa

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K0004105

Figure -3 Fuel injector identification is critical as each engine has a unique fuel injection pressure. The fuel nozzle is specifically matched to the fuel injector by engine model and/or engine speed.

4-3-6

4. ENGINE

63(&,$/ 6(59,&( 722/6 1R

1

7RRO QDPH

Torque wrench

Locally available

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For tightening nuts and bolts to the specified torque 001438-00X

2

Fuel injector removal tool

YANMAR Part No. 129470-92305

Used in conjunction with a slide hammer to remove the fuel injectors (2-valve cylinder heads) K0001618

0($685,1* ,167580(176 1R

1

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Fuel injector tester

Locally available

$SSOLFDWLRQ For observing injection spray pattern of fuel injection nozzle and measuring injection pressure

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K0000581

Dial indicator*1 2

Mituotoyo 2050SB - Locally available

Check and adjust fuel injection timing 001429-00X

Extension rod*1

Mituotoyo 303613 - Locally available (M14) TNV82-88 - YANMAR Part No. 158090-51831

3

Fuel injection pump plunger adapter*1

(M16) TNV94-106 - YANMAR Part No. 158090-51841

Mount dial indicator to fuel injection pump

K0002690

4

Plunger adapter clamp

YANMAR Part No. 23000-013000

Clamps stem of dial indicator in plunger adapter K0002691

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4-3-7

4. ENGINE

)8(/ 6<67(0 ',$*5$0

K0000034B

1 – Diesel fuel tank 2 – Fuel filter/water separator 3 – Electric fuel pump 4 – Fuel filter 5 – Air bleed orifice 6 – Fuel supply line 7 – Low pressure gallery 8 – Pressure control valve 9 – Trochoid pump 10 – Oil seal 11 – Fuel injection pump cam

12 – Engine crankcase 13 – Tappet 14 – High pressure gallery 15 – Overflow orifice 16 – Accumulator 17 – Timer piston 18 – Mono-plunger 19 – Distributor shaft 20 – Fuel return line 21 – High-pressure fuel injection lines 22 – Fuel injector

Figure -4

4-3-8

4. ENGINE

)8(/ 6<67(0 &20321(176 18 1

2

3 5 4

17 16

6

15

12

20

14 19

11 10

13 21

9

7 8 K0002017

1 – High-pressure fuel injection lines 2 – Fuel return line 3 – Return line-to-cylinder head bolt 4 – Fuel injector 5 – Injection line grommet 6 – Front plate or timing gear case 7 – Gear case cover 8 – Fuel injection pump drive gear nut 9 – Lock washer 10 – Fuel injection pump drive gear assembly (Do not remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub!)

11 – Coolant lines for cold start device*1 12 – Fuel injection pump insulator 13 – Diesel fuel injection pump 14 – Rear fuel injection pump support 15 – Fuel filter/water separator 16 – Electric fuel supply pump 17 – Fuel filter 18 – Fuel filter housing 19 – Stop solenoid*1 20 – Cold start device (CSD)*2 21 – Trochoid fuel pump

Figure -5

4-3-9

4. ENGINE

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Figure

4-3-1

4. ENGINE

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NOTICE

5HPRYDO RI )XHO ,QMHFWLRQ 3XPS

Remove or install the high-pressure fuel injection lines as an assembly whenever possible.

Disassembling the high-pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines.

1. Loosen the cooling fan V-belt.

2. Remove the engine coolant fan guard (if equipped), engine coolant fan )LJXUH

, spacer )LJXUH

if equipped, Vpulley )LJXUH

and cooling fan V-belt )LJXUH

.

7. Finish loosening all the fuel line nuts and remove the high-pressure fuel lines as an assembly being careful not to bend any of the fuel lines. Be sure to protect the fuel system from contamination by covering all open connections.

8. Disconnect the coolant lines from the cold start device )LJXUH

on the fuel injection pump. Plug the open ends of the lines to minimize leakage and prevent contamination.

9. Disconnect the fuel return lines from the fuel return fitting )LJXUH

Plug the open ends of the lines to minimize leakage and prevent contamination.

Figure 3. Close any fuel valves in the fuel supply line.

1

4. Place a drain pan under the fuel injection pump to catch any spillage.

4

5. Remove the high-pressure fuel injection lines as an assembly )LJXUH

.

1RWH 7R SUHYHQW ³URXQGLQJ´ WKH IXHO OLQH QXWV DOZD\V XVH D ³OLQH´ RU ³IODUH QXW´ ZUHQFK :KHQ ORRVHQLQJ WKH IXHO OLQH QXWV DOZD\V KROG WKH IXHO LQMHFWLRQ SXPS GHOLYHU\ YDOYHV ZLWK D ³EDFN XS´ ZUHQFK WR SUHYHQW ORRVHQLQJ RI WKH GHOLYHU\ YDOYHV 6. First loosen the fuel line nuts at the fuel injectors and then at the fuel injection pump.

4-3-1

3

2

K0002094

Figure

4. ENGINE

10. Remove the fuel supply line )LJXUH

.

Plug the open end of the line to minimize leakage and prevent contamination.

K0000153A

Figure

Figure 11. Remove the throttle cable from the fuel injection pump.

14. Disconnect the lube oil line )LJXUH

and the clamp )LJXUH

from the pump.

12. Separate the stop solenoid wiring connector )LJXUH

.

13. Remove the rear fuel injection pump bracket(s) )LJXUH

from the fuel injection pump.

1RWH &RQILJXUDWLRQ RI WKH IXHO LQMHFWLRQ SXPS UHDU EUDFNHWV PD\ YDU\ GHSHQGLQJ engine model.

NOTICE Take care to not damage or bend the oil line. In some applications, it may be preferable to remove the complete oil line assembly from the engine before proceeding.

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Figure 4-3-1

K0000593B

4. ENGINE

17. To aid in reassembly, make reference marks on the fuel injection pump drive gear, and on either the gear case cover or idler gear.

15. Remove the fuel injection pump drive gear cover )LJXUH

from the gear case cover )LJXUH

.

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NOTICE After marking the position of the pump drive gear, do not rotate the engine crankshaft. Rotating the crankshaft will cause the fuel injection pump to become misaligned.

2

• On TNV88 model engines, the idler gear is not visible. Make a reference mark on the fuel injection pump drive gear )LJXUH

and a matching mark on the bore of the gear case opening )LJXUH

.

1

K0002039

Figure 16. Do not loosen or remove the four bolts )LJXUH

retaining the pump drive gear to the hub. Loosen the drive gear mounting nut )LJXUH

, leaving the hub attached to the gear.

K0000575A

Figure

NOTICE Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub. Do not disassemble the fuel injection pump drive gear from the hub. Correct fuel injection timing will be very difficult or impossible to achieve.

K0000162A

Figure

4-3-1

4. ENGINE

18. Hold the gear train using a large socket wrench on the crankshaft pulley nut. Loosen the fuel injection pump drive gear retaining nut )LJXUH

and turn it out to the end of the fuel injection pump shaft. (Until the tip of the camshaft is hidden.)

20. Once the fuel injection pump drive gear and hub assembly has “popped” loose from the tapered fuel injection pump drive shaft, carefully remove the drive gear nut )LJXUH

and lock washer )LJXUH

.

19. Remove the pump drive gear and hub as an assembly using an appropriate two-bolt gear puller )LJXUH

K0000162B

Figure

K0000574

Figure

21. Locate the mark stamped into the upper outside mounting boss of the fuel injection pump.

Highlight this mark and make a corresponding mark on the gear case or front plate )LJXUH

1RWH 2Q 719 PRGHOV WKH LQMHFWLRQ SXPS GULYH JHDU ZLOO UHPDLQ ³FDSWXUHG´ LQ WKH JHDU FDVH

K0000593A

Figure 1RWH 6RPH PRGHO HQJLQHV PD\ UHTXLUH WKH LQWDNH PDQLIROG DQG IXHO LQMHFWLRQ SXPS LQVXODWRU (Figure , (2)) EH UHPRYHG WR DFFHVV WKH LQQHU IXHO LQMHFWLRQ SXPS (Figure , (1)) UHWDLQLQJ QXWV

4-3-1

4. ENGINE

NOTICE Do not rotate the crankshaft with the injection pump removed.

24. If the fuel injection pump requires servicing, it must be sent to an authorized YANMAR FIE repair facility for repair and calibration, or replaced with a new fuel injection pump.

NOTICE

K0000263A

Figure 22. If required, remove the intake manifold and fuel pump insulator to access the fuel injection pump mounting nuts.

1RWH 7KH 03 IXHO LQMHFWLRQ SXPSV 719 PRGHO HQJLQHV DUH IDVWHQHG WR WKH JHDU FDVH ZLWK WKUHH

VWXGV DQG QXWV 23. Remove the fuel injection pump )LJXUH

. For purposes of future injection timing purposes, record the fuel injection pump timing index number located on the boss on the engine side (back) of the of the fuel injection pump )LJXUH

.

K0002047

Figure

4-3-1

• Never remove or attempt to remove the tamper-proof devices from the full-load fuel adjusting screw or the high-speed throttle limit screw on the fuel injection pump and governor assembly. These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed.

• Never attempt to make any adjustments to these sealed adjustment screws. If adjustments are required, they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper-proof seals.

• Tampering with or removing these devices may void the “YANMAR Limited Warranty.”

4. ENGINE

,QVWDOODWLRQ RI )XHO ,QMHFWLRQ 3XPS

1. Align the pump drive gear with the idler gear using the reference marks made earlier.

TNV82 - 88 model engines )LJXUH

.

For electronically controlled engine

:$51,1* 5HSODFLQJ WKH IXHO LQMHFWLRQ SXPS LQYROYHV UHZULWLQJ WKH IXHO LQMHFWLRQ GDWD LQ WKH ( (&8 %H VXUH WR FRQWDFW \RXU ORFDO <$10$5 GHDOHU EHIRUH UHSODFLQJ WKH IXHO LQMHFWLRQ SXPS )DLOXUH WR UHZULWH WKH IXHO LQMHFWLRQ GDWD EHIRUH UHSODFLQJ WKH IXHO LQMHFWLRQ SXPS ZLOO YRLG WKH HQJLQH ZDUUDQW\

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K0000575B

Figure

NOTICE If installing a new or recalibrated fuel injection pump, locate and record the timing index number located on the pump housing boss on the engine side of the new or recalibrated fuel injection pump )LJXUH

. This number will be used to calculate and adjust the final fuel injection timing.

1RWH 7UHDW WKH WLPLQJ LQGH[ QXPEHU DV LI LW KDV D GHFLPDO SRLQW

2. If installing the fuel injection pump on an engine with the front gear case cover removed, the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks $ % & on the fuel injection pump drive gear, idler gear, and crankshaft drive gear. Ensure all three timing marks )LJXUH $ % &

are aligned.

B

1 2 3 4 5 6 7

K0002047

Figure

B

C C A A

– Fuel injection pump drive gear – Camshaft drive gear – Auxiliary drive gear (optional) – Crankshaft drive gear – Direction of rotation – Oil pump drive gear (4TNV94L - 4TNV106) – Idler gear

Figure

4-3-1

K0001709A

4. ENGINE

• Align the reference marks )LJXUH

previously made on both the fuel injection pump mounting flange and gear case or front plate.

3. Install a new O-ring on the pump mounting flange. Apply grease to the O-ring to hold it in place during installation of the injection pump.

1RWH (QVXUH WKH WDSHUHG VXUIDFH RI WKH IXHO LQMHFWLRQ SXPS VKDIW LV FOHDQ DQG GU\ 4. Align the key on the fuel injection pump shaft with the keyway in the fuel injection pump drive gear hub. Reinstall the fuel injection pump into the fuel injection pump drive gear and gear housing. Reinstall the pump retaining nuts finger tight.

5. Reinstall the fuel injection pump drive gear lock washer )LJXUH

and nut )LJXUH

. Do not lubricate the threads of the nut or shaft. Hold the crankshaft pulley bolt with a socket wrench and tighten the drive gear nut to the specified torque.

6HH 6SHFLDO 7RUTXH &KDUW RQ SDJH

K0000593A

Figure • Tighten the fuel injection pump retaining nuts to specification. 6HH 6SHFLDO 7RUTXH &KDUW RQ SDJH

K0000162B

Figure ,I UHLQVWDOOLQJ WKH RULJLQDO IXHO LQMHFWLRQ SXPS

4-3-1

4. ENGINE

,I LQVWDOOLQJ D QHZ IXHO LQMHFWLRQ SXPS

• Calculate the difference between the timing index numbers )LJXUH

of the fuel injection pump that you removed and the replacement fuel injection pump. 6HH &DOFXODWLRQ H[DPSOH EHORZ.

• Reinstall the timing grid sticker, provided with the new fuel injection pump, onto the back of the gear case/front plate )LJXUH

Align the “standard mark” )LJXUH

with the reference mark )LJXUH

made on the gear case during disassembly.

K0002047

Figure $GMXVWLQJ WKH IXHO LQMHFWLRQ WLPLQJ WR FRPSHQVDWH IRU WKH GLIIHUHQFH LQ SXPS WLPLQJ LQGH[ QXPEHUV

&DOFXODWLRQ H[DPSOH

7LPLQJ LQGH[ QXPEHU Original injection pump = 6.8

Replacement injection pump = 7.3 Difference = +0.5

• If the difference between the timing index numbers is a positive number, the fuel injection pump mounting position must be advanced )LJXUH

(rotated away from the engine) as compared to the “standard mark” )LJXUH

by the calculated positive amount, adjust the fuel injection pump to the calculated value.

• If the difference between the timing index numbers is a negative number, the replacement injection pump must be retarded )LJXUH

(rotated toward the engine) by the calculated negative amount.

K0002139

Figure

• Each mark on the timing sticker represents 0.5° timing change.

4-3-1

4. ENGINE

The above calculated difference indicates that the replacement fuel injection pump is to be installed at +0.5° (advanced) from the “Standard Mark” )LJXUH

on the timing sticker.

Tighten the fuel injection pump mounting nuts to specification. 6HH 6SHFLDO 7RUTXH &KDUW RQ SDJH 6. Reinstall the rear bracket(s) )LJXUH

to the fuel injection pump. Tighten the rear support bolts.

1RWH &RQILJXUDWLRQ RI WKH IXHO LQMHFWLRQ SXPS UHDU EUDFNHWV PD\ YDU\ GHSHQGLQJ RQ WKH PRGHO

K0002124A

Figure

K0000153A

In this case, rotate the top of the fuel injection pump away from the cylinder block until the mark on the outside upper mounting boss )LJXUH

of the fuel injection pump aligns with the +0.5° mark on the timing sticker.

Figure 7. Reconnect the throttle linkage and the stop solenoid connector )LJXUH

.

8. Reconnect the lube oil line )LJXUH

and clamp )LJXUH

.

K0002125A

Figure

Figure

4-3-

K0000593B

4. ENGINE

9. Apply ThreeBond Liquid Gasket No. 1212, YANMAR Part No. 977770-1212F, or equivalent sealant to the sealing surface of the pump cover. Install the pump cover and tighten the cover bolts.

13. Reinstall the coolant pump V-pulley )LJXUH

, spacer )LJXUH

(if equipped) and engine coolant fan )LJXUH

.

10. Reconnect the fuel return lines, fuel supply line and coolant lines to the fuel injection pump.

11. Reinstall the fuel injection high-pressure lines.

Tighten the nuts to specification. 6HH 6SHFLDO 7RUTXH &KDUW RQ SDJH

NOTICE

When reinstalling a new or repaired fuel injection pump, it is important to add engine oil to the fuel injection pump to provide lubrication for initial start-up. Add 5 - 7 oz (150 - 200 cc) of clean engine oil to the fuel injection pump at the fill plug located in the upper outside section of the governor housing.

12. If equipped, verify the fuel injection pump insulator )LJXUH

is not damaged. Reinstall the insulator and intake manifold if previously removed.

K0000163A

Figure 14. Reinstall the cooling fan V-belt )LJXUH

DQG Ddjust it.

15. Reinstall the cooling fan guard (if equipped).

16. Prime the fuel system. 6HH 3ULPLQJ WKH )XHO 6\VWHP RQ SDJH 17. Operate the engine and check for fuel and coolant leaks.

K0000263A

Figure

4-3-2

4. ENGINE

,'/( 68% 635,1* $'-8670(17

NOTICE Not all engines are equipped with an idle sub spring. This adjustment will not fix an engine misfire, and proper engine diagnosis is required before adjustment. The idle sub spring adjustment is required following a Fuel Injection Pump (FIP) replacement; 6HH )XHO ,QMHFWLRQ 3XPS RQ SDJH The MP FIP is shown, but the procedure is the same for the MIL FIP. 1. Start the engine and run at high idle for a minimum of 5 minutes to allow the engine to reach the correct operating temperature.

4. To reduce engine hunting, first rotate the adjusting bolt counterclockwise to confirm the idle sub spring is not influencing the governor lever. Next, confirm the high idle speed is properly set according to specification.

Readjust the high idle speed as necessary before adjusting the idle sub spring.

5. After high idle speed is corrected, rotate the adjusting bolt clockwise to increase the idle sub spring’s influence on the governor lever.

The engine rpm should increase ~ 10 to 15 min-1 (rpm), but should remain within the high idle specification tolerance. If not, repeat the procedure by reducing the high idle speed to the lower end of the specification and repeat the adjustment procedure.

2. After the engine has reached operating temperature, remove the cap nut )LJXUH

.

K0007038-00X

Figure 6. While holding the adjusting bolt, tighten the locknut to 16 to 18 N·m (141 to 159 lb-in.).

K0007035-00X

Figure 3. While holding the adjusting bolt )LJXUH

, loosen the locknut )LJXUH

approximately one turn.

7. If engine hunting continues, repeat the procedure. When complete, confirm the high idle speed remains within the specification ± the allowable tolerance.

8. Install the cap nut, making sure the seal washer )LJXUH

is in place. Tighten the cap nut to 16 to 18 N·m (141 to 159 lb-in.).

4-3-2

4. ENGINE

The FIR number is determined by the complete engine model number. The engine model number is located on the engine nameplate )LJXUH .

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MODEL

1. Locate and record the fuel injection pump timing index number )LJXUH

stamped into the boss on the engine side of the fuel injection pump housing )LJXUH

. Treat this number as though there is a decimal point between the two digits. i.e. 68 = 6.8

DISPLACEMENT

ENGINE NO.

M ADE I N J AP AN 043923-00X00

Figure EXAMPLE: The following example is for an engine model 3TNV82A-DSA. K0000040B

• Find the FIR number for the engine model in the engine data sheet. Locate and record the FIR number (The FIR number for this engine is

Figure

• Insert the numbers you have recorded into the following equation: (Fuel injection pump timing index number × 2) + FIR number = FIT° (Fuel injection timing in degrees)

■ î IXHO LQMHFWLRQ WLPLQJ K0002047

• Record the calculated fuel injection timing specification.

Figure 2. Refer to the “Engine Data Sheet” under “OEM data” on YANMAR distributor website (http://distributor.yanmar.co.jp) to find the FIR number for the engine model.

4-3-2

4. ENGINE

&KHFNLQJ )XHO ,QMHFWLRQ 7LPLQJ

1RWH 6RPH IXHO PD\ GUDLQ IURP WKH IXHO LQMHFWLRQ SXPS GXULQJ WKLV SURFHVV 0DNH SURYLVLRQV WR FRQWDLQ DQ\ VXFK VSLOODJH 1. Turn off the fuel valve in the fuel supply hose and the fuel return hose.

2. Clamp shut the fuel injection pump fuel return hose leading to fuel filter )LJXUH

.

K0002068A

Figure 5. Install a dial indicator )LJXUH

, Mitutoyo No. 2050SB or equivalent, with a 30 mm extension, YANMAR Part No. 158090-51870 or Mitutoyo No. 303613, into the adapter. Secure with the YANMAR Part No. 23000-013000 plunger adapter clamp )LJXUH

at approximately the midpoint of its travel.

K0002087

Figure

NOTICE Clean the top of the fuel injection pump to prevent any contamination when the fuel injection pump plunger plug is removed.

3. Remove the forward fuel injection pump plunger plug )LJXUH

on the top of the fuel injection pump.

4. Install a dial indicator adapter and clamp into the pump plunger opening.

K0002069

1RWH 8VH WKH <$10$5 SDUW QR 0 DGDSWHU IRU WKH 03 IXHO LQMHFWLRQ SXPSV 719 PRGHO HQJLQHV RU <$10$5 SDUW QR IRU WKH 0 DGDSWHU XVHG RQ WKH 03 IXHO LQMHFWLRQ SXPSV 719 PRGHO HQJLQHV DQG <$10$5 SDUW QR SOXQJHU DGDSWHU FODPS (Figure , (1))

4-3-2

Figure 1RWH 7KH IROORZLQJ UHIHUHQFHV WR WKH GLUHFWLRQ RI URWDWLRQ DUH IDFLQJ WKH FRRODQW SXPS HQG RI WKH HQJLQH DQG DUH DGMXVWHG E\ WXUQLQJ WKH FUDQNVKDIW SXOOH\

4. ENGINE

1RWH 7KH 7'& 7RS 'HDG &HQWHU PDUN FDQ EH LGHQWLILHG E\ WKH F\OLQGHU QXPEHUV VWDPSHG QHDU WKH 7'& PDUN RQ WKH IO\ZKHHO

6. Using a wrench on the crankshaft pulley bolt, rotate the crankshaft in a clockwise direction while looking through the flywheel inspection port )LJXUH

. Rotate the crankshaft until the injection timing marks on the flywheel are visible.

If you are uncertain as to the timing degree designation of the timing marks on the flywheel timing grid, you can determine the timing degree designation by measuring the timing grid.

• First measure the distance between two of the “longer” marks on the timing grid. (They are 5° apart.) Then measure the distance from the TDC mark to the first “longer” mark on the timing grid. Divide that measurement by the distance between the two “longer” marks. The resulting answer will tell you how many degrees there are between the TDC mark and the first “longer” mark.

K0002070

Figure

• EXAMPLE: If the distance between the two “longer” marks is approximately 2.0 cm and the distance from the TDC mark is approximately 4.0 cm, the answer is approximately 2. This indicates there is 10° (2 × 5°) between the TDC mark and the first “longer” mark on the timing grid. That means the first “longer” mark on the timing grid indicates 10° BTDC, the second “longer” mark indicates 15° BTDC and the third timing mark indicates 20° BTDC. If the answer is 3, that indicates there is 15° (3 × 15°) between the TDC mark and the first “longer” mark and that the first “longer” mark indicates 15° BTDC with the second and third “longer” marks indicating 20° BTDC and 25° BTDC respectively.

7. Typical flywheel markings are as shown in )LJXUH

.

1RWH $ W\SLFDO IO\ZKHHO ZLOO KDYH PXOWLSOH WLPLQJ JULGV GHSHQGLQJ RQ WKH QXPEHU RI F\OLQGHUV $Q\ JULG FDQ EH XVHG WR FKHFN WKH IXHO LQMHFWLRQ WLPLQJ The flywheel shown in )LJXUH is for a YANMAR “Standard Specification” DI engine.

Flywheels used on some “OEM Specific” DI engines may be marked differently. You should contact that specific OEM for information on the identification of the timing marks.

8. Highlight the timing reference mark )LJXUH

on the flywheel housing or engine back plate )LJXUH

.

Highlight the TDC (Top Dead Center) mark )LJXUH

on the flywheel.

9. Highlight the target timing mark )LJXUH

on the flywheel as calculated in 'HWHUPLQLQJ WKH )XHO ,QMHFWLRQ 7LPLQJ 6SHFLILFDWLRQ RQ SDJH

K0002071

1 2 3 4 5

– 10° BTDC (Before Top Dead Center) – 15° BTDC – 20° BTDC – Direction of rotation – TDC (Top Dead Center)

Figure 4-3-2

4. ENGINE

10. Rotate the crankshaft counter-clockwise until the dial indicator shows that the injection pump plunger is at the bottom of its stroke. Rock the crankshaft back and forth slightly to confirm a point where the dial indicator shows no movement. Zero the dial indicator.

1 4

11. Slowly rotate the crankshaft clockwise until the dial indicator shows a pump plunger lift of 2.5 mm (0.098 in.).

K0002065

Figure

12. Check the position of the flywheel target timing mark (previously determined) )LJXUH

in relation to the timing reference mark )LJXUH

on the flywheel housing or engine back plate. If the two marks are aligned, the fuel injection timing is correct. If the marks do not align, the fuel injection timing must be adjusted. 6HH $GMXVWLQJ )XHO ,QMHFWLRQ 7LPLQJ RQ SDJH 13. If the injection timing is correct, remove the dial indicator and adapter. Replace the pump plunger plug and its copper gasket and tighten to specifications. Replace the flywheel inspection port cover. Open the fuel supply valve and remove the clamp from the fuel supply hose and the fuel return hose.

K0002066

14. Prime the fuel system. Operate the engine and check for leaks.

$GMXVWLQJ )XHO ,QMHFWLRQ 7LPLQJ

If the timing marks did not align when performing the &KHFNLQJ )XHO ,QMHFWLRQ 7LPLQJ RQ SDJH , the following steps must be performed to properly time the engine.

1. Leave the dial indicator installed in the fuel injection pump. Do not disturb the reading on the dial indicator.

K0002142

Figure

2. Rotate the flywheel until the target timing mark )LJXUH

and the timing reference mark )LJXUH

on the flywheel housing or back plate are aligned.

NOTICE Do not rotate the crankshaft during the remainder of this procedure.

4-3-2

4. ENGINE

4. Loosen the nuts fastening the fuel injection pump to the gear case or front plate. Loosen the rear bracket(s) on the fuel injection pump.

1RWH /RRVHQLQJ WKH KLJK SUHVVXUH LQMHFWLRQ OLQH QXWV RQ WKH IXHO LQMHFWLRQ SXPS PD\ PDNH URWDWLQJ WKH SXPS HDVLHU 5. Rotate the fuel injection pump until the dial indicator reads 2.5 mm (0.098 in.).

6. To “advance” the injection timing, rotate the top of the fuel injection pump away from the engine.

7. To “retard” the injection timing, rotate the top of the fuel injection pump toward the engine.

K0002066

Figure 3. Note the reading on the dial indicator )LJXUH

. If the reading is less than 2.5 mm (0.098 in.), the fuel injection timing is “retarded.” If the dial indicator reading is greater than 2.5 mm (0.098 in.), the fuel injection timing is “advanced”.

8. When the dial indicator reads 2.5 mm (0.098 in.) of pump plunger lift and the target timing mark on the flywheel aligns with the reference mark on the flywheel housing or engine back plate, the injection timing is correct.

9. Tighten the fuel injection pump mounting nuts and rear bracket(s).

10. Remove the dial indicator and adapter. Replace the plug in the pump plunger opening and tighten it to specification. If removed, install the intake manifold and pump insulator. Tighten the high-pressure injection line nuts to specification. Open the fuel supply valve, remove the clamp from the fuel return line and prime the fuel system. Operate the engine and check it for leaks.

K0002069

Figure 1RWH 6RPH PRGHO HQJLQHV UHTXLUH WKH LQWDNH PDQLIROG DQG IXHO LQMHFWLRQ SXPS LQVXODWRU EH UHPRYHG WR DFFHVV WKH LQQHU IXHO LQMHFWLRQ SXPS UHWDLQLQJ QXWV

4-3-2

4. ENGINE

)8(/ ,1-(&7256

• Finish loosening all the fuel line nuts and remove the high-pressure fuel lines as an assembly being careful not to bend any of the fuel lines. Be sure to protect the fuel system from contamination by covering all open connections.

5HPRYDO RI )XHO ,QMHFWRUV

■ YDOYH F\OLQGHU KHDG 1. Close any fuel valves in the fuel supply line.

3. Remove the return fuel hoses )LJXUH

from one side of each fuel injector.

2. Remove the high-pressure fuel injection lines as an assembly )LJXUH

.

4. Remove the bolts and washers that secure the fuel injector retainers )LJXUH

to the cylinder head.

5. Remove the fuel injector retainer

K0000154A

Figure 1RWH 7R SUHYHQW ³URXQGLQJ´ WKH IXHO OLQH QXWV DOZD\V XVH D ³OLQH´ RU ³IODUH QXW´ ZUHQFK :KHQ ORRVHQLQJ WKH IXHO OLQH QXWV DOZD\V KROG WKH IXHO LQMHFWLRQ SXPS GHOLYHU\ YDOYHV ZLWK D ³EDFN XS´ ZUHQFK WR SUHYHQW ORRVHQLQJ

K0002092A

Figure 4-3-48 6. Remove the fuel injector.

• Loosen the fuel line nuts at the fuel injectors and then at the fuel injection pump.

NOTICE Remove or install the high-pressure fuel injection lines as an assembly whenever possible.

Disassembling the high-pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines.

4-3-2

1RWH 7KH IXHO LQMHFWRUV FDQ XVXDOO\ EH UHPRYHG E\ PDQXDOO\ SXOOLQJ WKHP RXW RI WKH IXHO LQMHFWRU ZHOOV ,I WKH IXHO LQMHFWRUV FDQQRW EH PDQXDOO\ UHPRYHG XVH WKH IXHO LQMHFWRU UHPRYDO WRRO <$10$5 3DUW 1R DQG D VOLGH KDPPHU SXOOHU (Figure ) • Attach a slide-hammer puller to the fuel injector removal tool using a 3/8-16 puller rod.

4. ENGINE

2

1

3

5

4

6

K0000815

Figure K0002088

• Tap the fuel injector out of the cylinder head using the slide hammer.

Figure 4-3-50

7. Remove the injector nozzle protector )LJXUH

and seat )LJXUH

from the cylinder head.

8. Repeat the steps to remove the remaining fuel injectors.

■ 4-valve cylinder head 1. Close any fuel valves in the fuel supply line.

Note: The fuel injectors can be removed by manually pulling them out of the fuel injector wells.

6. Remove the injector nozzle protector (Figure 4-3-50, (5)) and seat (Figure 4-3-50, (6)) from the cylinder head. Discard both items.

7. Repeat steps to remove the remaining fuel injectors.

2. Remove the valve cover.

3. Remove the injector return line (Figure 4-3-50, (1)). Be careful not to bend the line.

4. Remove the fuel injector mounting clamp bolts (Figure 4-3-50, (2)). Lift the injector mounting clamps (Figure 4-3-50, (3)) away from injector.

5. Remove the fuel injector (Figure 4-3-50, (4)) from the cylinder head.

4-3-2

4. ENGINE

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Figure 1

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4. Pump the operating lever of the tester slowly, observing the pressure reading at the point where the fuel injector begins spraying fuel )LJXUH .

See )LJXUH for injector ID location.

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)DLOXUH WR FRPSO\ PD\ UHVXOW LQ PLQRU RU PRGHUDWH LQMXU\

NOTICE Never use a steel wire brush to clean fuel injectors.

Damage to the nozzle and other components is likely to result.

1. Thoroughly clean the fuel injector nozzle using clean diesel fuel and a brass wire brush.

2. Visually inspect the fuel injectors and nozzle protectors for deposits or damage. Clean, repair or replace as necessary.

1RWH )RU WHVWLQJ WKH IXHO LQMHFWRU XVLQJ DQ LQMHFWLRQ QR]]OH WHVWHU 2SHUDWH WKH WHVWHU IROORZLQJ WKH LQIRUPDWLRQ SURYLGHG E\ WKH WHVWHU PDQXIDFWXUHU 8VH FOHDQ ILOWHUHG IXHO RU ),( FDOLEUDWLRQ IOXLG IRU WKH WHVW

5. Pump the operating lever slowly to hold the pressure steady at a point just below the opening pressure and hold it for 5 seconds.

Observe the injector to see that it is sealing properly and is not “dripping”. If fuel leaks from the return line fitting, check that the nozzle case nut is tight. Service or replace the injector if fuel continues to leak from either the return line fitting or nozzle.

6. Pump the operating lever more rapidly to repeatedly “pop” the injector and observe the spray pattern. The pattern should be a very fine uniform spray )LJXUH 2 If a dripping or an uneven pattern is seen )LJXUH 3 , service or replace the injector.

3. Using the correct adapter, connect a fuel injector to a nozzle tester. Aim the fuel injector into a suitable container to catch the fuel spray.

4-3-

4. ENGINE

K0001336A

Figure 2

K0001337A

Figure 3

If the fuel injector fails any of these tests, it should be serviced or replaced as necessary. If the pressure is outside specified limits, adjust the pressure. 6HH $GMXVWLQJ )XHO ,QMHFWRU 3UHVVXUH RQ SDJH

K0002093

1 – Fuel return passage 2 – Injector ID location 3 – Injector body 4 – Pressure adjusting shims 5 – Spring 6 – Spring seat 7 – Valve stop spacer 8 – Nozzle valve 9 – Nozzle body 10 – Nozzle case nut

'LVDVVHPEO\ DQG ,QVSHFWLRQ RI )XHO ,QMHFWRUV

NOTICE Never use a steel wire brush to clean fuel injectors.

Damage to the nozzle and other components is likely to result.

1. Clean carbon from used injectors using clean diesel fuel. Hardened deposits or varnish can be cleaned using a brass wire brush.

Figure 4 2. Place the fuel injector in a soft-jawed vise with the nozzle pointing up.

3. Remove the nozzle case nut.

4. Carefully remove the injector from the vise.

5. Turn the injector over and remove the nozzle body, nozzle valve, valve stop spacer, nozzle spring seat, nozzle spring, and shims.

4-3-

4. ENGINE

6. Inspect the sealing surfaces )LJXUH 5

between the valve stop spacer and nozzle body for nicks or scratches. Check the contact area between the valve stop spacer and the nozzle valve )LJXUH 5

for scoring, or pitting. Use a magnifier glass to inspect the area.

$GMXVWLQJ )XHO ,QMHFWRU 3UHVVXUH The fuel injectors open when pressure reaches a predetermined pressure threshold. They close when the pressure is reduced below that threshold.

The pressure threshold can be adjusted by adding or removing shims )LJXUH 7

.

K0001333A

Figure 5

7. Perform a nozzle valve slide test:

1- Wash nozzle body and valve in clean diesel fuel.

2- While holding the nozzle body vertical, pull the nozzle valve about 2/3 of the way out )LJXUH 6 .

3- Release the valve. It should fall smoothly to its seat by it’s own weight.

K0002093

1 – Fuel return passage 2 – Injector ID location 3 – Injector body 4 – Pressure adjusting shims 5 – Spring 6 – Spring seat 7 – Valve stop spacer 8 – Nozzle valve 9 – Nozzle body 10 – Nozzle case nut K0001332A

Figure 7

Figure 6 8. Replace the fuel injector assembly if it fails any inspection.

The injection pressure will change by approximately 1.9 MPa for every 0.1 mm in shim thickness.

4-3-

4. ENGINE

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See the parts catalog for available shims.

■ YDOYH F\OLQGHU KHDG

NOTICE Each pressure adjusting shim removed or added changes the pressure threshold by approximately 1.9 MPa. Adding adjusting shims increases the threshold pressure. Removing adjusting shims reduces the pressure threshold.

1. Reinsert a new nozzle seat )LJXUH 8

and nozzle protector )LJXUH 8

in the cylinder head for each injector.

2. Reinstall a O-ring on to each injector body.

1. Disassemble the fuel injector assembly. 6HH 'LVDVVHPEO\ DQG ,QVSHFWLRQ RI )XHO ,QMHFWRUV RQ SDJH .

4. Reinstall the fuel injector retainers )LJXUH 8

and torque the retaining bolts to specification.

5. Reinstall the fuel return hoses )LJXUH 8

, one on each side of each injector.

6. Reinstall the fuel high-pressure fuel line assembly and tighten the nuts using a “line” or “flare nut” wrench.

3. Reinsert each fuel injector into the cylinder head.

2. Remove or add adjusting shims as needed.

3. Reassemble the fuel injector assembly. 6HH 5HDVVHPEO\ RI )XHO ,QMHFWRUV RQ SDJH .

4. Retest the fuel injector. 6HH 7HVWLQJ RI )XHO ,QMHFWRUV RQ SDJH . If the injector cannot be adjusted to the appropriate pressure, discard the fuel injector.

5HDVVHPEO\ RI )XHO ,QMHFWRUV 1. Secure the injector in a soft-jawed vise with the nozzle end up.

2. Reinstall the shims, nozzle spring, nozzle spring seat, valve stop spacer, nozzle valve, and nozzle body.

3. Reinstall the nozzle case nut. Tighten it to specification. 6HH 6SHFLDO 7RUTXH &KDUW RQ SDJH 4 3-5.

K0002092A

Figure 8 7. Prime the fuel system.

8. Operate the engine and check for fuel and coolant leaks.

4-3-

4. ENGINE

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,QWURGXFWLRQ This section of the 6HUYLFH 0DQXDO describes the procedures necessary to service the 4TNV84 engine coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model engines. For specific part detail, see the parts catalog for the engine you are working on. &RROLQJ 6\VWHP 'LDJUDP

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K0000573A-01X

1 2 3 4

– Cylinder head – Thermostat – Engine coolant pump – Radiator

5 – Coolant recovery tank 6 – Engine oil cooler*1 7 – Cylinder block

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Figure 4-4-1

4-4-2

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K0000031A-01X

1 2 3 4 5 6 7

– Thermostat cover – Thermostat cover gasket – Thermostat – Thermostat O-ring – Special O-ring – Engine coolant pump – Temperature switch

8 – Gasket 9 – Engine coolant pump gasket 10 – V-belt 11 – Engine coolant pump V-pulley 12 – Spacer 13 – Engine coolant fan 14 – Water temperature sensor (Electronically controlled engine)

Figure 4-4-2

4-4-3

4. ENGINE

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2. Remove the radiator cap (Figure , (1)).

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3. Remove the drain plug or open the drain cock (Figure , (1)) at the lower portion of the radiator and drain the coolant.

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Figure 4. Drain the coolant from the engine block.

• On models equipped with an oil cooler, remove the coolant hose (Figure , (1)) at the oil cooler.

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Figure

NOTICE Make sure the engine and engine coolant are not hot.

1. Before removing the engine coolant pump or thermostat, it will be necessary to drain the engine coolant. Drain the coolant into a clean container if the coolant is to be reused.

Otherwise, properly dispose of the coolant.

4-4-4

4. ENGINE

Disassembly of Engine Coolant Pump

• On models not equipped with an oil cooler, remove the coolant drain plug (Figure , (1)) from the engine block.

1. Remove the thermostat cover (Figure , (1)).

Discard the gasket.

K0000027B

Figure 5. Loosen the alternator mounting bolts. Loosen and remove the V-belt and rotate the alternator away from the engine and out of the way.

6. Remove the engine coolant fan guard (if equipped), engine coolant fan (Figure , (1)), spacer (Figure , (2)) and engine coolant pump V-pulley (Figure , (3)).

K0000267AX

Figure

2. Remove the thermostat (Figure , (2)).

Discard the O-ring. Remove the temperature switch (Figure , (3)) and gasket (Figure , (4)). Discard the gasket.

K0000163B

Figure 7. Disconnect the coolant hoses and the temperature switch lead wire from the engine coolant pump.

8. Remove the engine coolant pump (Figure , (4)). Discard the gasket.

4-4-5

4. ENGINE

Cleaning and Inspection

■ Water temperature sensor

■ Temperature switch

1. Inspect the water temperature sensor to make sure that it is properly operating. As shown in the following figure, connect an electric resistor to the coupler of the water temperature sensor (Figure , (1)).

1. Check for proper operation of the temperature switch. Connect a continuity light or ohmmeter to the temperature switch. Connect one lead to the terminal of the switch (Figure , (1)) and WKH RWKHU OHDG WR WKH PHWDO SRUWLRQ RI WKH VZLWFK )LJXUH

K0000576AX

Figure Figure

2. Place the temperature switch and an accurate thermometer (Figure , (3)) in engine coolant.

2. Dip the water temperature sensor and an accurate thermometer (Figure , (2)) into the cooling water.

3. Slowly increase temperature of the fluid using an external heat source.

3. Measure the electric resistance value while slowly raising the cooling water temperature using an external heat source.

4. The temperature switch is operating properly if the continuity light or ohmmeter indicates continuity when the fluid temperature reaches 107 °C - 113 °C.

4. The resistance value at each of the following temperatures is within the permissible range specified, the water temperature sensor is correctly operating.

Cooling water temperature (°C)

4-4-6

Resistance (k:)

20

+0.14 2.45 -0.13

80

0.318 ± 0.008

100

(0.1836)

4. ENGINE

■ Thermostat

Reassembly of Engine Coolant Pump

1. Check for proper operation of the thermostat.

Place the thermostat (Figure , (1)) and an accurate thermometer (Figure , (2)) in warm water.

1. Reinstall the thermostat (Figure , (1)) and a new O-ring.

K0000578A

Figure 2. Slowly increase the temperature of the water using an external heat source.

3. The thermostat is operating properly if it starts to open at the temperature value stamped on the flange of the thermostat, and fully opens as the temperature of the water is increased.

K0001623AX

Figure 2. Reinstall the thermostat cover (Figure , (2)) and a new gasket.

Tighten the thermostat cover bolts.

■ Radiator cap 1. Check for proper operation of the radiator cap.

Install the radiator cap (Figure , (1)) on a cooling system tester.

3. Reinstall the temperature switch (Figure , (3)) and a new gasket (Figure , (4)).

Installation of Engine Coolant Pump

1. Position the engine coolant pump on the engine and install a new gasket. Install a new special O-ring (Figure , (5)) on assembly between the engine coolant pump and the joint.

K0000579A

NOTICE

Figure

Use a new special O-ring between the engine coolant pump and the joint. Be sure to use the special O-ring for each engine model. Although the O-ring dimensions are the same as a commercially available O-ring, the material is different.

2. Apply 75 - 105 MPa to the radiator cap. The radiator cap relief valve must open within the specified range.

4-4-7

4. ENGINE

8. Fill the radiator and engine with engine coolant.

See Drain, flush and refill cooling system with new coolant on page 5-24.

2. Reinstall the engine coolant pump bolts.

Tighten the bolts.

3. Inspect and reinstall the coolant hoses and the temperature switch lead wire.

NOTICE

4. Reinstall the engine coolant pump V-pulley (Figure , (1)), spacer (Figure , (2)) engine coolant fan (Figure , (3)) and engine coolant fan guard (if equipped).

• Only use the engine coolant specified. Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale and / or shorten engine life.

• Prevent dirt and debris from contaminating the engine coolant. Carefully clean the radiator cap and the surrounding area before you remove the cap.

• Never mix different types of engine coolants.

This may adversely affect the properties of the engine coolant.

K0000163C

Figure 5. Inspect the condition of the V-belt. There must be clearance (Figure , (1)) between the V-belt and the bottom of the pulley groove. If there is no clearance (Figure , (2)) between the V-belt and the bottom of the pulley groove, replace the V-belt.

K0000584

Figure 6. Reinstall the V-belt. Tighten the V-belt to the proper tension. See Check and adjust cooling fan V-belt on page 5-13.

7. Reinstall and tighten the drain plug or close the drain cock in the radiator. Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler.

4-4-

4. ENGINE

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10.040 mm

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9.940 mm

Rotor clearance

0.033 - 0.060 mm

0.100 mm

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/XEULFDWLRQ 6\VWHP 'LDJUDP

Oil filter Turbocharger* Bypass valve Oil cooler*

Fuel injection pump Oil pressure switch

Cylinder body - main gallery Pressure regulator valve Oil pump

Oil suction pipe strainer

Idle gear shaft Piston cooling nozzles*

Camshaft bearing

Crank journal

Rocker arm bearing

Crank pin

Rocker arm

Tappet cam face Oil pan K0000042E

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.

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Figure 4-5-10

(Follow LOCTITE package instructions.) Tighten the pump cover screws to 6.9 ± 1.5 N·m.

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4-5-

4. ENGINE

Disassembly of Oil Pump

TROCHOID OIL PUMP

NOTICE

Oil Pump Components The oil pump on these model engines is located in the front gear case and is driven by the same gear train that drives the camshaft and fuel injection pump. You must remove the front gear case cover to gain access to the oil pump.

3

7

1

2

If the oil pump must be replaced, replace it as an assembly only. Do not replace individual components.

Remove the cooling water fan guard (if equipped), cooling fan (Figure 4-5-14, (3)), spacer (Figure 4-5-14, (2)), cooling water pump V-pulley (Figure 4-5-14, (1)), and V-belt.

6 3

2

5

4 1 K0000163C

1 2 3 4 5 6 7

– Body – Shaft – Inner rotor – Outer rotor – Cover – Drive gear – Pressure regulator valve

Figure 4-5-13

Figure 4-5-14 1. Remove the crank shaft pulley and gear case cover. SeeRemoval of timing gear case cover on page 6-69.

2. Remove the lubricating oil pump assembly mounting bolts. Remove the lubricating oil pump assembly (Figure 4-5-15, (1)) from the gear case flange (Figure 4-5-15, (2)).

3. You can remove by hand the lubricating oil pump cover (Figure 4-5-13, (5)) and outer rotor (Figure 4-5-13, (4)).

1

2

4-5-9

Figure 4-5-15

4. ENGINE

Cleaning and inspection

■ Outer rotor to inner rotor tip clearance

Clean the lubricating oil pump, pressure regulator valve (Figure 4-5-13, (7)), and rotor inserting portion.

Check the parts for wear or flaw. Replace the parts with new ones as needed.

Inspect the tip clearance between the outer and inner rotors. To inspect this, insert a feeler gauge between the inner rotor tooth tip (Figure 4-5-17, (1)) and the outer rotor tooth tip (Figure 4-5-17, (2)), and measure the clearance.

NOTICE 1

• Never overfill the engine with engine oil.

• Always keep the oil level between the upper and lower lines on the oil cap/dipstick.

■ Check outer rotor outside clearance 2

Inspect the outside diameter clearance of the outer rotor. To inspect this, insert a feeler gauge between the outer rotor (Figure 4-5-16, (1)) and the lubricating oil pump body (Figure 4-5-16, (2)).

Figure 4-5-17

1

Record the measurement(s) and see Outer rotor to inner rotor tip clear ance on page 4-5-2 for the service limits.

■ Check outer rotor side clearance Inspect the side clearance between the lubricating oil pump body and the outer rotor. To measure the side clearance, use a straight edge and feeler gauge (as shown in Figure 4-5-18) or a depth micrometer.

2

Figure 4-5-16 Record the measurement(s) and seeOuter rotor outside clearance on page 4-5-2 for the service limits.

Figure 4-5-18 Record the measurement(s) and seeOuter rotor outside clearance on page 4-5-2 for the service limits.

4-5-10

4. ENGINE

■ Check rotor shaft clearance

Reassembly of Oil Pump

Inspect the rotor shaft clearance. Measure the outside diameter of the rotor shaft (Figure 4-5-19, (1)) and the inside diameter of the cover.

1. Apply clean lubricating oil to the lubricating oil pump body and inner rotor assembly as well as to the outer rotor.

Determine the clearance by subtracting the outside diameter of the rotor from the inside diameter of the cover.

2. Insert the outer rotor into the lubricating oil pump body and inner rotor assembly and install the cover.

3. Replace the packing with new one.

4. Install the lubricating oil pump assembly to the gear case flange by tightening the bolts with the specified torque.

1

5. Install the gear case cover. For more information, See Installation of gear case cover on page 4-2-46.

6. Install the crank shaft pulley.

2

Figure 4-5-19

7. Install the cooling water pump V-pulley (Figure 4-5-20, (1)), spacer (Figure 4-5-20, (2)), cooling water fan (Figure 4-5-20, (3)), and fan guard (if equipped).

Record the measurement(s) and see Rotor shaft clearance <Trochoid type 4TNV88-B> on page 4-5-3 for the service limits.

2

3

1 K0000163C

Figure 4-5-20 8. Install the V-belt. Adjust the belt to uniform tensile strength.

4-5-11

4. ENGINE

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4-6-1

4. ENGINE

,QWURGXFWLRQ This section of the Service Manual covers the servicing of the starter motor. YANMAR Part No. 12990077010 is standard equipment on 4TNV94 - 98 model engines and is used in this section to show the service procedures for a representative starter motor. For specific part detail, see the YANMAR Parts Catalog for the engine you are working on.

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12912977010

Denso

2280000251

DC12 V-1.6 hp (1.2 kW)

11.5

90 A MAX

3000

8

280 Max

9.81N·m

900

12940777010

Denso

2280003732

DC12 V-1.9 hp (1.4 kW)

11.5

90 A MAX

3000

8.5

350 Max

13.2 N·m

1000

12960877010

Hitachi

S114817A

DC12 V-1.9 hp (1.4 kW)

11

90 A MAX

2700

8.4

250 Max

8.3 N·m

1000

12924277010

Hitachi

S114883

DC12 V-2.3 hp (1.7 kW)

11

90 A MAX

2300

8

370 Max

15.1 N·m

880

12913677011

Hitachi

S13-332

DC12 V-3.1 hp (2.3 kW)

11

140 A MAX

4100

7.7

400 Max

11.0 N·m

1400

12961277011

Hitachi

S25166A

DC24 V-5.3 hp (4.0kW)

24

100 A MAX

3500

18

400 Max

30.4 N·m

1000

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4-6-2

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4-6-3

Inspect fuel system.

YES

Is revolution normal?

YES

Does engine crank?

YES

Engine does not start?

Is the shift lever at NEUTRAL position?

NO

NO

Inspect condition of engine.

YES

Is starter motor solenoid switch actuating sound heard?

YES

Is battery fully charged and terminals clean?

YES

NO

Repair or replace starter motor.

Replace engine oil.

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5HSDLU PHVKLQJ EHWZHHQ SLQLRQ DQG ring gear or replace as needed.

Inspect wiring up to solenoid switch and repair if necessary. .H\ VZLWFK 6DIHW\ UHOD\ 6ROHQRLG VZLWFK DVVHPEO\ (OHFWULFDO FRQQHFWLRQV

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K0000102E

5HSDLU RU UHSODFH NH\ VZLWFK VWDUWLQJ motor relay or magnetic switch assembly.

Engine does not stop even when key switch is turned OFF.

If a problem occurs: Immediately disconnect battery negative terminal.

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NO

NO

NO

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Solenoid switch assembly contact defective. Repair or replace.

YES

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Does starter motor operate?

NO

Slow Revolution

Does engine turn when starter motor is replaced?

YES

Is the engine oil viscosity correct?

YES

Is battery fully charged and terminals clean?

Pinion roller clutch or reduction gear damaged.

Inspect and replace.

YES

Pinion and ring gear meshing normal?

YES

Is starter motor operating?

Move shift lever to NEUTRAL position.

NO (slow revolution)

NO

NO

4. ENGINE

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K0000103A

1 – Pinion shaft 2 – M4 bolts (3 used) 3 – Bearing retainer 4 – Pinion clutch assembly 5 – Return spring 6 – Pinion stop 7 – Retaining ring 8 – Gear housing 9 – Shift lever 10 – Torsion spring 11 – Plunger 12 – Dust covers (shims)

13 – Magnetic switch assembly (solenoid) 14 – Cover 15 – M6 bolts (2 used) 16 – Armature assembly 17 – Field coil assembly 18 – Positive (+) brushes 19 – Negative (-) brushes 20 – Brush holder assembly 21 – Rear cover 22 – M5 through bolts (2 used) 23 – M4 bolts (2 used)

Figure 4-6-1

4-6-4

4. ENGINE

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1. Loosen the M8 nut from the magnetic switch (solenoid) assembly )LJXUH .

Disconnect the wire from the magnetic switch.

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K0000104

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Figure 2. Remove the two M4 bolts )LJXUH

securing the rear cover )LJXUH

to the brush holder assembly )LJXUH

.

5HPRYDO RI 6WDUWHU 0RWRU 1. Disconnect the battery cables at the battery, negative (-) cable first.

2. Remove the electrical wires from the magnetic switch assembly.

3. Remove the starter mounting bolts )LJXUH

. Remove the starter motor from the flywheel housing.

K0000105A

Figure 3. Remove the two M5 through bolts )LJXUH

. Separate the rear cover )LJXUH

, field coil assembly )LJXUH

with the armature assembly )LJXUH

from the gear housing )LJXUH

.

K0002126

Figure

4-6-5

4. ENGINE

4. Pull the brush springs up using a brush spring puller. On the negative (-) side, bring the brush spring into contact with the side of the brush for lifting from the commutator surface. On the positive (+) side, remove the brush from the brush holder assembly (Figure , (1)).

1

2

4

3

K0000108A

Figure 8. Disassemble the dust cover (Figure , (3)) and shift the lever (Figure , (4)) from the gear housing.

K0000106A

Figure 5. Remove the brush holder assembly (Figure , (1)) from the armature assembly (Figure , (3)).

K0000109A

Figure 9. Remove the three M4 bolts (Figure , (1)) securing the bearing retainer assembly (Figure , (2)) to the gear housing.

Remove the bearing retainer assembly from the gear housing.

K0000107A

Figure 6. Pull the armature assembly (Figure , (3)) out from the field coil assembly (Figure , (2)).

7. Remove the two M6 bolts (Figure , (1)) retaining the magnetic switch assembly (Figure , (2)) to the gear housing.

Remove the magnetic switch assembly, dust cover(s)(Figure , (3)) and torsion spring (Figure , (4)) from the gear housing.

K0000110A

Figure 10. Remove the pinion clutch assembly (Figure , (3)) from the bearing retainer assembly.

4-6-6

4. ENGINE

Cleaning and Inspection

11. Using a flat-blade screwdriver, remove the retaining ring (Figure , (1)) from the shaft of the pinion.

■ Armature Commutator surface inspection If the commutator surface is rough, polish the surface with a #500 to #600 emery cloth (Figure ).

K0000111A

Figure 12. Disassemble the pinion stop (Figure , (3)), return spring (Figure , (4)), pinion clutch assembly (Figure , (1)), and pinion shaft (Figure , (5)).

K0000117

Figure Measure commutator outside diameter Measure the commutator outside diameter (Figure ). Replace the armature if the measurement is less than the limit.

K0000112A

Figure 11-11

K0000113

Figure See Starter Motor Specifications on page for the service limit.

4-6-7

4. ENGINE

Measure commutator insulation depth Measure the depth of the insulating material (Figure , (1)) between commutator segments (Figure , (2)). If the depth measures less than the limit, use a hacksaw blade (Figure , (3)) to remove the insulating material until the depth is within the limit.

Armature coil continuity test Check for continuity between the commutator segments using a multimeter (Figure ).

The multimeter should indicate continuity.

A normal commutator condition is indicated in (Figure , (4)). An abnormal commutator condition is indicated in (Figure , (5)).

3

K0000114

Figure If the multimeter does not indicate continuity, replace the armature.

2

1

4

5

Armature coil insulation test Check for continuity between a commutator segment and the shaft or armature using a multimeter (Figure ). The multimeter should not indicate continuity.

K0000118

Figure See Starter Motor Specifications on page for the service limit.

K0000115

Figure If the multimeter indicates continuity, replace the armature.

4-6-8

4. ENGINE

Measure armature and commutator run-outs Measure the armature core run-out and the commutator run-out using a dial indicator (Figure ). Replace the armature if either of the measurements is less than the limit.

Field coil insulation test Check for continuity between the field coil terminal and the yoke using a multimeter (Figure ).

The multimeter should not indicate continuity. ,I WKH PXOWLPHWHU LQGLFDWHV FRQWLQXLW\ UHSODFH WKH ILHOG FRLO DVVHPEO\

K0000116

Figure See Starter Motor Specifications on page K0000120

for the service limit.

Figure

■ Field coil

Measure brush length Measure the length of the brush (Figure ).

Replace the brush if the length is less than the limit.

Field coil continuity test Check for continuity between the field coil terminals using a multimeter (Figure ).

The multimeter should indicate continuity.

If the multimeter does not indicate continuity, replace the field coil assembly.

K0000121

Figure See Starter Motor Specifications on page K0000119

for the service limit.

Figure

4-6-9

4. ENGINE

■ Magnetic switch If the starter motor becomes wet, replace the magnetic switch even if the magnetic switch assembly function is normal.

Shunt coil continuity test Check for continuity between the “S” terminal and the switch body using a multimeter (Figure ).

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Series coil continuity test Check for continuity between the “S” and “M” terminals using a multimeter (Figure ).

The multimeter should indicate continuity.

If the multimeter does not indicate continuity, replace the magnetic switch.

K0000125

Figure

K0000124

Coil resistance test See Starter Motor Specifications on page for the service limit.

Figure

4-6-10

4. ENGINE

Contact continuity test Depress the plunger at the bottom of the magnetic switch. Check for continuity between the “B” and “M” terminals using a multimeter (Figure ).

The multimeter should indicate continuity.

If the multimeter does not indicate continuity, replace the magnetic switch.

Slide the pinion clutch assembly on the shaft. It . should slide smoothly on the shaft (Figure ) Rust, too much grease or damage could prevent the pinion clutch from sliding smoothly. If the pinion clutch assembly does not slide smoothly, clean the shaft and pinion clutch assembly or replace the damaged component.

K0000128

Figure K0000126

Figure

■ Pinion clutch assembly Pinion clutch assembly inspection Manually rotate the pinion clutch assembly in the drive direction (Figure ). It should rotate freely in the drive direction and is locked by turning it in the opposite direction. Replace the pinion clutch assembly if the results are different.

Ball bearing inspection Rotate each ball bearing while holding the p inion clutch assembly (Figure ). Replace the ball bearing if it does not rotate smoothly or has excessive play.

K0000129

Figure

K0000127

Figure

4-6-11

4. ENGINE

Reassembly of Starter Motor 1. Apply the appropriate starter bendix grease (obtain locally) to the pinion shaft. Reassemble the pinion shaft (Figure , (5)), pinion clutch assembly (Figure , (1)), return spring (Figure , (4)) and pinion stop (Figure , (3)). Reinstall the retaining ring (Figure , (2)) in the groove in the pinion shaft. Slide the piston stop over the retaining ring.

5. Reassemble the magnetic switch assembly to the gear housing. Pry the pinion away from the gear housing to allow installation of the magnetic switch assembly (Figure ).

K0000131

Figure

6. Secure the magnetic switch assembly to the gear housing using the two M6 bolts.

K0000112A

Figure 2. Reinstall the pinion clutch assembly into the bearing retainer assembly.

7. Carefully install the armature assembly (Figure , (1)) into the field coil assembly (Figure , (2)).

3. Reinstall the bearing retainer assembly and pinion assembly to the gear housing. Reinstall and tighten the three M4 bolts.

4. Apply a small amount of high temperature lithium grease (obtain locally) to the sliding portions of the shift lever (Figure , (1)). Reassemble the torsion spring (Figure , (2)), shift lever and dust cover(s) (Figure , (3)), plunger (Figure , 4) and magnetic switch assembly (Figure , (5)).

K0000269

Figure 8. Position the brush springs in brush holders (Figure ). Reinstall the brushes in the brush holders. Reversing the brushes will cause the starter motor to turn backwards.

K0000268

K0000106A-2

Figure

Figure

4-6-12

4. ENGINE

9. Carefully install the brush holder assembly to the armature assembly.

5. If the measured L dimension is outside the standard range, adjust the dust covers to obtain the standard range. Dust covers (Figure , (1)) are available in 0.5 mm and 0.8 mm thicknesses.

10. Reinstall the field coil assembly with the armature assembly to the gear housing.

11. Reinstall the rear cover to the brush holder assembly. Securely tighten the two bolts.

12. Reinstall the two M4 through bolts (Figure ). Securely tighten the through bolts. Reconnect the wire to the magnetic switch assembly. Tighten the M8 nut. Reinstall the cover over the connection.

K0000133

Figure

K0000104

Figure

Check Pinion Projection Length 1. Connect the positive (+) lead from a battery to the “S” terminal.

2. Connect the negative (-) lead to the “M” terminal.

3. Lightly pull the pinion away from the gear housing.

4. Turn the switch ON and measure the pinion moving distance L in the thrust direction (Figure ). Perform this test within 10 seconds. See Starter Motor Specifications on page 11-5 for the service limit.

K0000132

Figure

4-6-13

4. ENGINE

No-Load Test

6. Use a suitable tachometer to monitor the rpm of the starter.

Test the characteristics of the starter motor by performing a no-load test.

7. Turn the switch to the ON position. Monitor the rpm, amperage draw and voltage. For test specifications, see 3TNV82A to 4TNV88 Standard and Optional and 4TNV94L to 4TNV106T - Standard and Optional on page 11-4 for the appropriate starter motor.

NOTICE The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no-load test.

Installation of Starter Motor

1. Secure the starting motor in a vise or other suitable fixture.

1. Reinstall the starter motor to the flywheel housing.

2. Connect an ammeter (Figure , (1)) in series between the battery positive (+) terminal (Figure , (2)) and the main positive (+) terminal (Figure , (3)) on the starter motor.

2. Reinstall the starter mounting bolts (Figure , (1)). Tighten the bolts to specification. See Tightening Torques for Standard Bolts and Nuts.

Note: The ammeter and all wire leads used in this test must have a capacity equal to or greater than the amperage draw specification for the starter motor being tested.

0

K0002126

Figure

3. Reconnect the electrical wires to the magnetic switch assembly (solenoid). Be sure to place the cover over the battery positive (+) cable connection.

K0002127A

Figure

4.

3. Connect a wire lead between the mounting base of the starter motor (Figure , (4)) and the battery negative terminal (Figure , (5)).

4. Connect a voltmeter (Figure , (7)) to the battery negative (-) terminal (Figure , (5)) and the main positive (+) battery terminal (Figure , (3)) on the starter motor.

5. Install a switch (Figure , (6)) in a circuit between the battery positive (+) terminal (Figure , (2)) and the starter magnetic switch (solenoid) terminal (Figure , (8)) on the starter motor.

4-6-14

Reconnect the battery cables at the battery.

4. ENGINE

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OFF

OFF

Not abnormal.

Inspect auxiliary diode.

ON

Check condition of L terminal.

Inspect diode negative (-) side.

Excessive voltage drop between BAT and batt ( + side) terminal.

Inspect diode positive (+) side.

Inspect or replace V-belt.

Inspect alternator.

Inspect rotor assembly and brushes.

Replace the battery indicator.

Battery indicator is available from driven machine manufacturer.

Battery voltage is between 13 and 15 volts.

Does battery indicator come ON?

Battery voltage minus L terminal voltage is less than 0.5 volt.

OFF

Replace regulator.

With engine idling, turn light switch ON.

With engine idling, measure voltage at L terminal and at battery.

Battery voltage minus L terminal voltage is greater than 0.5 volt.

ON

Ground drive machine side L terminal. Does battery indicator turn on?

Battery voltage greater than 15.5 volts.

Battery indicator is dim.

Battery indicator is dim.

Battery indicator flashes.

Battery indicator ON.

Disconnect harness L terminal and IG terminal at alternator

1) Use a fully charged battery 2) DC voltmeter: 0 to 30 V, 0.5 class 3) The check method is also applicable to the bench test

Notes:

With engine running at 1500 rpm, measure voltage at battery.

OFF

Does battery indicator come ON?

Increase engine speed to 1500 rpm. Turn light switch ON.

OFF

At idle, does battery indicator turn OFF?

Start Engine.

ON

Turn key switch ON. Does battery indicator turn ON?

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4-8-1

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For measuring compression pressure YANMAR Gauge Set Part No. TOL-97190080

Compression gauge kit

K0000849

Adapter for direct injection 2-valve cylinder head YANMAR Adapter Part No. 119802-92950

130 K0000850

4-9-1

4. ENGINE

7URXEOHVKRRWLQJ %\ 0HDVXULQJ &RPSUHV VLRQ 3UHVVXUH Compression pressure drop is one of the major causes of increasing blow-by gas (engine oil contamination or increased engine oil consumption as a resultant phenomenon) or starting failure.

The compression pressure is affected by the following factors: 1. Degree of clearance between the piston and cylinder 2. Degree of clearance at the intake/exhaust valve seat 3. Gas leak from the nozzle gasket or cylinder head gasket The pressure will drop due to increased parts wear.

Pressure drop reduces the durability of the engine.

A pressure drop may also be caused by a scratched cylinder or piston, dust entrance from the dirty air cleaner element or a worn or broken piston ring. Measure the compression pressure to determine the condition of the engine.

. Turn off the fuel supply valve in the fuel supply line. Disconnect the fuel injection pump stop solenoid at the connector. This prevents the fuel injection pump from injecting fuel during compression testing. . Before installing the compression gauge ((Figure , (1)) 2 valve engine, crank the engine with the stop solenoid disconnected for a few seconds to clear the cylinder of any residual fuel. . Install a nozzle seat at the tip end of the compression gauge adapter. Install the compression gauge and the compression gauge adapter at the cylinder to be measured. . Crank the engine until the compression gauge reading is stabilized.

Compression Pressure Measurement Method 1. Warm up the engine.

2. Stop the engine. Remove the high-pressure fuel injection lines as an assembly from the engine.

Figure

3. Remove the fuel injector from the cylinder to be measured. See Removal of Fuel Injectors on page .

NOTICE Remove or install the high-pressure fuel injection lines as an assembly whenever possible.

Disassembling the high-pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines.

. After performing the compression check remove the compression gauge and compression gauge adapter from the cylinder. . Reinstall the fuel injector, high-pressure fuel injection lines, and reconnect the stop solenoid.

See Reassembly of Fuel Injectors on page .

1 . Turn on the fuel supply valve and reconnect the injection pump stop solenoid.

1 . Prime the fuel system.

Check for leaks.

Test the engine.

4-9-2

4. ENGINE

Standard compression pressure (reference value) Compression pressure at 250 min-1 (rpm)

Engine model

4TNV88

Standard

Limit

3.33 - 3.53 MPa

2.65 - 2.85 MPa

Deviation between cylinders

0.2 - 0.3 MPa

Engine speed and compression pressure (use for reference)

4 MPa

3TNV88 4TNV88 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T

3TNV84 4TNV84

3 MPa 3TNV82A

2 MPa

3TNV84T 4TNV84T

200

2 Engine speed (min-1)

Figure

4-9-

K0000802E

4. ENGINE

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4-9-

4-9-

Little

Engine starts later then ever

Engine not start (stall after serial combustion)

c

c c

c c

c

c

c

c

c

c

c

c

c c

c

Fan belt elongation

Thermostat fault

c

c

Water jacket cracks

c

c

c

c

c

c

c

c

Cooling water

c

c

c

c

c

c

c

c c

c

c

c

c

c

Lubricant diluted with fuel

Insufficient cooling water quantity

c

c

c

c

c

Engine vibration too big c

c

c

c

Lubricant consumption too much

c

c

c

c

Lubricant mixed with water

c

c

c

c

c

Oil pressure too low (oil pressure lamp on)

c

c

c

c

c

c

c

Lubricant

Overheated (water temperature lamp on)

Insufficient radiator cooling

Radiator super cooled

Engine vibration isolating support loose, damage

Open/close timing failure of intake/exhaust valve

Governor misalignment

Wear of intake/exhaust valve guide

Gear backlash too big

Foreign material entered into combustion chamber

Connecting rod bolt loose

Wear of crank pin metal and journal metal

Reverse assembling of piston ring

c

c

Seizure of crank pin metal or bearing parts

c

c

c

c

c

ECU indicator lamp not on just after key-on

c

ECU indicator lamp on just after key-on (2 seconds)

Wear of piston ring, piston or cylinder

Closed gap position fault of piston ring

Speed change by accelerator not available (constant speed)

c

c

Specified speed setting not available

c

Poor acceleration

c

Return to low speed not smooth

c

Engine not start (not even initial combustion)

c c

Knocking noise at combustion too high

c

Combustion noise uneven

c

None

c

Hunting

Noise/vibration

Water temperature too low c

c

Intake

Pressure down (air cleaner lamp on) c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

Blow-by too much

Pressure up

Exhaust At work

Exhaust temperature up c

c

c

c

c

c

Fuel consumption too much c

c

Fuel

Fuel mixed with water (oil-water separator lamp on)

Insufficient engine output

Noise other than combustion from engine

c

Hunting

Exhaust color

Normal

At work

White

Without load

Electrics/electronics

Battery charge defect (charge lamp on)

Defective rotation control

Black

Exhaust fume

ECU indicator lamp flashing

Engine stall after start

White exhaust color

Starter rotates ECU indicator lamp not on just after key-on (2 seconds)

Defective start

Much

Piston ring sticking or breakage

Cylinder head gasket blow-out

Intake/exhaust valve seizure

Compression failure at valve seat

Intake/exhaust valve clearance incorrect

Cause

Engine system

Cooling water system

Black exhaust color

Starter not rotate

Prescribed ECU control function not operate

Symptoms and conditions of failures

Fuse meltdown, disconnection (repeated)

Failure Diagnostic List

Valve clearance adjustment

See Disassembly of Engine Coolant Pump on page .

Inspection or replacement

See Disassembly of Engine Coolant Pump on page .

See Engine Coolant System Check on page .

Repair or replacement Adjustment of belt tension

See Disassembly of Engine Coolant Pump on page .

Water leak inspection of cooling water system

See Disassembly of Engine Coolant Pump on page Thermostat replacement or check for fan belt loose

Thermostat replacement

Repair or replacement of faulty parts

See Measuring and Adjusting Valve Clearance on page .

See Inspection of valve guides on page .

Measurement and replacement Adjustment

See Disassembly of Engine on page .

See Checking timing gear backlash on page .

Disassembling and repair Gear mesh adjustment

See Inspection of crankshaft on page .

See Torque for Bolts and Nuts on page 6-21.

Measurement and replacement

See Reassembly of pistons on page .

See Reassembly of pistons on page .

Correction of assembling

Tightening at specified torque

See Inspection of crankshaft on page .

Horning work and usage of over-sized parts

Correction of closed gap position

See Reassembly of pistons on page .

See Honing and Boring on page .

Piston ring replacement

Repair or replacement

See Removal of intake/exhaust valves on page .

See Removal of cylinder Head on page .

Correction or replacement of intake/exhaust valve Gasket replacement

See Valve face and valve seat on page

See Measuring and Adjusting Valve Clearance on page

Referenced page number

Valve seat facing

Valve clearance adjustment

Action

4. ENGINE

Fuel filter contaminated too early

Lubricant consumption too much

Overheated (water temperature lamp on)

Oil pressure too low (oil pressure lamp on)

Lubricant mixed with water

Lubricant diluted with fuel

Engine vibration too big

Noise other than combustion from engine

Combustion noise uneven

Knocking noise at combustion too high

Speed change by accelerator not available (constant speed)

Much

Little

None

Engine starts later then ever

Engine not start (stall after serial combustion)

Engine not start (not even initial combustion)

ECU indicator lamp on just after key-on (2 seconds)

ECU indicator lamp not on just after key-on

c

c

Exhaust At work

c c

c

c

c

Fuel

c

c

Electrics/electronics

Action

c

Air entered into fuel system

Exhaust pipe clogged

Engine operation at high temperature or high land

Air filter clogged

Sealing defect of fuel tank

Operation defect of CSD valve

Strainer at feed pump inlet clogged

Priming not available

Defective spray of fuel injection nozzle

Fuel injection quatity too much

Insufficient fuel feeding to fuel injection pump Uneven injection quantity of fuel injection pimp

c

c

c

c

c

Fuel filter clogged

Fuel pipe clogged, cracked

c

Water entered into fuel system

Incorrect fuel

Fuel injection pump with injection timing excessively retarded

Fuel injection pump with injection timing excessively advanced

Excess filling into crankcase Stopper solenoid fault

Insufficient lubricant quantity

Insufficient discharge rate of trochoid pump

Lubricant system leakage

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

c

See Testing of Fuel Injectors on page .

See Testing of Fuel Injectors on page .

See Fuel System Components on page .

Inspection and adjustment Valve in priming pump pinched dust (disassembled cleaning)

Cleaning of exhaust pipe

Consideration of matching output reduction with load

Check of fuel tank and cap, as well as installation of genuine parts Cleaning of air filter

Replacing the pump Replacement of CSD valve

Cleaning of strainer

See Testing of Fuel Injectors on page .

Inspection and adjustment

See Priming the Fuel System on page 4- .

See Checking and Adjusting Fuel Injection Timing on page .

See Checking and Adjusting Fuel Injection Timing on page .

See Stop Solenoid on page .

See Disassembly of Oil Pump on page .

See Disassembly of Oil Pump on page .

See Disassembly of Oil Pump on page .

Referenced page number

Inspection and adjustment

Check of fuel tank cock, fuel filter, fuel pipe, fuel feed pump

Cleaning or replacement

Bleeding

Cleaning or replacement

Drainage of fuel filter

Usage of correct fuel

Inspection and adjustment

Inspection and adjustment

Inspection and replacement

Engine oil check

Replenishment of correct lubricant

Cleaning, adjustment or replacement

c

Water temperature too low

Regulator valve fault

c

Pressure down (air cleaner lamp on)

Cleaning or replacement

c

Pressure up

c

Specified speed setting not available

Intake

Blow-by too much

Lubricant filter clogged

Poor acceleration

Cooling water

Exhaust temperature up

Repair

Return to low speed not smooth

Lubricant

Fuel consumption too much

Inspection and repair

Hunting

Noise/vibration

Fuel filter contaminated too early

c

Hunting

Exhaust color

Fuel mixed with water (oil-water separator lamp on)

Insufficient engine output

Normal

At work

White

Without load

Battery charge defect (charge lamp on)

Defective rotation control

Black

Exhaust fume

ECU indicator lamp flashing

Engine stall after start

White exhaust color

Starter rotates ECU indicator lamp not on just after key-on (2 seconds)

Defective start

Prescribed ECU control function not operate

c

Cause

Lubricant system

Fuel system

4-9-

Intake

Black exhaust color

Starter not rotate

Fuse meltdown, disconnection (repeated)

Symptoms and conditions of failures

4. ENGINE

4-9-

ECU faulty (ECU self diagnosis failure)

ECU failure lamp disconnected

Operation defect of rack actuator (Level that ECU can’t detect)

Rack position sensor signal error (Level that ECU can’t detect)

Speed sensor signal error (Cause of noise etc. that ECU can’t detect)

Water temperature sensor signal error (Error at which level ECU can’t detect)

Accelerator sensor signal error (Error at which level ECU can’t detect)

The start assist relay may be faulty.

(Error of contact that ECU can’t detect)

Actuator relay fault (Error of contact that ECU can’t detect)

Main relay fault (Error other than contact sticking that ECU can’t detect)

Failure, disconnection, short-circuit of starter relay

Instantaneous interruption of key switch

Key switch fault, disconnection

Battery voltage descent

Wiring short-circuit (insulator broken), electric power load of added device too big

Wiring disconnection

Alternator fault

Starter fault

Fuse meltdown, disconnection

Cause

Electric system

c

c

c

c

c

c

ECU indicator lamp not on just after key-on

c

c

c

c

c

c

ECU indicator lamp on just after key-on (2 seconds)

c

c

c

c

c

c

c

Engine not start (not even initial combustion)

c

Engine not start (stall after serial combustion)

c

c

Engine starts later then ever

c

c

c

c

c

c

c

c

c

c

c

c

None

c

Specified speed setting not available

c

c

Return to low speed not smooth c

c

Hunting c

c

c

c

c

c

c

c

c

c

Hunting

Poor acceleration

Much

Little

At work

Exhaust color

Normal

Without load

White

Noise/vibration

Knocking noise at combustion too high c

c

Combustion noise uneven c

c

c

c

Lubricant

Cooling water Intake

c

Fuel

Fuel mixed with water (oil-water separator lamp on)

Blow-by too much

Pressure up

Pressure down (air cleaner lamp on)

Water temperature too low

Overheated (water temperature lamp on)

Lubricant mixed with water

Lubricant diluted with fuel

Engine vibration too big

Noise other than combustion from engine

Exhaust At work

Electrics/electronics

-

c

c

Battery charge defect (charge lamp on)

Insufficient engine output

c

ECU indicator lamp flashing

Defective rotation control

Black

Exhaust fume

c

c

c

c

c

c

ECU indicator lamp not on just after key-on (2 seconds)

Engine stall after start

White exhaust color

Starter rotates

c

c

Prescribed ECU control function not operate

Defective start

Black exhaust color

Starter not rotate

c

c

Fuse meltdown, disconnection (repeated)

Symptoms and conditions of failures

Monitor the accelerator sensor by the diagnosis tool.

See Removal of Alternator on page .

See Starter Motor on page .

Referenced page number

Replace the ECU.

Replace the lamp.

Repair or replace the harness.

Repair or replacement of fuel injection pump

Repair or replacement of fuel injection pump

Cleaning or replacement of speed sensor Repair or replacement of fuel injection pump

Check the movement of rack actuator by the diagnosis tool.

Monitor the rack position sensor signal by the diagnosis tool.

Monitor the engine rotational speed by the diagnosis tool.

Replacement of water temperature sensor Monitor the cooling water temperature by the diagnosis tool.

Repair or replacement of accelerator sensor

Replacement of start assist relay

Replacement of actuator relay

Repair or replacement of harness Replacement of main relay

Repair or replacement of harness Replacement of starter relay

Key switch replacement

Repair or replacement of harness Key switch replacement

Inspection and charging of battery

Inspection, repair or replacement of harnesses Review of added devices

Repair or replacement of harness disconnection

Repair or replacement of alternator

Repair or replacement of starter

Inspection and replacement of fuse Repair or replacement of harness

Action

4. ENGINE

Fuel filter contaminated too early

Fuel consumption too much

Exhaust temperature up

Oil pressure too low (oil pressure lamp on)

Lubricant consumption too much

Speed change by accelerator not available (constant speed)

4-9-

Malfunction by ECU self-diagnosis

Disconnection/short-circuit of rack actuator relay

Main relay “OFF” not available

Disconnection/short-circuit of start assist relay

Disconnection/short-circuit of CSD solenoid valve

Disconnection/short-circuit of EGR valve motor

CAN communication error

Engine over speed

Operation defect of rack actuator

Rack position sensor signal error

Speed sensor signal error

Disconnection/short-circuit of accelerator sensor

Disconnection/short-circuit of water temperature sensor

ECU control function operating

Cause

Engine stop or operation limits by ECU failure diagnosis function

ECU indicator lamp on just after key-on (2 seconds)

Engine not start (stall after serial combustion)

ECU indicator lamp not on just after key-on

Noise/vibration

Lubricant

Cooling water Intake

Combustion noise uneven

Knocking noise at combustion too high

Fuel

Electrics/electronics

Action

Hunting c

Hunting

Return to low speed not smooth

Poor acceleration

c

c

c c

c

c

c c

c

c

c

c

c

c

c

Normal

c

c

c

White

c

c

c

c

ECU Replacement

Repair or replacement of harness Relay replacement

Relay replacement

Repair or replacement of harness Relay replacement

Repair or replacement of harness Replacement of CSD valve solenoid

Repair or replacement of harness Replacement of EGR valve

Repair or replacement of harness ECU Replacement

Check operating machine’s driving.

Check speed sensor signal.

Repair or replacement of harness Repair or replacement of fuel injection pump

Repair or replacement of harness Repair or replacement of fuel injection pump

Repair or replacement of harness Repair or replacement of fuel injection pump

Repair or replacement of harness Replacement of accelerator sensor

Noise other than combustion from engine

c

Engine vibration too big

Repair or replacement of harness Replacement of water temperature sensor

Lubricant consumption too much

Not failure Implement regular usage

Lubricant diluted with fuel

c

Lubricant mixed with water

c

Oil pressure too low (oil pressure lamp on)

c

Overheated (water temperature lamp on)

c

Water temperature too low

c

Pressure down (air cleaner lamp on)

c

Pressure up

Exhaust At work

Blow-by too much

Insufficient engine output

Exhaust temperature up

c

c

None

Exhaust color

Fuel consumption too much

c

c

c

Engine not start (not even initial combustion)

c

Engine starts later then ever

c

c

Little

At work

Fuel filter contaminated too early

c

c

c

Much

Without load

Fuel mixed with water (oil-water separator lamp on)

Defective rotation control

Black

Exhaust fume

Battery charge defect (charge lamp on)

Engine stall after start

ECU indicator lamp flashing

Speed change by accelerator not available (constant speed)

White exhaust color

Starter rotates ECU indicator lamp not on just after key-on (2 seconds)

Defective start

Prescribed ECU control function not operate

Specified speed setting not available

Black exhaust color

Starter not rotate

Fuse meltdown, disconnection (repeated)

Symptoms and conditions of failures

Check the causes of engine stop or starter restraint by a diagnosis tool.

Referenced page number

4. ENGINE

&+$37(5

(/(&75,& 6<67(0 (OHFWULF (TXLSPHQW RI 0DFKLQH

Localisation of fuse and relays .............. .

2 Identification of fuses ................... 2 3 Identification of relays .................. 3 4 Identification of connectors .......... 4 Electric diagram ................... ... ......... .............

Steering column 2 Engine line ........

3 Cabine line ........ 3 4 Electric system description ........ 4

5. ELECTRIC SYSTEM

(OHFWULF (TXLSPHQW RI 0DFKLQH Localisation of fuse and relays

5. ELECTRIC SYSTEM

2 Identification of fuses No.

Name

1 2 3 4 5 6 7

Electric card fuse Glow plugs relay Injection pump relay Starting key fuse Starting motor fuse Optional Power supply: high beam

8 9

Suffix

Ampere

1 2 3 4

40 A 40 A

F6B

30 A 30 A 30 A 7,5 A 15 A

Power supply: low beam

F6C

15 A

Power supply: relay K14 - front work lights (internal side)

F7A

15 A

10

Power supply: external lights switch

F7B

20 A

11 12 13 14 15 16 17

Power supply: relay K13 – rear work lights Power supply +30: relays K13 - K14 and lights switch Power supply +30: beacon switch relay Instruments lighting – rocking keys – front/rear right position lights Power supply +30: hazard warning lights switch – clock display Power supply +15 hazard warning lights switch – control lever - turn signals Speed switch - relays K2 - K5 - K8 - K10 - K12

F7C F8A F8B F8C F9A F9B F9C

15 A 10 A 10 A 3A 10 A 7,5 A 7,5 A

18

Control lever power supply button - stop/tail lights line solenoid valve

F10A

15 A

19

Power supply: alarm buzzer – multipurpose instrument – road safety switch jack locking switch

F10B

5A

20

Power supply: diesel pump relay – engine stop solenoid valve – starting aid solenoid valve alternator

F10C

5A

Power supply: cab interior lights – radio set – lighter

F11A F11B

10 A 10 A

F11C

3A

21 22 23

5 F6A

Power supply: windscreen wipers Power supply: licence plate lights – front/rear left position lights

F6C F6B

F6A

F11C

2

F11A F11B

1

F10C F10B

F10A

F9C F9B

F9A

F8C F8B

F8A

F7C F7B

F7A

3

4

5

5. ELECTRIC SYSTEM

3 Identification of relays No. 1 2 3 4 5 6 7

Name

Suffix K2 K3

Forward speed control Buzzer with parking brake engaged 1st and 2nd speed control Front windscreen wiper Optional 1st and 2nd gear light Start-up enabling command

K4 K5 K7 K8 K9

8

Reverse speed control

K10

9 10

Low and high beam control

K11

Optional Rear work lights control

K12 K13 K14 R3 R4 R5 R6 6

11 12 13 14 15

Front work lights control Instruments check timer Hazard warning lights intermittence

16 17

Starting aid injection pump timer Glow plugs timer Injection pump relay

18

Starting motor relay

7

19

Glow plugs relay

8

K12

K10

K11

K9 R4

K8

6

K7

7 8

K5

K3

K4

R3

K2 K14

K13

R5

3

R6

5. ELECTRIC SYSTEM

4 Identification of connectors No. 1 2 3 4

Name

Suffix X1 X2

Driving column line (21 way) Driving column line (21 way) Rear engine line (13 way) Rear engine line (7 way)

6 7

Driving column line (21 way) Rear engine line (7 way) Rear engine line (11 way)

X3 X4 X5 X6 X7

8

Supply for cab wiring

X8

9

Anti-thieft device line - optional (9 way)

X9

10

Front lights line (9 way)

5

X10

X10

X9

X8

X7

X6

X5

X4

X3

X2

X1

4

2-1

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5. ELECTRIC SYSTEM

2 (OHFWULF diagram

+0:45*$,

$0//&$5 50 STEERING $0-6./

4501 40-&/0*%

4501 &/(*/&

$0//&$5 50 STEERING $0-6./

4&/403 '0 -&7&-

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5. ELECTRIC SYSTEM

5-2-2 Engine line

)&"5*/( 48*5$)

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5. ELECTRIC SYSTEM

5-2-3 Cabine line

$0//&$5 50 STEERING $0-6./

2 3

5. ELECTRIC SYSTEM

2 4 Electric system description

2 4

&+$37(5

+<'5$8/,& 6<67(0 6-1 Hydraulic Circuit .................................................................................. 6-1-1 6-1-1 Valve setting chart ..................................................................... 6-1-1 6-1-2 Pressure outlets ......................................................................... 6-1-1 6-2 Circuit operation .................................................................................. 6-2-1 6-2-1 Loader ....................................................................................... 6-2-1 6-2-2 Steering ..................................................................................... 6-2-2 6-2-3 Loader quick-coupling (optional) ................................................ 6-2-3 6-3 Hydrostatic Transmission .................................................................... 6-3-1 6-3-1 Valve setting chart ..................................................................... 6-3-1 6-3-2 Description of operation ............................................................. 6-3-2 6-3-3 Hydrostatic balancing ................................................................. 6-3-3 6-3-4 Hydrostatic pump ....................................................................... 6-3-4 6-3-5 Working pressure control ........................................................... 6-3-5 6-3-6 Pressure relief control valves ..................................................... 6-3-6 6-3-7 Towing procedure with hydrostatic moto ................................... 6-3-7 6-3-8 Overfeeding pressure control .................................................... 6-3-8 6-3-9 Idling adjustment ........................................................................ 6-3-8 6-3-10 Control valve operation and start point setting ........................ 6-3-9 6-3-11 Control valve diagram .............................................................. 6-3-10 6-3-12 Hydrostatic motor ..................................................................... 6-3-11 6-3-13 Checking the hydrostatic motor displacement change ............ 6-3-12 6-4 Troubleshooting ................................................................................... 6-4-1 6-4-1 Pump / Motor ............................................................................. 6-4-1 6-4-2 Equipment .................................................................................. 6-4-2

6. HYDRAULIC SYSTEM

1 Hydraulic Circuit 1 Valve setting chart No. 1 2 3 4 5 6

Name

Suffix

MAIN RELIEF VALVE - LOADER LOADER BUCKET ANTISHOCK VALVE (End – plate side) LOADER BUCKET ANTISHOCK VALVE (Rod side) OVER LOAD VALVE - FRONT SHOVEL ARM POWER STEERING MAIN RELIEF VALVEN OVER LOAD VALVE - POWER STEERING

Setting pressure

V.G.C. V.A.B.C.F.

Mpa 20 30*

V.A.B.C.A. V.A.S.C. V.G.I. V.A.I.

26* 25* 21±0,5 26*

Note : Pressure datas shown on the chart have to be obtained with diesel engine running at 1700 ÷ 1750 r.p.m. and with hidraulic oil at normal temperature (50 ÷ 70 °C) Those marked with the symbol * must be checked on a testing ground, their pressure values relate to a 2 to 3 liter delivery.

Diesel engine idling rpm 950±50 Engine max. R.P.M. 3200±50

Engine R.P.M. under load 2400±50 Standard drive shaft R.P.M.

1° gear

= 950±20

2° gear

= 1930 ÷ 1970

Optional drive shaft R.P.M. with HA engine

1° gear

= 720±20

2° gear

= 2400±20

The manufacturer accepts no responsibility for defects attributable to the tampering with any valves of the system.

Repair must be carried out only by authorised personnel in case of evident reduction of the performance.

6-1-2 Pressure outlets

It is possible to check the pressure of the various hydraulic circuits in one single zone of the machine, where there are 3 pressure outlets (points G):

G

forward hydrostatic circuit pressure,

reverse hydrostatic circuit pressure, hydraulic plant pressure and steering hydraulic circuit.

6-1-1

. ):%3"6-*$ 4:45&.

6-2 Circuit Operation 6-2- Loader OPTIONAL

B

20 MPa

A

B

D 25 MPa

A

30 MPa

C 26 MPa

C

D

Attachment Lift

Bucket

In

G

G

A) LOADER MAIN VALVE (V.G.C.) Adjustment is made by removing the plug with an Allen wrench and checking the pressure (with a 0 / 30 MPa pressure gauge) on the delivery line of the hydraulic pump (G). Start the diesel engine and warm up the hydraulic fluid to a temperature 50 ÷ 70 °C. Setting pressure 20 MPa. B) ROD SIDE LOADER BUCKET ANTISHOCK VALVE End-plate side (V.A.B.C.F) Setting pressure 30 MPa. C) ROD SIDE LOADER BUCKET ANTISHOCK VALVE Rod side (V.A.B.C.A.) Setting pressure 26 MPa. D) LOADER LIFTING ANTISHOCK VALVE (V.A.S.C.) Setting pressure 25 MPa. 6-2-1

. ):%3"6-*$ 4:45&.

Steering

B

B

3

2 1 B

A

A Hydraulic System

G

EF

CF

LS S

G

IN

1) SUCKING 2) STEERING 3) HYDRAULIC CIRCUIT A) HYDRAULIC POWER STEERING MAIN RELIEF VALVE (V.G.I.) Adjustment is made by removing the plug with an Allen wrench and checking the pressure on the delivery line of the hydraulic pump (G). Start the diesel engine and warm up the hydraulic fluid to a temperature 50 ÷ 70 °C. Setting pressure 21±0,5 MPa B) HYDRAULIC POWER STEERING ANTISHOCK VALVE (V.A.I.) Valves cannot be adjusted on the machine. Require the manufacturer a kit of preset valves.

Setting pressure 26 MPa. 6-2-2

. ):%3"6-*$ 4:45&.

3 Loader quick-coupling (optional) OPTIONAL

20 MPa 30 MPa

A B

25 MPa

26 MPa

Attachment

Bucket

Lift In

A

1 1

A) AUXILIARY CIRCUIT CLOSING FUNCTION SOLENOID VALVE

B

B) AUXILIARY CIRCUIT OPENING FUNCTION SOLENOID VALVE 1) DISTRIBUTOR TIE RODS DRIVING TORQUE : (KGM 2,5 – 2,8 - LB.FT 18 – 20)

6-2-3

6. HYDRAULIC SYSTEM

6-3 Hydrostatic Transmission 6-3-1 Valve setting chart No. 1 2 3 4 5

Name

Model

Hydrostatic pump type

6 7 8

Hydrostatic motor type Stationary throttle on solenoid valve (T) Engine throttle (passage valves) V.P.E.T.I Working pressure (engine. 2800 ± 25 rpm.)

V.T.I.safety valve pressure V.S.T.I.supercharge valve pressure Adjustement valve diaphragm Hole (D.A.)

9

Pump pressure housing

3-

A10VG 45DA A10VM 63EZ

Setting or Size

1 mm 0,3 mm 36 MPa 37 MPa 2,5 MPa 5 mm max 0,15 ÷ 0,2 MPa (50 ÷ 70 °C)

6. HYDRAULIC SYSTEM

3-2 Description of operation The hydrostatic transmission installed on our machine V7 is the close loop type and consists of a wobble plate pump with adjustable displacement which is directly connected to the diesel engine through a flexible coupling, and a variable displacement hydraulic motor with slanted body tightly fastened to the reduction gear (power divider). Motion is transmitted by Cardan shafts to the differential gears and to the four drive wheels.

1 2

3

5

4

6

1- DIESEL ENGINE 2- HYDROSTATIC PUMP 3- HYDROSTATIC MOTOR 4- REDUCTION GEAR – POWER DIVIDER 5- FRONT DIFFERENTIAL GEAR 6- REAR DIFFERENTIAL GEAR

3 2

6. HYDRAULIC SYSTEM

3-3 Hydrostatic balancing If the torque of the diesel engine is higher than that absorbed by the pump, the pump reaches it’s maximum flow.

If, by increasing the working pressure, the engine torque is exceeded, then the engine speed and the pilot pressure get reduced.

As a result, the pump is set at a lower displacement until the engine speed stops getting reduced, i.e. when the delivered and the absorbed torques are balanced.

36±0,5 MPa

2,5±0,1 MPa

3 3

6. HYDRAULIC SYSTEM

3-4 Hydrostatic pump A) Hydraulic servo control B) Two pressure relief valves : one for forword motion and one for reverse motion C) Booster pump (filling) D) Power absorption control valve E) Booster pump valve F) Two solenoid valves for motion reversal G) Working pressure control valve H) Hydraulic pump and steering unit

F

G

A

F

B

3 4

C

B

E

D

H

6. HYDRAULIC SYSTEM

3-5 Working pressure control To check the working pressure in forward and reverse gear, insert a pressure gauge (0 - 60 MPa scale) in the points indicated (MA) and (MI).

Start the diesel engine and warm up the hydraulic oil to 50 ÷ 70 °C. Now lift the machine.

WARNING

For safety reasons, no one must stand in front of or behind the machine during the test. nd

Pull the parking brake lever and engage the 2 forward speed by increasing the engine speed gradually; the pressure value will increase gradually until reaching a value of 36 MPa at 2800 ± 25 r.p.m.

1

MA

G

MI

G

1)

WORKING PRESSURE CONTROL VALVE

MA) FORWARD SPEED MI)

REVERSE SPEED

3 5

6. HYDRAULIC SYSTEM

3-6 Pressure relief control valves The V.T.I. pressure relief (or safety) valves on the high pressure line never work and are set at 37 MPa. (They must never be tampered with).

The valves start working when the working pressure is higher than the value envisaged.

To check the pressure start the diesel engine and warm up the hydraulic fluid to a temperature 50 ÷ 70 °C.

1

1a

2a

2

1)

FORWARD SPEED V.T.I.

1a) FORWARD SPEED PRESSURE INTAKE 2)

REVERSE SPEED V.T.I.

2a) REVERSE SPEED PRESSURE INTAKE

3-6

6. HYDRAULIC SYSTEM

3-7 Towing procedure with hydrostatic motor In case of repair or break, cut out the high-pressure valve of the pump (see drawing).

To do this, turn detail (1) of the valve one turn and a half. When the machine is towed with a hydrostatic drive, the hydraulic motor works like a pump and through the high pressure system valve delivers an oil amount sufficient to protect the system.

When towing the following must be considered: • A reasonable towing speed (about 1 km/h) • A limited towing travel (about 1 to 2 km) • The motor overheating (about 80°C) • After towing lock detail (n°1) back in the original position.

1

1

3 7

6. HYDRAULIC SYSTEM

3-8 Overfeeding pressure control Insert a 0 to 6 MPa scale pressure gauge in the suitable coupling in point (G).

Start the diesel engine and warm up the oil 50 ÷ 70°C. At 2600 ± 50 r.p.m. the pressure value must be 2,5 MPa.(as shown in the table).

The V.S.T.I. overfeeding valve (adjustable with spacers) is shown in point (1).

G

1

3-9 Idling adjustment If the neutral cannot be engaged, proceed with the following checks.

First of all make sure that that the working pressures are all regular and that there are no other troubles (such as mechanical breaks etc.).

MECHANICAL ZERO Lift the front part of machine with the help of the bucket and the rear part using a lifter of adequate characteristics.

WARNING Be sure that no one stands in front of or behind the machine during the test.

Adjust screw (1) which corresponds to the zero setting adjuster of the servo control piston.

1

3 8

6. HYDRAULIC SYSTEM

3- 0 Control valve operation and start point setting The power absorption control valve (D) is used to prevent the diesel engine from getting over loaded.

Oil flows from the booster/filling pump (C) (with internal gears and fixed displacement) which is directly driven by the diesel engine.

As a result, the flow will be proportional to the speed of the diesel engine.

The pilot pressure (higher or lower depending on the engine r.p.m.) produced inside the control valve is delivered to the servo control piston (A) of the variable displacement pump.

In this way, the wobble plate moves and the pump flow changes, thus causing the machine to move.

The whole process takes place only when one of solenoid valves (F) on the pump control unit is energized thus allowing the pilot oil to reach the servo control piston (A) of the variable displacement pump.

Keep in mind that the machine does not move until the pilot pressure reaches 0,6 MPa (corresponding to 1100±50 r.p.m. of the diesel engine).

This is due to the fact that the variable displacement pump is kept in its middle position (stationary vehicle) by the springs of the pump servo control cylinder, with the engine idling, even if the running direction solenoid valve is energized.

When the pilot pressure gets higher, the plate of the variable displacement pump starts wobbling and therefore oil starts flowing to the hydraulic motor.

If the diesel engine speed is other than the one expected, act on the adjustment screw (1).

A

F

C D

1

3 9

6. HYDRAULIC SYSTEM

3-11 Control valve diagram

12345-

CONTROL VALVE DIAPHRAGM PRELOAD POSITIONING PIN SPRING GAS PEDAL PRELOAD AS A FUNCTION OF ROTATION SPEED

Typical control valve diagram (indicative values).

3 0

6. HYDRAULIC SYSTEM

3- 2 Hydrostatic motor The variable displacement motor is equipped with a two-fixed-point setting system controlled by an electromagnet (maximum and minimum displacement, without any intermediate position).

When no voltage is applied to the electromagnet the variable displacement motor is set to the minimum displacement (transfer speed). st The motor moves to its maximum displacement corresponding to the 1 speed, i.e. the working speed only when the electromagnet is energized

1

3

2

1) GEARSHIFT SOLENOID VALVE 2) HYDROSTATIC ENGINE THROTTLE 3) DISPLACEMENT ADJUSTMENT SCREW: (NOT TO BE TAMPERED WITH).

Inside the hydrostatic motor control unit, there is a fix throttle that modulates the passage from one gear to the other making the system smoother. (passage value: 0.3)

3 1

6. HYDRAULIC SYSTEM

3- 3 Checking the hydrostatic motor displacement change Insert a 0 to 60 MPa scale pressure gauge in point (1).

Start the diesel engine and warm up the hydraulic oil 50 ÷ 70°C. Lift the front part of machine with the help of the bucket and the rear part using a lifter of adequate characteristics.

WARNING Do not let anyone stand in front of or behind the machine during the tests.

Pull the parking brake lever and step down on the service brake.

When the diesel engine runs at max. speed, we should have the following condition: A) 1st speed engaged (energized electromagnet) – the reading of the working pressure on the pressure gauge should be 36 MPa. B) 2nd speed engaged (electromagnet not energized) -no pressure should be read on the pressure gauge.

If we read even just a minimum pressure, this means that the hydraulic motor is not set to its minimum displacement and therefore the machine cannot reach its maximum speed.

1

3 2

6. HYDRAULIC SYSTEM

6-4 Troubleshooting 6-4- Pump / Motor

4 1

6. HYDRAULIC SYSTEM

4-2 Equipment

4

97 Service Manual 0M54 (1WL 1 1st edition : Jan. 2016 2nd edition : Apr. 2017

KWWS ZZZ \DQPDU FV Copyright c 2015 YANMAR CONSTRUCTION EQUIPMENT (8523 6 $ 6.

All Rights Reserved. This manual may not be reproduced or copied in whole or in part, without the written consent of YANMAR CONSTRUCTION EQUIPMENT (8523( 6 $ 6.