Case Mini Excavator CX35B CX39B Series 2 Service Manual 47574272B - PDF DOWNLOAD by www.heydownloads.com

SERVICE MANUAL CX35B CX39B Series 2

Mini Excavator

1/1

Part number 47574272B

CX35B CX39B Series 2 Mini Excavator

SERVICE MANUAL

Part number 47574272B English March 2014

SERVICE MANUAL CX35B CX39B

47574272B 24/03/2014 EN

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11 47574272B 24/03/2014

[35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12 [35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 [35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14 [35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15

Frames and ballasting ................................................................. 39 [39.101] Upper frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 [39.103] Swing ring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.3

Tracks and track suspension ........................................................ 48 [48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 [48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4

Cab climate control ..................................................................... 50 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.510] Cab or platform harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

Booms, dippers, and buckets ....................................................... 84 47574272B 24/03/2014

[84.114] Boom pivoting support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1 [84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2 [84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3 [84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.4

Dozer blade and arm................................................................... 86 [86.110] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.110] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

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INTRODUCTION

47574272B 24/03/2014

Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Basic instructions - How to use maintenance standards and precautions . . . . . . . . . . . . . . . . . . . . 17 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Product identification - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Part identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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INTRODUCTION

Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.

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INTRODUCTION

Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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INTRODUCTION

Personal safety NOTICE: The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance. The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes a careful use of the systems very important when performing maintenance operations. Sound knowledge of the system and or components is important before the removal or disassembly of any component. Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in this section. The following is a list of basic precautions that must always be observed. 1. Read and understand all Warning plates and decals on the machine before Operating, Maintaining or Repairing this machine. 2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewellery, confine long hair and loose clothing before working on this machinery. 3. Disconnect the battery and hang a “Maintenance in Progress” tag in the operator’s seat. Remove starter key. 4. If possible, make all repairs with the machine parked on a level and firm surface. Block the machine so it does not roll while working on or under the machine. Hang a “Maintenance in Progress” tag in the operator’s seat. 5. Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or stops for the jack before carrying out any disassembly operation. NOTICE: Do not operate this machine unless you have read and understood all instructions contained in this manual. Improper machine operation is dangerous and could result in injury or death. 6.

Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system under pressure.

Lower the bucket, dozer or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, blade or other attachment is blocked correctly to prevent it from dropping unexpectedly.

Use steps and grab handles when mounting or dismounting a machine. Remove any debris or mud from steps, walkways or work platforms before using them. Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work, platforms to perform safe repair operations.

To avoid back injury, use a hoist when lifting components which weigh 20 kg (44.09 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

10. To avoid burns, be alert for hot parts and surfaces immediately after stopping the machine such as hot fluids in lines, tubes and compartment covers. 11. Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry the cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely. 12. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. Danger is even greater if the machine has just been stopped, as liquids might be boiling hot. 13. Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work. 14. Reinstall all clamps with the same spare part number. Do not use clamps of inferior quality if replacement is necessary. 47574272B 24/03/2014

INTRODUCTION

15. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and skilled in welding procedures. Determine the type of metal being welded and select the correct welding procedure and electrodes, rods or wires to provide a metal weld strength at least equivalent to that of the parent metal. Make sure to disconnect the battery before any welding operation is performed. 16. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 17. Be sure all protective devices, including guards and shields, are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is complete. 18. Performing maintenance and repair operations while the bucket is lifted is dangerous, because there is the possibility of a device falling. Do not fail to lower such device and place the bucket to the ground before starting the operation. 19. Loose or dirty fuel, lubrication and hydraulic systems, pipes and hoses may cause fires. Do not bend or strike high-pressure lines, do not install bent or damaged lines. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil jet that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. 20. Tighten connections to the correct torque. Make sure that all protections against burns, the clamps and the operatorâ&#x20AC;&#x2122;s protective devices are correctly installed in order to prevent excessive heat, vibrations or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly. 21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. 22. Be careful when servicing or separating the tracks. Chips can fly when removing or installing a track pin. Wear safety glasses and long sleeve protective clothing. Tracks can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.

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INTRODUCTION

General precautions for repairs Preparation before disassembling

1. Understanding operating procedure Read OPERATION AND MAINTENANCE MANUAL carefully to understand the operating procedure. 2. Cleaning machines Remove soil, mud, and dust from the machine before carrying it into the service shop to prevent loss of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while reassembling. 3. Inspecting machines Identify the parts to be disassembled before starting work, determine the disassembling procedure by yourself considering the workshop situations etc., and request procurement of necessary parts in advance. 4. Recording Record the following items for communication and prevention of recurring malfunction. 1. Inspection date and place 2. Model name, applicable machine number, and hour meter read 3. Trouble condition, place and cause. 4. Visible oil leakage, water leakage and damage 5. Clogging of filters, oil level, oil quality, oil contamination and loosening of connections 6. Result of consideration if any problem exists based on the operation rate per month calculated from hourmeter indication after the last inspection date. 5. Arrangement and cleaning in service shop 1. Tools required for repair work. 2. Prepare space to place the disassembled parts. 3. Prepare oil containers for draining oil etc.

Safety in disassembling and assembling

1. Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses. 2. Suspend warning tag â&#x20AC;&#x153;DO NOT OPERATEâ&#x20AC;? from the doorknob or the operating lever, and have a preliminary meeting before starting work. 3. Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine. 4. Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency. 5. Choose a hard, level and safe place, and place the attachment on the ground securely. 6. Use a lifter such as a crane to remove heavy parts ( 20 kg (44 lb) or more) from the machine. 7. Use proper tools, and replace or repair defective tools. 8. Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

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INTRODUCTION

Disassembling and assembling hydraulic equipment

1. Removing hydraulic equipment 1. Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter. 2. Carefully drain oil of the removed pipes into a containers without spilling on the floor. 3. Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion. 4. Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench. 2. Disassembling hydraulic equipment 1. Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after modification. 2. When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training. 3. Provide matching marks to facilitate reassembling work. 4. Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself. 5. Use the special jig and tools without fail if they are specified. 6. If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause. 7. Place the removed parts in order and attach tags to facilitate the reassembling. 8. Note the location and quantity of parts commonly applied to multiple locations. 3. Inspecting parts 1. Ensure that the disassembled parts are free from seizure, interference and uneven contact. 2. Measure and record wear condition of parts and clearance. 3. If the problem is found in a part, repair or replace it with a new one. 4. Reassembling hydraulic equipment 1.

Turn On the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts.

Perform rough and finish cleaning before assembling.

Remove washing oil by air and apply clean hydraulic or gear oil for assembling.

Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance.

Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied.

Remove rust preventive agent from the new parts before use.

Fit bearings, bushings and oil seals using special jigs.

Assemble the parts utilizing matching marks.

Ensure all the parts are completely assembled after the work.

5. Installing hydraulic equipment 1. Ensure hydraulic oil and lubricant are properly supplied. 2. Perform air bleeding when: 1. Hydraulic oil changed 2. Parts of suction side piping replaced 3. Hydraulic pump installed 4. Slewing motor installed 5. Travel motor installed 6. Hydraulic cylinder installed 47574272B 24/03/2014

INTRODUCTION

NOTICE: Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment. 3. Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug, starting the engine and keep it in low idle condition. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug. 4. Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more than 5 min at low speed without load. NOTICE: Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance. 5. Perform air bleeding of pilot line by performing a series of digging, slewing and travel. 6. Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

Electrical equipment

Do not disassemble electrical equipment.

Handle it carefully not to drop and give a shock.

Turn the key Off prior to connecting and disconnecting work.

Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion.

Connect the connector and ensure it is completely locked.

Turn the key Off prior to touching the terminal of starter or generator.

Remove the ground (earth) terminal of battery when handling tools around the battery or its relay.

Do not splash water on the electrical equipment and connectors during machine washing.

Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector.

If moisture adhesion is found, dry it completely before the connection. Battery electrolyte is hazardous. Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or loss of eyesight. If the exposure occurs, take the following emergency measures and seek the advice of a medical specialist. • When skin exposed: Wash with water and soap sufficiently. • When eyes exposed: Immediately wash away with city water continuously for more than 10 min. • When a large amount of the liquid flows out: Neutralize with sodium bicarbonate or wash away with city water. • When swallowed: Drink a large amount of milk or water. • When clothes exposed: Immediately undress and wash.

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INTRODUCTION

Hydraulic parts

1. O-ring • Ensure O-rings have elasticity and are not damaged before use. • Use the appropriate O-rings. O-rings are of different kinds and made of different materials, and they have a different hardness to be applied to a variety of parts, such as moving or fixed parts, subject to high pressure and exposed to corrosive fluids, even if their size is same. • Fit the O-rings without distortion and bend. • Always handle floating seals as a pair. 2. Flexible hose (F hose) • Use the appropriate parts. Different parts are used depending on the working pressure even the size of fitting and the total length of the hose is same. • Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized.

Welding repair 1. Refer repair welding to qualified personnel according to the appropriate procedure. 2. Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment. 3. Move away the articles in advance that may cause fire if exposed to sparks. 4. Before starting the repair of the attachment, do not fail to cover the plated surface of the piston rod with flameproof sheet to prevent it from being exposed to sparks.

Environmental measure 1. Run the engine at the place that is sufficiently ventilated. 2. Industrial waste disposal Dispose of the following parts according to the relevant regulations: Waste oil and waste container Battery 3. Precautions for handling hydraulic oil Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures: • When an eye exposed: Immediately wash away with city water sufficiently till stimulative feeling vanishes. • When swallowed: Do not let vomit, and receive medical treatment immediately. • When skin exposed: Wash with water and soap sufficiently. 4. Others Use replacement parts and lubricants authorized as the genuine parts.

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INTRODUCTION

Torque Torque specifications for capscrews and nuts The following torque specifications are indicated in case the actual torque value of a fastener is unknown. Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance. Retighten the loosened ones, and install new ones for the dropped off. For the new machine, the check and retightening of them must be carried out at first 50 h operation. For the replacement of them, make sure to use the same size of manufacturer’s genuine parts. Refer to the table below for the tightening and retightening of capscrews. • The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening torque for such capscrews, consult with an authorized our Distributor. Over-tightening may cause damages on the parts to be fixed. • If the operator’s manual specifies a different torque, use such value regardless of the table below. • Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is provided for smaller size of capscrews, M5 or less.

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TULI12EXN4032AA

INTRODUCTION

Metric coarse thread standard tightening torque values. Be certain to tighten all capscrews and nuts to proper torque values Classifi4.8T cation Nominal dimen- No lubrication Oil lubrication sion 3.9 - 4.9 N·m 3.3 - 4.1 N·m M6 X 1 (2.88 - 3.61 lb (2.43 - 3.02 lb ft) ft) 9.6 - 11.8 N·m 8.1 - 9.9 N·m M8 X (7.08 - 8.70 lb (5.97 - 7.30 lb ft) 1.25 ft) 19.6 - 23.6 N·m 16.1 - 19.7 N·m M10 X (11.87 - 14.53 lb (14.46 1.5 ft) 17.41 lb ft) 32.4 - 40.2 N·m 28.5 - 34.3 N·m M12 X (21.02 - 25.30 lb (23.90 1.75 ft) 29.65 lb ft) 52 - 63.8 N·m 44.1 - 53.9 N·m (32.53 - 39.75 lb (38.35 M14 X 2 ft) 47.06 lb ft) 79.5 - 97.1 N·m 67.6 - 81.4 N·m (49.86 - 60.04 lb (58.64 M16 X 2 ft) 71.62 lb ft) 110 - 134 N·m 93 - 113 N·m M18 X (68.59 - 83.34 lb (81.13 2.5 ft) 98.83 lb ft) 155 - 189 N·m 130 - 158 N·m M20 X (114.32 (95.88 2.5 139.40 lb ft) 116.53 lb ft) 206 - 246 N·m 172 - 212 N·m M22 X (126.86 (151.94 2.5 156.36 lb ft) 181.44 lb ft) 265 - 323 N·m 206 - 264 N·m (151.94 (195.45 M24 X 3 194.72 lb ft) 238.23 lb ft) 392 - 470 N·m 314 - 392 N·m (289.12 (231.59 M27 X 3 346.65 lb ft) 289.12 lb ft) 529 - 647 N·m 441 - 539 N·m M30 X (325.26 (390.17 3.5 397.55 lb ft) 477.2 lb ft)

7T No lubrication

10.9T Oil lubrication No lubrication

7.3 - 8.9 N·m 8.6 - 10.6 N·m (5.38 - 6.56 lb (6.34 - 7.82 lb ft) ft) 21.5 - 25.5 N·m 17.6 - 21.6 N·m (12.98 (15.86 - 18.81 lb 15.93 lb ft) ft) 41.2 - 51 N·m 35.3 - 43.1 N·m (26.04 (30.39 - 37.62 lb 31.79 lb ft) ft) 71.6 - 87.2 N·m 59.8 - 73.6 N·m (44.11 (52.81 - 64.32 lb 54.28 lb ft) ft) 96 - 116 N·m 113 - 139 N·m (70.81 (83.34 85.56 lb ft) 102.52 lb ft) 171 - 211 N·m 145 - 177 N·m (106.95 (126.12 130.55 lb ft) 155.63 lb ft) 236 - 294 N·m 206 - 246 N·m (151.94 (174.06 181.44 lb ft) 216.84 lb ft) 334 - 412 N·m 285 - 343 N·m (246.35 (210.21 303.88 lb ft) 252.984 lb ft) 451 - 549 N·m 383 - 461 N·m (282.49 (332.64 340.02 lb ft) 404.92 lb ft) 568 - 706 N·m 471 - 569 N·m (347.39 (418.94 419.67 lb ft) 520.72 lb ft) 843 - 1039 N·m 687 - 843 N·m (621.76 (506.71 766.33 lb ft) 621.76 lb ft) 1158 - 1412 N·m 971 - 1187 N·m (716.17 (854.10 875.49 lb ft) 1041.44 lb ft) 1304 716 - 872 N·m 598 - 736 N·m 1549 - 1903 N·m 1598 N·m M33 X (1142.48 (441.06 (528.09 (961.78 3.5 1403.58 lb ft) 542.85 lb ft) 643.20 lb ft) 1178.62 lb ft) 1677 932 - 1128 N·m 775 - 951 N·m 2000 - 2452 N·m 2049 N·m (1475.12 (571.61 (687.41 M36 X 4 (1236.89 1808.5 lb ft) 701.42 lb ft) 831.97 lb ft) 1511.26 lb ft)

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15.6 - 19.2 N·m (11.51 - 14.16 lb ft) 38.3 - 46.1 N·m (28.25 - 34.00 lb ft) 74.6 - 92.2 N·m (55.02 - 68.00 lb ft) 128 - 158 N·m (94.41 116.53 lb ft) 206 - 246 N·m (151.94 181.44 lb ft) 304 - 382 N·m (224.22 281.75 lb ft) 432 - 530 N·m (318.63 390.91 lb ft) 598 - 736 N·m (441.06 542.846 lb ft) 814 - 990 N·m (600.38 730.19 lb ft) 1042 - 1278 N·m (768.54 942.60 lb ft) 1533 - 1867 N·m (1130.68 1377.03 lb ft) 2065 - 2535 N·m (1523.07 1869.72 lb ft)

Oil lubrication 13.2 - 16.2 N·m (9.74 - 11.95 lb ft) 31.4 - 39.2 N·m (23.16 - 28.91 lb ft) 63.7 - 77.5 N·m (46.98 - 57.16 lb ft) 109 - 133 N·m (80.39 - 98.10 lb ft) 172 - 210 N·m (126.86 154.89 lb ft) 255 - 313 N·m (188.08 230.86 lb ft) 363 - 441 N·m (267.74 325.26 lb ft) 500 - 618 N·m (368.78 455.813 lb ft) 677 - 833 N·m (499.33 614.39 lb ft) 843 - 1039 N·m (621.76 766.33 lb ft) 1233 - 1507 N·m (909.41 1111.51 lb ft) 1744 - 2136 N·m (1286.31 1575.43 lb ft)

2796 - 3424 N·m 2345 - 2875 N·m (1729.58 (2062.22 2120.49 lb ft) 2525.41 lb ft) 3608 - 4412 N·m 3027 - 3693 N·m (2232.60 (2661.12 2723.82 lb ft) 3254.12 lb ft)

INTRODUCTION

Metric coarse thread standard tightening torque values. Be certain to tighten all capscrews and nuts to proper torque values Classifi4.8T cation Nominal dimen- No lubrication Oil lubrication sion 8.5 - 10.5 N·m 10.2 M8 X 1 12.4 N·m (7.52 (6.27 - 7.74 lb ft) - 9.15 lb ft) 20.6 16.8 - 20.5 N·m 24.6 N·m M10 X (12.39 - 15.12 lb (15.19 1.25 ft) 18.14 lb ft) 35.3 30.4 - 36.2 N·m 43.1 N·m M12 X (22.42 - 26.70 lb (26.04 1.25 ft) 31.79 lb ft) 83.4 - 101 N·m 69.7 - 85.3 N·m (51.41 - 62.91 lb (61.51 M16 X 1.5 ft) 74.49 lb ft) 167 - 205 N·m 139 - 171 N·m (102.52 (123.17 M20 X 1.5 126.12 lb ft) 151.2 lb ft) 285 - 343 N·m 236 - 294 N·m (174.06 (210.21 M24 X 2 216.84 lb ft) 252.98 lb ft) M30 X 2

578 - 696 N·m (426.31 513.34 lb ft)

M33 X 2

765 - 941 N·m (564.24 694.05 lb ft)

M36 X 3

962 1178 N·m (709.53 868.85 lb ft)

7T No lubrication

10.9T Oil lubrication No lubrication

Oil lubrication

22.5 - 26.5 N·m 18.6 - 22.6 N·m 40.2 - 48.0 N·m 33.6 - 41.2 N·m (16.6 - 19.55 lb (5.38 - 6.56 lb (29.65 - 35.4 lb (24.78 - 30.39 lb ft) ft) ft) ft) 43.2 - 53.0 N·m 37.3 - 45.1 N·m 78.5 - 96.1 N·m 66.6 - 80.4 N·m (57.90 - 70.88 lb (49.12 - 59.3 lb (27.51 (31.86 - 39.09 lb ft) ft) 33.26 lb ft) ft) 116 - 142 N·m 76.5 - 94.1 N·m 64.7 - 78.5 N·m 138 - 170 N·m (85.56 - 104.73 lb (101.78 (47.72 (56.42 - 69.40 lb ft) 125.39 lb ft) 57.90 lb ft) ft)

152 - 186 N·m 324 - 402 N·m (238.97 (112.11 296.5 lb ft) 137.19 lb ft) 304 - 362 N·m 657 - 795 N·m (484.58 (224.22 586.36 lb ft) 267.00 lb ft) 510 - 628 N·m 1122 - 1358 N·m (827.54 (376.16 1001.61 lb ft) 463.19 lb ft) 1039 2245 481 - 579 N·m 1253 - 1527 N·m 1275 N·m 2755 N·m (354.77 (924.17 (766.33 (1655.83 427.05 lb ft) 1126.26 lb ft) 940.39 lb ft) 2031.98 lb ft) 3016 1395 636 - 776 N·m 1674 - 2046 N·m 3684 N·m 1705 N·m (1234.68 (469.09 (2224.49 (1028.90 1509.05 lb ft) 572.35 lb ft) 2717.18 lb ft) 1257.54 lb ft) 1744 3778 804 - 980 N·m 2104 - 2556 N·m 2136 N·m 4622 N·m (593.00 (1551.83 (1286.31 (2786.51 722.81 lb ft) 1885.21 lb ft) 1575.43 lb ft) 3409.01 lb ft) 176 - 216 N·m (129.81 159.31 lb ft) 363 - 441 N·m (267.74 325.26 lb ft) 617 - 755 N·m (455.08 556.86 lb ft)

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275 - 333 N·m (202.83 245.61 lb ft) 549 - 667 N·m (404.92 491.95 lb ft) 932 - 1128 N·m (687.41 831.97 lb ft) 1874 - 2286 N·m (1382.19 1686.07 lb ft) 2515 - 3065 N·m (1854.97 2260.63 lb ft) 3147 - 3853 N·m (2321.11 2841.83 lb ft)

INTRODUCTION

Application of screw locking and sealing compounds Service LOCTITE速 LOCTITE速 LOCTITE速 LOCTITE速

Screw locking compound Sealing compound

242 262 271 515

Features Low strength Middle strength High strength Sealing

Screw and tool sizes Edge bolt Nominal screw size (d) M6 M8 M10 M12 M16 M20

B Tool size 10 mm 13 mm 17 mm 19 mm 24 mm 30 mm

Nominal screw size (d) M24 M30 M36 M42 M48

B Tool size 36 mm 46 mm 55 mm 65 mm 75 mm

TULI12EXN4033AB

TULI12EXN4034AB

Capscrew (socket bolt) Nominal screw size (d) M6 M8 M10 M12 M14 M16 M18

B Tool size 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 14 mm

Nominal screw size (d) M20 M24 M30 M36 M42 M48

B Tool size 17 mm 19 mm 22 mm 27 mm 32 mm 36 mm

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INTRODUCTION

Torque specifications for joints and hoses Joints for piping (with O-ring) Nominal screw size (PF)

Wrench size

1/8

14 mm

1/4

19 mm

3/8

22 mm

1/2

27 mm

3/4

36 mm

41 mm

Tightening torque 17 N·m (12.5 lb ft) ± 2 N·m (1.5 lb ft) 36 N·m (26.6 lb ft) ± 2 N·m (1.5 lb ft) 74 N·m (54.6 lb ft) ± 5 N·m (3.7 lb ft) 108 N·m (79.7 lb ft) ± 9.8 N·m (7.2 lb ft) 162 N·m (119.5 lb ft) ± 9.8 N·m (7.2 lb ft) 255 N·m (188.1 lb ft) ± 9.8 N·m (7.2 lb ft)

SMIL13MEX0048XA

SMIL13MEX0049XA

Hydraulic hose ( 30 °C flare type) Nominal screw size (PF)

Wrench size

1/8

17 mm

1/4

19 mm

3/8

22 mm

1/2

27 mm

3/4

36 mm

41 mm

Tightening torque 15 N·m (11.1 lb ft) ± 2.0 N·m (1.5 lb ft) 29 N·m (21.4 lb ft) ± 4.9 N·m (3.6 lb ft) 49 N·m (36.1 lb ft) ± 4.9 N·m (3.6 lb ft) 78 N·m (57.5 lb ft) ± 4.9 N·m (3.6 lb ft) 118 N·m (87.0 lb ft) ± 9.8 N·m (7.2 lb ft) 137 N·m (101.0 lb ft) ± 15 N·m (11.1 lb ft)

NOTE: The application of the tightening torque is subject to a dry condition.

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INTRODUCTION

Torque specifications for sleeve type tube fitting Sleeve type tube fittings Tube size Outside diameter x thickness 10 mm (0.4 in) x 1.5 mm (0.1 in)

Wrench size

19 mm

15 mm (0.6 in) x 2.0 mm (0.1 in)

27 mm

18 mm (0.7 in) x 2.5 mm (0.1 in)

32 mm

22 mm (0.9 in) x 3.0 mm (0.1 in)

36 mm

28 mm (1.1 in) x 4.0 mm (0.2 in)

41 mm

35 mm (1.4 in) x 5.0 mm (0.2 in)

55 mm

Tightening torque 44 N·m (32.5 lb ft) ± 4.9 N·m (3.6 lb ft) 147 N·m (108.4 lb ft) ± 20 N·m (14.8 lb ft) 177 N·m (130.5 lb ft) ± 20 N·m (14.8 lb ft) 216 N·m (159.3 lb ft) ± 20 N·m (14.8 lb ft) 275 N·m (202.8 lb ft) ± 29 N·m (21.4 lb ft) 441 N·m (325.3 lb ft) ± 44 N·m (32.5 lb ft)

SMIL13MEX0050XA

47574272B 24/03/2014

INTRODUCTION

Basic instructions - How to use maintenance standards and precautions Application 1. For new machine; his manual is to be used to check the actual performance and functions of the machine compared with the PERFORMANCE STANDARDS. 2. At specific self-inspection (as per LOCAL RULES); The maintenance standards are used to make them as the criteria to determine the time for reconditioning, adjustment and replacement. 3. At deterioration of performance; This manual is of the criteria of safe and economical judgment whether the deterioration of performance on the machine would be caused by any faults or normal deterioration due to machine operation for a long period. 4. For replacement of major components: This manual is of the standard to determine the time for replacement to recover the performance of major components such as pump, etc.

Terminology 1. Standard values: These are of the standard values to assemble and regulate a new machine. Where special notes are not given, these values are based on the machine with standard structure (the machine with standard attachments and shoes). 2. Standard values for repair: These are of the values at which the reconditioning is required. In order to ensure the performance and safety, it is strictly prohibited to use the machine with the parts and components being over the standard values. 3. Serviceability limit: This is of the service limit for each part and component at which the reconditioning is impossible and they must be replaced to new ones. All the parts and components which are estimated to exceed the serviceability limit up to the next periodical inspection and maintenance, should be also replaced to new ones. The machine operation with the parts and components which have exceeded the serviceability limit, causes increase of troubles and down time of the machine, and also causes safety problems.

Precautions for judgment 1. Evaluation for measured data: It is inevitable some variation on the measured data due to differences between measuring conditions, peculiar variability on a new machine, old and new versions of the machine and measuring characteristics. The judgment for the measured data should be comprehensively conducted based on the extent of level of the measured data, instead of mere comparison with the standard values. 2. Determination for reconditioning, adjustment or replacement: There are two kinds of deterioration of machine performance; one is due to normal wear with time elapsing of operation, and the other is recoverable to the standard values with the adjustment for pressure, etc. Therefore, the determination for reconditioning, adjustment or replacement should be conducted taking various factors into consideration such as operating hours, working conditions and maintenance conditions of the machine, so that the machine is able to be operated at the optimum performance level.

Other precautions 1. Parts with aging effect: The rubber products such as hydraulic hoses, O-rings, oil seals, etc. are deteriorated with the aging effect. It is necessary to replace them to new ones at periodical intervals or at every overhaul. 2. Parts required periodical replacement: It is recommendable to designate the important hoses critical to secure the safety as Very Important Parts (V.I.P.), and periodically replace with new ones.

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INTRODUCTION

3. Inspection and replacement of lubricants: It is necessary for the user of the machine to fully familiarize himself with the procedures and precautions to handle the machine in safe and carry out the maintenance, as well as the procedures for inspection and lubrication. Refer to the OPERATION AND MAINTENANCE MANUAL as well.

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INTRODUCTION

General specification Speed and gradeability Detail

Rubber crawler

Rotation speed Travel speed

Low (1st) 2.5 km/h (1.6 mph)

Gradient

Steel crawler 8.9 RPM High (2nd) Low (1st) High (2nd) 4.5 km/h 2.5 km/h 4.5 km/h (2.8 mph) (1.6 mph) (2.8 mph) 58 % ( 30 ° )

Engine Model Type Number of cylinders-bore x stroke Total displacement Rated output Maximum torque Starter Generator

YANMAR 3TNV88-PYB Vertical, 4-cycle water-cooled diesel engine 3 - ø 88 mm (3.5 in) x 90 mm (3.5 in) 1.642 l (0.43 US gal) 21.2 kW (28.8 Hp) / 2400 RPM 98.4 N·m (72.6 lb ft) / 1440 RPM 12 V x 1.7 kW (2.3 Hp) 12 V x 55 A

Hydraulic components Hydraulic pump Hydraulic motor Hydraulic motor with reduction gear (travel) Control valve Cylinder (boom, arm, swing, bucket, dozer) Return filter

Variable displacement axial piston + gear pump Axial piston 2-axial pistons, 2-speed motor 10-spools multiple control valve Double action cylinder Safety valve containing/filter type (30μ)

Swing and dozer Type Boom swing angle Dozer stroke (up/down)

Boom swing by hydraulic cylinder 60 ° 70 ° 560 mm (22 in) / 410 mm (16 in) 540 mm (21.3 in) / 440 mm (17.3 in)

Right Left CX35B CX39B

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INTRODUCTION

Operating mass Models

Versions

CX35B CX35B CX39B CX39B

Canopy Cab Canopy Cab

Rubber belt Long arm Standard counterweight Big bucket ( 84 kg (185 lb)) Fuel ( 42 kg (93 lb)) Operator ( 75 kg (165 lb))

Operating mass ISO 6016* 3360 kg (7408 lb) 3500 kg (7716 lb) 3760 kg (8289 lb) 3900 kg (8598 lb)

* The operating mass is measured with this configuration

Additional mass Models

Versions

CX35B CX35B CX39B CX39B

Canopy Cab Canopy Cab

Differential of rubber-steel crawler 100 kg (220.5 lb) 100 kg (220.5 lb) 100 kg (220.5 lb) 100 kg (220.5 lb)

Differential of long-short arm

Additional counterweight

Front guard

-18 kg (-39.7 lb) -18 kg (-39.7 lb) -16 kg (-35.3 lb) -16 kg (-35.3 lb)

250 kg (551 lb) 250 kg (551 lb) 250 kg (551 lb) 250 kg (551 lb)

– 18 kg (39.7 lb) – 18 kg (39.7 lb)

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INTRODUCTION

Weight CX35B Model Complete machine (Operating mass ISO 6016) Superstructure assembly Upper frame Canopy / cab Engine Hydraulic pump Radiator Hydraulic tank Fuel tank Swing bracket Swing cylinder Swing motor Control valve Counterweight Guards, bonnets Boom cylinder Lower structure assembly Lower structure Fittings Travel motor Lower roller Idle wheel Idler adjuster Sprocket

Rubber track Canopy Cab

Steel track Canopy

Cab

3360 kg (7408 lb) 3500 kg (7716 lb) 3460 kg (7628 lb) 3600 kg (7937 lb)

1650 kg (3638 lb) 1790 kg (3946 lb) 1650 kg (3638 lb) 1790 kg (3946 lb) ← ← ← 375 kg (827 lb) 85 kg (187 lb) 220 kg (485 lb) 85 kg (187 lb) 220 kg (485 lb) ← ← ← 155 kg (342 lb) ← ← ← 28 kg (62 lb) ← ← ← 3 kg (176 lb) ← ← ← 42 kg (93 lb) ← ← ← 4 kg (176 lb) ← ← ← 93 kg (205 lb) ← ← ← 37 kg (82 lb) ← ← ← 38 kg (84 lb) ← ← ← 25 kg (55 lb) ← ← ← 380 kg (838 lb) ← ← ← 92 kg (203 lb) ← ← ← 35 kg (77 lb) ← ← 1060 kg (2337 lb) 1160 kg (2557 lb) ← ← ← 310 kg (683 lb) ← ← ← 42 kg (93 lb) ← ← ← 42 kg (93 lb) x 2 ← ← ← 6 kg (13 lb) x 8 ← ← ← 27 kg (60 lb) x 2 ← ← ← 14 kg (31 lb) x 2 ← ← ← 9 kg (20 lb) x 2 131 kg (289 lb) x ← – ← Rubber track 2 – – – 178 kg (392 lb) x 2 Steel track ← ← ← Rotary control valve 22 kg (49 lb) ← ← ← 145 kg (320 lb) Dozer blade ← ← ← Dozer blade cylinder 27 kg (60 lb) ← ← ← Attachment assembly 370 kg (816 lb) ← ← ← Boom assembly 170 kg (375 lb) ← ← ← 123 kg (271 lb) Boom ← ← ← Arm cylinder 31 kg (68 lb) ← ← ← Arm assembly [ 1.47 m (4.82 ft)] 120 kg (265 lb) ← ← ← 84 kg (185 lb) Arm ← ← ← Bucket cylinder 22 kg (49 lb) ← ← ← 10 kg (22 lb) Bucket links ← ← ← 4 kg (9 lb) x 2 Idler link ← ← ← Bucket assembly (standard) 76 kg (168 lb) ← ← ← Fluids assembly 80 kg (176 lb) ← ← ← Hydraulic oil 42 kg (93 lb) ← ← ← 32 kg (71 lb) Fuel ← ← ← 4 kg (9 lb) Coolant NOTE: Bucket weight is shown with standard bucket weight.

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INTRODUCTION

CX39B Model Complete machine (Operating mass ISO 6016) Superstructure assembly Upper frame Canopy / cab Engine Hydraulic pump Radiator Hydraulic tank Fuel tank Swing bracket Swing cylinder Swing motor Control valve Counterweight Guards, bonnets Boom cylinder Lower structure assembly Lower structure Fittings Travel motor Lower roller Idle wheel Idler adjuster Sprocket Rubber track Steel track Rotary control valve Dozer blade Dozer blade cylinder Attachment assembly Boom assembly Boom Arm cylinder Arm assembly [ 1.59 m (5.22 ft)] Arm Bucket cylinder Bucket links Idler link Bucket assembly (standard) Fluids assembly Hydraulic oil Fuel Coolant

Rubber track Canopy Cab

Steel track Canopy

Cab

3760 kg (8289 lb) 3900 kg (8598 lb) 3860 kg (8510 lb) 4000 kg (8818 lb) 1900 kg (4189 lb) 2040 kg (4497 lb) 1900 kg (4189 lb) 2040 kg (4497 lb) ← ← ← 375 kg (827 lb) 85 kg (187 lb) 220 kg (485 lb) 85 kg (187 lb) 220 kg (485 lb) ← ← ← 155 kg (342 lb) ← ← ← 28 kg (62 lb) ← ← ← 3 kg (176 lb) ← ← ← 42 kg (93 lb) ← ← ← 4 kg (176 lb) ← ← ← 93 kg (205 lb) ← ← ← 37 kg (82 lb) ← ← ← 38 kg (84 lb) ← ← ← 25 kg (55 lb) ← ← ← 680 kg (1499 lb) ← ← ← 92 kg (203 lb) ← ← ← 35 kg (77 lb) ← ← 1160 kg (2557 lb) 1260 kg (2778 lb) ← ← ← 370 kg (816 lb) ← ← ← 42 kg (93 lb) ← ← ← 42 kg (93 lb) x 2 ← ← ← 6 kg (13 lb) x 8 ← ← ← 27 kg (60 lb) x 2 ← ← ← 14 kg (31 lb) x 2 ← ← ← 9 kg (20 lb) x 2 ← – ← 141 kg (311 lb) x 2 – – – 191 kg (421 lb) x 2 ← ← ← 22 kg (49 lb) ← ← ← 155 kg (342 lb) ← ← ← 27 kg (60 lb) ← ← ← 460 kg (1014 lb) ← ← ← 184 kg (406 lb) ← ← ← 140 kg (309 lb) ← ← ← 34 kg (75 lb) ← ← ← 140 kg (309 lb) ← ← ← 93 kg (205 lb) ← ← ← 22 kg (49 lb) ← ← ← 10 kg (22 lb) ← ← ← 4 kg (9 lb) x 2 ← ← ← 82 kg (181 lb) ← ← ← 80 kg (176 lb) ← ← ← 42 kg (93 lb) ← ← ← 32 kg (71 lb) ← ← ← 4 kg (9 lb)

NOTE: Bucket weight is shown with standard bucket weight.

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INTRODUCTION

Capacities Component to be filled

Quantity

Consumable

Engine oil pan

2.8 - 6.7 l (0.74 1.77 US gal)

CASE AKCELA NO. 1™ ENGINE OIL SAE 10W-30 CASE AKCELA NO. 1™ ENGINE OIL SAE 15W-40

Travel motor Upper rollers Idler wheels Radiator (1) Fuel tank Hydraulic oil tank (2) Attachment and dozer pin Swing cylinder pin Slewing bearing Idler adjuster Operating lever and pedal Rotation gear Air conditioning Compressor

0.7 l (0.18 US gal) CASE AKCELA GEAR 45 cm³ 135 H EP 80W-90 (2.75 in³) 80 cm³ (4.88 in³) 1.6 l CASE AKCELA (0.42 US PREMIUM ORGANIC gal) ANTI-FREEZE 38 l (10 US — gal) 38 l (10 US AKCELA HYDRAULIC gal) EXCAVATOR FLUID

Manufacturer specifications

International specifications

MS 1121 API CI 4/CH-4 ACEA E7/E5 MS 1121

MS 1316

API GL 5

—

ASTM D 3306

—

EN 590

MS 1230

—

AKCELA Multi purpose grease

251 H EP

NLGI 2

AKCELA Moly grease

251 H EP-M

NLGI 2

R134A

—

SANDEN SP-10 LUBRICANT

—

20 places 1 place 2 place — 1 place 0.7 kg (1.54 lb) 120 cm³ (7.32 in³)

NOTE: (1) Coolant to be mixed with water at 50 %. Cooling system total volume: ~ 4.6 l (1.22 US gal) NOTICE: (2) Hydraulic system total volume: ~ 54.4 l (14.37 US gal). If the machine was filled with biodegradable hydraulic oil PANOLIN HLP SYNTH 46 (option), take note that this oil cannot be mixed with mineral hydraulic oil.

Temperature operating ranges

Engine Travel motor, upper rollers and idler wheels Hydraulic system

Consumable CASE AKCELA NO. 1™ ENGINE OIL CASE AKCELA GEAR 135 H EP 80W-90 AKCELA HYDRAULIC EXCAVATOR FLUID

Viscosity SAE 10W-30 SAE 15W-40

Temperature operating range -25 °C - +25 °C -15 °C - +40 °C

SAE 80W-90

-25 °C - +45 °C

ISO VG 46

-20 °C - +50 °C

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INTRODUCTION

Use of biodegradable oils When you use biodegradable oil, please refer to following: • There are two types of biodegradable oil available: vegetable-based and synthetic-based. We recommend using synthetic oils, because vegetable ones have a maximum operating temperature of 80 °C (176 °F). For this reason, the degradation of vegetable-based oil occurs more rapidly, and they have a reduced service life. • Do not mix bio-oil with original factory-filled mineral oil; in case it is necessary to use bio-oil, flush the hydraulic system that was filled with bio-oil three times. • If you use bio-oil, the performance of the rotation brake and that of the parking/travel brake will be reduced, because of the lower friction factor of bio-oil compared to that of mineral oil.

Use of coolant • There are two types of coolant depending on the corrosion inhibitors base: ORGANIC-base and INORGANIC base. • Mini excavators is ORGANIC-base type factory filled. • Both type can be used, BUT THEY CANNOT BE MIXED. Flush the cooling system before change coolant type.

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INTRODUCTION

Product identification Machine identification plate 1. Commercial name 2. Product identification number 3. Operating mass 4. Engine power ( ISO 14396) 5. Year of construction 6. Machine category (Hydraulic excavator <6t)

SMIL13MEX0016AB

SMIL13MEX0017AB

Engine identification plate 7.

Engine model

Output

Displacement

10. Engine number

Hour counter

LELI11E0004AB

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INTRODUCTION

Tip/Roll Over Protective Structure (TOPS/ ROPS) and Falling Object Protective Structure (FOPS) (1) identification plate in the cab (2) identification plate on the canopy

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LELI11E0006BB

LELI11E0189AB

INTRODUCTION

Product identification - Machine orientation The terms right-hand, left-hand, front, and rear are used in this manual to indicate the sides as they are seen from the operator seat when the travel motors are positioned at the rear and the operator is facing the direction in which the machine advances (forward). A B C D E

Front of machine Rear of machine Left side of machine Right side of machine Travel motor

SMIL13MEX0002AB

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INTRODUCTION

Part identification

TULI12EXN6006GB

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Engine Oil filter Radiator Reservoir tank Air cleaner Muffler Fuel tank Hydraulic oil tank Hydraulic pumps Slewing motor Swing cylinder Control valve Travel lever

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Safety lever Canopy Operating lever Dozer control lever Throttle lever Gauge cluster Battery Swivel joint Travel motor Slewing ring Idler adjuster Lower roller Upper roller

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27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Rubber crawler Dozer Dozer cylinder Boom Boom cylinder Arm cylinder Light Arm Link Bucket cylinder Bucket

SERVICE MANUAL Engine CX35B CX39B

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

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Engine - 10 Engine and crankcase - 001

CX35B CX39B

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine and crankcase Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 General specification - 3TNV88A-PYB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FUNCTIONAL DATA Engine External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SERVICE Engine Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspect - Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Inspect – Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Inspect – Every 250 hours or 3 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Inspect – Every 500 hours or 6 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Inspect – Every 1000 hours or one year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Inspect – Every 2000 hours or 2 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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Engine - Engine and crankcase

Engine and crankcase - Torque Tightening torques for main bolts and nuts Part

Engine model

Thread diameter x Tightening torque pitch

3TNV82A

M9 X 1.25

TNV84~88

M10 X 1.25

4TNV94L·98

M11 X 1.25

4TNV106(T)

M13 X 1.5

3TNV82A

M8 X 1.0

TNV84~88

M9 X 1.0

4TNV94L·98

M10 X 1.0

4TNV106(T)

M11X1.0

TNV82A~88

M10 X 1.25

4TNV94L·98·106(T)

M14 X 1.5

3TNV82A

M10 X 1.25

TNV84~88

M12 X 1.5

4TNV94L·98

M11 X 1.25

4TNV106(T)

M14 X 1.5

TNV82A~88

M14 X 1.5

4TNV94L·98·106(T)

M14 X 1.5

TNV82A~88

M8 X 1.25

4TNV94L·98·106(T)

M8 X 1.25

TNV82A~88

M14 X 1.5

Cylinder head screws

Connecting rod bolt

Flywheel set bolt

Bearing cap set bolt

Crankshaft pulley set bolt

Fuel nozzle setscrew

Fuel pump drive gear set nut

4TNV94L·98·106(T)

M18 X 1.5

TNV82A~88

M12 X 1.5

4TNV94L·98·106(T)

M12 X 1.5

Fuel return pipe joint bolt 4TNV94L·98·106(T)

M6 X 1.0

Rocker arm cover set bolt

4TNV106(T)

M8 X 1.25

EPA flange setscrew

4TNV106(T)

M18 X 1.5

Fuel injection pipe set bolt

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61.7 - 65.7 N·m (45.5 - 48.5 lb ft) 85.3 - 91.1 N·m (62.9 - 67.2 lb ft) 103.1 - 112.9 N·m (76.0 - 83.3 lb ft) 188.0 - 197.8 N·m (138.7 - 145.9 lb ft) 37.2 - 41.2 N·m (27.4 - 30.4 lb ft) 44.1 - 49 N·m (32.5 - 36.1 lb ft) 53.9 - 58.8 N·m (39.8 - 43.4 lb ft) 78.5 - 83.4 N·m (57.9 - 61.5 lb ft) 83.3 - 88.2 N·m (61.4 - 65.1 lb ft) 186.2 - 205.8 N·m (137.3 - 151.8 lb ft) 76.4 - 80.4 N·m (56.3 - 59.3 lb ft) 93.2 - 98.1 N·m (68.7 - 72.4 lb ft) 108.1 - 117.9 N·m (79.7 - 87.0 lb ft) 186.2 - 205.8 N·m (137.3 - 151.8 lb ft) 112.7 - 122.7 N·m (83.1 - 90.5 lb ft) 107.9 - 127.5 N·m (79.6 - 94.0 lb ft) 24.4 - 28.4 N·m (18.0 - 20.9 lb ft) 22.6 - 28.4 N·m (16.7 - 20.9 lb ft) 78 - 88 N·m (57.5 64.9 lb ft) 113 - 123 N·m (83.3 - 90.7 lb ft) 29.4 - 34.3 N·m (21.7 - 25.3 lb ft) 19.6 - 24.5 N·m (14.5 - 18.1 lb ft) 7.8 - 9.8 N·m (5.8 7.2 lb ft) 16.7 - 22.5 N·m (12.3 - 16.6 lb ft) 113 - 123 N·m (83.3 - 90.7 lb ft)

Lubricating oil application (thread portion, and seat surface)

Applied

Not applied

Not applied Not applied Not applied

Engine - Engine and crankcase

Tightening torques for standard bolts and nuts Piece

Nominal thread diameter x pitch M6 X 1 M8 X 1.25 M10 X 1.5

Hexagon bolt (7T) and nut M12 X 1.75 M14 X 1.5 M16 X 1.5

Plug

PT 1/8 PT 1/4 PT 3/8 PT1/2 M8 M10

Pipe joint bolt

M12 M14 M16

Tightening torque

Observations

9.8 - 11.8 N·m (7.2 - 8.7 lb ft) 22.6 - 28.4 N·m (16.7 20.9 lb ft) 44.1 - 53.9 N·m (32.5 39.8 lb ft) 78.4 - 98 N·m (57.8 - 72.3 lb ft) 127.5 - 147.1 N·m (94.0 108.5 lb ft) 215.7 - 235.4 N·m (159.1 173.6 lb ft) 9.8 N·m (7.2 lb ft) 19.6 N·m (14.5 lb ft) 29.4 N·m (21.7 lb ft) 58.8 N·m (43.4 lb ft) 12.7 - 16.7 N·m (9.4 - 12.3 lb ft) 19.6 - 25.4 N·m (14.5 18.7 lb ft) 24.5 - 34.3 N·m (18.1 25.3 lb ft) 39.2 - 49.0 N·m (28.9 36.1 lb ft) 49.0 - 58.8 N·m (36.1 43.4 lb ft)

Use 80% of the value at left when the tightening part is aluminum. Use 60% of the value at left for 4T bolts and lock nuts.

NOTE: Lubricating oil is not applied to threaded portion and seat surface.

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Engine - Engine and crankcase

Engine - General specification Engine nomenclature

TULI12EXN4778FA

Engine specification class Classification CL VL

Load Constant load Variable load

Engine speed Constant speed Variable speed

Available engine speed 1500 - 1800 RPM 2000 - 3000 RPM

* The engine specification class (CL or VL) is described in the specifications table.

Engine specification 1. The information described in the engine specifications tables (the next page and after) is for standard engine. To obtain the information about the engine installed in each machine, refer to the manual provided by the Manufacturer. 2. Engine rating conditions are as follows ( SAE J1349, ISO 3046/1) • Atmospheric condition: Ambient temperature 25 °C (77 °F), atmospheric pressure 100 kPa (1 bar), relative humidity 30% • Fuel temperature: 25 °C (77 °F) (fuel injection pump inlet) • With cooling fan, air cleaner, exhaust silencer ( Yanmar standard part) • After running-in hours. Output allowable deviation: ± 3 %

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Engine - Engine and crankcase

3TNV82A Engine name Engine specification class Type Combustion chamber Number of cylinders Cylinder bore stroke Displacement Rotation Continu- speed ous rating Output

3TNV82A VL

Vertical, in-line, 4-cycle, water-cooled diesel engine Direct injection 3 82 mm (3.2 in) x 84 mm (3.3 in) 1.331 l (0.4 US gal) 1500 RPM 9.9 kW (13.5 Hp) 1500 RPM

1800 – RPM 12.0 kW – (16.3 Hp) Rotation 1800 2000 2200 2400 2500 2600 2800 3000 speed RPM RPM RPM RPM RPM RPM RPM RPM Rated 13.2 kW 14.6 kW 16.0 kW 17.5 kW 18.2 kW 19.0 kW 20.4 kW 21.9 kW output 11.0 kW (29.8 (27.7 (25.8 (24.7 (23.8 (21.8 (19.9 (17.9 Output (15 Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Maximum no-load 1600 1895 2180 2375 2570 2675 2780 2995 3180 speed (±25) RPM RPM RPM RPM RPM RPM RPM RPM RPM Order of ignition 1-3-2-1(No. 1 cylinder on flywheel side) Flywheel Power take-off Rotating direction Counterclockwise (viewed from flywheel) Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Electrical system Starting system ASTM fuel No. 2-D type TT Appropriate fuel CASE AKCELA Applicable lubricant ENGINE OIL CASE AKCELA ENGINE OIL 10W-30 15W-40 Lubricant Total 3.6 l (1.0 US gal) 5.5 l (1.5 US gal) capacity 1.2 l (0.3 US gal) 2.2 l (0.6 US gal) (oil pan)* Effective Coolant volume 1.8 l (0.5 US gal) (engine only) Engine Overall 553 mm (21.8 in) 528 mm (20.8 in) dimenlength sions ** Overall 489 mm (19.3 in) (with width crankshaft Vpulley Overall 565 mm (22.2 in) diameheight ter and housing) Engine mass (dry) ** 138 kg (304.2 lb) 128 kg (282.2 lb) (with flywheel housing) Fan (standard) 335 mm (13.2 in) O/D, 6 blades pusher type Fan V-belt diameter 120 mm (4.7 in) x 110 mm (4.3 in) x 110 mm (4.3 in) (standard) 90 mm (3.5 in) * Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

3TNV84 Engine name 3TNV84 Engine specification VL CL class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion Direct injection chamber Number of cylinders 3 Cylinder bore stroke 84 mm (3.3 in) x 90 mm (3.5 in) Displacement 1.496 l (0.4 US gal) Rotation 1500 1800 – RPM RPM Continu- speed ous rat11.3 kW 13.5 kW ing – (18.4 (15.4 Output Hp) Hp) Rotation 1500 1800 2000 2200 2400 2500 2600 2800 3000 speed RPM RPM RPM RPM RPM RPM RPM RPM RPM Rated 23.0 kW 24.6 kW 12.4 kW 14.8 kW 16.4 kW 18.1 kW 19.7 kW 20.5 kW output 21.3 kW (33.4 (27.9 (31.3 (26.8 (24.6 (22.3 (20.1 (16.86 Output (29 Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Maximum no-load 1600 1895 2180 2400 2590 2690 2810 2995 3210 speed (±25) RPM RPM RPM RPM RPM RPM RPM RPM RPM Order of ignition 1-3-2-1(No. 1 cylinder on flywheel side) Flywheel Power take-off Rotating direction Counterclockwise (viewed from flywheel) Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Electrical system Starting system ASTM fuel No. 2-D type TT Appropriate fuel CASE AKCELA Applicable lubricant ENGINE OIL CASE AKCELA ENGINE OIL 10W-30 15W-40 Lubricant Total 6.7 l (1.8 US gal) capacity 1.9 l (0.5 US gal) (oil pan)* Effective Coolant volume 1.8 l (0.5 US gal) (engine only) Overall Engine 589 mm (23.2 in) 564 mm (22.2 in) length dimensions ** Overall 486 mm (19.1 in) (with fly- width wheel Overall 622 mm (24.5 in) housing) height Engine mass (dry) ** 161 kg (354.9 lb) 155 kg (341.7 lb) (with flywheel housing) Fan (standard) 335 mm (13.2 in) O/D. 6 blades pusher type Crankshaft V pulley 120 mm (4.7 in) x diameter and fan 110 mm (4.3 in) x 110 mm (4.3 in) 90 mm (3.5 in) V-belt diameter (standard) * Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

3TNV84T Engine name 3TNV84T Engine specification VL CL class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion Direct injection chamber Number of cylinders 3 Cylinder bore stroke 84 mm (3.3 in) x 90 mm (3.5 in) Displacement 1.496 l (0.4 US gal) Rotation 1500 1800 – RPM RPM Continu- speed ous rat16.5 kW 14.0 kW ing – (22.4 Output (19 Hp) Hp) Rotation 1500 1800 2000 2200 2400 2500 2600 2800 3000 speed RPM RPM RPM RPM RPM RPM RPM RPM RPM Rated 25.9 kW 26.8 kW 29.1 kW 15.8 kW 18.8 kW output 30.9 kW 25.0 kW (39.6 (36.44 (25.6 (35.2 (21.48 Output (42 Hp) (34 Hp) Hp) Hp) Hp) Hp) Hp) Maximum no-load 1600 1895 2590 2700 2810 2995 3210 speed (±25) RPM RPM RPM RPM RPM RPM RPM Order of ignition 1-3-2-1(No. 1 cylinder on flywheel side) Flywheel Power take-off Rotating direction Counterclockwise (viewed from flywheel) Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Electrical system Starting system ASTM fuel No. 2-D type TT Appropriate fuel CASE AKCELA Applicable lubricant ENGINE OIL CASE AKCELA ENGINE OIL 10W-30 15W-40 Lubricant Total 6.7 l (1.8 US gal) capacity 1.9 l (0.5 US gal) (oil pan)* Effective Coolant volume 2.0 l (0.5 US gal) (engine only) Overall Engine 589 mm (23.2 in) 564 mm (22.2 in) length dimensions ** Overall 486 mm (19.1 in) (with fly- width wheel Overall 622 mm (24.5 in) housing) height Engine mass (dry) ** 161 kg (354.9 lb) 155 kg (341.7 lb) (with flywheel housing) Fan (standard) 350 mm (13.8 in) O/D. 6 blades pusher type Crankshaft V pulley 120 mm (4.7 in) x diameter and fan 110 mm (4.3 in) x 110 mm (4.3 in) 90 mm (3.5 in) V-belt diameter (standard) * Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

3TNV88 Engine name 3TNV82A Engine specification VL CL class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion Direct injection chamber Number of cylinders 3 Cylinder bore stroke 88 mm (3.46 in) x 90 mm (3.54 in) Displacement 1.642 l (0.43 US gal) Rotation 1500 1800 – RPM RPM Continu- speed ous rat12.3 kW 14.8 kW ing – (20.1 (16.72 Output Hp) Hp) Rotation 1500 1800 2000 2200 2400 2500 2600 2800 3000 speed RPM RPM RPM RPM RPM RPM RPM RPM RPM Rated 13.5 kW 16.3 kW 18.0 kW 19.9 kW 21.6 kW 22.6 kW 23.5 kW 25.2 kW 27.1 kW output (36.85 (34.3 (31.95 (30.7 (29.37 (27.1 (24.5 (22.2 (18.35 Output Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Maximum no-load 1600 1895 2180 2400 2590 2700 2810 2995 3210 speed (±25) RPM RPM RPM RPM RPM RPM RPM RPM RPM Order of ignition 1-3-2-1(No. 1 cylinder on flywheel side) Flywheel Power take-off Rotating direction Counterclockwise (viewed from flywheel) Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Electrical system Starting system ASTM fuel No. 2-D type TT Appropriate fuel CASE AKCELA Applicable lubricant ENGINE OIL CASE AKCELA ENGINE OIL 10W-30 15W-40 Lubricant Total 4.7 l (1.2 US gal) 7.2 l (1.9 US gal) capacity 1.8 l (0.5 US gal) 3.5 l (0.9 US gal) (oil pan)* Effective Coolant volume 2.0 l (0.5 US gal) (engine only) Overall Engine 589 mm (23.2 in) 564 mm (22.2 in) length dimensions ** Overall 486 mm (19.1 in) (with fly- width wheel Overall 622 mm (24.5 in) housing) height Engine mass (dry) ** 155 kg (341.7 lb) (with flywheel housing) Fan (standard) 350 mm (13.8 in) O/D. 6 blades pusher type Crankshaft V pulley 120 mm (4.7 in) x diameter and fan 110 mm (4.3 in) x 110 mm (4.3 in) 90 mm (3.5 in) V-belt diameter (standard) * Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

4TNV84 Engine name 4TNV84 Engine specification VL CL class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion Direct injection chamber Number of cylinders 4 Cylinder bore stroke 84 mm (3.31 in) x 90 mm (3.54 in) Displacement 1.995 l (0.53 US gal) Rotation 1500 1800 – RPM RPM Continu- speed ous rat14.9 kW 17.7 kW ing – (24.1 (20.26 Output Hp) Hp) Rotation 1500 1800 2000 2200 2400 2500 2600 2800 3000 speed RPM RPM RPM RPM RPM RPM RPM RPM RPM Rated 16.4 kW 19.5 kW 21.9 kW 24.1 kW 26.3 kW 27.4 kW 28.5 kW 30.7 kW 32.9 kW output (44.73 (41.7 (38.75 (37.3 (35.76 (32.8 (29.8 (26.5 (22.3 Output Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Maximum no-load 1600 1895 2180 2400 2590 2700 2810 2995 3210 speed (±25) RPM RPM RPM RPM RPM RPM RPM RPM RPM Order of ignition 1-3-4-2-1(No. 1 cylinder on flywheel side) Flywheel Power take-off Rotating direction Counterclockwise (viewed from flywheel) Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Electrical system Starting system ASTM fuel No. 2-D type TT Appropriate fuel CASE AKCELA Applicable lubricant ENGINE OIL CASE AKCELA ENGINE OIL 10W-30 15W-40 Lubricant Total 7.4 l (2.0 US gal) capacity 2.3 l (0.6 US gal) (oil pan)* Effective Coolant volume 2.7 l (0.7 US gal) (engine only) Overall Engine 683 mm (26.9 in) 658 mm (25.9 in) length dimensions ** Overall 498.5 mm (19.6 in) (with fly- width wheel Overall 617 mm (24.3 in) housing) height Engine mass (dry) ** 183 kg (403.4 lb) 170 kg (374.8 lb) (with flywheel housing) Fan (standard) 370 mm (14.6 in) O/D. 6 blades pusher type Crankshaft V pulley 120 mm (4.7 in) x diameter and fan 110 mm (4.3 in) x 110 mm (4.3 in) 90 mm (3.5 in) V-belt diameter (standard) * Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

4TNV84T Engine name Engine specification class Type Combustion chamber Number of cylinders Cylinder bore stroke Displacement Rotation speed Continuous rating Output

Rated output

Rotation speed Output

Maximum no-load speed (±25) Order of ignition Power take-off Rotating direction Cooling system Lubrication system Starting system Appropriate fuel Applicable lubricant Lubricant Total capacity (oil pan)* Effective Coolant volume (engine only) Overall Engine di- length mensions Overall ** (with width flywheel housing) Overall height Engine mass (dry) ** (with flywheel housing) Fan (standard) Crankshaft V pulley diameter and fan V-belt diameter (standard)

4TNV84T VL

Vertical, in-line, 4-cycle, water-cooled diesel engine Direct injection 4 84 mm (3.31 in) x 90 mm (3.54 in) 1.995 l (0.53 US gal) 1500 RPM 19.1 kW (25.97 Hp) 1500 RPM

1800 RPM

–

24.3 kW (33.0 Hp)

–

1800 RPM

2000 RPM

2200 RPM

2400 2600 2800 RPM RPM RPM 33.5 kW 35.7 kW 38.6 kW 21.3 kW 26.9 kW 27.9 kW 30.5 kW (48.54 (45.55 (52.5 Hp) (29.0 Hp) (36.6 Hp) (37.9 Hp) (41.5 Hp) Hp) Hp) 1600 1895 2180 2400 2590 2810 2995 RPM RPM RPM RPM RPM RPM RPM 1-3-4-2-1(No. 1 cylinder on flywheel side) Flywheel Counterclockwise (viewed from flywheel) Radiator Forced lubrication with trochoid pump Electrical system ASTM fuel No. 2-D type TT CASE AKCELA CASE AKCELA ENGINE OIL 10W-30 ENGINE OIL 15W-40 7.4 l (1.95 US gal) 3.4 l (0.90 US gal) 2.7 l (0.70 US gal) 683 mm (26.9 in)

649 mm (25.6 in) 498.5 mm (19.6 in) 713 mm (28.1 in)

183 kg (403.4 lb)

170 kg (374.8 lb) 370 mm (14.6 in) O/D. 6 blades pusher type

120 mm (4.7 in) x 90 mm (3.5 in)

110 mm (4.3 in) x 110 mm (4.3 in)

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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3000 RPM 41.2 kW (56.02 Hp) 3210 RPM

Engine - Engine and crankcase

4TNV88 Engine name 4TNV88 Engine specification VL CL class Type Vertical, in-line, 4-cycle, water-cooled diesel engine Combustion Direct injection chamber Number of cylinders 4 Cylinder bore stroke 88 mm (3.46 in) x 90 mm (3.54 in) Displacement 2.190 l (0.58 US gal) Rotation 1500 1800 – RPM RPM Continu- speed ous rat16.4 kW 19.6 kW ing – (26.6 (22.3 Output Hp) Hp) Rotation 1500 1800 2000 2200 2400 2500 2600 2800 3000 speed RPM RPM RPM RPM RPM RPM RPM RPM RPM Rated 18.0 kW 21.6 kW 24.1 kW 26.5 kW 28.8 kW 30.1 kW 31.3 kW 33.7 kW 35.4 kW output (48.13 (45.8 (42.56 (40.92 (39.16 (36.0 (32.8 (29.4 (24.5 Output Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Hp) Maximum no-load 1600 1895 2180 2400 2590 2700 2810 2995 3210 speed (±25) RPM RPM RPM RPM RPM RPM RPM RPM RPM Order of ignition 1-3-4-2-1(No. 1 cylinder on flywheel side) Flywheel Power take-off Rotating direction Counterclockwise (viewed from flywheel) Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Electrical system Starting system ASTM fuel No. 2-D type TT Appropriate fuel CASE AKCELA Applicable lubricant ENGINE OIL CASE AKCELA ENGINE OIL 10W-30 15W-40 Lubricant Total 5.8 l (1.53 US gal) 8.6 l (2.27 US gal) capacity 2.3 l (0.61 US gal) 4.2 l (1.11 US gal) (oil pan)* Effective Coolant volume 2.7 l (0.70 US gal) (engine only) Overall Engine 683 mm (26.9 in) 658 mm (25.9 in) length dimensions ** Overall 498.5 mm (19.6 in) (with fly- width wheel Overall 618 mm (24.3 in) housing) height Engine mass (dry) ** 183 kg (403.4 lb) 170 kg (374.8 lb) (with flywheel housing) Fan (standard) 370 mm (14.6 in) O/D. 6 blades pusher type Crankshaft V pulley 120 mm (4.7 in) x diameter and fan 110 mm (4.3 in) x 110 mm (4.3 in) 90 mm (3.5 in) V-belt diameter (standard) * Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

4TNV94L Engine name Engine specification class Type Combustion chamber Number of cylinders Cylinder bore stroke Displacement Rotation Continuous speed rating Output

Rated output

4TNV94L CL

VL Vertical, in-line, 4-cycle, water-cooled diesel engine Direct injection 4 94 mm (3.7 in) x 110 mm (4.33 in) 3.053 l (0.81 US gal)

1500 RPM

1800 RPM

–

26.1 kW (35.5 Hp)

31.3 kW (42.6 Hp)

–

Rotation speed

1500 RPM

1800 RPM

2000 RPM

2200 RPM

2400 RPM

2500 RPM

Output

29.1 kW (39.6 Hp)

34.6 kW (47.0 Hp)

35.3 kW (48.0 Hp)

38.2 kW (51.9 Hp)

41.6 kW (56.56 Hp)

43.0 kW (58.46 Hp)

1600 RPM

1895 RPM

2180 RPM

2400 RPM

2590 RPM

2700 RPM

Maximum no-load speed (±25) Order of ignition Power take-off Rotating direction Cooling system Lubrication system Starting system Appropriate fuel Applicable lubricant Lubricant Total capacity (oil Effective pan)* Coolant volume (engine only) Overall Engine dimensions length ** (with Overall width flywheel Overall housing) height Engine mass (dry) ** (with flywheel housing) Fan (standard) Crankshaft V pulley diameter and fan V-belt diameter (standard)

1-3-4-2-1(No. 1 cylinder on flywheel side) Flywheel Counterclockwise (viewed from flywheel) Radiator Forced lubrication with trochoid pump Electrical system ASTM fuel No. 2-D type TT CASE AKCELA ENGINE CASE AKCELA ENGINE OIL 15W-40 OIL 10W-30 10.2 l (2.69 US gal) 4.5 l (1.19 US gal) 4.2 l (1.11 US gal) 719 mm (28.3 in) 498 mm (19.6 in) 717 mm (28.2 in) 245 kg (540.1 lb)

235 kg (518.1 lb)

410 mm (14.6 in) O/D, 6 blades pusher type 130 mm (5.1 in) x 130 mm (5.1 in)

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

4TNV98 Engine name Engine specification class Type Combustion chamber Number of cylinders Cylinder bore stroke Displacement Rotation Continuous speed rating Output

Rated output

Rotation speed Output

Maximum no-load speed (±25) Order of ignition Power take-off Rotating direction Cooling system Lubrication system Starting system Appropriate fuel Applicable lubricant Lubricant Total capacity (oil Effective pan)* Coolant volume (engine only) Overall Engine dimensions length ** (with Overall width flywheel Overall housing) height Engine mass (dry) ** (with flywheel housing) Fan (standard) Crankshaft V pulley diameter and fan V-belt diameter (standard)

4TNV98 CL

VL Vertical, in-line, 4-cycle, water-cooled diesel engine Direct injection 4 98 mm (3.9 in) x 110 mm (4.33 in) 3.318 l (0.88 US gal)

1500 RPM

1800 RPM

–

30.9 kW (42.0 Hp)

36.8 kW (50.0 Hp)

–

1500 RPM

1800 RPM

2000 RPM

2200 RPM

2400 RPM

2500 RPM

34.6 kW (47 Hp)

41.2 kW (56 Hp)

41.9 kW (57 Hp)

45.6 kW (62 Hp)

49.3 kW (67 Hp)

51.1 kW (69 Hp)

1600 RPM

1895 RPM

2180 RPM

2400 RPM

2590 RPM

2700 RPM

235 kg (518.1 lb)

410 mm (14.6 in) O/D. 6 blades pusher type 130 mm (5.1 in) x 130 mm (5.1 in)

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

4TNV98T Engine name Engine specification class Type Combustion chamber Number of cylinders Cylinder bore stroke Displacement Rotation Continuous speed rating Output Rated output

4TNV98T VL

Vertical, in-line, 4-cycle, water-cooled diesel engine Direct injection 4 98 mm (3.9 in) x 110 mm (4.33 in) 3.318 l (0.88 US gal) 1500 RPM 1800 RPM

–

37.9 kW (51.5 Hp)

–

45.6 kW (62 Hp)

Rotation speed

1500 RPM 1800 RPM 2000 RPM 2200 RPM 2400 RPM 2500 RPM 2600 RPM

Output

41.9 kW 50.4 kW 50.7 kW (56.97 Hp) (68.52 Hp) (68.93 Hp)

55.5 kW (75.5 Hp)

60.3 kW 62.5 kW 64.0 kW (81.99 Hp) (84.98 Hp) (87.02 Hp)

Maximum no-load speed 1600 RPM 1895 RPM 2180 RPM 2400 RPM 2590 RPM 2700 RPM 2700 RPM (±25) Order of ignition 1-3-4-2-1(No. 1 cylinder on flywheel side) Flywheel Power take-off Rotating direction Counterclockwise (viewed from flywheel) Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Electrical system Starting system ASTM fuel No. 2-D type TT Appropriate fuel CASE AKCELA Applicable lubricant CASE AKCELA ENGINE OIL 15W-40 ENGINE OIL 10W-30 Lubricant 10.2 l (2.69 US gal) Total capacity (oil 4.5 l (1.19 US gal) Effective pan)* Coolant volume (engine 4.2 l (1.11 US gal) only) Overall 715 mm (28.1 in) Engine length dimensions Overall ** (with 575 mm (22.6 in) width flywheel Overall housing) 779 mm (30.7 in) height Engine mass (dry) ** 258 kg (568.8 lb) 245 kg (540.1 lb) (with flywheel housing) Fan (standard) 430 mm (16.9 in) O/D. 8 blades pusher type Crankshaft V pulley diameter and fan V-belt 130 mm (5.1 in) x 130 mm (5.1 in) diameter (standard) * Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

4TNV106 Engine name Engine specification class Type Combustion chamber Number of cylinders Cylinder bore stroke Displacement Rotation Continuous speed rating Output

Rated output

4TNV106 CL

VL Vertical, in-line, 4-cycle, water-cooled diesel engine Direct injection 4 106 mm (4.2 in) x 125 mm (4.92 in) 4.412 l (1.17 US gal)

1500 RPM

1800 RPM

–

41.2 kW (56.0 Hp)

49.3 kW (67.03 Hp)

–

Rotation speed

1500 RPM

1800 RPM

2000 RPM

2200 RPM

2400 RPM

2500 RPM

Output

45.6 kW (62.0 Hp)

54.4 kW (73.96 Hp)

56.6 kW (76.95 Hp)

61.4 kW (83.5 Hp)

65.5 kW (89.06 Hp)

67.7 kW (92.05 Hp)

1600 RPM

1895 RPM

2180 RPM

2400 RPM

2590 RPM

2700 RPM

Maximum no-load speed (±25) Order of ignition Power take-off Rotating direction Cooling system Lubrication system Starting system Appropriate fuel Applicable lubricant Lubricant Total capacity (oil Effective pan)* Coolant volume (engine only) Overall Engine dimensions length ** (with Overall width flywheel Overall housing) height Engine mass (dry) ** (with flywheel housing) Fan (standard)

7.5 l (1.98 US gal) 6.0 l (1.59 US gal)

808 mm (31.8 in)

776 mm (30.6 in)

629 mm (24.8 in)

803 mm (31.6 in)

345 kg (760.6 lb)

330 kg (727.5 lb)

500 mm (19.7 in) O/D. 7 blades pusher type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

150 mm (5.9 in) x 150 mm (5.9 in)

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

4TNV106T Engine name Engine specification class Type Combustion chamber Number of cylinders Cylinder bore stroke Displacement Rotation speed Continuous rating Output Rotation speed Rated output

Output

Maximum no-load speed (±25) Order of ignition Power take-off Rotating direction Cooling system Lubrication system Starting system Appropriate fuel Applicable lubricant Lubricant capacity Total (oil pan)* Effective Coolant volume (engine only) Engine Overall length dimensions ** Overall width (with flywheel Overall height housing) Engine mass (dry) ** (with flywheel housing) Fan (standard)

4TNV106T VL CL Vertical, in-line, 4-cycle, water-cooled diesel engine Direct injection 4 106 mm (4.2 in) x 125 mm (4.92 in) 4.412 l (1.17 US gal) – 1500 RPM 1800 RPM 51.5 kW 61.8 kW – (70.0 Hp) (84.02 Hp) 1500 RPM 1800 RPM 2000 RPM 2200 RPM 56.8 kW 68.0 kW 69.9 kW 72.0 kW (77.2 Hp) (92.45 Hp) (95.04 Hp) (97.9 Hp) 1600 RPM 1895 RPM 2180 RPM 2400 RPM 1-3-4-2-1(No. 1 cylinder on flywheel side) Flywheel Counterclockwise (viewed from flywheel) Radiator Forced lubrication with trochoid pump Electrical system ASTM fuel No. 2-D type TT CASE AKCELA ENGINE OIL CASE AKCELA ENGINE OIL 10W-30 15W-40 14.0 l (3.7 US gal) 9.0 l (2.38 US gal) 7.5 l (1.98 US gal) 6.0 l (1.59 US gal) 808 mm (31.8 in) 776 mm (30.6 in) 629 mm (24.8 in) 628.6 mm (24.7 in) 866 mm (34.1 in)

866 mm (34.1 in)

355 kg (782.6 lb)

340 kg (749.6 lb)

500 mm (19.7 in) O/D. 7 blades pusher type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

150 mm (5.9 in) x 150 mm (5.9 in)

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

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Engine - Engine and crankcase

Engine - Special tools Special tools No.

Applicable model and tool size Model “L1” “L2”

Name

Valve guide tool (for extracting valve guide)

* Locally manufactured Model 3TNV82A 4TNV84 3TNV84(T) 3/4TNV88

“d2”

3TNV82A 4TNV94L98(T) 4TNV106(T) 4TNV84 3TNV84(T) 3/4TNV88 4TNV84T

Valve guide tool (for inserting valve guide)

Illustration “d1”

4TNV84T

5.5 20 75 mm mm mm (2 (0.22 (0.79 .95 in) in) in) “L1” 12 mm (0.47 in) 15 mm (0.59 in) 8.5 mm (0.33 in)

“L2” 60 mm (2 .36 in) 65 mm (2 .56 in) 60 mm (2 .36 in)

4TNV94L·98(T)

7 mm 60 (0.28 mm (2 in) .36 in)

4TNV106(T)

13.5 65 mm mm (2 (0.53 .56 in) in)

* Locally manufactured

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“d1” 13 mm (0.51 in) 14 mm (0.55 in) 11 mm (0.43 in) 13 mm (0.51 in) 13 mm (0.51 in)

9 mm (0.35 in) “d2” 19 mm (0 .75 in) 20 mm (0 .79 in) 17 mm (0 .67 in) 16 mm (0 .63 in) 16 mm (0 .63 in)

Engine - Engine and crankcase

No.

Applicable model and tool size Model “L1” “L2” 25 85 mm mm (3 3TNV82A (0.98 .35 in) in) 20 100 mm mm (3 TNV84~88 (0.79 Connecting .94 in) in) rod bushing 20 replacer (for 100 mm removal/ mm (3 4TNV94L·98 (0.79 installation .94 in) in) of connecting rod bushing) 20 100 mm mm (3 4TNV106(T) (0.79 .94 in) in) Allowance: d1 -0.3 - -0.6 mm (-0.012 - -0.024 in) d2 -0.3 - -0.6 mm (-0.012 - -0.024 in) * Locally manufactured Valve spring compressor (for removal/ installation of valve spring) Model “d1” “d2” “d3” “L1” 15 12 21 15.8 .2 mm mm mm (0 mm 3TNV82A (0.47 (0.8 .62 in) (0.6 in) 3 in) in) 4TNV84 16 22 13.5 18.8 .2 3TNV84(T) mm mm mm (0 mm 4TNV88 (0.8 (0.53 .74 in) (0.6 7 in) in) 4 in) Stem seal 12 19 11.5 inserter for .9 10.0 mm mm inserting mm mm (0 4TNV84T (0.7 (0.45 stem seal) (0.5 .39 in) 5 in) in) 1 in) 15 12 21 11.8 .5 mm mm mm (0 mm 4TNE94L·98 (0.47 (0.8 .46 in) (0.6 in) 3 in) 1 in) 15 12 21 15.5 .2 mm mm mm (0 mm 4TNE106(T) (0.47 (0.8 .61 in) (0.6 in) 3 in) in) Filter wrench (for removal/ Standard tool available on the market installation of L.O. filter) Name

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Illustration “d1” 23 mm (0.91 in) 26 mm (1.02 in) 30 mm (1.18 in) 37 mm (1.46 in)

“d2” 26 mm (1 .02 in) 29 mm (1 .14 in) 33 mm (1 .3 in) 40 mm (1 .57 in)

“L2”

“L3”

65 mm (2.56 in)

4 mm (0.16 in)

65 mm (2.56 in)

4 mm (0.16 in)

65 mm (2.56 in)

4 mm (0.16 in)

65 mm (2.56 in)

4 mm (0.16 in)

65 mm (2.56 in)

4 mm (0.16 in)

Engine - Engine and crankcase

No.

Applicable model and tool size Model “L1” “L2” 18 70 mm mm (2 TNV82A~88 (0.71 .76 in) in) 18 70 mm Camshaft mm (2 4TNV94L·98 (0.71 bushing tool .76 in) in) (for extracting camshaft 18 70 bushing) mm mm (2 4TNV106(T) (0.71 .76 in) in) Allowance: d1 -0.3 - -0.6 mm (-0.012 - -0.024 in) d2 -0.3 - -0.6 mm (-0.012 - -0.024 in) * Locally manufactured Model Name

TNV82A Flex-Hone (for re-honing TNV88~ of cylinder 4TNV94L liner) 4TNV98

“d2” 48 mm (1 .89 in) 53 mm (2 .09 in) 61 mm (2 .4 in)

Cylinder bore 78 - 84 mm (3.07 3.31 in) 83 - 95 mm (3.27 3.74 in) 89 - 101 mm (3.5 - 3.98 in) 95 - 108 mm (3.74 4.25 in)

Not used

4TNV106(T)

Piston insertion tool (for inserting piston)

* The above piston insertion tool is applicable to 60 - 125 mm (2.36 - 4.92 in) diameter pistons.

Piston ring replacer (for 10. removal/ installation of piston ring)

11.

Illustration “d1” 45 mm (1.77 in) 50 mm (1.97 in) 58 mm (2.28 in)

Crankshaft pulley installing tool. Locally manufactured

Available on the market

Standard tool locally manufactured (for 4TNV94L)

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Engine - Engine and crankcase

Measuring instruments No.

Name

Applicable model and tool size Standard tool Measurements of shaft bending, and strain and gap of surfaces

Dial gauge

Test indicator

Magnetic stand

Standard tool For holding the dial gauge when measuring using a dial gauge, standing angles adjustable

Micrometer

Standard tool For measuring the outside diameters of crankshaft, pistons, piston pins, etc.

Cylinder gauge

Calipers

Depth micrometer

Square

Standard tool For measuring valve spring inclination and straightness of parts

V-block

Standard tool For measuring shaft bend

Standard tool Measurements of narrow or deep portions that cannot be measured by dial gauge

Standard tool For measuring the inside diameters of cylinder liners, rod metal, etc. Standard tool For measuring outside diameters, depth, thickness and width

Standard tool For measuring of valve sink

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Illustration

Engine - Engine and crankcase

No.

Name

10. Torque wrench

Applicable model and tool size

Illustration

Standard tool For tightening nuts and screws to the specified torque

Standard tool For measuring gaps between ring and ring groove, and shaft joints during assembly

11.

Thickness gauge

12.

Standard tool Cap tester

For checking water leakage

13.

Standard tool Battery coolant tester

For checking concentration of antifreeze and the battery electrolyte charge status

14.

Standard tool Nozzle tester

15.

Standard tool Digital thermometer

For measuring injection spray pattern of fuel injection nozzle and injection pressure

For measuring temperatures

A: Sensor

16.

Contact type

For measuring engine revolutions by contacting the revolving shaft

Photoelectric type

For measuring revolution by sensing the reflective mark on the outer periphery of the revolving shaft

Standard tool Speedometer

A: Resolving shaft B: Reflective mark

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Engine - Engine and crankcase

Applicable model and tool size

No.

Name

17.

Standard tool Circuit tester

18.

Part number: 380000303 Compression gauge kit

For measuring resistance, voltage and continuity of electrical circuits

For measuring compression pressure

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Illustration

Engine - Engine and crankcase

Engine - General specification - 3TNV88A-PYB Engine model Type No. of cylinders - bore x stroke Total displacement Compression ratio Rated output Maximum torque Low idling High idling Fuel consumption rate Allowable tilting angles Rotating direction Order of ignition Injection time (injection time before top dead centre) Fuel injection pressure Valve action Valve clearance

Intake valve Exhaust valve Intake valve Exhaust valve

Thermostat action Compression pressure Lubrication oil pressure Dimensions L x H x W Dry weight Injection governor Fuel filter Lubrication system Cooling system Starter capacity Generator capacity Starting aid Cooling water capacity: max / engine Engine oil volume: max / effective

3TNV88-PYB Vertical, 4-cycle water-cooled diesel engine 3- 88 mm (3.46 in) x 90 mm (3.54 in) 1.642 l (0.43 US gal) 19.1 22.2 kW (30.18 Hp) at 2400 RPM 98.4 N·m (72.58 lb ft) at 1400 RPM 1225 - 1275 RPM 2565 - 2615 RPM Less than 180 g (6 oz)/ h Continuous; 30° for all direction Counterclockwise as viewed from flywheel side 1-3-2-1 13°-15° 200 - 210 Kg/cm² (2845 - 2987 psi) Open Close b.T.D.C. 10° - 20° a.B.D.C. 40° - 50° b.T.D.C. 51 - 61° a.B.D.C. 13° - 23° 0.2 mm (0.01 in) in cold condition 0.2 mm (0.01 in) in cold condition Start 69.5 - 72.5 °C (157.10 - 162.50 °F) / Fully open 85 °C (185.00 °F) 3.33 - 3.53 MPa (483 - 512 psi) at 250 RPM 0.44 MPa (64 psi) at 2300 RPM 585 mm (23.03 in) x 521 mm (20.51 in) x 648 mm (25.51 in) 155 kg (341.72 lb) Mechanical centrifugal governor (All speed type) Paper-element cartridge Forced lubrication with trochoid pump Coolant / radiator 12 V x 1.7 kW (2.31 Hp) 12 V X 55 A Air heater ( 12 V - 400 W) 4.0 l (1.06 US gal) / 2.0 l (0.53 US gal) 6.7 l (1.77 US gal) / 2.8 l (0.7 US gal)

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Engine - Engine and crankcase

Rated output: 22.2 kW (30 Hp) / 2400 RPM

TULI12EXN6019GA

T. F. PS.

Shaft torque Fuel consumption rate Power output F ρ x 1000 245 = 0.835 x 1000 = 6.21 α

Oil consumption volume =

F. P.

Fuel consumption rate ( g/kWh ) Shaft output ( kW )

GT. Sd.

Exhaust temperature Smoke: Bosch

ρ. α.

Specific weight Standard load factor ( 0.60 - 0.70 )

xPxα x 21.2 x α

Fuel consumption in normal operation: 3.73 - 4.35 l/hour (0.99 - 1.15 US gal/hour) (load factor: ( 0.60 - 0.70 ))

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Engine - Engine and crankcase

Engine - Service limits No. 1.

Inspection item Gap at intake/exhaust valve heads

TNV82A~98 4TNV106(T)

Between Used part alternator and crank New part pulley Between Used part V-belt tension alternator at 98 N and radiator New part (22 lb) fan Between Used part radiator fan and crank New part pulley 3TNV82A~TNV88(VM) Fuel injection 4TNV94L~106(T) pressure 3TNV82A~TNV88(CL) TNV82A

Compression TNV84 pressure (at 250 min-1 ) 3/4TNV84T TNV88-106

3TNV82A, 84 Coolant 3TNV84T, 88 capacities 4TNV84(T) 0.88 (Only engine 4TNV94L98(T) body) 4TNV106(T) 3TNV82A

3TNV84(T)/88

Lubricating oil 4TNV84(T)/88 capacity (oil pan) 4TNV94L/98(T)

4TNV106(T) (CL class)

4TNV106(T) (VM class)

Standard value 0.15 - 0.25 mm (0.01 0.01 in) 0.25 - 0.35 mm (0.01 0.01 in) 10 - 14 mm (0.39 - 0.55 in)

Limit value

8 - 12 mm (0.31 - 0.47 in)

7 - 10 mm (0.28 - 0.39 in) 5 - 8 mm (0.20 - 0.31 in) 9 - 13 mm (0.35 - 0.51 in) 7 - 11 mm (0.28 - 0.43 in) 21.57 - 22.55 MPa (3129 3271 psi) 19.6 - 20.6 MPa (2843 2988 psi) 3.06 - 3.26 MPa (444 473 psi) 3.14 - 3.34 MPa (455 484 psi) 2.84 - 3.04 MPa (412 441 psi) 3.33 - 3.53 MPa (483 512 psi) 1.8 l (0.48 US gal) 2 l (0.53 US gal) 2.7 l (0.71 US gal) 4.2 l (1.11 US gal) 6.0 l (1.59 US gal) Full Effective 1.9 l 5.5 l (1.45 US (0.50 US gal) gal) 2.8 l 6.7 l (1.77 US (0.74 US gal) gal) 3.4 l 7.4 l (1.95 US (0.90 US gal) gal) 4.5 l 10.5 l (2.77 US (1.19 US gal) gal) 9.0 l 14.0 l (3.70 US (2.38 US gal) gal) 7.5 l 14.0 l (3.70 US (1.98 US gal) gal)

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2.35 - 2.55 MPa (341 - 370 psi) 2.45 - 2.65 MPa (355 - 384 psi) 2.31 - 2.59 MPa (335 - 376 psi) 2.65 - 2.85 MPa (384 - 413 psi) -

Engine - Engine and crankcase

No.

Inspection item 3TNV82A~98 4TNV98T 4TNV106(T) Lubricating oil (VM, WO balancer) pressure 4TNV106(T) (CL, WO balancer) 4TNV106(T) (VM, W balancer) Oil pressure switch operating pressure

Thermostat

All models All models option

10. Thermo switch actuating temperature

Standard value at rated speed 0.29 - 0.39 MPa (42 - 57 psi)

Limit value at low idle speed

0.39 - 0.49 MPa (57 - 71 psi) 0.06 MPa (9 psi) or above 0.31 - 0.49 MPa (45 - 71 psi) 0.34 - 0.44 MPa (49 - 64 psi) 0.04 - 0.06 MPa (6 - 9 psi) Valve opening temperature 69.5 - 72.5 °C (157 - 163 °F) 80 - 84 °C (176 - 183 °F) 107 - 113 °C (225 - 235 °F)

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Full opening lift 8 mm (0.31 in) or more 85 °C (185 °F) 10 mm (0.39 in) or more 95 °C (203 °F) -

Engine - Engine and crankcase

Engine - External view 1.

Filler port (engine oil)

Turbocharger

Air intake port (from air cleaner, optional)

Lifting eye

Coolant pump

Fan

Crankshaft V-pulley

V-belt

Filler port (engine oil)

10. Drain plug (engine oil) 11. Engine oil 4TNV106T)

cooler

(4TNV98T,

4TNV106

and

12. Engine oil filter 13. Dipstick (engine oil) 14. Fuel injection pump 15. Governor lever 16. Fuel filter 17. Fuel cock 18. Fuel filter mounting 19. Lifting eye 20. Engine name plate 21. Rocker arm cover 22. Flywheel 23. Starter motor 24. Exhaust manifold 25. Generator NOTE: This illustration shows the 4TNV98T engine (with turbocharger). The drain plug (engine oil) location depends on the engine installed on the machine unit to be on the fuel injection pump side (above illustration) or starter motor side. TULI12EXN4782CA

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Engine - Engine and crankcase

Engine - Static description 1. Emission reduction New fuel injection pressure • Mono plunger • Higher injection pressure • Injection timing, speed timer, load timer, cold start timer control

2. Noise reduction Higher stiffness cylinder block Higher stiffness gear-case

3. Emission reduction Injection nozzle • Low suck volume • Multi injection holes

4. Emission reduction Cylinder head • Optimal nozzle angle • Optimal swirl ratio • Optional valve timing

5. Emission reduction Piston • New combustion chamber

Noise reduction New lube oil pan • Change rotor shape for low pulsation • Driven by crankshaft directly

6. Emission reduction Cylinder head

TULI12EXN4783CB

• 4 valve/cylinder (intake-2, exhaust-2) • Optimal installation of the injection nozzle vertical installation and location of the centre of cylinder • Optimal valve timing

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Engine - Engine and crankcase

7. Emission reduction New fuel injection nozzle • Low suck volume • Multi injection holes

8. Emission reduction New fuel injection pump • Mono plunger • Higher injection pressure • Mechanical control of injection timing, speed timer, load timer, cold start timer

9. Emission reduction Piston • New combustion chamber

Noise reduction (only applied for 4TNV84T) New lube oil pan • Change rotor shape for low pulsation • Driven by crankshaft directly

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Engine - Engine and crankcase

Engine - Service instruction Periodic maintenance schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. : User-maintenance : Parts replacement : Shop-inspection Maintenance period Classification

Whole

Fuel system

Lubricating oil system

Piece

Daily

Every 50 h

Every 250 h or 3 months

Visual check around the machine Fuel tank level check and fuel supply Fuel tank drain Water separator (Option) draining Fuel system bleeding Water separator cleaning Fuel filter element replacement Lube oil level check and replenishment Lube oil replacement Lube oil filter replacement

2nd time and 1st time thereafter

Coolant level check and replenishment Radiator fin cleaning

Coolant pump

V-belt tension check

2nd time and 1st time thereafter

Coolant change Coolant/water path flushing and maintenance Fuel pipe and coolant Rubber hose pipe inspection and maintenance Inspection and Injection adjustment of governor governor lever and accelerator

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Every 500 h or 6 months

InspecEvery tion every 2000 h 1000 h or two or one years year

Engine - Engine and crankcase

Maintenance period Classification

Piece

Daily

Every 50 h

Every 250 h or 3 months

Every 500 h or 6 months

InspecEvery tion every 2000 h 1000 h or two or one years year

Air cleaner cleaning and element replacement Air intake system

Diaphragm assy inspection

(2 years)

Turbocharger blower cleaning* Warning lamp and instruments function check Electrical system Battery electrolyte level check and battery recharging Intake/exhaust valve head clearance Cylinder adjustment head Intake/exhaust valve seat lapping Fuel injection nozzle pressure inspection Fuel injection Fuel injection timing pump and adjustment nozzle Fuel injection pump inspection and adjustment *EPA allows servicing the emission related parts every 1500 - 3000 h

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Engine - Engine and crankcase

Engine - Inspect - Daily Inspection Be sure to check the following points before starting an engine every day: No. 1. 2. 3. 4. 5. 6. 7. 8.

Inspection item Visual check around the machine Fuel tank level check and fuel supply Lube oil level check and replenishment Coolant level check and replenishment Fuel pipe and coolant pipe inspection and maintenance Inspection and adjustment of governor lever and accelerator Warning lamp and instruments function check Water separator draining

Visual check around the machine If any problem is found, do not use before the engine repairs have been completed. • Oil leak from the lubrication system • Fuel leak from the fuel system • Coolant leak from the water cooling system • Damaged parts • Loosened or lost screws • Fuel, radiator rubber hoses, cracked V-belt, loosened clamp

Fuel tank level check and fuel supply Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary.

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Engine - Engine and crankcase

Lube oil level check and replenishment (a) Checking oil level Check the lubricating oil level with the dipstick (A), after adjusting the position of the machine so that the engine is horizontal. Insert the dipstick fully and check the oil level. The oil shall not be contaminated heavily and have appropriate viscosity. No coolant water or diesel fuel shall be mixed. When lube oil is supplied after the engine has been running, check the lube oil level after about 10 min after the engine shutdown so that the lube oil has filled the oil pan.

TULI12EXN4788BB

The level shall be between the upper (AU) and lower (AL) limit lines on the dipstick (A). Model 3TNV82A 3TNV84(T) 88 4TNV84(T) 88 4TNV94L98(T) 4TNV106(T) (CL class) 4TNV106(T) (VM class)

Total volume 5.5 l (1.45 US gal) 6.7 l (1.77 US gal) 7.4 l (1.95 US gal) 10.5 l (2.77 US gal) 14.0 l (3.70 US gal) 14.0 l (3.70 US gal)

Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit. (b) Replenishing oil pan with lube oil If the remaining engine oil level is low, remove the filler port cap (B) and fill the oil pan with the specified engine oil to the specified level through the filler port (C). NOTE: The oil should not be overfilled to exceed the upper limit line. Otherwise a naturally-aspirated engine may intake lube oil in the combustion chamber during the operation, then white smoke, oil hummer or urgent rotation may occur, because the blow-by gas is reduced in the suction air flow. In case of turbocharged engine oil may jet out from the breather or the engine may become faulty.

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Effective volume 1.9 l (0.50 US gal) 2.8 l (0.74 US gal) 3.4 l (0.90 US gal) 4.5 l (1.19 US gal) 9.0 l (2.38 US gal) 7.5 l (1.98 US gal)

Engine - Engine and crankcase

Coolant check Daily inspection of coolant water should be done only by coolant recovery tank. NOTICE: Never open the radiator filler cap (R) while the engine and radiator are still hot. Steam and hot water will spurt out and seriously burn you. Wait until the radiator is cooled down after the engine has stopped, wrap the filler cap with a rag piece and turn the cap slowly to gently release the pressure inside the radiator. Securely tighten the filler port plug (R) after checking the radiator. Steam can spurt out during engine running, if tightening loose. (a) Checking coolant water volume Check the coolant level in the expansion tank (C). If the water level is close to the LOW mark, open the coolant expansion tank plug (H) and replenish the tank with soft clean water up to the FULL mark. The level shall be between the upper and lower limit lines on the dipstick. (b) Replenishing radiator with water If the coolant recovery tank water level is lower than the LOW mark, open the radiator cap (R) and check the coolant water level in the radiator. Replenish the radiator with coolant, if the level is low. â&#x20AC;˘ Check the coolant level while the engine is cool. Checking when the engine is hot is dangerous. And the water volume is expanded due to the heat. â&#x20AC;˘ Daily coolant level check and replenishing shall be done only from the expansion tank. Usually do not open the radiator cap to check or replenish. T.

Tighten

Loosen

TULI12EXN4789AB

NOTICE: If the coolant water runs short quickly or when the radiator runs short of water with the coolant expansion tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the coolant expansion tank water level during operation is not abnormal. The increased water in the coolant expansion tank returns to the radiator when the engine is cooled down. If the water level is normal in the coolant expansion tank but low in the radiator, check loosened clamping of the rubber hose between the radiator and coolant recovery tank or tear in the hose. Engine: The radiator shall be filled up. Coolant water volume in an engine 1.8 l (0.48 US gal)

Model 3TNV82A 3TNV84(T) 3TNV88 4TNV84(T) 4TNV88 4TNV94L 4TNV98(T) 4TNV106(T)

2.0 l (0.53 US gal) 2.7 l (0.71 US gal) 4.2 l (1.11 US gal) 6.0 l (1.59 US gal)

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Engine - Engine and crankcase

Engine coolant water capacity may differ from the above volume depending on an engine installed on a machine unit.

Fuel pipe and coolant pipe inspection and maintenance Check the rubber hoses for fuel and coolant water pipes cracked. If the cracked hose is found, replace it with new one. Check the loosened clamp. If found, tighten it.

Inspection and adjustment of governor lever and accelerator Make sure the accelerator of the machine unit can be operated smoothly before starting the engine. If it feels heavy to manipulate, lubricate the accelerator cable joints and pivots. Adjust the accelerator cable if there is a dislocation or excessive play between the accelerator and the governor lever. Refer to Engine - Inspect â&#x20AC;&#x201C; Every 250 hours or 3 months (10.001) .

Warning lamp and instruments function check Before and after starting the engine, check to see that the alarm function normally. Failure of alarm cannot warn the lack of the engine oil or the coolant water. Make it a rule to check the alarm operation before and after starting engine every day. Refer to each manual for machine units in details.

Water separator draining Drain off the water separator (W) whenever there is a lot of drain collected in the water separator at the bottom of the cup (C) even if the time for periodic inspection has not elapsed yet. The cup of the water separator (C) is made of semi-transparent material and, in the cup itself, the red colored floating ring (FR) which rises on the surface of the drain is installed to visualize the amount of drain. A level sensor connected to a warning device on the gauge cluster is provided as optional device. Drain off the water separator in the following manner: 1.

Prepare a waste oil container collecting waste oil.

Close the fuel cock (FC).

Loosen the drain cock (DC) at the bottom of the water separator, and drain off any water collected inside.

Tighten the drain cock (DC) manually.

Air bleeding from fuel system.

NOTE: If no drain drips when the drain cock is opened, loosen the air bleeding bolt (A) on the top of the water separator by turning counterclockwise 2 - 3 times using screwdriver. (This may occur in case of the water separator position is higher than the fuel oil level in the fuel tank). After draining, be sure to tighten the air bleeding bolt (A).

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TULI12EXN4795AB

Engine - Engine and crankcase

Inspection after initial 50 h operation Be sure to check the following points after initial 50 h operation, thereafter every 250 h or 3 months operation. No. 1. Lube oil and filter replacement 2. V-belt tension check

Inspection item

1. Lubricating oil change and filter replacement (1st time) NOTICE: When an engine is still hot, be careful with a splash of engine oil which may cause burns. Replace engine oil after the engine oil becomes warm. It is most effective to drain the engine oil while the engine is still warm. In early period of use, the engine oil gets dirty rapidly because of the initial wear of internal parts. Replace the engine oil earlier. Lube oil filter should also be replaced when the engine oil is replaced. The procedure of lube oil and lube oil filter replacement is as follows: A. Drain engine oil • Prepare a waste oil container collecting waste oil. • Remove the oil filler cap to drain easily while draining the lube oil. • Loosen the drain plug (DP) using a wrench (customer procured) to drain the lube oil. • Securely tighten the drain plug after draining the lube oil. • DP. Drain plug. The location depends on the engine installed on the machine unit. NOTE: Use a socket wrench or a closed wrench when removing or tightening a drain plug. Do not use a spanner because there is the possibility that the spanner slips and you get hurt.

TULI12EXN4790BB

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Engine - Engine and crankcase

B. Replacing oil filter • Turn the lube oil filter (E) counterclockwise using a filter wrench (customer procured) to remove it. • Clean the mounting face of the oil filter. • Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface, and tighten it further to 3/4 of a turn with the filter wrench. Tightening torque: 20 - 24 N·m (15 - 18 lb ft) C. Oil filling and inspection • Fill with new engine oil until it reaches the specified level. NOTICE: Do not overfill the oil pan (O) with engine oil. Be sure to keep the specified level between upper and lower limit on the dipstick (D). T.

Tighten

Loosen

• Warm up the engine by running for 5 min while checking any oil leakage. • Stop the engine after warming up and leave it stopping for about 10 min to recheck the engine oil level with dipstick and replenish the engine oil. If any oil is spilled, wipe it away with a clean cloth.

TULI12EXN4791BB

TULI12EXN4792AB

2. V-belt tension check When there is not enough tension in the V-belt (V), the V-belt will slip making it impossible for the alternator (A) to generate power and cooling water pump and cooling fan (R) will not work causing the engine to overheat. Check and adjust the V-belt tension (deflection) in the following manner: NOTE: Be especially careful not to splash engine oil on the V-belt, because it will cause slipping, stretching and aging of the belt. 1.

Press the V-belt with your thumb [approximately 98 N (22 lb)] in the middle of the V-belt span to check the tension (deflection). Available positions to check and adjust the V-belt tension (deflection) are at the A, B or C direction as shown in the Fig. 6. You may choose a position whichever you can easily carry out the check and adjustment on the machine unit.

• “New V-belt” refers to a V-belt which has been used less than 5 min on a running engine. • “Used V-belt” refers to a V-belt which has been used on a running engine for 5 min or more. The specified deflection to be measured at each position should be as follows:

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Engine - Engine and crankcase

Direction For used V-belt For new V-belt

A 10 - 14 mm (0.39 - 0.55 in) 8 - 12 mm (0.31 - 0.47 in)

B 7 - 10 mm (0.28 - 0.39 in) 5 - 8 mm (0.20 - 0.31 in)

C 9 - 13 mm (0.35 - 0.51 in) 7 - 11 mm (0.28 - 0.43 in)

2. If necessary, adjust the V-belt tension (deflection). To adjust the V-belt tension, loosen the setscrew (S) and move the alternator (A) to tighten the V-belt. (Adjust the V-belt tension inserting a bar (AV)). After replacing with a new V-belt and adjusting it, run the engine for 5 min and readjust the deflection to the value in the table above. 3. After replacing with a new V-belt and adjusting it, run the engine for 5 min and readjust the deflection to the value in the table above. 4. Visually check the V-belt for cracks, oiliness or wear. If any, replace the V-belt with new one. TULI12EXN4793AB

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Engine - Engine and crankcase

Engine - Inspect – Every 50 hours Be sure to check the following points before starting an engine every day. Inspection item No. 1. Fuel tank drain 2. Fuel system bleeding 3. Battery electrolyte level check and battery recharging

Fuel tank drain 1.

Prepare a waste oil container collecting waste oil.

Remove the drain plug (D) of the fuel tank (F) to drain (water, dust, etc.) from the fuel tank bottom.

Drain until fuel with no water and dust flow out. Then tighten the drain plug firmly.

TULI12EXN4794AB

TULI12EXN4796BB

Fuel system bleeding Bleed the fuel system according to the following procedures. When there is air in the fuel system, the fuel injection pump (FI) will not be able to operate. 1.

Check the fuel oil level in the fuel tank. Refuel if insufficient.

Open the cock (FC) of the water separator (W).

Loosen the air bleeding bolt (A) on the water separator by turning counterclockwise 2 -3 times using a screwdriver or a spanner.

When the fuel coming out is clear and not mixed with any bubble, tighten the air bleeding bolt (A).

Feed fuel with the fuel priming pump (FP) or electro-magnetic fuel feed pump.

• In case the engine uses the electro-magnetic fuel feed pump. Turn the starter switch to the “ON” position and hold it in the position for 10 - 15 s to operate the fuel feed pump. • In case the engine uses the electro-magnetic fuel feed pump (FP). The priming pump is on the top of the fuel filter mounting. Move the priming pump up and down to feed fuel until feel your hand slightly heavy. • Water separator (W) (Installed on the pipe line) • Fuel filter (FF) (Mounting with fuel priming pump) (option)

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Engine - Engine and crankcase

Battery electrolyte level check and battery recharging WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0006A

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply could result in death or serious injury. W0111A

NOTICE: Make sure to turn off the battery switch or disconnect the negative cable (-) before inspecting the electrical system. Failure to do so could cause short-circuiting and fires. Always disconnect the (-) Negative battery cable first before disconnecting the battery cables from battery. An accidental â&#x20AC;&#x153;short-circuitâ&#x20AC;? may cause damage, fire and or personal injury. And remember to connect the (-) Negative battery cable (back onto the battery) LAST. NOTICE: Keep the area around the battery well ventilated, paying attention to keep away any fire source. During operation or charging, hydrogen gas is generated from the battery and can be easily ignited.

Battery structure AP. Anode plate BC. Battery case C. Cap CO. Cover CP. Cathode plate G. Glass mat S. Separator T. Terminal

TULI12EXN4797AB

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Engine - Engine and crankcase

Electrolyte level • Check the electrolyte level (EL) in the battery. When the amount of fluid nears the lower limit (LL), fill with battery fluid (available in the market) to the upper limit (UL). If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode. • Battery fluid tends to evaporate more quickly in the summer, and the fluid level should be checked earlier than the specified times. • If the engine cranking speed is so slow that the engine does not start up, recharge the battery. • If the engine still will not start after charging, replace the battery.

TULI12EXN4798AB

TULI12EXN4799AB

• Remove the battery from the battery mounting of the machine unit after daily use if letting the machine unit leave in the place that the ambient temperature could drop at 15 °C (59 °F) or less. And store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature.

Battery charge Use a battery tester or hydrometer and check the battery condition. If the battery is discharged, recharge it.

Measurement with a battery tester (BT) When checking the battery with the batter tester, connect the red clip of the tester to the battery positive (+) terminal and black clip to the battery negative (-) terminal by pinching them securely, and judge the battery charge level from the indicator position. Green zone: Normal Yellow zone: Slightly discharged Red zone: Defective or much discharged

Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement.

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The specific gravity of battery electrolyte is defined with 20 °C (68 °F) as the standard. Since the specific gravity increases or decreases by 0.0007 when the temperature varies by 1 °C (34 °F) correct the value according to the equation below.

TULI12EXN4800AA

S20 = St + 0.007(t-20) t = Electrolyte temperature at measurement St = Specific gravity at measurement S20 = Converted specific gravity at 20 °C (68 °F) Specific gravity and remaining battery charge Specific gravity ( 20 °C (68 °F)) 1.28 1.26 1.24 1.23

Discharged quantity of electricity 0% 10% 20% 25%

Remaining charge 100% 90% 80% 75%

(F). Float (GT). Glass tube (RB). Rubber bulb

TULI12EXN4801AB

TULI12EXN4802AA

1. Terminals Clean if corroded or soiled. 2. Mounting bracket Repair or replace it if corroded. Retighten if loosened. 3. Battery appearance Replace the battery if cracked or deformed. Clean with fresh water if contaminated.

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Engine - Inspect – Every 250 hours or 3 months Be sure to check the following points every 250 h or 3 months operation, whichever comes first. No. 1. 2. 3. 4. 5. 6.

Inspection item Lube oil and filter replacement Radiator fin cleaning V-belt tension check Inspection and adjustment of governor lever and accelerator Air cleaner cleaning and element replacement Water separator cleaning

Lube oil and filter replacement (The second replacement and after) Replace the engine oil every 250 h operation from 2nd time and on. Replace the engine oil filter at the same time.

Radiator fin cleaning NOTICE: Beware of dirt from air blowing. Wear protective equipment such as goggles to protect your eyes when blowing compressed air. Dust or flying debris can hurt eyes. Dirt and dust “DD” adhering on the radiator fins (RF) reduce the cooling performance, causing overheating. Make it a rule to check the radiator fins daily and clean as needed. • Blow off dirt and dust from fins and periphery with compressed air ( 0.19 MPa (28 psi) or less in order not to damage the fins). • If contaminated heavily, apply detergent, thoroughly clean and rinse with tap water shower. NOTICE: Never use high pressure water or air from close by fins or never attempt to clean using a wire brush. Radiator fins (RF) can be damaged.

V-belt tension check (The second time and after) Check and adjust the V-belt tension.

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TULI12EXN4803AB

Engine - Engine and crankcase

Inspection and adjustment of governor lever and accelerator The governor lever (GL) and accelerating devices (accelerating lever, pedal, etc.) of the machine unit are connected by an accelerating wire or rod. If the wire becomes stretched or the connections loose, the deviation in the position may result and make operation unsafe. Check the wire periodically and adjust if necessary. Do not strongly move the accelerating wire or accelerating pedal. It may deform the governor lever or stretch the wire to cause irregular engine speed control. Checking and adjusting procedure are as follows: • Check that the governor lever (GL) of the engine makes uniform contact with the high idling (H) and low idling (LI) limiting screws when the accelerating devices are in the high idling speed or low idling speed position. • If either the high or the low idling speed side does not make contact with the limiting screw, adjust the accelerating wire. Loosen the accelerating wire fastening screw (AF) and adjust the wire to contact with the limiting screw. NOTICE: Never loosen the limiting screws. It will impair the safety and performance of the product and functions and result in shorter engine life.

TULI12EXN4804BB

TULI12EXN4805AB

Air cleaner cleaning and element replacement NOTICE: Beware of dirt from air blowing. Wear protective equipment such as goggles to protect your eyes when blowing compressed air. Dust or flying debris can hurt eyes. The engine performance is adversely affected when the air cleaner element (E) is clogged by dust. So periodical cleaning after disassembly is needed. • Undo the clamps (L) on the dust pan (DP) and remove the dust pan. • Loosen the wing nut on the element and pull out the element (E).

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• Blow air ( 0.29 - 0.49 MPa (42 - 71 psi) ) from inside the element to blow dust off as shown in the figure on the right. Apply the air blowing pressure as low as possible so as not to damage the element (OE). If having the air cleaner with double elements, never remove and clean the inner element (IE). The purpose of installing the inner element (IE) is of protecting the engine from the penetration of dust during engine operation when leaving the outer element (OE) nonreinstalled after removing it or when damaging the outer element unexpectedly during engine operation. • Replace the element with a new one, if the element is damaged, excessively dirty or oily. • Remove the inside dust cover of the dust pan (DP), and clean the inside of the dust pan. • Reinstall the element (OE) with a new wing screw (do not drop the gasket). Reattach the inside dust cover to the dust pan (DP) and install the dust pan to the air cleaner case (AC) directing the TOP mark (AM) upwards. NOTICE: When the engine is operated in dusty conditions, clean the element more frequently. Do not run the engine with removed air cleaner or element, as this may cause foreign material to enter and damage the engine.

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TULI12EXN4806AB

Engine - Engine and crankcase

Water separator cleaning Periodically wash the water separator element (E) and inside cup (C) with clean fuel. • Prepare a waste oil container collecting waste oil. • Close the fuel cock (FC). • Loosen the drain cock (DC) and drain. • Turn the retaining ring (F) counterclockwise and remove the cover (C). (Disconnect the coupler of the lead wire for drain sensor before removing the cup if it is with drain sensor). • Wash the element (E) and inside cup (C) with clean fuel. Replace the element with new one if any damaged. • Insert the element to the bracket (O-ring) and after putting the float ring (FR) in the cup, install it to the bracket by tightening the retaining ring (F) clockwise. Tightening torque: 15 - 20 N·m (11.1 - 14.8 lb ft) • Close the drain cock (DC) (connect the coupler if with drain sensor). • Be sure to bleed air in the fuel system.

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TULI12EXN4807AB

Engine - Engine and crankcase

Engine - Inspect – Every 500 hours or 6 months Be sure to check the following points every 500 h or 6 months operation, whichever comes first. Inspection item No. 1. Fuel filter element replacement 2. Air cleaner cleaning and element replacement

Fuel filter element replacement Replace the fuel filter at specified intervals, before it is clogged with dust to adversely affect the fuel flow. Also, replace the fuel filter after the engine has fully been cooled. • Close the fuel cock of the water separator. • Remove the fuel filter using a filter wrench (customer procured). When removing the fuel filter, hold the bottom of the fuel filter with a piece of rag to prevent the fuel oil from dropping. If you spill fuel, wipe such spillage carefully. • Clean the filter mounting surface and slightly apply fuel oil to the gasket of the new fuel filter. • Install the new fuel filter manually turning until it comes into contact with the mounting surface, and tighten it further to 1/2 of a turn using a filter wrench. Tightening torque for 3TNV82A to 4TNV106(T): 20 24 N·m (14.8 - 17.7 lb ft) • Be sure to bleed air in the fuel system. NOTICE: Be sure to use genuine Yanmar part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shorten engine life.

Air cleaner cleaning and element replacement Replace the air cleaner element periodically even if it is not damaged or dirty. When replacing the element, clean inside of the dust pan at the time. If having the air cleaner with double elements, never remove and clean the inner element. If the engine output is still not recover (or the dust indicator still actuates if having the air cleaner with a dust indicator) even though the outer element has replaced with new one, replace the inner element with new one.

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TULI12EXN4808AA

Engine - Engine and crankcase

Engine - Inspect – Every 1000 hours or one year Be sure to check the following points every 1000 h or one year operation, whichever comes first. No. 1. 2. 3. 4. 5.

Inspection item Coolant change Diaphragm assy inspection Turbocharger blower cleaning* Intake/exhaust valve head clearance adjustment Fuel injection nozzle pressure inspection

Coolant change Coolant water contaminated with rust or water scale reduces the cooling effect. Even when antifreeze agent (LLC) is mixed, the coolant water gets contaminated due to deteriorated ingredients. Replace the coolant water at least once a year. • Remove the radiator cap (R). • Loosen the drain plug (D) (drain plug selection depends on the machine) at the lower portion of the radiator and drain coolant. • After draining the coolant, tighten the drain plug (D). • Fill radiator and engine with coolant water. NOTICE: Beware of scalding by hot water. Wait until the temperature goes down before draining the coolant water. Otherwise, hot water may splash to cause scalding.

TULI12EXN4809BB

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Diaphragm assy inspection Inspect the diaphragm assy on the rocker arm (RA) cover every 1000 h or 2 years. • Loosen the screws (T) and remove the diaphragm assy, and check whether oil penetrates between the diaphragm (DC) and the cover (RA). If oil or other enters the diaphragm assy, the diaphragm will not work properly. • Check the damages of the diaphragm (D) rubber and the spring (S). If necessary, replace with new ones. NOTE: When a diaphragm (D) is damaged, pressure control inside the crankcase becomes insufficient, and troubles such as combustion defect and so on occur. Upon lubricating oil replacement or lubricating oil supply, the amount of lubricating oil must not be beyond the standard upper limit. If the lubricating oil quantity is beyond the upper limit or the engine is operated beyond the maximum allowable angle, the amount of oil mist can penetrate the combustion chamber and oil may boil.

TULI12EXN4810AB

Turbocharger blower cleaning* When the engine speed seems too low or the exhaust gas colour is strange, the blades of the turbocharger- blower may be dirty. Wash the turbine blower in such a case. A. General items • As for washing, use washing liquid and clear water. • Washing time is the time when about 10% of the boost pressure decreases more than that of usual operation state as a standard. • Disassemble and clean the turbocharger periodically because the whole of the turbocharger cannot cleaned with this method. B. Washing point • A specified quantity of washing liquid/water is poured with a filler (e.g. oil sprayer) from the air inlet of the blower gradually (about then seconds) at the normal load (3/4-4/4) of an engine. And, perform this work at no-load after load running of the engine, if it is difficult to pour the liquid into the blower at load running. Specified quantity of washing liquid/water. Turbocharger model: RHB31, RHB51 Injection amount, one time: 20 cm³ (1.22 in³) NOTICE: It causes an accident when large quantity of washing liquid is poured rapidly into a turbocharger. • Pour the same amount of clear water as washing liquid/water into the blower about 3 - 5 min later after the washing liquid/water injection and wash it. NOTICE: It causes an accident when large quantity of water is poured rapidly into a turbocharger.

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• Repeat the washing after then minutes when there is no change with the boost pressure or the exhaust gas temperature after washing. When there is no change at all even if it repeats 3-4 times, disassemble and maintain the turbocharger because of the cruel dirt of the blower or other causes. • Operate the engine at load for at least 15 min after washing, and dry.

Intake/exhaust valve clearance adjustment Make measurement and adjustment while the engine is cold. A. Valve clearance measurement • Remove the rocker arm cover above cylinder head. • Set the No.1 cylinder (N) in the compression TDC (top dead centre) Turn the crankshaft to bring the piston of cylinder No.1 to its compression top dead centre while watching the rocker arm (RA) motion, timing scale and the top mark (T) position of the crankshaft (C) pulley. (Position where both the intake and exhaust valves are closed). NOTE: The crankshaft shall be turned clockwise as seen from the radiator side. The No. 1 cylinder (N) position is on the opposite side of the radiator and the ignition order shall be 1-3-4-2-1 at 180° intervals. Since the intake and exhaust valve rocker arms (RA) are operated the same and there is a clearance “V” between the arm and valve generally at the top dead centre, the position can be checked by means of the play when the arm head is held with hand. Also see that the crankshaft (T) pulley top mark is positioned at zero on the timing scale. If there is no valve “V” clearance, inspection in the disassembled state is necessary since the valve seat may be worn abnormally.

TULI12EXN4811AB

TULI12EXN4812AB

TULI12EXN4813AB

Valve clearance measurement In case of 2-valve cylinder head insert a thickness gauge between the rocker arm (RA) and valve cap, and record the measured valve (V) clearance. In case of 4-valve head insert a thickness gauge between the rocker arm (RA) and the valve bridge (VB), and record the measured valve (V) clearance. (Use it as the data for estimating the wear state).

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Adjusting other cylinders In case of 4-cylinder engines, turn the crankshaft by 180째 and make adjustment for the No. 3 cylinder. Then adjust the No. 4 and No. 2 cylinders in this order. The cylinder to be adjusted first does not have to be the No. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 180째 each time. In case of 3-cylinder engines, turn the crankshaft by 240째 and make adjustment for the No. 3 cylinder. Then adjust the No. 2 cylinder in this order. The cylinder to be adjusted first does not have to be the No. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240째 each time. The adjustment method of reducing the flywheel turning numbers (for reference): Ignition order of 3 cylinder engines: 1 3 2 For 3 cylinder engines Set No.1 cylinder to the compression T.D.C. and adjust the clearance of the mark of the below table. Next, turn the flywheel once (the suction/exhaust valve of No. 1 cylinder is in the position of the overlap T.D.C. at this time), and adjust the clearance of the mark. Cylinder No. 1 Valve No. 1 compression T.D.C.

1 Inlet

2 Drain

Inlet

3 Drain

Inlet

Drain The first time The second time

No. 1 overlap T.D.C. For 4 cylinder engines Set no.1 cylinder to the compression T.D.C. and adjust the clearance of the mark of the below table. Ignition order of 3 cylinder engines: 1 3 4 2 Next, turn the flywheel once, and adjust the clearance of the mark. Cylinder No. 1 Valve

1 Inlet

2 Drain

Inlet

3 Drain

Inlet

4 Drain

Inlet

Drain The first time The second time

No. 1 compression T.D.C. No. 4 overlap T.D.C.

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Valve clearance inspection and adjustment â&#x20AC;˘ Loosen the setscrews In case of 2-valve cylinder head loosen the lock nut and adjusting screw, and check the valve for any inclination of valve cap (VC), entrance of dirt or wear. AB. Abnormal NO. Normal

TULI12EXN4814AB

TULI12EXN4815AB

TULI12EXN4816AB

TULI12EXN4817AA

In case of 4-valve cylinder head loosen the lock nut and adjusting screw of rocker arm. Be careful that excessive tension is not applied to the valve bridge (VB), and loosen a locknut of valve bridge (VB). NOTE: When loosening a locknut of a valve bridge (VB), loosen the locknut while fixing the valve bridge with a wrench (W) so that the valve may not lean.

Push the bridge head so that a valve bridge (VB) and two valve stem heads may contact each other uniformly, and adjust an adjusting bolt (AJ) so that a gap of the valve stem (AC) head may become 0. Tighten a locknut (RN) after a valve bridge (VB) is fixed with a wrench.

Measuring valve clearance Insert a 0.2 mm (0.008 in) or 0.3 mm (0.012 in) thickness gauge between the rocker arm and valve cap/valve bridge, and adjust the valve clearance. Tighten the adjusting screw.

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Model 3TNV82A~98 4TNV106(T)

Standard valve clearance 0.15 - 0.25 mm (0.01 - 0.01 in) 0.25 - 0.35 mm (0.01 - 0.01 in)

NOTE: When tightening a valve bridge (VB) locknut of 4valve head, tighten a locknut after fixing a valve bridge with a wrench (W) so that a bridge may not rotate and a valve may not lean. • Apply oil to the contact surface between adjusting screw and push rod. • Adjusting other cylinders. In case of 4-cylinder engines, turn the crankshaft by 180° and make adjustment for the no. 3 cylinder. Then adjust the no. 4 and no. 2 cylinders in this order. The cylinder to be adjusted first does not have to be the no. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 180° each time. In case of 4-cylinder engines, turn the crankshaft by 240° and make adjustment for the no. 3 cylinder. Then adjust the no. 2 cylinder in this order. The cylinder to be adjusted first does not have to be the no. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240° each time.

TULI12EXN4818AB

Fuel injection nozzle pressure inspection NOTICE: Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it.

Injection pressure measurement

TULI12EXN4819AB

Model 3TNV82A TNV88 (CL) 3TNV82A TNV88 (CL) 4TNV94L 4TNV106 (T)

Standard 19.6 - 20.6 MPa (2843.0 - 2988.0 psi) 21.6 - 22.6 MPa (3133.1 - 3278.1 psi)

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NOTE: As for the opening pressure of the brand-new fuel nozzle, about 0.5 MPa (72.5 psi), it decreases during engine operation for about 5 h because of the initial wear of the spring etc. Therefore, adjust it to 0.5 MPa (72.5 psi) or higher than the standard value indicated in the table above when adjusting a new spare fuel nozzle. Remove carbon deposit at the nozzle hole thoroughly. before measurement. • Connect the fuel injection valve to the high pressure pipe of the nozzle tester (NT). • Operate the nozzle tester (NT) lever slowly and read the pressure at the moment when the fuel injection (IN) from the nozzle starts. • If the measured injection (IN) pressure is lower than the standard level, replace the pressure adjusting shim with a thicker one. Thickness of pressure adjusting shims: 0.13 mm (0.01 in), 0.15 mm (0.01 in), 0.18 mm (0.01 in), 0.4 mm (0.02 in), 0.5 mm (0.02 in), 0.8 mm (0.03 in) Injection pressure adjustment: The injection pressure is increased by approx. 1.9 MPa (275.6 psi), when the adjusting shim thickness is increased by 0.1 mm (0.0039 in).

Informative: fuel injection valve structure

TULI12EXN4820FB

F. N. NB.

F.O. return pipe joint Nozzle Nozzle body

NS. NV. NZ.

Nozzle spring Nozzle valve Nozzle spring seat

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NC. NH.

PA. VS.

Nozzle case nut tightening: from 39.2 - 44.1 N·m (29 - 33 lb ft) Nozzle holder

Pressure adjusting shim Valve stop spacer

Spray pattern inspection After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness. Seat oil tightness check • After injecting a few times, increase the pressure gradually. Hold the pressure for about 5 s at a little before the valve opening pressure of 1.96 MPa (284 psi), and check to see that oil does not drip from the tip end of the nozzle. • If extreme oil leak from the overflow joint exists during injection by the nozzle tester, check after retightening. If much oil is leaking, replace the nozzle assembly.

TULI12EXN4821AA

TULI12EXN4822AA

TULI12EXN4823AA

Spray and injection states • Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection. • If normal injection as shown below cannot be obtained, replace the fuel injection valve. • No extreme difference between angles “θ” • No extreme injection angle difference “α” • Finely atomized spray • Excellent spray departure

Nozzle valve sliding test Wash the nozzle valve in clean fuel oil. Place the nozzle body vertically and insert the nozzle into the body to about 1/3 of its length. The valve is normal if it smoothly falls by its own weight into the body. In case of a new nozzle, remove the seal peel, and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thoroughly remove rust-preventive oil before using the nozzle. Note that a new nozzle is coated with rust-preventive oil and is pasted with the seal peel to shut-off outer air.

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Nozzle punch mark (P) 1. Design code 2. Number of hole (4 hole) 3. Diameter of hole (Ă¸ 0.24) 4. Size P, size S 5. Injection angle 6. Nozzle insertion angle Code A: Angled No code: No angle

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SMIL13MEX0076AB

TULI12EXN4824AB

Engine - Engine and crankcase

Engine - Inspect â&#x20AC;&#x201C; Every 2000 hours or 2 months Be sure to check the following points every 2000 h or one year operation, whichever comes first. Inspection item No. 1. Coolant water path flushing and maintenance 2. Fuel pipe and coolant pipe inspection and maintenance 3. Intake/exhaust valve seat lapping Fuel injection timing adjustment 4. Fuel injection pump inspection and adjustment

Coolant water path flushing and maintenance Rust and water scale will accumulate in the cooling system through many hours of operation. This lowers the engine cooling effect. Oil coolers (Attached to turbocharged engines and some of naturally aspirated engines) quickly deteriorate the lube oil. The cleaning and maintenance of the following parts are necessary in accordance with the coolant water replacement. Cooling system parts: Radiator, cooling water pump, thermostat, cylinder block, cylinder head, oil cooler.

Fuel pipe and coolant pipe inspection and maintenance Check the rubber hoses for fuel and coolant water pipes cracked. If cracked or degraded, replace them with new one. Replace the rubber hoses at least every 2 years even if 2000 h have not elapsed yet.

Intake/exhaust valve seat lapping The adjustment is necessary to maintain proper contact of the valves and seats.

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Fuel injection timing adjustment/fuel injection pump inspection and adjustment The fuel injection timing and the fuel injection pump are adjusted so that engine performance may become the best condition. As for the inspection and adjustment of the fuel pump, it is based on the service manual of the MP pump of the separate volume. The fuel injection timing is adjusted by the following procedure: As for the engine, which adopts a MP type fuel injection pump, the fuel injection angle (θi) (note) is adjusted for the fuel injection timing adjustment, because the adjusting method of fuel injection timing like an in-line fuel pump cannot be applied. NOTE: The fuel injection angle (θi) (cam angle) is the difference from the injection valve opening angle while the fuel injection pump being driven by a motor and the angle at the plunger lift 2.5 mm (0.10 in) of the fuel pump. And, as for the actual fuel injection angle (θi), the measured value is recorded on the pump body by each every fuel pump.

A. C.

I. NL. θi.

Angle at plunger lift 2.5 mm (0.10 in) Cam angle

TULI12EXN4826AB

TULI12EXN4827AB

Injection start angle Nozzle lift Injection angle

The adjustment of fuel injection angle (θi) In case that a fuel pump cover, installed with a gear case cover and the fuel pump are removed, and reassembled, the procedure of fuel injection angle adjustment is as follows. NOTE: Never loosen four flange screws, which fasten a pump flange and a fuel pump drive gear at the time of the removal of the fuel pump. When it is loosened, the adjustment of the fuel injection timing becomes very difficult.

D. F. G.

Fuel pump driving gear Fuel injection pump Idle gear

GI. F. M.

Gear installation, do not loosen nuts Fuel injection pump I.D. mark

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• Before removing a fuel pump ( FJ) drive gear ( GC), make identification marks ( M) on the gearing part of the pump drive gear and the idle gear with paint and so on ( MG). • Make the mark-off line to the gear case precisely in accordance with the position of mark-off line of the fuel pump ( MP). • Before removing a fuel pump, put the standard mark of a sticker ( MS) for fuel injection angle adjustment in accordance with the mark-off line of the fuel pump ( MP) and paste it on the gear case. FS. Fuel pump side GS. Gear case side

TULI12EXN4828AB

TULI12EXN4829AB

TULI12EXN4830AB

• Remove a fuel pump, and read the fuel injection angle recorded in that fuel pump. • Read the injection angle recorded on a reassembled fuel pump and calculate the difference from the injection angle of the disassembled fuel pump. (When re-installation does the same fuel pump, the angular difference is zero). Fuel injection angle difference (cam angle) = (The fuel injection angle of a reassembled fuel pump) (The fuel injection angle of a disassembled previous fuel pump) NOTE: Tell the fuel pump number to Yanmar, and inquire the injection angle of the pump when it is hard to find out. • Put the fuel pump ( FJ) on the gear case ( GC) temporarily and install the drive gear on the cam shaft with checking the identification marks ( M), which were put on the fuel pump drive gear and the idle gear at the time of the disassembling. MO. Mark-off line

Tighten the installation nut of a pump drive gear. Model

Tightening torque

Lubricating oil application (thread portion, and seat surface)

3TNV82A~TNV88 4TNV94L/98/106(T)

78 - 88 N·m (58 - 65 lb ft) 113 - 123 N·m (83 - 91 lb ft)

Not applied

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• Adjust the injection angle difference, (calculated in the above 5), at 0.25° in the unit in the installation angle of the fuel pump while reading the mark (minimum 0.5° and cam angle) of the adjustment sticker ( MS). NOTE: Push down the fuel pump in the outside direction of the cylinder block at +1° when a injection angle difference is +1°. Push it down to the cylinder block side when a difference is -1°. • Tighten the fuel pump installation nuts. MP. Mark-off line on fuel pump TULI12EXN4831AB

TULI12EXN4832AA

TULI12EXN4833AA

Supplementary explanation 1 The installation angle of the fuel pump is as follows:

Model 3TNV82A~TNV88 4TNV94L/98/106(T) 4TNV106(T)

Installation angle 25° 13° 11.5°

Supplementary explanation 2 When the injection time is advanced “A” or delayed “D”, the installation angle of the fuel pump is adjusted. When fuel injection timing is advanced for example at 2°, loosen the nuts (P), which fix the fuel pump on the gear case, and turn the fuel pump body in the outside direction of the cylinder block at 1°, and tighten the pump installation nuts. And, when fuel injection timing is delayed, a pump is turned in that reverse direction.

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Engine - Adjust Perform the adjusting operation of a engine as follows after the maintenance job: 1. Supply fuel, lubricating oil and coolant. NOTE: Check the levels of the lubricating oil and coolant water again after test running (for about 5 min) and add as required. 2. Start the engine, and carry out idling at a low revolution ( 700 - 900 RPM) for a few minutes. 3. Run in the engine for about 5 min at the rated revolution (no-load). Check any water, fuel or oil leak and existence of abnormal vibration or noise. Also check the oil pressure, coolant water temperature and exhaust gas color. 4. Adjust the no-load minimum and maximum revolutions according to the specifications. 5. Perform loaded operation as required.

Adjusting the no-load maximum or minimum speed 1. After warming the engine up, gradually raise the speed and set it at the no-load maximum revolution. 2. If the no-load maximum revolution is out of the standard, adjust it by turning the high idle (H) limiting screw. 3. Then set the no-load minimum speed by adjusting the low idle (LI) limiting screw.

TULI12EXN4834BB

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Standards Engine specification class CL

Rating speed 1500 RPM 1800 RPM 2000 RPM 2200 RPM 2400 RPM 2500 RPM 2600 RPM 2800 RPM 3000 RPM

No-load maximum 1575 1870 2180 2395 2590 2700 2785 2970 3185

1625 RPM 1920 RPM 2230 RPM 2445 RPM 2640 RPM 2750 RPM 2835 RPM 3020 RPM 3235 RPM

No-load minimum 1200 RPM or more

800 RPM or more ( 1100 RPM or more for 4TNV106(T))

NOTE: The engine speed may differ from the above standard depending on an engine installed on a machine unit.

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Engine - Storing Observe the following instructions when the engine is to be stored for a long period without operation: 1. Always drain coolant water in a cold season or before a long storage. (This is unnecessary when antifreeze is used.) NOTE: Negligence of water draining will cause the coolant water remaining inside the engine to be frozen and expanded to damage the engine parts. Water draining procedure: • Remove the radiator cap. • Loosen the water draining cock under the radiator to drain water from the inside. • Loosen the drain cock on the side surface of the cylinder to drain water from the inside. • After draining water, tighten the radiator cap and drain plug and cocks. 2. Remove the mud, dust and oil deposit and clean the outside. 3. Perform the nearest periodic inspection before the storage. 4. Drain or fill the fuel oil fully to prevent condensation in the fuel tank. 5. Disconnect the battery cable from the battery negative (-) terminal. 6. Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing or entrance. 7. Select a well-ventilated location without moisture and dust for storage. 8. Perform recharging once a month during storage to compensate for self-discharge.

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Engine - Prepare 1. Remove the side cover and the bonnet. 2. Remove the canopy. 3. Remove the negative side terminal of the battery. 4. Remove the counterweight. 5. Remove the control stand. 6. Remove the air cleaner. â&#x20AC;˘ Remove the air cleaner together with the bracket for installing the water separator. 7. Remove the silencer. 8. Remove the radiator. 9. Remove the pump or disconnect the hose connected to the pump.

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Engine - Remove 1. Disconnecting fuel hose. Disconnect each hose from the position marked with

2. Disconnecting cable connector. 1.

Disconnect the terminal B of the starter motor (M-1) on the positive cable of the battery.

Disconnect the grounding cable of the engine.

NOTICE: Prepare a worktable capable of enduring the weight of the engine and stably receiving the removed engine. 3. Removing engine. 1.

Loosen four M12 X 120 capscrews (12) fixing the engine on the rubber mount (6) to remove the engine.

: 19 mm 2. Lifting engine. Pass a wire rope through the two lifting eyes at the top of the engine and lift the engine. Weight: Approximately 155 kg (0.2 ton) 3. Place the engine stably on the worktable.

TULI12EXN6336BB

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Engine - Engine and crankcase

TULI12EXN6338GB

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Engine - Install Install the engine in reverse order of the removal. See the following table for the tightening torque and the sealant:

TULI12EXN6337AA

Tightening torque: Piece

Name

Tool

10 and 11

Screw M10

19 mm

M12 Bolt

22 mm

• Use the mount rubber (6) with identification color of “yellow” (three places). • Use the mount rubber (7) with identification color of “red” (one place).

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Torque 46.1 N·m (34.0 lb ft) Apply LOCTITE® 262 79.4 N·m (58.6 lb ft) Apply LOCTITE® 262

Engine - Engine and crankcase

TULI12EXN6338GB

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Engine - Disassemble Introduction Make preparation as follows before starting engine inspection and service: 1. Fix the engine on a horizontal base. NOTICE: Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work. 2. Remove the coolant water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven machine and engine, and drain coolant water, lubricating oil and fuel. 3. Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as to prevent any foreign matter from entering the engine.

CAUTION Eye injury hazard! Wear protective goggles when using compressed air. Failure to comply could result in minor or moderate injury. C0035A

NOTE: Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit shall be replaced. Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use should be replaced even when the measured value then satisfies the standard or limit.

Complete disassembly Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application. Therefore, description in this chapter is started with the steps to be taken just after the peripheral parts have been removed.

Step 1 Removal parts 1. Thoroughly remove sand, dust, dirt and soil from the surface of the engine. 2. Drain coolant water and lubricating oil from the engine.

Step 2 Removal parts 1. Remove turbocharger and exhaust manifold. 2. Remove intake manifold and surge tank.

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Step 3 Removal parts 1.

Close the fuel cock valve of the fuel tank.

Remove high-pressure fuel pipe.

Remove fuel return pipe.

Loosen the tightening nut on fuel injection nozzle retainer and extract the retainer and fuel injection nozzle. *) Fuel injection nozzle for Indirect injection system is screwed type.

Observations 1.

If nozzle seat is left on the cylinder head, remove the cylinder head before extracting nozzle seat.

To prevent dust from entering fuel injection nozzle, fuel injection pump and high-pressure fuel pipe, seal their respective threads with a tape or the like.

Whenever extracting fuel injection nozzle, replace nozzle protector with a new one.

Step 4 Removal parts 1. Remove rocker arm cover assembly.

Step 5 Removal parts 1. Remove valve rocker arm shaft assembly. 2. Remove the push rod. Observations 1.

Attach a tag with the reference No. of each cylinder to the push rod in order.

Remove valve cap from the intake/exhaust valve head.

Note that tappet of the indirect injection system can be removed at the same time when push rod is extracted.

Attach a tag to tappet for each cylinder No. to put the tappet in order.

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Step 6 Removal parts 1.

Remove the fan mounting screw, and then remove the fan.

Loosen the adjusting screw for the V-belt adjuster, and then remove the V-belt.

Remove alternator.

Remove the spacer for cooling fan and V-pulley.

Observations 1. Never turn down alternator vigorously toward the cylinder block. Otherwise, your finger may be nipped and alternator broken.

Step 7 Removal parts 1. Remove lubricating oil filter assembly. 2. Extract dipstick form the oil dipstick hole.

Step 8 Removal parts 1. Disconnect fuel return pipes. 2. Remove the fuel filter.

Step 9 Removal parts 1.

Disconnect coolant water pipe from the cooling water pump.

Remove thermostat assembly.

Remove the cooling water pump.

Step 10 Removal parts 1.

Remove cylinder head mounting screw.

Remove cylinder head assembly.

Remove cylinder head gasket.

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Observations 1.

Lay a cardboard or the like on the floor and place cylinder head assembly on it so as not to damage the combustion surface.

Order of loosening the cylinder head mounting screws.

To remove the intake/exhaust valves from cylinder head assembly, take the following steps:

• Using a valve spring compressor, compress valve spring and remove valve cotter. • Remove valve retainer and valve spring. TULI12EXN4873AA

TULI12EXN4874AA

• Remove intake valve and exhaust valve. 1B. Disassembly 4 cylinder head 1D. Disassembly 3 cylinder head 2C. Camshaft side 3F. Fan side

Step 11 Removal parts 1. Remove crankshaft V-pulley mounting screw. 2. Using a puller, extract crankshaft V-pulley. Observations 1. Extract crankshaft V-pulley by hitting the screw of the puller using a plastic hammer or the like.

Step 12 Removal parts 1.

Remove oil pan mounting screw under gear case.

Remove gear case mounting screw.

Remove gear case

Observations 1. Never fail to remove the reinforcing screw from the centre of the gear case. 2. When removing the gear case, carefully protect oil seal from damage.

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Step 13 Removal parts 1. Remove the nut from fuel injection pump drive gear. Extract fuel injection pump drive gear using a puller. Observations 1. Before removing fuel injection pump, make sure of the position of the arrow of the pump body for adjusting fuel injection timing as well as the position of the scribed line of the gear case flange. (Applies only to direct injection system.)

Step 14 Removal parts 1. Remove lubricating oil pump.

Step 15 Removal parts 1. Remove starting motor from flywheel housing sing.

Syep 16 Removal parts 1. Remove the flywheel mounting screw. 2. Remove the flywheel. Observations 1. Carefully protect the ring gear from damage.

Step 17 Removal parts 1. Remove flywheel housing. 2. Remove oil seal case with a screwdriver or the like by utilizing grooves on both sides of oil seal case. Observations 1. Carefully protect the ring gear from damage mage.

Step 18 Removal parts 1. Remove oil pan and spacer. Observations 1.

Put the cylinder block with the attaching surface of the cylinder head facing down.

Carefully protect the combustion surface of the cylinder block from damage.

For indirect injection system, be careful to the possibility of the tapped to drop off when the cylinder block is turned upside down, because the tappet is cylindrical in shape.

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Step 19 Removal parts 1.

Remove idle gear shaft, and then remove idle gear.

Remove the mounting screw of thrust bearing through the hole of the camshaft gear. Remove camshaft assembly.

Observations 1. Turn the cylinder block aside and carefully prevent tappet from jamming on the cam. 2. Preheat camshaft gear and camshaft assembly to 180Â°, 200Â° which are shrink fitted, before removing them.

Step 20 Removal parts 1. Remove gear case flange.

Step 21 Removal parts 1. Remove lubricating oil strainer.

Step 22 Removal parts 1. Remove crankpin side cap of the connecting rod. While turning crankshaft, place piston in the bottom dead center (BDC). Observations 1.

Before extracting piston, remove carbon deposits from the upper wall of the cylinder using fine sandpaper, while taking care not to damage the inner surface of the cylinder.

Make sure that the No. of the protection of the connecting rod matches the No. of the cylinder.

Take care not to let crankpin metal fall when removing connecting rod crankpin side cap.

Step 23 Removal parts 1.

Remove the main bearing cover screw. While shaking main bearing cap, remove main bearing cap together with lower main bearing metal.

Extract crankshaft, taking care not to damage it.

Remove upper main bearing metal.

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Observations 1.

Before extracting crankshaft, measure the side gap around it. Apply a dial gauge (D1) to the end of crankshaft (C2). Force the crankshaft on both sides in the axial direction to measure the thrust gap. Alternatively, insert a thickness gauge directly between the base thrust metal and the thrust surface of the crankshaft to measure the gap. If the limit size is exceeded, replace the thrust metal with a new one. Thrust gap (all models)

Notice on the removal of thrust metal. • When removing thrust metal, ascertain the position and direction where thrust metal is installed in relation to the cap. • Make sure that the thrust metal groove is outward in relation to the cap.

TULI12EXN4875BB

Step 24 Removal parts 1. Remove piston and connecting rod assembly. Observations To selectively remove a desired piston and connecting rod assembly without extracting crankshaft, take the steps itemized below: • Remove carbon deposits from the upper wall of the cylinder using fine sandpaper, taking care not to damage the inner surface of the cylinder. • While turning the crankshaft, with the connecting rod cap removed, raise the piston up to the top dead center (TDC). • Extract the piston rod/connecting rod assembly while tapping the connecting rod at the large end with the handle of a plastic hammer or the like.

Step 25 1. Remove tappet.

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Engine - Assemble To reassemble the engine components, follow the disassembly procedure in reverse order. However, follow the precautions below particularly before and during reassembly. 1. Cleaning the component Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft. Ensure that they are free from chips, dust, sand, and other foreign matter. 2. Parts to be replaced during reassembly Be sure to replace the following parts with new ones during assembly: • Valve rod gasket • Head gasket packing • Nozzle protector and nozzle seat of the fuel injection valve • Various copper packing, O-rings and gasket packing

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Engine - Check Trouble diagnosis Cause ClasGrsifioup caNo. tion Trouble 1* The starter motor does 1 Trounot turn ble 1 Starter rotates but hard start 2 to start 1 Idling not smooth Rota2 Medium speed hunting tion 2 High speed not smooth trou3 Not reach maximum ble speed Engine output not Per1 enough form3 Overheat ance Knocking at high drop 2 temperature Large amount of black 1 exhaust gas White exhaust gas Excessive oil 2 consumption Other Excessive fuel trou- 4 3 consumption ble Engine not stop when 4 key turned Off When key is turned Off, power supply 5 disconnected but engine not stop 1* 2* 3* 4* 5* 6* 7* 8* 9*

Serviceman Inspection Visual check Filters Fluid Gas/fluid 2* 3* 4* 5* 6* 7* 8* 9* 10* 11* 12* 13* 14* 15* 16* 17*

No fuel or leakage Air or water entered fuel system Oil filter clogged Air cleaner clogged Primary fuel filter clogged Fuel filter clogged Fan belt slip Breather hose clogged or depressed Coolant level

10* 11* 12* 13* 14* 15* 16* 17*

Poor quality fuel or leakage Improper specific gravity of battery electrolyte Improper viscosity or level of engine oil, or leakage Poor quality fuel or heavy oil used Large amount of blow by gas Gas leakage through valve gasket Excessive amount of engine oil Improper battery electrolyte level

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ClasGrsifioup caNo. tion 1 Trouble 1 start 2 1 Rota2 tion 2 trou3 ble

Cause

Trouble 1* The starter motor does not turn Starter rotates but hard to start Idling not smooth Medium speed hunting High speed not smooth Not reach maximum speed Engine output not enough

Serviceman Engine Mechanism Electric Electric 2* 3* 4* 5* 6* 7* 8*

Engine Dealer Suction/ Fuel system exhaust system 9* 10* 11* 12* 13* 14* 15* 16*

Per1 formOverheat 3 ance Knocking at high 2 drop temperature Large amount of black 1 exhaust gas White exhaust gas Excessive oil 2 consumption Other Excessive fuel trou- 4 3 consumption ble Engine not stop when key 4 turned Off When key is turned Off, power supply 5 disconnected but engine not stop 1* 2* 3* 4* 5* 6* 7* 8*

Fuse Start key switch Safety relay Connector and wiring Glow relay Glow plugs pre-heating Stop solenoid valve Starter motor

9* 10 11* 12* 13* 14* 15* 16*

Generator current limiter Feed pump function Check injection timing Check nozzle Injection pump Valve clearance Valve spring fatigue Air filter and muffler

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ClasGrsifioup caNo. tion 1 Trouble 1 start 2 1 Rota2 tion 2 trou3 ble

Engine dealer

Cause

Trouble The starter motor does not turn Starter rotates but hard to start Idling not smooth Medium speed hunting High speed not smooth Not reach maximum speed Engine output not enough

LubricaCooltion sysing tem 1* 2* 3* 4* 5* 6* 7* 8*

Mechanical 9* 10* 11* 12* 13* 14* 15* 16*

Per1 formOverheat 3 ance Knocking at high drop 2 temperature Large amount of black 1 exhaust gas White exhaust gas Excessive oil 2 consumption Other Excessive fuel trou- 4 3 consumption ble Engine not stop when key 4 turned Off When key is turned Off, power supply 5 disconnected but engine not stop 1* 2* 3* 4* 5* 6* 7* 8*

Oil gets into combustion chamber through piston/valve guide Check relief valve Fuel mixed Thermostat inspection Oil cooler element damaged Compression pressure low Control rack movement not smooth Governor spring fatigue

Crank shaft oil seal defective

10 11* 12* 13* 14* 15* 16*

Piston liner worn Piston ring worn Valve spring fatigue Internal part seizure Check fuel feed Defective head gasket Flywheel gear damaged

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Starting trouble Starter not rotate

TULI12EXN4512GA

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The starter rotates but does not start

TULI12EXN4513GA

NOTE: Check with the engine start key being in â&#x20AC;&#x153;ONâ&#x20AC;? position.

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Engine - Engine and crankcase

Engine rotation trouble

TULI12EXN4514GA

NOTE: Check the above items at a coolant temperature above 50 °C (122 °F).

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Output drops down Engine output not enough

TULI12EXN4515HA

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NOTE: Check in the condition of operating at high speed.

Knocking at high temperature

TULI12EXN4516EA

NOTE: Check at an engine coolant temperature above 50 째C (122 째F).

Other trouble Exhaust trouble

TULI12EXN4517FA

NOTE: Check at an engine coolant temperature above 50 째C (122 째F).

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NOTE: A breather mechanism of blow-by gas reduction system is applied to the engine as shown in the right drawing. Remove and plug the suction manifold to check blow-by gas. 1.

Diaphragm cover

Spring

Centre plate

Diaphragm

Remove this side

Bonnet

Breather baffle

Breather pipe

Baffle plate

10. Plug 11. Suction manifold

TULI12EXN5240BB

Excessive oil consumption

TULI12EXN4518EA

NOTE: Check in the condition of no engine oil leakage.

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Engine excessive fuel consumption

TULI12EXN4519EA

NOTE: Check in the condition the proper fuel is used.

Engine not stop when key turned Off

TULI12EXN4520EA

NOTE: Check with the engine start key being in “OFF” position.

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Engine - Service instruction Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and prevent the recurrence of the trouble. 1. What is the most recurring symptom of the trouble situation? (e.g. strange exhaust gas colour) 2. Investigation of the past records of the engine Check a client control ledger, and examine the history of the engine. • Investigate the engine model name and the engine number. (Mentioned in the engine label). Examine the machine unit name and its number in the same way. • When was the engine maintained last time? • How much period and/or time has it been used after it was maintained last time? • What kind of problem was there on the engine last time? What kind of maintenance was carried out? 3. Hear the occurrence phenomenon from the operator of the engine in detail. 5 Modes + 1 for “5W1H” phenomenon occurrence: when, where, who, what, why and how. • When did the trouble happen at what kind of time? • Was there anything changed before the trouble? • Did the trouble occur suddenly, or was there what or a sign? • Has any related phenomenon occurred? (e.g. Strange exhaust color and starting failure at the same time) 4. After presuming a probable cause based on the above investigation, investigate a cause systematically by the next troubleshooting guide, and find out the cause of sincerity.

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Troubleshooting by measuring compression pressure Compression pressure drop is one of major causes of increasing blow-by gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the following factors: • Degree of clearance between piston and cylinder • Improper clearance of intake/exhaust valve • Gas leak from nozzle gasket or cylinder head gasket In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use of the engine. A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring. Measure the compression pressure to diagnose presence of any abnormality in the engine.

Compression pressure measurement method • After warming up the engine, remove the fuel injection pipe and valves from the cylinder to be measured. • Crank the engine before installing the compression gauge adapter. 1.

* Perform cranking with the stop handle at the stop position (no injection state).

* See Engine - Service limits (10.001) for the compression gauge and compression gauge adapter.

• Install the compression gauge and compression gauge adapter at the cylinder to be measured.

TULI12EXN4841AB

1. Never forget to install a gasket at the tip end of the adapter. • With the engine set to the same state as in 2, *1, crank the engine by the starter motor until the compression gauge reading is stabilized.

Standard compression pressure Engine compression pressure list (reference value) Engine mode 3TNV82A 3/4TNV84 3/4TNV84T TNV88 106 (T)

Compression pressure at 250 RPM Limit value Standard value 3.06 - 3.26 MPa 2.35 - 2.55 MPa (444 - 473 psi) (341 - 370 psi) 3.14 - 3.34 MPa 2.45 - 2.65 MPa (455 - 484 psi) (355 - 384 psi) 2.84 - 3.04 MPa 2.35 - 2.55 MPa (412 - 441 psi) (341 - 370 psi) 3.33 - 3.53 MPa 2.65 - 2.85 MPa (483 - 512 psi) (384 - 413 psi)

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Deviation among cylinders

0.2 - 0.3 MPa (29 - 44 psi)

Engine - Engine and crankcase

Engine speed and compression pressure (for reference)

TULI12EXN4842FA

CP. Compression pressure (MPa)

ES. Engine speed (RPM)

Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below.

No.

Piece Air cleaner element

2. 3. 4.

Valve clearance Valve timing Cylinder head gasket

Intake/exhaust valve Valve seat

Piston Piston ring Cylinder

Cause Clogged element Broken element Defect element seal portion Excessive or no clearance Incorrect valve clearance Gas leak from gasket

Corrective action Clean the element Replace the element

Adjust the valve clearance Adjust the valve clearance Replace the gasket Tighten the cylinder screws again to the specified tightening torque (See Cylinder heads - Disassemble (10.101) ) Lap the valve seat. (See Gas leak due to worn valve seat or foreign matter Valve seat - Regrind (10.101) ) trapping Replace the intake/exhaust Sticking valve valve Gas leak due to scratching Perform honing and or wear use oversize parts. (See Cylinder heads Disassemble (10.101) -“Cylinder block”, “Link rod” and Cylinder heads Adjust (10.101)

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Quick reference table for troubleshooting The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service life.

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Trouble symptom

Starting failure Engine starts but stops soon Exhaust smoke

Cause

Engine system

Turbocharger

Improper clearance of intake/exhaust valve. Compression leakage from valve seat Seizure of intake/exhaust valve Blowout from cylinder head gasket Seized or broken piston ring Worm piston ring, piston or cylinder Seized crankpin metal or bearing Improper arrangement of piston ring joints Reverse assembly of piston rings Worm crankpin and journal bearing Loosened connecting rod bolt Foreign matter trapped in combustion chamber Excessive gear backlash Seizure of intake/exhaust valve Defective battery Improper open/close timing of intake/exhaust valves Fouled blower Waste gate malfunction Worn floating bearing

Engine does not start.

None

Little

Much

Insufficient engine output Exhaust colour

Normal

White

Black

Strange exhaust gas colour During work

White

Black

Hunting High knocking sound during combustion

Abnormal engine sound

Uneven combustion sound

Corrective action During idling

During work Adjust the valve clearance.

Lap the valve seat. O

O O

Reassembly correctly.

Tighten to the specified torque.

Disassemble and repair.

Adjust gear meshing. Measure and replace. Regular.

O O O

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Measure and replace.

O O

Replace the piston ring. Perform honing and use oversize parts. Repair or replace. Correct the ring joint positions.

O O

Correct or replace. Replace the gasket.

Adjust the valve clearance. Wash the blower. Disassemble and inspect. Disassemble and inspect.

Engine - Engine and crankcase

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Trouble symptom

Large engine vibration

Cause

Engine system

Turbocharger

Lubricating oil

Difficulty in Engine exreturning cessive fuel Excessive to low consump- consumpspeed tion tion

Coolant

Corrective action

Diluted with fuel

Much Mixture Low L.O. blow-by Overheat- Low water Pressure with gas ing temperature drop water pressure

O O

Exhaust temperature rise O

O O

O O O O

Adjust the valve clearance. Lap the valve seat. Correct or replace. Replace the gasket.

Pressure rise

O O

Air intake

Replace the piston ring. Perform honing and use oversize parts. Repair or replace. Correct the ring joint positions. Reassembly correctly. Measure and replace. Tighten to the specified torque.

Disassemble and repair.

Adjust gear meshing. Measure and replace. Regular. Adjust the valve clearance. Wash the blower. Disassemble and inspect. Disassemble and inspect.

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Trouble symptom

Starting failure Engine starts but stops soon Exhaust smoke Engine does not start.

Cause

Cooling Water System

Little

Much

Normal

White

Excessive cooling effect of radiator Insufficient cooling effect of radiator

Black

High knocking sound during combustion

Abnormal engine sound

Uneven combustion sound

Corrective action During idling

During work Defective thermostat (kept closed) Defective thermostat (kept opened) or slipping fan belt Water leak check in cooling water system Repair or replace. Adjust the belt tension. Check or replace.

O O O O O

Use proper lubricating oil.

Repair. Check and repair. Clean or replace. Clean, adjust or replace. Add proper lubricating oil. Check and adjust.

O O

Fuel filter clogged Air entrance in fuel system Clogged or cracked fuel pipe

O O O

Insufficient fuel supply to fuel injection pump

Uneven injection volume of fuel injection pump Excessive fuel injection volume Poor spray pattern from fuel injection nozzle

Clogged strainer at feed pump inlet

White

Hunting

Water entrance in fuel system

Priming failure

Black

Strange exhaust gas colour During work

Insufficient coolant water level

Cracked water jacket Slackened fan belt Faulty thermostat Improper properties of lubricating oil Leakage from lubricating oil piping system Insufficient delivery from Lubricating system trochoid pump Clogged lubricating oil filter Defective pressure regulating valve Insufficient lubricating oil level Too early timing of fuel injection Too late timing of fuel injection pump Improper properties of fuel oil

Fuel system

None

Insufficient engine output Exhaust colour

Check and adjust. O O

Check and adjust. Check and adjust.

O O

Use proper fuel oil. Perform draining from the fuel filter. Clean or replace. Bleed air. Clean or replace. Check the fuel tank cock, fuel filter, fuel pipe and fuel feed pump.

Check and adjust. Foreign matter trapped in the valve inside the priming pump. (Disassemble and clean).

O O

Clean the strainer.

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Trouble symptom

Large engine vibration

Cause

Cooling Water System

Lubricating system

Fuel system

Lubricating oil

Excessive cooling effect of radiator Insufficient cooling effect of radiator

Difficulty Engine in returning excessive fuel Excessive to low Diluted speed consumption consumption with fuel

Coolant

Corrective action Mixture with water

Much Low L.O. blow-by gas pressure

Overheating

Exhaust Low water Pressure Pressure temperature temperature drop rise rise Defective thermostat (kept closed)

Insufficient coolant water level Cracked water jacket Slackened fan belt Faulty thermostat Improper properties of lubricating oil Leakage from lubricating oil piping system Insufficient delivery from trochoid pump Clogged lubricating oil filter Defective pressure regulating valve Insufficient lubricating oil level Too early timing of fuel injection pump Too late timing of fuel injection pump Improper properties of fuel oil Water entrance in fuel system Fuel filter clogged Air entrance in fuel system Clogged or cracked fuel pipe Insufficient fuel supply to fuel injection pump Uneven injection volume of fuel injection pump Excessive fuel injection volume Poor spray pattern from fuel injection nozzle

Air intake

O O O

O O

Defective thermostat (kept opened) or slipping fan belt Water leak check in cooling water system Repair or replace. Adjust the belt tension. Check or replace. Use proper lubricating oil.

Repair.

Check and repair.

Clean or replace.

Clean, adjust or replace.

Add proper lubricating oil. Check and adjust.

O O

Check and adjust. Use proper fuel oil. Perform draining from the fuel filter. Clean or replace. Perform air bleeding. Clean or replace. Check the fuel tank cock, fuel filter, fuel pipe and fuel feed pump.

O O O

Check and adjust.

Check and adjust. Check and adjust.

Priming failure

Foreign matter trapped in the valve inside the priming pump.

Clogged strainer at feed pump inlet

Clean the strainer.

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Trouble symptom

Starting failure Engine starts but stops soon Exhaust smoke Engine does not start.

Cause

Air/Exhaust Gas System

Electrical system

Air cleaner clogged Engine used at high temperatures or at high altitude Clogged exhaust pipe

Starter motor defective Alternator defective Open-circuit in wiring Battery voltage drop

None

Little

Much O

Insufficient engine output Exhaust colour

Normal

White

Black O

Strange exhaust gas colour During work

White

Black O

Hunting High knocking sound during combustion

Abnormal engine sound

Uneven combustion sound O

Corrective action During idling

During work Clean. Study output drop and load matching. Clean.

Repair or replace. Repair or replace. Repair. Inspect and change the battery.

O O O O

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Trouble symptom

Large engine vibration

Cause

Air/Exhaust Gas System

Electrical system

Lubricating oil

Air cleaner clogged Engine used at high temperatures or at high altitude Clogged exhaust pipe

Difficulty Engine in returning excessive fuel Excessive to low Diluted speed consumption consumption with fuel

Coolant

Air intake Corrective action

Mixture with water

Much Low L.O. blow-by gas pressure

Overheating O

Exhaust Low water Pressure Pressure temperature temperature drop rise rise O Clean. Study output drop and load O matching. O Clean.

Repair or replace. Repair or replace. Repair. Inspect and change the battery.

Starter motor defective Alternator defective Open-circuit in wiring Battery voltage drop

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Index Engine - 10 Engine and crankcase - 001 Engine - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Engine - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Engine - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Engine - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Engine - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine - General specification - 3TNV88A-PYB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine - Inspect - Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Engine - Inspect – Every 1000 hours or one year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Engine - Inspect – Every 2000 hours or 2 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Engine - Inspect – Every 250 hours or 3 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Engine - Inspect – Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Engine - Inspect – Every 500 hours or 6 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Engine - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Engine - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Engine - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Engine - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Engine - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine - Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Engine and crankcase - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Pan and covers - 102

CX35B CX39B

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Contents Engine - 10 Pan and covers - 102

FUNCTIONAL DATA Pan and covers Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Pan and covers Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine oil pan Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Pan and covers - Component identification NOTE: This figure shows the 3TNV84.

TULI12EXN5012GB

1. 2. 3. 4. 5. 6. 7.

Oil screen Oil pan spacer Oil pan Oil suction pipe Piston and connecting rod Flywheel housing Bearing cap

8. 9. 10. 11. 12. 13. 14.

Crankshaft Tappet Piston ring Oil seal case Flywheel Oil seal Gear case flange

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Engine - Pan and covers

Pan and covers - Disassemble Disassemble in the order of the numbers shown in the illustration (See Pan and covers - Component identification (10.102)) • Perform all steps of the cylinder head disassembly procedure. • Perform all steps in the gear train disassembly procedure. • Remove the oil pan. (See “Point 1” of Engine oil pan - Disassemble (10.102) ). • Remove the lubricating oil suction pipe. • Remove the piston with the rod. (See “Point 2” of Connecting rods and pistons - Disassemble (10.105) ). • Remove the mounting flange (See “Point 3” of Crankshaft and flywheel - Disassemble (10.103) ). • Remove the bearing metal caps. (See “Point 4” of Crankshaft and flywheel - Disassemble (10.103) ). • Remove the crankshaft. (See “Point 5” of Crankshaft and flywheel - Disassemble (10.103)). • Remove the tappets. • Remove the pistons and rings. (See “Point 6” of Piston - Disassemble (10.105) ). • Remove the oil seal from the mounting flange.

Reassembly procedure Reverse order of the disassembly procedure.

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Engine oil pan - Disassemble Point 1: Oil pan Disassembly Sealant is applied to the oil pan mounting surface on the block. Carefully operate so as not to damage or distort the bonding surface. 1. Thickness gauge 2. Crankshaft

TULI12EXN5013AB

Reassemble Apply sealant before reassembly.

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Index Engine - 10 Pan and covers - 102 Engine oil pan - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pan and covers - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pan and covers - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Valve drive and gears - 106

CX35B CX39B

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Contents Engine - 10 Valve drive and gears - 106

TECHNICAL DATA Valve drive and gears Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Valve drive and gears Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Valve drive and gears Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Valve drive and gears - Service limits Camshaft Inspection item Side gap Bending (1/2 the dial gauge reading) 3TNV82A-TNV88 Cam height 4TNV94LÂˇ98 4TNV106(T) Shaft outside diameter / Metal inside diameter Bushing inside diameter Camshaft outside Gear side diameter Tolerance Bushing inside diameter TNV82A~TCamshaft outside Intermediate NV88 diameter Tolerance Bushing inside diameter Camshaft outside Flywheel side diameter Tolerance Bushing inside diameter Camshaft outside Gear side diameter Tolerance Bushing inside diameter 4TNV94L/ Camshaft outside Intermediate 98(T) diameter Tolerance Bushing inside diameter Camshaft outside Flywheel side diameter Tolerance Bushing inside diameter Camshaft outside Gear side diameter Tolerance Bushing inside diameter 4TNV106( Camshaft outside Intermediate T) diameter Tolerance Bushing inside diameter Camshaft outside Flywheel side diameter Tolerance

Standard value 0.05 - 0.2 mm (0.002 - 0.01 in) 0 - 0.02 mm (0.00 - 0.0008 in) 38.6 - 38.8 mm (1.52 - 1.53 in) 43.4 - 43.6 mm (1.71 - 1.72 in) 50.9 - 51.1 mm (2.00 - 2.01 in)

Limit value 0.3 mm (0.01 in) 0.05 mm (0.002 in) 38.35 mm (1.51 in) 43.15 mm (1.70 in) 50.65 mm (1.99 in)

44.99 - 45.055 mm (1.77 - 1.77 in)

45.13 mm (1.78 in)

44.925 - 44.95 mm (1.77 - 1.77 in)

44.89 mm (1.77 in)

0.04 - 0.13 mm (0.002 - 0.01 in) 45 - 45.025 mm (1.77 - 1.77 in)

0.24 mm (0.01 in) 45.1 mm (1.78 in)

44.91 - 44.935 mm (1.77 - 1.77 in)

44.875 mm (1.77 in)

0.065 - 0.115 mm (0.003 - 0.005 in) 45 - 45.025 mm (1.77 - 1.77 in)

0.225 mm (0.01 in) 45.1 mm (1.78 in)

44.925 - 44.95 mm (1.77 - 1.77 in)

44.89 mm (1.77 in)

0.05 - 0.1 mm (0.002 - 0.004 in) 49.99 - 50.055 mm (1.97 - 1.97 in)

0.21 mm (0.01 in) 50.13 mm (1.97 in)

49.925 - 49.95 mm (1.97 - 1.97 in)

49.89 mm (1.96 in)

0.04 - 0.13 mm (0.002 - 0.01 in) 50 - 50.025 mm (1.97 - 1.97 in)

0.24 mm (0.01 in) 50.1 mm (1.97 in)

49.91 - 49.935 mm (1.96 - 1.97 in)

49.875 mm (1.96 in)

0.065 - 0.115 mm (0.003 - 0.005 in) 50 - 50.025 mm (1.97 - 1.97 in)

0.225 mm (0.01 in) 50.1 mm (1.97 in)

49.925 - 49.95 mm (1.97 - 1.97 in)

49.89 mm (1.96 in)

0.05 - 0.1 mm (0.002 - 0.004 in) 57.98 - 58.05 mm (2.28 - 2.29 in)

0.21 mm (0.01 in) 58.105 mm (2.29 in)

57.91 - 57.94 mm (2.28 - 2.28 in)

57.875 mm (2.28 in)

0.04 - 0.14 mm (0.002 - 0.006 in) 58 - 58.03 mm (2.28 - 2.28 in)

0.25 mm (0.01 in) 58.105 mm (2.29 in)

57.895 - 57.925 mm (2.28 - 2.28 in)

57.86 mm (2.28 in)

0.075 - 0.135 mm (0.003 - 0.005 in) 58 - 58.03 mm (2.28 - 2.28 in)

0.245 mm (0.01 in) 58.105 mm (2.29 in)

57.91 - 57.94 mm (2.28 - 2.28 in)

57.875 mm (2.28 in)

0.05 - 0.12 mm (0.002 - 0.005 in)

0.23 mm (0.01 in)

Idle gear shaft and bushing Inspection item Shaft outside diameter Bushing inside diameter Tolerance

Standard value 45.95 - 45.975 mm (1.81 - 1.81 in) 46 - 46.025 mm (1.81 - 1.81 in) 0.025 - 0.075 mm (0.001 - 0.003 in)

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Limit value 45.9 mm (1.81 in) 46.075 mm (1.81 in) 0.175 mm (0.01 in)

Engine - Valve drive and gears

Backlash of each gear Model 3TNV82A~88 4TNV94L 4TNV98(T) 4TNV106(T)

Inspection item Crank gear, cam gear, idle gear, fuel injection pump gear and P.T.O. gear Crank gear, cam gear, idle gear, fuel injection pump gear and P.T.O. gear Lubricating oil pump gear Balancer drive gear (only for 4TNV106(T))

Standard value

Limit value

0.07 - 0.15 mm (0.003 - 0.006 in)

0.17 mm (0.01 in)

0.08 - 0.14 mm (0.003 - 0.006 in)

0.16 mm (0.01 in)

0.09 - 0.15 mm (0.004 - 0.006 in)

0.17 mm (0.01 in)

0.12 - 0.18 mm (0.005 - 0.007 in)

0.2 mm (0.008 in)

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Valve drive and gears - Component identification NOTE: This figure shows the 3TNV84.

TULI12EXN5005GB

1. 2. 3. 4. 5. 6. 7.

Camshaft driving gear Coolant pump Crankshaft pulley Gear case Fuel injection pump Idler gear Crankshaft gear

8. 9. 10. 11. 12. 13. 14. 15.

Starter motor Flywheel Cam shaft Gear case flange Oil seal Fuel pump spacer Flywheel housing Donâ&#x20AC;&#x2122;t disassemble: pump flange (16), fuel pump drive gear (17), flange bolt (18)

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Valve drive and gears - Disassemble Disassemble in the order of the numbers shown in the illustration. • Perform all steps in. • Remove the cooling water pump. • Remove the crankshaft pulley (“Point 1”). • Remove the gear case cover (“Point 2”). • Remove the fuel injection pump (“Point 3”). • Remove the idle gear assy (“Point 4”). • Remove the P.T.O. drive gear (“Point 5”). • Remove the starting motor. • Remove the flywheel (“Point 6”). • Remove the camshaft assy (“Point 7”). • Remove the gear case (“Point 8”). • Remove the oil seal from the gear case cover.

Point 1 Disassembly • Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley setscrew. When removing the pulley using the gear puller, use a pad and carefully operate so as not to damage the thread. Set the gear puller securely to prevent the pulley from being damaged.

Reassemble • Apply grease MG2 to the oil seal lips. For the oil seal with double lips dust seal, further slightly apply engine oil on the lips so as not to damage them. • Clean by wiping off any oil on both taper surfaces using detergent. • Be sure to use the crankshaft pulley installing tool so as not to damage the oil seal lips. • When installing the crankshaft pulley, apply lube oil to the setscrew to tension it and carefully assemble so as not to damage the oil seal. Model

Tightening torque 112.7 - 122.7 N·m (83 - 90 lb ft) 107.9 - 127.5 N·m (80 - 94 lb ft)

3TNV82A~TNV88 4TNV94L/98/106(T)

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Engine - Valve drive and gears

Point 2 Reassemble • When installing the gear case, do not forget to install the two reinforcing screws at the centre. • Measure the backlash of each gear. 5. Rotating direction

TULI12EXN5006AB

3TNV82A~88 Crankshaft gear (4) Crankshaft gear (2) Fuel injection pump (1) Idle gear (7), P.T.O. gear (3) Lubricating oil pump gear (6) 4TNV94L-106(T) Crankshaft gear (4) Crankshaft gear (2) Fuel injection pump (1) Idle gear (7), P.T.O. gear (3) Balancer gear (only 4TNV106(T)) Lubricating oil pump gear (6)

Standard value

Limit value

0.07 - 0.15 mm (0.00 - 0.01 in)

0.17 mm (0.01 in)

0.11 - 0.19 mm (0.00 - 0.01 in)

0.21 mm (0.01 in)

Standard value

Limit value

0.08 - 0.14 mm (0.00 - 0.01 in)

0.16 mm (0.01 in)

0.12 - 0.18 mm (0.00 - 0.01 in) 0.09 - 0.15 mm (0.00 - 0.01 in)

0.20 mm (0.01 in) 0.17 mm (0.01 in)

• Apply sealant and install the gear case by correctly positioning the two dowel pins.

Point 3 Disassembly • Remove the mounting nut of the fuel injection pump drive gear, remove the gear using the gear puller, and remove the fuel injection pump. Do not forget to remove the stay on the rear side. When extracting the gear using the gear puller, use a pad at the shaft and carefully operate so as not to damage the thread.

Reassemble • Tightening torque for fuel pump drive gear nut (without lube oil). Model

Tightening torque 78 - 88 N·m (58 - 65 lb ft) 113 - 123 N·m (83 - 91 lb ft)

TNV82A~88 4TNV94L/98/106(T)

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Engine - Valve drive and gears

Point 4 Reassemble • Assemble crankshaft gear (A), fuel injection pump drive gear (B) and camshaft gear (C) at the same time by aligning with idle gear (A), (B) and (C) marks. • Install the idle gear shaft with the oil hole facing upward.

Point 5 Reassemble • Install the P.T.O. drive gear with its inner spline side facing the flywheel.

Point 6 Disassembly • Install a screw to be used as a handle in the hole at the end face of the flywheel and remove carefully so as not to damage the ring gear.

Reassemble • Flywheel mounting screw: apply lube oil Model

Tightening torque 83.3 - 88.2 N·m (61 - 65 lb ft) 186.2 - 205.8 N·m (137 - 152 lb ft)

3TNV82A~88 4TNV94L/98/106(T)

Point 7 Disassembly Measure the camshaft side gap (10).

TULI12EXN5007AB

Piece Side gap

Standard value 0.05 - 0.20 mm (0.00 - 0.01 in)

• If the measured side gap (10) exceeds the limit, replace the thrust metal (9).

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Limit value 0.30 mm (0.01 in)

Engine - Valve drive and gears

Disassembly • Since the camshaft gear (8) is shrink-fit, heat it to 180 - 200 °C (356 - 392 °F) for extraction. • For camshaft removal, raise the engine with its mounting flange at the bottom. After removing the thrust metal mounting screw from the camshaft gear hole, extract the camshaft carefully so as not to damage the bearing bushing. • Rotate the camshaft a few turns before extracting it to prevent the tappet from being caught by the cam. • After removing the camshaft, set the engine horizontal and fix it on the base. NOTICE: Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the horizontal position. Proceed carefully so as not to lose balance.

Point 8 Reassemble • Do not forget to install the oil pan mounting screws on the bottom side when installing the gear case. • Apply sealant and install the gear case by matching the two dowel pins.

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Engine - Valve drive and gears

Valve drive and gears - Measure Cam shaft Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and gear damage. A. Shaft bend measurement Support the camshaft with V blocks (12). Rotate the camshaft and measure the runout at the center of the camshaft and at each journal with a dial gauge (11), half of the runout is the bend.

TULI12EXN5008AB

Piece Bend

Standard value 0 - 0.02 mm (0 - 0.00 in)

Limit value 0.05 mm (0.00 in)

B. Intake/exhaust cam height measurement Model 3TNV82A~88 4TNV94LÂˇ98 4TNV106(T)

Standard value 38.600 - 38.800 mm (1.52 - 1.53 in) 43.400 - 43.600 mm (1.71 - 1.72 in) 50.900 - 51.100 mm (2.00 - 2.01 in)

Limit value 38.350 mm (1.51 in) 43.150 mm (1.70 in) 50.650 mm (1.99 in)

C. Measurement of camshaft outer diameter and bearing hole diameter. Measure the camshaft outer diameter with a micrometer (13). The oil clearance shall be calculated by subtracting the measured camshaft outside diameter from the camshaft bushing inside diameter after insertion to the cylinder measured with a cylinder gauge.

TULI12EXN5009AB

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Engine - Valve drive and gears

Model

Position

Gear side

Piece Bushing inside diameter Camshaft outside diameter Oil clearance

3TNV82A~TNV88

Middle position

Bushing inside diameter Camshaft outside diameter Oil clearance

Flywheel side

Bushing inside diameter Camshaft outside diameter Oil clearance

Gear side

Bushing inside diameter Camshaft outside diameter Oil clearance

TNV94L/98(T)

Middle position

Bushing inside diameter Camshaft outside diameter Oil clearance

Flywheel side

Bushing inside diameter Camshaft outside diameter Oil clearance

Gear side

Bushing inside diameter Camshaft outside diameter Oil clearance

4TNV106(T)

Middle position

Bushing inside diameter Camshaft outside diameter Oil clearance

Flywheel side

Bushing inside diameter Camshaft outside diameter Oil clearance

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Standard value 44.990 - 45.055 mm (1.77 - 1.77 in) 44.925 - 44.950 mm (1.77 - 1.77 in) 0.040 - 0.130 mm (0.00 - 0.01 in) 45.000 - 45.025 mm (1.77 - 1.77 in) 44.910 - 44.935 mm (1.77 - 1.77 in) 0.065 - 0.115 mm (0.00 - 0.00 in) 45.000 - 45.025 mm (1.77 - 1.77 in) 44.925 - 44.950 mm (1.77 - 1.77 in) 0.050 - 0.100 mm (0.00 - 0.00 in) 49.990 - 50.055 mm (1.97 - 1.97 in) 49.925 - 49.950 mm (1.97 - 1.97 in) 0.040 - 0.130 mm (0.00 - 0.01 in) 50.000 - 50.025 mm (1.97 - 1.97 in) 49.910 - 49.935 mm (1.96 - 1.97 in) 0.065 - 0.115 mm (0.00 - 0.00 in) 50.000 - 50.025 mm (1.97 - 1.97 in) 49.925 - 49.950 mm (1.97 - 1.97 in) 0.05 - 0.100 mm (0.00 - 0.00 in) 57.980 - 58.050 mm (2.28 - 2.29 in) 57.910 - 57.940 mm (2.28 - 2.28 in) 0.040 - 0.140 mm (0.00 - 0.01 in) 58.000 - 58.030 mm (2.28 - 2.28 in) 57.895 - 57.925 mm (2.28 - 2.28 in) 0.075 - 0.135 mm (0.00 - 0.01 in) 58.000 - 58.030 mm (2.28 - 2.28 in) 57.910 - 57.940 mm (2.28 - 2.28 in) 0.050 - 0.120 mm (0.00 - 0.00 in)

Limit value 45.130 mm (1.78 in) 44.890 mm (1.77 in) 0.240 mm (0.01 in) 45.100 mm (1.78 in) 44.875 mm (1.77 in) 0.225 mm (0.01 in) 45.100 mm (1.78 in) 44.890 mm (1.77 in) 0.210 mm (0.01 in) 50.130 mm (1.97 in) 49.890 mm (1.96 in) 0.240 mm (0.01 in) 50.100 mm (1.97 in) 49.875 mm (1.96 in) 0.225 mm (0.01 in) 50.100 mm (1.97 in) 49.890 mm (1.96 in) 0.210 mm (0.01 in) 58.105 mm (2.29 in) 57.875 mm (2.28 in) 0.250 mm (0.01 in) 58.105 mm (2.29 in) 57.860 mm (2.28 in) 0.245 mm (0.01 in) 58.105 mm (2.29 in) 57.875 mm (2.28 in) 0.230 mm (0.01 in)

Engine - Valve drive and gears

Idler gear Mainly check the bushing seizure and wear, and gear damage (18). Measurement of shaft outer diameter (17) and bushing inner diameter. 15. Idler gear 16. Shaft

TULI12EXN5010AB

Piece Shaft outside diameter Bushing inside diameter Tolerance

Standard value 45.950 - 49.975 mm (1.81 - 1.97 in) 46.000 - 46.025 mm (1.81 - 1.81 in) 0.025 - 0.075 mm (0.00 - 0.00 in)

P.T.O. drive gear Mainly check sticking of bearings on both sides, gear damage and looseness, and gear shaft damage and wear.

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Limit value 45.900 mm (1.81 in) 46.075 mm (1.81 in) 0.175 mm (0.01 in)

Engine - Valve drive and gears

Valve drive and gears - Assemble Reverse order of the disassembly procedure.

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Engine - Valve drive and gears

Valve drive and gears - Replace Oil seal replacement (gear case side) 1. Replace the oil seal with a new one when the gear case is disassembled. Extract the used oil seal. 2. Insert a new oil seal. Fit the position of the oil seal i sertion to the end face of the gear case. 3. Apply grease to the oil seal tips. For the oil seal with double lips (19) (dust seal), further, slightly apply engine oil on the oil seal lip so as not to damage them, when installing the pulley. NOTE: Pay attention not to drop any oil on the taper surface of the crankshaft. If dropped, clean by wiping off using detergent. 4. Carefully install the crankshaft pulley (21) so as not to damage the oil seal lips. Especially for the engine installed the (oil/dust) seal with double lips, be sure to use the crankshaft pulley installing tool (20).

TULI12EXN5011BB

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Index Engine - 10 Valve drive and gears - 106 Valve drive and gears - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Valve drive and gears - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve drive and gears - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valve drive and gears - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Valve drive and gears - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Valve drive and gears - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Cylinder heads - 101

CX35B CX39B

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Contents Engine - 10 Cylinder heads - 101

TECHNICAL DATA Cylinder heads Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Cylinder heads Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Cylinder heads Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Valves Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Valve seat Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Engine - Cylinder heads

Cylinder heads - Service limits Cylinder head Inspection item Combustion surface distortion Inlet 3TNV82A (2-valve head) Drain TNV84~88 Inlet (2-valve head) Valve sink 4TNV84T(4-valve) Drain Inlet 4TNV94L·98(T) (4-valve head) Drain Inlet 4TNV106(T) (4-valve head) Drain Inlet Valve seat Seat angle Drain (2-valve, 4-valve) Seat correction angle

Standard value 0.05 mm (0.002 in) or less 0.35 - 0.55 mm (0.01 - 0.02 in) 0.30 - 0.50 mm (0.01 - 0.02 in) 0.30 - 0.50 mm (0.01 - 0.02 in)

Limit value 0.15 mm (0.01 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in)

0.30 - 0.50 mm (0.01 - 0.02 in)

0.8 mm (0.03 in)

0.36 - 0.56 mm (0.01 - 0.02 in) 0.35 - 0.55 mm (0.01 - 0.02 in) 0.5 - 0.7 mm (0.02 - 0.03 in) 0.7 - 0.9 mm (0.03 - 0.04 in) 120° 90° 40.15°

0.8 mm (0.03 in) 0.8 mm (0.03 in) 1 mm (0.04 in) 1.2 mm (0.05 in) -

Intake/exhaust valve and guide

3TNV82A (2-valve head)

4TNV84 3TNV84(T) 3/4TNV88 (2-valve head)

4TNV84T (4-valve head)

4TNV94L 4TNV98(T) (4-valve head)

Inspection item Valve guide inside Valve stem outside Inlet diameter Tolerance Valve guide inside Valve stem outside Drain diameter Tolerance Valve guide inside Valve stem outside Inlet diameter Tolerance Valve guide inside Valve stem outside Drain diameter Tolerance Valve guide inside Valve stem outside Inlet diameter Tolerance Valve guide inside Valve stem outside Drain diameter Tolerance Valve guide inside Valve stem outside Inlet diameter Tolerance Valve guide inside Valve stem outside Drain diameter Tolerance

Standard value 7.000 - 7.015 mm (0.28 - 0.28 in)

Limit value 7.08 mm (0.28 in)

6.945 - 6.960 mm (0.27 - 0.27 in)

6.90 mm (0.27 in)

0.040 - 0.070 mm (0.002 - 0.003 in) 7.000 - 7.015 mm (0.28 - 0.28 in)

0.18 mm (0.01 in) 7.08 mm (0.28 in)

6.940 - 6.955 mm (0.27 - 0.27 in)

6.90 mm (0.27 in)

0.045 - 0.075 mm (0.002 - 0.003 in) 8.010 - 8.025 mm (0.32 - 0.32 in)

0.18 mm (0.01 in) 8.10 mm (0.32 in)

7.955 - 7.975 mm (0.31 - 0.31 in)

7.90 mm (0.31 in)

0.035 - 0.070 mm (0.28 - 0.00 in) 8.015 - 8.030 mm (0.32 - 0.32 in)

0.18 mm (0.01 in) 8.10 mm (0.32 in)

7.955 - 7.960 mm (0.31 - 0.31 in)

7.90 mm (0.31 in)

0.045 - 0.075 mm (0.002 - 0.003 in) 6.000 - 6.015 mm (0.24 - 0.24 in)

0.18 mm (0.01 in) 6.08 mm (0.24 in)

5.960 - 5.975 mm (0.23 - 0.24 in)

5.90 mm (0.23 in)

0.025 - 0.055 mm (0.001 - 0.002 in) 6.000 - 6.015 mm (0.24 - 0.24 in)

0.15 mm (0.01 in) 6.08 mm (0.24 in)

5.945 - 5.960 mm (0.23 - 0.23 in)

5.90 mm (0.23 in)

0.040 - 0.070 mm (0.002 - 0.003 in) 7.000 - 7.015 mm (0.28 - 0.28 in)

0.17 mm (0.01 in) 7.08 mm (0.28 in)

6.945 - 6.960 mm (0.27 - 0.27 in)

6.90 mm (0.27 in)

0.040 - 0.070 mm (0.002 - 0.003 in) 7.000 - 7.015 mm (0.28 - 0.28 in)

0.17 mm (0.01 in) 7.08 mm (0.28 in)

6.940 - 6.955 mm (0.27 - 0.27 in)

6.90 mm (0.27 in)

0.045 - 0.075 mm (0.002 - 0.003 in)

0.17 mm (0.01 in)

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Engine - Cylinder heads

Inspection item Valve guide inside Valve stem outside Inlet diameter Tolerance 4TNV106(T) (4-valve head) Valve guide inside Valve stem outside Drain diameter Tolerance 3TNV82A 4TNV84, 3TNV84(T), 4TNV88 Valve guide projection 4TNV84T from cylinder head 4TNV94L, 4TNV98(T) 4TNV106(T) Valve guide driving-in method

Standard value 7.008 - 7.020 mm (0.28 - 0.28 in)

Limit value 7.08 mm (0.28 in)

6.945 - 6.960 mm (0.27 - 0.27 in)

6.92 mm (0.27 in)

0.048 - 0.075 mm (0.00 - 0.00 in) 7.008 - 7.020 mm (0.28 - 0.28 in)

0.16 mm (0.01 in) 7.08 mm (0.28 in)

6.960 - 6.975 mm (0.27 - 0.27 in)

6.90 mm (0.27 in)

0.033 - 0.060 mm (0.001 - 0.002 in) 11.7 - 12.0 mm (0.46 - 0.47 in)

0.18 mm (0.01 in) -

14.7 - 15.0 mm (0.58 - 0.59 in)

8.2 - 8.5 mm (0.32 - 0.33 in) 9.7 - 10.0 mm (0.38 - 0.39 in) 13.4 - 13.6 mm (0.53 - 0.54 in) Cold-fitted

Valve spring

Free length

Inclination

Inspection item 3TNV82A (2-valve) 4TNV84, 3TNV84(T), 4TNV88 (2-valve) 4TNV84T(4-valve) 4TNV94L, 4TNV98(T), (4-valve) 4TNV106(T) (4-valve) 3TNV82A (2-valve) 4TNV84, 3TNV84(T), 4TNV88 (2-valve) 4TNV84T(4-valve) 4TNV94L, 4TNV98(T), (4-valve) 4TNV106(T) (4-valve)

Standard value 44.4 mm (1.75 in)

Limit value 43.9 mm (1.73 in)

42.0 mm (1.65 in)

41.5 mm (1.63 in)

37.4 mm (1.47 in) 39.7 mm (1.56 in) 50.6 mm (1.99 in) -

36.9 mm (1.45 in) 39.2 mm (1.54 in) 50.1 mm (1.97 in) 1.4 mm (0.06 in)

1.4 mm (0.06 in)

1.3 mm (0.05 in) 1.4 mm (0.06 in) 1.5 mm (0.06 in)

Rocker arm and shaft Model TNV82A~88 4TNV94L/98(T)/ 106(T)

Inspection item Arm shaft hole diameter Shaft outside diameter Tolerance Arm shaft hole diameter Shaft outside diameter Tolerance

Standard value 16.000 - 16.020 mm (0.63 - 0.63 in) 15.966 - 15.984 mm (0.63 - 0.63 in) 0.016 - 0.054 mm (0.00 - 0.00 in) 18.500 - 18.520 mm (0.73 - 0.73 in) 18.470 - 18.490 mm (0.73 - 0.73 in) 0.010 - 0.05 mm (0.0004 - 0.002 in)

Limit value 16.07 mm (0.63 in) 15.94 mm (0.63 in) 0.13 mm (0.01 in) 18.57 mm (0.73 in) 18.44 mm (0.73 in) 0.13 mm (0.01 in)

Push rod Inspection item Bend

Standard value -

Limit value 0.03 mm (0.001 in)

Cylinder block Inspection item 3TNV82A TNV84 TNV88 Cylinder inside diameter 4TNV94L 4TNV98 4TNV106(T)

Standard value 82 - 82.03 mm (3.23 - 3.23 in) 84 - 84.03 mm (3.31 - 3.31 in) 88 - 88.03 mm (3.46 - 3.47 in) 94 - 94.03 mm (3.70 - 3.70 in) 98 - 98.03 mm (3.86 - 3.86 in) 106 - 106.03 mm (4.17 - 4.17 in) 47574272B 24/03/2014

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Limit value 82.2 mm (3.24 in) 84.2 mm (3.31 in) 88.2 mm (3.47 in) 94.13 mm (3.71 in) 98.13 mm (3.86 in) 106.13 mm (4.18 in)

Engine - Cylinder heads

Inspection item Roundness Cylinder bore Inclination

Standard value

Limit value

0.01 mm (0.0004 in) or less

0.03 mm (0.001 in)

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Engine - Cylinder heads

Cylinder heads - Component identification 2-valve cylinder head NOTE: This figure show the 3TNV84.

TULI12EXN4876GB

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Oil cooler Fan Thermostat Fuel filter V-pulley Oil screen Fuel injection valve Inlet manifold Exhaust manifold Rocker arm cover

11. 12. 13. 14. 15. 16. 17. 18. 19.

Spacer Oil/water separator Coolant pump Gear case Cylinder block Head gasket packing Thermo switch Cylinder head Joint

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Engine - Cylinder heads

Cylinder heads - Disassemble Disassemble in the order of the numbers shown in the illustration. • Remove the alternator assy (“Point 1”). • Remove the fan, pulley and V belt. • Remove the thermostat case (“Point 2”). • Remove the fuel filter and fuel oil piping (“Point 3”). • Remove the oil level gauge assy. • Remove the oil filter (“Point 4”). • Remove the fuel injection pipes (“Point 5”). • Remove the intake manifold assy. • Remove the exhaust manifold assy. • Remove rocker arm cover assembly. • Remove the rocker shaft assy, push rods and valve caps (“Point 6”). • Remove the cylinder head assy and head gasket (“Point 7”). • Remove the fuel injection valves and fuel return pipe (“Point 8”). • Remove the intake/exhaust valves, stem seals and valve springs (“Point 9”). • Remove the rocker arms from the rocker shaft.

Point 1 Disassembly Loosen the mounting screws while supporting the alternator (A). NOTICE: Do not tilt the alternator (A) towards the cylinder block in haste since it may damage the alternator or pinch a finger.

TULI12EXN4879AB

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Engine - Cylinder heads

Reassemble Replace the belt (4) with a new one if cracked, worn or damaged. Carefully prevent the belt from being smeared with oil or grease. 1. Set screw 3. Generator 5. C.W. pump 6. Crank pulley

TULI12EXN4880AB

Point 2 Reassemble Check the thermostat function.

Point 3 Reassemble Replace the fuel filter element with a new one.

Disassembly Cover the fuel pipe opening with tape to prevent intrusion of foreign matters.

Point 4 Reassemble Replace the oil filter with a new one. After fully tightening the filter manually, retighten it with a filter wrench by 3/4 turn.

Point 5 Disassembly Cover the fuel injection pipe (8) and pump inlets and outlets with tape or the like to prevent intrusion of foreign matters.

Point 6 Removing pipe seals (7) of 4-valve head.

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Engine - Cylinder heads

Disassembly Take-off a rocker arm cover in case of 4-valve head after removing fuel injection pipes (8) and pipe seals (7). NOTE: Attention is necessary because a fuel nozzle (9) is caught in a pipe seal and the pipe seal is damaged when a rocker arm cover is lifted with a pipe seal sticking to the rocker arm cover.

TULI12EXN4881AB

TULI12EXN4882AB

Insert a minus screwdriver (12) in the slit part of the rocker arm cover (10), and remove it when removing a pipe seal. 13. Cap nut of fuel injection pipe

Reassemble Replace the used pipe seal (11) with a new one when removing a pipe seal.

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Engine - Cylinder heads

Breather system (A reductor to intake air system of blow-by gas) Emitting blow-by gas is harmful to natural environment. Therefore blow-by gas reductor is adopted to TNV series naturally- aspirated engines as breather system (turbocharged engines emit blow-by gas). The system of model 3/4TNV84 is shown as a representative of that breather system in the 5. Some of the combustion gas (16) passes through the clearance between the cylinder and the piston, piston ring, and flows to the crankcase. This is called blow-by gas (16). While it passes into the cylinder head and the rocker arm cover (RA), the blow-by gas mixes with splash oil and becomes sprayed-oil-mixedwith-blow-by-gas passing through the baffle plate (BP) inside a rocker arm cover (RA). And it passes through a diaphragm assy, and an intake manifold (IM), and is reduced in the combustion chamber. Pressure inside a crankcase is controlled by the function of the diaphragm assy, and suitable amount of blow-by gas is reduced in intake air system. 14. Cover 15. Center plate 17. Blow-by gas flow to diaphragm space 18. Diaphragm part

TULI12EXN4883BB

TULI12EXN4884BA

Disassembling When a rocker arm cover (RA) is taken-off, check whether oil or the like enter the diaphragm (D) space from a small hole on the side of a diaphragm cover or not without disassembling the diaphragm. NOTE: When a diaphragm (D) is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring (S), much blow-by gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning. When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and so on, it is considered that oil leakage from the joint of a oil pan, a oil seal and so on will occur. When a diaphragm (D) is damaged, blow-by is discharged from the breathing hole on the side of diaphragm cover, and not reduced in the intake manifold (IM). Therefore, be careful of the diaphragm trouble. At lubricating oil replacement or lube oil supply The amount of lubricating oil isnâ&#x20AC;&#x2122;t to be beyond the standard upper limit (in the engine horizontallity, the up per limit mark of the dip stick). Since the blow-by gas reductor is adopted, be careful that the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur, when the lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine. 47574272B 24/03/2014

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Engine - Cylinder heads

Reassemble Replace the diaphragm with new one, when it is damaged.

Point 7 19. Fan side 20. Camshaft side 21. Assembly 22. Disassembly

TULI12EXN4885CB

Disassembly Keep the removed push rods by attaching tags showing corresponding cylinder Nos.

Reassemble Always apply oil to the contact portions of the push rods and clearance adjusting screws.

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Engine - Cylinder heads

Point 8 Disassembly Loosen the cylinder head screws in two steps in the given order. Place the cylinder head assy on a paper board to prevent the combustion face from any damage.

Reassemble Remove the head gasket with a new one. Uniformly install the head screws manually after applying oil on the threaded and seat portions. They shall be tightened in two steps in the reverse of the order for disassembly. Tightening torque First step Second step

4TNV106(T) TNV82A TNV84-88 4TNV94L/98 30.0 - 34.0 N·m (22.1 41.1 - 46.9 N·m (30.3 49.0 - 58.8 N·m (36.1 88.3 - 98.1 N·m (65.1 - 25.1 lb ft) - 34.6 lb ft) - 43.4 lb ft) - 72.4 lb ft) 188.0 - 197.8 N·m 61.7 - 65.7 N·m (45.5 85.3 - 91.1 N·m (62.9 103.1 - 112.9 N·m (76.04 - 43.4 lb ft) (138.7 - 145.9 lb ft) - 48.5 lb ft) - 67.2 lb ft)

Point 9 Disassembly Carefully remove the fuel injection valve so as not to leave the top end protector from being left inside the cylinder.

Reassemble Replace the fuel filter element with a new one.

Point 10 Disassembly When removing each intake/exhaust valve from the cylinder head, use a valve spring compressor and compress the valve spring and remove the valve cotter). Keep each removed intake/exhaust valve after attaching a tag showing the corresponding cylinder No. If cotter burr is seen at the shaft of each intake/exhaust valve stem, remove it with an oilstone and extract the valve from the cylinder head.

TULI12EXN4886AA

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Engine - Cylinder heads

Reassemble Replace the stem seal with a new one when an intake/ exhaust valve is disassembled. Carefully install each valve after oil application so as not to damage the stem seal. Different stem seals are provided for the intake and exhaust valves. Do not confuse them since those for exhaust valves are marked with yellow paint. After assembling the intake/exhaust valve, stem seal, valve spring, seat, and cotter, tap the head of the valve stem lightly for settling. Do not forget to install the valve cap.

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Engine - Cylinder heads

Cylinder heads - Measure Cylinder head Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove carbon deposit and bonding agent, and check the surface state. A. Appearance check Check mainly discoloration and crack. If crack is suspected, perform color check. B. Combustion surface distortion Apply a straight-edge (1) in two diagonal directions and on four sides of the cylinder head, and measure distortion with a thickness gauge (2). TULI12EXN4887AB

Distortion

Standard value 0.05 mm (0.002 in) or less

Limit value 0.15 mm (0.006 in)

C. Valve sink Measure with the valve inserted to the cylinder head. (depth micrometer (3))

TULI12EXN4888AB

TULI12EXN4889AA

4. Valve sinking depth

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Engine - Cylinder heads

Valve stem clearance Standard value 0.35 - 0.55 mm (0.014 0.022 in) 0.30 - 0.50 mm (0.012 0.020 in) 0.30 - 0.50 mm (0.012 0.020 in) 0.30 - 0.5 mm (0.012 0.020 in) 0.36 - 0.56 mm (0.014 0.022 in) 0.35 - 0.55 mm (0.014 0.022 in) 0.5 - 0.7 mm (0.020 0.024 in) 0.7 - 0.9 mm (0.028 0.035 in)

Inlet 3TNV82A (2-valve head) Drain 4TNV84 3TNV84(T) 3/4TNV88 (2-valve head)

Inlet

4TNV84(T) 4TNV94/ 98(T) (4-valve head)

Inlet

Drain

Drain Inlet

4TNV106(T) (4-valve head) Drain

Limit value 0.8 mm (0.031 in) 0.8 mm (0.031 in) 0.8 mm (0.031 in) 0.8 mm (0.031 in) 0.8 mm (0.031 in) 0.8 mm (0.031 in) 1.0 mm (0.039 in) 1.2 mm (0.047 in)

D. Seat contact Apply a thin coat of minium on the valve seat (5). Insert the valve in the cylinder and push it against the seat to check seat contact. Standard: Continuous contact all around

TULI12EXN4890AB

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Engine - Cylinder heads

Valve guide Mainly check damage and wear on the inside wall. Apply the service part code when replacing a part. 6. Measuring positions

TULI12EXN4891AA

TULI12EXN4892AA

7. Measuring positions

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Engine - Cylinder heads

Valve stem clearance Model

Part name

Position Valve guide inside

Intake valve

Rod outer diameter Tolerance

3TNV82A (2-valve head)

Valve guide inside Exhaust valve

Rod outer diameter Tolerance Valve guide inside

Intake valve 4TNV84 3TNV84(T) 3/4TNV88 (2-valve head)

Rod outer diameter Tolerance Valve guide inside

Exhaust valve

Rod outer diameter Tolerance Valve guide inside

Intake valve

Rod outer diameter Tolerance

4TNV84T (4-valve head)

Valve guide inside Exhaust valve

Rod outer diameter Tolerance Valve guide inside

Intake valve

Rod outer diameter Tolerance

4TNV94L 4TNV98(T)(4valve head)

Valve guide inside Exhaust valve

Rod outer diameter Tolerance

Standard value 7 - 7.015 mm (0.2756 0.2762 in) 6.945 - 6.96 mm (0.2734 0.2740 in) 0.04 - 0.07 mm (0.0016 0.0028 in) 7.00 - 7.015 mm (0.2756 0.2762 in) 6.94 - 6.955 mm (0.2732 0.2738 in) 0.045 - 0.075 mm (0.0018 - 0.0030 in) 8.01 - 8.025 mm (0.3154 0.3159 in) 7.955 - 7.975 mm (0.3132 - 0.3140 in) 0.035 - 0.07 mm (0.0014 0.0028 in) 8.015 - 8.03 mm (0.3156 0.3161 in) 7.955 - 7.97 mm (0.3132 0.3138 in) 0.045 - 0.075 mm (0.0018 - 0.0030 in) 6 - 6.015 mm (0.2362 0.2368 in) 5.96 - 5.975 mm (0.2346 0.2352 in) 0.025 - 0.055 mm (0.0010 - 0.0022 in) 6 - 6.015 mm (0.2362 0.2368 in) 5.945 - 5.96 mm (0.2341 0.2346 in) 0.04 - 0.07 mm (0.0016 0.0028 in) 7 - 7.015 mm (0.2756 0.2762 in) 6.945 - 6.96 mm (0.2734 0.2740 in) 0.04 - 0.07 mm (0.0016 0.0028 in) 7 - 7.015 mm (0.2756 0.2762 in) 6.94 - 6.955 mm (0.2732 0.2738 in) 0.045 - 0.075 mm (0.0018 - 0.0030 in)

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Limit value 7.08 mm (0.279 in) 6.92 mm (0.272 in) 0.16 mm (0.007 in) 7.08 mm (0.279 in) 6.90 mm (0.272 in) 0.18 mm (0.007 in) 8.10 mm (0.319 in) 7.90 mm (0.311 in) 0.18 mm (0.007 in) 8.10 mm (0.319 in) 7.90 mm (0.311 in) 0.18 mm (0.007 in) 6.08 mm (0.239 in) 5.90 mm (0.232 in) 0.15 mm (0.006 in) 6.08 mm (0.239 in) 5.90 mm (0.232 in) 0.17 mm (0.007 in) 7.08 mm (0.279 in) 6.90 mm (0.272 in) 0.17 mm (0.007 in) 7.08 mm (0.279 in) 6.90 mm (0.272 in) 0.17 mm (0.007 in)

Engine - Cylinder heads

Model

Part name

Position Valve guide inside

Intake valve

Rod outer diameter Tolerance

4TNV106(T) (4-valve head)

Valve guide inside Exhaust valve

Rod outer diameter Tolerance

Standard value 7.008 - 7.02 mm (0.2759 0.2764 in) 6.96 - 6.975 mm (0.2740 0.2746 in) 0.033 - 0.06 mm (0.0013 0.0024 in) 7.008 - 7.02 mm (0.2759 0.2764 in) 6.945 - 6.96 mm (0.2734 0.2740 in) 0.048 - 0.075 mm (0.0019 - 0.0030 in)

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Limit value 7.08 mm (0.279 in) 6.92 mm (0.272 in) 0.18 mm (0.007 in) 7.08 mm (0.279 in) 6.90 mm (0.272 in) 0.18 mm (0.007 in)

Engine - Cylinder heads

Intake/exhaust valve Mainly clean and check damage and wear at the valve stem and seat. A. Seat contact: As explained above B. Stem outside diameter: As explained above C. Valve head thickness (8)

TULI12EXN4893AA

Model TNV82A~88 4TNE94Âˇ95 4TNE106(T)

Piece Inlet Drain Inlet Drain Inlet Drain

Standard value 1.34 mm (0.053 in) 0.45 mm (0.018 in) 1.71 mm (0.067 in) 1.65 mm (0.065 in) 2.00 mm (0.079 in) 2.00 mm (0.079 in)

Limit value 0.5 mm (0.0197 in) 0.5 mm (0.0197 in) 1 mm (0.039 in)1 1 mm (0.039 in) 1.3 mm (0.051 in)1.3 1.3 mm (0.051 in)

D. Valve stem bend Limit value: 0.01 mm (0.0004 in) 9. Length 10. Stool

TULI12EXN4894AB

E. Overall length

3TNV82A TNV84~88 4TNV94Âˇ98 4TNV106(T)

Intake/Exhaust Intake/Exhaust Intake/Exhaust Intake/Exhaust

Standard value

Limit value

115 mm (4.53 in) 126 mm (4.96 in)

114.5 mm (4.51 in) 125.5 mm (4.94 in)

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Engine - Cylinder heads

Valve spring Mainly inspect damage and corrosion. 11. Free length

TULI12EXN4895AA

12. Inclination

TULI12EXN4896AA

3TNV82A TNV84~88 4TNV94Âˇ98 4TNV106(T)

Free length standard 44.4 mm (1.75 in) 42 mm (1.65 in) 47.5 mm (1.87 in) 50.6 mm (4.96 in)

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Inclination 1.2 mm (0.0472 in) 1.2 mm (0.0472 in)

Engine - Cylinder heads

Valve rocker arm Mainly inspect valve head cap contact surface, inside surface defects and wear. Slight surface defects shall be corrected with an oilstone.

TULI12EXN4897AA

Model

TNV82A~88

Piece Arm hole diameter Shaft outside diameter Tolerance

4TNV94/98(T)

Arm hole diameter

4TNV106(T)

Shaft outside diameter Tolerance

Standard value 16 - 16.02 mm (0.630 - 0.631 in) 15.97 - 15.98 mm (0.6287 0.6291 in) 0.016 - 0.054 mm (0.0006 0.0021 in) 18.50 - 18.52 mm (0.7283 0.7291 in) 18.47 - 18.49 mm (0.7272 0.728 in) 0.01 - 0.05 mm (0.0004 - 0.002 in)

Limit value 16.07 mm (0.633 in) 15.94 mm (0.628 in) 0.13 mm (0.005 in) 18.57 mm (0.633 in) 18.44 mm (0.633 in) 0.13 mm (0.633 in)

Rocker arm shaft Mainly inspect seizure and wear at the surface in sliding contact with the arm. The rocker shaft diameter shall be as specified in the paragraph Valve rocker arm.

TULI12EXN4898AA

TULI12EXN4899AA

Push rod Mainly inspect the surface in contact with the tappet and adjusting screw. Slight surface defects shall be corrected with an oilstone. Bend limit: 0.03 mm (0.001 in) or lower

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Engine - Cylinder heads

Valve clearance adjusting screw Mainly inspect the surface in contact with the push rod. Slight surface defects shall be corrected with an oilstone.

Rocker arm spring Mainly inspect surface defects and corrosion.

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Engine - Cylinder heads

Cylinder heads - Assemble 1. Reverse order of the disassembly procedure. 1.

Rocker arm cover

Rocker arm shaft

Adjustment

Rocker arm

Rocker arm support

Intake valve

Exhaust valve

Cylinder head

Split pin

10. Spring holder 11. Valve spring 12. Stem seal 13. Valve guide 14. Valve bridge 15. Valve cap

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TULI12EXN4877BA

TULI12EXN4878BA

Engine - Cylinder heads

Cylinder heads - Inspect Cylinder block Especially clean head surface, cylinder bores and oil holes, and check after removing any carbon deposit and bonding agent.

TULI12EXN5023AA

TULI12EXN5024AB

Appearance check Check if there is any discoloration or crack. If crack is suspected, perform color check. Sufficiently clean the oil holes and check they are not clogged.

Cylinder bore and distortion Measure at 20 mm (0.79 in) below the crest of the liner, at 20 mm (0.79 in) from the bottom end and at the center.

Roundness Roundness is found as follows though it is the simple method. Measure cylinder diameters of the “A” direction and the “B” direction on each section of “a”, “b” and “c”. Roundness is the maximum value among those difference values.

Cylindricity Cylindricity is found as follows though it is the simple method. Measure cylinder diameters of “a”, “b” and “c” sections in the “A” direction, and calculate the difference in maximum value and minimum value of the measured diameters. In the same way measure and calculate the difference in the “B” direction. Cylindricity is the maximum value between those difference values.

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Engine - Cylinder heads

Piece

Model 3TNV82A TNV84 TNV88

Cylinder inside diameter

4TNV94L 4TNV98 4TNV106(T)

Cylinder bore

Roundness Cylindricity

All TNV

Limit value Standard value 82.000 - 82.030 mm 82.200 mm (3.24 in) (3.23 - 3.23 in) 84.000 - 84.030 mm 84.200 mm (3.31 in) (3.31 - 3.31 in) 88.000 - 88.030 mm 88.200 mm (3.47 in) (3.46 - 3.47 in) 94.000 - 94.030 mm 94.130 mm (3.71 in) (3.70 - 3.70 in) 98.000 - 98.030 mm 98.130 mm (3.86 in) (3.86 - 3.86 in) 106.000 106.030 mm (4.17 106.130 mm (4.18 in) - 4.17 in) 0.01 mm (0.0004 in) 0.03 mm (0.001 in) or less

If the limit is exceeded or any surface defect is found, repair by boring and honing. Use an oversized piston (and new piston rings) as required Oversized piston ( 0.25 mm (0.01 in), with piston rings) Model

Standard 82.250 mm (3.24 in)

3TNV82A 3TNV84(T) 4TNV84 4TNV84T 3/4TNV88 4TNV94L 4TNV98 4TNV106 4TNV106T

84.250 mm (3.32 in) 84.250 mm (3.32 in) 88.250 mm (3.47 in) 94.250 mm (3.71 in) 98.250 mm (3.87 in) 106.250 mm (4.18 in) 106.250 mm (4.18 in)

Cylinder dimension after boring and honing Model 3TNV82A 3TNV84(T) 4TNV84 3/4TNV88 4TNV94L 4TNV98 4TNV106(T)

Cylinder dimension

Honing angle

Surface roughness

Roundness/ Cylindricity

82.250 - 82.280 mm (3.24 - 3.24 in) 84.250 - 84.280 mm (3.32 - 3.32 in) 88.250 - 88.280 mm (3.47 - 3.48 in) 94.250 - 94.280 mm (3.71 - 3.71 in) 98.250 - 98.280 mm (3.87 - 3.87 in) 106.250 106.280 mm (4.18 - 4.18 in)

30 - 40 Â°

Rmax 1.0 Ăˇ 3.5

0.01 mm (0.0004 in) or less

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Engine - Cylinder heads

Cylinder heads - Adjust Cylinder bore correction 1. Slight uneven worn, flawed, etc. shall be corrected by honing only. If the cylinder is unevenly worn partially, flawed or otherwise damaged and cannot be repaired simply by honing, rebore the cylinder first and then hone. 2. Items to be prepared for honing • Flex-Hone (64) (see No.8 of Engine - Special tools (10.001)) • Electric drill (65) • Honing fluid (66) (50:50 of lubricating and diesel oil) (67) TULI12EXN5041AB

TULI12EXN5042AA

3. Apply the honing fluid to the Flex-Hone and turn the electric drill at 300 - 1200 RPM. Then insert the FlexHone into the cylinder bore while turning it, and move it up and down for about 30 s to obtain a honing mark with a cross hatch angle of 30° to 40°. NOTE: Avoid faster revolution than 1200 RPM since it may cause breakdown. Do not insert or extract the Flex-Hone in stopped state because the cylinder will be damaged.

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Engine - Cylinder heads

TULI12EXN5043FA

H1. H2. H3. 64.

Time for honing Boring and honing interval Service life of cylinder block Increase in L.O.C.

65. 66. 67.

Honing Boring Honing

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Engine - Cylinder heads

Valves - Replace 1. Use a valve guide extraction tool and extract the valve guide from the cylinder head. 2. Put liquid nitrogen or ether (or alcohol) with dryice added in a container and put the valve guide for replacement in it for cooling. Then insert it in with a valve guide inserting tool. NOTICE: Do not touch the cooled valve guide with bare hands to avoid skin damage. 3. Check the inside diameter and finish to the standard inside diameter as required with a reamer. 4. Check the projection from the cylinder head. 6. Valve guide extracting and inserting tool 7. Projection 8. Valve guide 9. Cylinder head

TULI12EXN5002AB

Model 3TNV82A 4TNV84 3TNV84(T) 4TNV88 4TNV84T 4TNV94L 4TNV98(T) 4TNE106(T)

Number valves 2 valves

Projection 11.7 - 12.0 mm (0.46 - 0.47 in) 14.7 - 15 mm (0.58 - 0.59 in) 8.2 - 8.5 mm (0.32 - 0.33 in)

4 valves

9.7 - 10 mm (0.38 - 0.39 in) 13.4 - 13.6 mm (0.53 - 0.54 in)

Valve stem seal replacement Always use a new seal after the intake/exhaust valve is disassembled. Since the one for the exhaust valve is marked with yellow paint, do not confuse the intake and exhaust valves. 1. Apply engine oil to the lip. 2. Push with the inserting tool for installation. 10. Valve stem seal inserting tool 11. Stem seal 12. Valve guide 13. Cylinder head TULI12EXN5003AB

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Engine - Cylinder heads

3. Measure and check the projection of valve stem seal to keep proper clearance between valve guide and stem seal.

TULI12EXN5004BB

Model 3TNV82A 4TNV84 3TNV84(T) 4TNV88 4TNV84T 4TNV94L 4TNV98(T) 4TNE106(T)

Number valves 2 valves

Projection 15.7 - 16.0 mm (0.62 - 0.63 in) 18.7 - 19 mm (0.74 - 0.75 in) 9.9 - 10.2 mm (0.39 - 0.40 in)

4 valves

11.7 - 12 mm (0.46 - 0.47 in) 15.4 - 15.6 mm (0.61 - 0.61 in)

14. Stem seal 15. Valve guide 16. Tolerance 17. Stem seal projection 18. Valve guide projection

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Engine - Cylinder heads

Valve seat - Regrind NOTE: Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. After correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder or compound. 1. If the seat surface is slightly roughened: perform “A” and “B” as described below. “A”: Lap the valve and seat with a mixture of valve compound and engine oil. “B”: Lap with engine oil only. 2. If the seat is heavily roughened but the width is almost normal, correct with a seat grinder or seat cutter (3) first. Then perform lapping “A” and “B”. Seat cutter angle: Inlet: 120° Drain:90° TULI12EXN4900AB

TULI12EXN5001AB

3. If the seat is heavily roughened and the width is much enlarged, grind the seat inner surface with a seat grinder (4) whose center angle is 40°, then grind the seat outer surface with a grinder whose center angle is 150° to make the seat width match the standard. Then perform seat correction as described in 2), and then carry out lapping “A” and “B”. 5. Grindstone Grinding wheel angle θ1: 40 θ2: 150

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Index Engine - 10 Cylinder heads - 101 Cylinder heads - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Cylinder heads - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cylinder heads - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder heads - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylinder heads - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cylinder heads - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cylinder heads - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Valves - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Engine - 10 Connecting rods and pistons - 105

CX35B CX39B

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Contents Engine - 10 Connecting rods and pistons - 105

TECHNICAL DATA Connecting rods and pistons Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE Connecting rods and pistons Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Piston Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - Connecting rods and pistons

Connecting rods and pistons - Service limits Piston Especially clean the combustion surface, circumference, ring grooves and piston pin hubs, and check after removing any carbon deposit. Any burr at a ring groove or snap ring groove shall be removed. If crack is suspected, perform color check.

TULI12EXN5029AA

Piston outside diameter measurement Measure the long diameter at “H” mm from the bottom end of the piston of the oval hole in the vertical direction to the piston pin hole Piston outside diameter Model 3TNV82A 3,4TNV84(T) 3,4TNV88 4TNV94L 4TNV98(T) 4TNV106(T)

Outside diameter Standard value 81.950 - 81.980 mm (3.23 - 3.23 in) 83.945 - 83.975 mm (3.30 - 3.31 in) 87.945 - 87.975 mm (3.46 - 3.46 in) 93.945 - 093.955 mm (3.70 - 3.70 in) 97.940 - 097.950 mm (3.86 - 3.86 in) 105.930 0105.960 mm (4.17 4.17 in)

Limit value 81.905 mm (3.22 in) 83.900 mm (3.30 in) 87.900 mm (3.46 in)

Clearance between piston and cylinder 0.035 - 0.065 mm (0.001 - 0.003 in) 0.04 - 0.07 mm (0.002 - 0.003 in)

Measurement position (“H”)

22 - 25 mm (0.87 0.98 in)

93.900 mm (3.70 in)

22 mm (0.87 in)

97.895 mm (3.85 in) 0.05 - 0.08 mm (0.002 - 0.003 in)

22 mm (0.87 in)

105.880 mm (4.17 in)

30 mm (1.18 in)

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Engine - Connecting rods and pistons

If the clearance between piston and cylinder exceeds the limit, use an oversized piston. (Refer to the tables of oversized pistons, oversized piston rings and cylinder boring dimension.

TULI12EXN5030AA

TULI12EXN5031AA

Piston pin hole measurement Measurement of piston pin outer diameter and piston pin inner diameter. Calculate the clearance between piston pin and piston pin hole. If any data exceeds the limit, replace the part with a new one. Model

3TNV82A

Piece Pin inner diameter Pin outside diameter Tolerance Pin inner diameter

3TNV84~88

Pin outside diameter Tolerance Pin inner diameter

4TNV94L 4TNV98(T)

Pin outside diameter Tolerance Pin inner diameter

4TNV106(T)

Pin outside diameter Tolerance

Standard value 23.000 - 23.009 mm (0.91 0.91 in) 22.995 - 23.000 mm (0.91 0.91 in) 0.000 - 0.014 mm (0.00 0.001 in) 26.000 - 26.009 mm (1.02 1.02 in) 25.995 - 26.000 mm (1.02 1.02 in) 0.000 - 0.014 mm (0.00 0.001 in) 30.000 - 30.009 mm (1.18 1.18 in) 29.989 - 30.000 mm (1.18 1.18 in) 0.000 - 0.02 mm (0.00 0.001 in) 37.000 - 37.011 mm (1.46 1.46 in) 36.989 - 37.000 mm (1.46 1.46 in) 0.000 - 0.022 mm (0.00 0.001 in)

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Limit value 23.039 mm (0.91 in) 22.965 mm (0.90 in) 0.074 mm (0.003 in) 26.039 mm (1.03 in) 25.965 mm (1.02 in) 0.074 mm (0.003 in) 30.039 mm (1.18 in) 29.959 mm (1.18 in) 0.08 mm (0.003 in) 37.039 mm (1.46 in) 36.959 mm (1.46 in) 0.08 mm (0.003 in)

Engine - Connecting rods and pistons

Pin. Hole.

Measure at position “a”, “b” and “c” in direction “A” and “B”. Measure at positions “a”, “b” and “c” in direction “A” and “B”.

Piston ring, ring groove and end clearance measurement • Except for the top ring (46), to measure the piston ring groove width, first measure the width of the piston ring. Then insert the piston ring into the ring. Then insert the piston ring into the ring groove. Insert a thickness gauge in between the piston ring and groove to measure the gap between them. Obtain the ring groove width by adding ring width to the measured side clearance. • To measure the end clearance, push the piston ring into the sleeve using the piston head, insert a thickness gauge in end clearance to measure. The ring shall be pushed in to approx. 30 mm (1.18 in) above the bottom end of the cylinder. For the top ring, measure only the piston ring joint end clearance in normal state.

TULI12EXN5032AA

TULI12EXN5033AA

TULI12EXN5034BB

47. Second ring 48. Oil ring “49”. Width “50”. Shim 51. Head surface 52. Cylinder block 53. Piston ring “54”. Joint end clearance

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Piston ring dimension Model

Piece

Piece Ring groove width Ring width

Top ring Side gap End clearance Ring groove width Ring width TNV82A/84

Second ring Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance Ring groove width Ring width Top ring Side gap End clearance Ring groove width Ring width

TNV88

Second ring Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance

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Limit value Standard value 2.065 - 2.080 mm (0.08 - 0.08 in) 1.970 - 1.990 mm 1.950 mm (0.08 in) (0.08 - 0.08 in) 0.075 - 0.11 mm (0.003 - 0.004 in) 0.2 - 0.4 mm (0.01 0.490 mm (0.02 in) 0.02 in) 2.035 - 2.050 mm 2.150 mm (0.08 in) (0.08 - 0.08 in) 1.970 - 1.990 mm 1.950 mm (0.08 in) (0.08 - 0.08 in) 0.045 - 0.08 mm 0.200 mm (0.01 in) (0.002 - 0.003 in) 0.2 - 0.4 mm (0.01 0.490 mm (0.02 in) 0.02 in) 4.015 - 4.030 mm 4.130 mm (0.16 in) (0.16 - 0.16 in) 3.970 - 3.990 mm 3.950 mm (0.16 in) (0.16 - 0.16 in) 0.025 - 0.06 mm 0.180 mm (0.01 in) (0.001 - 0.002 in) 0.2 - 0.4 mm (0.01 0.490 mm (0.02 in) 0.02 in) 2.060 - 2.075 mm (0.08 - 0.08 in) 1.970 - 1.990 mm 1.950 mm (0.08 in) (0.08 - 0.08 in) 0.07 - 0.105 mm (0.003 - 0.004 in) 0.2 - 0.4 mm (0.01 0.490 mm (0.02 in) 0.02 in) 2.025 - 2.040 mm 2.140 mm (0.08 in) (0.08 - 0.08 in) 1.970 - 1.990 mm 1.950 mm (0.08 in) (0.08 - 0.08 in) 0.035 - 0.07 mm 0.190 mm (0.01 in) (0.001 - 0.003 in) 0.2 - 0.4 mm (0.01 0.490 mm (0.02 in) 0.02 in) 4.015 - 4.030 mm 4.130 mm (0.16 in) (0.16 - 0.16 in) 3.970 - 3.990 mm 3.950 mm (0.16 in) (0.16 - 0.16 in) 0.025 - 0.06 mm 0.180 mm (0.01 in) (0.001 - 0.002 in) 0.2 - 0.4 mm (0.01 0.490 mm (0.02 in) 0.02 in)

Engine - Connecting rods and pistons

Model

Piece

Piece Ring groove width Ring width

Top ring Side gap End clearance Ring groove width Ring width 4TNV94LÂˇ9 8

Second ring Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance Ring groove width Ring width Top ring Side gap End clearance Ring groove width Ring width

4TNV106(T)

Second ring Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance

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Standard value 2.040 - 2.060 mm (0.08 - 0.08 in) 1.940 - 1.960 mm (0.08 - 0.08 in) 0.08 - 0.12 mm (0.003 - 0.005 in) 0.250 - 0.45 mm (0.01 - 0.02 in) 2.080 - 2.095 mm (0.08 - 0.08 in) 1.970 - 1.990 mm (0.08 - 0.08 in) 0.09 - 0.125 mm (0.004 - 0.005 in) 0.45 - 0.65 mm (0.02 - 0.03 in) 3.015 - 3.030 mm (0.12 - 0.12 in) 2.970 - 2.990 mm (0.12 - 0.12 in) 0.025 - 0.06 mm (0.001 - 0.002 in) 0.25 - 0.45 mm (0.01 - 0.02 in) 2.52 - 2.54 mm (0.10 - 0.10 in) 2.44 - 2.46 mm (0.10 - 0.10 in) 0.06 - 0.1 mm (0.002 - 0.004 in) 0.3 - 0.45 mm (0.01 0.02 in) 2.070 - 2.085 mm (0.08 - 0.08 in) 1.970 - 1.990 mm (0.08 - 0.08 in) 0.08 - 0.115 mm (0.003 - 0.005 in) 0.45 - 0.6 mm (0.02 0.02 in) 3.015 - 3.030 mm (0.12 - 0.12 in) 2.970 - 2.990 mm (0.12 - 0.12 in) 0.025 - 0.06 mm (0.001 - 0.002 in) 0.3 - 0.5 mm (0.01 0.02 in)

Limit value 1.920 mm (0.08 in) 0.540 mm (0.02 in) 2.195 mm (0.09 in) 1.950 mm (0.08 in) 0.245 mm (0.01 in) 0.730 mm (0.03 in) 3.130 mm (0.12 in) 2.950 mm (0.12 in) 0.180 mm (0.01 in) 0.550 mm (0.02 in) 2.42 mm (0.10 in) 0.540 mm (0.02 in) 2.185 mm (0.09 in) 1.950 mm (0.08 in) 0.235 mm (0.01 in) 0.680 mm (0.03 in) 3.130 mm (0.12 in) 2.950 mm (0.12 in) 0.180 mm (0.01 in) 0.600 mm (0.02 in)

Engine - Connecting rods and pistons

Link rod Appearance check Inspect the portion near the boundary of the chamfered portion and I-beam section of the big and small ends of the connecting rod as well as the portion near the oil hole of the bushing at the small end for cracks, deformation, and discoloration.

TULI12EXN5035AB

Measurement of twist (56) and parallelism (55) Use a connecting rod aligner (58) and measure twist and bends. 57. Mandrel Piece

Limit dimension

Standard dimension 0.03 mm (0.001 in) or less per 100 mm (3.937 in)

Twist and parallelism

0.08 mm (0.003 in)

Rod small end measurement Measure the pin outside diameter.

TULI12EXN5036AB

Model 3TNV82A

Piece Piston pin bushing inner diameter Pin outside diameter Tolerance

TNV84~88

Piston pin bushing inner diameter Pin outside diameter Tolerance

Standard value 23.025 - 23.038 mm (0.91 0.91 in) 22.995 - 23.000 mm (0.91 0.91 in) 0.025 - 0.043 mm (0.001 0.002 in) 26.025 - 26.038 mm (1.02 1.03 in) 25.995 - 26.000 mm (1.02 1.02 in) 0.025 - 0.043 mm (0.001 0.002 in)

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Limit value 23.068 mm (0.91 in) 22.967 mm (0.90 in) 0.101 mm (0.004 in) 26.068 mm (1.03 in) 25.967 mm (1.02 in) 0.101 mm (0.004 in)

Engine - Connecting rods and pistons

Model 4TNV94LÂˇ98

Piece Piston pin bushing inner diameter Pin outside diameter Tolerance

4TNV106(T)

Piston pin bushing inner diameter Pin outside diameter Tolerance

Standard value 30.025 - 30.038 mm (1.18 1.18 in) 29.987 - 30.000 mm (1.18 1.18 in) 0.025 - 0.051 mm (0.001 0.002 in) 37.025 - 37.038 mm (1.46 1.46 in) 36.989 - 37.000 mm (1.46 1.46 in) 0.025 - 0.049 mm (0.001 0.002 in)

Limit value 30.068 mm (1.18 in) 29.959 mm (1.18 in) 0.109 mm (0.004 in) 37.068 mm (1.46 in) 36.961 mm (1.46 in) 0.107 mm (0.004 in)

If the bushing is to be replaced because the oil clearance exceeds the limit, use spare part. 60. Cylinder gauge

TULI12EXN5037BB

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Engine - Connecting rods and pistons

Rod big end measurement Measure the crankpin and bushing. Calculate the oil clearance of a crank pin metal and a crank pin from the measured values of the crank pin metal inner diameter and the crank pin outside diameter. Replace a crank pin metal if the oil clearance becomes about the limit dimension of the below table. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Also use an undersized metal. When measuring the inside diameter of the rod big end, install the crankpin metals in the rod big end not to mistake the top and bottom of the metals and tighten the rod screws by the standard torque. 61. Cylinder gauge

TULI12EXN5038BB

Tightening torque of connecting rod screw Model

Tightening torque

3TNV82A TNV84/88 4TNV94L/98 4TNV106(T)

37.2 - 41.2 N路m (27 - 30 lb ft) 44.1 - 49 N路m (33 - 36 lb ft) 53.9 - 58.8 N路m (40 - 43 lb ft) 78.5 - 83.4 N路m (58 - 62 lb ft)

Lubricating oil application (threaded portion and bearing seat surface) Lube oil applied

Standard of rod big end Model

3TNV82A

Piece Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance

TNV84/88

Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance

Standard value 42.952 - 42.962 mm (1.69 1.69 in) 43.000 - 43.042 mm (1.69 1.69 in) 1.487 - 1.500 mm (0.06 0.06 in) 0.038 - 0.090 mm (0.06 0.06 in) 47.952 - 47.962 mm (1.89 1.89 in) 48.000 - 48.026 mm (1.89 1.89 in) 1.492 - 1.500 mm (0.06 0.06 in) 0.038 - 0.074 mm (0.001 0.003 in)

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Limit value 42.902 mm (1.69 in) 0.150 mm (0.01 in) 47.902 mm (1.89 in) 0.150 mm (0.01 in)

Engine - Connecting rods and pistons

Model

4TNV94L/98

Piece Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance

4TNV106(T)

Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance

Standard value 57.952 - 57.962 mm (2.28 2.28 in) 58.000 - 58.026 mm (2.28 2.28 in) 1.492 - 1.500 mm (0.06 0.06 in) 0.038 - 0.074 mm (0.001 0.003 in) 63.952 - 63.962 mm (2.52 2.52 in) 64.016 - 64.042 mm (2.52 2.52 in) 1.984 - 1.992 mm (0.08 0.08 in) 0.054 - 0.09 mm (0.002 0.004 in)

Limit value 57.902 mm (2.28 in) 0.150 mm (0.01 in) 63.902 mm (2.52 in) 0.150 mm (0.01 in)

Tappet Mainly check the tappet contact surface with the cam and push rod. Slight surface defects shall be corrected with an oilstone.

Tappet stem outside diameter measurement 62. Abnormal contact surface 63. Normal contact surface

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TULI12EXN5039AB

TULI12EXN5040AA

Engine - Connecting rods and pistons

Model

TNV84~88

4TNV94LÂˇ98

4TNV106(T)

Piece

Standard value 12.000 - 12.025 mm (0.47 Tappet hole inner diameter 0.47 in) 11.975 - 11.990 mm (0.47 Rod outer diameter 0.47 in) 0.01 - 0.05 mm (0.0004 Tolerance 0.0020 in) 12 - 12.018 mm (0.47 Tappet hole inner diameter 0.47 in) 11.975 - 11.990 mm (0.47 Rod outer diameter 0.47 in) 0.01 - 0.043 mm (0.000 Tolerance 0.002 in) 14 - 14.018 mm (0.55 Tappet hole inner diameter 0.55 in) 13.966 - 13.984 mm (0.55 Rod outer diameter 0.55 in) 0.015 - 0.052 mm (0.001 Tolerance 0.002 in)

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Limit value 12.045 mm (0.47 in) 11.955 mm (0.47 in) 0.09 mm (0.004 in) 12.038 mm (0.47 in) 11.955 mm (0.47 in) 0.083 mm (0.003 in) 14.038 mm (0.55 in) 13.946 mm (0.55 in) 0.092 mm (0 in)

Engine - Connecting rods and pistons

Connecting rods and pistons - Service limits Ring and piston Piston Inspection item 3TNV82A 3,4TNV84(T) Piston outside diameter 3,4TNV88 (Measure in the direction 4TNV94L vertical to the piston pin) 4TNV98(T) 4TNV106(T) 3TNV82A 3,4TNV84(T) Piston diameter measure 3,4TNV88 position (Upward from the bottom end of the piston) 4TNV94L 4TNV98(T) 4TNV106(T) Hole inside diameter 3TNV82A Pin outside diameter Tolerance Hole inside diameter TNV84~88 Pin outside diameter Tolerance Piston pin Hole inside diameter 4TNV94LÂˇ98 Pin outside diameter Tolerance Hole inside diameter 4TNV106(T) Pin outside diameter Tolerance

Standard value 81.95 - 81.98 mm (3.23 - 3.23 in) 83.945 - 83.975 mm (3.30 - 3.31 in) 87.945 - 87.975 mm (3.46 - 3.46 in) 93.945 - 93.955 mm (3.70 - 3.70 in) 97.94 - 97.95 mm (3.86 - 3.86 in) 105.93 - 105.96 mm (4.17 - 4.17 in) 16 mm (0.63 in) 24 mm (0.94 in) 24 mm (0.94 in) 22 mm (0.87 in) 22 mm (0.87 in) 30 mm (1.18 in) 23 - 23.009 mm (0.91 - 0.91 in) 22.995 - 23 mm (0.91 - 0.91 in) 0.000 - 0.014 mm (0.00 - 0.0006 in) 26 - 26.009 mm (1.02 - 1.02 in) 25.995 - 26 mm (1.02 - 1.02 in) 0.000 - 0.014 mm (0.00 - 0.0006 in) 0.000 - 30.009 mm (0.00 - 1.18 in) 29.989 - 30 mm (1.18 - 1.18 in) 0.000 - 0.02 mm (0.00 - 0.001 in) 37 - 37.011 mm (1.46 - 1.46 in) 36.989 - 37 mm (1.46 - 1.46 in) 0.000 - 0.022 mm (0.00 - 0.0009 in)

Limit value 81.905 mm (3.22 in) 83.9 mm (3.30 in) 87.9 mm (3.46 in) 93.9 mm (3.70 in) 97.895 mm (3.85 in) 105.88 mm (4.17 in) 23.039 mm (0.91 in) 22.965 mm (0.90 in) 0.074 mm (0.003 in) 26.039 mm (1.03 in) 25.965 mm (1.02 in) 0.074 mm (0.003 in) 30.039 mm (1.18 in) 29.959 mm (1.18 in) 0.08 mm (0.003 in) 37.039 mm (1.46 in) 36.959 mm (1.46 in) 0.08 mm (0.003 in)

Standard value 2.065 - 2.08 mm (0.08 - 0.08 in) 1.97 - 1.99 mm (0.08 - 0.08 in) 0.075 - 0.11 mm (0.003 - 0.004 in) 0.2 - 0.4 mm (0.01 - 0.02 in) 2.035 - 2.05 mm (0.08 - 0.08 in) 1.97 - 1.99 mm (0.08 - 0.08 in) 0.045 - 0.08 mm (0.002 - 0.003 in) 0.2 - 0.4 mm (0.01 - 0.02 in) 4.015 - 4.03 mm (0.16 - 0.16 in) 3.97 - 3.99 mm (0.16 - 0.16 in) 0.025 - 0.06 mm (0.001 - 0.002 in) 0.2 - 0.4 mm (0.01 - 0.02 in)

Limit value 1.95 mm (0.08 in) 0.49 mm (0.02 in) 2.15 mm (0.08 in) 1.95 mm (0.08 in) 0.2 mm (0.01 in) 0.49 mm (0.02 in) 4.13 mm (0.16 in) 3.95 mm (0.16 in) 0.18 mm (0.01 in) 0.49 mm (0.02 in)

Piston ring Model

3TNV82A TNV84

Inspection item Ring groove width Ring width Top ring Side gap End clearance Ring groove width Ring width Second ring Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance

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Engine - Connecting rods and pistons

Inspection item Ring groove width Ring width Top ring Side gap End clearance Ring groove width Ring width Second ring TNV88 Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance Ring groove width Ring width Top ring Side gap End clearance Ring groove width Ring width 4TNV94LSecond ring /98 Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance Ring groove width Ring width Top ring Side gap End clearance Ring groove width Ring width 4TNV106( Second ring T) Side gap End clearance Ring groove width Ring width Oil ring Side gap End clearance Model

Standard value 2.06 - 2.075 mm (0.08 - 0.08 in) 1.97 - 1.99 mm (0.08 - 0.08 in) 0.070 - 0.105 mm (0.003 - 0.004 in) 0.2 - 0.4 mm (0.01 - 0.02 in) 2.025 - 2.04 mm (0.08 - 0.08 in) 1.97 - 1.99 mm (0.08 - 0.08 in) 0.035 - 0.07 mm (0.001 - 0.003 in) 0.2 - 0.4 mm (0.01 - 0.02 in) 4.015 - 4.03 mm (0.16 - 0.16 in) 3.97 - 3.99 mm (0.16 - 0.16 in) 0.025 - 0.06 mm (0.001 - 0.002 in) 0.2 - 0.4 mm (0.01 - 0.02 in) 2.04 - 2.06 mm (0.08 - 0.08 in) 1.94 - 1.96 mm (0.08 - 0.08 in) 0.08 - 0.12 mm (0.003 - 0.005 in) 0.25 - 0.45 mm (0.01 - 0.02 in) 2.08 - 2.095 mm (0.08 - 0.08 in) 1.97 - 1.99 mm (0.08 - 0.08 in) 0.09 - 0.125 mm (0.004 - 0.005 in) 0.45 - 0.65 mm (0.02 - 0.03 in) 3.015 - 3.03 mm (0.12 - 0.12 in) 2.97 - 2.99 mm (0.12 - 0.12 in) 0.025 - 0.06 mm (0.001 - 0.002 in) 0.25 - 0.45 mm (0.01 - 0.02 in) 2.52 - 2.54 mm (0.10 - 0.10 in) 2.44 - 2.46 mm (0.10 - 0.10 in) 0.06 - 0.1 mm (0.002 - 0.004 in) 0.3 - 0.45 mm (0.01 - 0.02 in) 2.07 - 2.085 mm (0.08 - 0.08 in) 1.97 - 1.99 mm (0.08 - 0.08 in) 0.08 - 0.115 mm (0.003 - 0.005 in) 0.45 - 0.6 mm (0.02 - 0.02 in) 3.015 - 3.03 mm (0.12 - 0.12 in) 2.97 - 2.99 mm (0.12 - 0.12 in) 0.025 - 0.06 mm (0.001 - 0.002 in) 0.3 - 0.5 mm (0.01 - 0.02 in)

Limit value 1.95 mm (0.08 in) 0.49 mm (0.02 in) 2.14 mm (0.08 in) 1.95 mm (0.08 in) 0.19 mm (0.01 in) 0.49 mm (0.02 in) 4.13 mm (0.16 in) 3.95 mm (0.16 in) 0.18 mm (0.01 in) 0.49 mm (0.02 in) 1.92 mm (0.08 in) 0.54 mm (0.02 in) 2.195 mm (0.09 in) 1.95 mm (0.08 in) 0.245 mm (0.01 in) 0.73 mm (0.03 in) 3.13 mm (0.12 in) 2.95 mm (0.12 in) 0.18 mm (0.01 in) 0.55 mm (0.02 in) 2.42 mm (0.10 in) 0.54 mm (0.02 in) 2.185 mm (0.09 in) 1.95 mm (0.08 in) 0.235 mm (0.01 in) 0.68 mm (0.03 in) 3.13 mm (0.12 in) 2.95 mm (0.12 in) 0.18 mm (0.01 in) 0.6 mm (0.02 in)

Link rod Inspection item Thrust clearance

Standard value 0.2 - 0.4 mm (0.01 - 0.02 in)

Limit value -

Rod small end Model 3TNV82A

TNV84-88

4TNV94LÂˇ98

Inspection item Bushing inside diameter Pin outside diameter Tolerance Bushing inside diameter Pin outside diameter Tolerance Bushing inside diameter Pin outside diameter Tolerance

Standard value 23.025 - 23.038 mm (0.91 - 0.91 in) 22.995 - 23 mm (0.91 - 0.91 in) 0.025 - 0.043 mm (0.001 - 0.002 in) 26.025 - 26.038 mm (1.02 - 1.03 in) 25.995 - 26 mm (1.02 - 1.02 in) 0.025 - 0.043 mm (0.001 - 0.002 in) 30.025 - 30.038 mm (1.18 - 1.18 in) 29.987 - 30 mm (1.18 - 1.18 in) 0.025 - 0.051 mm (0.001 - 0.002 in)

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Limit value 23.068 mm (0.91 in) 22.967 mm (0.90 in) 0.101 mm (0.004 in) 26.068 mm (1.03 in) 25.967 mm (1.02 in) 0.101 mm (0.004 in) 30.068 mm (1.18 in) 29.959 mm (1.18 in) 0.109 mm (0.004 in)

Engine - Connecting rods and pistons

Model 4TNV106(T)

Inspection item Bushing inside diameter Pin outside diameter Tolerance

Limit value Standard value 37.025 - 37.038 mm (1.46 - 1.46 in) 37.068 mm (1.46 in) 36.989 - 37 mm (1.46 - 1.46 in) 36.961 mm (1.46 in) 0.025 - 0.049 mm (0.001 - 0.002 in) 0.107 mm (0.004 in)

Tappet

TNV84-88

4TNV94L.98

4TNV106(T)

Inspection item Standard value Tappet hole (block) inside diameter 12 - 12.025 mm (0.47 - 0.47 in) Tappet stem outside diameter 11.975 - 11.99 mm (0.47 - 0.47 in) 0.01 - 0.05 mm (0.0004 - 0.002 in) Tolerance Tappet hole (block) inside diameter 12 - 12.018 mm (0.47 - 0.47 in) Tappet stem outside diameter 11.975 - 11.99 mm (0.47 - 0.47 in) 0.01 - 0.043 mm (0.0004 - 0.002 in) Tolerance Tappet hole (block) inside diameter 14 - 14.018 mm (0.55 - 0.55 in) Tappet stem outside diameter 13.966 - 13.984 mm (0.55 - 0.55 in) 0.015 - 0.052 mm (0.001 - 0.002 in) Tolerance

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Limit value 12.045 mm (0.47 in) 11.955 mm (0.47 in) 0.09 mm (0.004 in) 12.038 mm (0.47 in) 11.955 mm (0.47 in) 0.083 mm (0.003 in) 14.038 mm (0.55 in) 13.946 mm (0.55 in) 0.092 mm (0.004 in)

Engine - Connecting rods and pistons

Connecting rods and pistons - Disassemble Point 2: Piston w/rod Disassembly • Measure the connecting rod side gap. Standard value: 0.20 - 0.40 mm (0.01 - 0.02 in) • Carefully remove the carbon deposit on top of the cylinder so as not to damage the inner side of the cylinder. • Set the piston at the BDC position and remove the connecting rod cap. Then set the piston at the TDC (top dead centre) position, and push the connecting rod big end with a wooden bar or a hammer. Proceed carefully so as not to cause the cylinder block catch the rod big end. Set the rod caps and crankpin metals in their correct combinations.

Reassemble • Apply oil especially carefully to the sliding contact surfaces of the pistons, rods and rings. • Use the piston insertion tool to insert each piston w/rod in the cylinder block and install the bearing metal cap. Rod bolt tightening torque Model

Standard (apply lube oil) 37.2 - 41.2 N·m (27 - 30 lb ft) 44.1 - 49 N·m (33 - 36 lb ft) 53.9 - 58.8 N·m (40 - 43 lb ft) 78.5 - 83.4 N·m (58 - 62 lb ft)

3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

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Engine - Connecting rods and pistons

Piston - Disassemble Point 6: Piston pin and rings Disassembly • Using the piston ring replacer, remove the piston rings. • Remove the circlip and remove the piston pin by pushing it out.

TULI12EXN5019AB

TULI12EXN5020BB

Reassemble Install each piston ring on the piston, with the punched manufacturer’s mark facing upward (23). 24. Oil ring joint 25. Second ring joint 26. Top ring joint 27. Expander joint

Reassemble The piston ring joints shall be staggered at 120° intervals. Do not position the top ring joint vertical to the piston pin. The coil expander joint shall be opposite to the oil ring joint.

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Engine - Connecting rods and pistons

Reassemble When installing the piston pin to the rod and piston, the punched match mark on the big end of the connecting rod shall be opposite to the size mark on the piston top. 28. Camshaft side 29. Nozzle side 30. Piston ID mark 31. Flywheel side cylinder size mark 32. Embossed mark (flywheel side) 33. Match mark

TULI12EXN5021BB

TULI12EXN5022AB

Reassemble Install the piston in the cylinder clock with the punched mark on the big end of the rod on the nozzle side. (The embossed mark at the connecting rod I-beam section shall be on the flywheel side). 34. Engraved mark 35. Camshaft side 36. Flywheel side

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Index Engine - 10 Connecting rods and pistons - 105 Connecting rods and pistons - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Connecting rods and pistons - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connecting rods and pistons - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - 10 Crankshaft and flywheel - 103

CX35B CX39B

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Contents Engine - 10 Crankshaft and flywheel - 103

TECHNICAL DATA Crankshaft and flywheel Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Crankshaft Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Crankshaft and flywheel Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Crankshaft oil seal Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - Crankshaft and flywheel

Crankshaft and flywheel - Service limits Crankshaft Inspection item Bending (1/2 the dial gauge reading) Pin outside diameter Metal inside diameter 3TNV82A Metal thickness Tolerance Pin outside diameter Metal inside diameter TNV84~88 Metal thickness Tolerance Crankpin Pin outside diameter Metal inside diameter 4TNV94LÂˇ98 Metal thickness Tolerance Pin outside diameter Metal inside diameter 4TNV106(T) Metal thickness Tolerance Journal outside diameter Metal inside diameter 3TNV82A Metal thickness Tolerance Journal outside TNV84~88 diameter Metal inside diameter Selective pairing Metal thickness Tolerance Crank journal Journal outside 4TNV94LÂˇ98 diameter Metal inside diameter Selective pairing Metal thickness Tolerance Journal outside 4TNV106(T) diameter Metal inside diameter Selective pairing Metal thickness Tolerance

Standard value 42.952 - 42.962 mm (1.69 - 1.69 in) 43 - 43.042 mm (1.69 - 1.69 in) 1.487 - 1.5 mm (0.06 - 0.06 in) 0.038 - 0.09 mm (0.001 - 0.004 in) 47.952 - 47.962 mm (1.89 - 1.89 in) 48 - 48.026 mm (1.89 - 1.89 in) 1.492 - 1.5 mm (0.06 - 0.06 in) 0.038 - 0.074 mm (0.001 - 0.003 in) 57.952 - 57.962 mm (2.28 - 2.28 in) 58 - 58.026 mm (2.28 - 2.28 in) 1.492 - 1.5 mm (0.06 - 0.06 in) 0.038 - 0.074 mm (0.001 - 0.003 in) 63.952 - 63.962 mm (2.52 - 2.52 in) 64.016 - 64.042 mm (2.52 - 2.52 in) 1.984 - 1.992 mm (0.08 - 0.08 in) 0.054 - 0.09 mm (0.002 - 0.004 in)

Limit value 0.02 mm (0.001 in) 42.902 mm (1.69 in) 0.15 mm (0.01 in) 47.902 mm (1.89 in) 0.15 mm (0.01 in) 57.902 mm (2.28 in)

46.952 - 46.962 mm (1.85 - 1.85 in)

46.902 mm (1.85 in)

47 - 47.032 mm (1.85 - 1.85 in) 1.987 - 2 mm (0.08 - 0.08 in) 0.038 - 0.08 mm (0.001 - 0.003 in)

0.15 mm (0.01 in)

53.952 - 53.962 mm (2.12 - 2.12 in)

53.902 mm (2.12 in)

54 - 54.02 mm (2.13 - 2.13 in) 1.995 - 1.99 mm (0.08 - 0.08 in) 0.038 - 0.068 mm (0.001 - 0.003 in)

0.15 mm (0.01 in)

64.952 - 64.962 mm (2.56 - 2.56 in)

64.902 mm (2.56 in)

65 - 65.02 mm (2.56 - 2.56 in) 1.995 - 2.01 mm (0.08 - 0.08 in) 0.038 - 0.068 mm (0.001 - 0.003 in)

0.15 mm (0.01 in)

75.952 - 75.962 mm (2.99 - 2.99 in)

75.902 mm (2.99 in)

76.014 - 76.034 mm (2.99 - 2.99 in) 2.488 - 2.503 mm (0.10 - 0.10 in) 0.052 - 0.082 mm (0.002 - 0.003 in)

0.15 mm (0.01 in)

Standard value 0.13 - 0.23 mm (0.01 - 0.01 in)

Limit value 0.28 mm (0.01 in)

0.15 mm (0.01 in) 63.902 mm (2.52 in) 0.15 mm (0.01 in)

Thrust bushing Inspection item Crankshaft side gap All models

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Engine - Crankshaft and flywheel

Crankshaft - Service limits Crankshaft Mainly check seizure and wear of the crankpins and journals. Since the crankshaft gear is shrink-fitted, heat to 180 - 200 Â° when extraction is necessary.

TULI12EXN5025AA

TULI12EXN5026BB

Shaft portion color check After washing the crankshaft, inspect it by means of color check or a magnaflux inspector. Replace it if cracked or heavily damaged. Slight defects shall be corrected by grinding.

Crankshaft bend Support the crankshaft journals at both ends with Vblocks (40). Use a dial gauge (39) and measure the runout (38) at the center journal while rotating the shaft to inspect the bend (37). Limit value: 0.02 mm (0.00 in) or lower

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Engine - Crankshaft and flywheel

Crankpin and journal measurement Measure the outer diameter, roundness and taper at each crankpin (42) and journal. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Replace if the defect is excessive.

TULI12EXN5027BB

Crankpin Model and Item 3TNV82A

Pin outside diameter Metal thickness Oil clearance

TNV84~88

Pin outside diameter Metal thickness Oil clearance

4TNV94LÂˇ98

Pin outside diameter Metal thickness Oil clearance

4TNV106(T)

Pin outside diameter Metal thickness Oil clearance

Standard value 42.952 - 42.962 mm (1.69 1.69 in) 1.487 - 1.500 mm (0.06 0.06 in) 0.038 - 0.09 mm (0.001 0.004 in) 47.952 - 47.962 mm (1.89 1.89 in) 1.492 - 1.500 mm (0.06 0.06 in) 0.038 - 0.074 mm (0.001 0.003 in) 57.952 - 57.962 mm (2.28 2.28 in) 1.492 - 1.500 mm (0.06 0.06 in) 0.038 - 0.074 mm (0.001 0.003 in) 63.952 - 63.962 mm (2.52 2.52 in) 1.984 - 1.992 mm (0.08 0.08 in) 0.054 - 0.09 mm (0.002 0.004 in)

If the oil clearance exceeds the limit, use an undersized bearing. 47574272B 24/03/2014

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Limit value 42.902 mm (1.69 in) 0.150 mm (0.01 in) 47.902 mm (1.89 in) 0.150 mm (0.01 in) 57.902 mm (2.28 in) 0.150 mm (0.01 in) 63.902 mm (2.52 in) 0.150 mm (0.01 in)

Engine - Crankshaft and flywheel

Undersized crankpin bearing ( 0.25 mm (0.01 in)) Model

Standard thickness 1.612 - 1.625 mm (0.06 - 0.06 in) 1.617 - 1.625 mm (0.06 - 0.06 in) 1.617 - 1.625 mm (0.06 - 0.06 in) 2.109 - 2.117 mm (0.08 - 0.08 in)

3TNV82A TNV84~88 4TNV94L·98 4TNV106(T) Pin machining dimension Model Ø Ø Ø Ø

3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

Pin machining dimension 42.702 - 42.712 mm (1.68 - 1.68 in) 47.702 - 47.712 mm (1.88 - 1.88 in) 57.702 - 57.712 mm (2.27 - 2.27 in) 63.702 - 63.712 mm (2.51 - 2.51 in)

Crank journal Model and Item 3TNV82A

Standard value 46.952 - 46.962 mm (1.85 1.85 in) 1.987 - 2.000 mm (0.08 0.08 in) 0.038 - 0.08 mm (0.001 0.003 in) 53.952 - 53.962 mm (2.12 2.12 in) 1.995 - 1.990 mm (0.08 0.08 in) 0.038 - 0.068 mm (0.001 0.003 in) 64.952 - 64.962 mm (2.56 2.56 in) 1.995 - 2.010 mm (0.08 0.08 in) 0.038 - 0.068 mm (0.001 0.003 in) 75.952 - 75.962 mm (2.99 2.99 in) 2.488 - 2.503 mm (0.10 0.10 in) 0.052 - 0.082 mm (0.002 0.003 in)

Journal outside diameter Metal thickness Oil clearance

TNV84~88 (selective assembly)

Journal outside diameter Metal thickness Oil clearance

4TNV94L·98 (selective assembly)

Journal outside diameter Metal thickness Oil clearance

4TNV106(T) (selective assembly)

Journal outside diameter Metal thickness Oil clearance

Limit value 46.902 mm (1.85 in) 0.150 mm (0.01 in) 53.902 mm (2.12 in) 0.150 mm (0.01 in) 64.902 mm (2.56 in) 0.150 mm (0.01 in) 75.902 mm (2.99 in) 0.150 mm (0.01 in)

If the oil clearance exceeds the limit, use an undersized bearing. Undersized crankpin bearing ( 0.25 mm (0.01 in)) Model 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

Standard thickness 2.112 - 2.125 mm (0.08 - 0.08 in) 2.112 - 2.125 mm (0.08 - 0.08 in) 2.112 - 2.125 mm (0.08 - 0.08 in) 2.605 - 2.618 mm (0.10 - 0.10 in)

Crankshaft Journal machining dimension Model 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

Pin machining dimension Ø 46.702 - 46.712 mm (1.84 - 1.84 in) Ø 53.702 - 53.712 mm (2.11 - 2.11 in) Ø 64.702 - 64.712 mm (2.55 - 2.55 in) Ø 75.702 - 75.712 mm (2.98 - 2.98 in) 47574272B 24/03/2014

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Engine - Crankshaft and flywheel

Dimension “R” and finishing precision of crankshaft journal and pin. As for grinding processing of journal and pin, machine it by using the grinding wheel of the dimension “R” of below table. Surface finishing precision standard on journal and pin: Ry = 0.8S surface polishing (43) Surface finishing precision standard on the thrust side of crankshaft arm: 1,6 (44) Crankpin

TULI12EXN5028AB

(45) Crank journal Model 3TNV82A TNV84~88 4TNV94L·98(T) 4TNV106(T)

Standard thickness 3.5 mm (0.14 in) + 0.3 mm (0.01 in)/0 94 mm (3.70 in) + 0.3 mm (0.01 in)/0

NOTE: lf the oil clearance is excessive though the thicknesses of the journal and crankpin metals are normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals. lf rust or surface roughening exists on the rear side of the metals, coat it with blue or minimum. Then assemble the crankpin metal to the connecting rod, and tighten the rod screw to the specified torque to check the metal for contact. lf the contact surface occupies 75% or more, the metal is normal. lf the contact surface is smaller, the metal interference is insufficient. Replace the metal with a new one. Thrust metal inspection 1. Inspect any damage or wear. 2. Measure side gap and thrust metal thickness. Side gap and thrust metal thickness Model TNV82A~88 4TNV94L·98 4TNV106(T)

Side gap Limit value Standard value 0.14 - 0.22 mm (0.01 - 0.01 in) 0.13 - 0.23 mm (0.01 - 0.01 in) 0.13 - 0.23 mm (0.01 - 0.01 in)

Thrust metal thickness Limit value Standard value 1.930 - 1.980 mm 1.850 mm (0.07 in) (0.08 - 0.08 in) 1.930 - 1.980 mm 1.850 mm (0.07 in) (0.08 - 0.08 in) 2.43 - 2.48 mm (0.10 - 2.35 mm (0.09 in) 0.10 in)

If the side gap is exceeded, use an oversized thrust metal. Oversized metal ( 0.25 mm (0.01 in)) Model 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

Standard thickness 2.15 mm (0.08 in) 2.15 mm (0.08 in) 2.055 - 2.105 mm (0.08 - 0.08 in) 2.555 - 2.605 mm (0.10 - 0.10 in)

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Crankshaft and flywheel - Disassemble Point 3: Mounting flange Disassembly Place the engine on a stable base with the cylinder block upper surface facing down, and remove the mounting flange carefully so as not to damage the combustion surface.

Reassemble Apply sealant and install the mounting flange by matching the two dowel pins. After assembly, raise the engine with its mounting flange on the bottom side. NOTICE: Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Proceed carefully so as not to lose balance.

Point 4: Journal bearing cap Disassembly Before removing the journal bearing, measure the crankshaft side gap. Measure it in either method because there are the next two methods. 1.

Install a dial gauge on the cylinder block (3), and move the crankshaft (4) forwards and backwards, and measure the side gap as shown in the Fig 2.

TULI12EXN5014AA

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2. Put a thickness gauge (7) directly in the clearance between the thrust metal (5) and the crankshaft (4), and measure clearance. Side gap standard Model: All models Standard value: 0.13 - 0.23 mm (0.01 - 0.01 in) Limit value: 0.28 mm (0.01 in) 6. Bearing cap 7. Thrust face

TULI12EXN5015BB

Reassemble If the side gap exceeds the standard, replace the thrust metal (5) with an oversize one. Machine the standard width (8) of the crankshaft thrust part into the dimension of the below table at the same time. Refer to a parts catalogue when ordering the part. The surface finishing precision: 1,6. 0.25 mm (0.010 in) Oversized thrust metal (0.25 DS) 0.25 DS 3TNV82A TNV84~88 4TNV94LÂˇ98 4TNV106(T)

2.055 2.055 2.055 2.555

Standard thickness - 2.105 mm (0.08 - 0.08 in) - 2.105 mm (0.08 - 0.08 in) - 2.105 mm (0.08 - 0.08 in) - 2.605 mm (0.10 - 0.10 in)

The standard width of the crankshaft thrust part Model 3TNV82A TNV84~88 4TNV94LÂˇ98 4TNV106(T)

Standard thickness 25.250 - 25.271 mm (0.99 - 0.99 in) 28.250 - 28.271 mm (1.11 - 1.11 in) 32.250 - 32.275 mm (1.27 - 1.27 in) 36.250 - 36.275 mm (1.43 - 1.43 in)

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Engine - Crankshaft and flywheel

Disassembly Remove the bearing caps, cap side bearings, and thrust metals (14). Place each thrust metal with identification of the position and direction. The position number of reassembling is punched on a metal cap (except for both ends) and a cylinder block. 10. Flywheel side 11. Gear side 12. Cap side main bearing metals 13. Block side main bearing metals

TULI12EXN5016BB

TULI12EXN5017AB

TULI12EXN5018AB

Reassemble • Carefully install each thrust metal so that the grooved one is positioned away from the cap. • Do not confuse the upper (15) and lower (17) main bearing metals. The main bearing upper rings (block side) (15) have a hole (16), which the lower rings do not have. The “arrow” mark on the cap (22) shall face the flywheel. Tighten the screws of the cap of the main bearing (18). 19. Thrust metal 20. Groove

Main bearing cap screw tightening torque (apply lube oil) 21. Mark

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Model 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

Standard thickness 76.4 - 80.4 N·m (56 - 59 lb ft) 93.2 - 98.1 N·m (69 - 72 lb ft) 108.1 - 117.9 N·m (80 - 87 lb ft) 186.2 - 205.8 N·m (137 - 152 lb ft)

Point 5: Crankshaft Disassembly Remove the crankshaft. Remove each main bearing metal upper (block side) and pair it with the metal cap side lower metal. NOTICE: Carefully prevent damage to the bearing or finger injury when removing the crankshaft because it is heavy.

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Crankshaft oil seal - Replace Oil seal replacement (flywheel housing side) 1. Replace oil seal, when a flywheel housing is removed. Extract the used oil seal. 2. Insert a new oil seal with the oil seal insertion tool. 3. Apply lithium grease.

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Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Crankshaft and flywheel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Crankshaft and flywheel - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankshaft oil seal - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - 10 Fuel tanks - 216

CX35B CX39B

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tanks Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Fuel tanks

Fuel tanks - Prepare 1. Remove the floor mats, the floor covers and the floor plate. 2. Remove the cover assembly on the left lower side. 3. Remove the battery. 4. Remove the stopper plate of the battery. Two capscrews M10 X 20 : 17 mm Tightening torque: 52 NÂˇm (38.4 lb ft)

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Engine - Fuel tanks

Fuel tanks - Remove 1. Open the fuel filler cap (B2) and loosen the drain cock (B11) to drain fuel. Tank capacity: 38 l (10.04 US gal) 2. Disconnect the hoses (2) and (3) for the fuel inlet and outlet, the hose (B4) for the fuel supply port, and two air bleed hoses (A3). 3. Loosen the M10 X 20 sems-bolt (B10) to remove the flange (B12) together with the drain hose (B13). : 17 mm 4. Disconnect connector (A13) for the level sensor. 5. Remove two M10 X 20 capscrews (B8).

TULI12EXN6306AA

TULI12EXN6307BA

: 17 mm 6. Remove the fuel tank (A1) together with the bracket assembly (B15).

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Engine - Fuel tanks

Fuel tanks - Install Assemble the fuel tank in reverse order of the removal and tighten the screws to the specified torque shown in the following table:

TULI12EXN6307BA

Piece B8 B10

Name Screw M10 Screw M10

Tool 17 mm 17 mm

B38

Clip

Screw driver

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Torque 46.1 N路m (34.0 lb ft) 34 N路m (25.1 lb ft) 0.49 - 0.78 N路m (0.4 - 0.6 lb ft) 0.36 - 0.58 N路m (0.3 - 0.4 lb ft)

Index Engine - 10 Fuel tanks - 216 Fuel tanks - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel tanks - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel tanks - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Fuel injection system - 218

CX35B CX39B

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Contents Engine - 10 Fuel injection system - 218

FUNCTIONAL DATA Fuel injection system Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Injection pump Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Fuel injection system Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - Fuel injection system

Fuel injection system - Functional diagram

TULI12EXN5055FA

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

Fuel tank Water separator Fuel feed electric pump Fuel filter Orifice Pressure control valve Low pressure gallery Trochoid pump Oil seal Engine oil Engine crankcase Cam

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

High pressure gallery Fuel injection valve Injection pump Overflow orifice Tappet Fuel return Joint Nozzle Accumulator Timer piston Plunger Distributor shaft

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Engine - Fuel injection system

Fuel injection system - Component identification NOTE: This figure shows the 3TNV84.

TULI12EXN5056GA

1. 2. 3. 4. 5. 6. 7. 8. 9.

V-belt / V-pulley Fuel injection valve Fan Donâ&#x20AC;&#x2122;t disassemble: pump flange, fuel pump drive gear Drive gear nut Fuel pump spacer Water separator Fuel injection pump Cylinder head

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10. 11. 12. 13. 14. 15. 16. 17. 18.

Fuel filter Fuel injection valve Inlet manifold Coolant pump Camshaft driving gear Crankshaft gear Gear case Oil seal Crankshaft pulley

Engine - Fuel injection system

Injection pump - Static description Fuel injection pump/governor Only the outline of the MP fuel pump is explained in this chapter. Refer to the MP pump service manual of the separate volume for the disassembly and assembly.

Introduction It is described about the features of the fuel injection pump, YDP-MP, manufactured by Yanmar, disassembly, assembly and adjustment procedure. Fuel injection pump is the most important equipment, which is enable to make the sensitive adjustment according to the variable load of the engine. Therefore all of the parts are required not only very precise machining but also finest, assembling with top. The careful arrangement of keeping off the dust and the rust when disassemble, adjustment and reassemble of the fuel injection pump is made in the market. Yanmar YDP-MP Pump is a distributor type pump which is unified of Mono-plunger, a distributing shaft, a hydraulic head which equipped the delivery valve for each cylinder, pump housing which has a cam shaft internally and governor. The fuel, which is pressurized by the up and down movement of the plunger driven by the cam-rotation, is supplied through the distributor shaft, which is rotating accordingly. There are two models of Yanmar pump: YDP-MP2 and YDP-MP4, and the plunger diameter and the fuel cam diameter differ.

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TUPH12EXN5054AA

Engine - Fuel injection system

Fuel injection system - Disassemble Disassembly from the engine body. • Remove the fan, pulley and V belt. • Remove the fuel injection pipe, fuel oil piping, fuel return pipe and rear stay. See “Point 1”. • Remove the fuel injection pump cover (the cover of the drive gear). • Make ID marks on the gearing part of the pump drive gear and the idle gear with paint and so on. See “Point 2”. • Loosen a fuel pump drive gear nut, and remove a pump drive gear from the fuel pump by using a gear puller. See “Point 3”.

TULI12EXN5057AA

TULI12EXN5058AA

TULI12EXN5059AB

• Remove a drive gear nut carefully not to drop it to the inside of the gear case. • Record the installation angle of the fuel pump precisely by using a mark-off line and a sticker. See “Point 4”. • Remove the fuel injection pump. See “Point 3”. Fuel pump (4 cylinder) (Fig. 1) Fuel pump (3 cylinder) (Fig. 2) 19. Fuel injection valve 20. Fuel pump 21. Governor side 22. Drive side 23. Cylinder No. 1 24. Engine

Point 1 Disassembly • Block an entrance with the tape so that trash may not enter the fuel injection pipe and the fuel injection pump (25).

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Engine - Fuel injection system

Point 2 Disassembly • After putting the I.D. marks (26) on the gearing part of the pump drive gear (30) and the idle gear (27) with paint and so on, remove the gear installation nut (29). NOTE: Do not remove the four flange screws (28).

Reassemble • Reassemble the pump driving gear while checking the I.D. marks (30) on the driving gear (26) and idle gear (27). Tightening torque of the gear installation nut Lubricating oil application (threaded portion and seat surface)

Model TNV82A~88 4TNV94~106(T)

78 - 88 N·m (58 - 65 lb ft) 113 - 123 N·m (83 - 91 lb ft)

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Not applied

Engine - Fuel injection system

Point 3 Disassembly There is an acoustic material part to name as fuel pump spacer (32) between the fuel pump (33) and the cylinder block (31). Loosen fuel pump mounting screws with a closed wrench (36) while disassembling the fuel pump. NOTE: An intake manifold may obstruct the disassembly of the fuel pump (33) by the engine model. Remove the fuel pump after removing the intake manifold (35) first. 34. Cylinder head

Reassemble When installing a fuel pump on the gear case, put a fuel pump spacer between the cylinder blocks, and install it.

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TUPH12EXN5060AB

TUPH12EXN5061AB

Engine - Fuel injection system

Fuel injection system - Assemble Reverse the disassembly procedure and adjust the fuel injection timing finally.

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Index Engine - 10 Fuel injection system - 218 Fuel injection system - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel injection system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel injection system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel injection system - Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Injection pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - 10 Air cleaners and lines - 202

CX35B CX39B

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Contents Engine - 10 Air cleaners and lines - 202

SERVICE Air cleaners and lines Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Air cleaners and lines

Air cleaners and lines - Prepare Open the rear bonnet assembly (1).

SMIL13MEX0073AB

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Engine - Air cleaners and lines

Air cleaners and lines - Remove 1. Loosen the clip (5) to remove the air hoses (2) and (3). : Minus driver 2. Loosen two M8 X 20 (7) and two M8 X 25 (8) sems-bolts to remove the air cleaner assembly (1). : 13 mm

TULI12EXN6315BB

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Engine - Air cleaners and lines

Air cleaners and lines - Install Assemble the air cleaner in reverse order of the disassembly. â&#x20AC;˘ Tightening torque Sems-bolts (7) and (8): 23.5 NÂˇm (17 lb ft)

TULI12EXN6315BB

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Index Engine - 10 Air cleaners and lines - 202 Air cleaners and lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air cleaners and lines - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air cleaners and lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Turbocharger and lines - 250

CX35B CX39B

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Contents Engine - 10 Turbocharger and lines - 250

TECHNICAL DATA Turbocharger General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUNCTIONAL DATA Turbocharger Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Turbocharger Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Interior washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DIAGNOSTIC Turbocharger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Turbocharger - General specification Applicable engine model (application) Turbocharger model Turbocharger specification Turbine type Blower (compressor) type Lubrication method Max. continuous allowable speed Max. continuous allowable gas inlet temperature Dry weight N

3TNV84T(CL, VM) 4TNV84T(CL) RHB31

3TNV84T(VM)

4TNV106T(CL, VM)

RHB51 Standard (w/waste gate) Radial flow Centrifugal External lubrication

RHF5

250.000

180.000 750

NOTE: VM application is provided with the waste gate.

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Turbocharger - Torque RHF5 type Piece Turbine housing setscrew Compressor housing setscrew Thrust bearing set screw Seal plate set screw Blower impeller set nut (left-handed screw)

Thread diameter M8 M5 M3 M3 M5

Tightening torque 27 - 29 N·m (19.9 - 21.4 lb ft) 4.2 - 5.2 N·m (3.1 - 3.8 lb ft) 1.2 - 1.4 N·m (0.9 - 1 lb ft) 1.2 - 1.4 N·m (0.9 - 1 lb ft) 1.8 - 2.2 N·m (1.3 - 1.6 lb ft)

RHB31/RHB51 type Piece Waste gate actuator setscrew

Thread diameter M5 M6

Lock plate setscrew M8 Thrust bearing set screw

Seal plate set screw

Blower impeller set nut (left-handed screw)

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Tightening torque RHB31 RHB51 3.9 - 4.9 N·m 3.9 - 4.9 N·m (2.9 - 3.6 lb ft) (2.9 - 3.6 lb ft) 11.8 - 12.8 N·m 11.8 - 12.8 N·m (8.7 - 9.4 lb ft) (8.7 - 9.4 lb ft) 11.8 - 12.8 N·m 27.0 - 28.9 N·m (8.7 - 9.4 lb ft) (19.9 - 21.3 lb ft) 1.2 - 1.4 N·m 1.2 - 1.4 N·m (0.9 - 1 lb ft) (0.9 - 1 lb ft) 1.2 - 1.4 N·m 1.2 - 1.4 N·m (0.9 - 1 lb ft) (0.9 - 1 lb ft) 0.9 - 1.1 N·m 1.8 - 2.2 N·m (0.7 - 0.8 lb ft) (1.3 - 1.6 lb ft)

Engine - Turbocharger and lines

Turbocharger - Service limits

TULI12EXN5064EA

Compression side

Turbine side

RHF5 type Turbine shaft journal outside diameter (“A”) Turbine shaft seal ring groove width (“E”) Compressor side seal ring Turbine shaft groove width (“G1”) Compressor side seal ring groove width (“G2”) Turbine shaft run-out Journal bearing inside diameter (“C”) Journal bearing outside Bearing diameter (“D”) Bearing housing inside diameter (“B”) Thrust bearing width (“J”) Thrust bushing Thrust bushing groove dimension (“K”) Turbine side (bearing housing) (“F”) Compressor side (seal ring) Seal ring fixing area (“H1”) Compressor side (seal ring)(“H2”) Rotor play in axial direction Rotor play in radial direction

Standard dimension

Wear limit

7.99 - 8.00 mm (0.31 - 0.31 in)

7.98 mm (0.31 in)

1.25 - 1.28 mm (0.05 - 0.05 in)

1.29 mm (0.05 in)

1.22 - 1.23 mm (0.05 - 0.05 in)

1.31 mm (0.05 in)

1.02 - 1.03 mm (0.04 - 0.04 in)

1.11 mm (0.04 in)

0.002 mm (0.00 in)

0.011 mm (0.00 in)

8.01 - 8.03 mm (0.32 - 0.32 in)

8.04 mm (0.32 in)

12.32 - 12.33 mm (0.49 0.49 in) 12.40 - 12.41 mm (0.49 0.49 in) 3.99 - 4.01 mm (0.16 - 0.16 in) 4.04 - 4.05 mm (0.16 - 0.16 in) 15.00 - 15.02 mm (0.59 0.59 in) 12.40 - 12.42 mm (0.49 0.49 in) 10.00 - 10.02 mm (0.39 0.39 in) 0.03 - 0.06 mm (0.00 - 0.00 in) 0.08 - 0.13 mm (0.00 - 0.01 in)

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12.31 mm (0.48 in) 12.42 mm (0.49 in) 3.98 mm (0.16 in) 4.07 mm (0.16 in) 15.05 mm (0.59 in) 12.45 mm (0.49 in) 10.05 mm (0.40 in) 0.09 mm (0.00 in) 0.17 mm (0.01 in)

Engine - Turbocharger and lines

RHB31/RHB51 type Standard dimension RHB31 RHB51

Turbine shaft

Bearing

Thrust bushing

Turbine shaft journal outside diameter (“A”) Turbine shaft seal ring groove width (“E”) Compressor side seal ring groove width (“G1”) Compressor side seal ring groove width (“G2”) Turbine shaft run-out Journal bearing inside diameter (“C”) Journal bearing outside diameter (“D”) Bearing housing inside diameter (“B”) Thrust bearing width (“J”) Thrust bushing groove dimension (“K”) Turbine side (bearing housing) (“F”)

Wear limit RHB31

RHB51

6.257 - 6.263 mm (0.25 - 0.25 in)

7.99 - 8.00 mm (0.31 - 0.31 in)

6.25 mm (0.25 in) 7.98 mm (0.31 in)

1.038 - 1.062 mm (0.04 - 0.04 in)

1.25 - 1.28 mm (0.05 - 0.05 in)

1.07 mm (0.04 in) 1.29 mm (0.05 in)

1.02 - 1.03 mm (0.04 - 0.04 in)

1.22 - 1.23 mm (0.05 - 0.05 in)

1.04 mm (0.04 in) 1.31 mm (0.05 in)

0.82 - 0.83 mm (0.03 - 0.03 in)

1.02 - 1.03 mm (0.04 - 0.04 in)

0.84 mm (0.033 in)

1.11 mm (0.04 in)

0.002 mm (0.00 in)

0.005 mm (0.00 in)

0.011 mm (0.00 in)

6.275 - 6.285 mm (0.25 - 0.25 in)

8.01 - 8.03 mm (0.32 - 0.32 in)

6.29 mm (0.25 in) 8.04 mm (0.32 in)

9.940 - 9.946 mm 12.32 - 12.33 mm 9.93 mm (0.39 in) (0.39 - 0.39 in) (0.49 - 0.49 in)

12.31 mm (0.48 in)

9.995 12.40 - 12.41 mm 10.01 mm 12.42 mm 10.005 mm (0.39 (0.49 - 0.49 in) (0.39 in) (0.49 in) - 0.39 in) 3.59 - 3.61 mm 3.99 - 4.01 mm 3.58 mm (0.14 in) 3.98 mm (0.16 in) (0.14 - 0.14 in) (0.16 - 0.16 in) 3.632 - 3.642 mm (0.14 - 0.14 in)

4.04 - 4.05 mm (0.16 - 0.16 in)

3.65 mm (0.14 in) 4.07 mm (0.16 in)

11.00 15.00 - 15.02 mm 11.03 mm 15.05 mm 11.018 mm (0.43 (0.59 - 0.59 in) (0.43 in) (0.59 in) - 0.43 in) 9.987 Seal ring fixing 12.40 - 12.42 mm 10.04 mm 12.45 mm Compressor side 10.025 mm (0.39 area (0.49 - 0.49 in) (0.40 in) (0.49 in) (seal ring) (“H1”) - 0.39 in) 10.05 mm Compressor side 7.968 - 8.00 mm 10.00 - 10.02 mm 8.01 mm (0.32 in) (0.31 - 0.31 in) (0.39 - 0.39 in) (0.40 in) (seal ring) (“H2”) 0.022 - 0.053 mm 0.03 - 0.06 mm Rotor play in axial direction 0.07 mm (0.00 in) 0.09 mm (0.00 in) (0.00 - 0.00 in) (0.00 - 0.00 in) 0.061 - 0.093 mm 0.08 - 0.13 mm Rotor play in radial direction 0.12 mm (0.00 in) 0.17 mm (0.01 in) (0.00 - 0.00 in) (0.00 - 0.01 in)

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Turbocharger - Special tools In addition to the general tools, the following special tools are required for turbocharger disassembly and reassembly: Name

Use

Illustration

Bar

For removing thrust bearing and thrust bushing Material: Copper or brass

Pliers

For removing floating bearing circlip

Pliers

For removing seal ring

Torque driver for TORX screw (multifunctional type) 0.5 - 4.9 N·m (0 - 4 lb ft)

For thrust bearing installation (for M3): 1.3 N·m (1 lb ft)

Item sold on market

For seal plate installation (for M3): 1.3 N·m (1 lb ft)

Box wrench

For fixing turbine shaft (mm dodecagonal)

Torque wrench (single purpose)

For following bolts and nuts: M8: mm, Nm M8: mm, Nm M5: mm, Nm

Box only may be used

Name: Probe Usage: For measuring play in axial and radial directions: To be installed on a dial gauge

TULI12EXN5074EA

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Engine - Turbocharger and lines

Turbocharger - Dynamic description

TULI12EXN5062FA

AI. AO. GI. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Air inlet Air outlet Gas inlet Part name Turbine shaft Oil sprayer Turbine side seal ring Seal plate Journal bearing Thrust bushing Compressor housing Hexagon head screw M5 M5 spring washer Compressor side clamp

GO. Gas outlet OI. Oil inlet OO. Oil outlet No. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Part name Turbine housing Hexagon head screw M6 Turbine side clamp Lock washer Bearing housing Stopper clip M3 countersunk flat head screw Compressor wheel Shaft end nut Heat protector

1. Turbine The exhaust gas from the engine is accelerated at the nozzle portion in the turbine housing and blown onto the turbine impeller to rotate the turbine shaft. This is called the turbine. A seal ring and heat insulating plate are installed to prevent the bearing from adverse influence of the gas. 2. Compressor The compressor impeller installed on the turbine shaft rotates with the shaft to suck and compress air for feeding into the intake manifold. This is called “blower” or “compressor”. 3. Bearings Thrust bearing As the turbine shaft is constantly applied with a thrust force, this bearing prevents the shaft from being moved by the thrust force. 47574272B 24/03/2014

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Engine - Turbocharger and lines

Radial bearing A floating bearing is adopted. Since the bearing moves with the turbine shaft as the oil films are formed both inside and outside the bearing, the bearing sliding speed is slower than the turbine shaft speed, resulting in higher dynamic stability. 4. Compressor side sealing mechanism To prevent the intake air and oil form leaking, a seal ring and a seal plate are provided to form a double wall structure on the rear side of the compressor impeller. 5. Exhaust valve When the blower side pressure (intake air pressure) exceeds the specified level, the exhaust gas at the turbine inlet is partially bypassed to the exhaust discharge side to control the turbine RPM so as to maintain the intake pressure at the specified level for improving the response to load variation in the low to medium speed range and to minimize black smoke generation. It consists of a control assembly separated from the turbocharger and a valve assembly installed in the turbine impeller chamber.

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Engine - Turbocharger and lines

Turbocharger - Component identification

TULI12EXN5063GA

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Engine - Turbocharger and lines

No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Part name Turbine shaft Oil sprayer Seal ring (turbine side) Seal plate Journal bearing Thrust bushing Compressor housing Flanged nut Spring washer Clamp Turbine housing Edge bolt Lock plate Thrust bushing Bearing housing Stopper clip Edge bolt

No. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Part name Impeller Locknut Heat protector Seal ring Seal ring Edge bolt Lock washer Liquid gasket Waste gate actuator Hose Adapter Clip Stopper clip Waste gate valve Link plate Edge bolt Washer

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Turbocharger - Inspect Periodic inspection intervals Periodically inspect the turbocharger for the overall conditions and fouling. The inspection interval varies with the operating conditions, but refer to the table below for the guideline for each application. Application For vehicles (automobiles) For construction machinery For farming machinery For marine use Rotor rotation Rotor play Overhaul and overall inspection Oil filter cleaning and inspection Replacement of engine oil

Every 6 months or 60.000 km (37.3 miles) Every 6 months or 500 h Every 6 months or 200 h Every 6 months or 1500 h X

Inspection interval Every 12 months or Every 24 months or 150.000 km (93.2 miles) 300.000 km (186.4 miles) Every 12 months or 1000 h Every 24 months or 2000 h Every 12 months or 400 h Every 24 months or 800 h Every 12 months or 3000 h Every 24 months or 6000 h X X

Based on engine operation manual

Rotor rotation inspection Inspect the rotor rotation by listening to any abnormal sound generation during rotation. For inspection with a sound detecting bar, bring the tip end of the bar into strong contact with the turbocharger case and raise the engine speed gradually. If any high pitch sound is generated at intervals of 2 - 3 s, the rotation is abnormal. Since the bearing or rotor may be defective in this state, either replace or overhaul the turbocharger.

TULI12EXN5065BC

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Engine - Turbocharger and lines

Rotor play check Remove the turbocharger from the engine and inspect the rotor play in the axial and radial directions according to the procedure below. After removing the turbocharger from the engine, always bind the oil inlet and outlet holes with adhesive tape. AP. Axial play (Maintenance standard: From 0.03 - 0.06 mm (0.001 0.002 in)) (Wear limit: 0.09 mm (0.004 in)) DG. Dial gauge MB. Magnet base MT. Move the turbine shaft in the axial direction TW. Turbine wheel chamber

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Turbocharger - Adjust Waste gate valve adjustment procedure Rotor play in radial direction

TULI12EXN5066FB

DG. Dial gauge MB. Magnet base MT. Move the turbine shaft in the radial direction at the same time on the left and right sides

OI. Oil inlet OU. Oil outlet RP. Radial play (Maintenance standard: From 0.08 - 0.13 mm (0.00 - 0.01 in)) (Wear limit: 0.17 mm (0.01 in))

It is indispensable to adjust the waste gate valve opening pressure and lift after its overhaul or inner parts replacement. Negligence of this adjustment will adversely affect the engine performance. NOTE: If the adjustment is impossible, give up overhaul but replace the whole turbocharger assembly.

Method for checking the waste gate valve opening pressure and lift Equipment Prepare the equipment shown in the Fig. 2.

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Measuring instruments and devices Dial gauge Pressure gauge Pressure regulating valve Pressure relief valve Pressure gauge

Capable of measuring 0 - 10 mm (0 - 0.39 in) (A flat head type is recommendable) Mercury column or electrical type (capable of measuring from 0 - 1500 mm Hg (0 59.05 in Hg)) Allowing gradual adjustment in a range between 0 - 2 kgf (0 - 4 lbf) Used for suppressing the air supply pressure at 5 kgf (11 lbf) or less Bourdon tube pressure gauge (from 0 - 10 kgf (0 - 22 lbf))

TULI12EXN5067FB

A. C. CA. DG. M. N.

Adapter Clip Compressed air Dial gauge Manometer Hose

PG. PR. PV. WA. WG.

Pressure gauge Pressure regulating valve Pressure reducing valve Waste gate actuator Waste gate valve

Check method 1. Set the manometer control pressure â&#x20AC;&#x153;Pcâ&#x20AC;? applied to the waste gate actuator to 0 and set the dial gauge to the zero point. 2. Gradually open the pressure regulating valve and measure the Pc value when the actuator rod is operated by 2 mm (0.08 in). 3. For the hysteresis, let the rod move to 3 mm (0.12 in) first. The gradually close the pressure regulating valve, measure the pressure when the rod is moved to 2 mm (0.08 in) and obtain the difference from the pressure measured in b above.

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Engine - Turbocharger and lines

Precautions • Set the dial gauge on the extension line of the actuator rod. • The piping and joints shall completely be free from leak. • Fix the turbocharger and dial gauge securely. • If an electric manometer is used, it shall have sufficient precision. • Even when an electric manometer is used, use of a mercury column type manometer in combination is recommended for calibration and daily check. • The speed for increasing/decreasing Pc by means of the pressure regulating valve shall be very slow near the measuring point. If the mm position is exceeded, restart from the beginning. • Do not apply more then 0.49 MPa (71 psi) to the actuator.

Waste gate actuator leak test Apply 0.12 MPa (17 psi) to the actuator and keep this condition for 1 min. The actuator is correctly operating if pressure is 0.11 MPa (16 psi) or higher.

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Engine - Turbocharger and lines

Turbocharger - Prepare 1. Inspect the turbine wheel and compressor impeller for any undesirable contact and the rotor for smooth rotation. 2. Measure the rotor play. â&#x20AC;˘ Rotor end play. â&#x20AC;˘ Rotor radial play.

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Engine - Turbocharger and lines

Turbocharger - Disassemble The mounting angles of the turbine housing, bearing housing and compressor housing are determined according to its mounting state on the engine. Put match marks before starting disassembly. NOTE: The number after each part is the one described in the structural drawing in Turbocharger - Component identification (10.250) .

Compressor housing removal • Remove the flanged hexagon head screw (8) and the plate on the compressor side (10). • Remove compressor impeller (7). NOTE: Liquid gasket is applied on the surface of compressor housing (7) where bearing housing (15) is mounted. When disassembling compressor housing (7), carefully operate so as not to damage the compressor impeller.

Compressor impeller removal • Set a box spanner ( 10 mm (0.39 in)) on the turbine side end of the turbine shaft, and remove shaft end clamp (18). NOTE: Pay attention to the loosening direction since the shaft end nut has left-handed screw. • Remove compressor impeller (18).

Turbine housing removal • Remove hexagon nut (12) and turbine side keep plate (13). • Remove turbine housing (11).

Turbine shaft extraction • Hold heat insulating plate (20) lightly with a hand, and extract turbine shaft (1). NOTE: If the turbine shaft is hard to be extracted, tap the compressor side end of the shaft lightly with a wooden hammer. • Remove heat insulating plate (20).

Seal plate removal • Use the Torx driver and loosen M3 Torx T-type machine screw (17) for seal plate mounting. • Remove seal plate (4). NOTE: Liquid gasket has been applied to the seal plate and bearing housing mounting surface. • Remove oil thrower (2) from the seal plate.

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Engine - Turbocharger and lines

Slide bearing and thrust bushing removal • Use the Torx driver and loosen the M3 Torx T-type machine screw for thrust bearing installation. • Use the bar (copper) and remove thrust bearing (6) and thrust bushing.

Floating bearing removal • Use the stop ring pliers and remove circlip (16) from bearing housing (15). • Remove floating bearing (5) from bearing housing (15).

Seal ring removal • Remove turbine side seal ring (3) from turbine shaft (1). • Remove compressor side seal ring (small) and compressor side seal ring (large) from oil thrower (2).

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Turbocharger - Interior washing 1. Inspection before washing Visually inspect each part before washing to check trace of seizure, wear, foreign matter or carbon adhesion. Carefully inspect for identifying the cause of trouble especially when a fault has occurred. Major inspection items Check points Carbon adhesion state

Lubrication status (wear, seizure, discoloration, etc.)

Oil leaking

Checking position Turbine shaft 1, turbine side seal ring and rear side of turbine wheel Heat insulating plate 20 mounting portion and inside of bearing housing 15 Turbine shaft 1, journal portion and thrust bushing oil thrower 2 Floating bearing 5 and thrust bearing 6 Bearing housing 15 and inner wall of bearing fitting ring Inner wall of turbine housing 11 Outer surface of bearing housing 11 and heat insulating plate 20 mounting portion Turbine shaft 1, turbine side seal ring and rear side of turbine wheel Inner wall of compressor housing 7 Rear side of compressor impeller 18 Surface and seal ring inserting portion of seal plate 4

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2. Washing procedure Keep the following in mind when washing the parts: Tools and detergent

Piece Turbine shaft

Tools • Bucket (500 x 500)

Procedure Boil the turbine in the washing bucket Do not strike the blade to remove the carbon

• Heat source: Steam or gas burner • Brush Detergent • Standard carbon removing agent

Turbine wheel chamber

Tools • Same as for turbine shaft Detergent • Same as for turbine shaft

Blower blade and chamber

Tools • Bucket (500 x 500) • Brush Detergent

Others

Immerse in the detergent until the carbon and other deposits are softened Use a plastic scraper or hand hair scrubber to remove the softened deposits Protect the bearing surface and seal ring groove on the turbine shaft so as not to be damaged Any deposit remaining on the turbine shaft due to improper washing may cause unbalancing. Be sure to remove thoroughly. Never use a wire brush Boil the turbine in the washing bucket Immerse in the detergent until the carbon and other deposits are softened Use a plastic scraper or hard hair scrubber to remove the softened deposits Immerse in the washing bucket until the deposit is softened Use a plastic scraper or hard hair scrubber to remove the softened deposits. Never use a wire brush

Wash all other parts with diesel oil Clean the lubricating oil path by blowing with compressed air Be especially careful so as not to damage or corrode the parts

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Turbocharger - Inspect Compressor housing (7) Inspect the compressor housing for any contact trace with the compressor impeller, surface defect, dent or crack at joint surface, and replace it if defective.

Turbine housing (11) Inspect any trace of contact with the turbine wheel, exfoliation due to degradation by oxidation of the cast surface, thermal deformation or crack. Replace with a new one of defective.

Compressor impeller (18) Inspect any contact trace, chipping, corrosion or deformation. Replace with a new one of defective.

Turbine shaft (1) • Inspect any contact trace, chipping, thermal discoloration or deformation at the turbine wheel. Check the shaft portion for bend, the journal portion for thermal discoloration or abnormal wear, and the seal ring groove for surface defect or wear. Replace with a new one if defective. • Measure the turbine shaft journal outside diameter “A” and seal ring groove width “E”. Replace with a new turbine shaft if beyond the wear limit.

TULI12EXN5075AA

Wear limit of journal outside diameter “A” RHF5 – 7.98 mm (0.31 in) RHB51 – 7.98 mm (0.31 in) RHB31 – 6.25 mm (0.25 in) Wear limit of ring groove width “E” RHF5 – 1.29 mm (0.05 in) RHB51 – 1.29 mm (0.05 in) RHB31 – 1.07 mm (0.04 in) • Measure the turbine shaft run-out, and replace with a new turbine shaft if it exceeds 0.011 mm (0.0004 in).

Heat insulating plate (20) Inspect the heat insulating plate for any contact trace, thermal deformation or corrosion. Replace with a new part if defective

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Thrust bushing, oil sprayer (2) and thrust bearing (6) Inspect each part for wear, surface defect and discoloration. Replace with a new one if defective even within the wear limit. A. Thrust bushing Measure the distance between grooves “K” of the thrust bushing, and replace with a new one if the wear limit is exceeded. Wear limit RHF5 – 4.07 mm (0.16 in) RHB51 – 4.07 mm (0.16 in) TULI12EXN5076AB

RHB31 – 3.65 mm (0.14 in) B. Oil thrower (2) Measure the seal ring groove widths “G1” and “G2”, and replace with a new one if the wear limit is exceeded. Wear limit RHF5 – “G1”: 1.31 mm (0.05 in), “G2”: 1.11 mm (0.04 in) RHB51 – “G1”: 1.31 mm (0.05 in), “G2”: 1.11 mm (0.04 in) RHB31 – “G1”: 1.04 mm (0.04 in), “G2”: 0.84 mm (0.03 in) C. Thrust bearing (6) Measure the thrust bearing width “J”, and replace with a new one if the wear limit is exceeded. Wear limit RHF5 – 3.98 mm (0.16 in) RHB51 – 3.98 mm (0.16 in) RHB31 – 3.58 mm (0.14 in)

Floating bearing (5) • Inspect the floating bearing for abnormal wear, discoloration or surface defect. Replace with a new one of defective. • Measure the inside diameter “C” and outside diameter “D”. Replace the bearing if either wear limit is exceeded. Wear limit RHF5 – Outside diameter “D”: 12.31 mm (0.48 in) Inside diameter “C”: 8.04 mm (0.32 in) RHB51 – Outside diameter “D”: 12.31 mm (0.48 in) Inside diameter “C”: 8.04 mm (0.32 in) RHB31 – Outside diameter “D”: 9.93 mm (0.39 in) Inside diameter “C”: 6.29 mm (0.25 in)

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Bearing housing (15) • Inspect the housing for cast surface exfoliation due to oxidation and degradation, dent or crack. • Inspect circlip (16) for chipping or crack, and replace with a new one if defective. • Measure the “B” and “F” portions of the bearing housing shown in the Fig 3. • Replace with a new one if either wear limit is exceeded. Wear limit of bearing housing inside diameter “B” RHF5 – 12.42 mm (0.49 in) RHB51 – 12.42 mm (0.49 in) RHB31 – 10.01 mm (0.39 in) Wear limit of turbine side seal ring inserting portion “F” RHF5 – 15.05 mm (0.59 in) RHB51 – 15.05 mm (0.59 in) RHB31 – 11.03 mm (0.43 in) • (BF) Bearing fitting ring • (CS) Compressor side • (IP) Inner plate • (TS) Turbine side TULI12EXN5077BB

TULI12EXN5078AA

Seal plate (4) • Inspect the seal plate for any contact trace, joint surface defect, dent or crack. Replace it if defective. • Measure the seal ring inserting dimensions “H1” and “H2” on the compressor side, and replace the seal ring with a new one if either wear limit is exceeded. Wear limits RHF5 – “H1”: 12.45 mm (0.49 in), “H2”: 10.05 mm (0.40 in) RHB51 – “H1”: 12.45 mm (0.49 in), “H2”: 10.05 mm (0.40 in) RHB31 – “H1”: 10.04 mm (0.40 in), “H2”: 8.01 mm (0.32 in)

Seal rings Replace seal rings with new ones. Inspect keep plates (10), (13) and screws for any deformation, and replace defective parts with new ones. Also replace M3. Torx machine screws with new ones.

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Turbocharger - Pre-assemble 1. Prepare general tools, special tools, liquid gasket and LOCTITE® 242 before reassembling the turbocharger. 2. Always replace the following parts with new ones: • Turbine side seal ring 1pc. • Compressor side seal ring (large) 1pc. • Compressor side seal ring (small) 1pc. • M3 machine screws 3pcs. • M3 machine screws 4pcs. AO. Applicable only to the one closest the turbine FA. For all other than above FM. Floating metal LO. Lubricating oil inlet MU. Match up contact surface VT. View from the turbine 1. Snap ring

TULI12EXN5079BB

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Turbocharger - Assemble Floating bearing installation • Use the snap ring pliers and install inner circlip (16) on bearing housing (15). • Install floating bearing (5) in bearing housing (15). • Use the snap ring pliers and install outer circlip (16) on bearing housing (15). NOTE: The circlip joint shall be positioned as shown in Turbocharger - Pre-assemble (10.250) . The rounded side of the circlip shall face the bearing. Apply lubricating oil on the floating bearing before reassembly.

Turbine shaft installation • Fit the seal ring onto turbine shaft (1). • Install heat insulating plate (20) on the turbine side of bearing housing (15). • Apply lubricating oil on the journal portion of the turbine shaft and insert the shaft from the turbine side of bearing housing (15). NOTE: Carefully operate so as not to damage the floating bearing by the turbine shaft. The seal ring joint shall be positioned on the lubricating oil inlet side after centering with the turbine shaft.

Thrust bearing installation • Fit thrust bushing on turbine shaft (1). • Apply lubricating oil on the bearing portion of thrust bearing (6) and install it in bearing housing (15). • Apply LOCTITE® on the threaded portion of M3 Torx T machine screw (17) for thrust bearing installation, and use Torx torque driver for installation by tightening to the specified torque. Tightening torque: 1.2 - 1.4 N·m (0.89 - 1.03 lb ft).

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Seal plate installation • Fit the seal ring on oil thrower (2). • Insert oil thrower (2) into seal plate (4). NOTE: The seal ring joint portion shall be positioned as illustrated at Fig. 1. VC. View from the compressor • Apply liquid gasket on the seal plate mounting surface on the compressor side of bearing housing (15). NOTE: See the Fig. 2 below for the applying position.

TULI12EXN5080AA

TULI12EXN5081BB

Applying thickness: 0.1 - 0.2 mm (0.0039 - 0.0079 in) • Install seal plate (4) on bearing housing (15). • Apply LOCTITE® on the threaded portion of M3 machine screw for seal plate mounting, and tighten it with a torque screwdriver. Tightening torque: 1.2 - 1.4 N·m (0.89 - 1.03 lb ft) CP. Carefully prevent the liquid gasket from leaking out to this area LG. Liquid gasket applying position

Compressor impeller installation • Fit compressor impeller (18) onto turbine shaft (1). • Set a box spanner 10 mm (0.39 in) on the turbine side end of turbine shaft (1), and tighten shaft end nut (19). NOTE: Since the shaft end nut has left-handed screw, pay attention to the tightening direction. Tightening torque: 1.8 - 2.2 N·m (1.33 - 1.62 lb ft)

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Turbine housing installation • Install bearing housing (15) on turbine housing (11) by aligning the match marks put before disassembly. NOTE: In case of part replacement, check the oil inlet and outlet positions and the exhaust gas inlet position before reassembly. • Install the turbine side keep plate and tighten hexagon head screw M8X12. Tightening torque: 275 - 295 N·m (203 - 218 lb ft)

Compressor housing installation • Apply liquid gasket on the compressor side flange of bearing housing (15). NOTE: See “Seal plate installation” (3) for the portion to be applied. Applying thickness: 0.1 - 0.2 mm (0.0039 - 0.0079 in) • Check the mark and install the compressor housing (7) on the bearing housing (15). NOTE: When a part is replaced, confirm a position of an oil entrance and a position of an air exit, and assemble it. • Install the keep plate (10) on compressor side, and tighten hexagon head screw M8X8. Tightening torque: 48 N·m (35 lb ft).

Rotor play measurement See the inspection procedure in Turbocharger Inspect (10.250) for the measurement method. If the rotor play does not satisfy the standard, reassembly is necessary since assembly error or use of a wrong part is conceivable. Service standard of rotor play in axial direction RHF5 – 0.03 - 0.06 mm (0.0012 - 0.0024 in) RHB51 – 0.03 - 0.06 mm (0.0012 - 0.0024 in) RHB31 – 0.022 - 0.053 mm (0.0009 - 0.0021 in) Service standard of rotor play in radial direction RHF5 – 0.08 - 0.013 mm (0.0031 - 0.0005 in) RHB51 – 0.08 - 0.013 mm (0.0031 - 0.0005 in) RHB31 – 0.061 - 0.093 mm (0.0024 - 0.0037 in)

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Turbocharger - Service instruction When installing the turbocharger on the engine or handling the turbocharger after installation, strictly observe the instructions given below. Especially pay careful attention for preventing foreign matter entrance into the turbocharger.

Instructions for turbocharger installation Lubrication system • Pour new lubricating oil through the oil filler port before installation on the engine, and manually turn the turbine shaft to lubricate the floating and thrust bearings. • Flush the oil inlet pipe from the engine and outlet pipe, and check no crushed pipe nor dirt or foreign matter remaining in the pipes. • Connect the pipes securely so as to ensure no oil leak from joints. Intake system • Check no foreign matter or dirt in the intake line. • Connect securely to prevent any air leak from joints with the intake duct and air cleaner. Exhaust system • Check no dirt or foreign matter in the exhaust system. • Since heat resistant steel is used for the bolts and nuts, do not use general bolts and nuts for installation. Always apply anti-seizure agent on fastening bolts and nuts to be tightened. (Use heat-resistant hexagon bolts for the turbine housing). • Connect exhaust pipes securely to prevent gas leak from each pipe joint.

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Turbocharger - Troubleshooting Problem Insufficient intake air volume

Turbocharger revolution failure

Possible Cause Clogging of air cleaner element

Correction Replace or wash the element

Blocked air intake port Leak from a joint in intake line Deposit of impurities in oil sticking on the turbine side seal portion to make turbine revolution heavy Sticking bearing

Correct to the normal state Check and repair Turbocharger overhaul (disassembly and washing) with lubricating oil replacement

Turbocharger overhaul (disassembly and repair) Insufficient lubrication or clogged lubrica- Lubricating oil line inspection, repair of detion piping fective portion and lubricating oil replacement Excessively high oil temperature Rotating part replacement or washing Unbalanced rotating part Strict observance of instructions in operation manual Insufficient warming up or sudden stop Inspection and repair of each engine part from loaded operation (no-load operation) Contact or breakdown of turbine wheel or Perfect foreign matter elimination in disassembled state, followed by inspection and blower vane repair of individual air cleaner and engine Excessive revolution components Excessive exhaust temperature rise Foreign matter invasion Worn bearing Turbocharger overhaul (disassembly and repair) Reassemble Assembly defect Influence of exhaust Exhaust gas leak before the turbocharger Joint inspection and correction resistance to decrease its revolutions Deformed or clogged exhaust pipe to de- Correct to the normal state crease turbocharger revolutions White smoke generation Clogged or deformed oil return pipe caus- Repair or pipe replacement ing oil flow to the blower or turbine side Excessive bearing wear causing abnormal Turbocharger disassembly and repair wear or damage of seal ring Excessive bearing wear causing abnormal Turbocharger disassembly and repair Sudden oil decrease wear or damage of seal ring Decrease in output Gas leak from any part in exhaust piping Inspection and repair of defective portion Air leak from discharge side of blower Element cleaning or replacement Clogging of air cleaner element Fouled or damaged turbocharger Turbocharger disassembly and repair or replacement Hard carbon deposit on the turbine side Turbocharger disassembly and washing Poor (slow) response (starting) of turbocharger (wheel sealing portion) to make turbine with lubricating oil replacement shaft revolution heavy Incomplete combustion Engine combustion state inspection, followed by improvement of combustion to normal state Abnormal sound Excessively narrowed gas path due to Turbocharger disassembly and washing generation clogged nozzle in turbine wheel chamber or reverse flow of blower discharge in acceleration (generally called â&#x20AC;&#x153;surgingâ&#x20AC;?) Turbocharger disassembly and repair or reContact rotating part placement Vibration Loosened intake, exhaust or oil pipe con- Turbocharger installation status check and nection with the turbocharger repair of defective portion Damaged bearing, contact between rotat- Turbocharger disassembly with repair or ing part and adjacent part, or chipping of replacement, or perfect removal of foreign turbine wheel or blower vane due to foreign matters in case of foreign matter invasion matter invasion Unbalanced rotating part Repair or replacement of rotating part 47574272B 24/03/2014

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Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Turbocharger - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Turbocharger - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Turbocharger - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Turbocharger - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Turbocharger - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Turbocharger - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Turbocharger - Interior washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Turbocharger - Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Turbocharger - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Turbocharger - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Turbocharger - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Turbocharger - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Turbocharger - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Turbocharger - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Engine - 10 Intake and exhaust manifolds and muffler - 254

CX35B CX39B

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Contents Engine - 10 Intake and exhaust manifolds and muffler - 254

SERVICE Intake and exhaust manifolds and muffler Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Prepare 1. Remove the bonnet assembly. 2. Remove the cover assembly.

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Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Remove 1. Loosen three M8 X 20 sems-bolts (8) to remove the cover (16). : 13 mm 2. Remove capscrew (7) and M10 nut (19) to loosen the clamp (4), and loosen four M8 nuts (9-1) to remove U bolt (27) then disconnect the exhaust tube (3). : 17 mm 3. Loosen four M8 nuts (9-2) fastening the exhaust manifold for the engine to remove the silencer. : 13 mm 4. Loosen four M8 X 20 capscrews (14) to remove the muffler (1).

TULI12EXN6318BB

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Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Install Install the muffler in reverse order of the removal and tighten the screws and nuts to the specified torque shown in the following table:

TULI12EXN6318BB

Piece 7 8 9-1 9-2 14

Name Capscrew ( M10) Sems-bolt ( M8) Nut ( M8) for U-bolt Nut ( M8) for manifold Nut ( M8)

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Tool 17 mm 13 mm 13 mm 13 mm 13 mm

Torque 23.5 N·m (17 lb ft) 23.5 N·m (17 lb ft) 10.8 N·m (8.0 lb ft) 23.5 N·m (17 lb ft) 23.5 N·m (17 lb ft)

Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Intake and exhaust manifolds and muffler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intake and exhaust manifolds and muffler - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Intake and exhaust manifolds and muffler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Engine cooling system - 400

CX35B CX39B

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Contents Engine - 10 Engine cooling system - 400

FUNCTIONAL DATA Engine cooling system Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Water pump Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Radiator Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cap - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Coolant thermostat Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Water pump Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - Engine cooling system

Engine cooling system - Functional diagram

TULI12EXN5051FA

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Engine - Engine cooling system

Water pump - Component identification Cooling water pump components NOTE: This figure shows the 4TNV84.

TULI12EXN5052GB

1. 2. 3. 4. 5.

Thermostat cover Thermostat Coolant pump Cylinder head Joint

6. 7. 8. 9.

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Thermo switch V-pulley Spacer Fan

Engine - Engine cooling system

Radiator - Prepare 1. Remove the right side cover assemblies (1) and (4), and the bonnet assembly (2). 2. Remove the counterweight. 3. Remove the duct (6) for the radiator. Two M8 X 20 sems-bolts (21). : 13 mm tightening torque 23.5 NÂˇm (17 lb ft) In order to facilitate the work, remove the related covers and components if necessary.

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TULI12EXN6281BB

TULI12EXN4957AB

Engine - Engine cooling system

Radiator - Remove 1. Draining water from radiator 1.

Remove the radiator cap.

Loosen the clip (A8), then remove the plug (A14) to drain water. Volume: About 1.6 l (0.4 US gal)

2. Draining hydraulic oil in oil cooler (23) 1.

Release the pressure in the hydraulic circuit.

Remove the oil cooler hoses (21) and (22), and then plug the inlet/outlet ports of the oil cooler and the openings of the hoses.

3. Disconnect the hose (A4) of reservoir (A5) by removing the clip (A8). 4. Remove the radiator hoses (A2) and (A3) fixed by clip (A7). Tools: Cutting pliers and minus screwdriver 5. Removing radiator Loosen two M8 X 20 (B6) and two M10 X 25 (B3) capscrews to remove the radiator assembly. : 13 mm and 17 mm Weight: 10 kg (22.0 lb)

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TULI12EXN6333BB

TULI12EXN6334AB

Engine - Engine cooling system

Radiator - Install 1. Assembly the radiator in reverse order of the disassembly. 2. Apply LOCTITE® 262 on the capscrews (B3) to fix the radiator by them. 3. Apply Loctite Hi-Tack gasket sealant to the fittings of radiator hoses (A2) and (A3) prior to the connection. 4. Install the fan (24) and shroud (25), adjusting their positions according to Fig. 1. Position the fan at a distance of 27.5 mm (1.1 in) from radiator shroud. Adjust the clearance between the fan and radiator shroud so that it is set to 15 mm (0.6 in) around the circumference.

TULI12EXN6335AB

Tightening torque for related parts Piece B6 B3

Name Nut M8 Capscrew M10

5. Feed cooling water (LLC: Long Life Coolant).

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Tool 13 mm 17 mm

Torque 23.5 N·m (17.3 lb ft) 46.1 N·m (34.0 lb ft)

Engine - Engine cooling system

Radiator Cap - Check Water leak check in cooling water system Check coolant water leakage from the cooling water system visually. If any problem is found, Inspect as follows: 1.

Fill coolant water to the normal level in the radiator, and install the cap tester (CT) on the radiator.

Operate the manual pump to set the pressure to 0.075 - 0.105 MPa (10.9 - 15.2 psi). If the cap tester (CT) pressure gauge reading drops then, water is leaking from the cooling water system. Check the water leaking point.

TULI12EXN4837AB

TULI12EXN4838AB

Radiator cap inspection Install the radiator cap (RC) on the cap tester. Set the instrument pressure to 0.075 - 0.105 MPa (10.9 - 15.2 psi) and check that the cap is open. If the cap does not open, replace the cap since it is abnormal.

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Engine - Engine cooling system

Coolant thermostat - Inspect Place the thermostat (TE) in a container filled with water. Heat it while measuring the water temperature (Thermometer (TH)), and see that the thermostat (TE) is actuated at following temperature: Model: All models Valve opening temperature: 69.5 - 72.5 Â°C* Full open lift (temperature): 8 mm (0.31 in) or more ( 85 Â°C (185 Â°F)) * Valve opening temperature is carved on the flange.

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TULI12EXN4839BB

TULI12EXN4840AB

Engine - Engine cooling system

Water pump - Disassemble Disassembly (reverse the procedure below for assembly) 1. Remove alternator. 2. Remove the fan, V-belt and pulley. 3. Remove the cooling water pump (“Point 1”). 4. Remove the thermostat (“Point 2”). Point 1 Disassemble-Reassemble: Check to see that the cooling water pump (12) bearing is free from abnormal noise, sticking or play and water leakage from the bearing. If replacement is necessary, replace the whole cooling water pump assy. NOTE: Replace the O-ring (10) of the cooling water pump with new one when disassembling. And, be sure to use the special O-ring for each engine model, because the material is different, although the dimension is the same as a commercial part. Point 2 Disassemble: Check the thermostat function. 11. Joint

TULI12EXN5053AB

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Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine cooling system - Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Radiator - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator Cap - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Water pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Water pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - 10 Engine lubrication system - 304

CX35B CX39B

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Contents Engine - 10 Engine lubrication system - 304

TECHNICAL DATA Engine lubrication system Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine lubrication system Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Engine lubrication system Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Engine lubrication system

Engine lubrication system - Service limits Lubricating oil system (trochoid pump) Outside clearance of outer rotor Model 3TNV82A~88 4TNV94L/98 4TNV106(T)

Limit value 0.3 mm (0.01 in) 0.25 mm (0.01 in) 0.25 mm (0.01 in)

Standard value 0.12 - 0.21 mm (0.005 - 0.01 in) 0.1 - 0.155 mm (0.004 - 0.006 in) 0.1 - 0.165 mm (0.004 - 0.006 in)

Side clearance of outer rotor Model 3TNV82A~88 4TNV94L/98 4TNV106(T)

Standard value 0.02 - 0.07 mm (0.001 - 0.003 in) 0.05 - 0.1 mm (0.002 - 0.004 in) 0.03 - 0.12 mm (0.001 - 0.005 in)

Limit value 0.12 mm (0.005 in) 0.15 mm (0.006 in) 0.17 mm (0.007 in)

Inside clearance of inner rotor Piece

Items

Inside clearance of inner rotor Width across flat clearance of inner rotor

Gear hub diameter Rotor diameter Width across flats of gear hub Width across flats of rotor

Standard value 53.05 - 53.15 mm (2.09 - 2.09 in) 53.45 - 53.55 mm (2.10 - 2.11 in) 49.45 - 49.75 mm (1.95 - 1.96 in) 49.95 - 50.05 mm (1.97 - 1.97 in)

Standard value

Limit value

0.3 - 0.5 mm (0.01 - 0.02 in)

0.6 mm (0.02 in)

0.2 - 0.6 mm (0.01 - 0.02 in)

0.7 mm (0.03 in)

Rotor shaft clearance Model 4TNV94L/98

4TNV106(T)

Inspection item Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance

Standard value 12.98 - 13.02 mm (0.51 - 0.51 in) 12.955 - 12.975 mm (0.51 - 0.51 in) 0.035 - 0.065 mm (0.001 - 0.003 in) 13 - 13.02 mm (0.51 - 0.51 in) 12.955 - 12.965 mm (0.51 - 0.51 in) 0.035 - -0.065 mm (0.001 -0.003 in)

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Limit value 13.05 mm (0.51 in) 12.945 mm (0.51 in) 0.105 mm (0.004 in) 13.05 mm (0.51 in) 12.945 mm (0.51 in) 0.105 mm (0.004 in)

Engine - Engine lubrication system

Engine lubrication system - Functional diagram

TULI12EXN5044GA

NOTE: It varies in the specifications of each model whether Oil cooler and Piston cooling of the * mark are attached.

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Engine - Engine lubrication system

Engine lubrication system - Component identification Trochoid pump (3TNV82A~TNV88)

TULI12EXN5045AB

TULI12EXN5046AB

Trochoid pump (4TNV94L/98/106) 1. Outer rotor 2. Inner rotor 3. Cover 4. Control valve 5. Gear case 6. Punch 7. Crankshaft 8. Mark

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Engine - Engine lubrication system

Engine lubrication system - Disassemble Disassembly (reverse the procedure below for assembly) 1. Loosen the belt, and remove the radiator pulley, fan and V-belt. 2. Remove the crankshaft pulley. 3. Remove the gear case cover. 4. Remove the lubricating oil pump assy from the gear case for 4TNV94/98/106 (“Point 1”). Remove the lube oil cover from gear case cover for 3TNV82A-88 (“Point 1”). 5. Remove the pressure regulating valve from the lubricating oil pump body (“Point 2”).

Point 1 Disassembly Check if the pump rotates smoothly and see that there is no play between the shaft and gear, and inner rotor.

Reassemble NOTE: Always check if the pump rotates smoothly after installation on the gear case. Running the engine when the pump rotation is heavy may cause the pump to be burnt. 3TNV82A-88 • Apply lube oil to rotor (outer/inner) insertion part. • Assemble the outer rotor so that the mark of the end face may become a cover side when inserting it in the gear case. • Fasten a lube oil pump cover by the standard torque. Tightening torque: 5.4 - 8.4 N·m (4.0 - 6.2 lb ft). • When replacing the lube oil pump, replace the whole assy. 4TNV94L/98/106 • Apply lube oil to lube oil pump insertion part of gear case. • Install the outer rotor in the gear case so that the punch mark on the end face is seen. • When replacing the lube oil pump, replace the whole assy.

Point 2 Disassemble-reassemble Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation is detected.

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Engine - Engine lubrication system

Engine lubrication system - Clearance 1. Outside clearance and side clearance of outer rotor Insert a gap gauge between a outer rotor and a pump body, and measure the clearance. (1) Outer case (5) Gear case

TULI12EXN5047AB

Outside clearance Model 3TNV82A~88 4TNV94L/98 4TNV106(T)

Standard value 0.12 - 0.21 mm (0.0047 - 0.0083 in) 0.100 - 0.155 mm (0.0039 - 0.0061 in) 0.100 - 0.165 mm (0.0039 - 0.0065 in)

Limit value 0.30 mm (0.0118 in) 0.25 mm (0.0098 in) 0.25 mm (0.0098 in)

When measuring a side clearance, put a right-angle gauge to the pump body, insert a gap gauge and measure the clearance.

TULI12EXN5048AA

Side gap Model 3TNV82A~88 4TNV94L/98 4TNV106(T)

Standard value 0.02 - 0.07 mm (0.0008 - 0.0028 in) 0.05 - 0.10 mm (0.002 - 0.0039 in) 0.03 - 0.12 mm (0.0012 - 0.0047 in)

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Limit value 0.12 mm (0.0047 in) 0.15 mm (0.0059 in) 0.17 mm (0.0067 in)

Engine - Engine lubrication system

2. Inner rotor and gear hub clearance (3TNV82A4TNV88) Piece

Piece

Inside clearance of Gear hub inner rotor diameter Rotor inner diameter Width across Width across flat clearance of inner flats of gear hub rotor Width across flats of rotor

Standard dimension 53.05 - 53.15 mm (2.09 2.09 in) 53.45 - 53.55 mm (2.10 2.11 in) 49.45 - 49.75 mm (1.95 1.96 in) 49.95 - 50.05 mm (1.97 1.97 in)

Standard clearance

Standard clearance limit

0.3 - 0.5 mm (0.0118 0.0197 in)

0.6 mm (0.0236 in)

0.2 - 0.6 mm (0.0079 0.0236 in)

0.7 mm (0.0276 in)

(8) Crank gear (9) Inner rotor (10) Width across flats of rotor (11) Rotor inner diameter

TULI12EXN5049AB

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Engine - Engine lubrication system

3. Rotor shaft clearance (4TNV94L/98/106) Measure the outside diameter of rotor shaft (12) and the shaft hole diameter of gear case (13). Calculate the clearance from that difference. (14) Shaft outside diameter (15) Bearing inner diameter

TULI12EXN5050AB

Model 4TNV94L/98

4TNV106(T)

Inspection item Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance

Standard value 12.980 - 13.020 mm (0.5110 - 0.5126 in)

Limit value 13.05 mm (0.5138 in)

12.955 - 12.97 mm (0.5100 - 0.5106 in)

12.945 mm (0.5096 in)

0.035 - 0.065 mm (0.0014 - 0.0026 in) 13.000 - 13.020 mm (0.5118 - 0.5126 in)

0.105 mm (0.0041 in) 13.05 mm (0.5138 in)

12.955 - 12.965 mm (0.5100 - 0.5104 in)

12.945 mm (0.5096 in)

0.035 - 0.065 mm (0.0014 - 0.0026 in)

0.105 mm (0.0041 in)

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Index Engine - 10 Engine lubrication system - 304 Engine lubrication system - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine lubrication system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine lubrication system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine lubrication system - Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine lubrication system - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

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SERVICE MANUAL Hydraulic systems CX35B CX39B

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11 [35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12 [35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 [35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14 [35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15

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CX35B CX39B

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Contents Hydraulic systems - 35 Hydraulic systems - 000

TECHNICAL DATA Hydraulic systems General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hydraulic systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schematic frame 01 - Standard specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic schematic frame 02 - Hydraulic circuit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic schematic frame 03 - Schematic piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Hydraulic schematic frame 04 - Hydraulic lines Boom&Arm safety valves . . . . . . . . . . . . . . . . . . . . . . . . . 55 Hydraulic schematic frame 05 - 2nd auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

SERVICE Hydraulic systems Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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Hydraulic systems - Hydraulic systems

Hydraulic systems - General specification For the hydraulic circuit diagram, refer to Hydraulic systems - Hydraulic schematic frame 01 - Standard specification (35.000) of supporting data that is provided at the and of this manual. No. 1. 2. 3. 4.

Standard specification Name Pump assembly Control valve Swing motor Travel motor

5. Boom cylinder 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 23. 24. 25. 26.

Canopy Cab

Arm cylinder Bucket cylinder Swing cylinder Dozer blade cylinder Rotary control valve Attachment control valve Travel control valve Solenoid valve Dozer control valve Shuttle valve Auxiliary control valve Return filter (element) Suction strainer Pilot valve filter Check valve Lock valves Selector valve Oil coolant Hydraulic oil tank

CX35B Model No. AP2D18LV3RS7 EV310054 MSG-27P-16E-17 GM04VA ø80-ø45-585 ø80-ø45-559 ø75-ø45-541 ø65-ø40-497 ø80-ø45-488 ø100-ø50-160 YV-7200 PV48M2042 PVD6P4001 2KWE5G-30/G12WS-249A PV6P

Y-457400 Y-2389

NOTE: This is for reference only, because the model number might be changed due to improvement. NOTE: The version with air-conditioned has a modified pump assembly (with the same P/N).

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Hydraulic systems - Hydraulic systems

For the hydraulic circuit diagram, refer to Hydraulic systems - Hydraulic schematic frame 01 - Standard specification (35.000) of supporting data that is provided at the and of this manual. No. 1. 2. 3. 4.

Standard specification Name Pump assembly Control valve Swing motor Travel motor

5. Boom cylinder 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 23. 24. 25. 26.

Canopy Cab

CX39B Model No. AP2D18LV3RS7 EV310054 MSG-27P-16E-17 GM04VA ø80-ø45-578 ø80-ø45-555 ø80-ø45-560 ø65-ø40-497 ø80-ø45-488 ø100-ø50-160 YV-7200 PV48M2042 PVD6P4001 2KWE5G-30/G12WS-249A PV6P

Y-457400 Y-2389

NOTE: This is for reference only, because the model number might be changed due to improvement. NOTE: The version with air-conditioned has a modified pump assembly (with the same P/N).

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview Function and features of hydraulic circuit The hydraulic circuits are built up with the following functions and features in order to achieve easy operation, safety and high working efficiency. Performance

Device

Operation Straight travelling

Travel

Slewing Easy operation and safety Tool

Others

Pump High working performance

Travel Tool

Low fuel consumption

Electricity

Preventing overrunning of travel motor Parking brake Slewing (with dozer) independent circuit Auto slewing parking brake

Features Straight travel guaranteed by a balanced operation of travel with combined operations Preventing overrunning on a slope

Automatic braking at parking Constant slewing speed when operating in simultaneous operation condition Protecting against slewing drift on a slope Graduality during starting and stopping of Slewing shockless function slewing Hydraulic pilot control system Gradual operation control Dozer (with slewing) independent Secure the travel straight when travelling and working with dozer circuit. Prevention of contamination of the hydraulic Closed pressurized hydraulic oil oil and improvement of the pump self-suction tank efficiency Removing dirt of suction side Suction strainer Prevention of malfunctions in the pilot system Pilot valve filter Preventing contamination of hydraulic oil Return filter Effective use of engine power with variable Power control pump (Power shifting by P3 pump) Improving working efficiency with 2 travel 2 speeds travelling speeds shifting P3 pump oil flow conflux in arm or Speed increased by conflux P3 pump oil piping (when no dozer or slewing used) N and B operation While waiting for the truck to dump, the engine Deceleration push button speed changes continuously and the fuel (Note: optional) consumption and the noise are reduced

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schematic frame 01 - Standard specification No. 1 2 2-3 2-4L 2-4R 2-5 2-6 2-7 2-8 2-9 2-10 3 4L 4R 5 6 7 8 9 10 11 12 13 13-1 14 15 16 17 18 19 20 22 23 24 25 26 28 29 30 31 201 202 203 204 304

Name Pump assy Control valve Slewing control valve section Left travel motor control valve section Right travel motor control valve section Boom control valve section Arm control valve section Bucket control valve section Swing control valve section Dozer control valve section Service control valve section Swing motor Travel left motor Travel right motor Boom cylinder Arm cylinder Bucket cylinder Swing cylinder Dozer blade cylinder Rotary control valve Attachment control valve Travel control valve Solenoid valve Pilot relief valve Dozer control valve Shuttle valve Auxiliary control valve Return filter (element) Suction strainer In-line filter Check valve Three-way valve Oil coolant Hydraulic oil tank Travel 1-2 speed change over Lever lock Nibbler and breaker pilot valve Nibbler breaker Selector valve Nibbler cylinder Main relief valve P1, P2 Main pressure relief valve P3 Over load relief valve Over load relief valve Slew relief valve

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SMIL13MEX0293JB

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Hydraulic systems - Hydraulic schematic frame 02 - Hydraulic circuit operation Color coding standard for hydraulic Less than 0.34 MPa (49 psi) Blue Feed, drain circuit Return, make-up circuit 0.34 - 0.59 MPa (49 - 86 psi) Green Secondary pilot pressure 0.59 - 3.5 MPa (86 - 508 psi) Violet Primary pilot pressure 3.5 - 3.9 MPa (508 - 566 psi) Red Orange Main pump drive pressure 4.9 - 23 MPa (711 - 3336 psi) Blue At valve selection When proportional valve is operating Red valve Active and operating Red solenoid Displaying the flow circuit and stand-by circuit when operating Regarding the electrical symbols in this manual, refer to the electric circuit diagram

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Neutral circuit Pilot circuit 1. Pilot primary pressure circuit The oil delivered from the A4 port on pump assy. (1) enters into the solenoid valve (13) through the line filter (19). The pressurized oil from the port A2 of the solenoid valve (13) with the safety lock lever released (in the operating condition) is supplied to the P ports of the pilot valves for attachment (11), travel (12) and dozer (14). Since the operating circuit is fully closed in the neutral position, the oil delivered by the pump other than the oil supplied to the Pp1 port of the control valve loses its flowing passage, and returns to the hydraulic tank (24) through the relief valve (set pressure: 3.5 MPa (508 psi) built in the solenoid valve (13). The oil supplied to the Pp1 port is led to the tank passage through the pilot passages provided to the service spool and through the pilot passages provided to the right and left travel spools. 2. Pilot secondary pressure circuit While the pilot valves (11), (12) and (14) are being in neutral, the pilot secondary pressure is not generated. By means of operating the operating lever, the secondary pressure is generated in accordance with its motion and led to the control valve (2) from the pilot valve to shift each spool of shifting valve.

Main circuit 1. Variable pump circuit The delivered oil from A1 and A2 ports on variable pump enters into P1 and P2 ports on control valve (2) respectively. All the discharged oil from these two ports finally returns to the hydraulic oil tank (24), through each valve of travel left, boom and bucket for the P1 oil, and through each valve of travel right, swing, service and arm for the P2 oil. 2. Third pump circuit The oil delivered from A3 port on 3rd pump enters into P3 port on control valve (2). The whole amount of oil discharged through the port P3 returns to the hydraulic oil tank (24) through the selector valves for the dozer and slewing and the independent travel and flow conflux valves.

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SMIL13MEX0294JB

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Travel operating circuit Hydraulic pilot system allows to operate, through the control levers, the 2-speed travel.

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2nd speed operating circuit (Independent-forward travel) Pilot circuit 1. Shifting signal for 2nd speed travel. When the â&#x20AC;&#x153;Rabbit and Turtleâ&#x20AC;? mark (at the power cut-off, it automatically takes back for 1st speed) on the knob of travel right lever is pushed down, it actuates the 1st and 2nd speed travel shifting valve of solenoid valve (13). The pressurized oil signal for 2nd speed is generated by the solenoid valve (13) and led to travel motor (4) through swivel joint (10), and shifts the 2nd speed shifting valve (404). 2. Changing travel valve spool The pilot secondary pressure is generated from pilot valve (12) by the operation for travel forward. The pressurized oil is led to the Pb7 and Pb6 ports on control valve (2) to shift the travel valve spool.

Main circuit 1. Circuit up to travel motor (4) The delivered oil from A1 and A2 ports on variable pump enters into the P1 and P2 ports of control valve (2), and led to the B7 and B6 ports through the travel valve. Then it is led to the A and B ports on left and right travel motors respectively through the swivel joint (10). 2. Travel motor A. The pressurized oil supplied to the travel motor shifts the spool of the counterbalance valve (brake valve) (408), releases the parking brake (403), opens the hydraulic circuit having closed by the check valve (407) and rotates the travel motor. It actuates the speed shifting valve (404) when the 2nd speed signal is sent. The high-pressure oil pumped through the shuttle valve (406) passes through the speed change valve (404), actuates the speed shifting piston (401) so that the engine rotates at high speed but with a low torque. B. When the motor reaches near to a self-running condition (over-running) at going down a slope and so on, the oil pressure of supply side gets down to lower pressure, and the counter balance valve [brake valve] (408) spool moves to the neutral position with the spring force. As the results, the passage in return oil side is throttled, and the motor speed is suppressed by a back-pressure, then the motor is controlled to the speed corresponding to the supplied oil volume of the pump. C. The counterbalance valve spool is so designed that it is gradually shifted by a throttle effect to stop or start the motor absorbing shock at the start and stop of the machine. D. When load increases during high speed travel, the speed automatically shifts to the 1st speed, resulting in low speed and high torque.

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SMIL13MEX0295JB

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Slew operating circuit Hydraulic pilot system allows to operate, through the left control lever, the slewing.

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Slew (left) operating circuit Pilot circuit 1. Slew valve spool shifting With operation for slew (left), the pilot secondary pressure oil is generated from the pilot valve (11), and led to the Pb2 port of control valve (2) to shift the slew valve spool. 2. Releasing parking brake The pilot primary pressure is always led to PG port on the timer valve (303). With the slew operation, the operating pilot secondary pressure is led to SH port on the timer valve (303) through the shuttle valve (15) to shift the spool. It leads the pilot primary pressure 3.5 MPa (508 psi) to the parking brake to release it. (Similarly, the arm in operation releases the slewing brake). 3. Activating parking brake When the slew operating lever is returned to neutral position to stop slewing, the pilot secondary pressure disappears causing to shift the timer valve (303), then the pressurized oil is shut down. The oil in the brake cylinder is discharged due to spring force, and drained through the throttle in the timer valve (303). Thus the braking is activated with some time interval for 2.5 - 5.0 s to smoothly absorb the slewing inertia at its stop of motion.

Main circuit 1. Supply circuit for slewing motor (3) The oil delivered from the A3 port on hydraulic oil pump (1) is supplied to the B port on slewing motor (3) through the P3 port on control valve (2) and slew valve to drive the slewing motor. 2. Slewing motor (3) A. The relief valve (304) relieves rapidly increased pressure at start and stop of the machine to ease shock. B. The make-up valve (check valve) (305) has a function to replenish oil from the return oil circuit that is led to the tank [ T2 port on control valve (2)] to the slewing motor, to prevent the slewing motor from the cavitation due to negative pressure generated in it because of inertia on the slewing mass.

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SMIL13MEX0296JB

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Bucket operating circuit Hydraulic pilot system allows to operate, through the right control lever, the bucket.

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Bucket digging operation circuit Pilot circuit 1. Bucket spool shifting When the operating lever is put at bucket digging position, the pilot secondary pressure oil is generated from the pilot valve (11). The pressurized oil entered into the Pb10 port on control valve (2) shifts the bucket valve spool.

Main circuit 1. Supply circuit for cylinder (7) The oil delivered from A1 port on variable pump of pump assy. (1) enters into P1 port on control valve (2). The pressurized oil from B10 port through bucket valve is supplied to the head side of bucket cylinder (7) to activate the digging work. The return oil from the rod side of cylinder (7) enters into A10 port on control valve (2) and returns into the tank through bucket valve.

Bucket dumping operating circuit Pilot circuit 1. Bucket spool shifting When the operating lever is moved to bucket dumping position, the pilot secondary pressure oil is supplied from pilot valve (11), and enters into Pa10 port on control valve (2) to shift the bucket valve spool.

Main circuit 1. Supply circuit for cylinder (7) Similar to the case for bucket digging, the pressurized oil delivered from A1 port on variable pump enters into P1 port on control valve (2). The oil supplied from A10 port through bucket valve is entered into the rod side of bucket cylinder (7) to activate the bucket dumping.

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SMIL13MEX0297JB

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Boom operating circuit Hydraulic pilot system allows to operate, through the right control lever, the boom.

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Boom up operating circuit Pilot circuit 1. Boom spool shifting When the operating lever is put at boom up position, the pilot secondary pressure oil is generated from pilot valve (11). The pressurized oil entered into Pa8 port on control valve (2) shifts the boom valve spool.

Main circuit 1. Supply circuit for cylinder (5) The oil delivered from A1 port on variable pump of pump assy. (1) enters into P1 port on control valve (2). The oil supplied from B9 port through boom valve and lock valve is entered into the head side of boom cylinder (5) to up the boom.

Boom down operating circuit Pilot circuit 1. Boom spool shifting When the operating lever is put at boom down position, the pilot secondary pressure oil is generated from pilot valve (11), and enters into Pa8 port on control valve (2) to shift the boom valve spool. At the same time, the pilot secondary pressure is led to the boom lock valve (206) to push up the check valve and open the oil path from closed condition.

Main circuit 1. Supply circuit for cylinder (5) and return oil circuit The pressurized oil delivered from A1 port on variable pump is led to boom valve provided on control valve (2), and supplied to the rod side of boom cylinder (5) to down the boom. The oil returned from the head side of cylinder (5) enters into B9 port on control valve (2), and returns to the tank through the boom lock valve (206) and boom valve. Its flow rate is restricted by the throttle effect in boom valve, accordingly the boom is lowered at a stable speed. A. Boom lock valve (206) This is of a check valve mechanism to prevent the boom from lowering due to its own weight while the boom valve is being at neutral position.

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SMIL13MEX0298JB

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Arm operating circuit Hydraulic pilot system allows to operate, through the left control lever, the arm, with a return oil recirculation during performing of light load digging works.

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Arm in operating circuit Pilot circuit 1. Shift for arm spool At the arm in operation, the pilot secondary pressure generated from the pilot valve (11) is led to the Pa3 port on control valve (2) to shift the arm valve spool. Furthermore, the pilot secondary pressure acts to the SH port on timer valve (303) through the shuttle valve (15) to release the parking brake. Since the spool of the arm valve shifts to close the pilot passage, the pressure of pilot oil through the Pp1 port equals to the supply pressure. Thus the pressure overcomes the spring forces of the independent travel and flow conflux valves to shift the valve spool.

Main circuit 1. Supply circuit for cylinder (6) Delivery oil from A2 port on the variable displacement pump enters into P2 port on control valve (2). The pressurized oil from the P3 port joins with the oil from the P2 port through the independent travel and flow conflux valves. The joined oil flows out from the A3 port through the arm valve and is supplied to the head side of the arm cylinder (6) to perform arm in work. 2. Return line from cylinder (6) The return oil from the rod side of arm cylinder enters into the B3 port on control valve (2), and is led to the return line from the T1 port through arm valve, then return to the tank.

Operating circuit for arm out Pilot circuit At the operation for arm out, the pilot secondary pressure is generated from the pilot valve (11), and led to the Pb3 port on control valve (2) to shift the arm valve spool. The independent travel and flow conflux valves are actuated as in the excavating operation.

Main circuit As in the case of excavating operation, the oil having flown into the control valve (2) joins with the pressurized oil from P2 and P3, flows out from the B3 port and is supplied to the rod side of the arm cylinder to perform arm out work.

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SMIL13MEX0299JB

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Swing operating circuit This function is activated by means of control pedal, which controls the valve activation cable. This function is activated regardless to the safety lock lever position.

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Swing (left) operating circuit Swing operation When depress the left side of swing pedal, the swing valve spool in control valve (2) is shifted by the cabling mechanism. Since the pilot oil pressure is not utilized for it is activated regardless to the safety lock lever.

Main circuit 1. Supply circuit for cylinder (8) The delivered oil from A2 port on variable pump enters into P2 port on control valve (2), and comes out from A5 port through cylinder valve, and is supplied to the head side of cylinder (8) to activate the swing (left). A. At activation of the swing valve spool for both left and right swing motions, a part of appropriate volume of oil is returned to the tank through the P2 bypass circuit due to the throttle effect on the spool. Then supplying volume of oil to the cylinder is restricted to ensure the slow and stable swing motions for both leftward and rightward.

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SMIL13MEX0341JB

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Dozer operating circuit Hydraulic pilot system allows to operate, through the dozer control lever, the dozer.

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Dozer down operating circuit Dozer operation When the operating lever is pushed forward, the pilot secondary pressure is generated from the pilot valve (14) to shift the dozer valve spool through the Pb1 port of the control valve (2).

Main circuit 1. Supply circuit for cylinder (9) The oil delivered from A3 port of the hydraulic pump (1) enters into P3 port on control valve (2), and is led to B1 port through dozer valve. The pressurized oil passed through swivel joint (10) is supplied to the head side of dozer cylinder (9) to activate dozer down motion.

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SMIL13MEX0342JB

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Travel / dozer combined operating circuit At the combined operation of travel and dozer at the same time, the straight travelling is secured with this function.

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Travel (1st speed forwarding) / dozer down operating circuit Pilot circuit Both the travel and dozer are operated by the lever using the pilot oil system. The operation of each lever directly shifts the travel valve spool and dozer valve spool in the control valve (2) respectively.

Main circuit The oil delivered from A1 and A2 ports on the variable pump (1) enters into P1 and P2 ports on control valve (2), and each flow of left and right is led to swivel joint (10) and travel motor (4) respectively through each travel valve of left and right. The oil delivered from A3 port on the third pump enters into P3 port on control valve (2), then it is led to the dozer cylinder (9) through dozer valve and swivel joint (10). 1. The dozer is operated by the pressurized oil supplied by the third pump which has no relation with travel circuit. Then there is no variation on the supply volume of pressurized oil for both travel motors of left and right even though the dozer is operated during travelling. Thus the straight travelling is secured. (The slewing is operated in the same way as the dozer). 2. As the above mentioned, the travelling speed is not changed from the single operation for travelling securing the straight travelling.

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SMIL13MEX0343JB

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Travel / boom combined operating circuit At the combined operation of travel and boom at the same time, the straight travelling is secured with this function.

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Travel (1st speed forward) / boom up operating circuit Pilot circuit The travelling/boom up is of the pilot oil hydraulic system with lever operation. By means of pushing forward of travel operating lever and pulling this side of boom up operating lever, the pilot secondary pressure shifts the travel valve spool and/or boom spool in the control valve (2). Thus the pilot passage of the boom valve is closed to make the pressure of the oil from the Pp1 port equal to the supply pressure. Therefore the hydraulic pressure overcomes the spring force of the independent travel and flow conflux valves to shift the valve spool.

Main circuit The delivered oil from A1 and A2 ports on variable pump enters into P1 and P2 ports on control valve (2) respectively. The whole amount of oil from the P1 and P2 ports is supplied to the travel motor in the same way as operating the independent travel. The oil flows from the travel valve through the B7 and B6 ports and the swivel joint (10) to the right and left travel motor (4). The oil delivered from the port A3 of the hydraulic pump (1) is supplied to the boom cylinder. The oil through the P3 port of the control valve (2) flows through the dozer and slewing valves and through the shifted independent travel and flow conflux valves to the boom valve. The oil from the B9 port through the boom and block valves is supplied to the head side of the boom cylinder (5). 1. When the travel and other attachments (boom, arm, bucket, swing and additional equipment) are operated in combination, the independent travel and conflux valves are actuated. Thus the attachments are actuated only by oil supplied from the P3 port. Therefore the oil of the P1 and P2 ports is utilized only by the travel to secure stable travel in the combined operation.

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SMIL13MEX0344JB

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Hydraulic nibbler and breaker operating circuit Hydraulic pilot system allows to operate, through the slider and the pushbutton located on the right control lever, the hydraulic nibbler and the breaker.

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Nibbler close operating circuit Pilot circuit 1. Shift for attachment spool Sliding movement of slider located on right control lever allows the pilot secondary oil to flow from A1 port of solenoid valve (16). The sliding movement of slider controls hydraulic flow rate to the attachment. Pressurized oil enters into Pa4 port of control valve (2) and shifts the attachment spool.

Main circuit 1. Supply circuit for cylinder The oil delivered from A2 port of variable displacement pump of pump assy. (1) enters into P2 port of control valve (2) and, through the A4 port, supplies bottom side of nibbler cylinder (nibbler closing). 2. Return circuit Return flow coming from nibbler cylinder enters into B4 port of control valve (2) and reaches the discharge circuit through the T1 port, then reaches the hydraulic tank.

Nibbler opening circuit Pilot circuit 1. Shift for attachment spool Sliding movement of slider located on right control lever allows the pilot secondary oil to flow from A2 port of solenoid valve (16). The sliding movement of slider controls hydraulic flow rate to the attachment. Pressurized oil enters into Pb4 port of control valve (2) and shifts the attachment spool.

Main circuit 1. Supply circuit for cylinder The oil delivered from A2 port of variable displacement pump of pump assy. (1) enters into P2 port of control valve (2) and, through the B4 port, supplies rod side of nibbler cylinder (nibbler opening). 2. Return circuit Return flow coming from nibbler cylinder enters into A4 port of control valve (2) and reaches the discharge circuit through the T1 port, then reaches the hydraulic tank.

Hydraulic breaker blow circuit Change the valve position of selector valve (22) to the position for breaker.

Pilot circuit 1. Press the button on the grip of right control lever, and secondary pilot pressure flows out from A1 port of solenoid valve (16). The pressurized oil which entered into Pa4 port of control valve (2) switches the attachment spool.

Main circuit 1. Supply circuit for breaker The oil delivered from A2 port of variable displacement pump of pump assy. (1) flows in the P2 port of control valve (2): flow is led to the A4 port of the control valve through the attachment spool, thus feeding the breaker inlet. 2. Return line from breaker The return oil of breaker flows through the selector valve (22), and the oil returns directly to hydraulic tank (24).

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SMIL13MEX0345JB

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Hydraulic systems - Hydraulic schematic frame 03 - Schematic piping

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SMIL13MEX0346JB

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Hydraulic systems - Hydraulic schematic frame 04 - Hydraulic lines Boom&Arm safety valves

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NO. 1 2 2A 2B 3 4 5 6

NAME PUMP ASSY CONTROL VALVE BOOM CONTROL VALVE SECTION DIGGING CONTROL VALVE SECTION HYDRAULIC OIL TANK BOOM CYLINDER HOLDING VALVE DIGGING CYLINDER HOLDING VALVE PRESSURE SWITCH SE22

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SMIL13MEX0063JB

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Hydraulic systems - Hydraulic schematic frame 05 - 2nd auxiliary circuit The 2nd auxiliary circuit allows to operate the swing motion of the boom or the front attachment rotation. The selection in cabin operates on a switch valve located on the frame, that switches on selected hydraulic line.

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NO. 1

NAME SWITCH VALVE

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SMIL13MEX0288JB

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Hydraulic systems - Service instruction STANDARD VALUE TABLE Model Qty.

Piece Hydraulic oil cleanliness (class)

Measurement of condition

Hydraulic oil temperature (tank surface)

Coolant temperature (radiator surface) Low idling Engine speed

High idling Deceleration

Main pressure relief valve

Boom • Bucket • Travel (LH)

Arm • Swing • Travel (RH) • Service

Dozer • *1st slewing

Pilot pressure relief valve

*2 Port (overload) Pressure relief valve

Pilot line

–

Boom

Head rod

Arm

Head rod

Bucket

Head

Dozer

Head

*1st slew

LH/RH

CX35B CX39B Standard Standard Repair limit Repair limit value value – – 8±1 8±1 50 - 60 °C 50 - 60 °C – – (122.00 (122.00 140.00 °F) 140.00 °F) 60 - 90 °C 60 - 90 °C – – (140 (140 194 °F) 194 °F) 1175 1175 – – 1225 RPM 1225 RPM 2525 2525 – – 2575 RPM 2575 RPM 1175 1175 – – 1225 RPM 1225 RPM 23.0 23.0 23.6 MPa 23.6 MPa – – (3336 (3336 3423 psi) 3423 psi) 23.0 23.0 23.6 MPa 23.6 MPa – – (3336 (3336 3423 psi) 3423 psi) 20 - 21 MPa 20 - 21 MPa – – (3336 (2901 3046 psi) 3046 psi) 3.1 3.1 - 3.9 MPa 3.9 MPa – – (450 (450 566 psi) 566 psi) 22.6 22.6 27.5 MPa 27.5 MPa – – (3989 (3989 4700 psi) 4700 psi) 20.6 20.6 25.5 MPa 25.5 MPa – – (3699 (3699 4410 psi) 4410 psi) 22.6 22.6 25.5 MPa 25.5 MPa – – (3278 (3278 3699 psi) 3699 psi) 22.6 22.6 27.5 MPa 27.5 MPa – – (3699 (3699 4410 psi) 4410 psi) 20 - 21 MPa 20 - 21 MPa – – (2901 (2901 3046 psi) 3046 psi)

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Model Qty.

Piece Rubber belt

Crawler time (5 rev.)

Travel

Steel crawler

Travel speed 10 m

Rubber belt Steel crawler

Low High Low High Low High Low High

Travel deviation

Drift due to gravity

w / P.B. ( 5 min)

CX35B Standard Repair limit value 31.6 - 34.8 s 43 s 18.0 - 19.8 s 24 s 32.3 - 35.7 s 44 s 18.4 - 20.2 s 25 s 13.8 - 15.2 s 19 s 7.9 - 8.7 s 11 s 14.2 - 15.6 s 19 s 8.1 - 8.9 s 11 s 0 - 140 mm 280 mm (0.00 (3.54 in) 5.51 in) 0 - 60 mm 90 mm (0.00 (3.54 in) 2.36 in)

*1. The pressure for slew is controlled by the relief valve attached to the slew motor. *2. Reference value for checking of pressure (tightening the adjusting nut of the main pressure relief valve).

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CX39B Standard Repair limit value 31.6 - 34.8 s 43 s 18.0 - 19.8 s 24 s 32.3 - 35.7 s 44 s 18.4 - 20.2 s 25 s 13.8 - 15.2 s 19 s 7.9 - 8.7 s 11 s 14.2 - 15.6 s 19 s 8.1 - 8.9 s 11 s 0 - 140 mm 280 mm (0.00 (3.54 in) 5.51 in) 0 - 60 mm 90 mm (0.00 (3.54 in) 2.36 in)

Hydraulic systems - Hydraulic systems

Model Qty.

Piece Slew time per 2–revolution

Slewing

Overrun when slewing stops Drift due to gravity Ext. Ret. Ext. Ret. Ext. Ret. Ext. Ret. Ext. Ret. Ext. Ret.

Canopy Boom Cab Arm

Cylinder speed

Bucket Swing Dozer

Cylinders Boom Arm Cylinder gravity move

( 10 min)

Bucket Dozer Bucket tip

( 5 min)

Swing

Bucket tip play Slewing bearing Slew bearing play

Rubber Crawler

Crawler tension Steel

CX35B CX39B Repair Repair Standard Standard limit limit value value 13.1 13.1 18 s 18 s 14.5 s 14.5 s 69 69 130 mm 119 mm 130 mm 119 mm (5.12 in) (2.72 (5.12 in) (2.72 4.69 in) 4.69 in) – – 0 mm (0 in) 0 mm (0 in) 2.4 - 3.2 s 3.6 s 2.4 - 3.2 s 3.6 s 2.3 - 3.1 s 3.5 s 2.3 - 3.1 s 3.5 s 2.2 - 3.2 s 3.3 s 2.2 - 3.2 s 3.3 s 2.1 - 2.9 s 3.2 s 2.1 - 2.9 s 3.2 s 2.2 - 3.2 s 3.6 s 2.2 - 3.2 s 3.6 s 1.2 - 2.0 s 2.1 s 1.2 - 2.0 s 2.1 s 2.1 - 2.9 s 3.2 s 2.1 - 2.9 s 3.2 s 1.1 - 1.9 s 1.9 s 1.1 - 1.9 s 1.94 s 5.3 - 7.1 s 7.9 s 5.3 - 7.1 s 7.9 s 4.2 - 5.6 s 6.3 s 4.2 - 5.6 s 6.3 s 2.0 - 2.8 s 3.1 s 2.0 - 2.8 s 3.1 s 1.6 - 2.4 s 2.4 s 1.6 - 2.4 s 2.4 s ≤ 12 mm 24 mm ≤ 12 mm 24 mm (0.47 in) (0.94 in) (0.47 in) (0.94 in) ≤ 5 mm ≤ 5 mm 10 mm 10 mm (0.2 in) (0.2 in) (0.39 in) (0.39 in) ≤ 3 mm 6 mm ≤ 3 mm 6 mm (0.12 in) (0.24 in) (0.12 in) (0.24 in) ≤ 3 mm 6 mm ≤ 3 mm 6 mm (0.12 in) (0.24 in) (0.12 in) (0.24 in) ≤ 150 mm 300 mm ≤ 150 mm 300 mm (5.91 in) (11.81 in) (5.91 in) (11.81 in) ≤ 6.00 mm 12 mm ≤ 6.00 mm 12 mm (0.24 in) (0.47 in) (0.24 in) (0.47 in) 60 - 80 mm 60 - 80 mm 120 mm 120 mm (2.4 (2.4 (0.5 in) (0.5 in) 3.15 in) 3.15 in) 0.6 0.6 2.6 mm 1.8 mm 2.6 mm 1.8 mm (0.1 in) (0.02 (0.1 in) (0.02 0.07 in) 0.07 in) 70 - 80 mm 70 - 80 mm – – (2.76 (2.76 3.15 in) 3.15 in) 115 115 130 mm 130 mm – – (4.53 (4.53 5.12 in) 5.12 in)

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Hydraulic systems - Hydraulic systems

MEASURING ENGINE SPEED 1. Measuring instruments 1.

The speedometer (1) (measures the engine speed through the application for a sampling tool (2) to one of the injection pipes).

Surface thermometer (measuring the surface temperature getting contact of the probe with the surface of hydraulic oil tank and radiator)

TULI12EXN4114AB

TULI12EXN4115AA

2. Engine warming up operation Start up the engine, and make the coolant temperature within the range of 60 - 90 째C (152.60 - 221.00 째F). Check the coolant temperature with the coolant thermometer on the control panel. The white color zone shows approx. 67 - 105 째C (152.60 - 221.00 째F) of temperature range. Therefore, when the indicator is located at around centre of the white zone, it is suitable for the engine operation.

3. Engine speed measurement 1.

Apply the pick up of speedometer to one of convenient injection pipes. (Refer to Fig. 1)

Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD VALUE TABLE.

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4. Speed adjustment Low (3) / high (4) idling speed is low. The proper engine speed is obtained with the length of accelerator wire as shown in the right sketch. When the engine speed is lower than the standard speed, adjust the length of wire with loosening the capscrew (9) of throttle lever side. NOTICE: However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer.

TULI12EXN4116CB

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Hydraulic systems - Hydraulic systems

SMIL13MEX0094BB

Standard for hydraulic oil pressure measurement 1. Hydraulic instruments • 6.86 MPa (995 psi) pressure gauge: 1 set • 49 MPa (7107.45 psi) pressure gauge: 3 set • Surface thermometer: 1 set • Pressure measuring kit and oil analyzing • Equipment: 1 set 2. Measuring cleanliness of hydraulic oil NOTICE: After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value exceeds the standard value, replace the return filter and/or change the hydraulic oil.

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Main circuit pressure Measuring conditions Engine speed: High idling Hydraulic oil temperature: 50 - 60 째C (122 - 140 째F) Coolant temperature (on radiator surface): 60 - 90 째C (140 - 194 째F)

TULI12EXN4118BB

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Hydraulic systems - Hydraulic systems

Pressure measuring procedures 1.

After releasing pressure in the hydraulic oil tank, and setting a 49 MPa (7107 psi) pressure gauge to either of pressure detecting ports ( G1, G2 or G3, PF 1/4 with plug), operate the circuit to be measured to measure the relief pressure.

When the main relief pressure is being within the standard range, the measurement for the overload relief pressure may be omitted.

If the main pressure relief valve detects a pressure which is lower than the standard limit, tighten the valve by half a turn [pressure increases by 12.2 MPa (1770 psi)], then measure pressure at overload relief valve.

After adjusting pressure at the overload relief valve, take pressure back within the standard limit of the main relief valve.

Operating circuit Boom, bucket and travel (left) Arm, travel (right), swing and attachment Dozer and slewing

Pressure detecting port Port location Dimensions G1 PF 1/4

TULI12EXN6059AB

TULI12EXN6060AB

Pressure relief valve MR1 MR2 MR3

Attaching position of overload relief valve OR1 OR2 OR3 OR4

Bucket digging Raised boom Lower boom Operating arm

OR5 OR6 OR7 OR8

Free arm Dozer down Slewing right Slewing left

Set pressure 1. Control valve: main relief valve and overload relief valve A. Loosen the locknut (2) and adjust pressure by turning the setscrew (1), roughly with one full turn. Main relief valve and overload relief valve: Approximately 12.2 MPa (1770 psi) Clockwise turning: increasing setting pressure Counterclockwise turning: decreasing setting pressure B. After the adjustment, tighten the locknut and hold the setscrew so that it does not turn. C. Again activate the relief valve to check the stable setting pressure. Tightening torque for nut (2): 19.6 NÂˇm (14 lb ft) 47574272B 24/03/2014

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TULI12EXN6061AB

Hydraulic systems - Hydraulic systems

2. Slewing motor: pressure relief valve A. Loosen the locknut (2). Then adjust the setting pressure turning the setscrew (1). Roughly with one full turn: Approximately 9.8 MPa (1421 psi) Clockwise turning: increasing setting pressure Counterclockwise turning: decreasing setting pressure B. After the adjustment, tighten the locknut and hold the setscrew so that it does not turn. Tightening torque for nut (2): 34.3 N·m (25 lb ft) TULI12EXN6062AB

Pilot circuit pressure Measuring conditions Engine: high idling Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) Coolant temperature: 60 - 90 °C (140 - 194 °F) at radiator surface

TULI12EXN6063AB

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Hydraulic systems - Hydraulic systems

Measurement Releasing pressure in the hydraulic oil tank of hydraulic system, and setting a 6.86 MPa (995 psi) pressure gauge to the pressure detecting port ( G4, PF 1/4 with plug) (4), measure the pilot relief pressure. Pressure detecting port Port location Dimensions G4 PF 1/4

Pressure relief valve PR1

Set pressure Adjust it with the relief valve attached to the solenoid valve (5). 1.

Loosen the locknut (2), then turn the setscrew (1) to adjust pressure. Clockwise turning: pressure increases. Counterclockwise turning: pressure decreases.

After the adjustment, lock the setscrew with the lock nut holding the setscrew not to allow its turning.

Again actuate the relief valve, and verify that the set pressure is being stable. Tightening torque: Lock nut (2): 7.8 N·m (6 lb ft) Pressure relief valve (PR1): 44 N·m (32.5 lb ft) Capscrew (3): 7.8 N·m (6 lb ft)

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TULI12EXN6064AB

Hydraulic systems - Hydraulic systems

MEASURING TRAVEL PERFORMANCES Test procedures Measure 3-time each. Apply average data of the above for judgement.

Travel 1. Travel speed (5 revolutions) • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: raise the machine using both attachment and dozer blade. • Set the crawlers in motion. After one full revolution, measure the time required for 5 full revolutions.

TULI12EXN4125AA

TULI12EXN4126AA

TULI12EXN4127AA

2. Travel speed ( 10 m (33 ft)) • Engine: rated rpm • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: travel position • Set machine in motion. Starting after a running of 5 m (16 ft), measure the time required to travel 10 m (33 ft). Do this on level and hard ground. • Travel position: Fully extend the arm and bucket cylinders and place the hoe attachment so that its lowest part is even with the machine’s minimum ground clearance level. The hoe attachment must be in a no-load and the dozer blade must not touch the ground.

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Travel deviation • Engine: rated RPM • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: travel position • Measure the deviation “X” at the point of half of 10 m (33 ft) travel after 5 m (16 ft) preliminary running. Do this on level and hard ground.

TULI12EXN4128AA

TULI12EXN4129AA

Movement drift due to gravity Measure the movement distance of machine on a slope due to machine’s own weight, holding the machine for 5 min on the slope. Measuring conditions: • Engine: stopped • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Gradient: 15° (Approx. 1/3.73) • Machine position: fully extending the boom, arm and bucket cylinders, and fully contracting the dozer cylinder.

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Drain rate on travel motor Preparation 1. Apply stopper pins (1) for both travel sprockets of left and right. 2. Stop the engine, and release air in the hydraulic oil tank. 3. Connect a hose to the drain port of travel motor, and receive the drained oil in a container. 4. Apply a plug to the drain piping at tank side. NOTICE: Make sure of the rotating direction of travel motor referring to the right sketch. Otherwise, the rib (A) may be broken by the stopper pin (1).

TULI12EXN4130BB

TULI12EXN4132AA

2. Measurement: • Engine: at rated speed • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Machine position: locking the travelling, and allowing relief on the travel motor • Measure the drained volume of oil for 30 s of relief.

Moving speed 1 a

Standard value 1.5 l (0.4 US gal)/ 30 s or less

Drain rate of travel motor Standard value for repair

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Serviceability limit 3 l (0.8 US gal)/ 30 s or more

Hydraulic systems - Hydraulic systems

MEASURING SLEW PERFORMANCES Test procedures Measure 3-time each. Apply average data of the above for judgement.

Slew time • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: completely retract the arm cylinder, fully extend the bucket cylinder and place so that boom foot pin (B) and bucket pin (A) are matching height. Place the dozer blade on the ground. • With the hoe attachment in a no-load, drive 1 rotation, then measure the time required for the next 2 rotations.

SMIL13MEX0095AB

SMIL13MEX0096AB

SMIL13MEX0097AB

Overrun when slewing stops • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: Same as that for measuring slew time. • Prior to measuring, draw matching marks on the outer race of the slew bearing and lower frame at exactly 180 degrees slew from the starting point. Then with the hoe attachment in a no-load, slew 180 degrees from starting point (A). At which point return the operating lever to neutral (B). Measure the distance between the position marks and the point the hoe attachment stops (C).

Slew drift due to gravity • Engine: stopped • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Gradient: 15° • Measurement position: Same as that for measuring slew time. • Slew the upper slewing structure and stop at right angle to the slope, then draw matching marks on the slew bearing’s outer race and the lower frame. Then measure the distance (A) that develops between the marks after 5 minutes. Measure in both directions. right and left.

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Drain rate of travel motor 1. Preparation 1. Stop the engine, and release air in the hydraulic oil tank. 2. Disconnect the slew motor drain hose at the return side to the hydraulic oil tank. Then receive the drain oil to a container. Install plug on bore of tank after removing drain hose. 2. Measurement • Engine: at rated speed • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Machine position: pushing a fixture with the side of bucket, operating the engine.

SMIL13MEX0098AA

• Measure the drained volume of oil for 30 s relieving at full stroke of the slewing operation.

Standard value 4.2 or less

DRAIN RATE OF SLEW MOTOR Standard value for repair -

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Use 9 or more

Hydraulic systems - Hydraulic systems

MEASURING ATTACHMENT OPERATING PERFORMANCES Test procedures Measure 3-time each. Apply average data of the above for judgement.

Cylinder speed 1. Boom cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: completely retract the arm cylinder, fully extend the bucket cylinder and place the dozer blade on the ground. • Then measure the time required for the bucket to reach its highest point (lowest point) from its lowest point (highest point) placing on the ground. (Do not include the cushioning time).

SMIL13MEX0099AA

SMIL13MEX0100AA

SMIL13MEX0101AA

2. Arm cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: completely retract the arm cylinder, fully extend the bucket cylinder, position the arm horizontally and place the dozer blade on the ground. • Then measure the time required for the arm cylinder to completely retract (extend) from a fully extended state (retracted state).

3. Bucket cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: completely retract the arm cylinder, position the arm horizontally and place the dozer blade on the ground. • Then measure the time required for the arm bucket cylinder to completely retract (extend) from a fully extended state (retracted state).

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4. Swing cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: the same used to measure the slewing time. • While swinging the boom left (right) to right (left), measure the time required for a full stroke each way.

SMIL13MEX0102AA

SMIL13MEX0103AA

5. Dozer cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: using the hoe attachment lift up the dozer blade side. • Then, up and down the dozer blade with full stroke, measure the time required per stroke in each direction.

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Gravity drift of cylinders 1. Boom, arm, bucket, dozer, bucket tip • Bucket: standard ( 500 mm (19.7 in) for CX35B models and 600 mm (23.6 in) for CX39B models) • Engine: stopped • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Measurement position: completely retract the dozer and arm cylinders, fully extend the bucket cylinder and position the bucket pin to the same height as the boom foot pin. • Maintain the position for 10 min then measure the change of rod length and distance of the bucket tip. SMIL13MEX0104AA

SMIL13MEX0105AA

2. Swing cylinder • Engine: stopped • Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F) • Gradient: 15° • Measurement position: Same as that for measuring slew time. • Slew the upper slewing structure and stop at right angle to the slope, then measure the change in rod length after 5 minutes.

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MEASURING SLEW BEARING PERFORMANCES Test procedures Measure 3-time each. Apply average data of the above for judgement.

Slew bearing-bucket tip play • Measurement position: completely retract the arm cylinder and fully extend the bucket cylinder. • Move the tips of the bucket teeth from side to side (left and right) and measure the play.

SMIL13MEX0106AA

SMIL13MEX0107AA

SMIL13MEX0108AA

Slew bearing play 1. Attach a dial gauge to the bottom face of the slew bearing’s outer-race located in front of the upper slewing structure.

2. Raise the crawler on one side off the ground and set the dial gauge to zero.

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3. Then raise the opposite crawler and read the dial gauge.

SMIL13MEX0109AA

TULI12EXN4131AA

MEASURING CRAWLER TENSION Crawler tension • Raise the machine completely off the ground using the hoe attachment and dozer blade. Then measure the distance (A) (of sag) between the centre point on the crawler frame and top of the crawler shoe. NOTICE: In the case of rubber crawlers, measurements should be taken with setting the joint (“M” or “∞” mark) in the top centre position. A. Distance B. Rubber C. Steel

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Service instruction General precautions Troubleshooting provides the procedure to investigate the cause of trouble when a problem occurs. This manual describes how to systematically solve a specific problem as quickly as possible. For the troubleshooting concerning the inside of equipment, refer to the troubleshooting for each manual of the equipment.

Confirm actual troubled conditions at site Get to the site as quickly as possible. Verify the machine model, serial number, situation of trouble and field, and notify possible arrival time to the user.

TULI12EXN5236AA

TULI12EXN5237AA

TULI12EXN5238AA

Verify background of trouble occurred. 1. Model name and serial number. 2. Kind of attachment. Check that the combination of attachments was proper and that the operating manner was not unreasonable. 3. Operating time on the hourmeter. 4. Record of troubles. First trouble or repeated trouble. 5. History of the trouble and additional modifications. Reoccurrence of the same trouble in the past or trouble due to additional modification. How to diagnose trouble 1. Verify defective part. 2. Reproduce the troubled conditions. 3. Where the defective part can not be verified, surmise the possible causes systematically. 4. Verify the surmised cause. 5. Report estimated repairing method, procedures and term to the user.

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Explanation of the cause of trouble 1. Explain the cause of trouble to the user. For example, explain the oil leakage through the piston is caused by defect on the piston rod. And the proper operating manner of the machine should be explained to the user to prevent recurrence of the same kind of trouble. 2. Handling of damaged parts The damaged parts to be claimed and returned are the evidence, so they should be handled with care. For example, protect them from invasion of water, soil, etc., into ports on a hydraulic equipment, etc., at the returning them. And also use care not to give any damages and breakage for transport.

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Trouble diagnosis: hydraulic system TOOL Attachment operational failure (excluding swing operations)

SMIL13MEX0177FA

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Attachment speed is slow

SMIL13MEX0178GA

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Attachment operating power is low

SMIL13MEX0179FA

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Malfunction of attachment

SMIL13MEX0180GA

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TRAVEL OPERATION Travel operational failure

SMIL13MEX0181FA

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Travel speed is slow

SMIL13MEX0182GA

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Travel power is low

SMIL13MEX0183FA

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It deviates in travel independent operation

SMIL13MEX0184GA

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SLEWING OPERATION Slewing operational failure

SMIL13MEX0185FA

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Slewing speed is slow

SMIL13MEX0186FA

SMIL13MEX0187FA

Slewing power is low

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Malfunction of slewing operation

SMIL13MEX0188FA

PUMP Engine speed is reduced due to pump load

SMIL13MEX0189EA

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Hydraulic systems - Hydraulic systems

Malfunction of pump

SMIL13MEX0190GA

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schematic frame 03 - Schematic piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic systems - Hydraulic schematic frame 01 - Standard specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic systems - Hydraulic schematic frame 02 - Hydraulic circuit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic systems - Hydraulic schematic frame 04 - Hydraulic lines Boom&Arm safety valves . . . . . . . . . . . . . . . 55 Hydraulic systems - Hydraulic schematic frame 05 - 2nd auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic systems - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Hydraulic systems - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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Hydraulic systems - 35 Reservoir, cooler, and filters - 300

CX35B CX39B

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Contents Hydraulic systems - 35 Reservoir, cooler, and filters - 300

SERVICE Oil reservoir Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Prepare 1. Swing approximately 90 ° to the right to facilitate to remove the tank. 2. Unlock and open the right upper cover. 3. Remove the left right lower cover. 4. Remove the floor cover. 5. Remove the inspection cover (1-5) of the control stand. Six M8 X 20 sems-bolts (1-8) : 13 mm TULI12EXN6308AB

SMIL13MEX0068BB

6. Place an oil collecting container (1) under the hose (2). 7. After releasing internal pressure of the hydraulic oil tank, gradually loosen the hose (2) to drain hydraulic oil. : 22 mm Tank capacity: 38 l (10 US gal) • Spread a vinyl sheet under the solenoid valve to prevent contamination around the valve due to oil leakage. • Releasing tank pressure. Press the cap boot of breather assembly (A15) with a finger to release the internal pressure. NOTE: Press and hold the boot until air-relieving sound stops. 8. Remove the control valve. 9. Remove the solenoid valve. 10. In addition, remove the harness and hose clamped on the tank. • Remove the multi-control valve (option) if it is equipped.

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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Remove 1. Disconnecting the delivery hose. 1. Remove the guide (30). 2. Remove the clip (25). : Minus driver 3. Remove the hose (11). : Minus driver (A15) Cap boot

TULI12EXN6310AB

2. Removing return oil hose and drain oil hose. Disconnect each hose from the position marked with *. : 19 mm , 22 mm and 36 mm : Minus driver

TULI12EXN6311FB

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Hydraulic systems - Reservoir, cooler, and filters

3. Removing hydraulic oil tank. Loosen four M12 X 30 capscrews (B1) to remove the hydraulic oil tank (A1). : 19 mm Weight: Approximately 42 kg (92.6 lb)

TULI12EXN6312BB

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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Install 1. Clean hydraulic oil tank, hose, and components. 2. Install the tank in reverse order of the removal. The specified tightening torque is shown in the following table: • Apply LOCTITE® 262 to B1. Piece B1 B14 D13 16.17.A13,B33

Name M12 Bolt Plug PF 3/8 Clip Clip

Tool 17 mm 22 mm Minus driver Minus driver

Torque 79.4 N·m (58.6 lb ft) 73.5 N·m (54.2 lb ft) 2.94 N·m (2.2 lb ft) 5.39 N·m (4 lb ft)

Thread size PF 1/4 PF 3/8 PF 1/2 PF 3/4

Spanner used 19 mm 22 mm 27 mm 36 mm

O-ring type fitting 26.5 N·m (19.5 lb ft) 73.5 N·m (54.2 lb ft) 108 N·m (79.7 lb ft) 162 N·m (119.5 lb ft)

30° flare type fitting 29.4 N·m (21.7 lb ft) 49 N·m (36.1 lb ft) 78.5 N·m (57.9 lb ft) 118 N·m (87 lb ft)

3. After the install, fill the tank with the specified hydraulic oil and check the oil level with the level gauge (A1-11). Oil quantity: About 38 l (10.0 US gal) 4. Air bleeding. 1.

Start the engine.

Run the engine in low idle condition for two or 3 min. Then extend and retract each cylinder several times to bleed air from the circuit.

5. Rechecking oil level. Stop the engine in the posture shown in Fig. 1 to recheck oil level. In addition, ensure no oil leakage is found on each part.

TULI12EXN4940AA

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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil reservoir - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Oil reservoir - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Oil reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Variable displacement pump - 106

CX35B CX39B

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Contents Hydraulic systems - 35 Variable displacement pump - 106

TECHNICAL DATA Pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Pump Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Variable displacement pump Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pump Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Hydraulic systems - Variable displacement pump

Pump - General specification

TULI12EXN6119FA

No. S1 A1, A2 A1G, A2G A3 A4 R1

Ports name Suction port Delivery port Pressure port Delivery port Pilot delivery port Air bleed port (with breather valve)

Model Pump Working pressure Displacement Delivery flow Control system Rating speed Weight

Dimensions SAE 1 1/2 PF 1/2 PF 1/8 PF 1/2 PF 3/8 M10 X 1 AP2D18LV3RS7

Trochoid pump P4 3.5 MPa 23 MPa (3336 psi) 20 MPa (2901 psi) (508 psi) 8.6 cm³/rev 5.1 cm³/rev 16 cm³/rev (1.0 in³/rev) x 2 (0.5 in³/rev) (0.3 in³/rev) 20.6 l/min (5.4 US 12.2 l/min 38.4 l/min (10.1 US gpm) x 2 gpm) (3.2 US gpm) Total power shift control by tilting angle (power shift) 2400 RPM 27.5 kg (61 lb) Piston pump P1 + P2

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Gear pump P3

Hydraulic systems - Variable displacement pump

Pump - Special tools Tools Name Allen wrench Plastic hammer Snap ring pliers Snap ring pliers

Quantity One each 1 1 1

Torque wrench

Grease

Little

Adhesive agent

Little

Size (nominal) 4, 6, 8 and 10 Medium type For hole (snap ring 22) For shaft (snap ring 20) Possible to tighten to the specified torque – LOCTITE® type “high tack sealant #98”

Jig 1. Working bench. Plate which is used to place the pump facing downward. If the shaft end does not contact with work bench, the square timber is available instead of it. 2. Jig for removing and installing cover. Used to assemble and disassemble to preserve the shaft.

Disassembly Prevent the cover from rising diagonally due to the control spring when removing 4 socket bolt ( M12).

Assembly Install the cover on the housing keeping it horizontal. The right figure shows the construction of jig. This is of the construction to push the cover applying the machined end of hexagon socket set screw ( M16 X 150). (Note 1) to the adjusting screw. (Note 1) When the socket bolt is used, machine 15 mm (0.6 in) from the top end in ø 8 mm (0.31 in). TULI12EXN6358BA

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Hydraulic systems - Variable displacement pump

Pump - Dynamic description

TULI12EXN6120FB

1. 2. 3. 4.

Shaft assembly Swash plate assembly Rotary group Cover assembly

5. 7. 8. 9.

Spring assembly Gear pump assembly Housing assembly Trochoid pump assembly

Piston pump • This pump is a variable displacement double piston pump which delivers two equal flows with one cylinder block, and has only one inlet port, but the flow is separated into two flows by the control plate on the cover and is led to two delivery ports provided on the cover. • The hydraulic pressure produced by delivery oil resists against the spring force and tilts the plate. Delivery changes, because the piston stroke changes according to the plate’s tilting angle. • The 3rd pump or pilot pump is installed on the same shaft with a coupling.

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Hydraulic systems - Variable displacement pump

Operation • Pump operation Displacement q (cm3) q=ηXd2 /4XtanαXDXZ/2X10-3 s (Stroke) (Number of piston)

TULI12EXN4150GB

1. 2. 3. 4. 5. 6.

Piston Bottom dead point Cylinder block Control plate Suction port P2 side output

7. 8. 9. 10. 11. 12.

P1 side output Delivery port Suction stroke Delivery stroke Top dead point Plate (sliding surface)

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Hydraulic systems - Variable displacement pump

A. The cylinder block is fitted on the spline and rotates with the drive shaft. B. The piston fitted in the cylinder block follows the movements of the sliding surface of the plate. C. The piston moves to increase the capacity from the bottom dead point to the top dead point, the pressure oil flows from the inlet port into cylinder block through the control plate. (Suction stroke 9) D. But as the piston moves to decrease the capacity from the top dead point to the bottom dead point, the pressure oil is sent out to the delivery port. (Delivery stroke 10) E. By changing the tilting angle of the plate (sliding surface), delivery varies. F. The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside of the control valve. G. The oil sucked from the outside port of the cylinder block is delivered from the delivery port outside of the control plate.

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Hydraulic systems - Variable displacement pump

Control

TULI12EXN4151GB

13. 14. 15. 16.

Spring Plate Piston Piston for P3 shift

â&#x2C6;&#x2018;PI. Q. At. S.

Total pressure â&#x2C6;&#x2018;P Flow rate Minimum flow control Shift control line

A. The piston sliding on the surface of the plate acts on the plate through the hydraulic pressure due to the delivery pressure P1 and P2. B. The spring is located in the position which is in opposition to the delivery oil pressure. C. When the hydraulic pressure acting on the plate through the piston drops below the setting load of the spring, the plate is fixed at the maximum tilting angle. D. When the hydraulic pressure acting on the plate through the piston exceeds the load of the spring, the plate is tilted to the position in which pressure balances the force of the spring itself. (Control line, Area A) E. The control line is shifted after the hydraulic pressure P3 acts on the shift piston.

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Hydraulic systems - Variable displacement pump

Adjusting procedure of setting torque

TULI12EXN4152FB

17. 18. 19.

Spring seat Cover Set screw

22. 23. 24.

20. 21.

Spring guide Tighten

â&#x2C6;&#x2018;P. Q.

Loosen Hexagon nut Starting pressure of tilting Total pressure Flow rate

A. Setting procedure 1. Loosen the hexagon nut. 2. Set the power line by tightening or loosening the adjusting screw.

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Hydraulic systems - Variable displacement pump

Pump - Component identification Inner construction Drive shaft

TULI12EXN4153EB

No. Name 1 Shaft 2 Ring 3 Snap ring (for shaft)

Quantity 1 1 1

No. 4 Key 5 Shim 6 Shim

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Name

Quantity 1 1 1

Hydraulic systems - Variable displacement pump

Swash plate (plate)

TULI12EXN4154FB

No. Name 1 Plate 2 Guide (suction) 3 Bushing (suction)

Quantity 1 1 1

No. Name 4 Guide (delivery) 5 Bushing (delivery)

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Quantity 1 1

Hydraulic systems - Variable displacement pump

Rotary group

TULI12EXN6126FB

No. 1 2 3 4

Name Piston Cylinder block Cup Guiding

Quantity 10 1 1 1

No. 5 6 7 8

Name Spring Parallel pin Spring seat Snap ring (for hole)

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Quantity 1 3 1 1

Hydraulic systems - Variable displacement pump

Control spring

TULI12EXN6127EB

No. 1 2 3 4 5 6 7

Name Spring seat Spring seat Cover Set screw Spring Spring O-ring

Quantity 1 1 1 1 1 1 1

No. 8 9 10 34 44 54

Name Capscrew ( M8 X 30 ) Nut Spring Shim Shim Shim

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Quantity 2 1 1 2 2 2

Hydraulic systems - Variable displacement pump

Cover

TULI12EXN6128GB

No. 1 2 3 4 5 6

Name Cover Control plate Parallel pin Screw M12 X 40 ) Seal Cap

Quantity 1 1 1 3 1 3

No. 7 8 9 10 12

Name Bearing Cap Screw M12 X 55 ) Cap Orifice

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Quantity 1 2 1 3 1

Hydraulic systems - Variable displacement pump

Gear pump

TULI12EXN4158FB

No. 1 2 3 4 5 6 7 8

Name Housing Cover Gear Gear Side plate assembly Plate Guiding Coupling

Quantity 1 1 1 1 2 13 2 1

No. 9 10 11 12 13 14 15

Name O-ring O-ring Square ring Square ring O-ring Screw M12 X 25 Screw M10 X 20

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Quantity 2 1 1 2 1 2 4

Hydraulic systems - Variable displacement pump

Housing

TULI12EXN6130FB

No. 1 2 3 4 5 6 7 8 9 12

Name Housing Oil seal Bearing Piston Parallel pin Disk spring O-ring O-ring Spacer Guiding

Quantity 1 1 1 1 1 5 1 1 1 1

No. 16 18 19 20 22 23 30 31 32

Name Sleeve Shim Shim Shim Spacer Snap ring Shim Shim Shim

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Quantity 1 1 1 1 1 1 1 1 1

Hydraulic systems - Variable displacement pump

Trochoid pump

TULI12EXN4160FB

No. 1 2 3 4 5

Name Gear Housing Side plate (A) O-ring Spring pin

Quantity 1 1 1 1 1

No. 6 7 8 9

Name Edge bolt Side plate (B) Spring pin Plate

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Quantity 3 1 1 1

Hydraulic systems - Variable displacement pump

Variable displacement pump - Prepare 1. Remove the cover assembly. 2. Remove the counterweight. 3. Depressurize the hydraulic oil tank and drain the hydraulic oil. â&#x20AC;˘ Spread a vinyl sheet under the pump to prevent contamination due to oil leakage. 4. Remove the filler neck (C1) of the fuel supply port to improve workability. Two capscrews M8 X 16 (C7) TULI12EXN6297AB

: 13 mm Tightening torque: 23.5 NÂˇm (17.3 lb ft)

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Hydraulic systems - Variable displacement pump

Variable displacement pump - Remove 1. Disconnecting hoses and fittings connected to the pump. â&#x20AC;˘ Attach a tag to each hose for identification. 1.

Loosen four M12 X 35 capscrews (19) to remove the tube (14). : 10 mm

2. Remove the pilot delivery hose (B23). : 22 mm 3. Remove the main pump delivery hoses (8), (9) and (10). : 27 mm 2. Loosen two M12 X 30 capscrews (C4) to remove the pump (C8). : Ball joint type 10 mm Pump weight: 28 kg (61.7 lb)

TULI12EXN6298BB

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Hydraulic systems - Variable displacement pump

Variable displacement pump - Install Install the pump in reverse order of the removal according to the tightening torque and sealant instructions. 1. Apply grease to the spline part of the pump input shaft. Grease: M62 or equivalent (Molybdenum disulfide extreme pressure multipurpose grease). 2. Insert the pump spline part to the coupling. 3. Fix the pump by the capscrew (C4). : Ball joint type 10 mm 4. Install the main pump delivery hoses (8), (9), and (10) and the pilot delivery hose (B23).

TULI12EXN4918BB

C4 C5 C8 C9 C10

85.3 N·m (62.9 lb ft) 85 - 94 N·m (62.7 - 69.3 lb ft) Apply no Loctite as microcapsule coating has been applied. Apply grease Air bleed valve 64.7 N·m (47.7 lb ft) Apply LOCTITE® 262

Tightening torque Thread size PF 3/8 PF 1/2

Spanner used 22 mm 27 mm

O-ring type fitting 73.5 N·m (54.2 lb ft) 108 N·m (79.7 lb ft)

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30° flare type fitting 49.0 N·m (36.1 lb ft) 78.5 N·m (57.9 lb ft)

Hydraulic systems - Variable displacement pump

5. Tighten the capscrew (19) to install the suction tube (14). : 10 mm 6. When the suction hose (12) is removed, apply sealant on the inserted portion of the hose and fix the tube with the clip (25). : Minus driver T = 5.4 NÂˇm (4.0 lb ft) 7. Supply the tank with hydraulic oil (approximately 38 l (10 US gal)). 8. Loosen the air bleed valve of the pump to release air from the casing, and fill it with hydraulic oil (See Fig. 1). : 10 mm 9. Reinstall each component removed in the above removal preparation. 10. After starting the engine, release air.

TULI12EXN6298BB

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Hydraulic systems - Variable displacement pump

Pump - Disassemble Cautions for disassembling 1. Never attempt acting on the adjusting screw unless aboslutely necessary. 2. Take the utmost care during disassembly not to knock or drop any part.

Removing gear pump 1. Remove two capscrews ( M10 X 25). : 8 mm â&#x20AC;˘ Pay attention not to miss O-ring (two places) fitted on the housing.

TUPH12EXN6359AA

TUPH12EXN6360AA

TUPH12EXN6361AA

2. Remove the coupling.

Removing trochoid pump 1. Remove three M5 X 12 capscrews. : 4 mm

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Hydraulic systems - Variable displacement pump

2. Remove the case, side plate (A) and gear. â&#x20AC;˘ Use two M5 X 90 screws.

TUPH12EXN6362AA

TUPH12EXN6363AA

TUPH12EXN6364AA

TUPH12EXN6365AA

3. Take the gear out of the casing.

4. Remove the side plate (A) from the casing.

5. Remove the side plate (B) from the cover.

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Hydraulic systems - Variable displacement pump

6. Remove the key of the shaft.

TUPH12EXN6366AA

TUPH12EXN6367AA

Disassembling main pump 1. Removing cover Since the control spring is strong, remove three ( M12 X 40) and one ( M12 X 55) capscrews while pressing the cover with jig. : 10 mm

TULI12EXN6371AA

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Hydraulic systems - Variable displacement pump

2. Removing cover Loosen hexagon socket set screw (1) of jig slowly keeping the cover horizontal with jig and remove the cover. â&#x20AC;˘ Pay attention not to drop the control plate attached on the back side.

TUPH12EXN6368AA

TULI12EXN6372AB

TUPH12EXN6369AA

TUPH12EXN6373AA

3. Remove the packing.

4. Removing control spring section A. Remove two springs (inside and outside) and the guide.

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Hydraulic systems - Variable displacement pump

B. Remove the spring seat.

TUPH12EXN6374AA

TUPH12EXN6375AA

TULI12EXN6377AB

TUPH12EXN6376AA

5. Removing rotary group A. Remove the shim (3) and then remove the C-snap rings (20 for shaft (4)). Snap ring pliers (20 for shaft)

B. Place the pump laterally and remove the rotary group from the shaft.

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Hydraulic systems - Variable displacement pump

6. Removing shaft Wind protective tape on the spline section, and draw the shaft out straight taking care not to damage the oil seal.

TUPH12EXN6378AA

TUPH12EXN6379AA

TUPH12EXN6380AA

TULI12EXN6382AB

7. Removing swash plate section A. Remove the swash plate.

B. Remove the guide. â&#x20AC;˘ Orientation: Put marks (6) to avoid directional errors, like right and left, etc.

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Hydraulic systems - Variable displacement pump

8. Disassembling cover section A. Remove the control plate.

TUPH12EXN6381AA

TUPH12EXN6426AA

TUPH12EXN6427AA

B. Remove the two screws ( M8 X 30) to remove the cover from the control spring. : 6 mm

C. Remove the spring seat.

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Hydraulic systems - Variable displacement pump

9. Disassembling housing section A. Remove the piston, coned disk spring, distance piece and shim of P3 shift side.

TUPH12EXN6428AA

TULI12EXN6430AB

TUPH12EXN6429AA

B. Remove the parallel pin and sleeve (Ă¸6) of P3 shift side.

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Hydraulic systems - Variable displacement pump

C. Remove piston of Pz shift side.

TUPH12EXN6432AA

TULI12EXN6431AB

TUPH12EXN6433AA

TUPH12EXN6434AA

D. Remove parallel pin and sleeve (Ă¸8.5) of Pz shift side.

E. Removing minimum flow stopper Remove the snap ring (22 for hole). Snap ring pliers (22 for shaft)

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Hydraulic systems - Variable displacement pump

F. Remove the guide, disk spring, distance piece and shim.

TUPH12EXN6435AA

TUPH12EXN6436AA

TUPH12EXN6437AA

TUPH12EXN6438AA

10. Disassembling gear pump ( GSP2) A. Loosen the hexagon head screws ( M10 X 20). : 8 mm

B. Remove the cover.

C. Remove the square ring.

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Hydraulic systems - Variable displacement pump

D. Remove two plates, guide and O-ring.

TUPH12EXN6439AA

TUPH12EXN6440AA

E. Remove the drive gear, idle gear and side plate.

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Hydraulic systems - Variable displacement pump

Pump - Assemble Cautions for assembling 1. Wash each part thoroughly. 2. During disassembling, take utmost care not to damage the part or allow foreign materials to enter. 3. As a rule, the O-ring and oil seal should not be reused. 4. In out assembly work, the torque wrench is used to control the torque. Be sure to use the torque wrench. Assemble the main pump in reverse order of disassembly. 1. Assembly of main pump 1. Assembling housing section A. Install the parallel pin and sleeve (Ă&#x2DC; 6 mm (0.24 in)) of the P3 shift side into the housing.

TUPH12EXN6441AA

TUPH12EXN6442AA

TULI12EXN6444AB

B. Install the piston (8), the taper disk of the spring (7), the spacer and the shim (9) of P3 on the shift side, inside the housing. â&#x20AC;˘ Be careful to the orientation of the disk spring (7).

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Hydraulic systems - Variable displacement pump

C. Install the parallel pin and sleeve (Ã&#x2DC; 10 mm (0.39 in)) of Pz shift side.

TUPH12EXN6443AA

TULI12EXN6431AB

TUPH12EXN6445AA

D. Install the piston of Pz shift side.

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Hydraulic systems - Variable displacement pump

E. Installing minimum flow stopper. Install the guide (10), disk spring (11), distance piece and shim (12) in the housing. â&#x20AC;˘ Be careful of direction of a disk spring.

TUPH12EXN6446AA

TULI12EXN6449AB

TUPH12EXN6447AA

F. Place snap ring (22 for hole) in. Snap ring pliers (22 for shaft)

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Hydraulic systems - Variable displacement pump

2. Installing swash plate A. Place the guide in the housing. â&#x20AC;˘ Place in paying attention to the matchmark (6) put on at disassembling.

TUPH12EXN6448AA

TULI12EXN6450AB

TUPH12EXN6451AA

B. Build the swash plate into the housing.

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Hydraulic systems - Variable displacement pump

3. Installing shaft Wind protective tape on the spline section taking care not to flaw on the oil seal and insert the shaft straight. â&#x20AC;˘ Ensure that the shim (14) is placed on the bearing (13).

TUPH12EXN6452AA

TULI12EXN6455AB

TUPH12EXN6453AA

TUPH12EXN6454AA

4. Installing rotary group A. Insert 10 pistons in the retainer.

B. Apply grease on the spherical section of the guide.

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Hydraulic systems - Variable displacement pump

C. Placing guide between the retainer and cylinder block, and insert the pistons into bores on the cylinder block. â&#x20AC;˘ Apply grease on the shoe end.

TUPH12EXN6456AA

TUPH12EXN6457AA

TUPH12EXN6458AA

TULI12EXN6460AB

5. Installing rotary group A. Install the rotary group aligning it to the spline of the shaft.

B. Fit the snap ring (2) (20 for shaft (4)) and insert the shim (3). Snap ring pliers (20 for shaft)

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Hydraulic systems - Variable displacement pump

6. Installing control spring section A. Apply grease on the spherical section of the spring seat and install the control spring section.

TUPH12EXN6459AA

TUPH12EXN6461AA

TUPH12EXN6462AA

TUPH12EXN6463AA

B. Insert two springs (inside and outside) and the guide.

7. Assembling cover A. Insert the spring seat in the cover.

B. Install the cover for the control spring section and tighten the screws (two M8 X 30). : 6 mm Tightening torque: 28 - 35 NÂˇm (21 - 26 lb ft)

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Hydraulic systems - Variable displacement pump

C. Apply grease on the rear surface of the control plate to prevent it from dropping and place it in the cover aligning the hole for positioning pin.

TUPH12EXN6464AA

TUPH12EXN6465AA

TUPH12EXN6466AA

TULI12EXN6469AB

8. Assembling cover A. Fit the packing.

B. Tighten the hexagonal socket (1) set screw of the jig slowly keeping the cover horizontal and install the cover.

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Hydraulic systems - Variable displacement pump

C. Fasten the cover with three M12 X 40 screws and a M12 X 55 screws. : 10 mm Tightening torque: 98 - 123 N·m (72 - 91 lb ft)

TUPH12EXN6467AA

TUPH12EXN6468AA

TULI12EXN6470AB

TUPH12EXN6471AA

9. Trochoid pump A. Insert the key in the shaft.

T. Trochoid pump side R. Round side C. Cover side • Insert the key directing the round side to the trochoid pump side.

B. Assemble the side plate (B) onto the cover.

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Hydraulic systems - Variable displacement pump

C. Place the gear (inner rotor) through the shaft. â&#x20AC;˘ Install aligning the matchmark to the side plate (B) side.

TUPH12EXN6472AA

TULI12EXN6475AB

TUPH12EXN6473AA

TUPH12EXN6474AA

Inner rotor

M. I.D. mark O. Outer rotor

D. Install the side plate (A) into the casing.

E. Install the gear (outer rotor) (O) into the casing. â&#x20AC;˘ Direct the matchmark side to the side plate (B) side.

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Hydraulic systems - Variable displacement pump

F. Install the casing to the cover.

TUPH12EXN6476AA

TUPH12EXN6477AA

TUPH12EXN6478AA

TUPH12EXN6479AA

G. Tighten the three M5 X 12 screws. : 4 mm Tightening torque: 6.9 - 8.3 NÂˇm (5 - 6 lb ft)

10. Installing gear pump A. Fit the coupling to the shaft end on the main pump side.

B. Connect the gear pump to the main pump.

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Hydraulic systems - Variable displacement pump

C. Fasten the gear pump with two ( M10 X 25) capscrews. : 8 mm Tightening torque: 55 - 69 NÂˇm (41 - 51 lb ft)

TUPH12EXN6480AA

TUPH12EXN6481AA

TULI12EXN6483AA

TUPH12EXN6440AA

11. Assembling gear pump A. Fit the square ring to the plate on the assembling side of gear pump (GSP2). Then pay attention to the suction and delivery.

D. Delivery side S. Suction side

B. Install the drive gear and idle gear in the side plate.

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Hydraulic systems - Variable displacement pump

C. Install the drive gear, (G) idle gear and side plate into the housing.

TUPH12EXN6482AA

TUPH12EXN6486AA

TULI12EXN6484AB

TUPH12EXN6439AA

4. Insert the O-ring into the guide (G), and install it onto the plate.

Large chamfered side

E. Install the plate, guide and O-ring into the housing. Then pay attention to the suction and delivery direction.

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Hydraulic systems - Variable displacement pump

D. Delivery side S. Suction side

TULI12EXN6485AA

TUPH12EXN6438AA

TUPH12EXN6437AA

TUPH12EXN6436AA

F. Fit the square ring.

G. Install the cover to the housing.

H. Fix the housing and the cover with four M10 X 20 capscrews. : 8 mm Tightening torque: 55 - 69 NÂ·m (41 - 51 lb ft)

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Hydraulic systems - Variable displacement pump

Pump - Service instruction Parts replacement standard Piece Piston assembly (1) and cylinder block (2)

Replacement criterion Replace Visual inspection • To be free from flaw, galling and wear (Especially the sliding section)

Remedy

• Check clearance between the piston (1) outer diameter and inner diameter of the cylinder block (2) D-d≤ 0.06 mm (0.002 in)

Piece Piston shoe (3) and piston (4)

Replacement criterion • Piston shoe (3) and piston (4)

TULI12EXN4300AB

TULI12EXN4301AB

Remedy Replace

• Check the play in the axial direction of the piston (4) and shoe shaft (3) ε≤ 0.2 mm (0.01 in)

Piece Shaft

Replacement criterion Shaft • • Check the wear of the oil seal (5) Wear amount≤ 0.025 mm (0.001 in) 5. Oil seal installing range

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Remedy Replace

Hydraulic systems - Variable displacement pump

TULI12EXN4302AB

Piece Control plate

Replacement criterion Check the sliding surface for flaw

Remedy Replace it when the flaw is severe

TULI12EXN4303AB

Piece Guide (6) and retainer (7)

Replacement criterion Check if it is free from galling and step wear Check if it is free from galling and step wear

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Remedy Replace it in a set if it is impossible to repair After repairing with lapping, clean it to remove the lapping compound

TULI12EXN4304AB

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Index Hydraulic systems - 35 Variable displacement pump - 106 Pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pump - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Pump - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Variable displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Variable displacement pump - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Variable displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Hydraulic systems - 35 Main control valve - 359

CX35B CX39B

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Contents Hydraulic systems - 35 Main control valve - 359

TECHNICAL DATA Stacked control valves General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Stacked control valves Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Main control valve Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Stacked control valves Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

DIAGNOSTIC Stacked control valves Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Relief valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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Hydraulic systems - Main control valve

Stacked control valves - General specification

TULI12EXN4174GB

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Dozer Slewing Supply and independent travel Digging Service Swing Travel right Feed Travel left Boom

11. 12. 13. A. B. C. D. E. F. G. H.

Boom lock Bucket Manual operation Pilot port 16 - PF 1/4 (Pa1รทPa10 / Pb1รทPb10) Drain port Dr1 PF 1/4 Tank port T2 PF 1/2 Pump port P1, P3 2- PF 1/2 Pump port P3, PF 3/8 Actuator port 18 - PF 3/8 (A1-A10 / B1-B10) Tank port T1 PF 1/2 Pp1 PF 1/4

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EV310054 Swing Valve Travel left, travel right, boom, arm, bucket slewing, dozer, attachment independent operation Pilot travel and conflux Delivery P1, P2 – 38.4 l/min (10.1 US gpm), P3 → 20.6 l/min (5.4 US gpm) P1, P2: 23 - 23.5 MPa (3336 - 3409 psi) at 38.4 l/min (10.1 US gpm) Setting pressure at main ( MR1, MR2) pressure relief valve P1, P2, P3 P3: 20.0 - 20.5 MPa (2901 - 2974 psi) at 20.6 l/min (5.4 US gpm) ( MR3) B1, A3, B3, B10 port ( OR6, OR4, OR5, OR1) 25.5 - 26 MPa (3699 - 3771 psi) at Setting pressure at over load 5 l/min (1.3 US gpm) relief valve B8, B9 port ( OR3, OR2) 27.5 - 28 MPa (3989 - 4061 psi) at 5 l/min (1.3 US gpm) Model (type) Manual

Stacked control valves - Special tools Required tools and others Preliminary preparation of the following tools is required for the disassembly and the assembly of the control valve. In addition, the following tools are necessary for the disassembly and the assembly of this valve, but the tools necessary for the disassembly and the assembly of the port connection and the link joint are not included. Tools Allen wrench Wrench Socket wrench Torque wrench Torque wrench Magnet Pliers Screw driver (–) Tweezer

Qty. One each One each One each 1 1 1 1 1 1

Prepare wash oil, hydraulic oil, grease, LOCTITE® 242, tag and marker (felt-tip pen) beforehand.

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Observations

1.96 - 19.6 N·m (1.4 - 14.5 lb ft) 19.6 - 117.7 N·m (14.5 - 86.8 lb ft)

Hydraulic systems - Main control valve

Stacked control valves - Component identification

TULI12EXN6492FB

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Dozer section (Qty. 1) Slewing section (Qty. 1) P3 inlet and travel straight conflux section (Qty. 1) Arm section (Qty. 1) Service section (Qty. 1) Swing section (Qty. 1) Travel (right) section (Qty. 1) P1 and P2 inlet section (Qty. 1) Travel (left) section (Qty. 1) Boom section (Qty. 1)

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Boom lock section (Qty. 1) Bucket section (Qty. 1) Main pressure relief valve P1, P2 (Qty. 2) Main relief valve P3 (Qty. 1) Pressure relief valve (Qty. 4) Pressure relief valve (Qty. 2) Anti-cavitation valve (Qty. 1) Edge bolt (Qty. 4) Nut (Qty. 4) Manual operation (Qty. 1)

The control valve is roughly classified into the following four sections: • Manual operation section: Swing • Pilot section: Travel right and left, boom, arm, bucket, slewing, independent travel and conflux, dozer blade, service (nibbler and breaker) • Accessory section: P1 and P2 inlets, and P3 inlet (common with travel straight and conflux) • Accessory section (valve): P1, P2, P3 main relief, overload relief, anti-cavitation, boom lock

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Hydraulic systems - Main control valve

Manual operation: Swing (item 6)

TULI12EXN4306FB

1. 2a. 2b. 2c. 2d. 2e. 2f. 2g. 3. 4.

Body (Qty. 1) Spool (Qty. 1) O-ring (Qty. 1) Dust wiper (Qty. 1) Oil seat retainer (Qty. 1) Spring seat (Qty. 2) Spring (Qty. 1) Spool end (Qty. 1) O-ring (Qty. 1) Dust wiper (Qty. 1)

5. 6. 7. 8. 9. 10. 11. 12. 13.

Oil seat retainer (Qty. 1) Check valve (Qty. 1) Spring (Qty. 1) O-ring (Qty. 2) Cap (Qty. 1) Screw M5 X 10 (Qty. 2) Cover (Qty. 1) Screw M5 X 18 (Qty. 2) Anti-cavitation valve (Qty. 1)

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Hydraulic systems - Main control valve

Pilot operation: Slewing (item 2)

TULI12EXN4307FB

1. 2a. 2b. 2c. 2d. 2e. 3. 4.

Body (Qty. 1) Spool (Qty. 1) Spring seat (Qty. 1) Spring (Qty. 1) Spring seat (Qty. 1) Spool end (Qty. 1) Load check valve (Qty. 1) Spring (Qty. 1)

5. 6. 7. 8. 9. 10.

O-ring (Qty. 1) Cap (Qty. 1) O-ring (Qty. 2) Cover (Qty. 1) Cover (Qty. 1) Screw M5 X 10 (Qty. 4)

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Hydraulic systems - Main control valve

Main relief valve ( P1, P2, P3) and overpressure relief valve

TULI12EXN4308FB

1. 2. 3. 4. 5. 6. 7. 8.

Socket (Qty. 1) Pressure regulating valve (Qty. 1) Piston (Qty. 1) Valve cap (Qty. 1) Body (Qty. 1) Poppet (Qty. 1) Set screw (Qty. 1) Lock nut M14 (Qty. 1)

9. 10. 11. 12. 13. 14. 15. 16.

Spring (Qty. 1) Spring (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 2) Backup ring (Qty. 2) O-ring (Qty. 1) Spring guide (Qty. 1)

Drawing A. (Only for overload relief valve and main relief valve).

Anti-cavitation valve 1. 2. 3. 4. 5. 6. 7. 8.

Anti-cavitation valve (Qty. 1) Body (Qty. 1) Cap (Qty. 1) Spring (Qty. 1) Backup ring (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1)

TULI12EXN4309AB

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Hydraulic systems - Main control valve

Stacked control valves - Hydraulic schema Dozer spool Swing spool Travel independent and 3. conflux spool 4. Arm spool 5. Service spool 6. Boom swing spool 7. Travel right spool 8. Travel left spool 9. Boom spool 10. Bucket spool 11. P1 ( RV1) relief valve 1. 2.

12. P2 ( RV2) relief valve 13. P3 ( RV3) relief valve

23. P1 by-pass passage 24. P2 by-pass passage

14. B1 Over load relief valve

25. P3 by-pass passage

15. 16. 17. 18. 19. 20. 21. 22.

26. 27. 28. 29. 30. 31.

A3 Over load relief valve B3 Over load relief valve B8 Over load relief valve B9 Over load relief valve B10 Over load relief valve Boom lock valve Anticavitation valve Over load relief plug

TULI12EXN6150BA

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P1 parallel passage P2 parallel passage P3 parallel passage Pp1 Pilot passage Tank passage Feed

Hydraulic systems - Main control valve

Stacked control valves - Dynamic description Neutral position P1: The oil delivered from the hydraulic pump flows from the P1 port of the control valve (hereafter called a C/V) into the left travel spool section through the passage of the supply section. At the spool neutral position, the entered oil passes through the by-pass of the spool leading from the left travel to the boom because the spool does not cut-off the by-pass and flows out to the tank circuit through the by-pass of the spool for the bucket and the by-pass leading to the tank.

P2: The oil delivered from the hydraulic pump flows from the P2 port of C/V into the right travel spool section through the passage of the supply section. At the spool neutral position, the entered oil passes through the by-pass of the spools for the right travel, boom swing and service, and flows out to the tank circuit through the by-pass circuit leading from the by-pass of the spool for service.

P3: The delivery from the hydraulic pump flows from the (C/V) P3 port into the parallel circuit of swing and dozer operation. Since the spool does not shut-off the by-pass passage in the neutral spool condition, the oil having flown into the parallel passage flows out to the tank passage through the by-pass passages of the spools for the dozer and slewing and through the by-pass passage of the P3 supply section. NOTICE: As the flow from the pump is fed into each line (P1, P2, P3), the switching sections of respective line shown below are in operable condition. Therefore, donâ&#x20AC;&#x2122;t operate them except when working. P1 line: Left travel, boom, bucket P2 line: Right travel, boom swing, service and arm P3 line: Dozer, slewing [service and arm]

Pp1: The delivery oil from the gear pump flows from the (C/V) Pp1 port into the pilot circuit through the orifice provided on P3 supply section. (Two systems for shifting independent travel and for shifting arm and service flow conflux). In the neutral spool condition, the oil of the independent travel shifting side flows out to the tank passage through the passages provided to the right and left travel spool and the swing spool. Therefore the pilot circuit pressure becomes equal to the tank pressure, the received pressure of the independent travel valve is equal to the tank pressure, and consequently the independent travel spool does not switch. Moreover, the oil of the flow conflux shifting side flows out to the tank passage through the passage provided to the service spool. Since the pilot passage pressure equals to the tank pressure and the receiving pressure of the flow conflux piston equals to the tank pressure, the flow conflux spool is not shifted. NOTICE: When the engine is stopped (when each hydraulic pump is stopped), the actuator does not function even when being loaded by the self weight, because the pilot pressure does not act on the pilot control spool (except for the condition where the accumulator, etc. is attached and the pressure remains due to the pipe volume). On the spool of boom swing which directly actuates the spool, the port on the loaded side is led to the tank circuit with the operating direction making it unable to hold the load, consequently the actuator may be actuated causing danger. Therefore, even if the engine is stopped, when there are people around the machine or it may be in contact with implements, donâ&#x20AC;&#x2122;t use the control lever.

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Hydraulic systems - Main control valve

TULI12EXN4181GA

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

Dozer Slewing Supply and independent travel Digging Service Swing Travel (right) Feed Travel (left) Boom Boom lock Bucket By-pass passage to tank P3 side parallel passage

C. D. E. F. G. H. I. L. M. N. O. P1. Q.

From by-pass passage of tank to tank passage Tank passage P3 side by-pass passage Independent travel - flow conflux spool From P3 port P2 side by-pass passage From P2 pump Pilot passage for independent travel Orifice Piston for conflux Pilot passage for conflux From P1 pump P1 side by-pass passage

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Hydraulic systems - Main control valve

Pilot operating section Boom lifting operation While lifting, the pressure of the secondary pilot circuit enters through port Pa8 and moves the spool for the operation of the boom. And with the movement of the spool, as the by-pass circuit is cut at the boom switching section, the oil received through the P1 port flows from the parallel circuit through the check valve installed on the upper part of the spool by-pass circuit for the travel operation into the parallel circuit on the boom switching section. With the movement of the spool, as the circuit from the passage leading to the boom lock section to the bridge passage is opened, the oil entered in the parallel circuit passes through the load check valve on the boom switching section and flows into the boom lock section through the bridge passage. The oil entered in boom section opens the lock valve and is fed into the boom cylinder head side. On the other hand, the return oil from the boom cylinder rod side flows into the B8 port, and with the movement of the spool the oil flows out into the tank circuit that is connected by the notch of the spool. Consequently, the boom cylinder extends and raises the boom. The oil from the Pp1 port passes through the orifice provided on the P3 supply section and flows into the pilot circuit. The oil entered into the pilot circuit flows from the travel switching section to the tank circuit, and the pilot circuit pressure becomes equal to the tank pressure, consequently the independent travel spool is not switched.

TULI12EXN4182FA

9. 10. 11. 14.. P. R.

Travel (left) Boom Boom lock Boom cylinder From P1 pump Parallel passage

S. T. U. W.

Pilot passage Bridge passage By-pass passage The oil entered in through the Pp1 port flows out from the travel switching section into the tank circuit

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Hydraulic systems - Main control valve

Manual operation section Left swing operation With the left swing operation, the swing spool moves to the pushâ&#x20AC;&#x201C;in direction. With the movement of the spool, as the by-pass circuit is cut-off at the swing switching section, (a portion of the oil flows out to the by-pass (tank) circuit through the notch provided on the swing spool.), the oil entered through the P2 port flows into the parallel circuit through the check valve provided on the upper part of the travel spool by-pass circuit. With the movement of the spool, as the circuit from the A5 port to the bridge passage is open, the oil entered in the parallel circuit passes though the load check valve, flows into the A5 port through the bridge passage, and is fed into the swing cylinder head side. On the other hand, the return oil from the swing cylinder rod side flows into through the B5 port, and with the movement of the spool the return oil flows out to the tank circuit that is connected by the notch of the spool. Consequently, the swing cylinder extends, and the boom swings leftward. The oil from the Pp1 port passes through the orifice provided on the P3 supply section and flows into the pilot circuit. As the oil entered in the pilot circuit flows out from the travel switching section into the tank circuit, the pilot circuit pressure becomes equal to the tank pressure, and consequently the independent travel spool is not switched.

TULI12EXN4183FA

6. Swing 7. Travel (right) 15. Swing cylinder

T. U. W.

R. S.

Parallel passage Pilot passage

Bridge passage By-pass passage The oil entered in through the Pp1 port flows out from the travel switching section into the tank circuit Some oil flows into the by-pass passage

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Hydraulic systems - Main control valve

Flow conflux function This valve actuates the arm and additional attachments by using the combined flows of P2 and P3. The conflux circuit is only used to activate the arm and the additional attachments as described below. (The explanation shown below for moving the additional attachments is also applicable to the arm). The operation for the service shifts the spool for the service by the secondary pressure from the remote control valve. Since the spool shifting results in shut-off of the pilot and tank passages for flow conflux, the pressure in the flow conflux pilot passage equals to the Pp1 port supply pressure, which acts on the flow conflux piston to move it to the position where the piston collar contacts with the inner shoulder the valve. At the same time, the flow conflux piston moves the flow conflux and independent travel spools. Once the spool is shifted, the pressurized oil supplied from P3 flows into the second by-pass passage of P2 side through the parallel and by-pass passages of the slewing and dozer shifting and through the check valve provided to the P3 supply section, which is connected to the by-pass passage of the P2 side at the upstream (between swing and additional attachments) of the service shifting section, and also connected to the by-pass passage of the P2 side through the check valve at the P3 supply section. Therefore the flow of oil supplied from P3 joins in the parallel passage of the P2 side in proportion to an operating amount of the arm or the service. (The drawing below shows service operation).

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Hydraulic systems - Main control valve

TULI12EXN4184GA

3. 4. 5. G. H. I.

K. P. R. S. V.

Supply and independent travel Digging Service From P3 port P2 side by-pass passage From P2 pump

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The parallel passage of P2 side From P1 pump Parallel passage Pilot passage From P3 pump

Hydraulic systems - Main control valve

Independent travel function When both right and left travels is shifted, and one of boom, bucket and boom swing is shifted, the oil flows from the Pp1 port through the throttle into the pilot passage, in which pressure equals to the Pp1 port supply pressure because the pilot passage is shut-off from the tank passage. Then the Pp1 port supply pressure acts on the independent travel spool, and the spool moves until it contacts with the pilot cap overcoming the spring force. Once the spool is shifted, the pressurized oil supplied from P3 passes through the parallel and by-pass passages of the slewing and dozer shifting sections, and passes through the spool of the P3 supply section and the land of main unit to flow into the second parallel passage of the P1 side and the parallel passage of the P2 side. After these shifting, the pressurized oil supplied to P1 and P2 actuates the right and left travel, and the pressurized oil supplied to P3 actuates the other attachments. Therefore even if the travel and other attachment are simultaneously operated, the travel is correctly performed without deviating. The arm or service operated in the flow conflux position without relating to the independent travel function can be simultaneously performed with the travel in the same operability as the independent travel function.

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Hydraulic systems - Main control valve

TULI12EXN4185GA

1. 2. 3. 4.

Dozer Slewing Supply and independent travel Digging

G. H. K. Q. S.

From P3 pump P2 side by-pass passage The parallel passage of P2 side P1 side by-pass passage Pilot passage

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Hydraulic systems - Main control valve

Function of lock valve Piston holding When the boom spool is at neutral position, the pilot piston chamber (a) is connected to the drain passage through the pilot port ( Pb8â&#x20AC;&#x2122;) for releasing lock valve. And the piston chamber (b) is also connected to the drain passage through the drain port ( Dr1). Therefore the piston (A) is held at the position shown in the figure. And the hydraulic pressure to hold the boom cylinder is applied to the lock valve chamber as shown in the figure, pressing the needle valve and lock valve to their seats respectively. Then it prevents leakage on the head side of boom cylinder, and also prevents the arm cylinder from its movement due to leakage.

TULI12EXN4186GA

14. Boom cylinder 16. Lock valve chamber 17. Needle valve seat

18. Needle valve 19. Lock valve 20. Body seat

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Hydraulic systems - Main control valve

Function of lock valve (release) When the pilot pressure is applied to the pilot port ( Pb8â&#x20AC;&#x2122;) for releasing lock valve, the piston (A) is moved to the right side opening the needle valve through piston (B). At that time, the return oil from boom cylinder passes through the throttle on lock valve, then lock valve chamber â&#x2020;&#x2019; pilot piston chamber â&#x2020;&#x2019; drilled hole in turn, and flows into the tank path through the throttle hole (drilled hole) on boom spool pushing up the steel ball. The opening of the needle valve results in the pressure drop in the lock valve chamber. The return oil from the boom cylinder opens the lock valve, and flows into the tank passage through the notch (groove) of the boom spool and the throttle (drilled hole).

TULI12EXN4187GA

14. 16. 18. 19. 21.

Boom cylinder Lock valve chamber Needle valve Lock valve Steel ball

22. 23. 24. 25.

Pilot piston chamber Drilled hole Orifice To tank

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Hydraulic systems - Main control valve

Operation of relief valve Operation at relief condition â&#x20AC;˘ The pressure oil passes through the inside of the piston placed in the pressure regulating valve (main valve) and fills in (A) chamber inside of the piston through the orifice (B) to securely seat the pressure regulating valve and the socket, and the socket and the body seat.

TULI12EXN4188EA

24. 25. 26. 27.

Tank passage Piston Adjust valve spring Body seat

28. Shutter 29. Pressure regulating valve 30. Adjusting valve

â&#x20AC;˘ When the pressure of the oil in the P port reaches to the set pressure of the spring, the pressure oil acts on the adjust valve through the piston and opens the adjust valve. Then, the pressure oil passes through the inside of the piston, orifice (B), (A) chamber, ring orifice, and drilled hole (D) in order, and flows out to the tank circuit around the socket.

TULI12EXN8151EA

31.

Ring orifice (C)

â&#x20AC;˘ The pressure in (A) chamber drops because the adjust valve is open, consequently the pressure oil in the P port flows out to the tank circuit through the drilled hole (E).

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Hydraulic systems - Main control valve

TULI12EXN4190EA

â&#x20AC;˘ When the pressure on the P port drops lower than the spring set pressure of the adjust valve, the adjust valve is pushed against the seat by the adjust valve spring force of the adjust valve and the pressure in (A) chamber is equal to the pressure in the P port, consequently the adjust valve is also pushed against the seat and returns to the former condition (Fig. 8 ).

Suction operation â&#x20AC;˘ When the negative pressure is generated in the P port, the oil is supplied through the tank circuit. When the pressure of the tank circuit from the P port rises, the socket is pushed up. Consequently, the space between the body seat and the socket opens, and the oil flows from the tank passage into the P port and the space fills with the oil.

TULI12EXN4191EA

Operation of anti-cavitation valve â&#x20AC;˘ When the negative pressure is generated in the P port, the oil is supplied through the tank circuit. When the pressure from the P port rises, the valve is pushed up. Consequently, the space between the body seat and the socket opens, and the oil flows from the tank passage into the P port and the space fills with the oil.

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Hydraulic systems - Main control valve

TULI12EXN4192FA

24. 27. 28.

Tank passage Body seat Shutter

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Hydraulic systems - Main control valve

Main control valve - Prepare 1. Unlock and open the right upper cover. 2. Remove the lower cover. â&#x20AC;˘ Spread a vinyl sheet under the control valve to prevent contamination due to oil leakage. 3. Release the residual pressure in the circuit and the pressure in the hydraulic oil tank.

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Hydraulic systems - Main control valve

Main control valve - Remove 1. Disconnecting hoses. Disconnect all the hoses connecting to the control valve, and attach blind plugs and tags recording the installation place. â&#x20AC;˘ Remove the return hose to the hydraulic oil tank to improve workability.

TULI12EXN6300GB

Main hydraulic hose disconnection C/O. H/P. H/T. S/C. S/J.

Cooler oil in (upper) Hydraulic pump Hydraulic tank Swing Swivel joint

S/M. A. B. U.

Slewing motor Arm Boom Bucket

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Hydraulic systems - Main control valve

TULI12EXN6301HB

Pilot hydraulic hose disconnection C/B. P/V.

Control block Pilot valve

S/V.

Shuttle valve

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Hydraulic systems - Main control valve

2. Disconnecting rod. Turn the rod end (B14) to disconnect the control valve C/V from the swing cable (B4)

TULI12EXN6302AB

TULI12EXN6303AB

3. Removing control valve 1.

Loosen four M10 X 50 capscrews (2) to remove the control valve (10) with the bracket (1). : 17 mm Weight of removed parts: 33 kg (72.8 lb)

2. Loosen three M10 X 25 capscrews (4) to remove the control valve (10). : 17 mm Weight: 25 kg (55.1 lb)

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Hydraulic systems - Main control valve

Main control valve - Install 1. Install the control valve in reverse order of the removal. 2. Attach the capscrews (4). NOTE: Clean the mounting surface and take care to prevent deformation of the valve. : 17 mm Tightening torque: 65.7 N·m (48.5 lb ft) 3. Attach the capscrew (2). : 17 mm Tightening torque: 65.7 N·m (48.5 lb ft) A. Arm section B. Boom section B/L. Boom lock section D. Dozer section S. Switch S/C. Slewing section S/T. Supply and travel straight S/E. Service section S/O. Swing section T/R. Travel (right) section T/L. Travel (left) section U. Bucket section 4. Tighten the hose fittings to the following torque: TULI12EXN6304BB

Thread size PF 1/4 PF 3/8 PF 1/2 PF 3/4 PF 1

Spanner used 19 mm (0.7 in) 22 mm (0.9 in) 27 mm (1.1 in) 36 mm (1.4 in) 41 mm (1.6 in)

O-ring type fitting 36.3 N·m (26.8 lb ft) 73.5 N·m (54.2 lb ft) 108 N·m (79.7 lb ft) 162 N·m (119.5 lb ft) 255 N·m (188.1 lb ft)

5. Operate the attachment to check the performance. 6. Check the tank and piping for oil leakage and oil level.

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30° flare type fitting 29.4 N·m (21.7 lb ft) 49 N·m (36.1 lb ft) 78.5 N·m (57.9 lb ft) 118 N·m (87 lb ft) –

Hydraulic systems - Main control valve

Stacked control valves - Prepare Precautions for disassembly NOTICE: Precautions (These precautions must be observed to guarantee safety). The disassembly and assembly have fundamentally to be carried out at Manufacturerâ&#x20AC;&#x2122;s plant, but it they cannot be avoided, observe following precautions. 1. All hydraulic equipment is machined in precision and consequently the clearance of each part is very small. Therefore when disassembling and assembling, place the machine in the clean area to prevent it from the entry of dust, earth and sand. 2. Before disassembly, prepare the valve construction drawing to understand the construction clearly. 3. When removing the control valve from the machine, never forget to cap every port to prevent dust, etc from entering. And before disassembly, recheck that every post is capped and clean the outer surface of the assembly. The work should be carried out on the appropriate work bench which is covered by clean paper or rubber mat. 4. When it is required to leave it in the removed condition, apply rust preventives or seal them to protect them from rusting. 5. The control valve should be transported or moved holding the main body. Especially, after removing the pilot cover, carefully handle it paying attention not to touch the exposed surfaces. 6. Even when the movement is not smooth, never strike it. 7. In addition, after assembly of equipment, various tests {relief setting, leak test, flow resistance (pressure loss) test} are required, but these tests require hydraulic test equipment. Therefore, donâ&#x20AC;&#x2122;t remove the equipment which is impossible to adjust through respective test, even if the disassembly is possible technically.

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Hydraulic systems - Main control valve

Stacked control valves - Disassemble Drawing the spool out Place the control valve on work bench directing the actuator port upward. 1. In case of hydraulic pilot switching type, First, loosen and remove 2 washer socket bolts (10) with Allen wrench of 4 mm. Then, remove pilot cover (9). The spring section of the slewing spool is disposed, so draw out and take out spool assembly (2a) - (2e) slightly and horizontally (parallel to the spool hole) from the body holding the spring section. Other pilot spools can be taken out from the same face by the same procedure. Then, check that the O-ring (7) on the flange bottom installing the pilot cover on the body side is not separated.

TULI12EXN4310FB

2. In case of manual switching type, First, loosen and remove the 2 screws (12) with an Allen wrench of 4 mm . Then, remove end cover (11). The spring section of the swing spool is exposed; therefore, carefully draw out the spool assy. (2a) - (2g) horizontally, and parallely to the spool opening from the body (1) which contains the spring section. Then, pull the spool assembly carefully, or the spool seal [dust wiper (2c) and O-ring (2b)] moves to the edge section of the spool and the lip section may be damaged. Replace the removed O-ring with new one. If it absolutely has to be used, check that it is free from flaw, deformation and foreign matter adhered.

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Hydraulic systems - Main control valve

TULI12EXN4311FA

3. Precautions when replacing spool When replacing the spool, in no case should the spool be disassembled, but replace it with the new spool assembly. 4. In case of independent travel spool. First, loosen and remove the two sems-screws (11) with an Allen wrench of 4 mm . Then, remove pilot cover (10). Remove the spring (4) and the spring seat (3). Pull out the spool assembly (2) slowly and horizontally (parallely to the spool hole axis) from the valve by holding the end of the independent travel spool. At this time, ensure that the O-ring (9) in the bottom of the flange installing the pilot cover on the main body side is in place without coming off. Further loosen three socket bolts (20) with an Allen wrench to remove the body assemblies (16) - (19) and the piston (14). At this time, ensure that O-rings (9) in the installing surface of the body assembly on the main body side is in place without coming off.

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Hydraulic systems - Main control valve

TULI12EXN4312EA

Relief valve (Code: RV) How to remove the overpressure relief valve (Code: ORV) First, fix the valve on the work bench or ask people to hold down the valve. Then loosen the hexagonal section (opposite to the flat one, 22) of RV and ORV with a wrench of 22 mm . At the same time, do not remove the valves by applying the wrench to the opposite part, 19. NOTICE: The set pressure of the RV and ORV differs at the position, so tag every valve with respective attaching position. And handle the removed RV and ORV paying attention not to damage the seat section. The RV and ORV are essential for the performance and safety, but donâ&#x20AC;&#x2122;t disassemble the RV and ORV because it is very difficult to reset the pressure. When there is a failure, replace the assembly.

How to disassemble load check valve First, fix the valve on the work bench or ask people to hold down the valve. Loosen plug (9) at the center of the valve upper surface with spanner of 19 mm (or socket wrench). It may be difficult to loosen the plug because O-ring gets caught in the thread. Then, donâ&#x20AC;&#x2122;t force it to loosen, but tighten the plug once again and loosen it again. Take out spring (7), load check valve (6) through the hole used to remove the plug with tweezers or magnet. The travel switching, boom lock valve and service switching sections having different forms can be disassembled in the same manner.

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Hydraulic systems - Main control valve

TULI12EXN4313FB

Load check valve (dozer, slewing, arm, swing, boom, bucket)

Load check valve (Travel right and left switching, P3 supply and boom lock valve section)

Disassembling lock valve If the lock valve became abnormal, replace it with new one as assembly. The disassembling procedures described below are for reference only to check the cause for abnormality. At first, loosen two socket bolts (20) with a 5 mm (0.2 in) Allen wrench. Then remove the lock valve cover (1). NOTICE: Pay attention not to drop off and lose two positioning pins (9) and give any damages to them. Remove the exposed lock valve (2) and needle valve (10). Remove and store the needle valve firstly because it easily comes off. Do not disassemble the lock valve, store it as assembly ( (2), (8), (11)).

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Load check valve (Service switching section)

Hydraulic systems - Main control valve

TULI12EXN4314EA

Fix the lock valve cover with a vise, loosen and remove the bush (17) with a 26 mm (1.0 in) spanner (or socket wrench). NOTICE: Fix the lock valve cover with a vise at the side faces other than the port face. Remove the pistons B (15) and A1 (14) with a pair of pliers or a magnet, through the bushing hole. Mark the pistons (B) and (A1) to identify the direction in which they have been assembled. Do not disassemble the piston guide (13), and store it at assembly with the lock valve cover. Loosen the ball retainer (19) with a 4 mm (0.2 in). Allen wrench. Remove the Ă¸ 7 mm (0.28 in) steel ball (18) with a magnet through the bore for ball retainer.

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TULI12EXN4315AA

Hydraulic systems - Main control valve

Disassembling other parts Remove the other parts, not described in par. (1) through (3), in the following procedures: 1.

Service section Plug for actuator part Fix the valve directing the actuator port upward. Loosen and remove plug (11) on both right and left sides of the upper surface of the service change section with spanner of 21 mm or socket wrench).

Pilot cover of hydraulic pilot switching section. Loosen and remove the 2 screws (10) with an Allen wrench of 4 mm. Remove the pilot cover (8) horizontally. At the same time, ensure that the O-ring (7) in the bottom of the flange for securing the pilot cover on the main frame side is in place without coming off.

Spool seal of manual switching section. Loosen and remove the 2 screws (10) with an Allen wrench of 4 mm. The oil seal retainer (5) is also removed simultaneously. Remove the spool seal [O-ring (3) and dust wiper (4)] through the spool hole on the side of the main frame, paying attention not to damage the spool seal and switching main frame. Donâ&#x20AC;&#x2122;t reuse the O-ring. When it is required to be used again, check that it is free from flaw, deformation, foreign matter adhered, and so on before installation.

Plug in the bottom of boom lock valve section. Put the valve on work bench directing the actuator port downward. Remove the plug (8) in the middle of the bottom of the boom lock valve section with an Allen wrench of 6 mm, and also remove the O-ring (7).

TULI12EXN4316EA

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Hydraulic systems - Main control valve

TULI12EXN4317EB

Disassembling main frame of switching section Loosen and remove four M8 nuts (19) for fastening the main frame of the switching section on the valve side with a wrench (socket wrench) of 13 mm . Pull out the four screws (18) from the side and remove each main frame of the switching section. Then, care should be taken not to miss various O-rings fitted on the mating face of respective main frames. Do not remove a number of plugs screwed in the unnecessary holes for valve manufacturing of the main frame of the switching section unless required.

Cautions for disassembling NOTICE: The removed parts should be carried and stored carefully to prevent damage and contamination. And when the removed parts are applied, stored, or carried in the removed condition, fill up the holes after the removal of parts with cap, tape, etc. to protect it from entry of dust, dirt, etc.

Disassembling anticavitation valve NOTICE: Since the anticavitation valve is essential for the performance, replace it with the new assembly if necessary. Procedures for disassembling the valve to check for abnormality is shown below for reference.. Firstly, hold the hexagonal section having width across flats of 22 mm with a vise lightly. Loosen and remove the plug (3) with an Allen wrench of 8 mm. Remove the spring (4). Then push in the anti-cavitation valve (1) from the seat side while taking care not to damage the seat section. Pull out the O-ring (6) and backup ring (5) from the side from which the plug (3) was removed while taking care so that the rings are not damaged by the internal thread of the body (2).

Relief valve (Code: RV) Disassembly of overpressure relief valve (Code: ORV) NOTICE: Since the overload relief valve is essential for the performance and safety and the resetting of the pressure is very difficult, replace it with the new assembly when an abnormality is detected. For reference, how to disassemble for checking the abnormality is shown below. First, hold the body (5) with a vise at the hexagonal section of the opposing flat, 22. Loosen and remove adjusting screw (7) with allen wrench of 4 mm. Take out spring (9), the poppet (6) and spring guide (16) with tweezers, etc. Then, loosen and remove plug (4) with spanner of 19 mm, and the remaining parts can be taken out at the same time. And take out socket 1, piston ( 3), spring (10) and pressure regulating valve ( 2) in order.

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Hydraulic systems - Main control valve

Stacked control valves - Pre-assemble Precautions when assembling NOTICE: Observe the following for safety. 1. The unevenness of tightening torque and the contamination by dust during assembly may cause a failure. And observe the tightening torque specified in the description. 2. When assembling, check up on the valve construction drawing, identify the number of part, and ensure that there is no installation error and omission of part, etc. 3. After cleaning the parts required to use with cleaning solvent, immerse them in hydraulic oil as required and reassemble them. 4. Before applying LOCTITEÂŽ, clean and decrease the surface sufficiently, and apply it to two threads. (Over application may cause a malfunction due to the squeezing out.)

Precautions when fitting seals NOTICE: Observe the following for safety. 1. Replace seals with new ones when assembling. 2. Ensure that seals are free from deformation and flaw coming about when handling them. 3. Apply grease or hydraulic oil to the seals and seal fitting section to make the sliding smooth, unless otherwise specified. 4. Do not stretch the seals too much. Otherwise they may be permanently deformed. 5. Pay attention not to roll the O-ring when fitting. Because it is difficult for the twisted O-ring to be restored naturally after fitting, and it may cause oil leakage.

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Hydraulic systems - Main control valve

Stacked control valves - Assemble 1. Assembling the main frame of the switching section. Put all sections of main frame in order as shown in table directing the actuator port downward. Mark

Section (block)

JAA10 SR GE UO TP FY FZ CX XD BR EO KE VF

Dozer Slewing P3 inlet • travel straight Arm Service B/Swing Travel right P1, P2 inlet Travel LH Boom Boom lock Bucket NOTE: The symbols are engraved on the upper surface of the main frame of the switching section (actuator port face). NOTICE: Then, check that the mating surface of the main frame of each switching section is free from dust, etc. and the O-ring is securely fitted in the groove. And, insert four tie bolts (18) through the main frame of the switching section from the side, and tighten four M8 lock nuts (19) to the specified torque with socket wrench of 13 mm (1 in). Tightening torque = 16.7 - 17.7 N·m (12.3 - 13.1 lb ft) Observe the specified torque. When the lock nut is not tightened to the torque other than specified, it may cause a distortion and oil leakage of the main frame. At this time, don’t tighten the lock nuts at a time, but tighten four lock nuts to make uniform in several times. Tighten the lock nuts making the upper and lower, and right and left sides uniform with a plastic hammer, etc. following the sketch drawing, or make them uniform with press, etc. after tightening. 2. Plug in the bottom of boom lock valve section. Put it on work bench directing the actuator port of the valve downward. Fit the O-ring (7) securely to the counterbore in the middle of the boom lock valve section. Tighten plug (18) to the specified torque with Allen wrench of 6 mm . Tightening torque = 9.8 N·m (7.2 lb ft)

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Hydraulic systems - Main control valve

3. Assembling load check valve Put the load check valve of the valve on the work bench directing the actuator port upward. A. Sections other than travel, P3 supply, boom lock valve and service. Place load check valve (6) in the hole at the center of the valve in normal condition (direct the cap section downward), and check that it is placed in at the center. Fit spring (7) on the guide of the load check valve. Tighten the plug by hand so that the guide of the load check valve can be fitted on the guide of plug (9), and the spring can be in place. NOTICE: Then, check that O-ring (8) is fitted on the plug. Screw in with a certain amount, and tighten it to the specified torque with spanner of 19 mm (or socket wrench). Tightening torque = 39.2 N·m (28.9 lb ft) B. Travel, P3 supply, boom lock sections. Place the load check valve in the hole at the center of the valve in the normal direction (direct the cap section downward), and check that it is placed in at the center. Apply grease to the spring (4) and fit the plug in the guide. NOTICE: Then, ensure that the O-ring (5) is fitted on the plug (6). Tighten the plug by hand so that the guide of the load check valve installed on the main frame of the switching section can be fitted on the guide of the plug after checking that the check valve spring does not drop even when the plug is reversed up and down in this condition. Screw in with a certain amount, and tighten it to the specified torque with spanner of 19 mm (or socket wrench). Tightening torque = 39.2 N·m (28.9 lb ft) Assemble it paying attention to the correct position where two types of the load check valve are installed. 4. Assembling RV and ORV NOTICE: Tighten the RV and ORV to respective port for installation to the specified torque. Tightening torque = 39.2 N·m (28.9 lb ft) Observe the specified torque. When the respective valve is not tightened to the torque other than the specified, it may cause a distortion and oil leakage of the connection. Since the pressure settings of RV and ORV on each places differ, install them on the position as they were in order not to make a mistake referring to the tags attached when disassembling.

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Hydraulic systems - Main control valve

5. Assembling spool assembly A. In case of hydraulic pilot switching type. Insert respective spool assembly in the spool holes of the main frame of the switching section paying attention to the positions and directions so as not to make a mistake, after checking that respective spool assembly and the spool holes of the main frame of the switching section are free from dust, etc. and also O-ring (7) is securely fitted on the bottom of the flange of the main frame of the switching section (2 places before and after the main frame of the switching section). Then, apply a slight hydraulic oil to the spool before insertion. And, don’t force the insertion of the spool due to the difficulty to getting in, or it may cause malfunction, etc. Next, check that the spool moves smoothly by getting it in and out several times by hand, and be sure that there are no unsmooth movements or catching. Where there is no above feeling of the physical disorder, replace the set of the spool assembly and the main frame of the switching section. Install the pilot cover (9) on the flange section of the main frame of the switching section from the spring side of the spool assembly securely, and install it on the main frame of the switching section by tightening washer screw (10) with Allen wrench of 4 mm . Tightening torque = 5.9 - 6.9 N·m (4.4 - 5.1 lb ft) Fit the flange section on the opposite end of the main frame of the switching section so that pilot cover (8) snaps into the flange section of the main frame of the switching section after checking that O-ring (7) is placed in, and then install it on the main torque of the switching section with flange screw (10) tightening with Allen wrench of 4 mm (0.2 in) to the specified torque. Tightening torque = 5.9 - 6.9 N·m (4.4 - 5.1 lb ft) B. In case of manual switching, Insert respective spool in the spool holes of the main frame of the switching section paying attention to the position and direction after checking that respective spool assembly and the spool holes of the main frame of the switching section are free from dust, etc. NOTICE: Then, don’t force the insertion of the spool due to the difficulty to getting in, or it may cause malfunction, etc. Next, check that the spool moves smoothly by getting it in and out several times by hand, and be sure that there are no unsmooth movements or catching. And, install end cover (11) on the main frame of the switching section from the spring side of the spool assembly with screw (12) tightening with Allen wrench of 4 mm . Tightening torque = 5.9 - 6.9 N·m (4.4 - 5.1 lb ft) Do not tighten all screws at one time, but tighten them slightly and alternately several times so that they are uniformly tightened. And, fit O-ring (3), dust wiper (4) and oil seal retainer (5) in order on the spool prevented from the opposite end of the main frame of the switching section, and tighten the screw (10) with Allen wrench of 4 mm. Tightening torque = 5.9 - 6.9 N·m (4.4 - 5.1 lb ft) At this time, pay attention to the direction of the dust wiper (direct the lip outwards). Do not tighten the screws at one time, but tighten 2 socket bolts slightly so that oil seal presser is inserted in parallel. 47574272B 24/03/2014

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Hydraulic systems - Main control valve

C. In case of P3 supply and independent travel spool Ensure that the independent travel spool, piston and spool hole for the main frame of switching section are free from dust, and that the O-rings (9) and (15) are securely fitted in the flange bottom of the main frame of the P3 supply section (three places in front and back of the main frame of supply section). Then install the piston (14) in the flange section (the side of two O-ring grooves) of the main frame. Insert the socket bolts (20) to the pilot body assembly (16) - (19) to fix it temporarily to the main frame. NOTICE: At this time, roughly adjust the vertical and horizontal orientations of the pilot body against the main frame. Tighten three socket bolts with an Allen wrench of 4 mm (0.2 in) to the specified torque equally. Tightening torque = 5.9 - 6.9 NÂˇm (4.4 - 5.1 lb ft) Apply a small amount of hydraulic oil to the independent travel spool (2) and insert it through the spool hole opposite to the side where the pilot body assembly was installed, without mistaking front and rear orientation. Do not use excessive force to push in the spool if it is sticking. Then install the spring seat (3) and spring (4). Further fit the pilot cover (10) in the flange section of the main frame securely, and tighten the sems-bolt (11) with an Allen wrench of 4 mm (0.2 in) at the specified torque to fix the install the cover to the main frame. Tightening torque = 5.9 - 6.9 NÂˇm (4.4 - 5.1 lb ft)

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Hydraulic systems - Main control valve

6. Assembling lock valve If the lock valve became abnormal, replace it with new assembly. The assembling procedures described below are only for reference after disassembling to investigate the cause for abnormality. At first, fix the lock valve cover (1) with a vise at the side faces other than the port face. After fixing, insert the piston A1 (14) into the bore on piston guide (13) paying attention to its direction. Then insert the piston B (15) into the bore on the lock valve cover paying attention for its direction. After that, tighten the bush (17) with 26 mm wrench (or socket wrench) to the specified torque. Tightening torque = 58.8 - 68.6 N·m (43.4 - 50.6 lb ft) NOTICE: At that time, confirm the fact that the O-ring (16) has been surely installed to the bushing stopper. If the pistons ( A1 and B) are difficult to insert, do not try to insert them by force. It may lead to malfunction. After the insertion of pistons ( A1 and B), confirm smooth movement of them by taking them in and out with hand for several times. If the movement is not so smooth, replace the pistons ( A1 and B) to new ones together with the lock valve cover as assembly. After setting the ø 7 mm (0.28 in) steel ball to the place, tighten up the ball retainer (19) at the specified torque. Tightening torque = 7.8 - 9.8 N·m (5.8 - 7.2 lb ft) Now confirm that the O-ring (12) has been securely installed to the ball stopper. After confirmation for the fact that the flat O-ring has been surely installed to the inserting side of lock valve of lock valve body, set the lock valve assembly (2), (8), (11) and needle valve ( 10), and insert it into the bore for lock valve. Then aligning two positioning pins (9) on the lock valve cover with the bores on the lock valve body, slowly press the lock valve cover until getting touch with the lock valve body. Tightening torque = 9.8 - 10.8 N·m (7.2 - 8.0 lb ft) At that time, confirm that the needle valve ( 10) is surely placed on the seat inside the lock valve cover. Then tighten the socket bolts (20) with the 5 mm . Allen wrench to the specified torque. At the tightening, make sure to tighten up two socket bolts alternatively so that the lock valve cover does not incline.

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Hydraulic systems - Main control valve

7. Assembly pf pressure relief valve and overpressure relief valve. The relief valve is essential for the performance and safety, and it is very difficult to reset the pressure. Therefore, in case of the abnormality, replace it with a new assembly. The assembling procedures described below are only for reference after disassembling to investigate the cause for abnormality. First, place spring guide (16) in adjusting screw (7) and then place spring (9) in. Then, shake the adjusting screw lightly and be sure that the interference of spring guide (16) and spring (9) is sufficiently ensured. If the interference is insufficient, spring (9) pops out or the protrusion from adjusting screw (7) becomes larger. Thereafter fit poppet (6) in plug (4) and tighten adjusting screw (7) spring guide (16), spring (9) are already fitted lightly. At that time, tighten lock nut M14 (8) lightly. And place spring (10) and piston (3) in poppet (2), and place it in socket (1). And tighten body (5) and plug (4) to the specified torque after checking that piston (3) is inserted in the hole of the top end of plug (4). Tightening torque = 58.8 NÂˇm (43.4 lb ft) And adjust the pressure by adjusting screw (7) with Allen wrench of 4 mm , and tighten lock nut M14 (8) to the specified torque. Tightening torque = 19.6 NÂˇm (14.5 lb ft) Assemble the relief valves in the reverse procedure of the disassembly paying attention to the direction and order and observing the specified torque. Failure to do so may result in oil leakage or breakage. 8. Assembling anti cavitation valve The anti cavitation valve is essential for the performance and safety, so in case of abnormality replace it with a assembly. For reference, the procedure for disassembly and assembly is shown below: First, place anti cavitation valve ( 1) in body ( 2), and place spring (4) in it. Then tighten the plug to the specified torque. Tightening torque = 58.8 NÂˇm (43.4 lb ft) Assemble the anti cavitation valve by the reverse procedure of the disassembly paying attention to the direction and order and observing the specified torque. Failure to do so may result in oil leakage or breakage.

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Hydraulic systems - Main control valve

Stacked control valves - Service instruction Maintenance standard Parts inspection Part name

Inspection item

Criterion and corrective action 1) Replace it when there is flaw on the following section. • Sliding section against the spool, especially land section where the hold pressure is applied.

Main frame of switching section

Spool

Load check valve

Around spring

Around of seal of spool

Pressure relief valve

1) Existence of scratch, rust and corrosion • Seal pocket section the spool is placed in or flange section. • Seal section of the port in contact with O-ring. • A damaged seat section of the pressure relief valve and of the overpressure relief valve may cause malfunction, etc. 1) Replace it when there is scratch on the peripheral 1) Existence of scratch, rust and corrosion sliding surface 2) Insert spool in the hole of the main frame of the switching section, stroke it 2) In case the spool is not smooth, repair or replace it. while rotating. 1) In case there are flaws and scratches on the seat 1) Damage of load check valve and spring section, repair or replace it. 2) Insert load check valve in plug and 2) When it moves smoothly, normal, but if it moves experimentally operate it. unsmoothly, replace it. 1) Rust, corrosion, deformation and 1) Replace it when the movement is unsmooth or breakage of spring, spring seat, plug, and there is damage causing poor durability. cover 1) Hardening, deformation and flaw of 1) Replace O-ring 2) Deformation and flaw of dust wiper 2) Replace 3) Rust, corrosion and deformation of oil 3) Repair or replace seal retainer 1) Rust on outer surface 1) Replace 2) Contact surface of valve seat 2) In case there are flaw and dent, replace it. 3) Spring in abnormal condition 3) Replace 4) O-ring, backup ring 4) Replace all parts, as a general rule.

Cause of failure and corrective action 1. When abnormal condition is detected, check on the control valve, pump, cylinder, and motor for abnormality or failure on the circuit. For that, measure the pilot pressure, delivery pressure of the pump, load pressure, etc. And when a part of them is required to disassemble for checking, follow the procedure of the disassembly and assembly in the above description. 2. Since dust is very harmful for hydraulic equipment, pay attention to the dust proof. When a part of them is required to disassemble, before starting the work take a measure for dust protection. 3. Handle the movable section carefully. Even if there is a slight flaw, repair it with oil stone or replace it. When replaced, clean them. 4. Handle O-ring, etc. carefully in order not to damage the gasket surface. These flaws will cause oil leakage.

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Stacked control valves - Troubleshooting NOTE: * In case of abnormality marked with *, do not fail to replace with the new relief valve assembly. Problem Possible Cause Each attachment does not Malfunction of relief valve function, or the actuation is slow. (Poor power) Or there is no response • Dust caught between pressure regulating valve and seat * • Dust caught between poppet and seat * • Pressure regulating valve is stuck * • Breakage or permanent set in fatigue of spring * • Loosen of adjusting screw

When spool is placed on the neutral position, the natural drop of the cylinder is large

Correction Measure the pressure of relief valve

• Replace the assembly * • Replace the assembly * • Replace the assembly * • Replace the assembly *

• Readjust it, and tighten the lock nut to the specified torque Dust caught between the main frame and Disassemble and clean it. In case of severe spool, or stuck flaw, replace the main frame and spool The space between the main frame of the Replace spool switching section and the spool is too large

The spool is not returned to the neutral position completely • Dust caught between the main frame and spool, or stuck • Breakage or permanent set in fatigue of spring Malfunction of ORV Refer to the description marked with * Malfunction of lock valve • Dust caught in the seat section of the lock valve or needle valve • Stick of the lock valve or needle valve • Dust caught in the throttle of the lock valve When the cylinder is set • Malfunction of load check valve to the raise position, the Dust caught between load check valve and cylinder moves downward main frame reversely when starting the operation • Load check valve is stuck • Breakage and permanent set in fatigue of spring

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Measure pilot secondary pressure • Disassemble and clean, or when stuck, replace the main frame and spool together • Replace spring Measure the pressure of ORV Refer to the description marked with * Replace with a new lock valve section assembly (including the lock valve main body)

• Disassembly and cleaning. In case of the severe damage, replace the main frame and load check valve together

• Ditto • Replace spring * In case of abnormality marked with *, do not fail to replace with the new relief valve assembly.

Hydraulic systems - Main control valve

Relief valve - Troubleshooting NOTE: The relief valve is essential for the performance and the safety, and it is difficult to reset the pressure other if there is no facility in service shop, so when abnormality occurs, don’t fail to replace the assembly. The handling method is for reference, replace the assembly as a rule. Problem Pressure does not rise

Relief pressure is unstable The relief pressure is not within the limit of set values

Oil leakage

Possible Cause Correction The pressure adjusting valve of each relief • Check that the engagement valve of valve, poppet and piston are stuck, kept respective valve doesn’t get matters open, or got caught dust in the seat section caught in it of the valve • Each part slides freely • Clean all parts completely The adjusting valve of respective valve is • Replace the damaged part damaged, or the piston is stuck to the pop- Clean all parts completely • pet • Remove flaw on the surface Wear due to dust Disassemble and clean it Lock nut and adjusting screw are loose • Breakage and permanent set in fatigue of spring Malfunction of (RV) and (ORV) Damage on each seat section. Wear of O-ring

Adjusting pressure • Replace spring

Measure the pressure of RV and ORV Replace the worn or damaged part. Check that respective part move smoothly before installing Respective part is stuck due to dust en- Check that it is free from scratch, score and tered foreign matter before installing

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Index Hydraulic systems - 35 Main control valve - 359 Main control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Main control valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Main control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Relief valve - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Stacked control valves - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Stacked control valves - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Stacked control valves - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Stacked control valves - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Stacked control valves - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Stacked control valves - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Stacked control valves - Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Stacked control valves - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Stacked control valves - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Stacked control valves - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Stacked control valves - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Hydraulic systems - 35 Hydraulic hand control - 355

CX35B CX39B

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Contents Hydraulic systems - 35 Hydraulic hand control - 355

TECHNICAL DATA Hand control General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Hand control Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Hydraulic hand control Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hand control Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Hand control valve Prepare – Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remove – Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install – Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DIAGNOSTIC Hand control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Hand control - General specification

TULI12EXN6132GB

A. The adjust nut (opposing flats: 22): fix adjust nut by means of spanner (opposing flats: 22) when the lever is installed. Then tighten the mating lock nut to 40.7 - 41.3 NÂˇm (30.02 - 30.46 lb ft) OA. OT. PR. SP. T.

Operation angle (degree) Operation torque (Nm) Push rod stroke (mm) Secondary pressure (MPa) Tightening torque: 6- PF 1/4 Tightening torque = 27.4 - 31.4 NÂˇm (20.21 - 23.16 lb ft) Maximum primary pressure Delivery Weight

6.9 MPa (1001 psi) 15 l/min (4 US gpm) 1.6 kg (4 lb)

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Hydraulic systems - Hydraulic hand control

Hand control - Special tools No. a. b. c. d.

Name Torque wrench Screw driver (-) Screw driver (+) Wrench

Observations 15 - 100 NÂˇm (11 - 74 lb ft) W = 2-3, 4-5 Drawing 22 mm and 32 mm

Jig For disassembling and assembling the joint (301).

TULI12EXN4319BA

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Hydraulic systems - Hydraulic hand control

Hand control - Component identification

TULI12EXN4162GA

1. Apply LOCTITE® 277 (part of slant line) 2. Apply grease on top 3. Secondary pressure adjusting shims No. 101. 151. 201. 211. 212–1. 212–2. 241–1. 241–2. 301.

Name Housing (Qty. 1) Plate (Qty. 1) Spool (Qty. 4) Cap (Qty. 4) Push rod (2) (Qty. 2) Push rod (2) (Qty. 2) Spring (Qty. 2) Spring (Qty. 2) Joint M14 (1) (Qty. 1)

No. 213. 214. 216–1. 216–2. 217. 221. 302. 312. 501. 47574272B 24/03/2014

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Name Seal (Qty. 4) O-ring (Qty. 4) Spring seat (Qty. 2) Spring seat (Qty. 2) Washer 2 (3) (Qty. 4) Spring (Qty. 4) Disk (Qty. 1) Adjusting nut M14 (Qty. 1) Boot (Qty. 1)

Hydraulic systems - Hydraulic hand control

Port No. 1. 2. 3. 4.

Right pilot valve Operation Bucket digging Lower boom Bucket dump Raised boom

Port No. 1. 2. 3. 4.

Left pilot valve Operation Slewing left Free arm Slewing right Operating arm

TULI12EXN7217AA

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Hydraulic systems - Hydraulic hand control

Hand control - Dynamic description Operation Lever in neutral position. In this case, the force of the secondary pressure setting spring (241) that determines the output pressure of the pilot valve is not transmitted to the spool (201). Accordingly, the spool (201) is pushed up by the return spring (221) and spring seat (216) permitting the output port 2, 4 to connect with the tank port T. This makes the output pressure equal to the tank pressure.

TULI12EXN4164BB

TULI12EXN4165BB

When the Lever is tilted. When the lever is tilted, the push rod (212) strokes. The spool (201) and spring seat (216) moves downward to make the port P to connect with the port 2, 4. With the result that the oil of the pilot pump flow out to the port 2, 4, to produce a pressure.

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The lever being held. When the lever is tilted till the pressure of the port 2, 4 rises to an oil pressure corresponding to the set spring force, the hydraulic pressure is balanced with the spring (241) force. And when the pressure of the port (2), 4 rises above a set pressure, the port P are closed and the port T are opened. When the pressure of the port 2, 4 falls below a set pressure, the port P are caused to open and the port T are caused to close, thus holding the second pressure constant.

TULI12EXN4166BB

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Hydraulic systems - Hydraulic hand control

Hydraulic hand control - Prepare Since the same method applies to the right-hand and the left-hand pilot valve, only the method for the right-hand is described. 1. Disconnect the negative side terminal of the battery. 2. Release the residual pressure in the circuit and the pressure in the hydraulic tank. 3. Remove the right and left control boxes and the control panel. 4. Loosen sems-bolts (10) to remove the cover assembly (18) and (19). : Torx driver

TULI12EXN4964AB

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Hydraulic systems - Hydraulic hand control

Hydraulic hand control - Remove 1. Disconnect each hose at the position marked with * and attach a plug and tag to facilitate installation. 2. Shift the boot and remove four capscrews (A2). : 10 mm 3. Remove the pilot valve (A1). TK. Tank

TULI12EXN4965AB

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Hydraulic systems - Hydraulic hand control

Hydraulic hand control - Install 1. Install the pilot valve in reverse order of the removal to the following tightening torque: • Attaching sems-bolts (10). : Torx driver Tightening torque = 0.27 N·m (0.20 lb ft) • Installing hoses, etc. 1.

Bucket (H)

Bucket (R)

Boom (H)

Boom (R)

Slewing (L)

Slewing (R)

Arm (H)

Arm (R)

R. Right side L.

Left side

TULI12EXN4966BB

Tightening torque Thread size PF 1/4 PF 3/8

Spanner used 19 mm 22 mm

Fitting type O-ring 36.3 N·m (26.77 lb ft) –

NOTE: Take care of the tightening torque as the pilot valve is made of aluminum. 2. Pressurize the hydraulic tank. 3. Operate the attachment to check the performance. 4. Check the tank and piping for oil leakage and oil level.

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30° flare type fitting 29.4 N·m (22 lb ft) 49 N·m (36 lb ft)

Hydraulic systems - Hydraulic hand control

Hand control - Prepare General cautions for disassembly 1. Since all the parts are very precisely manufactured, carefully handle them without causing collision with each other or dropping. 2. Perform the work carefully without hammering or using excessive force even if the part is sticking. Otherwise burrs or damage may be produced, thus causing oil leaks and performance losses. 3. When leaving the parts in the disassembled condition, always take rust preventive and dust protective measures. Otherwise rust may be produced on other parts due to humidity or dust.

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Hydraulic systems - Hydraulic hand control

Hand control - Disassemble 1. Remove the handle lever (1) assembly and boot (2) from the casing (101). 2. Clean the pilot valve with white kerosene. â&#x20AC;˘ Screw a blind plug in each port in advance. 3. Hold the pilot valve with a vise by applying a copper or lead sheet.

TULI12EXN4320AB

TUPH12EXN4321AA

TUPH12EXN4322AA

TUPH12EXN4323AA

4. Apply wrenches to the adjusting nut (312) and the disk (302) across the flats to loosen and remove them.

5. Turn the joint (301) counterclockwise with a jig to loosen. NOTICE: When pulling off the joint, be careful that the joint is no sooner loosened than the plate (151), plug (211) and push rod (212) may pop up if the return spring (221) is too strong.

6. Remove the plate (151).

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Hydraulic systems - Hydraulic hand control

7. If the return spring (221) is not strong enough, use a minus screwdriver to extract the plug (211) which remains in the body (101) due to the resistance to the O-ring’s sliding. • Apply the tip of the flat screwdriver to the external groove of the plug (211) while preventing damage to the plug due to eccentric load. NOTICE: Make sure that the plug (211), when it opens, does not pop up due to the spring return force (221).

TUPH12EXN4324AA

TUPH12EXN4325AA

TUPH12EXN4326AA

TUPH12EXN4327AA

8. Remove the push rod (212), plug (211), pressure reducing valve section assembly, and return spring (221) from the casing (101). • Record the relation between the casing hole positions and these parts.

9. In order to disassemble the pressure reducing valve, shift the spring seat (216) laterally while pushing in the spring seat (216) to make the secondary pressure spring (241) deflect, and remove the valve from the spool (201) through the larger hole. • Be careful not to damage the surface of the spool (201). • Do not push down the spring seat (216) by more than 6 mm (0.24 in).

10. Separate the spool (201), spring seat (216), secondary pressure spring (241), and washer 2 (217). • Handle these parts as an assembly until assembling.

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Hydraulic systems - Hydraulic hand control

11. Pull out the push rod (212) from the plug (211).

TUPH12EXN4328AA

12. Remove the O-ring (214) and seal (213) from the plug (211). Remove the seal (213) using a small flat screwdriver 13. Cleaning parts 1. Clean the parts in a rough cleaning container containing white kerosene (rough cleaning). • Immerse the parts in the kerosene to facilitate the removal of dust and oil. Otherwise the parts may be damaged due to using excessive force. • Check the white kerosene for contamination and use clean one. Otherwise, the parts may be damaged, and cause a reduction of performance after reassembly. • Do not dry the parts with compressed air. Otherwise, parts may be damaged due to dust or humidity or rust. 2. Put a part in a finish cleaning container containing white kerosene and turn the part slowly to sufficiently clean the part including its interior (finish cleaning). Dry parts by wiping off kerosene with clean rag. 3. Rust prevention of parts. agent to the parts.

Apply rust preventive

• Do not leave the parts without applying rust preventive agent. Otherwise rust may be produced, leading to malfunction after assembly.

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TUPH12EXN4329AA

Hydraulic systems - Hydraulic hand control

Hand control - Pre-assemble General cautions for assembling work 1. Most of the general precautions for assembly operations are similar to those for assembly operations. 2. Remove metal chips or foreign substances from all the parts and ensure that the parts have no burrs or flaw prior to assembly. Remove burrs or flaws, if present, with a hone. 3. Replace the O-rings and backup rings with new ones in principle. 4. Be careful not to damage the O-rings and backup rings when fitting them. (Apply a small amount of grease to fit them smoothly.) 5. Apply grease to the parts to be installed in order to prevent them from dropping. 6. Tighten the screws to the tightening torque specified. Check the tightening torque by means of a torque wrench. 7. After finishing the assembly, screw blind plugs in all the ports to prevent dust intrusion.

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Hand control - Assemble 1. Insert the washer (217), secondary pressure spring (241), and spring seat (216) to the spool (201) in this order.

TUPH12EXN4330AA

TUPH12EXN4331AA

TUPH12EXN4332AA

2. Shift the spring seat (216) laterally while pushing in the spring seat (216) to make the secondary pressure spring (241) deflect, and install the valve to the spool (201) through the larger hole. â&#x20AC;˘ Do not push down the spring seat by more than 6 mm (0.24 in).

3. Install the return spring (221) into the casing (101). Install the pressure reducing valve assembly into the casing (101). â&#x20AC;˘ Install these parts into the position before disassembling.

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4. Insert the O-ring (214) and seal (213) into the plug (211). • Direct the lip of the seal (213) as shown in Fig. 5

TUPH12EXN4333AA

TULI12EXN4337AB

TUPH12EXN4334AA

TUPH12EXN4335AA

5. Install the push rod (212) into the plug (211). • Apply hydraulic oil to the surface of push rod (A).

6. Install the plug assembly into the casing (101). If spring return is not strong (221), the assembly may stop due to sliding resistance of the O-ring (214). • Do not use excessive force with the spool (201) inclined. Otherwise, the hole in the valve body may be damaged.

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7. If spring return (221) is too strong, install four assemblies at the same time using the plate (151) and temporarily fasten with the joint (301). NOTICE: Be careful to popping up of the plug assembly and plate (151).

TUPH12EXN4336AA

TUPH12EXN4338AA

8. Install the plate (151). Install the joint (301) to the casing (101) and tighten the joint to the specified torque using a jig.

9. Install the disk (302) into the joint (301). Then install and tighten the adjusting nut (312) to the specified torque while holding the disk (302) with a wrench. â&#x20AC;˘ Do not change the position of the disk (302) during tightening. NOTICE: Screw in until the disk contacts with four push rods (212) equally. Carefully adjust the screwing position of the disk (302) because excessive screwing may result in secondary pressure generation at the neutral position of the lever, leading to malfunction of the actual machine. TUPH12EXN4339AA

TUPH12EXN4340AA

10. Apply grease to the rotating section of the joint (301) and the push rod (212). 11. Install the handle lever assembly and boot to the casing (101).

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Hand control - Service instruction Piece

Quantity of liquid lost

Spool

Standard value Observations Replace with a complete set of pilot valve Condition: when the amount of leakage reaches more than 1000 cm³ (61 in³) or 2000 cm³ Primary pressure: 2.94 MPa (426.4 psi) Oil viscosity: 23 mm2/s (122 in³) at the neutral position of the handle or during operation, respectively Replace with a whole series of pilot valves The wear condition to the left is considered if the sliding section is worn by more than to correspond to the above amount of 10 μm, if compared to the non-sliding leakage section Replace when a wear amount of the tip is more than 1 mm (0.0394 in)

Push rod

Unnecessary play in operation section

Stable operation

Replace when a play more than 2 mm (0.1 in) due to wear and so on is found on Adjust the play generated in the the disk (302) or joint section (301) of the tightening/loosening section operation section Replace with a complete set of pilot valve when abnormal noise, hunting or primary pressure drop is generated during operation and the trouble cannot be remedied according to page Hand control - Troubleshooting (35.355)

NOTE: Replace seal such as O-ring with new ones after every disassembly.

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Hand control valve - Prepare â&#x20AC;&#x201C; Solenoid valve 1. Unlock and open the right upper cover (1). 2. Remove the right lower cover (4).

TULI12EXN6281BB

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Hand control valve - Remove â&#x20AC;&#x201C; Solenoid valve 1. Disconnect all the hoses connected to the solenoid valve (B1). Then attach a plug and a tag recording the connecting port to each of their openings. â&#x20AC;˘ Item (B33) is a drain hose for the hydraulic oil tank. When disconnecting this hose, take care of oil leakage. 2. Disconnect two connectors connected to the main harness. 3. Removing solenoid valve. Loosen two M8 X 20 capscrews (B5) to remove the solenoid valve (B1). : 13 mm

SMIL13MEX0376BB

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Hand control valve - Install – Solenoid valve 1. Install the solenoid valve in reverse order of the removal. 2. Tighten the fittings at the following torque: Piece B5 B34 C15

Name Screw M8 Screw M10 Screw M10

Tool 13 mm 17 mm 17 mm

Torque 33.3 N·m (24.6 lb ft) 65.7 N·m (48.5 lb ft) 21.5 N·m (15.9 lb ft)

Thread size PF 1/4 PF 3/8

Spanner used 19 mm 22 mm

O-ring type fitting 36.3 mm (1.4 in) 73.5 mm (2.9 in)

30° flare type fitting 29.4 N·m (21.7 lb ft) 49 N·m (36.1 lb ft)

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Hand control - Troubleshooting Problem Possible Cause Secondary pressure does Primary pressure is insufficient. not rise Springs (241-1), (241-2) are broken or fatigued. Clearance between spool (201) and valve body (101) is abnormally large. Play of handle portion is too much. Secondary pressure is unstable

Secondary pressure is high

Correction Secure primary pressure. Replace with new ones. Replace assembly.

Sliding parts are caught.

Disassembly and reassembly or replace handle portion. Correct.

Tank line pressure varies. Air has contained into pipeline. Tank line pressure is high.

Return directly to oil tank. Release air. Return directly to oil tank.

Sliding parts are caught.

Correct.

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Index Hydraulic systems - 35 Hydraulic hand control - 355 Hand control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Hand control - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hand control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hand control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hand control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hand control - Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hand control - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hand control - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hand control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hand control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Hand control valve - Install â&#x20AC;&#x201C; Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Hand control valve - Prepare â&#x20AC;&#x201C; Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hand control valve - Remove â&#x20AC;&#x201C; Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hydraulic hand control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic hand control - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic hand control - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Hydraulic systems - 35 Hydraulic foot control - 356

CX35B CX39B

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Contents Hydraulic systems - 35 Hydraulic foot control - 356

TECHNICAL DATA Pedal control General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Pedal control Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Pedal control Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIAGNOSTIC Pedal control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Pedal control - General specification

TULI12EXN4167GB

1. 4- M8 x P1.25 Tightening torque = 15.2 - 18.2 N·m (11.2 - 13.4 lb ft) 2. 2- PF 1/4 Tightening torque = 27.4 - 31.4 N·m (20.2 - 23.2 lb ft) 3. 4- PF1/4 Tightening torque = 27.4 - 31.4 N·m (20.2 - 31.4 lb ft) Model (type) Maximum primary pressure Delivery Weight

PVD6P4001 6.9 MPa (1001 psi) 10 l/min (2.64 US gpm) 3.9 kg (8.60 lb)

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Performance Characteristics â&#x20AC;˘ Required operating torque (damper) 11 - 14.8 NÂˇm (8.1 - 10.9 lb ft). Push rod speed 0.0275 m/s (0.0902 ft/ s). (the actual required torque is found by adding the operating torque of the damper in the valve operating torque in the left operating lines) SP. Secondary pressure (MPa) OT. Operation torque (Nm) PR. Push rod stroke (mm) OA. Operation angle (degree) TULI12EXN6138AA

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Pedal control - Special tools Special jig for removal of bushing.

TULI12EXN4343AA

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Pedal control - Sectional view

TULI12EXN4169GA

Torque

No. 101 102 201 202 203 210 211 212 213 214 217 218 224

Name Housing Casing (damper) Cover Plug (1) Grease cup Seal O-ring O-ring O-ring Push rod (1) Shim Spring seat Piston 47574272B 24/03/2014

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Qty. 1 1 2 4 4 4 4 4 2 4 4 4 4

Hydraulic systems - Hydraulic foot control

Torque 29.4 N路m (21.7 lb ft) 6.9 N路m (5.1 lb ft) 8.8 N路m (6.5 lb ft)

6.9 N路m (5.1 lb ft)

No. 225 251 252 261 271 301 311 313 324 335 336 413 414 420 471 472 501

Name Steel ball Cap Cap O-ring Edge bolt Spool Spring seat Washer Spring Spring Spring Cam shaft Bushing (1) Cam Steel ball Set screw Boots (bellows)

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Qty. 12 3 2 3 4 4 4 4 4 4 4 2 4 2 4 2 2

Hydraulic systems - Hydraulic foot control

Pedal control - Dynamic description Reducing valve When the lever is at neutral position, the spool is pushed up by the return spring (335) through spring seat (311), and is positioned at the neutral position in the right figure. Therefore, the pressure at delivery ports 1 and 2 is equivalent to that of port T because the delivery port is connected to only port T following the switched spool condition.

TULI12EXN4170BB

TULI12EXN4171BB

In case where the lever is tilted. By rotating cam (420) in clockwise, push rod (214) on the port 1 side is pushed down, and the spool moves down by way of spring seat (311), spring (324) for setting the secondary pressure, shim (217) and washer (313) and consequently the port P is connected to the port 1 and the supplied oil from the pilot pump flows into port 1 and generates pressure. When the pressure at port 1 rises to the pressure equivalent to the spring pressure for the secondary pressure setting set by tilting the control section, the hydraulic pressure applied to the spool balances the spring force, and maintains port 1 at a constant delivery pressure. The spool on the port 2 side is held at neutral position, and the return oil from the control valve is discharged through port T. A. B.

Neutral position Full stroke

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Dumping mechanism In case of neutral position, push rod (214) is pushed up by dumping spring (336) through piston (224), and holds at the position shown in the figure of page Pedal control - Sectional view (35.356) Where the control section is inclined from the neutral position, by rotating the cam clockwise, the push rod on the port 1 side is pushed down, and the piston also moves down. Then, the oil in the dumping piston chamber is discharged through the orifice, and the simultaneously generated pressure produces dumping force. On the other hand, the push rod on the port 2 side moves up by the dumping spring through the piston. Then, oil is sucked from the tank into the dumping piston chamber through three ball check valves. The oil outside of the piston chamber flows out through the passage leading to port T on the casing top end.

TULI12EXN4172GB

Operation when the lever is stroked from the neutral position

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1 2 3

Cam Orifice Push rod

4 5

Piston Steel ball

When stroking from the neutral position towards the mark Ă&#x17E;, the oil in the piston chamber on the right (left) side is discharged through the orifice, and the simultaneously generated pressure produces damping force.

Where the control section is inclined in the opposite direction from the full tilting After tilting the cam clockwise fully, if it is rotated counterclockwise, the push rod on the port 2 side is pushed down and the piston moves down. Then, the same as above, the oil in the damping piston chamber is discharged through restriction of piston, and the simultaneously generated pressure produces damping force. On the other hand, the push rod on the port 1 side is moved up by the force of the return spring and damping spring. Similarly oil is sucked from the tank into the damping piston chamber through three ball check valves. And the oil in the piston chamber flows out through the passage leading from the casing top end to the tank port. That is, either tilting operation from the neutral position to the full tilting position or the full tilting position to the neutral position is designed to produce the damping force.

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SMIL13MEX0211GB

1 3

Cam Push rod

4 6

Piston Damping spring

7 8

Neutral position Full stroke

Return spring

The oil outside of the piston is ows out through the passage leading to port T on the casing top end (In operation in 횧 direction) The oil in the piston chamber is discharged through the restriction, and the simultaneously generated pressure produces the damping force. (In operation in 횧 direction) When tilting in reverse direction from the neutral position, the push rod is pushed up by the force of the damping spring. (In operation in 횧 direction) Oil in T lines is sucked in the damper chamber through three ball check valves. (In operation in 횧 direction)

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When tilting the lever from direction Ă&#x17E; to condition ( ), the piston on the left side immediately acts as a dampener. The damping force is produced on both sides constantly

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Pedal control - Prepare Precautions for disassembly and assembly 1. Disassemble and assemble the pilot valve, making sure dust, dirt etc. do not enter into it. 2. Handle parts carefully not to damage. 3. Write down the installing positions of respective part during disassembly, and assemble respective part to the position as they were before.

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Pedal control - Disassemble 1. Stop respective port ( P, T, 1, 2, 3 and 4) of the valve with plugs and clean the outer surface. 2. Fix the cleaned valve with vise. 3. Remove bellows (501) from cover (201). 4. Remove set screw (472). : 6 mm 5. Contact pry bar (Ă¸7 or less) to one end of cam shaft (413), and strike it lightly with a hammer. 6. Remove cam (420). 7. Remove socket bolt (271). : 6 mm 8. Remove cover (201). 9. Remove the casing upper assembly and fix the assembly with vise, again. 10. Pull out the push rod (214) from the plug (202). 11. Remove plug (202) with grease cup (203), packing (210) and O-ring (212). 12. Remove piston (224). 13. Remove damping spring (336) from the casing. 14. Place spring seat (218) in casing (102) with tweezers. 15. Take out steel ball (225) using magnet. 16. Fix the lower casing assembly with vise, and take out O-rings ( (211) and (213)) from casing (101). 17. Remove reduction unit valve assembly and return spring (335) from casing (101). 18. Place cover (201) on the flat bench transverse, apply bushing (414) to special jig 1, strike it lightly with hammer, and pull the bushing out. 19. To disassemble the reduction unit valve, first push the valve seat (311) diagonally, so that the spring (324) generates secondary pressure, remove the valve from the spool (301) through the bigger opening. â&#x20AC;˘ Handle the assembled unit as an assembly. 20. Separate spool (301), spring (324) for secondary pressure setting, shim (217) and washer. â&#x20AC;˘ Handle the assembled unit as an assembly. There may be assemblies where the washer is not installed. SMIL13MEX0077AA

21. Remove grease cup (203) from plug (202). 22. Remove O-ring (212) from plug (202).

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Pedal control - Assemble 1. Clean all parts before assembly, and dry them by means of compressed air. Don’t use a rag. • Repair the parts damaged when being disassembled, clean them, apply oil to the moving section, and install the same parts on the positions where they are before. • Replace every O-ring and packing with new ones. 2. Install washer (313), shim (217), spring (324) for resetting the secondary pressure, and spring seat on spool (301) in order. 3. Pass spool (301) through the larger hole of spring seat (311), push the spring seat in, and install it making the spring for the secondary pressure deflect and shifting the spring seat laterally. 4. Fix casing (101) with vise, and place spring (335) for return in casing (101). 5. Place the reduction unit subassembly described above par. 2 and 3 in casing (101). • Install them on the positions as they were before. • When placing the reduction unit subassembly in, pay attention to the spool lower end so as not to bring into contact with the corner of the casing (C).

TULI12EXN8438AB

TULI12EXN8439AB

6. Place O-rings (211), (213) in casing (101). 7. Fix upper casing (102) with vise and place the steel ball in it. 8. Place spring seat (218) in casing (102) with tweezers. 9. Place damping spring (336) in casing (102). 10. Install piston (224). 11. Place O-ring (212) in plug (202). 12. Place packing (210) in plug (202). • Pay attention to the direction when placing the packing (P) in. • Apply grease slightly before placing packing (P) in.

13. Place grease cup (203) in plug (202).

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14. Install push rod (214) on plug (202). 15. Place the push rod subassembly which is assembled by the procedures in par. 11 to 14 in casing (102). 16. Put cover (201) on the flat work bench, press bushing (414) with special jig 1, and press fit the bushing striking lightly. 17. Fix the lower cover assembly which is assembled by the procedures in paragraph 2 to 6 with vise, and install the upper cover assembly which is assembled by the procedures in paragraph 7 to 15 on it. 18. Install cover (201) on casing (102). 19. Tighten socket bolt (271) to the specified torque. 20. Install cam (420) on cover (201). 21. Insert cam shaft (413) from the outside pressing cam (420). 22. Apply LOCTITEÂŽ 241 or equivalent to the thread of socket bolt. 23. Tighten socket bolt (472) to the specified torque. 24. Incline cam (420), apply grease to the top end of push rod (214), and fill grease cup (203) of plug (202) with grease. 25. After fitting the top end of bellows (501) in cam (420), fit the lower side in the groove of cover (201).

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Pedal control - Troubleshooting Problem Possible Cause Secondary pressure does Insufficient primary pressure not rise Permanent set in fatigue of spring (324) for setting of secondary pressure The gap between spool and casing is too large The control section is loosened Secondary pressure is Sliding part is not smooth unstable Variation of pressure of tank line Air contamination in piping Secondary pressure is Pressure of tank line is high high Sliding part is not smooth Damping does not work Air is accumulated in piston chamber Sliding part is not smooth Permanent set in fatigue of damping spring (336) Gap between damping piston (224) and casing (damper) (102) is too large Malfunction of check valve

Correction Secure primary pressure Replace it with new one Replace it with complete remote control valve Replace parts of control section Repair unsmooth section Return oil to oil tank directly Bleed air by operating several times Return oil to oil tank directly Repair unsmooth section Bleed air by operating several times Repair unsmooth section Replace it with new one

Replace it with complete remote control valve Disassemble and check on check valve section Orifice of damping piston (224) is too large Replace damping piston Damping torque is heavy Sliding part is not smooth Repair unsmooth section Orifice of damping piston (224) is clogged Repair or replace damping piston

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Index Hydraulic systems - 35 Hydraulic foot control - 356 Pedal control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Pedal control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pedal control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pedal control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pedal control - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pedal control - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pedal control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pedal control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Hydraulic systems - 35 Hydraulic swing system - 352

CX35B CX39B

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Contents Hydraulic systems - 35 Hydraulic swing system - 352

TECHNICAL DATA Hydraulic swing system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hydraulic swing system Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Hydraulic swing system Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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Hydraulic swing system - General specification

TULI12EXN6163FB

Hydraulic diagram Port A B M DB PG SH

Name Main port Main port Make up port Discharge port Slewing parking brake release port Slewing parking brake pilot port

Dimensions PF 3/8

PF 1/4

G5 G6

Indicator port

PF 1/8

Port for grease piping

PT 1/8

TULI12EXN6164AA

Rotational direction: Inlet A port: CW Inlet B port: CCW (View from shaft end)

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Model (type)

Hydraulic motor

Pressure relief valve Reduction unit Weight

Displacement Delivery Parking brake torque Parking brake releasing pressure Parking brake timing Set pressure Reduction ratio

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MSG-27P-16E-17 20.7 cm³/rev (1.26 in³/rev) 20.6 l/min (5.44 US gpm) 1022 N·m (753.79 lb ft) or higher 2 - 6.4 MPa (290 - 928 psi) 2.5 - 4.9 s 20.0 MPa (2901 psi) at 20.5 l/min (5.4 US gpm) 1/15.5 38 kg (83.8 lb)

Hydraulic systems - Hydraulic swing system

Hydraulic swing system - Component identification

TULI12EXN6165FA

1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Housing (Qty. 1) Pinion shaft (Qty. 1) Collar (Qty. 1) Plate (Qty. 1) Taper roller bearing (Qty. 1) Oil seal (Qty. 1) Taper roller bearing (Qty. 1) Shim t2 (shim select) (Qty. 2) Shim t3 (shim select) (Qty. 2) Shim t4 (shim select) (Qty. 2) Shim t5 (shim select) (Qty. 2) Shim t13 (Shim select) (Qty. 2) Shim t14 (shim select) (Qty. 2) Collar (Qty. 1) Bracket (Qty. 1) Thrust washer (Qty. 3) Inner race (Qty. 3) Needle bearing (Qty. 3) Planetary gear (Qty. 3) Thrust plate (Qty. 1) Drive gear (Qty. 1) Cap (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) Housing (Qty. 1) Ball bearing (Qty. 1) Shaft (Qty. 1)

37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 48-1. 48-2. 48-3. 48-4. 48-5. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58.

Spring seat (Qty. 2) Spring (Qty. 1) O-ring (Qty. 1) Cover (Qty. 1) Ball bearing (Qty. 1) Pin (Qty. 1) Valve plate (Qty. 1) Pin (Qty. 2) O-ring (Qty. 2) Screw M12 X 30 (Qty. 5) Orifice (Qty. 1) Timer valve assy. (Qty. 1) Sleeve (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) Spool (Qty. 1) Washer (Qty. 1) Spring (Qty. 1) O-ring (Qty. 1) Cap (Qty. 1) Relief valve assy. (Qty. 2) Check valve (Qty. 2) Spring (Qty. 2) Cap (Qty. 2) O-ring (Qty. 2) Cap (Qty. 2)

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23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

Thrust plate (Qty. 1) Cylinder block (Qty. 1) Collar (Qty. 1) Spring (Qty. 1) Washer (Qty. 1) Snap ring (Qty. 1) Pin (Qty. 3) Retainer holder (Qty. 1) Retainer plate (Qty. 1) Piston assy. (Qty. 9) Disk (Qty. 1) Brake piston (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1)

59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72.

O-ring (Qty. 2) Cap (Qty. 1) O-ring (Qty. 1) Screw M12 X 30 (Qty. 2) Name plate (Qty. 1) Rivet (Qty. 2) Thrust plate (Qty. 1) Sun gear (Qty. 1) Edge bolt (Qty. 4) Planetary gear (Qty. 4) Needle bearing (Qty. 4) Inner race (Qty. 4) Thrust washer (Qty. 4) Bracket (Qty. 1)

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TULI12EXN4196FB

53-1. 53-2. 53-3. 53-4. 53-5. 53-6. 53-7. 53-8.

Body (Qty. 1) Poppet (Qty. 1) Seat (Qty. 1) Spring seat (Qty. 1) Spring (Qty. 1) Cap (Qty. 1) Set screw (Qty. 1) O-ring (Qty. 1)

53-9. 53-10. 53-11. 53-12. 53-13. 53-14. 53-15.

O-ring (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) Backup ring (Qty. 2) Backup ring (Qty. 2) Piston (Qty. 1) Locknut (Qty. 1)

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Hydraulic systems - Hydraulic swing system

Hydraulic swing system - Dynamic description Swash plate motor The cylinder block (24) is equipped with 9 pistons (32). And the end face of cylinder block (24) is in contact with valve plate (43) having two crescent ports C and D (high and low pressure switching distributor). (Principles of torque generation) On leading the high pressure oil (pressure P) to the A port, the swash plate is pushed by the force of each piston (F=PXA, A: Piston cross sectional area) and the piston receives the reaction force from the swash plate for the piston and the directional torque of the reaction rotation is generated. And the sum total of the rotation directional torque produces a turning force in cylinder block (24) and the torque is conducted to shaft (22) through the spline resulting in the piston rotation. And, the output torque and the rotation number are found from the following equation. Where: • Output torque (T): (Nm) T=

100 x P x D x i x ŋm x ŋG 2 x π x 100

D: Displacement volume (cm3/rev) (cc/rev) P: Effective driving pressure (MPa) Q: Flow rate (l/min)

• Number of revolutions (N): (RPM) N=

Q x 1000 x ŋv DxI

ŋm: Mechanical efficiency (motor) (%x10-2) ŋv: Volumetric efficiency (motor) (%x10-2) i: Speed ratio of reduction unit ŋG: Reduction unit efficiency (%x10-2)

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Construction of slewing motor

TULI12EXN4197HB

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Parking brake The parking brake is of hydraulic release and chamber type multi-disk construction. • When parking brake is On, (Refer to Fig. 2 ) When the pressure oil for releasing the brake is cut-off, regarding the disk (33) joined to the exterior of the cylinder block with a spline, brake piston (34) which is secured with pin on the case is pushed by spring (38), and cylinder block (24) and casing (20) are fixed by the frictional force. Consequently the shaft is locked. • When parking brake is Off, (refer to Fig. 3 ) When the brake releasing pressure is led to brake cylinder chamber (C) through PG port, brake piston (34) operates resisting the force of spring (38), removing the friction with disk (33), and the shaft rotates freely. • Hydraulic timer (specification with hydraulic timer only) (Refer to Fig. 4 ) The hydraulic timer is provided to protect the parking brake from dragging and plays to secure delay time so that the parking brake does not actuate when the hydraulic dynamic brake is absorbing swing inertia energy, and the delay time is set by restricting the delivery oil from the cylinder chamber with orifice and by controlling the flow rate. By returning the control valve from motor rotating condition to the neutral position, the valve switching pressure “SH” interlocking with switching signal for the control valve lowers, and for the valve, the brake cylinder chamber is interlocked with the drain port through the valve as shown in the figure. (In this condition, the energy of the upper structure is transformed into heat energy and absorbed by the relief valve and the hydraulic dynamic braking action.). On the other hand, the oil led to the brake cylinder chamber (C) tries to move in the direction to push the disk by the spring force acting on the brake piston, but as the flow rate of the delivery oil from the brake cylinder chamber is controlled by the orifice of the valve, the brake piston is not in contact with the disk before an elapse of the specified time and the brake does not work.

When parking brake is On

TULI12EXN4198FB

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Parking brake is Off condition

TULI12EXN4199FB

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TULI12EXN4200GB

The above function is explained in the diagram shown in the next page. 48-5. 50. 73. 74. 75.

Spool Spring Orifice Brake cylinder chamber (C) Drain

A. B.

In P/B releasing In P/B operation

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Diagram

TULI12EXN4601GA

76. In this interval, main control valve is switched. 84. Uniform speed area 77. Time zone the flow is controlled by orifice. 85. Time (t) 78. In this interval, (PG) supply pressure is acting on. 86. Deceleration area hydraulic pressure dynamic brake 79. Releasing parking brake C. Shuttle valve switching outer signal pressure SH 80. Timer set time D. Pressure of parking brake cylinder chamber 81. In this interval, the parking brake does not E. Parking brake torque activate and does not drag 82. Set slewing speed F. Upperstructure slewing speed 83. Acceleration

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Hydraulic systems - Hydraulic swing system

Operation of relief valve The relief valve is used to decide the driving power and brake force when slewing the hydraulic excavator and each is equipped with main port A and B. And it is constructed so that the relief valve return oil returns in a circuit to the main low pressure line on the other side. And, it is provided with a shockless function to reduce the shock produced when speeding up or down. The relief valve is made up of the A. Area difference and direct operated type relief valve B. Shockless piston The installation of shockless type relief valve is effective for the reduction of the shock, reduction of the stress generated on the structure of the machine.

TULI12EXN6172FB

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The relief valve is operated by the following two steps.

1st step: When starting operation, the interior of the spring (5) is held in low pressure because shockless piston (14) moves. Consequently the pressure receiving area (S2) of poppet (2) becomes equal to the area (S1) of seat (3) and has a large pressure receiving area when compared with the area (S1) - (S2)for the regular relief set pressure. Therefore the low pressure holding time is decided by the diameter of the poppet orifice, the pressure receiving area of the free piston and the free piston stroke.

TULI12EXN4603FB

First operating point of pressure relief valve

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2nd step: After the movement of shockless piston (14), the pressure inside of spring chamber (5) rises and becomes equal to the pressure the front and behind of poppet (2). And the relief valve is operated by the regular set pressure.

TULI12EXN4604EB

2nd step: operation of relief valve The pressure wave forms in the conventional type (CT) and the shockless type (ST) are shown below.

TULI12EXN4605EA

Comparison of pressure wave forms P.

Pressure

Time

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Make-up valve (check valve, No. (54)) The make-up valve performs the following two functions. The 1st function is to prevent the cavitation produced when overrunning to avoid the overrun of the upper structure. The motor revolved by the inertia force of the upper structure causing the pumping action, and when the motor speed is over the speed equivalent to the oil quantity fed into the motor, the shortage of oil is made up from the outside to the motor main circuit through the make-up valve to protect the circuit from the generation of vacuum. The 2nd function is, when the closed circuit is formed between the control valve and the motor as when braking, to protect the circuit from the generation of the vacuum by making up the shortage due to the motor drain and valve leak from the make up valve to maintain the braking function in the regular circuit condition.

TULI12EXN4606GB

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Hydraulic systems - Hydraulic swing system

Reduction unit (2-stage planetary) Refer to the cross sectional view. The motor shaft (22) is connected to the drive gear (16) with the spline on it. The driving power on the hydraulic motor is transmitted from the drive gear (16) to the planetary gear (14) which is engaged to the drive gear. The planetary gear (14) is engaged to the ring gear on the reduction unit housing (1). Then it revolves around the ring gear with its rotation. The planetary gear (14) is held on the holder (10) with the bearing, and the holder (10) transmits the revolving motion of planetary gear (14) to the sun gear (66) which is engaged to the holder (10) with the spline on it. The sun gear (66) is engaged to the planetary gear (68), and transmits the revolving motion to the planetary gear (68) as the same routing as the first stage. Since the planetary gear (68) is held on the holder (72) with the bearing, the holder (72) transmits the revolving motion of the planetary gear (68) to the pinion shaft (2) which is engaged to it with the spline.

TULI12EXN6177GB

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Hydraulic swing system - Prepare 1. Remove the floor mat, the floor plate and the cover. 2. Release the residual pressure in the circuit and the pressure in the hydraulic tank.

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Hydraulic swing system - Remove 1. Disconnect six hoses (A7), (A10), (19) tank hydraulic, (20) tank hydraulic, (23) and (25) connected to the slewing motor (See Fig. 1 and Fig. 2). : 22 mm and 27 mm

TULI12EXN6342AB

TULI12EXN6343AB

TULI12EXN6344AB

TULI12EXN6345AB

2. Remove three pilot hoses (B25), (B26) and (B27) connected to the slewing motor. : 19 mm

3. Loosen five M12 X 40 capscrews (3) to remove the slewing motor (1). : 10 mm [a long type approximately 300 mm (11.8 in) in length required]. Weight: Approximately 38 kg (0.04 ton)

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Hydraulic systems - Hydraulic swing system

Hydraulic swing system - Install 1. Install the motor in reverse order of the removal according to the tightening torque shown below: 1.

Apply LOCTITE® 515 on the entire circumferential surface for mounting the slewing motor (1).

Install the capscrews (3) for fixing the motor. : 10 mm T = 115 N·m (84.82 lb ft) Apply LOCTITE® 262 to the capscrew.

3. Connect the hoses • Fill the casing with hydraulic oil through the motor drain port prior to connecting drain piping. Tightening torque Thread size PF 1/4 PF 3/8 PF 1/2

Spanner used 19 mm 22 mm 27 mm

O-ring type fitting 36.3 N·m (26.77 lb ft) 73.5 N·m (54.21 lb ft) 108 N·m (79.66 lb ft)

2. Check the hydraulic oil tank for the oil level. Supply oil if necessary. 3. At the start, run the motor in the low idling condition of the engine for a few minutes to check for oil leakage and abnormal noise.

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30° flare type fitting 29.4 N·m (21.68 lb ft) 49 N·m (36.14 lb ft) 78.5 N·m (57.9 lb ft)

Hydraulic systems - Hydraulic swing system

Hydraulic swing system - Disassemble Precautions before disassembling 1. Remove mud, dust, etc. on the outer surface. 2. Drain the hydraulic oil in piston motor case and the port circuit. 3. Select clean work area, and pay attention to the parts in order not to adhere mud, dust, etc. 4. Donâ&#x20AC;&#x2122;t disassemble the motor frequently more than necessary. Disassemble the slewing motor by the following procedure. 1. Separate the motor and the reduction unit. Fix the motor assembly with vise, and remove socket bolt (62).

TULI12EXN6534AB

TULI12EXN6535AB

TULI12EXN6536AB

2. Disassembling motor 1.

Fix the motor assembly with vise. Loosen the capscrew (46) and the cover (40).

NOTE: Be careful not to drop valve plate (43) when removing cover (40).

2. Remove valve plate (43) and pin (42). NOTE: Valve plate (43) may be left on the motor side.

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3. Take out ball bearing (41). Take out O-ring (45).

TULI12EXN6537AB

TULI12EXN6538AB

TULI12EXN6539AB

TULI12EXN6540AB

4. Disassemble check valve A. Loosen and remove plug (56).

B. Remove check valve (54) and spring (55).

5. Removing relief valve (53) A. Loosen plug (53-6) and remove relief valve assembly (53). NOTE: Donâ&#x20AC;&#x2122;t turn set bolt (53-7) to maintain the set pressure. Donâ&#x20AC;&#x2122;t disassemble relief valve assembly because it has an important function.

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6. Remove valve plate (43), pin (44) and O-ring (39). NOTE: The valve plate (43) may be left on the cover side.

TULI12EXN6541AB

TULI12EXN6542BB

7. Take out spring (38) and spring seat (37), and remove parking brake piston (34) by use of the gauge port (73) of casing (20). NOTE: The piston may pop out due to the air pressure, so be careful not to be injured. So, set the air pressure to low position, and adjust the pressure checking the removing condition of the piston. And, the parking brake timer should be removed after removing the brake piston. (Otherwise the parking brake timer may not be removed.)

8. Remove cylinder block, etc. Cylinder block (24) Collar (25) Spring (26) Washer (27) Snap ring (28) Pin (29) Retainer holder (30) Retainer plate (31) Piston assembly (32)

TULI12EXN6543AB

Disk (33)

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9. Remove retainer plate (31) and piston assembly (32).

TULI12EXN6544AB

TULI12EXN6545AB

TULI12EXN6546AB

TULI12EXN6547AB

10. Remove pin (29) and retainer holder (30).

11. Remove snap ring (28) keeping washer (27) pressed.

12. Remove collar (25), spring (26) and washer (27).

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13. Remove thrust plate (23).

TULI12EXN6548AB

TULI12EXN6549AB

TULI12EXN6550AB

TULI12EXN6551AB

14. Remove the shaft (22) tapping the top end of shaft with a hammer.

15. Remove ball bearing (21) and shaft (22). NOTE: Donâ&#x20AC;&#x2122;t reuse the removed ball bearing.

16. Disassembling timer valve (48) A. Remove plug (52).

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B. Remove spring (50), washer (49) and spool (48-5). C. Remove sleeve (48-1).

TULI12EXN6552BB

TULI12EXN6553BB

Disassembling reduction unit 1.

Remove O-ring (19) Thrust plate (15) Drive gear (16) Planetary gear (14) Needle bearing (13) Inner race (12) Thrust washer (11) Holder (10).

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Hydraulic systems - Hydraulic swing system

2. Remove the drive gear (66). 3. Remove holder (72) and other related parts. 4. Fix holder (72) to a vise, and loosen screw (67) to remove thrust plate (65). NOTE: Screw is difficult to remove because LOCTITEÂŽ was applied to it at assembling. Warming up screw with a drier is effective for easy removal. 5. Remove planetary gear (68), needle bearing (69) and inner race (70). NOTE: For taper roller bearings (5) and (7) and collar (3), replace the body assembly.

TULI12EXN6554AB

TULI12EXN6555AB

TULI12EXN6556AB

TULI12EXN6557AB

6. Remove collar (9) and shim (8). 7. Remove pinion shaft (2). NOTE: Be careful not to drop the shaft when removing. When it is difficult to pull it out, tap it by a hammer.

8. Separate the inner race from taper roller bearing (7).

9. Break oil seal (6) and take it out. NOTE: Donâ&#x20AC;&#x2122;t reuse the removed oil seal. When removing, be careful not to damage the outer race of taper roller bearing (5) and (7).

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10. Remove taper roller bearing (7), outer race and plug (17). The disassembly is now completed.

TULI12EXN6558AB

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Hydraulic systems - Hydraulic swing system

Hydraulic swing system - Assemble Cautions for assembling 1. Clean all parts with cleaning solvent, and blow air. 2. Handle the clean parts carefully without allowing dust to adhere and without producing dent, flaw, etc. 3. Replace the seal rings, the needle bearing and the pin with new ones. 4. Tighten the respective fastener to the specified torque. 5. Apply grease to the oil seal and O-ring before fitting. (Especially oil seal lip section) 6. There are many kinds of small item, so be careful not to miss them. (Especially drop in the hole.)

Assembling motor 7. Install relief valve assembly (53). T = 147 - 167 NÂˇm (108.42 - 123.17 lb ft)

TULI12EXN4374AB

TULI12EXN4375AB

8. Install check valve (54) and spring (55).

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9. Installing the plug (56). T = 37.2 - 41.2 NÂ·m (27.44 - 30.39 lb ft).

TULI12EXN4376BB

TULI12EXN4377BB

10. Fit O-rings (48-2), (48-3) and (48-4) on sleeve (48-1) .

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11. Install sleeve (48-1) on case (20), and place spool (48-5) , washer (49) and spring (50) in the hole of the sleeve. 12. Install plug (52) with O-ring (51). T = 79 - 89 NÂˇm (58.27 - 65.64 lb ft) NOTE: Fit the O-ring (51) with care, without damaging it.

TULI12EXN4378BB

TULI12EXN4379BB

13. Install collar (25), spring (26) and washer (27) on cylinder block (24). NOTE: Do not mistake the direction of installation T. Taper surface.

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14. Fit the snap ring (28) while keeping the washer (27) pressed.

TULI12EXN4380AB

TULI12EXN4381AB

TULI12EXN4382BB

15. Apply grease to pin (29) and insert it to cylinder block (24). 16. Install retainer holder (30).

17. Set piston assembly (32) on retainer plate (31), and install it in the cylinder block (24). NOTE: Apply enough hydraulic oil on the sliding section before installation.

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18. Press fit ball bearing (21) on shaft (22). NOTE: Install ball bearing (21) directing the snap ring (74) as shown in the 10

TULI12EXN4383AB

TULI12EXN4384AB

TULI12EXN4385AB

TULI12EXN4386AB

19. Press fit shaft (22) and ball bearing (21) on casing (20).

20. Apply grease on the back side of thrust plate (23) before installation. NOTE: No not mistake the direction of the thrust plate D. Direct the taper side toward the motor case side.

21. Install cylinder block (24), etc. NOTE: Be careful not to drop pin (29) when installing. Install disc (33).

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22. Apply grease to O-rings (35), (36) and install it on brake piston (34).

TULI12EXN4387AB

TULI12EXN4388BB

TULI12EXN4389AB

23. Place brake piston (34) in casing (20) paying attention to the hole position of pin (44). 24. Fit spring seat (37) and spring (38) without mistaking the direction.

25. Apply grease to O-ring (39) and place it in casing (20). Check if pin (44) can be built in the hole of casing (20) and brake piston (34). If not remove brake piston (34) and align the position again.

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26. Apply grease to O-ring (45) and pin (44) and install them on cover (40). Press fit ball bearing (41). 27. Install pin (42), and then install valve plate (43). Apply grease to the back face to prevent dropping.

TULI12EXN4390BM

TULI12EXN4391AC

28. Install cover (40), etc. on casing (20) without mistaking the position of pin (44). NOTE: Be careful not to drop pin (44) and valve plate (43).

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29. Tighten socket bolt (46) temporarily, and then tighten it to the specified torque with a torque wrench. T = 121 - 135 NÂˇm (89.25 - 99.57 lb ft)

TULI12EXN4392BC

TULI12EXN4914AB

TULI12EXN4915AB

Assembling reduction unit 1. Press fit oil seal (6). NOTE: Apply grease to the oil seal fitting section of housing (1) and around the oil seal before press fitting. D. Dimension after oil seal is press fitting

2. Press fit taper roller bearing (7) and install plug (17).

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3. Seal grease in taper roller bearing inner race (5) installed on pinion shaft (2). Brand name of grease: MG2 Sealing q’ty: 17 - 20 cm³ (1.04 - 1.22 in³)

TULI12EXN4916AB

TULI12EXN4917BB

SMIL13MEX0203AB

4. Install pinion shaft (2). Install inner race of raper roller bearing (7). NOTE: Apply grease to the lip section of oil seal (6) before installing pinion shaft (2).

5. Install thrust washer (71), inner race (70), needle bearing (69), planetary gear (68), thrust plate (65) and screw (67) on holder (72). NOTE: Tighten up screw (67) after applying LOCTITE® 242. Tightening torque: 3.9 - 0.5 N·m (2.9 - 0.4 lb ft)

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6. Install collar (9) and shim (8). 7. Install holder (72).

SMIL13MEX0111BB

SMIL13MEX0112BB

8. Install the drive gear (66). Install holder (10).

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9. Install the thrust washer (11), the inner race (12), the needle bearing (13), the planetary gear (14), the thrust plate (15) and the drive gear (16) of the support (10). 10. Apply grease to the O-ring (19) and fit it in the housing (1). 11. Selection for thrust plate (15). NOTE: When any components of the reduction unit were changed, select and install thrust plate corresponding to the measured value (E) referring to the table below.

Dimension E (measured value) Plate (15) thickness

SMIL13MEX0113BB

SMIL13MEX0114AA

Less than 66 mm (3 in)

66 - 72 mm (3 - 3 in)

more than 72 mm (3 in)

3.2 mm (0.1 in)

2.8 mm (0.1 in)

2.3 mm (0.1 in)

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Assembling motor assembly 1. Install the reduction unit on the motor assembly, tighten socket bolt (62) temporarily, and tighten it to the specified torque. T = 121 - 135 NÂˇm (89.25 - 99.57 lb ft) A. Align the protruded section with port.

TULI12EXN4397BB

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Hydraulic swing system - Service instruction Maintenance standard Replace each part referring to the list shown below:

Engine Part name Piston assembly (32)

Thrust plate (23) Retainer holder (30) Retainer plate (31) Valve plate (43) Brake piston (32) Cylinder block (24)

Maintenance standard Severe flaw and roughness of each sliding surface Too large gap from the assembly to cylinder block bore Upper limit of diameter clearance: 0.04 mm (0.0016 in) Large play of shoe ball Max. play (moving amount): 0.4 mm (0.016 in) Severe flaw and roughness of each sliding surface

Severe flaw and roughness of each sliding surface Severe wear or breakage of the mating surface Disk (33) Severe flaw or peeling of each sliding surface (Friction plate) Severe wear and peeling of mating surface Ball bearing (21), (41) Flaking and peeling of rolling contact surface Indentation of rolling contact surface Abnormality of bearing rotation (Noise, unsmooth rotation) Spring (26) Sever breakage and deformation O-ring (35), (36), (39), (45), (57), Flaw causing oil leakage, flaw causing insufficient sealing and permanent (59) and (61) deformation

Reduction unit Part name Pinion shaft (2) Plate (4) Taper roller bearing (5), (7)

Oil seal (6) Housing (1) Holder (10) Drive gear (16) Planetary gear (14) Inner race (12) and (70) Needle bearing (13) and (69) Planetary gear (14) and (68) Thrust plate (15), (23) and (65)

Maintenance standard Severe flaw, wear and flaking of gear tooth surface Severe flaw and wear Severe flaw, indentation and flaking of roller and race section Unsmooth rotation with noise * Replace the body assembly when required to replace the taper roller bearing Severe flaw, deformation and wear of lip section Hardening of lip section Severe flaw, wear and flaking of gear tooth surface * Replace the body assembly when it is necessary to replace the housing

Severe flaw, wear and flaking of rolling surface in contact with needle bearing Severe flaw, wear and flaking of needle bearing surface Severe flaw, wear and flaking of gear tooth surface Severe flaw, wear and flaking of rolling surface in contact with needle bearing Severe flaw, wear and seizure of sliding surface

Valve Part name Piston (53-14) Casing (20)

Maintenance standard Severe flaw of sliding section and roughness of sliding surface Too large gap between piston and case hole Upper limit of diameter clearance: 0.04 mm (0.0016 in)

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Part name Spring (50) Spring (55) Plug (56), (53-6) Check valve (54) O-ring (53-8) to (53-11) (57) Backup ring (53-12), (53-13) O-ring (48-8) to (48-4) (51)

Maintenance standard Sever breakage and deformation Flaw causing oil leakage, flaw causing insufficient sealing and permanent deformation

Others Part name Other plug and O-ring

Maintenance standard Flaw causing oil leakage, flaw causing insufficient sealing and permanent deformation

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Index Hydraulic systems - 35 Hydraulic swing system - 352 Hydraulic swing system - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Hydraulic swing system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic swing system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hydraulic swing system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic swing system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic swing system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic swing system - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hydraulic swing system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic swing system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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Hydraulic systems - 35 Hydraulic travel system - 353

CX35B CX39B

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Contents Hydraulic systems - 35 Hydraulic travel system - 353

TECHNICAL DATA Hydraulic travel system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Hydraulic travel system Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SERVICE Hydraulic travel system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Hydraulic travel system - General specification

TULI12EXN6178GB

E. Oil filling port F. Oil level check port G. Drain port No. Name Hydraulic oil fill / drain port A, B Discharge port D1, D2 P, P2, P3 Pressure gauge port

Size PF1/2 PF1/4 PF1/8

The relation between rotating direction of reduction unit and oil inlet and outlet port (View from X side) Rotation direction Clockwise Counterclockwise

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Oil outlet port B A

Hydraulic systems - Hydraulic travel system

Model (type) Rated output revolution (1st / 2nd) Reduction unit

Output torque (1st / 2nd) Reduction ratio Displacement (1st / 2nd)

Hydraulic motor

Working pressure Rated output revolution (1st / 2nd ) Delivery

Parking brake

2-Speed shifting pressure Automatic 2-speed shifting pressure Static friction torque Releasing pressure

Weight

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GM04VA 36.7 RPM / 64.0 RPM 3470 N·m (2559 lb ft) / 1900 N·m (1401 lb ft) 1 / 53.7 20.5 cm³/rev (1.3 in³/rev) / 11.5 cm³/rev (0.7 in³/rev) 23 MPa (3336 psi) 1970 RPM / 3439 RPM 41.2 l/min (10.9 US gpm) / 10.9 l/min (2.9 US gpm) 3.5 MPa (508 psi) 18.5 MPa (2683 psi) 32.4 N·m (24 lb ft) 0.89 MPa (129 psi) 43 kg (0.05 ton)

Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Special tools Standard tools No. 1 2

Name Allen wrench Socket wrench (ratchet handle)

Torque wrench

Torque wrench adaptor

5 6 7 8 9

Hexagon head Extension rod Hammer Plastic hammer Minus driver

Snap ring pliers

11 12

Cutting pliers (JIS B 4623) Lifting tool

13 14

Container Leather gloves

Size 8 (for M10 & PF 3/4), 10 (for M17), 14 (for M16)

Qty. 1 each

Barrel type

Dial type, about 12 N·m (8.85 lb ft) Dial type, about 90 N·m (66.38 lb ft) Dial type, about 280 N·m (206.52 lb ft) Nominal socket size 13 mm (0.51 in) Nominal rod size 8 mm (0.31 in) and 10 mm (0.39 in) For passing through shims of 3 mm (0.12 in) 150 mm (5.91 in) Nominal size 12 mm (0.47 in) L= about 300 mm (11.81 in) About 150 mm (5.91 in), 50 mm (1.97 in) For shaft For hole 200 mm (7.87 in) Lifting capacity: 300 kg (661.39 lb) or more Lifting eye (for M16) Eye (for PF 3/8) Wire with hooks Vat for general use: W450 x D300 x H120

1 each 1 each 1 1 1 1 1 1 1 2 1 set 2 2 1 2 1 pair

Tools Application item (Item in cross-sectional or exploded view) Disassembly and assembly Cleaning parts 104 and 149

149 Disassembly 161, 162, 163, and 112 Drying after cleaning

Name

Size

General workbench Cleaning bath

For rough and finish cleaning Pressing capacity: 1.96 kN Workbench for press (440.63 lb) or more Heating capacity: 100 °C (212 °F) or more Heating bath Volume 500 mm (19.69 in) x 500 mm (19.69 in) x 500 mm (19.69 in) Compressed air

Pressure 294 - 490 kPa (3 - 5 bar)

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Notes

Qty. 1 set 1 set 1 set

1 set

Hydraulic systems - Hydraulic travel system

Attachment No. 1

Name Working bench for travel motor (WB)

This is used to carry out the work for assembly and disassembly of travel motor easy and safe. Retainer metal (RM1) (RM)

This is used to insert spring (114), washer (110), snap ring (145) into cylinder block (104), and also used to remove spring (114) from cylinder block (104). Oil seal press fit tool (RM3)

For press fitting the oil seal (132) in the oil seal hole of the spindle (2). Jig for adjusting the preload to the bearing (JB)

No. 2

Name Fixing metal (FM)

This is used to connect the spindle (2) and hub (1). Retainer metal (RM2)

This is used to pull out bearing (149) from drive shaft (102).

Bearing press fit tool (BB)

For press fitting the ball bearing (24) in the hub (1). Steel rod (1) (SR)

For installing the ring nut (22) to the spindle (2).

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This is used to remove the ring (45) from the hub (1).

Hydraulic systems - Hydraulic travel system

No. 9

Name Long lifting eye (LE)

Application – “A” Hub – M12 Mandrel – M12 Travel motor– M12 This lifting eye is used to sling up travel motor, the spindle (2) and the hub (1). Pin punch (PP)

This is used to remove the outer race of floating seal (31). Floating seal (FS1) inserting jig (F/S)

No. 10

Name Spatula (SP)

This is used to remove the timing plate (109) from rear flange (201). Jig for cover removal (JC)

This is used to remove the cover (13) from the hub (1). Floating seal (F/S) inserting jig (II) (FS2)

For building the floating seal (31) into the hub (1). 15

Floating seal (F/S) inserting jig (FS3)

For building the floating seal (31) into the spindle (2).

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For building the floating seal (31) into the hub (1) and spindle (2).

Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Component identification

TULI12EXN6179HA

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Hydraulic systems - Hydraulic travel system

H. I. L. M. N.

Reduction unit Hydraulic motor Brake valve Parking brake High and low speed change mechanism

O. Q. R. S. T.

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Control valve Hydraulic pump High speed Low speed Hydraulic circuit

Hydraulic systems - Hydraulic travel system

TULI12EXN6180HA

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Hydraulic systems - Hydraulic travel system

1. 2. 3. 4. 5. 6. 7. 9. 11. 12. 13. 14. 22. 24. 27. 28. 29. 30. 31. 33. 35. 37. 39. 40. 41. 42. 43. 44. 45. 47. 54. 104.

105. 106.

161. 162. 163. 102. 103. 107.

Hub (Qty. 1) Spindle (Qty. 1) Carrier (Qty. 1) Sun gear (1) (Qty. 1) Planetary gear (1) (Qty. 3) Sun gear (2) (Qty. 1) Planetary gear (2) (Qty. 4) Thrust washer (1) (Qty. 2) Thrust collar (4) (Qty. 4) Thrust washer (3) (Qty. 7) Cover (Qty. 1) Coupling (Qty. 1) Ring nut (Qty. 1) Ball bearing (Qty. 2) Needle roller bearing with retainer (Qty. 3) Needle roller bearing with retainer (Qty. 4) Inner race (Qty. 3) Inner race (Qty. 4) Floating seal kit (Qty. 1) Floating seal (Qty. 2) Plug with flange (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) Cap (Qty. 2) Hexagon head screw (Qty. 7) Steel ball (Qty. 1) Parallel pin (Qty. 2) O-ring (Qty. 2) O-ring (Qty. 1) Ring (Qty. 1) Hexagon head screw (Qty. 2) Hexagon socket plug (Qty. 1) Cylinder and piston kit •Cylinder block (Qty. 104) •Piston kit ••Piston assembly •••Piston (Qty. 105) •••Crawler (Qty. 106) Piston kit (Qty. 1) •Piston assembly (Qty. 1) ••Piston (Qty. 1) ••Crawler (Qty. 1) •Seal ring (Qty. 1) Shaft (Qty. 1) Swash plate (Qty. 1) Retainer plate (Qty. 1)

108. 109. 110. 112. 113. 114. 115. 116. 132. 135. 139. 145. 149. 150. 151. 167. 177. 190.

201. 223. 263. 264. 221. 224. 225. 226. 227. 228. 230. 236. 237. 252. 254. 266. 268. 273. 275. 279. 280. 299. 241. 243.

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Thrust ball (Qty. 1) Timing plate (Qty. 1) Washer (Qty. 2) Piston (Qty. 1) Spring (Qty. 8) Spring (Qty. 1) Friction plate (Qty. 1) Separator plate (Qty. 2) Oil seal (Qty. 1) O-ring (Qty. 1) O-ring (Qty. 1) Snap ring (Qty. 1) Ball bearing (Qty. 1) Ball bearing (Qty. 1) Roller (Qty. 3) Pivot (Qty. 2) Parallel pin (Qty. 2) Spring (Qty. 1) Rear flange assembly (Qty. 1) • Rear flange kit (Qty. 1) •• Rear flange (Qty. 1) • Spool (Qty. 1) • Spool kit (Qty. 1) •• Spool (Qty. 1) •• Oil stopper (Qty. 1) • Plug (Qty. 2) • Plug (Qty. 2) • Stopper (Qty. 2) • Plug (Qty. 2) • Valve (Qty. 2) • Spring (Qty. 2) • Spring (Qty. 2) • O-ring (Qty. 2) • O-ring (Qty. 2) • Hexagon socket plug (Qty. 4) • Hexagon socket plug (Qty. 4) • Spring (Qty. 1) • Steel ball (Qty. 1) • O-ring (Qty. 2) • Orifice (Qty. 1) • Filter (Qty. 1) • Plug with flange (Qty. 1) • Name plate (Qty. 1) Parallel pin (Qty. 2) Edge bolt (Qty. 6)

Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Dynamic description Reduction unit 1. Operation This reduction gear unit is composed of two stage planetary gear mechanism. This reduction gear reduces the high speed of hydraulic motor and converts it low-speed, high-torque rotation. 2. Operation description The rotation of hydraulic motor shaft is transmitted to sun gear (4) of the first stage which is linked with shaft (102) in spline. Sun gear (4) is meshed with three planetary gears (5), and three planetary gears (5) mesh with hub (1) while rotating on their axis. At that time, the hub is rotated by the rotation of the planetary gears (5). The hub rotation is transmitted to carrier which is connected to planetary gears (5), and that causes sun gear (6) rotation of the second stage. The rotation of the gear (6) is transmitted to the hub via four planetary gears (7) of the second stage. The generated rotation of reduction gear is output rotation.

SMIL13MEX0165FB

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Hydraulic motor section (Brake valve, parking brake, high and lower speed change mechanism) 1. Operation Hydraulic motor Hydraulic motor is referred to as a swash plate type axial piston motor which converts the pressure oil power fed by pump into rotary motion. 2. Brake valve Travel motor controls the force of rotational inertia of the body to brake and stop the rotation smoothly. Check valve function to prevent hydraulic motor from cavitation. Open the port to release the parking brake force at travel motor operation, and close the port at a standstill. 3. Parking brake The parking brake is used to the prevent machine from running away or slipping while parking on a slope using the friction plate type brake mechanism, and is installed on the hydraulic motor. 4. High / Low speed shifting mechanism By means of changing the tilt angle of the swash plate to change the stroke volume of piston with help of the function on the shifting valve and control piston, the speed is shifted to high speed with low torque or low speed with high torque. Operation 1. Hydraulic motor Hydraulic oil fed by pump enters rear flange (201) of travel motor, and is led from timing plate (109) to cylinder block (104) through brake valve mechanism. This pressure oil is led to only the one side of Y1 â&#x20AC;&#x201C; Y2 tied between top dead point and bottom dead point of piston (105) stroke. And the pressure led to one side of cylinder block pushes 4 or 5 pistons (105), generating the power [F (N) = 100 x P (MPA) (psi) x A cm2)]. This power enters on swash plate (103), but wash plate is fixed having an angle (Îą) against axis of drive shaft (102), and divided into component of force (F2), (F3). And the radial component of force (F3) generate various torque (T = F3 x ri) against line Y1 Y2. The total torque [T = ÎŁ (F3 x ri)] is connected to turning effort, and rotates cylinder block (104) through piston (105). The cylinder block (104) is connected with drive shaft (102) with spline, and rotates drive shaft to transmit torque.

SMIL13MEX0166BB

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Hydraulic systems - Hydraulic travel system

2. Brake valve Operation (Brake released) The pressure oil is led to through port (A), opens valve (227), and led to port (C) on the section side of hydraulic motor to rotate hydraulic motor. At the same time, the pressure oil enters chamber (b) through passage (a) from the small hole of spool (223), and exerts on the end of spool to generate the force. Then the force of spring (228) slides the spool placed on the neutral position leftward. The sliding of spool forms the space (passage) between spool and rear flange with spool groove. This passage is connected to port (D) and port (B) of the return circuit of the hydraulic motor, and the return oil returns to tank side, enabling hydraulic motor to rotate. Then, the sliding of spool (223) leads pressure oil to port (P). The pressure oil led to port (P) moves piston (112) of parking brake, and releases parking braking force. (For details, refer to item â&#x20AC;&#x153;Parking brakeâ&#x20AC;?). If pressurized oil is supplied from port (B) the movements of spool (223) and valve (227) are reversed so that the hydraulic motor is rotated reversely.

SMIL13MEX0167BB

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Stop / Stall (braking action) If pressurized oil supply through the port (A) is suspended while travelling, the hydraulic force to push up the spool is lost, and the spool (223) which is slided to left side, tries to return to the neutral position through the stopper (225) due to the spring (228) force. At that time, through the oil in the chamber (b) tries to flow out to the port (A) side through the passage (a) in the spool, its flow is restricted and some back pressure is generated by the throttle effect in the passage (a) controlling the return speed of the spool. At the same time, the hydraulic motor tries to rotate with its inertia force even though the pressurized oil is suspended, and the return oil from the hydraulic motor tries to return to the port (B) side from the port (D) through the passages on spool groove and rear flange. When the spool entirely return to the neutral position, the passage on the hydraulic motor of the oil return side is completely closed by the spool, and the hydraulic motor ceases its rotation. While machine working, the brake valve smoothly stops rotation of the hydraulic motor which tries to rotate with its inertia force, by means of throttling the return side passage of the hydraulic motor, generating back pressure due to shape of the spool groove and controlling the return speed of the spool. On the other hand, when braking is operated, the hydraulic motor tries to rotate with its inertia force and to intake oil with its pumping function. However, because the intake side is closed its passage with the spool, the oil supply is suspended. This causes cavitation in the hydraulic motor. To prevent the cavitation, the valve (227) is operated by very slight negative pressure to open the passages of port (A) side and intake port (C) of the hydraulic motor. And when pressurized oil is supplied through the port (B), each motion of the above mentioned parts becomes symmetrical right and left to stop the hydraulic motor

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SMIL13MEX0168BB

Hydraulic systems - Hydraulic travel system

Self-travelling While machine is being operated, as the travel speed is increased due to steep slope, the oil flow rate of the hydraulic motor is higher than the supply flow rate of the hydraulic oil pump. The rotation of the hydraulic motor in this case is called a self-travelling (Overrun). While self-travelling, the oil pressure is lowered similar to the stopping condition. Then brake valve is moved similar to the stopping condition, throttles passage in the return side of hydraulic motor, and generate backing pressure. In addition, the force of inertia decreases the revolution of hydraulic motor to revolution having a balance with the supply flow rate of pump.

SMIL13MEX0169BB

SMIL13MEX0170BB

3. Parking brake Traveling The pressure oil led trough brake valve actuates on spool (223) of brake valve on the hydraulic motor section, opens passage to parking brake, and is led to cylinder chamber (a) compressed of spindle (2) and piston (112) on the reduction gear section. If the pressure of oil which is 0.89 MPa (129.09 psi) or higher it exceeds the force of spring moving piston (112) toward rear flange (201) side. This movement of piston (112) reduces the push power to separator plate (116) and friction plate (115), and makes the movement of friction plate (115) which is installed to cylinder block (104) on hydraulic motor section free releasing the brake power to cylinder block (104).

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Stopping If pressure oil from brake valve is cut, and the pressure in cylinder chamber (a) lowers 0.89 MPa (129.09 psi) or less, the piston (112) goes to rightward by the force of spring (113). Also, the force of the spring pushes mating plate (116) and friction plate (115), which is in a free state because piston (112) is pushed, against spindle (2) on the reduction gear section. The frictional force produced by the push power stops the rotation of cylinder block (104), and transmits braking torque 32.4 NÂˇm (23.9 lb ft) to hydraulic motor shaft. And since oil is controlled through the proper oil passage, it results in smooth operation.

SMIL13MEX0171BB

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Hydraulic systems - Hydraulic travel system

4. High / Low speed shifting mechanism Low speed When the pilot pressure (10) is not supplied through port (D), the valve (263) is pushed up to the upper position due to the spring (266) force and to the pressurized oil in (A) or (B), oil is cut off at valve (C) and oil in chamber (P) is released through the drain valve (263) (engine frame). Accordingly, the tilt angle of the swash plate (103) becomes the maximum Î¸ 1 resulting the maximum stroke volume and low speed rotation of the hydraulic motor.

SMIL13MEX0172FB

D. Drain

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Hydraulic systems - Hydraulic travel system

High speed When 3.5 MPa (507.7 psi) of the pilot pressure (10) is supplied through the port (D), it defeats the spring (263) force and pressurized oil through the port (A) or (B) to push down the valve (263) to lower position, the pressurized oil at the port (C) is led to the chamber (P) through the valve (263), and the piston (161) pushes the swash plate (103) up to the plane X and maintain it at its position. At that time, the tilt angle of the swash plate becomes the minimum Î¸ 2 resulting the minimum stroke volume and high speed rotation of the hydraulic motor.

SMIL13MEX0173FB

D. Drain

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Hydraulic systems - Hydraulic travel system

Automatic shifting to low speed during high speed operation If the load is increased while high speed operation, the oil pressure at the port (A) or (B) is also increased. And when the oil pressure reaches 18.5 MPa (2683.4 psi), it exceeds the pilot pressure (10) by 3.5 MPa (507.7 psi), and the valve (263) is pushed up to upper position, and oil in the chamber (P) is released through the drain valve (263) (engine frame). At that time, the swash plate (103) touches plane Y of spindle, and the tilting angle of the swash plate reaches the maximum value Î¸ 1 and is held in this position, thus resulting in a low speed rotation.

SMIL13MEX0174FB

D. Drain

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Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Exploded view

TULI12EXN6613HA

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Hydraulic systems - Hydraulic travel system

No. 1. 2. 3. 4. 5. 6. 7. 9. 11. 12. 13. 14. 22. 24. 27. 28. 29. 30.

Name Hub Mandrel Carrier Sun gear (1) Planetary gear (1) Sun gear (2) Planetary gear (2) Thrust washer (1) Thrust collar (4) Thrust washer (3) Cover Coupling Ring nut Ball bearing Needle roller bearing with retainer Needle roller bearing with retainer Inner race Inner race

Qty. 1 1 1 1 3 1 4 2 4 7 1 1 1 2 3 4 3 4

31.

Floating seal kit Floating seal

1 2

33. 35. 37. 39. 40. 41. 42. 43. 44. 45. 47. 54.

Plug with flange O-ring O-ring Cap Hexagon head screw Steel ball Parallel pin O-ring O-ring Ring Hexagon head screw Hexagon socket plug

1 1 2 2 7 1 2 2 1 1 2 1

105. 106.

Cylinder and piston kit Cylinder block Piston kit Piston assembly Piston Crawler

1 1 1 7 1 1

161. 162. 163.

Piston kit Piston assembly Piston Crawler Seal ring

1 1 1 1 1

104.

Name Shaft Swash plate Retainer plate Thrust washer Timing plate Washer Piston Spring Spring Friction plate Separator plate Oil seal O-ring O-ring Snap ring Ball bearing Ball bearing Roller Pivot Parallel pin Spring

Qty. 1 1 1 1 1 2 1 8 1 1 2 1 1 1 1 1 1 3 2 2 1

263. 264. 221. 224. 225. 226. 227. 228. 230. 236. 237. 252. 254. 266. 268. 273. 275. 279. 280. 299.

Rear flange assembly Rear flange kit Rear flange Spool Spool kit Spool Oil stopper Cap Cap Stop Cap Valve Spring Spring O-ring O-ring Hexagon socket plug Hexagon socket plug Spring Steel ball O-ring Orifice Filter Plug with flange Name plate

1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 4 4 1 1 2 1 1 1 1

241. 243.

Parallel pin Edge bolt

2 6

No. 102. 103. 107. 108. 109. 110. 112. 113. 114. 115. 116. 132. 135. 139. 145. 149. 150. 151. 167. 177. 190.

201. 223.

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Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Hydraulic schema No. A B D1 D2 P P2 P3

Name Oil inlet port Oil outlet port Discharge port Discharge port Pressure detecting port Pressure detecting port Pressure detecting port

Size PF 1/2 PF 1/2 PF 1/4 PF 1/4 PF 1/8 PT 1/8 PT 1/8

HS. High speed LS. Low speed TULI12EXN6612AA

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Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Remove 1. Remove the crawler assembly. 2. Place wooden block (3) under the lower frame (1) so the sprocket (2) is off the ground. 3. Remove the capscrews (A5) located inside the lower frame and remove the covers (A2). : 17 mm 4. Push the air bleeding cap with boots on hydraulic oil tank to release air in the tank.

TULI12EXN6397AB

TULI12EXN6398AB

TULI12EXN6399AB

5. Disconnect the joint of hydraulic piping connected with the travel motor, and plug the joints in order to prevent outflow of oil and entering of dust. : 19 mm and 22 mm 6. Loosen the capscrew M12 X 25 (B3) that fasten the travel motor to the lower frame. On that occasion, put a matching mark between the lower frame and the travel motor. : 10 mm 7. Apply a wire rope to a part near the sprocket of the travel motor for balancing, and remove the unit out of the lower frame. Weight of travel motor (5) with sprocket (2): 52 kg (115 lb)

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Hydraulic travel system - Install 1. If there are burrs and dirt on fitting part with which the travel motor are fastened, eliminate it beforehand. Place a wire sling in the travel unit with the same way as in the removing, and install it to the lower frame. 2. Coat the threaded part of the mounting capscrews (4) and (B3) with LOCTITE® 262 and tighten them. : 10 mm Tightening torque = 107 N·m (79 lb ft)

TULI12EXN4488AB

TULI12EXN6601AA

3. Reconnect the hydraulic pipings as before, and tighten the joints to the specified torque. • Fill the casing with hydraulic oil prior to perform drain piping.

Tightening torque Thread size PF 1/8 PF 1/4 PF 3/8 PF 1/2

Spanner used 17 mm 17 mm and 19 mm 22 mm 27 mm

Fitting type O-ring 16.7 N·m (12.32 lb ft) 36.3 N·m (26.77 lb ft) 73.5 N·m (54.21 lb ft) 108 N·m (79.66 lb ft)

30° flare type fitting 29.4 N·m (21.68 lb ft) 49.0 N·m (36.14 lb ft) -

4. Install the covers (A2) located inside the lower frame, and tighten capscrews (A5) : 17 mm

TULI12EXN6398AB

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5. Remove the wooden block (3) supporting the lower frame and install the crawler.

TULI12EXN6397AB

TULI12EXN6602AB

6. Check the oil level in the reduction unit of travel motor [See point 7 below] and replace or replenish with oil as required. Oil: CASE AKCELA GEAR 135 H EP 80W-90 Volume of oil: 700 cm³ (43 in³) : 8 mm 7. Checking oil level in reduction unit. A. Stop the machine so that the drain plug (8) of the reduction unit is located in the lowest position. B. Remove the level plug (7) and check the oil level and contamination. The oil level is proper if it is close to the plug bore. Replenish oil if necessary. • When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.

Tightening torque

Ref. Sprocket fixing capscrew M12 Travel motor fixing capscrew M12 Specifications and grade

Oil Volume

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Spec. Apply LOCTITE® 262 107 N·m (79 lb ft) Gear oil CASE AKCELA GEAR 135 H EP 80W-90 700 cm³ (43 in³)

Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Prepare Preparations for disassembly Prior to disassembling, carry out the following preparations: 1. Workbench preparation â&#x20AC;˘ Prepare workbench for travel motor. â&#x20AC;˘ Prepare workbench which is rigid enough to disassemble or assemble internal parts of travel motor and has a wide area for placing them to prevent them from moving or dropping during the work. â&#x20AC;˘ Cover workbench with rubber, vinyl, etc. 2. Preparations of tools and materials Prepare materials shown in Hydraulic travel system Special tools (35.353) .

General precautions for working NOTICE: Internal parts during disassembly are slippery as they are smeared by hydraulic oil. Handle them with extreme care not to drop them. Otherwise, you may be injured or they may be damaged. Combustible material such as kerosene is used to clean the parts. Handle it with extreme care not to cause fire or burns, as it catch fire easily. 1. Prior to disassembly, make a good judgment on the features etc. of the generated abnormalities to work according to the disassembling procedure. 2. All parts are manufactured in high precision. Therefore handle them with care not to bump them each other or drop them. 3. Work patiently not to forcibly strike or pry the sticking parts during disassembly. Otherwise it may result in generating burrs, damages, and performance deterioration. 4. Be careful not to leave the disassembled parts without appropriate protection. Otherwise they may be rusted by moisture and or contaminated by dust. 5. Put a match mark on each mating surface of part during disassembly. 6. Carry out the work putting every removed part in order, and taking care not to cause damage or loss. 7. Sealing parts shall be replaced in principle, even though no damage is found on them. Keep them on hand prior to disassembly. 8. Photos and figures of typical models are shown. Any partial difference between them and the product in use does not affect the disassembling procedure.

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Hydraulic travel system - Disassemble 1. Cleaning travel motor. 1.

Tighten the lifting eyes (LE) into the tapped holes of the spindle (2).

NOTICE: Screw two lifting eyes into the tapped holes of the spindle diagonally located with each other. 2. Pass a wire sling through the lifting eyes, lift up the travel motor by hoist, and carry into the cleaning bath. 3. Clean the travel motor with a car brush.

TULI12EXN6629AB

TULI12EXN6630AB

TULI12EXN6631AB

TULI12EXN6632AB

NOTICE: Since soil and sand are accumulated in the clearance (where the floating seal is fixed) between the hub (1) and the spindle (2), clean it with particular care.

2. Installing travel motor. 1. Place travel motor on a workbench. NOTICE: While aligning the threaded holes of the hub (1) and the workbench, place the travel motor in fixing holes of the workbench slowly. 2. Fix the travel motor with two socket bolts (F) on the workbench (WB).

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Hydraulic systems - Hydraulic travel system

3. Draining lubricating oil. 1.

Turn over the travel motor.

Loosen a plug (33) and two socket plugs (39). • If the plug (33) and the socket plugs (39) are removed and the travel motor is reversed, oil spills. Loosen them to such an extent that they can be turned by hand.

Turn over the travel motor.

Remove the plug (33) and two socket plugs (39) from the cover (13) and drain out the lubricating oil. • When draining out the lubricating oil, place a container under the workbench. (oil quantity 0.6 l (0.16 US gal))

TULI12EXN6633AB

TULI12EXN6634AB

TUPH12EXN6635AB

TULI12EXN6636AB

Remove the O-rings (37) from the plug (33) and two socket plugs (39).

4. Remove cover (13). 1.

Turn over the travel motor.

Remove the ring (45) with tool (SR).

Loosen two capscrews in the middle of the cover removal jig in the thread holes from which the plugs (33) and (39). (Two points)

Apply a block to two capscrews in the middle of the cover removal jig and tighten the screws to remove the cover (13) with tool (JC). • If it is difficult to remove the cover (13) due to resistance of the O-ring (35), lift the cover while lightly tapping the external periphery of the cover with a plastic hammer.

Remove the O-ring (35) from the hub (1). • Do not reuse the removed O-ring (35).

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Hydraulic systems - Hydraulic travel system

5. Removing drive gear 1 (4). 1.

Pull out the drive gear 1 (4) by hand.

Remove the steel balls (41) from the shaft (102). The coupling (14) may come off at the same time.

TUPH12EXN6637AA

6. Removing carrier assembly. 1.

Take out the carrier assembly from the hub (1).

Pull out the drive gear 2 (6) from the hub.

Remove the coupling (14) from the shaft (102).

TUPH12EXN6638AA

TUPH12EXN6639AA

TUPH12EXN6640AA

4. Disassembling carrier assembly. 1.

Loosen the hexagonal head screws (40) to remove three thrust washers 3 (12).

Remove three thrust washers (12), three planetary gears 1 (5), three needle roller bearings with retainers (27) and three bearing inner races (29) from the carrier (3).

5. Remove the thrust washer 1 (9) from the carrier (3).

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Hydraulic systems - Hydraulic travel system

7. Removing planetary gear 2 (7). 1.

Loosen four hexagonal head screws (40) and remove them from spindle (2).

TUPH12EXN6641AA

TUPH12EXN6642AA

TUPH12EXN6643AA

TUPH12EXN6644AA

2. Remove the four planetary gears 2 (7), the four needle bearings with cages (28) and the four inner races (30). 3. Remove four thrust collars 4 (11) from the spindle (2). 4. Remove the thrust washer 1 (9) from the spindle (2).

8. Removing rear flange 1.

Turn over the travel motor. â&#x20AC;˘ Follow the procedures below to make it easy to remove the plug when disassembling the interior of the rear flange (201). â&#x20AC;˘ Do not loosen the plugs unless disassembling the interior of the rear flange.

Loosen two plugs (224).

3. Loosen two plugs (226).

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Hydraulic systems - Hydraulic travel system

4. Loosen six socket bolts (243) and remove them from the rear flange (201).

TULI12EXN6645AB

TULI12EXN6646AB

TULI12EXN6647AB

TULI12EXN6648AB

5. Remove the rear flange (201) from the spindle (2). â&#x20AC;˘ Hold the rear flange by both hands, hold it up gently upright to remove it. Perform the work with care not to forcibly pry or strike the flange. Otherwise it may cause the timing plate (109) to drop and be damaged.

6. Remove the parallel pins (42) from the spindle (2).

7. Remove the O-rings (43) and (44) from the spindle (2). â&#x20AC;˘ Do not reuse the removed O-ring (43) and (44).

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Hydraulic systems - Hydraulic travel system

9. Removing rear flange fittings. 1.

Place the rear flange (201) on the workbench, with the mating surface for the spindle (2) facing up.

Remove the timing plate (109) from the rear flange (201). â&#x20AC;˘ It may be hard to remove the rear flange as the mating surface is stuck with oil. Insert a spatula (SP) into the draft groove of the mating surface on the rear flange side and hold the timing plate up. Then the rear flange comes off. If a sharp tool like a screwdriver is put into the mating surface, the mating surface may be damaged to cause an oil leakage. Do not use sharp tools.

TULI12EXN6649AB

TULI12EXN6650AB

TULI12EXN6651AB

TULI12EXN6652AB

Remove the parallel pins (241) from the rear flange (201).

4. Remove bearing (150) from the rear flange (201).

10. Removing brake valve parts from rear flange. 1.

Remove two plugs (224) from the rear flange (201).

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2. Remove two stoppers (225) and two springs (228) from the rear flange (201). 3. Remove the spool (223) from the rear flange (201). â&#x20AC;˘ To remove the spool (223), place your hand on one part of the plug port of the rear flange (201) and tilt it down. Then the spool (223) falls down. Hold the tip and remove it.

TULI12EXN6653AB

TULI12EXN6654AB

TULI12EXN6655AB

TULI12EXN6656AB

4. Remove two plugs (226) from the rear flange (201).

5. Remove two springs (230) and two valves (227) from the rear flange (201).

6. Remove O-ring (236) from plug (224). â&#x20AC;˘ Do not reuse the removed O-ring (236).

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7. Remove O-ring (237) from plug (226). â&#x20AC;˘ Do not reuse the removed O-ring (237).

TULI12EXN6657AB

TUPH12EXN6658AA

TUPH12EXN6659AA

11. Removing two-speed switching spool 1.

Remove the plug (221) from the rear flange (201).

Remove O-ring (273) from plug (221). â&#x20AC;˘ Do not reuse the removed O-ring (273).

3. Remove the spool (263) and the spring (266) from the rear flange (201).

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12. Removing the parking brake section NOTE: Install a protection cover (PC) on the piston (112). Otherwise the piston may fly out suddenly from the spindle (2) due to compressed air to cause injury. 1.

Blow compressed air (AH) into the passage hole for the parking brake of the spindle (2) and take out the piston (112) from the spindle (2).

Remove the O-rings (135) and (139) from the piston (112). • Do not reuse the removed O-ring (135) and (139). TULI12EXN6660AB

TULI12EXN6661AB

TULI12EXN6662AB

TULI12EXN6663AB

13. Disassembling hydraulic motor section • When placing the travel motor on its side, place an oil pan under the travel motor to receive oil flowing out from the travel motor. 1.

Incline travel motor 90°.

Drain oil out of the travel motor.

Remove two separator plates (116) and one friction plate (115).

Hold the cylinder block (104) by hand and turn it 2 or 3 times alternatively to separate the shoe (106) adhered on the swash plate (103). • Note that, if the cylinder block (104) is pulled out without separating the shoe (106), the shoe (106) left on the swash plate (103) may allow the parts (piston, shoe, etc.) on the cylinder block (104) to come off and drop into the spindle (2).

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5. Remove the cylinder block (104) from the drive shaft (102). 6. Remove piston assembly [piston (105) and shoe (106)] and the retainer plate (107) from the cylinder block (104). â&#x20AC;˘ When removing the cylinder block, hold the retainer plate (107) by both hands to remove it with the piston assembly. â&#x20AC;˘ The piston (105) and the bottom (106) are flattened in the spherical section so that they can be assembled into a single piece. It is not possible to remove the piston from the shoe without damaging the shoe. When replacement is required, replace the piston and shoe by a set (hereafter referred to as the piston assembly).

TULI12EXN6664AB

TULI12EXN6665AB

TULI12EXN6666AB

TULI12EXN6667AB

7. Remove the retainer plate (107) from piston assembly (105) and (106) [seven sets].

8. Remove the thrust ball (108) from the cylinder block (104).

9. Remove three rollers (151) from the cylinder block (104).

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14. Removing spring inside cylinder block 1.

Place the cylinder block (104) on the press bench. • Remove the spring, only when its replacement is necessary. • When removing the spring, align the centre of the retainer bushing (RM1) with the washer centre in order to prevent the cylinder block from being damaged by contact. • Put a vinyl sheet (VS) over the cylinder block so as not to damage the surface of the cylinder block. TULI12EXN6668AB

TULI12EXN6669AB

TULI12EXN6670AB

TULI12EXN6671AB

2. Place the retainer bushing (I) against the washer (110), remove the snap ring (145) from the groove inside the cylinder block (104). NOTICE: Release pressing force slowly. Otherwise the spring may fly out to cause injury.

3. Remove the snap ring (145), washer (110), spring (114), and washer (110) out of the cylinder block.

15. Removing swash plate 1.

Remove the swash plate (103) from the drive shaft (102). • When removing the swash plate (103), ensure that pivot (167) is not adhered on the swash plate (103).

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2. Pull the drive shaft (102) out of the spindle (2). Then the ball bearing (149) is removed together. • Be careful to lightly strike the tip of the shaft on the reduction side using a plastic hammer to allow the shaft to come off easily. Otherwise the shaft may pop out. 3. Remove two pivots (167) and two the parallel pins (177) from the spindle (2). 4. Take out the 2-speed switching piston kit (piston assembly and seal ring) and the spring (190) from the spindle (2). Piston assembly: piston (161), crawler (162), seal ring (163).

TULI12EXN6672AB

TULI12EXN6673AB

TULI12EXN6674AB

TUPH12EXN6675AB

16. Removing ball bearing. • Remove the ball bearing, only when its replacement is necessary. 1.

Place the retainer bushing (RM2) on the press bench and insert the drive shaft (102).

Hold down the tip of the drive shaft (102) by a press and remove the bearing (149) from the shaft.

• Do not reuse the ball bearing. CA.Compressed air (Air gun).

17. Removing engine. 1.

Apply the clamp plates (FM) to the spindle (2) in the equally spaced positions, and fasten three M16 x 2.0 x 150 (approximately) to the workbench. Tightening torque: 39 - 79 N·m (29 - 58 lb ft)

Turn over the travel motor. (Direct the reduction unit side upward).

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3. Remove two hexagon set screws (47).

TUPH12EXN6676AA

TUPH12EXN6677AA

TULI12EXN6678AB

TUPH12EXN6679AA

4. Loosen the ring nut (22) using a tightening jig (JB). â&#x20AC;˘ Do not reuse the removed ring nut (22) of which tooth flank may be damaged.

5. Remove the ring nut (22) from the spindle (2).

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18. Removing the ring nut. 1.

Turn over the travel motor. (direct the motor side upward).

Remove the clamp plates from the workbench.

Tighten two M16 eyebolts in the mounting thread holes of the spindle (2) in the diagonal position.

Hook a wire rope with hook to M16 eyebolts, and lift by a crane to remove the spindle (2) from the hub (1). At this time, the floating seal (31) and oil seal (132) will be removed together with the spindle (2). TUPH12EXN6680AA

TUPH12EXN6681AA

TUPH12EXN6682AB

TUPH12EXN6683AA

19. Removing main bearing. 1.

Remove the floating seal (31) from the hub (1). • Do not reuse the removed floating seal (31).

Apply a punch between the inside periphery of the hub (1) and the main bearing (24) to remove the main bearing using a hammer. • When the fit section of the outer race of ball bearing (24) comes out of hub (1), the ball bearing drop from the hub. Therefore place a receptacle under the workbench and spread a rubber mat on the receptacle so as not to damage the parts.

3. Turn over the travel motor. 4. Tapping the end face of outer race of ball bearing (24) with aluminum rod (pin punch) (PP) and hammer, remove the ball bearing from hub (1). • Remove ball bearing (24) little by little, tapping evenly the end face of outer race of the ball bearing at 3 or 4 points of the from the hub so that the ball bearing is not suck.

20. Removing spindle fittings. 1.

Remove the seal (31) from the spindle (2).

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2. Remove the oil seal (132) from the spindle (2). • Never reuse the removed oil seal (132).

TULI12EXN6684AB

TUPH12EXN6685AA

TUPH12EXN6686AA

21. Rough washing of parts. 1.

Separate the four parts, namely the hub (1), the spindle (2), the cover (13) and the rear flange (201) from the other parts (hereafter referred to as built-in parts).

Put the hub, spindle, cover and rear flange in a cleaning bath and clean them. • Carefully remove dust accumulated on the surfaces of parts to make them completely clean.

NOTICE: Kerosene is combustible. Be careful not to cause fire, burns, and injury. • Before cleaning stained parts, immerse them in kerosene until dust and stain become soft and are floated so as to prevent damage when cleaning. 3. Put the built-in parts in a rough cleaning bath containing kerosene and clean them.

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22. Finish cleaning. 1. Put parts in a finish cleaning bath containing kerosene and clean them well, turning them slowly. 2. Wipe off kerosene adhered to the parts using a clean waste cloth. â&#x20AC;˘ Dry the inner surfaces of the hub (1) and the spindle (2) in the dust-free and dry conditions by blowing compressed air on them. After drying, apply hydraulic oil to every part. â&#x20AC;˘ Dry the inner surface of the rear flange (201) and the hydraulic motor components in the dust-free and dry conditions by blowing compressed air on them. After drying, apply hydraulic oil to every part.

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TULI12EXN6687AB

TULI12EXN6688AB

Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Pre-assemble Preparation Prepare a workbench, tools and jigs as in the case of Hydraulic travel system - Special tools (35.353) .

General precautions for assembly 1. For assembly also, take the precautions described in Hydraulic travel system - Prepare (35.353) . 2. For assembly, remove any metallic dust or foreign material from all parts and make sure that the parts are free of burrs and dents which should be ground off using an oilstone. 3. Replace the O-rings, oil seals, and floating seals with new ones. 4. Bonding adhesive is applied to the threaded portions and tapped holes of spindle (2) and carrier (3) when assembling. Remove their grease by using the tap ( M8 X 1.25), and wash with solvent. After that, degrease solvent of the holes by spraying with compressed air. Replace hexagon head bolt (40) with new ones. 5. Be careful not to damage the O-rings, oil seals, and floating seals at installation (lightly apply grease to them for smooth installation). 6. Prior to assembly, apply clean hydraulic oil ( AKCELA HYDRAULIC EXCAVATOR FLUID) to movable and sliding portions of hydraulic motor components and valves. 7. Do not use rags during assembly to prevent malfunctions due to textile lints. 8. On completion of assembly, plug every opening to prevent the entry of dirt. 9. Photos and figures of typical models are shown. Any partial difference between them and the product in use does not affect the assembling procedure.

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Hydraulic travel system - Assemble NOTE: After replacing any of the following parts with new ones, adjust the preload of the ball bearing and thickness of the snap ring without fail. 1. Parts requiring preload adjustment of the ball bearing after their replacement: Hub (1), the spindle (2) and ball bearing (21). NOTE: When replacing any of the above parts, use the parts previously adjusted. Otherwise, the travel motor may malfunction resulting in premature breakage.

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Assembling hub section 1. Place the hub (1) on the press workbench on a support (S). 2. Insert the main bearing (24) in the hub (1). Place the main bearing press fit jig (BB) on the outer race of the main bearing (24). Push down the jig by a press to press fit the bearing into the hub (1). 3. Turn over the hub (1). 4. Press fit the main bearing (24) into the hub (1) in the same way as the above. • Be careful not to mistake orientation of the main bearing (24) when press fitting. TULI12EXN6689AB

TULI12EXN6690AB

TULI12EXN6691AB

TULI12EXN6692AB

5. Apply grease to the O-ring of the floating seal (31). Build the floating seal into the floating seal groove of the hub (1). • Apply a small amount of grease to the entire surface of the O-ring after removing it from the floating seal. • Place the FS inserting tool (FS1) , the floating seal and the FS inserting tool (FS2) in this order, and press in until the FS inserting tool (FS2) contacts with the FS inserting tool (FS1). Remove the FS inserting tools and ensure that the end surface of the hub is in alignment with the face of the floating seal at an accuracy of 1 mm (0.0394 in) or less. 6. Attach two lifting eyes (LE) to the tapped holes of the hub (1) in diagonal position. 7. Attach a wire with hooks to the lifting eyes, lift the hub (1) by a crane and then install the hub (1) on the workbench. • While aligning the tapped hole in the hub (1) with the fixing hole (F) in the workbench (WB) , carefully insert the hub (1) into the fixing hole (F) in the workbench. 8. Attach the hub (1) to the workbench (WB) by tightening the screws diagonally. NOTICE: Fully tighten the nuts. Otherwise, the travel motor may fall down to cause injury when it is turned over.

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Assembling spindle section 1. Apply grease to the O-ring of the floating seal (31), and fit the floating seal in the groove of the spindle (2). • Place the FS inserting tool (FS3), the floating seal and the FS inserting tool (FS2) in this order, and press in until the FS inserting tool (FS2) contacts with the FS inserting tool (FS3). • Remove the FS inserting tools and ensure that the end surface of the hub is in alignment with the face of the floating seal at an accuracy of 1 mm (0.04 in) or less.

TULI12EXN8730AB

TUPH12EXN8731AA

TUPH12EXN8732AB

TUPH12EXN8733AA

2. Attach two lifting eyes to the spindle (2) in diagonal position. 3. Attach a wire with hooks to lifting eyes, lift the spindle (2) by crane and then insert the spindle (2) in the hub (1) slowly. 4. Fix the hub (1) and the spindle (2) with the fixing plate in diagonal position. Tightening torque: 295 - 353 N·m (218 - 260 lb ft) 5. Turn over the travel motor. (Direct the reduction unit side upward.) 6. Tighten the ring nut (22) into the spindle using a tightening jig. Tightening torque: 353 - 431 N·m (260 - 318 lb ft)

7. Remove two hexagon set screws (47). Tightening torque: 4.8 - 5 N·m (3.54 - 3.69 lb ft)

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8. Turn over the travel motor. (Direct the motor side upward). 9. Remove the clamp plates from the workbench.

TUPH12EXN6697AA

Assembling motor parts inside spindle 1. Press fit the oil seal (132) into the spindle (2) using the oil seal press fit tool (RM3) and a hammer. • Apply AKCELA Moly grease to the lip of the oil seal before installing. • Be careful not to mistake the orientation of the oil seal. 2. Insert two parallel pins (177) into the pin holes of the spindle (2). 3. Apply AKCELA Moly grease to the semi-spherical surface of two pivots (167) and fit them to the parallel pins (177) installed to the spindle (2). 4. Apply grease to the spring pin (190) to install to the piston kit consisting of piston (161), shoe (162)and seal ring (163).

TULI12EXN8735AB

TUPH12EXN8736AA

TULI12EXN8737AB

5. Apply grease to the sliding surface of the piston assembly to install to the piston hole of the spindle (2).

Inserting shaft NOTICE: Carefully carry out the insertion work using leather gloves to prevent possible burns. Insert bearing (149) until it closely contacts the flange of the drive shaft (102). 1. Put the ball bearing (149) in a heating bath to heat it at 90 - 110 °C (194 - 230 °F) for 10 min and then insert it onto the drive shaft (102).

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2. Incline travel motor 90°. 3. Insert the shaft (102) into the spindle (2). • Insert the shaft (102) into the spindle (2) slowly and carefully. Otherwise the lip of the oil seal (132) fitted inside the spindle (2) may be damaged. Damage to the lip may cause oil leakage, leading to premature failure of the travel motor. 4. Install the swash plate (103) into the spindle (2). • Apply grease to an interface between the swash plate (103) and the spindle (2). • Align two pivots (167) installed in the spindle (2) with the pivot mounting holes of the swash plate to fit the swash plate (103) into the spindle (2).

TULI12EXN8738AB

TULI12EXN8739AB

TULI12EXN8740AB

TULI12EXN8741AB

Installing cylinder block 1. Place the washer (110), spring (114), washer (110), and snap ring (145) in this order, into the cylinder block (104). • Direct the sharp edge side of the snap ring (145) toward the inlet side. • Direct the sharp edge side of the washer (110) contacting the snap ring (145) towards the snap ring side. 2. Place the cylinder block (104) on the press bench. 3. Place the retainer metal (RM1) against the washer (110). While holding down the retainer metal (RM1) by pressing it, fit the snap ring (145) into the snap ring groove of the cylinder block (104) with a snap ring plier. • Pressing force of the spring (114) is more than 1180 N·m (870 lb ft). • Cover the cylinder block (104) with a vinyl sheet (VS) to prevent damage to the contact plane between the cylinder block (104) and the timing plate (109).

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Assembling hydraulic motor section 1. Put three rollers (151) into the holes of the cylinder block (104). 2. Place the thrust ball (108) on the cylinder block (104).

TUPH12EXN8742AA

TULI12EXN6806AB

TULI12EXN6807AB

3. Fit seven piston assemblies to the retainer plate (107). • After assembling, immerse the whole unit in hydraulic oil. 4. Fit the retainer plate (107) and the seven piston assemblies to the cylinder block (104). • Carefully match the retainer plate (107) with the spherical part of the thrust ball (108) for installation. 5. Insert the cylinder block (104) onto the drive shaft (102). • For installation, align the spline hole in the cylinder block (104) with the spline shaft of the drive shaft (102). • After installing the cylinder block, turn it by hand to make sure that it fits properly. If not, inspect it. • Do not take up the cylinder block (104). Otherwise the thrust balls (108) may come off, leading to abnormality in rotation.

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Installing parking brake Prior to installing, immerse the friction plate (115) in hydraulic oil. 1. Incline the workbench by 90°. 2. Assemble one friction plate (115) and two separator plates (116) into the cylinder block (104) alternately one by one. 3. Lightly coat the O-rings (135) and (139) with grease and install them into the O-ring grooves of the piston (112). 4. Install the piston (112) into the spindle (2). • If it is hard to fit the piston (112) into the spindle (2) due to the resistance of the O-rings (135) and (139), lightly tap the end face of the piston (112) with a plastic hammer.

TUPH12EXN8745AA

TUPH12EXN8746AA

TULI12EXN6810AB

TUPH12EXN8748AA

• Take care not to damage the O-rings when installing the piston (112).

Assembling brake valve parts inside rear flange 1. Fit two O-rings (237) to two plugs (226). • Coat the O-rings (237) with grease. 2. Install the valve (227) and spring (230) onto the plug (226), applying grease to them so as to connect all of them by adhesion of grease. 3. Insert the plug (226) with the valve (227) and spring (230) assembled in one piece, into the rear flange (201). • For insertion of the plug (226), place the rear flange (201) on the workbench, facing the tapped hole for plug mounting of the rear flange (201)upward and align the centre of tapped hole with the plug centre. This is intended to prevent the O-ring from being damaged and spring (230) from coming out of valve (227) due to contact between the bore of the rear flange and the valve. 4. After installing two plugs (226) to the rear flange (201), temporarily tighten them using an Allen wrench.

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5. Insert the spool (223) into the rear flange (201). • Apply hydraulic oil to the spool and insert the spool into the rear flange. • To install the spool, align the hole of the rear flange with the spool shaft centre so as to prevent the inner surface of the rear flange and the outer surface of the spool from being damaged due to interference. • Otherwise internal leaks will occur after reassembly, resulting in performance deterioration of the travel motor. TULI12EXN8749AB

TUPH12EXN8750AA

TULI12EXN8751AB

TUPH12EXN8752AA

6. Fix the O-ring (236) to the plug (224). 7. Install the spring retainer (225) and spring (228) into the plug (224). 8. Remove two plugs (224) from the rear flange (201). 9. Temporarily tighten two plugs (224) to the rear flange (201) with a wrench.

Assembling rear flange fittings 1. Installing two-speed switching spool inside rear flange. 1.

Insert the spring (266) and the spool (263) into the rear flange (201)

Fix the O-ring (273) to the plug (221). • Apply grease to the O-ring (273)

Tighten the plug (221) onto the rear flange (201).

Tighten the plug (221) in the rear flange (201) at the specified torque with an Allen wrench key. Tightening torque: 49.2 - 68.8 N·m (36 51 lb ft).

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2. Coat the ball bearing (150) with hydraulic oil and fit it to the rear flange (201). 3. Put two the parallel pins (241) into the pin holes in the rear flange (201). 4. Apply grease to the mating face of the timing plate (109) in contact with the rear flange (201).

TUPH12EXN8753AA

TUPH12EXN8754AA

TUPH12EXN8755AA

TUPH12EXN8756AA

5. Install the timing plate (109) into the rear flange (201), using the parallel pin (241) as a guide. • Install the timing plate (109) until it comes in close contact with the rear flange (201). This close contact prevents the timing plate (109) from falling out of the rear flange (201) when the rear flange is installed into the spindle (2). 6. Install eight springs (113) into the rear flange (201). • Sufficiently coat the springs (113) with grease and fix them so as not to allow them to drop from the rear flange (201).

Connecting rear flange with the spindle 1. Insert the O-rings (43) and (44) into the O-ring groove of the spindle (2). • Fit the O-rings (43) without applying grease. Otherwise grease may ooze out of the contact surface between the rear flange (201) and the spindle (2) if an oil leakage occurred.

2. Fix two the parallel pins (42) to the spindle (2). 3. Fill 0.3 l (0.08 US gal) of hydraulic oil into the spindle (2).

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4. Align two parallel pins (42) set in the spindle (2) with the pin holes of the rear flange and install the rear flange (201) into the spindle (2).

TUPH12EXN8757AA

TUPH12EXN8758AA

TUPH12EXN8759AA

TUPH12EXN8760AA

5. Screw six hexagonal bolts (243) into the spindle (2) and tighten them at the specified torque. Tightening torque: 24.5 - 34.3 N·m (18 - 25 lb ft)

6. Tighten the plug (226) at the specified torque. Tightening torque: 68.7 - 88.3 N·m (51 - 65 lb ft)

7. Tighten the plug (224) at the specified torque. Tightening torque: 181.3 - 210.7 N·m (134 - 155 lb ft)

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Installing the planetary gear carrier assembly 1. Insert three thrust washers (9), three bearing inner races (29), three needle roller bearings with cage (27) and three planetary gears 1 (5) in this order into the column section of the carrier (3). NOTE: If the tapped hole of carrier (3) is smeared oil or grease, degrease it by using the tap ( M8 X 1.25). Thereafter, clean it with solvent and dry the solvent from the holes by means of compressed air. Otherwise axial-force dose not occur enough, and it may cause bole to loosen.

TUPH12EXN8761AA

TUPH12EXN8762AA

TUPH12EXN8763AA

2. Tighten three hexagon head screws (40) with three thrust washers 3 (12) to fasten the carrier assembly to the column section of the carrier to the specified torque. Tightening torque: 24.5 - 34.3 N·m (18 - 25 lb ft) [Carrier assembly finished]

Tightening planetary gear 2 1. Turn over the travel motor. (Direct the reduction unit side upward.) 2. Install the thrust washer 1 (9) to the spindle (2). 3. Insert four thrust collars (11) and four inner races (30) into the column section of the spindle (2). 4. Insert four needle roller bearings with retainer (28) into the column section of the spindle (2). 5. Make four planetary gears 2 (7) intermesh with the internal teeth of the hub (1) to insert them into the column section of the spindle (2). • Clean the thread hole at the tip of the column section of the spindle (2) by removing oil and grease using degreasing agent if necessary. • Remove oil and grease from four hexagon head screws (40).

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6. Tighten four thrust washers 3 (12) into the column sections of the spindle (2) with four hexagon screws (40) at the specified torque. Tightening torque: 24.5 - 34.3 NÂˇm (18 - 25 lb ft)

TUPH12EXN8764AA

TUPH12EXN8765AA

TUPH12EXN8766AA

Installing sun gear 2 1. Install the coupling (14) to the shaft (102). 2. Make the sun gear 2 (6) mesh with the planetary gear 2 (7) to install.

Installing the planetary gear carrier assembly 1. Install the planetary gear carrier assembly mounted in item (11) while making it mesh with the drive gear 2 (6) and the internal teeth of the hub (1).

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Installing sun gear 1 1. Insert the sun gear 1 (4) into the coupling (14). Preassemble the steel balls (41) into the drive gear 1 (4). • Apply grease to the steel balls (41) to prevent them from dropping before assembling them onto the drive gear 1 (4). 2. Install the drive gear 1 (4) while making it mesh with the teeth of the three planetary gears 1 (5).

TUPH12EXN8767AA

TUPH12EXN8768AA

TUPH12EXN8769AA

Installing cover 1. Supply 0.6 l (0.16 US gal) of lubricating oil to the hub (1). • Apply grease to the O-ring (35) 2. Fit the O-ring (35) into the O-ring groove of the hub (1). 3. Install the cover (13) to the hub (1). • When it is difficult to fit the cover (13) into the hub (1), tap the periphery of the cover (13) lightly and uniformly with a plastic hammer. Otherwise the O-ring (35) may be damaged to cause oil leakage. Lubricating oil may also gush out through the thread hole.

4. Fit the O-ring (45) into the O-ring groove of the hub (1). • Avoid the position in which the mating port of the ring (45) faces the notch of the hub (1). 5. Install the O-rings (37) to two plugs (33) and (39). • Apply grease to the O-ring (37) lightly. 6. Tighten the plugs (33) and (39) into the cover (13) to the specified torque. Tightening torque: 49 - 68.6 N·m (36.1 - 51 lb ft)

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Removal of travel motor 1. Turn over the travel motor. (Direct the motor side upward). 2. Remove the travel motor mounting screws from the workbench. 3. Screw two eyebolts into the thread holes of the spindle (2). â&#x20AC;˘ Arrange the two eyebolts in the diagonal position. 4. Hook the wire rope with hook to the eyebolts to remove the travel motor from the workbench using a crane.

TUPH12EXN8770AA

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Hydraulic travel system - Service instruction Maintenance standard After disassembling GM motor, follow these standards to perform maintenance. Handle every part with care and, in particular, avoid damaging the moving and sliding portions. 1. Replace any seal (O-ring, oil seal, and floating seal) once used even if no damage is found. 2. Wear parts maintenance standard. 1. Replace any part heavily damaged visually. 2. Replace a part that shows the following abnormalities. Item No.

Part name

Hub

Mandrel

3. 4. 6. 5. 7. 9. 11. 12.

Carrier assembly Drive gear 1 Drive gear 2 Planetary gear 1 Planetary gear 2 Thrust washer 1 Thrust collar 4 Thrust washer 3

24. Main bearing 27. Needle bearing 28. 29. Inner bearing cup 30. 201. Rear flange 102. Shaft 103. Swash plate 104. Cylinder block

Piston assy 105. Piston 106. Crawler

107. Retainer plate

108. Thrust washer

Presence of defect Severe visual damage Pitting recognized on ring gear tooth flank Abnormal wear such as galling Severe visual damage Abnormal wear such as galling Abnormal wear such as galling

Standard value Allowable value (standard (criteria) dimension) –

–

Pitting recognized on tooth flank Flaking recognized on bearing rolling surface

–

Sliding surface discoloured and/or abnormally worn

–

Play 0.05 mm (0.002 in)

Play 0.15 mm (0.006 in)

–

Dent recognized Flaking recognized Uneven wear recognized Pitting recognized on roller Abnormal wear on cage end surface Flaking recognized on bearing rolling surface Scratch recognized on valve (263) sliding surface Oil seal (132) contacting surface worn Spline worn Seizure is recognized Spline worn Bore severely worn Scratch and uneven wear recognized on timing plate (109) sliding surface Clearance exists between piston (105) and bottom (106) Abnormal and uneven wear recognized on shoe surface Uneven wear recognized on shoe (106) sliding surface Scratch and uneven wear recognized on thrust ball (108) sliding surface Uneven wear recognized on retainer plate (107) sliding spherical surface

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Item No.

Part name

109. Timing plate 115. Friction plate 116. Mating plate 105. Piston 149. Ball bearing 150. 161. 162. 163. 223. 263.

Two-speed piston kit Piston Crawler Seal ring Spool

Presence of defect Seizure and uneven wear recognized on sliding surface Uneven wear recognized on both end surfaces Specified torque cannot be reached Seizure is recognized Scratch recognized on periphery Dent recognized Flaking recognized Wear recognized Uneven wear recognized on periphery Abnormal and/or uneven wear recognized on shoe surface Abnormal wear recognized on seal ring Uneven wear recognized on periphery Scratch recognized on periphery

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Standard value Allowable value (standard (criteria) dimension)

Braking torque 32.4 N·m (23.9 lb ft)

–

Hydraulic systems - Hydraulic travel system

Hydraulic travel system - Test Verification test After finishing maintenance of the GM motor, carry out performance verification tests according to the procedures below: 1. Measuring instruments to be used 1 2 3

Pressure gauge for 35 Kg/cmÂ˛ (498 psi) Measuring cylinder (for 5 l (1 US gal)) Stop watch

2. Test procedure

TULI12EXN6834FA

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2 1 1

Index Hydraulic systems - 35 Hydraulic travel system - 353 Hydraulic travel system - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Hydraulic travel system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic travel system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Hydraulic travel system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic travel system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic travel system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic travel system - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Hydraulic travel system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic travel system - Pre-assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Hydraulic travel system - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Hydraulic travel system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Hydraulic travel system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Hydraulic travel system - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic travel system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Hydraulic systems - 35 Hydraulic central joint - 354

CX35B CX39B

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Contents Hydraulic systems - 35 Hydraulic central joint - 354

TECHNICAL DATA Hydraulic swivel General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Hydraulic swivel Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Hydraulic central joint Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hydraulic swivel Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIAGNOSTIC Hydraulic swivel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Hydraulic swivel - General specification

TULI12EXN6188FA

Model (type) Port No. Maximum working pressure Pressure test Delivery Revolution Weigh Port size

YV-7200 A, B, C, D

E, F

G (Drain)

22.6 MPa (3278 psi)

17.7 MPa (2567 psi)

3.9 MPa (566 psi)

0.49 MPa (71 psi)

33.9 MPa (4917 psi) 35 l/min (9.2 US gpm)

26.6 MPa (3858 psi) 5.9 MPa (856 psi) 26 l/min (6.9 US 12 l/min (3.2 US gpm) gpm) 10 RPM max. 21.5 kg (47.4 lb) PF3/8 PF1/4

PF3/8

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0.735 MPa (107 psi) 5 l/min (1.3 US gpm)

PF1/4

Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Static description Components

TULI12EXN6189FB

1. 2. 3. 4. 5. 6. 7. 8.

Shaft (Qty. 1) Body (Qty. 1) Flange (Qty. 1) Thrust ring (Qty. 1) Pin (Qty. 1) Seal (Qty. 4) O-ring (Qty. 1) O-ring (Qty. 1)

9. 10. 11. 12. 13. 14. 15.

Seal ring (Qty. 1) Seal ring (Qty. 1) Snap ring (Qty. 1) Screw (Qty. 4) Plug (Qty. 3) Washer (Qty. 4) Back-up ring (Qty. 1)

Operation The swivel joint is installed in the slewing centre of the machine, and keeps the connection between hydraulic oil circuits regardless of the slewing angle of the upper frame. On the body (2) and shaft (1) which are able to independently rotate with each other, the necessary number of ports (3) are provided corresponding to the number of circuits. The necessary grooves are located both on the body (2) on its inner surface and on the shaft (1) on its outer surface, and they are sealed in their upper and lower parts with gaskets (4). The hydraulic oil flowing into the shaft from the port (3) is able to maintain its flow through the hydraulic circuit (5) between the body (2) and the shaft (1), so that the various circuits do not show obstructions due to an independent slewing between body (2) and shaft (1).

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TULI12EXN4627AB

Hydraulic systems - Hydraulic central joint

Hydraulic central joint - Prepare 1. Lift the machine by approximately 30 cm (11.81 in) and insert support blocks under the crawlers, namely front, rear, right and left, to secure the working area under the machine. 2. Remove the cover of the floor plate. 3. Loosen four M10 X 16 capscrews (A6) to remove the under cover (A5). : 17 mm 4. Release the residual pressure in the circuit and the hydraulic tank.

TULI12EXN4971AA

TULI12EXN4972AB

5. Disconnect the hose of the slewing motor. â&#x20AC;˘ Remove the canopy to facilitate to remove the swivel joints.

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Hydraulic central joint - Remove 1. Remove the upper-side drain hoses (25) and the connector (1), (4). : 19 mm 2. Disconnect all the other hoses connected to the swivel joint. Attach a plug and tag to each of the openings.

TULI12EXN6348AB

TULI12EXN6349AB

TULI12EXN6350AB

TULI12EXN6351AB

3. Removing stopper Loosen two M12 X 40 capscrews (A6) to remove the stopper (A3). : 19 mm [a long type approximately 300 mm in length required].

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Hydraulic systems - Hydraulic central joint

4. Removing rotary control valve Loosen four M12 X 40 capscrews (C2) to remove the swivel joint (C1) downward. : 19 mm Weight: 22 kg (48.5 lb)

TULI12EXN4979AB

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Hydraulic central joint - Install 1. Install the swivel joint in reverse order of the removal to the tightening torque shown below: Install the capscrews (C2). : 19 mm Tightening torque 102 N·m (25 lb ft) Apply LOCTITE® 262 to the capscrews. Install the capscrews (A6). : 19 mm Tightening torque = 115 N·m (85 lb ft) Connect the hoses. AL. AR. BL. BR.

(Upper) (Lower) (Upper) (Lower)

forward reverse forward reverse

L. R. TL. TR.

TULI12EXN4980AA

Dozer (H) Dozer (R) Travel motor (left) Travel motor (right)

Tightening torque Thread size PF 1/4 PF 3/8

Spanner used 19 mm 22 mm

O-ring type fitting 36.3 N·m (26.8 lb ft) 73.5 N·m (54.2 lb ft)

2. Reinstall all the removed parts. 3. Pressurize the hydraulic tank. 4. Check the performance.

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30° flare type fitting 29.4 N·m (21.7 lb ft) 49 N·m (36.1 lb ft)

Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Prepare General precautions • For disassembly and assembly, select the clean area and prepare clean containers to put the removed parts. • Clean around the port and remove the paints of the joint with wire brush. • Clean the removed parts with cleaning solvent, like light oil, etc. • Replace seals with new ones every disassembly, and apply grease lightly. • Check every part for severe wear and seizure, and remove burr, etc. with emery paper. • Check that seal groove is free from foreign substances, dust, etc.

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Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Disassemble 1. Loosen the screw and remove the flange (3). Fix the body (2) with vise. : 17 mm or : 17 mm

TULI12EXN6587AB

TULI12EXN6588AB

TULI12EXN6589AB

TULI12EXN6590AB

2. Take out O-ring (8), snap ring (11) and thrust ring (4).

3. Remove shaft (1) from the body (2). â&#x20AC;˘ Apply the knock pin (K) to the end face of the shaft, and strike it with hammer. â&#x20AC;˘ Choose the knock pin (K) made of copper, plastic, etc.

4. Remove the seal ring (10) from the shaft.

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Hydraulic systems - Hydraulic central joint

5. Remove the seal ring, etc. from the inside the body. â&#x20AC;˘ Be sure of the position of seal, etc. referring to the construction drawing. â&#x20AC;˘ Take out O-ring with the pointed tool like a gimlet.

TULI12EXN4903AA

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Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Assemble 1. Insert the seal rings into the body. • Check the seal position referring to the construction drawing. • Ensure that O-rings are free from twisting. • Do not deform nor bend the seal ring.

TULI12EXN4904AA

TULI12EXN4905AB

TULI12EXN4906AB

TULI12EXN4907AB

2. Assemble the dust seal ring (10) onto the shaft (1). • Apply enough grease to the lip section of the dust seal.

3. Install shaft (1) to body (2). • Apply hydraulic oil or grease around the shaft lightly. • Strike the shaft with a plastic hammer carefully not to damage seal.

4. Fit thrust ring (4) and snap ring (11). • Fit the snap ring in the groove correctly.

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Hydraulic systems - Hydraulic central joint

5. Fit O-ring (8) and install flange (3). 6. Install spring washer (14) and bolt (12). : 17 mm or : 17 mm • Tightening torque: 52 - 57 N·m (38 - 42 lb ft) • Put pipe through the locking pin of the shaft, and check that the shaft rotates smoothly at a torque of approximately 78 - 108 N·m (58 - 80 lb ft)

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TULI12EXN4908AB

Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Inspect Inspection after assembly After assembly is completed, check for leakage of oil in each circuit using the equipment shown below.

TULI12EXN8544FB

1. Connect a pipe (3) between the hydraulic pump (4) and the shaft (1) side port. 2. Connect a pressure gauge (5) to the body (2) side. 3. Increase the pressure gradually to 22.6 MPa (3278 psi) adjusting the relief valve (6), then perform 1 min leak test. â&#x20AC;˘ Open the neighboring ports on both sides and check visually for leakage from the ports. â&#x20AC;˘ Check the body for crack, which may cause oil leakage, by a dye check.

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Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Service instruction Maintenance standards Check Procedures and Remedy Remedy Replace the O-rings if there is leakage. Replace all seal parts. Replace all seal parts. Recondition in accordance with the service limit. Restore in accordance with the service limits. Replace the seal kit. Recondition in accordance with the service limits. Regarding the seal kit

Check procedure Place checked Seals which prevent external Check if oil is leaking out leakage of hydraulic oil â&#x20AC;&#x201C; 4000 h Disassemble All seal parts and check whether there All sliding portion Check for abnormal wear, is leakage or not defects, corrosion, etc. due to seizing, foreign material being caught, etc. When disassembling All parts. Check for abnormal wear, due to trouble defects, corrosion, etc. due to seizing, foreign material being caught, etc. Check interval 2000 h

Parts service limit Body and shaft Judgment criteria Wearing of surface treated with induction hardening, and coming off of surface due to seizing, foreign material getting caught, etc. Body and shaft sliding Abnormal wear or defects by 0.1 mm portion other than seals (0.0039 in) deep or deeper due to seizing or foreign material getting caught, etc. Defects less than 0.1 mm (0.0039 in) deep Portions which slide Wearing by 0.5 mm (0.0197 in) or against the thrust ring. more, or abnormal wear Wear less than 0.5 mm (0.0197 in) Defects due to seizing or foreign material getting caught, etc. which are within the wear limit of 0.5 mm (0.0197 in) and within repairable level

Part Seal parts and sliding portion

Remedy Replace

Replace Repair with an oil stone Replace Repair so that is smooth Repair so that is smooth

Flange and thrust ring Judgment criteria Part Portions of flange which slide against the Wearing by 0.5 mm (0.0197 in) or more, or shaft end abnormal wear Wear less than 0.5 mm (0.0197 in) Thrust ring Defects due to seizing or foreign material getting caught, etc. which are within the wear limit of 0.5 mm (0.0197 in) and within repairable level

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Remedy Replace Repair so that is smooth Repair so that is smooth

Hydraulic systems - Hydraulic central joint

Slipper seal Judgment criteria O-ring is excessively extruded from groove

Remedy Replace

Replace Slipper seal width is 1.5 mm (0.0591 in) or more smaller than width of the seal groove

Unequal wear of 0.5 mm (0.0197 in) or more

Replace

O-ring Judgment criteria O-ring is excessively extruded from groove

Remedy Replace

Unequal wear of 0.5 mm (0.0197 in) Replace or more

Backup ring Judgment criteria Thickness of 1.5 mm (0.06 in) or less Replace Width of 4 mm (0.16 in) or less.

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Remedy

Hydraulic systems - Hydraulic central joint

Hydraulic swivel - Troubleshooting Problem External oil leakage Internal oil leakage Shaft sticks

Possible Cause O-ring is defective Thrust ring is defective Excessive wear on sliding surfaces Shaft and body are stuck together

Flange looseness

Capscrew tightening is insufficient

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Correction Replace all the seal parts Replace all the seal parts Replace the assembly Carry out grinding and honing. If excessive looseness cause oil leakage, replace the assembly Retighten to the specified torque

Index Hydraulic systems - 35 Hydraulic central joint - 354 Hydraulic central joint - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic central joint - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic central joint - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic swivel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic swivel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic swivel - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic swivel - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic swivel - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic swivel - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic swivel - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic swivel - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Hydraulic systems - 35 Boom hydraulic system - 736

CX35B CX39B

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Contents Hydraulic systems - 35 Boom hydraulic system - 736

TECHNICAL DATA Boom cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Boom lifting cylinder holding valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA Boom cylinder Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Boom cylinder Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Boom lifting cylinder holding valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

DIAGNOSTIC Boom cylinder Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Hydraulic systems - Boom hydraulic system

Boom cylinder - General specification

TULI12EXN4628FB

A. B.

Fully retracted length Fully extended length

Part no. and manufacturing no. stamp position

CX35B Cylinder

Boom (canopy)

Boom (cab) Boom (cab with front guard)

Cylinder bore / Rod diameter ø 80 mm (3.15 in) / ø 45 mm (1.77 in) ø 80 mm (3.15 in) / ø 45 mm (1.77 in) ø 80 mm (3.15 in) / ø 45 mm (1.77 in)

Stroke

585 mm (23.03 in) 559 mm (22.01 in) 540 mm (21.26 in)

Centre distance of mounting pins Full extend B / Full retract A 1500 mm (59.06 in) / 915 mm (36.02 in) 1474 mm (58.03 in) / 915 mm (36.02 in) 1455 mm (57.28 in) / 915 mm (36.02 in)

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Cushion

Dry weight

35 kg (77 lb)

Rod side

35 kg (77 lb)

Hydraulic systems - Boom hydraulic system

CX39B Cylinder

Boom (canopy)

Boom (cab) Boom (cab with front guard)

Cylinder bore / Rod diameter ø 80 mm (3.15 in) / ø 45 mm (1.77 in) ø 80 mm (3.15 in) / ø 45 mm (1.77 in) ø 80 mm (3.15 in) / ø 45 mm (1.77 in)

Stroke

578 mm (22.76 in) 555 mm (21.85 in) 535 mm (21.06 in)

Centre distance of mounting pins Full extend B / Full retract A 1486 mm (58.50 in) / 908 mm (35.75 in) 1463 mm (57.60 in) / 908 mm (35.75 in) 1443 mm (56.81 in) / 908 mm (35.75 in)

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Cushion

Dry weight

35 kg (77 lb)

Rod side

35 kg (77 lb)

Hydraulic systems - Boom hydraulic system

Boom cylinder - Torque A. B. C.

Cylinder head Piston assembly Setscrew

TULI12EXN4410EB

Model

Cylinder

Cylinder head (A)

CX35B

Boom

450 N·m (332 lb ft)

CX39B

Boom

450 N·m (332 lb ft)

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Piston (B) 1150 N·m (848 lb ft) 1150 N·m (848 lb ft)

Setscrew (C) 16.2 N·m (12 lb ft) 16.2 N·m (12 lb ft)

Hydraulic systems - Boom hydraulic system

Boom cylinder - Special tools 1. Install jig (A) for press-fitting the head bushing. Applicable cylinder (Rod diameter; ØA = 45 mm (1.77 in))

TULI12EXN6270AA

TULI12EXN6271AA

TULI12EXN6272AA

TULI12EXN6273AA

2. Install jig (B) for press-fitting the pin bushing. Applicable cylinder (Rod diameter; ØB = 40 mm (1.57 in))

3. Sliding jig (C) for seal ring. Applicable cylinder (Liner diameter; ØC = 80 mm (3.15 in))

4. Pushing jig (D) for seal ring (18). Applicable cylinder (Liner diameter; ØD = 80 mm (3.15 in))

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Hydraulic systems - Boom hydraulic system

5. Reforming jig (E) for seal ring (18). Applicable cylinder (Liner diameter; Ă&#x2DC;E = 80 mm (3.15 in))

TULI12EXN6274AA

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Hydraulic systems - Boom hydraulic system

Boom lifting cylinder holding valve - General specification Technical data

SMIL13MEX0248FB

Description Anti-burst valve is a safety valve flanged directly to the boom cylinder. This valve is a check valve hydraulically controlled, with a spring load (1) for lock/meter the oil flow. Oil pressure in the cylinders loads the valve, without leakage. Overload or pressure peaks in the port C2 is detected by relief valve (2), that let the spool opening to discharge cylinder pressure and discharge into the tank. Valve (1) is provided of a device ( E) to lower the boom in emergency. Once the emergency boom lowering is completed, the screw ( E) must be restored to its original position and locked.

Boom lifting cylinder holding valve - Torque Please refer to the following data for the installation of all various fittings and hydraulic hoses. Fittings 1/4 G O-ring type joint 1/4 G 30° flare joint 3/8 G O-ring type joint 3/8 G 30° flare joint 1/2 G O-ring type joint

Tightening torque 34.3 - 38.3 N·m (25.3 - 28.2 lb ft) 24.4 - 34.4 N·m (28.2 - 25.4 lb ft) 68.5 - 78.5 N·m (50.5 - 57.9 lb ft) 44 - 54 N·m (32.5 - 39.8 lb ft) 98 - 118 N·m (72 - 87 lb ft)

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Hydraulic systems - Boom hydraulic system

Flexible hoses 1/4 G 3/8 G 1/2 G

Tightening torque 24.4 - 34.4 N·m (18.0 - 25.4 lb ft) 44 - 54 N·m (32.5 - 39.8 lb ft) 73.5 - 83.5 N·m (54.2 - 61.6 lb ft)

M-threads M8 M10

Tightening torque 29.9 - 36.7 N·m (22.1 - 27.1 lb ft) 25.5 - 37.5 N·m (18.8 - 27.7 lb ft)

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Boom cylinder - Component identification

TULI12EXN6192FB

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

Cylinder liner (Qty. 1) Pin bushing (Qty. 2) Cylinder rod (Qty. 1) Cylinder head (Qty. 1) Bushing (Qty. 1) U-ring (Qty. 1) Wiper ring (Qty. 1) O-ring (Qty. 2) Backup ring (Qty. 1) O-ring (Qty. 1) Bracket (Qty. 1) Spacer (Qty. 1)

13. 14. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Seal ring (Qty. 1) Collar (Qty. 1) Backup ring (Qty. 1) Piston (Qty. 1) Seal ring (Qty. 1) Slide ring (Qty. 2) Adjusting screw (Qty. 1) Ball (Qty. 1) Bearing (Qty. 1) Seal ring (Qty. 4) Grease nipple (Qty. 2)

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Boom cylinder - Dynamic description Fundamental function This is a kind of hydraulic actuator, and converts the energy in pressurized oil supplied by the hydraulic pump to a large force linear direction by means of the piston, as well as changing over the operating direction for either extension or retraction by means of actuating the valve lever to change over the direction of pressurized oil flow. Such conversion of energy force and change over the operating direction are of the fundamental function of this cylinder.

Function of each Parts The following description is based on a cylinder with a typical structure (boom cylinder). 1. Cylinder head assy. The cylinder head assy. also works as a bearing, pushing the bushing (5) into the cylinder head (4). Oil leakage is prevented by inserting the U-ring (6) into the bore of the cylinder head. The dust invasion is protected by pressing the wiper ring (7) into the bore of cylinder head. By inserting the cushion bushing (22) near the fully extended position of the cylinder, a high oil pressure generates so that the cylinder vibrations in the fully extended position are absorbed. And the cylinder head has another function of charging and discharging highly pressurized oil from the inside of cylinder tube to the port.

TULI12EXN6197EB

1. 8. 6. 10. 11. 12.

Cylinder liner O-ring Backup ring O-ring Bracket Spacer

13. Seal ring 14. Collar 16. backup ring

A. Bushing (5) The bushing (5) is pressed into the bore on cylinder head to support the cylinder rod. Along with the slide ring installed in the outer periphery of the piston, the bushing (5) bears the radial load acting on the cylinder, and performs a linear movement against the piston rod at a high pressure, thus minimizing the eccentricity of the cylinder rod, which negatively affects the seal ring by supporting one end. B. Wiper ring (7) The wiper ring (7) is located at the entrance where the piston rod comes in and out. Its function is to protect invasion of dust and water into the piston to secure good sealing effect of the U-ring (6), as well as to remove dust and mud adhered on the piston rod.

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2. Piston assy. The piston assy. has the seal ring (18) which is inserted at the centre portion of the piston (17), to prevent leakage of pressurized oil from either chamber of left or right to the other chamber. The slide rings (19) are inserted in both sides of the seal ring (18) to bear radial load imposed on the cylinder, and also to catch contaminations.

TULI12EXN6198FB

A. Seal ring (18) The location of seal ring (18) is the centre of piston. The seal ring (18) is to seal the circular gap between the piston and the cylinder tube utilizing a tension of the O-ring, to form both chambers of high pressure side and low pressure side isolating from each other making the piston as the border. B. Wiper ring (19) Two slide rings are provided at both sides of the seal ring (18) directly getting in touch with the cylinder tube. With the bushing (5), the slide rings (19) bear the radial load acting on the cylinder, generating a linear movement against the internal face of the cylinder at high pressure, thus reducing the eccentricity of the cylinder rod which negatively affects the sealing by supporting it at one end. And the slide ring has another function of burying and catching contaminations between the cylinder tube and the slide rings. C. Cushion bearing (22) The cushion bearing (22) is located between the piston and the stepped portion of piston rod. Along with the cylinder head, it has the function to create a circular area near to the fully extended position, and to restrict the oil to dampen the impact speed of the cylinder at the fully extended position, dampening vibrations. 25. Cushion stroke

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Boom cylinder - Prepare General precautions • Carry out the disassembly and assembly works in a clean work shop, and always keep disassembled parts at clean conditions. • Prior to disassembly, thoroughly clean the cylinder externally. • Use caution not to give any damages to the parts while carrying out the disassembly/assembly works. • Thinly apply grease or hydraulic oil to seals prior to installation. • After the installation of O-ring, confirm there is no twist on it. • Apply clean hydraulic oil to each sliding portion before the installation. • Ensure each sliding portion for no burr and defect, and its smooth sliding operation. • This manual describes mainly for the boom cylinder as an typical example. Refer to page Boom cylinder - Component identification (35.736) for the construction parts of the hydraulic cylinders when disassembling and reassembling the cylinders.

Necessary tools Though the required tools and jigs differ in types of cylinder, as a guide line, tools and jigs to be prepared are shown in table. Tool/Jig Hammer Screwdriver Chisel Vise Wrench Gimlet

Mask

Observations 1. Steel hammer 2. Wooden or plastic hammer Several kinds of minus driver of small and large sizes Flat chisel Capable to hold outer diameter of cylinder head and tube installing pin portion 1. Special wrench 2. Extension pipe for wrench A sharp-point tool may be used in place of gimlet 1. For installing seal ring 2. For pushing seal ring into groove 3. For reforming seal ring 4. For pressing bushing 1. Slide calipers

Measuring device

2. Micrometer 3. Cylinder gauge 4. V-block

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Boom cylinder - Disassemble Disassembly of cylinder assembly 1. Fix the clevis portion of tube with a vice, and hold the other end with a wooden stand to hold the cylinder in level. 2. Drain hydraulic oil remained in the cylinder. • Slowly move the piston rod so that the hydraulic oil does not spout out.

TULI12EXN4082AA

TULI12EXN4083AA

TULI12EXN4084AA

3. Make straight the locking fin for the cylinder head (4). • Use cautions bending/straightening of locking fin, because locking fin and cylinder tube are made with one-piece. 4. Loosen the cylinder head (4). • Prior to loosening the cylinder head, extract the cylinder rod (3) by 100 - 200 mm (3.94 - 7.87 in). • Cover the rod with an appropriate material to prevent it from unexpected dents. 5. Pull off the piston rod assembly from the tube. • Pull the piston rod in straight not to give any damages on the sliding surface.

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Cylinder rod disassembly 1. Fix the piston rod assembly in level. 2. Disassembly of the cylinder A. Remove the setscrew (20), then remove the steel ball (21). Since the setscrew (20) is caulked at two positions with a punch, take-off the caulked portion with a hand drill. B. Remove the piston (17) assembly. C. Remove the cushion bearing (22) (for boom cylinder only). 3. Disassembling of cushion bearing of retraction side (head side) (only for arm cylinder).

TULI12EXN4085AA

TULI12EXN4086AB

TULI12EXN4087AB

TULI12EXN4088AB

4. Remove cylinder head (4) and holder (11). (Only boom cylinders has a holder)

Disassembly of cylinder assembly 1. Remove the slide ring (19) from the piston (17). â&#x20AC;˘ Expand the split on the slide ring (19) as minimum as required to pull it off for axial direction. (two points) 2. Remove the seal ring assembly (18). â&#x20AC;˘ Cut the piston seal ring (18) or remove it using a screwdriver.

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Disassembly of cylinder head assembly 1. Remove the O-rings (8), (10) and backup ring (9) from the outer periphery of cylinder head (4).

TULI12EXN4089AB

TULI12EXN6244AB

2. Disassembling the holder (only boom cylinder) A. Remove collar (14). B. Remove cushion seal (13). C. Remove spacer (12). D. Remove O-ring (8) and backup ring (16) of outer diameter.

3. Remove the U-ring (6)

TULI12EXN6245AB

TULI12EXN4092AB

4. Remove the wiper ring (7). â&#x20AC;˘ Alternately tap inside of the metal ring of wiper ring at several positions, as shown in the Fig. 11, to push it out step by step from the groove.

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5. Remove the bushing (5) using a removal jig.

TULI12EXN6247AA

TULI12EXN4094AB

TULI12EXN4095AB

Disassembly of clevis portion 1. Remove the seal ring (23) from the clevis portion of cylinder tube (1) and the cylinder rod (3).

2. Remove the pin bushing (2). â&#x20AC;˘ Using a metal block (28), push it out with a press machine.

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Boom cylinder - Assemble Assembling clevis portion 1. With the installing jig (B), press the bushings (2) into the piston rod (3) and tube (1). • Prior to the work, apply hydraulic oil on the surface of parts.

TULI12EXN4096AB

TULI12EXN4097AB

TULI12EXN4098AB

2. With the setting tool (29), install the seal ring (23).

Assembling cylinder head 1. With installing jig (A), press-fit the bushing (5). • Prior to the work, apply hydraulic oil on inner periphery of the cylinder head (4). • At press-fitting the bushing (5) into the cylinder head (4), make the top surfaces of them in level without step.

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2. Install the U-ring (6).

TULI12EXN6245AC

TULI12EXN6254AB

TULI12EXN4099AB

TULI12EXN4089AB

3. Assembling holder (only for boom cylinder) A. Install spacer (12). B. Install the seal ring (13). C. Install collar (14). D. Install back-up ring (16) and O-ring (8).

4. Using the setting tool (30), install the wiper ring (7).

5. Install the back-up ring (9) and O-rings (8) and (10).

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Assembly of piston portion 1. Install the O-ring (31).

TULI12EXN6257AB

TULI12EXN4401AB

2. Set the sliding jig (C) on the piston (17), then quickly push the seal ring (18) with the pushing jig (D).

3. Since the seal ring (18) is extremely stretched at the installation, reform it with the reforming jig (E).

TULI12EXN4402AB

TULI12EXN4403AB

4. Install the slide ring (19). â&#x20AC;˘ Expand the split on the slide ring (19) as minimum as required to pull it off for axial direction. (Two points)

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Installation of cylinder rod assembly 1. Fix the piston rod (3) in level, and install the cylinder head assembly and holder onto it. 2. Installing procedures for cushion bearing of retraction side. (Only for arm cylinder)

TULI12EXN4404AA

TULI12EXN4405AB

TULI12EXN4406AA

TULI12EXN4407AA

3. Install the piston assembly A. Install the cushion bearing (22) (for boom cylinder only) and piston (17) on the piston rod (3), and tighten them up. Tightening torque for piston B. Put the steel ball (21) into the threaded bore, and securely tighten it with the setscrew (20). Caulk the setscrew with a punch at two points. Tightening torque for setscrew

Assembly of cylinder 1. Fix the tube in level, and install the piston rod assembly into it. • At the installation, align the centre of piston rod to the centre of tube and install the piston rod in straight position, paying attention not to damage seals.

2. Loosen the cylinder head (4). • Apply hydraulic oil on the packings (seals) prior to install. • Tightening torque for cylinder head

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3. Bend the locking fin on the tube to lock the cylinder head.

TULI12EXN4408AA

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Boom cylinder - Service instruction Maintenance standard Inspection after disassembly Inspection item Parts name

Cylinder rod

Cylinder liner

Cylinder head

Part to be inspected Neck of rod Stepped part to which piston is attached Threads Bend Plated surface

Rod Bushing at mounting part Welded part of bottom Tube at mounting part Tube inside Bushing at mounting part Bushing

Remedy

Inspection item Presence of crack

Replace

Presence of crack

Replace

Presence of seizure, etc. Measure amount of bend Wearing off of plating Rust on plating Presence of defect Wear of outside Wear of inside Presence of crack Presence of crack Presence of defect Wear of inside Wear of inside Defect of inside

Recondition or replace Refer to rod bend Replacement Replacement Recondition or replace Recondition or replace Replace Replace Replace Replace if oil leak is seen Replace Replace Replace

Repair procedure Replace sliding parts and seals according to the following references 1 2 3 4

Bushing Seals and slide rings Pin bushing Piston rod

Where 1/4 of circumference is worn in copper colour Replace them when cylinder is disassembled Where severe scuffing is appeared Where the bent 0.5 mm/m or more is appeared

Service limits Service limits represent the limits of wear on the sliding surfaces of the cylinder tube and the piston rod that have no such faults as may degrade the sealing effect. 1. Clearance between piston rod and rod bushing. Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25 mm (0.01 in). 2. Bend of piston rod. The allowable bend of the rod is maximum 0.5 mm (0.02 in)/ 1 m (39.37 in). For measurement, support both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center between the two V-blocks turn the piston rod, and read the difference between the maximum and minimum values on the dial indicator. â&#x20AC;˘ Even if the bend is within the allowable limit, the cylinder may not operate smoothly because of localized bend. Beware of it during function test after installation. Replace the rod if the cylinder makes a squeaking noise or dose not operate smoothly.

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Measuring method Distance between V-blocks: 1 m (39.37 in), 2 m (78.74 in) Deflectional value of the dial gauge: 1 mm (0.04 in), 2 mm (0.08 in) Remedy: Replace

TULI12EXN4409AB

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Boom cylinder - Inspect Inspection after installation 1. Unloaded performance test A. Put the cylinder horizontally at unloaded condition. B. Apply pressure slowly and alternately through the ports at both ends to operate the piston rod 5 or 6 times. C. Check that the cylinder operates normally.

E. F.

Pump Tank

G. H.

TULI12EXN4411AB

TULI12EXN4412AB

Control valve Hydraulic cylinder

2. Leakage test • External leakage. A. Apply test pressure for 3 min each to the rod retraction side and to the rod extension side of the cylinder. B. Confirm that rod seals, cylinder head tightening part, and each weld are free from abnormalities, such as external leakage and permanent deformation. • Internal leakage. A. Disconnect the hose from the rod extension side of the cylinder. B. Apply test pressure to the rod retraction side of the cylinder for 3 min. C. Measure the leakage from the rod extension side. • Leakage should be below 1 cm³ (0.1 in³) /min. E. F. G.

Pump Tank Control valve

H. I.

Hydraulic cylinder Internal leakage

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Bleeding air from hydraulic cylinder Bleed air from the cylinder after removing or installing it, or after disconnecting a hydraulic pipe. 1.

Start the engine, and let it idling for about 5 min.

Repeat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine. â&#x20AC;˘ Move the piston rod 100 mm (4 in) short of its stroke end. Do not extend or retract the rod until the end to prevent the relief condition.

Perform the above 2 procedures at high idling speed, then move the piston rod to its stroke end at low idling speed to reach the relief condition.

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Boom lifting cylinder holding valve - Remove Boom holding valve and pressure switch 1. Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity. Lower the dozer to the ground. Place the working attachment in front of the machine and extend the arms, so that they can be accessed. Place the bucket on the ground. Release hydraulic pressure and drain the hydraulic oil tank by following the instructions contained in the Operatorâ&#x20AC;&#x2122;s Manual. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position.

TULI12EXN9235AA

TULI12EXN9236AB

TULI12EXN9237AB

NOTICE: During these operations, pay attention to further hydraulic oil leaks; protect the machine and, if necessary, carry out the appropriate cleaning operations. 2. Remove the 3/8" hose (54) connected to the fitting (AP) and to the 3/8"-1/2" straight fitting (56) available in port V2 of the valve (60).

3. Disconnect the 3/8" draining hose (6) coming from the machine to the 1/4"-3/8" 90Â°-fitting (58) installed on port T of the valve (60).

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4. Disconnect the 1/4" pilot control hose (10) coming from the machine to the 1/4" 90Â°-fitting (64) installed on port P2 of the valve (60).

TULI12EXN9238AB

TULI12EXN9239AB

TULI12EXN7135AB

TULI12EXN9241AB

5. Disconnect the electric cable (12), coming from the machine, to the pressure switch (69) by means of the screw (AY) in the connector.

6. Remove the pressure switch (69) from 3/8"-1/4" straight fitting (68).

7. Disconnect rigid pipe (70) from valve (60).

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8. Remove the valve (60) with the fittings from bracket (49) of cover (AJ), by removing screws (62) and washers (61).

TULI12EXN9242AB

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Boom lifting cylinder holding valve - Install Boom holding valve and pressure switch 1. Preassemble the valve (60) of the boom cylinder: • In port (C2), install the 1/2" straight fitting (65), the 1/2"-1/2"-3/8" union tee (66) and the 3/8"-1/2" 90°-fitting (67), and do not tighten to facilitate a subsequent orientation of the pressure switch. • In port V2, screw on the 3/8"-1/2" straight fitting (56). • In port T, install the 1/4" union tee (59), the 90°-fitting (58) and the 3/8"-1/4" straight fitting (57). • In port P2, tighten the 1/4" straight fitting (63) and the 1/4" 90°-fitting (64). • Make sure that the fittings screwed in port P2 are turned clockwise (outwards) by 10°.

TULI12EXN9243AB

TULI12EXN9244AB

TULI12EXN7140AB

TULI12EXN7141AB

2. Assemble the new valve (60) together with the fittings onto the bracket (49) and fasten it by means of the hex. M8 X 50 screws (62) and the relevant D=8 washers (61). Apply some LOCTITE® 262 and tighten the hex. M8 X 50 screws (62) to a tightening torque of 33 N·m (24 lb ft). Reassemble the cover (AJ) of the boom cylinder.

3. Direct the brackets and the valve by turning them clockwise (outwards) by 15°. Connect the union tee 1/2" (65) on port C2 of valve (60) to the rigid pipe (70). Fix the final position of the valve, apply some LOCTITE® 262 and tighten the hex. M10 X 30 screws (52) to a tightening torque of 31.5 N·m (23 lb ft).

4. Screw on the 3/8"-1/4" straight fitting (68) on the pressure switch (69) and apply some Loctite 577 between them. Assemble the pressure switch together with fitting on the 3/8"-1/2" 90°-fitting (67) in port C2 of the valve (60). Before tightening, direct the pressure switch (69) by turning it clockwise (outwards) by 40°. Check that the pressure switch does not interfere with other machine parts during the various movements of the front attachment.

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5. Connect the electric cable (12), coming from the machine, to the pressure switch (69) by means of the screw (AY) in the connector.

TULI12EXN9247AB

TULI12EXN9248AB

TULI12EXN9249AB

TULI12EXN9250AB

6. Connect the 1/4" pilot control hose (10) coming from the machine to the 1/4" 90Â°-fitting (64) installed on port P2 of the valve (60).

7. Connect the 3/8" draining hose (6) coming from the machine to the 1/4"-3/8" 90Â°-fitting (58) installed on port T of the valve (60).

8. Install the 3/8" hose (54) and connect it to the fitting (AP) and to the 3/8"-1/2" straight fitting (56) available in port V2 of the valve (60).

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Boom cylinder - Troubleshooting Problem Possible Cause Correction Oil leakage from sliding Foreign matter is caught by U-ring or wiper Remove foreign matter face of piston rod. (A ring ring at its inside periphery shape oil is formed on piston rod and enlarged resulting dripping down of oil) Scuffing or fault on O-ring or wiper ring at Replace each part with new one its inside periphery Scuffing on sliding face of piston rod • Grind sliding face with a fine oil stone. (less than 1.6 s) • If leakage is not stopped by grinding, replace seals such as U-ring, etc. with new ones

Peeling off of hard chrome plating Oil leakage from outer Damage to the O-ring periphery of cylinder head Damages on back-up ring Oil leakage from welded Damages on welded portion on tube portion Piston movement due Foreign matter is caught by sliding face of to leakage. (In case a slide ring static load equivalent to the product of the multiplication between the max. working pressure and the cylinder area is applied to the rod, the maximum movement of the piston is larger than 0.5 mm (0.02 in) for 10 min) Scuffing or faulty condition on sliding face of slide ring Scuffing on sliding face of seal ring assembly Damage to the O-ring

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• If leakage is not stopped by replacing seals, replace piston rod Re-plating of hard chrome on piston rod Replace Replace Replace Remove foreign matter

Replace Replace Replace

Index Hydraulic systems - 35 Boom hydraulic system - 736 Boom cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Boom cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Boom cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Boom cylinder - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Boom cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Boom cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Boom cylinder - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Boom cylinder - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Boom cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Boom cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Boom cylinder - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Boom lifting cylinder holding valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Boom lifting cylinder holding valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Boom lifting cylinder holding valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Boom lifting cylinder holding valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic systems - 35 Dipper hydraulic system - 737

CX35B CX39B

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Contents Hydraulic systems - 35 Dipper hydraulic system - 737

TECHNICAL DATA Dipper cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Arm cylinder holding valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUNCTIONAL DATA Dipper cylinder Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Arm cylinder holding valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Dipper cylinder - General specification

TULI12EXN4628FB

A. B.

Fully retracted length Fully extended length

Part no. and manufacturing no. stamp position

CX35B Cylinder

Dipper

Cylinder bore / Rod diameter

Stroke

ø 75 mm (2.95 in) / ø 45 mm (1.77 in)

541 mm (21.30 in)

Centre distance of mounting pins Full extend B / Full retract A 1398 mm (55.04 in) / 857 mm (33.74 in)

Cushion

Dry weight

Head side

31 kg (68 lb)

Cushion

Dry weight

Head side

34 kg (75 lb)

CX39B Cylinder

Dipper

Cylinder bore / Rod diameter

Stroke

ø 80 mm (3.15 in) / ø 45 mm (1.77 in)

560 mm (22.05 in)

Centre distance of mounting pins Full extend B / Full retract A 1432 mm (56.38 in) / 872 mm (34.33 in)

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Dipper cylinder - Torque A. B. C.

Cylinder head Piston assembly Setscrew

TULI12EXN4410EB

Model

Cylinder

Cylinder head (A)

CX35B

Dipper

422 N·m (311 lb ft)

CX39B

Dipper

450 N·m (332 lb ft)

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Piston (B) 1090 N·m (804 lb ft) 1350 N·m (996 lb ft)

Setscrew (C) 16.2 N·m (12 lb ft) 16.2 N·m (12 lb ft)

Hydraulic systems - Dipper hydraulic system

Dipper cylinder - Special tools 1. Install jig (A) for press-fitting the head bushing. Applicable cylinder (Rod diameter; ØA = 45 mm (1.77 in))

TULI12EXN6270AA

TULI12EXN6271AA

TULI12EXN6272AA

TULI12EXN6273AA

2. Install jig (B) for press-fitting the pin bushing. Applicable cylinder (Rod diameter; ØB = 40 mm (1.57 in))

3. Sliding jig (C) for seal ring. Applicable cylinder (Liner diameter; ØC = 75 mm (2.95 in))

4. Pushing jig (D) for seal ring (18). Applicable cylinder (Liner diameter; ØD = 75 mm (2.95 in))

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5. Reforming jig (E) for seal ring (18). Applicable cylinder (Liner diameter; Ă&#x2DC;E = 75 mm (2.95 in))

TULI12EXN6274AA

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Arm cylinder holding valve - General specification Technical data

SMIL13MEX0249FA

Valve operation is same as boom cylinder holding valve. (It is not provided of emergency device.)

Arm cylinder holding valve - Torque Please refer to the following data for the installation of all various fittings and hydraulic hoses. Fittings 1/4 G O-ring type joint 1/4 G 30° flare joint 3/8 G O-ring type joint 3/8 G 30° flare joint 1/2 G O-ring type joint

Tightening torque 34.3 - 38.3 N·m (25.3 - 28.2 lb ft) 24.4 - 34.4 N·m (28.2 - 25.4 lb ft) 68.5 - 78.5 N·m (50.5 - 57.9 lb ft) 44 - 54 N·m (32.5 - 39.8 lb ft) 98 - 118 N·m (72 - 87 lb ft)

Flexible hoses 1/4 G 3/8 G 1/2 G

Tightening torque 24.4 - 34.4 N·m (18.0 - 25.4 lb ft) 44 - 54 N·m (32.5 - 39.8 lb ft) 73.5 - 83.5 N·m (54.2 - 61.6 lb ft)

M-threads M8 M10

Tightening torque 29.9 - 36.7 N·m (22.1 - 27.1 lb ft) 25.5 - 37.5 N·m (18.8 - 27.7 lb ft)

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Hydraulic systems - Dipper hydraulic system

Dipper cylinder - Component identification

TULI12EXN6194FB

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

Cylinder liner (Qty. 1) Pin bushing (Qty. 2) Cylinder rod (Qty. 1) Cylinder head (Qty. 1) Bushing (Qty. 1) U-ring (Qty. 1) Wiper ring (Qty. 1) O-ring (Qty. 1) Backup ring (Qty. 1) O-ring (Qty. 1) Piston (Qty. 1)

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Seal ring (Qty. 1) Slide ring (Qty. 2) Adjusting screw (Qty. 1) Ball (Qty. 1) Bearing (Qty. 1) Seal ring shock absorber (Qty. 1) Travel stop (Qty. 2) Snap ring (Qty. 1) Seal ring (Qty. 4) Grease nipple (Qty. 1) Grease nipple (Qty. 1)

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Arm cylinder holding valve - Remove 1. Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity. Lower the dozer to the ground. Place the working attachment in front of the machine and extend the arms, so that they can be accessed. Place the bucket on the ground. Release hydraulic pressure and drain the hydraulic oil tank by following the instructions contained in the Operator’s Manual. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position.

TULI12EXN5142AA

TULI12EXN7147AB

TULI12EXN7148AB

NOTICE: During these operations, pay attention to further hydraulic oil leaks; protect the machine and, if necessary, carry out the appropriate cleaning operations. 2. Disconnect the 3/8" hose (42) connected to one side to the 45° 3/8" fitting (45) available in port V2 of the valve (34) and, to the other side, to the rigid pipe (AU) available on the intermediate portion of the boom.

3. Disconnect the 3/8" draining hose (41) connected to one side to the 3/8"-1/4" 45°-fitting (33) available in port T of the valve (34) and, to the other side, to the 3/8" 90°-fitting (43) available on the first portion of the boom.

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4. Disconnect the 1/4" pilot control hose (38) connected it to one side to the 1/4" 90Â°-fitting (37) available in port Pil of the valve (34) and, to the other side, to the 1/4" 90Â°-fitting (37) available on the first portion of the boom.

TULI12EXN7149AB

TULI12EXN7150AB

TULI12EXN7151AB

5. Disconnect the rigid pipe (22) from 1/2" straight fitting (35) on port C2 of valve (34).

6. Remove the valve (34) with the fittings from bracket (26) removing the screws (29) and the relevant washers D=8 (28).

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Arm cylinder holding valve - Install 1. Preassemble the valve (34). • In port C2, install the 3/8"-1/2" straight fitting (35). • In port V2, tighten the 3/8"-1/2" straight fitting (40) and the 3/8" 45°-fitting (45). • In port T, install the 3/8"-1/4" 45°-fitting (33). • In port Pil, tighten the 1/4" straight fitting (36) and the 1/4" 90°-fitting (37).

TULI12EXN7152AB

TULI12EXN7151AC

TULI12EXN7153AB

TULI12EXN7149AC

2. Assemble the valve (34) together with the fittings onto the bracket (26) and fasten it by means of the hex. M8 X 20 screws (29) and the relevant D=8 washers (28). Apply some LOCTITE® 262 and tighten the screws to a tightening torque of 33 N·m.

3. Now it is possible to define the final position of the valve (34). Direct the brackets and the valve (34) as show in the figure. Connect the straight fitting (35) on port C2 of valve (34) to the rigid pipe (22). Fix the final position of the valve, apply some LOCTITE® 262 and tighten the hex. M10 X 30 screws (23) to a tightening torque of 31.5 N·m (23.2 lb ft).

4. Install the 1/4" pilot control hose (38) by connecting it on one side to the 1/4" 90°-fitting (37) available in port Pil of the valve (34) and, on the other side, to the 1/4" 90°-fitting (37) available on the first portion of the boom.

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5. Install the 3/8" draining hose (41) by connecting it on one side to the 3/8"-1/4" 45°-fitting (33) available in port T of the valve (34) and, on the other side, to the 3/8" 90°-fitting (43) available on the first portion of the boom.

TULI12EXN7148AC

TULI12EXN7147AD

TULI12EXN7154AB

6. Install the 3/8" hose (42) by connecting it on one side to the 3/8" 45°-fitting (45) available in port V2 of the valve (34) and, on the other side, to the rigid pipe (AU) available on the intermediate portion of the boom.

7. Direct and route between the “ears” of the boom all various hydraulic hoses: hose (38), hose (41) and hose (42) just installed.

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Index Hydraulic systems - 35 Dipper hydraulic system - 737 Arm cylinder holding valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Arm cylinder holding valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Arm cylinder holding valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Arm cylinder holding valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dipper cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dipper cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dipper cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dipper cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Excavator and backhoe bucket hydraulic system - 738

CX35B CX39B

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Contents Hydraulic systems - 35 Excavator and backhoe bucket hydraulic system - 738

TECHNICAL DATA Bucket cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Bucket cylinder Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Bucket cylinder - General specification

TULI12EXN4628FB

A. B.

Fully retracted length Fully extended length

Part no. and manufacturing no. stamp position

CX35B Cylinder

Bucket

Cylinder bore / Rod diameter

Stroke

ø 65 mm (2.56 in) / ø 40 mm (1.57 in)

497 mm (19.57 in)

Centre distance of mounting pins Full extend B / Full retract A 1272 mm (50.08 in) / 775 mm (30.51 in)

Cushion

Dry weight

None

22 kg (49 lb)

Cushion

Dry weight

None

22 kg (49 lb)

CX39B Cylinder

Bucket

Cylinder bore / Rod diameter

Stroke

ø 65 mm (2.56 in) / ø 40 mm (1.57 in)

497 mm (19.57 in)

Centre distance of mounting pins Full extend B / Full retract A 1272 mm (50.08 in) / 775 mm (30.51 in)

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Bucket cylinder - Torque A. B. C.

Cylinder head Piston assembly Setscrew

TULI12EXN4410EB

Model

Cylinder

Cylinder head (A)

CX35B

Bucket

343 N·m (253 lb ft)

CX39B

Bucket

343 N·m (253 lb ft)

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Piston (B) 550 N·m (406 lb ft) 550 N·m (406 lb ft)

Setscrew (C) 16.2 N·m (12 lb ft) 16.2 N·m (12 lb ft)

Hydraulic systems - Excavator and backhoe bucket hydraulic system

Bucket cylinder - Special tools 1. Install jig (A) for press-fitting the head bushing. Applicable cylinder (Rod diameter; ØA = 40 mm (1.57 in))

TULI12EXN6270AA

TULI12EXN6271AA

TULI12EXN6272AA

TULI12EXN6273AA

2. Install jig (B) for press-fitting the pin bushing. Applicable cylinder (Rod diameter; ØB = 40 mm (1.57 in))

3. Sliding jig (C) for seal ring. Applicable cylinder (Liner diameter; ØC = 65 mm (2.56 in))

4. Pushing jig (D) for seal ring (18). Applicable cylinder (Liner diameter; ØD = 65 mm (2.56 in))

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5. Reforming jig (E) for seal ring (18). Applicable cylinder (Liner diameter; Ă&#x2DC;E = 65 mm (2.56 in))

TULI12EXN6274AA

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Bucket cylinder - Component identification

TULI12EXN6194FB

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cylinder liner (Qty. 1) Pin bushing (Qty. 1) Cylinder rod (Qty. 1) Pin bushing (Qty. 1) Cylinder head (Qty. 1) Bushing (Qty. 1) U-ring (Qty. 1) Wiper ring (Qty. 1) O-ring (Qty. 1)

10. 11. 12. 13. 14. 15. 16. 17. 18.

Backup ring (Qty. 1) O-ring (Qty. 1) Piston (Qty. 1) Seal ring (Qty. 1) Slide seal ring (Qty. 2) Adjusting screw (Qty. 1) Ball (Qty. 1) Seal ring (Qty. 4) Grease nipple (Qty. 2)

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Index Hydraulic systems - 35 Excavator and backhoe bucket hydraulic system - 738 Bucket cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bucket cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bucket cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bucket cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Hammer and rotating bucket hydraulic system - 360

CX35B CX39B

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Contents Hydraulic systems - 35 Hammer and rotating bucket hydraulic system - 360

SERVICE Rotating bucket boom lines Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Rotating bucket valve Remove - Auxiliary selector valve (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install - Auxiliary selector valve (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rotating bucket hoses Remove - Auxiliary hydraulic lines (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install - Auxiliary hydraulic lines (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Rotating bucket boom lines - Prepare CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

AUX2 hydraulic PTO is a high pressure hydraulic circuit. AUX2 lines have to be unloaded before connecting and disconnecting hydraulic attachment. To unload AUX2 lines, proceed as follows: 1. Park the machine on a level surface and rest the attachment to the ground. 2. Shut down engine and set start key to ON position. 3. Set AUX2 selector switch to the right side. 4. Press left side of pedal for 2 s: the left side AUX line is thus unloaded. 5. Press right side of pedal for 2 s: the right side AUX line is thus unloaded.

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Rotating bucket boom lines - Remove 1. Disconnect the two 3/8G hoses (1) on dipper arm: L=820mm : 22 mm 2. Disconnect the two 3/8G hoses (2) on boom: L=2350mm for CX35B L=2500mm for CX39B : 22 mm

SMIL13MEX0201FB

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Rotating bucket boom lines - Install 1. Connect the two 3/8G hoses (1) on dipper arm: L=820mm. 2. Connect the two 3/8G hoses (2) on boom: L=2350mm for CX35B L=2500mm for CX39B 3. Tighten hoses to the specified torque: 44 - 54 NÂˇm (32 - 40 lb ft) : 22 mm

SMIL13MEX0201FB

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Rotating bucket valve - Remove - Auxiliary selector valve (AUX2) 1. Open the right hood (1) with the starter key.

SMIL13MEX0197AB

LELI11E0165AB

2. Fasten the hood with the suitable stay (2). 3. Remove the connector (3) from the auxiliary solenoid valve (4). 4. Disconnect hoses from the auxiliary solenoid valve. See Rotating bucket hoses - Remove - Auxiliary hydraulic lines (AUX2) (35.360). 5. Remove two screws M10 X 25 (5) to remove the bracket (7) with the auxiliary solenoid valve (4). Remove the washers (6).

SMIL13MEX0290FB

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6. Remove two screws M8 X 80 (8) and remove washers (9) to separate the bracket (7) and the auxiliary solenoid valve (4).

SMIL13MEX0251AB

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Rotating bucket valve - Install - Auxiliary selector valve (AUX2) 1. Use washers (9) and two screw M8 X 80 (8) to attach the bracket (7) and the auxiliary solenoid valve (4). Torque the screws to 29.9 - 36.7 NÂˇm (22.1 - 27.1 lb ft).

SMIL13MEX0251AB

2. Use washers (6) and two screw M10 X 25 (5) to attache the auxiliary solenoid valve (4) to the frame. Torque the screws to 58.8 - 72.6 NÂˇm (43.4 - 53.5 lb ft). 3. Connect hoses to the auxiliary solenoid valve. See Rotating bucket hoses - Install - Auxiliary hydraulic lines (AUX2) (35.360). 4. Plug the connector (3) to the auxiliary solenoid valve (4).

SMIL13MEX0290FB

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Rotating bucket hoses - Remove - Auxiliary hydraulic lines (AUX2) 1. Disconnect hoses on turret: • supply hose L=600 mm (1); • return hose L=700 mm (2); • AUX R hose L=2400 mm (3); • AUX L hose L=2400 mm (4); • SWING L hose L=630 mm (5); • SWING R hose L=480 mm (6). : 22 mm

SMIL13MEX0291FB

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Rotating bucket hoses - Install - Auxiliary hydraulic lines (AUX2) 1. Connect hoses on turret: • supply hose L=600 mm (1); • return hose L=700 mm (2); • AUX R hose L=2400 mm (3); • AUX L hose L=2400 mm (4); • SWING L hose L=630 mm (5); • SWING R hose L=480 mm (6). All hoses 3/8 G. : 22 mm 2. Tighten hoses to the specified torque: 3/8 G O-ring type joint: 63 - 77 N·m (46.5 - 56.8 lb ft) 3/8 G Hyd Hose 30° flare: 40.5 - 49.5 N·m (30 - 37 lb ft)

SMIL13MEX0291FB

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Index Hydraulic systems - 35 Hammer and rotating bucket hydraulic system - 360 Rotating bucket boom lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rotating bucket boom lines - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rotating bucket boom lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rotating bucket hoses - Install - Auxiliary hydraulic lines (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rotating bucket hoses - Remove - Auxiliary hydraulic lines (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rotating bucket valve - Install - Auxiliary selector valve (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rotating bucket valve - Remove - Auxiliary selector valve (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - 35 Swing arm hydraulic system - 739

CX35B CX39B

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Contents Hydraulic systems - 35 Swing arm hydraulic system - 739

TECHNICAL DATA Swing cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Swing cylinder Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Swing cylinder Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Hydraulic systems - Swing arm hydraulic system

Swing cylinder - General specification

TULI12EXN4628FB

A. B.

Fully retracted length Fully extended length

Part no. and manufacturing no. stamp position

CX35B Cylinder

Swing

Cylinder bore / Rod diameter

Stroke

ø 80 mm (3.15 in) / ø 45 mm (1.77 in)

488 mm (19.21 in)

Centre distance of mounting pins Full extend B / Full retract A 1286 mm (50.63 in) / 798 mm (31.42 in)

Cushion

Dry weight

None

37 kg (82 lb)

Cushion

Dry weight

None

37 kg (82 lb)

CX39B Cylinder

Swing

Cylinder bore / Rod diameter

Stroke

ø 80 mm (3.15 in) / ø 45 mm (1.77 in)

488 mm (19.21 in)

Centre distance of mounting pins Full extend B / Full retract A 1286 mm (50.63 in) / 798 mm (31.42 in)

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Hydraulic systems - Swing arm hydraulic system

Swing cylinder - Torque A. B. C.

Cylinder head Piston assembly Setscrew

TULI12EXN4410EB

Model

Cylinder

Cylinder head (A)

CX35B

Swing

450 N·m (332 lb ft)

CX39B

Swing

450 N·m (332 lb ft)

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Piston (B) 1240 N·m (915 lb ft) 1240 N·m (915 lb ft)

Setscrew (C) 16.2 N·m (12 lb ft) 16.2 N·m (12 lb ft)

Hydraulic systems - Swing arm hydraulic system

Swing cylinder - Special tools 1. Install jig (A) for press-fitting the head bushing. Applicable cylinder (Rod diameter; ØA = 45 mm (1.77 in))

TULI12EXN6270AA

TULI12EXN6271AA

TULI12EXN6272AA

TULI12EXN6273AA

2. Install jig (B) for press-fitting the pin bushing. Applicable cylinder (Rod diameter; ØB = 40 mm (1.57 in))

3. Sliding jig (C) for seal ring. Applicable cylinder (Liner diameter; ØC = 80 mm (3.15 in))

4. Pushing jig (D) for seal ring (18). Applicable cylinder (Liner diameter; ØD = 80 mm (3.15 in))

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5. Reforming jig (E) for seal ring (18). (Liner diameter; Ă&#x2DC;E = 80 mm (3.15 in))

TULI12EXN6274AA

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Swing cylinder - Component identification

TULI12EXN6195FB

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cylinder liner (Qty. 1) Pin bushing (Qty. 2) Cylinder rod (Qty. 1) Cylinder head (Qty. 1) Bushing (Qty. 1) U-ring (Qty. 1) Wiper ring (Qty. 1) O-ring (Qty. 1) Backup ring (Qty. 1)

10. 11. 12. 13. 14. 15. 16. 17.

O-ring (Qty. 1) Piston (Qty. 1) Seal ring (Qty. 1) Slide ring (Qty. 2) Adjusting screw (Qty. 1) Ball (Qty. 1) Seal ring (Qty. 4) Grease nipple (Qty. 1)

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Swing cylinder - Prepare 1. To make the removing work easy, swing by around 30Â° for leftward. 2. Disconnect all hoses from the bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all the openings. : 22 mm

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Hydraulic systems - Swing arm hydraulic system

Swing cylinder - Remove Removal of swing bracket (A9) 1. Removing the capscrew (C4) that is preventing the rod side pin (M) of swing cylinder (C11) from coming out, remove the pin (M). : 17 mm 2. Install the boom foot pin (A) to the original position on swing bracket (A9), then temporarily lift it up. 3. Removing two capscrews (B8) and (B9) those are preventing the pins (L1) and (L2) from coming out, remove the pins (L1) and (L2). : 17 mm 4. Remove the swing bracket (A9). bracket: 93 kg (205 lb) Removal of swing cylinder (C11)

Weight of swing

1. Disconnect 2 connecting hoses for the swing cylinder. : 22 mm 2. Removing the capscrew (C5) that is preventing the head side pin (N) of swing cylinder from coming out, remove the pin (N). : 19 mm 3. Take out the swing cylinder (C11) from the front side. Weight of swing cylinder: 37 kg (82 lb)

TULI12EXN4075CB

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Hydraulic systems - Swing arm hydraulic system

Swing cylinder - Install Installation is performed in the reverse order of removal, including the following workings. 1. Check the dust seal for damages, and replace the faulty dust seal to new one. 2. Replace the worn-out pin and bushing to new ones. 3. Before installing the pin, apply grease to the shaft area. 4. Refer to Fig. 1 for the shim adjustment at pin installing portion.

TULI12EXN4078GB

S. T.

Total clearance must be between 0.1 - 0.5 mm (0.00 - 0.02 in) after adjusting the shims Set this shim with the oil groove side positioned downward

W. Z.

Total clearance must be between 0.5 - 0.9 mm (0.02 - 0.04 in) after adjusting the shims Apply LOCTITEÂŽ 262

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Index Hydraulic systems - 35 Swing arm hydraulic system - 739 Swing cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Swing cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Swing cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Swing cylinder - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Swing cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Swing cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Swing cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hydraulic systems - 35 Dozer blade cylinders - 741

CX35B CX39B

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Contents Hydraulic systems - 35 Dozer blade cylinders - 741

TECHNICAL DATA Blade lifting cylinder General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Blade lifting cylinder Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Hydraulic systems - Dozer blade cylinders

Blade lifting cylinder - General specification

TULI12EXN4628FB

A. B.

Fully retracted length Fully extended length

Part no. and manufacturing no. stamp position

CX35B Cylinder

Dozer

Cylinder bore / Rod diameter

Stroke

ø 100 mm (3.94 in) / ø 50 mm (1.97 in)

160 mm (6.30 in)

Centre distance of mounting pins Full extend B / Full retract A 633 mm (24.92 in) / 473 mm (18.62 in)

Cushion

Dry weight

None

27 kg (60 lb)

Cushion

Dry weight

None

27 kg (60 lb)

CX39B Cylinder

Dozer

Cylinder bore / Rod diameter

Stroke

ø 100 mm (3.94 in) / ø 50 mm (1.97 in)

160 mm (6.30 in)

Centre distance of mounting pins Full extend B / Full retract A 633 mm (24.92 in) / 473 mm (18.62 in)

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Blade lifting cylinder - Torque A. B. C.

Cylinder head Piston assembly Setscrew

TULI12EXN4410EB

Model

Cylinder

Cylinder head (A)

CX35B

Dozer

647 N·m (477 lb ft)

CX39B

Dozer

647 N·m (477 lb ft)

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Piston (B) 1590 N·m (1173 lb ft) 1590 N·m (1173 lb ft)

Setscrew (C) 31.4 N·m (23 lb ft) 31.4 N·m (23 lb ft)

Hydraulic systems - Dozer blade cylinders

Blade lifting cylinder - Special tools 1. Install jig (A) for press-fitting the head bushing. Applicable cylinder (Rod diameter; ØA = 50 mm (1.97 in))

TULI12EXN6270AA

TULI12EXN6271AA

TULI12EXN6272AA

TULI12EXN6273AA

2. Install jig (B) for press-fitting the pin bushing. Applicable cylinder (Rod diameter; ØB = 40 mm (1.57 in))

3. Sliding jig (C) for seal ring. Applicable cylinder (Liner diameter; ØC = 100 mm (3.94 in))

4. Pushing jig (D) for seal ring (18). Applicable cylinder (Liner diameter; ØD = 100 mm (3.94 in))

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5. Reforming jig (E) for seal ring (18). Applicable cylinder (Liner diameter; Ă&#x2DC;E = 100 mm (3.94 in))

TULI12EXN6274AA

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Hydraulic systems - Dozer blade cylinders

Blade lifting cylinder - Component identification

TULI12EXN6196FB

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cylinder liner (Qty. 1) Pin bushing (Qty. 2) Cylinder rod (Qty. 1) Cylinder head (Qty. 1) Bushing (Qty. 1) U-ring (Qty. 1) Wiper ring (Qty. 1) O-ring (Qty. 1) Backup ring (Qty. 1)

10. 11. 12. 13. 14. 15. 16. 17. 18.

O-ring (Qty. 1) Piston (Qty. 1) Seal ring (Qty. 1) Slide seal ring (Qty. 2) Adjusting screw (Qty. 1) Ball (Qty. 1) Seal ring (Qty. 4) Grease nipple (Qty. 1) Grease nipple (Qty. 1)

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Index Hydraulic systems - 35 Dozer blade cylinders - 741 Blade lifting cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Blade lifting cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Blade lifting cylinder - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blade lifting cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47574272B 24/03/2014 EN

SERVICE MANUAL Frames and ballasting CX35B CX39B

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Contents Frames and ballasting - 39

[39.101] Upper frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 [39.103] Swing ring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.3

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CX35B CX39B

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Contents Frames and ballasting - 39 Upper frame - 101

TECHNICAL DATA Upper frame Special tools - Lifting jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Upper frame Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Frames and ballasting - Upper frame

Upper frame - Special tools - Lifting jig Quantity: 2 set. Material: mild steel. Unit: mm

SMIL13MEX0074HA

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Frames and ballasting - Upper frame

Upper frame - Prepare 1. Remove the floor plate and the floor cover. 2. Remove the canopy. 3. Remove the protections. 4. Remove the counterweight. 5. Drain hydraulic oil from the hydraulic tank. 6. Disconnect the upper-side drain hoses from the swivel joint. 7. Remove the stopper for the swivel joint. 8. Remove the attachment. 9. Needed tools • Lifting device for upper frame. • Two screws M20 X 110 • Two nuts M20 • Two nuts M20

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Frames and ballasting - Upper frame

Upper frame - Remove 1. Provide match-marks on the slewing bearing. Provide match-marks between the upper frame (1) and the outer race of slewing bearing (2).

TULI12EXN6355AB

TULI12EXN6354BB

2. Lifting upper frame temporarily. 1.

Attach the upper frame lifting jigs to the rear end of upper frame using the counterweight mounting holes.

Temporarily lift the upper frame at three points applying wire ropes (1) on a position of the swingbracket mounting hole for the front side and on two places of the rear end of the upper frame.

3. Removing bolt for mounting upper frame. Loosen the screw (5) and fifteen capscrews (4) fixing the outer race of the slew bearing to the upper frame. : 19 mm 4. Removing upper frame (2). Slightly lift the upper frame to ensure safety. Then remove it and place on a worktable capable of enduring the weight. Weight: Approximately 1180 kg (2601 lb) for CX35B Weight: Approximately 1300 kg (2866 lb) for CX39B

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Frames and ballasting - Upper frame

Upper frame - Install 1. Install the upper frame (1) in reverse order of the removal. 2. Cleaning contact surface. Clean the bottom surface of the upper frame and the top surface of the slewing bearing. • Apply LOCTITE® 515 (3) over the entire circumference of the outer race inside of the capscrew. 3. Fill the grease bath portion surrounding the gear teeth of the slewing bearing with about 2.5 kg (5.5 lb) of AKCELA Multi purpose grease. 4. Lifting method. 1.

Apply wire ropes to the upper frame (1) and lift up horizontally.

Check the match-marks provided at the disassembly.

Position the outer ring of the slewing ring according to figure 2. (6) is the ball insert bore.

Slowly lower the upper frame while aligning the match-marks and watching the engaging condition between the slewing pinion gear and the internal gear of the inner race of slewing bearing (2).

TULI12EXN6355AB

SMIL13MEX0499BB

5. Assembly slewing bearing (2) and upper frame (1). 1.

Apply LOCTITE® 262 on the reamer bolt (5) and on the fifteen capscrews (4) and temporarily tighten them.

Tighten the reamer bolt (5) and the opposite screws on the front, rear, right and left in pairs alternatively to the specified tightening torque. : 19 mm, tightening torque 115 N·m (84.8 lb ft) Apply LOCTITE® 262 to the screw and capscrews.

6. Install the components removed in the above removal preparation to the original position and check the performance.

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Index Frames and ballasting - 39 Upper frame - 101 Upper frame - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Upper frame - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Upper frame - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Upper frame - Special tools - Lifting jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Frames and ballasting - 39 Swing ring assembly - 103

CX35B CX39B

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Contents Frames and ballasting - 39 Swing ring assembly - 103

FUNCTIONAL DATA Swing bearing Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Swing ring assembly Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Swing bearing Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Frames and ballasting - Swing ring assembly

Swing bearing - Sectional view Components No. 1 2 3 4 5 6 7 9 10

Name Inner race Outer race Ball Spacer Spacer (adjusting) Cap Taper pin Seal ring Grease cup

Quantity 1 1 70 65 5 1 1 1 1 SMIL13MEX0089AB

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Frames and ballasting - Swing ring assembly

Swing ring assembly - Remove 1. Remove the upper slewing structure. 2. Remove capscrews (B) that fix the inner race of slewing bearing (A). 19 mm 3. Remove the grease in the inner race of slewing bearing. 4. Screw lifting-bolts in the slewing bearing (A), and lift it by crane. Weight of slewing bearing assebly: 42 kg (92.6 lb)

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SMIL13MEX0086AB

SMIL13MEX0087AA

Frames and ballasting - Swing ring assembly

Swing ring assembly - Install 1. Before installing the slewing bearing (A), clean thoroughly the bearing and the mating surface of the lower frame to be free from dirt, oil and other foreign materials. 2. Lift up the bearing and place it on the lower frame, aligning the (S) mark engraved on the inner race. 3. Coat the threads of the capscrews (B) with LOCTITE® 262 and tighten all capscrews temporarily. 4. Tighten the capscrews at 180 ° intervals alternately, and tighten them up to the specified torque. 19 mm Tightening torque: 115 N·m (84.8 lb ft) 5. Replenish 2.5 kg (5.5 lb) of AKCELA Multi purpose grease to the grease bath. 6. After installing the slewing bearing on the lower frame, install upper slewing structure according to the procedure of Upper frame - Install (39.101).

SMIL13MEX0379BB

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Frames and ballasting - Swing ring assembly

Swing bearing - Disassemble 1. Take off seal B (9) fitted in the groove on lower circumference of inner race (1), and place the bearing in level on a wooden block (W). 2. Remove taper pin (7), using a hammer and a push rod. 3. Remove plug (6) with and puller bolt making use of the threaded bore in the centre of the plug (6). 4. After removing plug (6), take out balls (3) and spacers (4), (5) from the bore in order, while rotating outer race (2) slightly.

SMIL13MEX0090AB

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Frames and ballasting - Swing ring assembly

Swing bearing - Assemble 1. Degrease thoroughly the groove for seal B (9) located in the outer circumference of inner race (1). Coat the grooves with adhesive Cyano Bond PO-1, fit seal B (9) and place inner race on a surface table. 2. Lift and lower outer race (2) slowly till the top surface of inner race (1) matches the bottom of the sealing groove of outer race (2). Place and adjusting washer under outer race (2) in order to support the outer race so the track surface of ball (3) is aligned. 3. Insert balls (3) and spacers (4) (5) coating with grease AKCELA Multi purpose grease alternately through the hole for plug (6) on outer race (2). SMIL13MEX0091AB

SMIL13MEX0092AB

SMIL13MEX0093AB

NOTICE: When inserting balls (3) and spacers (4) (5), the ball tracks must be aligned completely. To achieve it, outer race (2) should be adjusted. It is very dangerous to put you finger into the plug bore directly; always use a push rod (P) or a hooked rod (H).

4. Install plug (6) to outer race (2), confirming the direction and the position of the bore for taper pin (7). 5. Push taper pin (7) into bore, and caulk the head of the taper pin with a punch. 6. Confirm that grease nipple (10) is useful. Apply grease AKCELA Multi purpose grease and confirm that the outer race rotates smoothly and that the lip of the seal is not scored. Grease amount: 90 g (3.2 oz)

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Index Frames and ballasting - 39 Swing ring assembly - 103 Swing bearing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Swing bearing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Swing bearing - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Swing ring assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Swing ring assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Frames and ballasting - 39 Ballasts and supports - 140

CX35B CX39B

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Contents Frames and ballasting - 39 Ballasts and supports - 140

TECHNICAL DATA Counterweight Special tools - Lifting jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Counterweight Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Frames and ballasting - Ballasts and supports

Counterweight - Special tools - Lifting jig Quantity: 2 set. Material: Mild steel. Unit: mm

TULI12EXN6052HA

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Frames and ballasting - Ballasts and supports

Counterweight - Prepare 1. Remove the cover assemblies (1), (3), (4) and (5) as well as the bonnet assembly (2).

TULI12EXN6281BB

TULI12EXN8808AB

2. Lifting tools preparation • Lifting jigs for counterweight (C) • Two M12 X 35 screws (A) • Wire rope (Nylon sling (B))

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Frames and ballasting - Ballasts and supports

Counterweight - Remove 1. Remove the plate (9) and attach the lifting jigs for counterweight. 2. Put a rope through the lifting lugs and temporarily lift up the counterweight so that the rope is not slack. Counterweight weight: â&#x20AC;˘ 380 kg (837.8 lb) for CX35B â&#x20AC;˘ 680 kg (1499.1 lb) for CX39B 3. Loosen one M20 X 90 screw (2) and two M20 X 65 screws (3). : 30 mm 4. Remove the shims (5), (6) and (7) 5. Remove counterweight (1).

TULI12EXN6295BB

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Frames and ballasting - Ballasts and supports

Counterweight - Install 1. Install the counterweight in reverse order of the removal. 2. Reinstall the shims (5), (6), and (7). 3. Lifting counterweight. Make sure that all the three fixing bolts can be manually screwed. 4. Apply LOCTITEÂŽ 262 on the capscrews (2) and (3) and tighten them together with the washer (4). : 30 mm Tightening torque: 373 NÂˇm (275.1 lb ft) 5. Remove lifting jigs.

TULI12EXN6296AB

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Index Frames and ballasting - 39 Ballasts and supports - 140 Counterweight - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Counterweight - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Counterweight - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Counterweight - Special tools - Lifting jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47574272B 24/03/2014 EN

SERVICE MANUAL Tracks and track suspension CX35B CX39B

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Contents Tracks and track suspension - 48

[48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 [48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4

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CX35B CX39B

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Contents Tracks and track suspension - 48 Track frame and driving wheels - 130

TECHNICAL DATA Driving wheel Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Track frame and driving wheels Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Driving wheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Tracks and track suspension - Track frame and driving wheels

Driving wheel - Service limits Maintenance standard

TULI12EXN4485FA

Item Code Width of sprocket teeth A B

Sprocket outer diameter

Remedy Standard value Repairable level Service limit 24 mm (0.9 in) 21 mm (0.8 in) 20 mm (0.8 in) Replace ø 385.6 mm ø 378 mm Welding repair or ø 380 mm (15 in) (15.2 in) (15 in) replacement

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Tracks and track suspension - Track frame and driving wheels

Track frame and driving wheels - Overview Travel system components

TULI12EXN6703FB

2. 3. 4. 5.

Crawler Upper roller Lower roller Idle wheel

6. 7. 8. 9.

Idler adjust Sprocket Translation motor Slewing bearing

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Tracks and track suspension - Track frame and driving wheels

Driving wheel - Remove 1. Remove the crawler assembly. 2. Place wooden block (3) under the lower frame (1) so the sprocket (2) is off the ground. 3. Loosen capscrew ( M12) for the mounting of the sprocket by means of an Allen wrench and remove the sprocket (2). : 10 mm Single weight of sprocket (2): 9 kg (20 lb)

TULI12EXN4482AB

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Tracks and track suspension - Track frame and driving wheels

Driving wheel - Install 1. Check the fixing parts of the travel motor (5) and the sprocket (2), eliminate burrs and dirt thoroughly, and install the sprocket (2). 2. Apply LOCTITEÂŽ 262 to the threaded portion of capscrew to mount the capscrews (4) and fasten then temporarily. 3. Remove the wooden block (3) under the lower frame (1) and tighten capscrews (4) to specified torque to fix sprocket (2) and travel motor (5). : 10 mm 4. Install crawler.

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TULI12EXN4483AB

TULI12EXN4482AB

TULI12EXN4484AB

Index Tracks and track suspension - 48 Track frame and driving wheels - 130 Driving wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Driving wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Driving wheel - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Track frame and driving wheels - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Tracks and track suspension - 48 Tracks - 100

CX35B CX39B

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Contents Tracks and track suspension - 48 Tracks - 100

TECHNICAL DATA Tracks General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Tracks Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Track chain Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Rubber track Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Tracks and track suspension - Tracks

Tracks - General specification Crawler type Type Rubber belt

Steel track (optional)

Model

Width

CX35B

300 mm (11.81 in)

Total crawler width 1550 mm (61.02 in)

CX39B

300 mm (11.81 in)

CX35B

CX39B

Number of Link

Ground pressure CANOPY

CAB

29 kPa (4 psi)

30 kPa (4 psi)

1700 mm (66.93 in)

31 kPa (4 psi)

32 kPa (5 psi)

300 mm (11.81 in)

1550 mm (61.02 in)

31 kPa (4 psi)

32 kPa (5 psi)

300 mm (11.81 in)

1700 mm (66.93 in)

32 kPa (5 psi)

33 kPa (5 psi)

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Tracks and track suspension - Tracks

Tracks - Service limits Rubber crawler

TULI12EXN4438EB

L. C. H.

Distance between the bottom of frame and top of rubber crawler Core Height Ref.

Sag of rubber crawler “L”

Standard value 70 - 80 mm (2.76 3.15 in)

Cracks and notch on rubber crawler

None

Breakage of steel cord

None

Contact surface of rubber crawler and lower roller

None

Height “H” Lug projection “h”

76.5 mm (3.01 in) 25 mm (0.98 in)

Rubber cover

M. h.

Centre line of steel frame Lug projection

Repairable level

Serviceability limit

Remedy

—

Adjustment

Where the depth Where the depth of them does not of them reaches to reach to the steel cords the steel cords None Exist Where half Where 10 percent of cores are visible of cores are visible from from outside outside 51.5 mm — (2.03 in) —

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Replace

Replace Replace

Tracks and track suspension - Tracks

Steel crawler (track link)

TULI12EXN6723FB

A. B.

Link pitch Link height

Height of crawler lug

D. F.

Bushing outer diameter Track pin

G. I. L. M.

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Ă¸ Master pin Master pin Distance between the bottom of frame and top of rubber crawler Master link

Tracks and track suspension - Tracks

Symbol

Ref.

Link pitch

Link height Height of crawler lug Bushing outer diameter

C D

Interference of bushing and link

Interference of track pin and link

Fitting of master pin and link

H — L

Clearance gap of link Welding of link and crawler Slackening of steel crawler

Repairable Serviceability Remedy level limit 105 mm 107 mm 101.6 mm (4.00 in) (4.13 in) (4.21 in) Parts over the 60 mm (2.36 in) 57 mm (2.24 in) 56 mm (2.20 in) critical value in use should be 16.5 mm (0.65 in) 10 mm (0.39 in) 8 mm (0.31 in) replaced with link assembly ø 30 mm ø 28 mm ø 32.16 - 32.2 mm (1.27 - 1.27 in) (1.18 in) (1.10 in) Basic dimension Fit Fit ø 32.16 32.2 mm (1.266 Shaft Interference - 1.268 in) 0.11 - 0.20 mm Interference (0.004 0 ø 32 - 32.05 mm 0.008 in) (1.260 Hole 1.262 in) Replace ø 19.2 19.26 mm Shaft Interference (0.756 0.15 - 0.26 mm Interference 0.758 in) (0.006 0 ø 19 - 19.05 mm 0.010 in) (0.748 Hole 0.750 in) ø 18.93 18.98 mm Shaft Play (0.745 0.02 - 0.12 mm 0.747 in) — Replace link (0.001 ø 19 - 19.05 mm 0.005 in) (0.748 Hole 0.750 in) 4 mm (0.16 in) 6 mm (0.24 in) 0.9 mm (0.04 in) (One side) Replace (both side) (both side) Reference value

To be free from weld crack, blow hole, etc. 115 - 130 mm (4.53 - 5.12 in)

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—

Repair weld Adjust tension

Tracks and track suspension - Tracks

Tracks - Component identification Rubber crawler No. 1.

Name Rubber crawler assembly

Qty. per machine 2

â&#x20AC;˘ This standard machine provides rubber crawler.

TULI12EXN4436AB

TULI12EXN4437AA

Steel crawler No. 1. 1-2. 2. 2-2. 3. 4. 5.

Name Crawler (Master) Bushing Crawler Bushing Pin (Master) Pin (Crawler) Pin

CX35B 1 1 41 41 1 41 1

CX39B 1 1 44 44 1 44 1

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Tracks and track suspension - Tracks

Track chain - Remove 1. The crawler track link includes a set of master pin (6), which should be placed at the position front of the idle wheel.

TULI12EXN4425AB

TULI12EXN4426AB

TULI12EXN4427AB

2. Put square timbers (A) and (B) under the shoe at the top end of the crawler and between the crawler and the link over the track frame to reduce the load to the master pin.

3. Loosen grease nipple (G) for track spring adjustment, discharge grease in the cylinder and slack the tension of the shoe.

: 17 mm NOTICE: When loosening grease nipple for adjustment, donâ&#x20AC;&#x2122;t turn it more than one turn to loosen. When grease is remained, move the machine forward and backward slightly. Be careful that the grease nipple may be popped out.

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Tracks and track suspension - Tracks

4. Straighten the curve of lock pin, and draw out it striking by hammer. â&#x20AC;˘ Remove lock pin (8) with crawler. 5. Apply master pin drawing out jig (a) to the small diameter section of master pin (6), and draw it out striking by hammer. NOTICE: Especially pay attention to the idle wheel which may spring out due to the force of spring when drawing out master pin (6) to repair broken parts relating to the idle wheel. Be careful not to be injured by scattering materials, when large hammer is used.

TULI12EXN4428AB

TULI12EXN4429AB

TULI12EXN4430AB

NOTICE: Donâ&#x20AC;&#x2122;t approach the machine because the end of the crawler may drop just before extending the track link assembly to the ground while rotating the sprocket. Put wooden block just in case. 6. Move the machine back slowly, and remove the crawler extending it to the ground. Weight of steel crawler (one side): CX35B: 180 kg (397 lb) CX39B: 190 kg (419 lb)

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Tracks and track suspension - Tracks

Track chain - Install 1. Install the crawler to the position where the end of the track link engages with the sprocket placing the track link narrowing toward the end toward the drive wheel side as shown in the Fig. 1.

TULI12EXN8558AA

TULI12EXN4432AA

TULI12EXN4433AB

TULI12EXN4434AB

2. Move the machine forward slowly by inserting the bar in the master pin hole on the end of the crawler and assisting so that the sprocket engages with the track link, and also assist so that the crawler catches the normal position and engages with the idle wheel using pry-bar.

3. Hook chain block to the upper and lower parts of the crawler, and align the master pin hole pulling by the chain block.

4. Align master link holes on the both ends of the crawler link with the link holes inserting pry-bar, apply master pin drawing out jig (a) used when removed and press fit master pin by hammer. NOTICE: Be careful not to be injured by scattering materials, when large hammer is used. Apply molybdenum grease to the master pin before press fitting.

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Tracks and track suspension - Tracks

5. After press fitting master pin (6), insert lock pin (8) and bend the top end in advance. 6. After completion of installation, adjust the tension of crawler by the same procedure of the rubber crawler.

: 17 mm

TULI12EXN4435AB

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Tracks and track suspension - Tracks

Rubber track - Remove 1. Lift the one side of machine with attachment, as shown in Fig. 1, and place support under lower frame to support machine (S).

TULI12EXN4419AB

TULI12EXN4420AB

TULI12EXN4421AA

2. Loosen grease nipple for crawler adjuster, discharging grease in cylinder, and release tension of crawler. : 17 mm â&#x20AC;˘ When loosening the grease nipple (G) of the adjuster, do not loosen it more than one turn. â&#x20AC;˘ Where grease does not come out well, drive the crawler forward/reverse. The over loosening of grease nipple will cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple. Keep body and face away from the grease nipple for safety. 3. Put steel pipes (P) in the rubber crawler, turn the sprocket in the reverse direction slowly and when the rubber crawler has floated off the idler stop the rotating. 4. Slide the rubber crawler sideways, and remove it.

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Tracks and track suspension - Tracks

Rubber track - Install Installation is done in the reverse order of removal. 1. Engage the track with the sprocket, and insert it on the idler adjuster. 2. Put steel pipes (P) in the rubber crawler, turn the sprocket in the reverse direction slowly and when the rubber crawler has floated off the idler stop the rotating. 3. Slide the rubber crawler to the position to be set on idler exactly. 4. Confirm that the rubber crawler is engaged securely with the sprocket, idler and lower roller. 5. Tighten the grease nipple for the crawler adjuster, and adjust tension by feeding grease.

TULI12EXN4422AB

TULI12EXN4423AA

TULI12EXN4424AA

: 17 mm Tightening torque = 74 N·m (54.58 lb ft) Rubber crawler Appropriate tension “A”: CX35B: 70 - 80 mm (2.76 - 3.15 in) CX39B: 70 - 80 mm (2.76 - 3.15 in) Steel crawler Appropriate tension “B”: CX35B: 115 - 130 mm (4.53 - 5.12 in) CX39B: 115 - 130 mm (4.53 - 5.12 in)

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Index Tracks and track suspension - 48 Tracks - 100 Rubber track - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rubber track - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Track chain - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Track chain - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tracks - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tracks - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tracks - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Tracks and track suspension - 48 Track tension units - 134

CX35B CX39B

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Contents Tracks and track suspension - 48 Track tension units - 134

TECHNICAL DATA Track tensioner Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Idler wheel Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Track tensioner Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Idler wheel Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Track tension units Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Track tensioner Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Idler wheel Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Tracks and track suspension - Track tension units

Track tensioner - Service limits Maintenance standards Code A B C D E F

Ref. Spring set length Free length of spring Stroke Set length Outside view of piston Tightening torque of grease nipple

D/R Rubber crawler 196 mm (7.72 in) 247.3 mm (9.74 in) 20 mm (0.79 in) 352 mm (13.86 in) No scoring and rusting 74 N·m (54.58 lb ft)

TULI12EXN6392EB

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D/S Steel crawler ← ← ← 354 mm (13.94 in) ← ←

Tracks and track suspension - Track tension units

Idler wheel - Service limits

TULI12EXN6754FB

Code

Ref.

Crawler idler projection diameter

Tread diameter

C D

Flange width Tread width

Fitting shaft/ bearing

Fitting idler/ bearing

Oil Idler rotation Tightening torque

Standard value

Repairable level

Service limit

ø 341 - 344 mm (13.43 - 13.54 in)

ø 337 mm (13.27 in)

ø 339 mm (13.35 in)

Remedy

ø 299 mm ø 297 mm ø 304.5 - 305.5 mm (11.99 Replace (11.77 in) (11.69 in) 12.03 in) 27 mm (1.06 in) 22 mm (0.87 in) 20 mm (0.79 in) 71 mm (2.80 in) Basic dimension Fit Fit Fit Interference Replace shaft 0.002 Interference ø 35 mm or bearing 0.028 mm 0.002 mm (1.38 in) (0.0001 (0.0001 in) 0.0011 in) Play 0.004 mm Play (0.0002 in) ø 80 mm Replacement of 0.004 mm Interference (3.15 in) idler or bearing (0.0002 in) 0.039 mm (0.0015 in) Replenish Gear oil CASE AKCELA GEAR 135 H EP 80W-90 45 cm³ (2.75 in³) Roller rotates smoothly by hand Reassemble 66 N·m (48.68 lb ft) Retightening Apply LOCTITE® 262

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Tracks and track suspension - Track tension units

Track tensioner - Component identification

TULI12EXN6384FB

No. 1 2 3 4 5 6 7 8 9 10

Name Piston Grease cylinder Spring Plate Nut Pin Oil seal O-ring Split pin Grease cup

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Qty. 1 1 1 1 1 2 1 1 1 1

Tracks and track suspension - Track tension units

Idler wheel - Component identification

TULI12EXN6749FB

No. 1 2 3 4 5 6 7 8 9 10

Name Idler adjust Collar Collar Shaft Bearing Seal ring Snap ring Edge bolt Plug PT 1/8 Washer

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Qty. 1 1 1 1 2 2 1 2 1 2

Tracks and track suspension - Track tension units

Track tension units - Remove 1. Remove the crawler assembly. 2. Remove idler together with idler adjuster assembly, rolling it, using a pry-bar or equivalent. 3. Loosen capscrews ( M10 X 45) (c), and separate idler assembly (a) from idler adjuster assembly (b). : 17 mm Weight of idler assembly: 27 kg (60 lb) Weight of idler adjuster assembly: 14 kg (31 lb) NOTICE: The separated idler assembly (a) is easy to fall down. Lay it down so it does not fall down on your feet, utilizing wooden blocks.

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TULI12EXN4463AA

TULI12EXN8604AB

Tracks and track suspension - Track tension units

Track tension units - Install 1. Install idler assembly (a) to the idler adjuster assembly (b) by means of capscrews (c) in the reverse order of removing the idler assembly. Coat the threaded part of capscrews (c) with LOCTITE® 262 beforehand. : 17 mm Tightening torque = 66 N·m (49 lb ft) 2. The assembly of the idler and idler adjuster is to be installed to the lower frame so that the grease feeding plug (1) is positioned to upside, and the grease nipple (2) is facing to outside. 3. Following procedures of section (2), install the crawler assembly, and adjust the crawler tension.

TULI12EXN8604AB

TULI12EXN8605AB

• On that occasion, confirm the lubrication through the grease nipple is proper and that grease is not leaking from the grease cylinder.

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Tracks and track suspension - Track tension units

Track tensioner - Disassemble 1. Before disassembling and assembling the idler adjuster assembly, prepare spring setting jig (S). Capacity of hydraulic jack: More than 5 t (11023 lb) NOTICE: Large power is needed to set the spring. Prepare a special jig before disassembly and assembly. 2. Place a hydraulic jack between the jig base and the stand. 3. Loosen the holding-down nuts of the jig and draw out the retainer upward. 4. Draw out piston (1) from grease cylinder (2) of the idler adjuster assembly. TULI12EXN4474AC

TULI12EXN4475AB

TULI12EXN4476AB

TULI12EXN4477AA

5. Taken out oil seal (7) and O-ring (8) from grease cylinder (2). 6. Set the idler adjuster assembly on the stand of the jig (V), with its plate (4) side facing up. 7. Fit retainer plate (R) to plate (4) tighten holding down nuts alternately, and secure idler adjuster assembly. B. Base H. Holding-down nut R. Retainer plate S. Spring setting jig (V) J. Hydraulic jack

8. Remove split pin (9), press spring (3) lifting it with jack so that nut (5) can be turned freely, and remove nut (5).

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Tracks and track suspension - Track tension units

9. Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate (R) and take-off plate (4). The free length of the spring: approximately 247.3 mm (9.74 in) 10. Hook lifting eye-bolt (W) to screw M24 X 3 on grease cylinder (2) top end and hoist it. Lifting nut: M24 X 3 11. Remove the grease cylinder (2) and from the spring (3).

TULI12EXN6389AB

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Tracks and track suspension - Track tension units

Track tensioner - Assemble Perform assembly in the reverse order of disassembly. 1. Insert grease cylinder (2) into spring (3) and erect it in the center of the jig stand upright. 2. Install the plate (4) on top of spring (3). Center the rod of grease cylinder (2) and the holes in bracket (4). Attach the retainer plate (R) and four holding-down nuts (H). Fasten the nuts evenly all round fix the idler adjuster assembly to the jig body. 3. Extend the hydraulic jack, compress spring (3) to a set length and screw in nut (5) to the screwed part at the tip of grease cylinder (2). Set length of the spring: 196 mm (7.72 in)

TULI12EXN4479BB

TULI12EXN4480AB

4. Tighten nut (5) till the holes for locking split pins (9) are aligned, then fit split pin (9). : 36 mm 5. Remove the idler adjuster assembly from the jig. 6. Fit oil seal (7) and O-ring (8) to grease cylinder (2). • Apply grease on oil seal (7) and O-ring (8). 7. Fill up grease in grease cylinder (2), remove the grease nipple from piston (1) and press the piston by hand to discharge the inside air. • Push the piston in while directing the grease nipple hole downward to make it easier to release air. 8. Tighten grease nipple to piston (1). : 17 mm Tightening torque: 74 N·m (54.58 lb ft)

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Tracks and track suspension - Track tension units

Idler wheel - Disassemble 1. Remove plug (9), and drain out oil. [approximately 80 cm³ (5 in³)] : 5 mm 2. Remove the capscrew (8) for preventing coming off, and pull of the collars (2) and (3) from the shaft. : 17 mm 3. Remove the seals (6) and snap ring (7). 4. Supporting the idler (1) with the supporting stand (S), apply the shaft extruding jig (11) to the shaft and push it out together with the bearing (5) using a pressing machine. • Except the case that replacement of the bearing (5) is necessary, do not remove the bearing from the shaft (4).

TULI12EXN4467BB

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Tracks and track suspension - Track tension units

Idler wheel - Assemble 1. Apply AKCELA Moly grease to the shaft (4), and install the bearings (5). • In case of reuse of the bearing, confirm its smooth rotation, and no defect and rust on them. 2. Applying AKCELA Moly grease to the idler (1), press the shaft (4) together with the bearings into the idler. 3. Install the snap ring (7) and oil seal (6). 4. For the oil seal (6), first apply grease into the groove on lip portion of the seal body (6a). Then push the seal body (6a) and sleeve (6b) into the place evenly with the special pushing jig carefully not to give any distortion on the lip. • Replace the seal to new one at reassembly. • When the seal is not installed properly due to one sided pressing etc, replace it with new one. 5. Install the opposite seal (6) by the same procedure. 11. Shaft extruding jig 12. Seal pushing jig

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TULI12EXN4468BB

TULI12EXN4469AB

Tracks and track suspension - Track tension units

6. Insert the collar (2) to the shaft (4) and install the capscrew (8). 7. Install the collar (3) and the capscrew (8) of the opposite side in a similar way. : 17 mm 8. Fill in 80 cm³ (4.88 in³) of the gear oil CASE AKCELA GEAR 135 H EP 80W-90 through the plug hole in the idler (1). 9. Tighten plug (9). : 5 mm

TULI12EXN4470BB

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Index Tracks and track suspension - 48 Track tension units - 134 Idler wheel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Idler wheel - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Idler wheel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Idler wheel - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Track tension units - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Track tension units - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Track tensioner - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Track tensioner - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Track tensioner - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Track tensioner - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Tracks and track suspension - 48 Track rollers - 138

CX35B CX39B

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Contents Tracks and track suspension - 48 Track rollers - 138

TECHNICAL DATA Track frame roller Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Track support roller Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Track frame roller Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Track support roller Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Track frame roller Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Track support roller Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Tracks and track suspension - Track rollers

Track frame roller - Service limits

TULI12EXN4462EB

Code A B C

Item Flange outer diameter Tread outer diameter Flange width

Standard value

Repairable level

Service limit

ø 107 mm (4.213 in)

–

ø 85 mm (3.346 in)

ø 77 mm (3.031 in)

31 mm (1.220 in)

26 mm (1.02 in)

Basic dimension

– –

Clearance between shaft and bushing

Interference between roller and bushing

Oil Roller rotation

Tolerance

Fit

Welding ø 74 mm repair or (2.913 in) replacement 24 mm (0.94 in) Fit

-0.073 -0.040 mm Shaft Play (-0.003 0.1 -0.002 in) ø 30 mm – – 0.258 mm (1.181 in) +0.060 (0.004 +0.185 mm 0.010 in) Bushing (+0.002 +0.007 in) +0.10 +0.15 mm Bushing Interference (0.004 0.075 0.006 in) ø 34 mm Interference – 0.15 mm (1.339 in) 0 mm (0 in) 0 (0.003 +0.025 mm 0.006 in) Roller (0 +0.0010 in) Engine oil CASE AKCELA GEAR 135 H EP 80W-90 35 cm³ (2.136 in³) Roller rotates smoothly by hand

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Remedy

Replace bushing

Replenish Reassemble

Tracks and track suspension - Track rollers

Track support roller - Service limits

TULI12EXN4447EA

Code A B

Ref. Tread diameter Tread width

Standard value

Repairable level

ø 75 mm (2.95 in)

ø 71 mm (2.80 in)

98 mm (3.86 in)

–

Basic dimension

Interference between shaft and bearing

Fitting between roller and bearing

Interference between roller and cover

– –

Interference between roller and cover

Oil Roller rotation

Tolerance

Fit

Service limit ø 69 mm (2.72 in) –

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Replace

Fit

+0.002 +0.015 mm Shaft (+0.0001 0.002 Interfer+0.0006 in) 0.025 mm ø 25 mm ence – (0.98 in) (0.0001 - 0.002 mm -0.010 0.0010 in) (0.0001 in) - 0 mm Hole (-0.0004 0 in) -0.013 Play - 0 mm Shaft 0.004 mm (-0.0005 Play (0.0002 in) 0 in) ø 52 mm – 0.004 mm - Inter(2.05 in) -0.039 (0.0002 in) ference -0.009 mm 0.039 mm Hole (-0.0015 (0.0015 in) -0.0004 in) +0.034 +0.050 mm Shaft Interfer(+0.0013 Interence 0.009 +0.0020 in) ference ø 45 mm – - 0.050 mm 0.009 mm (1.77 in) 0 (0.0004 (0.0004 in) +0.025 mm 0.0020 in) Hole (0 +0.0010 in) +0.12 +0.14 mm Shaft (+0.0047 Inter0.074 +0.0055 in) 0.140 mm ference ø 63 mm – (0.0029 - 0.074 mm (2.48 in) 0 +0.046 mm 0.0055 in) (0.0029 in) Hole (0 +0.0018 in) Gear oil CASE AKCELA GEAR 135 H EP LS, 45 cm³ (2.75 in³) Roller rotates smoothly by hand

Remedy

Replace shaft or bearing

Replace roller or bearing

Replace cover

Replenish Reassemble

Tracks and track suspension - Track rollers

Track frame roller - Component identification

TULI12EXN4451FB

No. 1 2 3 4 5 6 7 8 9

Name Roller Collar Collar Shaft Bushing Stopper ring Seal O-ring Plug: PT 1/8

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Qty. 1 1 1 1 2 1 2 1 1

Tracks and track suspension - Track rollers

Track support roller - Component identification 1. 2. 3. 4. 5. 6. 7. 8. 9.

Roller (Qty. 1) Shaft (Qty. 1) Seal cover (Qty. 1) Cover (Qty. 1) Seal (Qty. 1) Bearing (Qty. 2) O-ring (Qty. 1) Snap ring (Qty. 1) Plug (Qty. 1)

TULI12EXN4444AB

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Tracks and track suspension - Track rollers

Track frame roller - Remove Quantity on one side: 4 pieces 1. Slightly loosen capscrews ( M14 X 50) (2) fastening lower roller assembly (1) to the lower frame. : 22 mm 2. As same as the case for removal of the crawler, loosen the grease nipple for crawler adjusting within one turn to discharge the grease, and release the tension on the crawler. : 17 mm 3. Lift the lower frame good enough to remove the lower roller, using the attachment.

TULI12EXN4448AB

TULI12EXN4449AA

4. After lifting the lower frame to a proper height, place square lumber under the lower frame to stabilize the machine. 5. Remove the capscrews (2) fastening the lower roller, and remove the lower roller assembly. : 22 mm Weight of lower roller assembly: 6 kg (13 lb)

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Tracks and track suspension - Track rollers

Track frame roller - Install 1. Installing position of lower roller. Install the lower roller assembly so that the plug (3) directs outward from the machine. 2. Coat the mounting capscrews (2) with LOCTITE® 262 in advance. Place the roller assembly (1) between the crawler and lower frame (4). Fasten the capscrews (2) temporarily. : 22 mm 3. Lower the machine in full contact with the ground and tighten the capscrews (2) as specified. : 22 mm T = 208 N·m (153 lb ft) 4. Tighten the grease nipple of the crawler adjuster. Lift the machine, and adjust the crawler tension by feeding grease. : 17 mm T = 74 N·m (54.58 lb ft)

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TULI12EXN4450AB

Tracks and track suspension - Track rollers

Track frame roller - Disassemble 1. Loosen the plug (9) to drain oil. : 5 mm 2. Remove snap ring (6). 3. Removing collar (2) and O-ring (8). Place the lower roller on the jig (A) so that the shaft (4) stands vertically. Apply the extruding jig (C) to the upper shaft end. Push the shaft (4) with a press or a hammer until the O-ring comes out from the collar (2) to remove the upper collar (with seal) and O-ring (8). 4. Removing shaft. Push the shaft further to remove the shaft (4) and the lower collar (with seal) (3) in one piece.

TULI12EXN6735AB

TULI12EXN6736AB

TULI12EXN4454AB

NOTICE: Prior to extruding the shaft, prepare a drain oil container to receive lubricating oil remaining in the lower roller. Otherwise the lubricating oil flows out to contaminate the work floor. 5. Removing collar (3). Place the shaft (4) with the collar (3) pulled out according to the above procedure on the jig (B). Apply the extruding jig (C) to the shaft to push it out using a press. (Note) The collar (3) is press fitted to the shaft (4). â&#x20AC;˘ Interference for reference: From 0.030 - 0.083 mm (0.0012 - 0.0033 in)

6. Removing the seal (7). Remove the seal (7) from the collars (2) and (3).

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Tracks and track suspension - Track rollers

7. Removing the seal (7). Take out the seal (7) from the roller (1).

TULI12EXN4455AB

TULI12EXN4456BB

8. Removing bushing (5). Cut-off the bushing (5) having very small thickness with a lathe or tear it off without damaging the bore. When an amount of wear of the bushing is small, place the roller (1) on the jig (A) and apply the tip of the extruding jig (D) to the end surface of the bushing (5) to hammer out the bushing. NOTICE: In order to avoid damage to the bore of the roller (1), hammer the bushing (5) lightly and change the jig applying position circumferentially little by little to push out the bushing slowly.

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Track frame roller - Assemble 1. Press fitting bushing (5) Align the centre of the bushing (5) with that of the bore of the roller (1) with the bushing press fit jig (E) inserted to the bushing (5) to push the bushing in with a press vertically. Press fit the opposite side bushing (5) too. • Apply molybdenum disulfide grease to the press fit section of the bushing to press fit the bushing at a normal temperature. • If the press fit failed due to eccentric pushing and so on, always replace the bushing with new one. 2. Press fitting collar (3) Press fit the collar (3), into which the seal (7) is built in advance, into the shaft (4) with a press.

TULI12EXN4457AB

TULI12EXN4458AB

TULI12EXN4459BA

• Press fit according to the arrow and dimensions shown in Fig. 2.

3. Installing roller side seal (7) Install the seals (7) into both ends of the roller (1). • Reuse the seals after ensuring that their surfaces are free from damage or rust. 4. Inserting roller (1) Insert the roller to the shaft (4).

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5. Install the O-ring (8) Install O-ring (8) to shaft groove. • Coat grease to O-ring. • Always replace the O-ring with new one prior to reassembling. 6. Installing collar (2) Insert the collar (2), into which the seal (7) is built in advance, into the shaft (4). • Insert it until the stopper ring groove of the shaft (4) is in alignment with the end surface of the collar (2). 7. Installing stopper ring (6) Fit the stopper ring (6) in the stopper ring groove of the shaft (4).

TULI12EXN4460BB

TULI12EXN4461AB

8. Oil supply Supply 35 cm³ (2.14 in³) of CASE AKCELA GEAR 135 H EP 80W-90 class engine oil through the plug (9) hole. 9. Leakage test Perform leakage test at an air pressure of 2.0 kgf (4.41 lbf) prior to tightening the plug (9). 10. Installing the plug (9) Apply oil resistant sealing agent to the plug (9), and screw it in the plug hole in the end surface of the collar (2). : 5 mm Tightening torque: 9.8 N·m (7.23 lb ft) NOTICE: After assembling the lower roller as a single unit, ensure that it shows no oil leakage and can be manually rotated.

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Track support roller - Remove 1. Loosen the grease nipple (G) for crawler adjusting within one turn to discharge grease and release tension on the crawler. : 17 mm NOTICE: Turn the grease nipple slowly paying attention not to turn more than one turn, and be careful for the spouting out grease.

TULI12EXN4435AB

TULI12EXN4440AB

2. Push up the crawler with a hydraulic jack, and place suitable wooden block (A) to keep a clearance between the crawler and lower frame. 3. Remove the fixing capscrews and nuts, and remove the upper roller from the lower frame. : 17 mm Weight of upper roller assembly: 3 kg (7 lb)

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Track support roller - Install NOTICE: Before installing the upper roller (A), make sure that sufficient oil is filled in and that the upper roller rotates smoothly by hand. If the oil volume is insufficient, refill oil, or if the upper roller does not rotate smoothly or oil is leaking, check the bearing and the seals and replace them where necessary. Oil: CASE AKCELA GEAR 135 H EP 80W-90 Volume: 45 cm³ (3 in³) 1. Insert the shaft of the upper roller (A) assembly into the lower frame. 2. Coat mounting capscrews with LOCTITE® 262 and tighten it to the torque. TULI12EXN4443AB

: 17 mm Tightening torque: 66 N·m (49 lb ft) • Install it so that the nut is located on the crawler idler side (B). • At installation, support the crawler with wooden blocks the same way as it was dismantled so it does not disturb the work. 3. After installing upper roller (A), tighten grease nipple for crawler adjuster, grease it, and adjust crawler tension. : 17 mm Tightening torque: 74 N·m (55 lb ft)

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Track support roller - Disassemble The seal cover (3) and cover (4) of both sides of upper roller are press-fitted into the roller (1). Therefore, this portion is usually not disassembled and assembled. If it is necessary, do as follows: 1. Remove plug (9), and drain out oil. : 5 mm 2. Remove seal cover (3) by means of drilling holes on or cutting it, then remove seal (5). 3. Remove snap ring (8). 4. Remove cover (4) utilizing threaded hole ( PT 1/8) on it or other means. 5. Place roller (1) with its end face on to the support base (C), and set the press-in jig (D). Pull out shaft (2) together with bearings (6) by means of a press machine or hammering. 6. If removing bearings (6) from shaft (2) is required, remove them by means of using a gear puller or other means.

TULI12EXN4445BB

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Track support roller - Assemble 1. Apply molybdenum grease to shaft (2), then install two bearings (6) on it. 2. Place roller (1) on to a plane base, applying a pad (B) to shaft (2) end, press it together with bearings (6) into roller (1) with a press machine or hammering. 3. Attach snap ring (8). 4. Applying grease to new O-ring (7), attach it to cover (4), then press it in roller (1). 5. Fit a new gasket (5). 6. Install new seal cover (3). 7. Fill 45 cmÂł (2.75 inÂł) of gear oil CASE AKCELA GEAR 135 H EP 80W-90 in the roller (1) through plug bore on cover (4). 8. Tighten plug (9). : 5 mm

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TULI12EXN4446AB

Index Tracks and track suspension - 48 Track rollers - 138 Track frame roller - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Track frame roller - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Track frame roller - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Track frame roller - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Track frame roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Track frame roller - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Track support roller - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Track support roller - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Track support roller - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Track support roller - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Track support roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Track support roller - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Cab climate control CX35B CX39B

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Contents Cab climate control - 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1

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CX35B CX39B

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Contents Cab climate control - 50 Air conditioning - 200

FUNCTIONAL DATA Air conditioning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Air conditioning Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Cab climate control - Air conditioning

Air conditioning - Overview

SMIL13MEX0127GB

1. 2. 3. 4.

Compressor Flexible hose Condenser Flexible hose

5. 6. 7. 8.

Receiver (dryer) Flexible hose Cooler unit/Evaporator Flexible hose

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Air conditioning - Dynamic description In the cooling process, the refrigerant that flows through the cooling circuit changes its phases from liquid to gas and viceversa during which process heat is transferred from the low temperature part (cabin) to the high temperature part (outside of the vehicle). Refrigerant used is the R134A. The quantity of refrigerant R134A present in the system is 650 - 750 g (23 - 26 oz). The portion of system that cools the air of cabin is the evaporator. The air is cooled through the refrigerant that takes heat off the surrounding area as evaporation heat as it evaporates in the cooling circuit. Since the part at which vaporization of the refrigerant takes place is the evaporator, cooled air is constantly delivered to the circumference of the evaporator by the blower fan. In the meantime, liquid refrigerant (slightly wet vaporized refrigerant) is fed into the evaporator, when "cooling" effect is attained. The compressive action of the compressor and the heat exchange (heat radiation) action of the condenser transform the refrigerant in a dry vapor state back to a liquid state. The compressor performs the function of suction, pumping and compressive.

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Air conditioning - Component identification

SMIL13MEX0128GB

Q. Compressor F. Flexible hose assy P. Condenser D. Tube assy H. Bracket

G. Receiver/Dryer C. Flexible hose assy J. Cooler unit/Evaporator E. Flexible hose assy

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SMIL13MEX0129GB

1. Grommet 7. Washer 8x17x1.6 19. Lock washer D=8 32. Screw M8x100. Tightening torque 20.7 - 25.3 NÂ·m (15.3 - 18.7 lb ft)

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SMIL13MEX0130GB

A. Tube assy (compressor - -> condenser) B. Tube assy (cooler unit - -> compressor) Q. Compressor R. Screw M8x35 T. Tightening torque 20.2 - 24.8 N路m (14.9 - 18.3 lb ft) 5. Screw M8x20. Tightening torque 20.7 - 25.3 N路m (15.3 - 18.7 lb ft) 6. Cover assy (5 attaching places) 7. Washer 8x17x1.6 17. Screw M10x30. Tightening torque 41.9 - 51.1 N路m (30.9 - 37.7 lb ft) (4 places) 19. Lock washer D=8 32. Screw M8x100. Tightening torque 20.7 - 25.3 N路m (15.3 - 18.7 lb ft) 33. Washer 10x25x3 37. Clip 39. Screw M8x20 45. Screw M8x25 48. Washer 8x17x3 (only right back side) 47574272B 24/03/2014

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SMIL13MEX0131FB

S. Air conditioning control panel

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SMIL13MEX0132FB

F. Flexible hose P. Condenser 4. Cover assy 5. Screw M8x20. Tightening torque 20.7 - 25.3 N·m (15.3 - 18.7 lb ft) (4 places) 7. Washer 8x17x1.6 9. Bracket 11. Washer 10x21x2 12. Lock washer D=10 13. Screw M10x25. Tightening torque 41.9 - 51.1 N·m (30.9 - 37.7 lb ft) (3 places) 19. Lock washer D=8

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SMIL13MEX0133FB

E. Flexible hose assy. Tightening torque 31.9 N·m (23.5 lb ft) J. Cooler unit K. Tee L. Flexible hose (L=270) M. Flexible hose (L=55) N. Flexible hose (L=1600) 11. Washer 10x21x2 12. Lock washer D=10 13. Screw M10x25. Tightening torque 41.9 - 51.1 N·m (30.9 - 37.7 lb ft) 14. Clip 36. Rubber 37. Clip 40. Clip. Tightening torque 2.4 - 3.4 N·m (1.8 - 2.5 lb ft) 41. Flexible hose – drain 42. Flexible hose – drain 50. Clip (3 places)

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SMIL13MEX0134FB

7. Washer 8x17x1.6 12. Lock washer D=10 16. Pulley 17. Screw M10x30. Tightening torque 41.9 - 51.1 N·m (30.9 - 37.7 lb ft) (3 places) 18. V-belt. Adjust belt tension applying a force of 19 N (4.3 lb) with max. 4 mm arrow 19. Lock washer D=8 20. Screw M8x50. Tightening torque 20.7 - 25.3 N·m (15.3 - 18.7 lb ft) 21. Plate 22. Screw M8x100. Tightening torque 20.7 - 25.3 N·m (15.3 - 18.7 lb ft) 23. Bracket

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SMIL13MEX0135FB

C. Flexible hose assy (tightening torque 12.7 - 14.7 N路m (9.4 - 10.8 lb ft) D. Tube assy G. Receiver/Dryer U. Tightening torque 7.8 - 11.8 N路m (5.8 - 8.7 lb ft) 5. Screw M8x20. Tightening torque 20.7 - 25.3 N路m (15.3 - 18.7 lb ft) 7. Washer 8x17x1.6 19. Lock washer D=8 21. Plate 38. Screw M6x20. Tightening torque 48 - 50 N路m (35 - 37 lb ft) 44. Screw M6x25 47. Washer 6x12x1.6 49. Lock washer D=6

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SMIL13MEX0136EB

7. Washer 8x17x1.6 19. Lock washer D=8 27. Grommet. Fix with adhesive 28. Grille 29. Duct 30. Strip 31. Screw M8x16. Tightening torque 21.5 - 23.5 NÂ·m (15.9 - 17.3 lb ft)

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Air conditioning - Hydraulic schema NO. 1 2 3

NAME PUMP ASSY HYDRAULIC OIL TANK SOLENOID TANK

SMIL13MEX0145GB

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Air conditioning - Electrical schema NO. 1 2 3

NAME CONDENSER MOTOR COMPRESSOR POWER SHIFT SOLENOID

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SMIL13MEX0146JA

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Air conditioning - Charging NOTICE: To avoid burns: Do not touch the hot areas (exhaust tube etc.) To avoid fire: if an abnormality is detected, stop operating immediately and contact our service shop for checking and repair. The operation in abnormal condition could cause fire. The disassembling by other than experts is not allowed. The imperfect repairing may cause injury due to abnormal operation and fire. Be careful not to splash water on interior parts like control panel and so on because it is not waterproofed, it could cause trouble and fire. To avoid injury: Do not insert tools or hand into air vent hole. Since the fan is rotating inside of casing, it may cause injury. Do not touch fan, compressor belt and so on when the engine is running. It may cause injury. Before cleaning, maintenance and checking, turn the cooler control switch off to stop operating. Do not loosen parts of refrigerating circuit. if the refrigerant for cooler gets in eyes and splashed on hands, it causes loss of sight and frostbite. Refrigerant with safety characteristics. This means that this refrigerant is non-flammable, non-explosive, nontoxic, non-irritating, tasteless and colourless. Nevertheless, it is necessary to take some precautions. Avoid any contact with the refrigerant. In case of skin contact with the refrigerant, immediately treat the skin. Wear the safety glasses to protect your eyes. If although these measures the coolant comes in contact with your eyes, rinse them immediately with cold and clean water and then obtain medical attention immediately. Empty the system before carrying out repairs on it. Do not let the refrigerant release in the surrounding areas. To suck it, only use duly approved aspirators. Regardless of the system being full of refrigerant or empty, heat determines a remarkable overpressure, which could not only damage the system, but also cause explosions. Never expose the air conditioning components to a flame or a too hot heat source, to prevent fire or explosion hazard, with following emission of toxic gas. Empty refrigerant cylinders must not be discarded. When full, refrigerant cylinders must not be exposed to sun rays or other heat sources for a long time. The maximum allowed temperature for a full refrigerant cylinder must not exceed 40 Â°C.

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The lack of refrigerant causes low efficiency of cooling. Run the engine at high idling and rotate the cooler at high speed. Then remove the rubber cap (1) , and inspect the flowing refrigerant condition from the sight glass (2) of the receiver dryer (3).

A. No bubbles: proper B. Bubbles appeared (Bubbles appear continuously): insufficient C. Transparent: over charged or no refrigerant If bubbles or transparent are detected, the system recharging must be performed. Replace of refrigerant in the air conditioner requires a vacuum generation procedure and a gas charging procedure. The vacuum generation procedure consists in removing moisture from the air conditioner circuit. In the event even a small quantity of moisture remains in the system, it would freeze in the small orifices of the expansion valve when in operation. This causes a clogging of the circuit or the formation of rust, with a series of operational troubles. Prior to filling the circuit with refrigerant, apply the vacuum and cause the boiling and vaporization of the moisture. In this manner, moisture is eliminated from the system.

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LELI11E0489BB

LELI11E0474AB

Cab climate control - Air conditioning

SMIL13MEX0137FA

The gas charging procedure consists in the filing the circuit with refrigerant, after applying a vacuum. The filling of the gas is not only depending upon the cooling performance of the air conditioner, but it influences also the useful working life of the circuit components. An excessive overloading increases considerably the pressure of the system and damages the cooling performance. On the contrary, a too low charging, results in an insufficient circulation of lubricant oil in the compressor, causing the wear of the moving parts of the compressor. NOTICE: The gas filling operation involves the handling of highly compressed gases; it is dangerous to handle the gas without complying strictly with the relevant procedures. The procedures and the protections described in this manual for the filling of refrigerant gas must be strictly adhered to.

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SMIL13MEX0138FA

Procedure for the vacuum generation Close high pressure valve (3) and low pressure valve (1) on gauge manifold (2). Connect the red charging pipe (5) and the blue one (6) to compressor service valves (8) (D) and (S) as described in the figure. NOTICE: Never exchange by mistake the high pressure pipe with the low pressure pipe when connecting them. install the pipe firmly until a click noise is heard. Connect the quick release joint of the charging pipe with the service valve of the compressor. If the charging pipe is connected in the opposite direction, mini-valve (9) of the compressor fails to open. SMIL13MEX0140AB

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Connect the central valve of the gauge manifold with charging pipe (4) of the vacuum pump (7). NOTICE: Some types of manifold are not equipped with an open/close valve in the central part. Open high pressure valve (3) and low pressure valve (1) of gauge manifold (2). Start the vacuum pump and let it operate 30 min to generate the vacuum. At the end of the vacuum phase for the prescribed time (vacuum value: lower than 750 mm Hg (29.5 in Hg) close the high pressure valve (3) and the low pressure valve (1) of the gauge manifold (2). Cut-off the vacuum pump. With the high pressure valve (3) and the low pressure valve (1) closed, check, after five minutes, that the pressure gauge dial does not return to zero.

SMIL13MEX0141AB

SMIL13MEX0142AB

SMIL13MEX0143AB

NOTE: In the event the pressure gauge moves toward zero, this indicates the presence of a leakage. Tighten again the connecting joints and apply the vacuum again, verifying that there are no further leakages.

Procedure for the charging of the gas After applying the vacuum repeatedly, exchange charging pipe (4)of the gauge manifold (2) , from the vacuum pump to the service can (9) . Open the valve of service can (10) . Close the high and low pressure valves of the gauge manifold. Press central bleeding valve (11) of the side service opening on the low pressure side of the gauge manifold using a screwdriver in order to let out the air in the charging pipe by the pressure of the refrigerant. Proceed with this operation until a whistle is heard coming from the bleeder. Open high pressure valve (3) of the gauge manifold and charge the refrigerant to a pressure of 0.1 MPa (14.5 psi). Once the charge is completed, close high pressure valve (3) of the gauge manifold and service valve (10) . NOTICE: Never start operating the compressor during this work. the starting of the compressor causes the blowing of the service can. Check that there are no leakages of gas in the cycle, using a gas leakage tester. Retighten and eliminate all points of leakage. NOTE: To check for gas leakages, always use a tester for R134A. Do not use one for flon gas service as it provides poor sensitivity. Make sure that high pressure valve (3) and low pressure valve (1) of the manifold and service valve can (10) are closed. Start the engine running it at 1400 - 1600 RPM (1400 1600 RPM) and open fully the door and windows of the cab. Activate the air conditioner, setting it at maximum ventilation speed and at lowest temperature. During the charging of the gas, set the discharge pressure of the compressor to 1.4 - 1.6 MPa (203.1 - 232.1 psi).

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Open low pressure valve (1) of the gauge manifold and service valve can (10) and fill with refrigerant until all air bubbles in sight window (12) Once the refrigerant change operation is terminated, close low pressure valve (1) of the gauge manifold and the service valve can (10).of the dryer disappear. Once the refrigerant change operation is terminated, close low pressure valve (1) of the gauge manifold and the service valve can (10). NOTICE: Do not open the high pressure valve of the manifold under any circumstance nor place the service can upside down. A. Correct quantity of gas

SMIL13MEX0144AB

B. Incorrect quantity of gas C. Overcharged system The level of refrigerant is correct only once the air conditioner is activated and through the inspection sight window, just a few air bubbles are seen and, afterward, a white colour slightly milky is seen. NOTE: When the air conditioner operates with an insufficient quantity of refrigerant, this has a negative effect on the compressor; on the contrary, when the refrigerant is charged with an excessive quantity, the cooling performance is lost. Also, the pressure of the system increases abnormally. Disassemble the manifold disconnecting the charging pipes from the compressor, as indicated here below: â&#x20AC;˘ press the quick release coupling of the charging pipe on the low pressure side against the service valve of the compressor so that the refrigerant doers not escape leaking when loosening the connection. As soon as the nut has been removed, disconnect the charging pipe from the service valve; â&#x20AC;˘ wait for the pressure in the high pressure site to decrease, indicated on the pressure gauge, to a value of 1.0 MPa (145.0 psi); â&#x20AC;˘ disconnect the red charging pipe from the high pressure side, in the same manner as described for the low pressure.

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Cab climate control - Air conditioning

Air conditioning - Service instruction - Troubleshooting

SMIL13MEX0139GA

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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Air conditioning - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air conditioning - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Air conditioning - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Air conditioning - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air conditioning - Service instruction - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

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SERVICE MANUAL Electrical systems CX35B CX39B

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.510] Cab or platform harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

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CX35B CX39B

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Contents Electrical systems - 55 Electrical system - 000

TECHNICAL DATA Electrical system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Electrical system Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SERVICE Electrical system Service instruction â&#x20AC;&#x201C; Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Electrical systems - Electrical system

Electrical system - General specification Electrical equipment list Group

Diode

Electric fittings

Lights

Engine

Relay

Sensors

Solenoid

Code D-1 D-2 D-3 D-4 D-12 D-13 D-14 D-18 E-1 E-2 E-3 E-4 E-6 E-7 E-8 E-11 E-12 E-13 E-14 E-17 E-18 E-26 L-1 L-2 L-5 M-1 M-2 M-3 M-4 M-6 R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 SE-1 SE-2 SV-1 SV-2 SV-3 SV-5 SV-12 PSV-D PSV-E

Part Name Diode Diode Diode Diode Diode Diode Diode Diode Fuse box Generator (alternator) Horn Fusible link ( 45 A) Gauge cluster Power socket Air heater Overload buzzer Heater (opt) Battery Sequence box Engine condenser Compressor Hour counter Room lamp Boom working light ( 55 W) Cab/canopy working light Starter motor Wiper motor (cab) Washer motor (cab) Deceleration motor Fuel pump Battery relay Safety relay Deceleration relay Timer unit Engine stop relay Charge indicator relay Cab / canopy working light Slew / swing select relay Fuel sensor Coolant sensor Lever lock solenoid 2-Speed select solenoid Engine stop solenoid Powershifting solenoid (radiator specifications) Swing selector solenoid Nibbler open proportional solenoid (right slide) Nibbler close proportional solenoid (left slide)

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Electrical systems - Electrical system

Group

Part Name (Key) starter switch Working lights switch 2nd Speed selector switch Wiper washer switch Engine coolant temperature switch Engine oil pressure switch Horn switch Lever lock switch Heater switch (opt) Deceleration switch Swing selector switch Hydraulic nibbler activation slider Overload pressure switch Overload switch

Code SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-9 SW-10 SW-11 SW-28 SW-35 SW-39 SW-40

Switch

Electrical equipment specifications D-1, 2, 3, 4, 12รท14, 18 Diode Horn Engine stop solenoid Engine stop relay Travel 1, 2 speed solenoid Battery relay

TULI12EXN4636AA

TULI12EXN4637AA

Slewing / swing Select relay Engine stop solenoid Max rated

Current Breakdown

3A 400 V

E-1 Fuse box F1 30 A F2 10 A F3 30 A F4 30 A F5 30 A F6 10 A

Wiper Heater Relay Solenoid Working light Horn Cab light Solenoid Engine stop Battery relay Gauge cluster

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Electrical systems - Electrical system

E-2 Generator Voltage : 10 A one, 30 A two Rating speed : 5000 RPM Current : 55 A Weight : 3.5 kg (8 lb)

TULI12EXN6401AA

TULI12EXN4640AA

TULI12EXN4641AA

E-3 Horn Rated voltage : 12 V Nominal current : 4.5 A Basic frequency : 425 Hz

E-4 Fuse Allowable current : 45 A

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Electrical systems - Electrical system

E-6 Gauge cluster Voltage of operation : 12 V 1.

Illumination (+)

Engine oil pressure (-)

Charge (-)

Engine coolant temperature (-)

Lamp power source -1 (+) [engine coolant, fuel, travel 2 speed]

Fuel (-)

Travel 2 speed (-)

Lamp power source-2 (+) [engine oil pressure, charge, air cleaner clogging]

Clogging air cleaner (-)

TULI12EXN4642AA

TULI12EXN4643AA

TULI12EXN4644AA

10. F/T IGN (+) 11. Fuel unit 12. F/T illumination GND (-) 13. Temperature unit 14. Not used A. Connector E-7 Power socket Voltage of operation : 12 V DC (water-proof type)

E-8 Air heater Engine starter Rated voltage : 11 V DC Nominal current : 36.5 A Rated output : 400 W Insulation resistance : 3 M ÎŠ or more / 500 V Megger

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Electrical systems - Electrical system

E-11 Overload buzzer Voltage : 12 V Current : 15 - 35 mA

TULI12EXN4646AA

E-12 Heater (opt) 1. Machine side 2. Heater side

TULI12EXN6410AA

TULI12EXN4648AA

TULI12EXN4649AA

E-13 Battery Type : 95D31L Voltage : 12 V Capacities : 74 AÂˇh Weight with electrolyte : 5.3 l (1.40 US gal)

E-14 Relay 1. Push button deceleration 2. Travel 1, 2 speed switch 3. Travel 1, 2 speed solenoid 4. Deceleration relay solenoid A. Input / output operation B. Electric circuit C. Pin arrangement

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Electrical systems - Electrical system

E-26 Hourmeter Rated voltage : 10 - 80 V DC

TULI12EXN4652AA

TULI12EXN4653AA

TULI12EXN4654AA

TULI12EXN4655AA

L-1 Lights (cab) Rated voltage : 12 V Bulb : 12 V - 10 W

L-2 Work light Effective area of lens : 82 cm² (13 in²) Bulb : Halogen 12 V - 55 W

L-5 Cab work light Effective area of lens : 54 cm² (8 in²) Bulb : Halogen 12 V - 55 W

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Electrical systems - Electrical system

M-1 Starter motor Rated voltage : 12 V DC Output : 1.7 kW (2.31 Hp) Nominal time : 30 s Rotation direction : Clockwise as seen from pinion Weight : 3.4 kg (7 lb) TULI12EXN4656AA

TULI12EXN4657AA

TULI12EXN4658AA

M-2 Windshield wiper motor Rated voltage : 12 V Wiping angle : 102 ° - 108 °

M-3 Washer motor Rated voltage : 12 V DC

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Electrical systems - Electrical system

M-4 Decelerator 1.

Ampère connector

AVS-0.85L

AVS-0.85LR

AVS-0.85LW

Cap

AVS-0.85B

AVS-0.85LY

Switch On: P1 Off: P2

PTC thermistor

TULI12EXN6425AB

TULI12EXN8193AA

TULI12EXN4661AA

10. Relay A. Circuit diagram Rated voltage : 12 V Stroke : 34 - 38 mm (1.34 - 1.50 in) Working force : 11 kg (24 lb) or more Working time : 1 or less Working current : 8.5 A or lower M-6 Fuel pump Rated voltage : 12 V DC Maximum working current : 1.5 A or lower Delivery : At open condition 24000 cm³/sec (24 in³/sec) or more

R-1.7 Battery relay Engine stop relay Rated voltage : 12 V DC Coil resistance : 72 Ω +/- 10% Insulation resistance : 20 M Ω ( 500 V)

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Electrical systems - Electrical system

R-2 Relay Protection of starter 1. Key switch 2. Battery 3. Starter 4. Controller A. Connector B. Connector

TULI12EXN4662AA

TULI12EXN4663AA

TULI12EXN4664AA

C. Connection diagram Rated voltage : 12 V DC Nominal : Continuous Temperature range : -30 - 80 °C (-22 - 176 °F) Nominal load : B terminal start (maximum 40 A) R3, 8, 9, 14 Deceleration relay Charge indicator relay Slewing / swing relay Rated voltage : 12 V DC Insulation resistance : 1 Ω or higher / 20 A, 20 °C (68 °F)

R-6 Relay Timer 1. Red (Acc) 2. Black (GND) 3. Red / White (relay) 4. Yellow (relay) Rated voltage : 12 V Exciting current : 1 A Timer : 1 s

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Electrical systems - Electrical system

SE-1 Fuel meter Rated voltage : 12 V Float position Resistance Allowable 1.

Ground (black)

Unit (yellow)

Thermistor (red)

Gauge

Waning lamp

Thermistor

Fuel unit

8 Stay earth

Low fuel warning

Full 10 Ω -4 - 0 Ω

1/2 38 Ω -

Empty 90 Ω 0 - 10 Ω

TULI12EXN4665AA

TULI12EXN4666AA

TULI12EXN4667AA

10. Tank SE-2 Coolant temperature sensor Temperature Resistance value

50 °C (122 °F)

80 °C (176 °F)

100 °C (212 °F)

120 °C (248 °F)

153.9 Ω

51.9 Ω

27.4 Ω

16.1 Ω

Rated voltage : 12 V DC Type : Thermistor type SV-1.2 Solenoid valve Safety lock lever / selection of 2nd speed 1. 6.8 - 8.8 N·m (5 - 6 lb ft) 2. 41 - 47 N·m (30 - 35 lb ft) 3. 6.8 - 8.8 N·m (5 - 6 lb ft) Rated voltage : 12 V DC Relief valve set pressure : 3.5 MPa (508 psi) Delivery : 15 l/min (4 US gpm) ( P port)

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Electrical systems - Electrical system

SV-3 Solenoid valve Engine stop 1. Ground (black) 2. Pull coil (white) 3. Hold coil (red) 4. Connector 5. Stroke: 7.4 mm (0.29 in) Rated voltage : 12 V DC

TULI12EXN4668AA

TULI12EXN4669AA

SMIL13MEX0292AB

Nominal current : Pull coil: 36.5 A, Hold coil: 0.49 A SV-5 Solenoid valve Powershift (air-con spec.) 1. Cord colour earth: black 2. Supply cord colour: red 3. Ampère mark ΙΙ 2P Rated voltage : 12 V DC Capacities : 12 W Operating pressure : 4.9 MPa (711 psi) Maximum delivery : 160 l/min (42 US gpm) SV-12 Swing selector solenoid Working pressure: 23 MPa (3336 psi) Flow max: 60 l/min (16 US gpm) Voltage: 13 V DC Power: 35 W Current: 2.7A Voltage tolerance: 10.2-14.5 V Duty cycle ED: 100 (1) Bidirectional diode (P6 K E33 CA)

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Electrical systems - Electrical system

PSV-D, PSV-E Nibbler open/close proportional solenoid Power supply : 12 V Current : 1600 mA Coil resistance : 2.7 - 3.7 Î© Max. working pressure : 7 MPa (1015 psi) Flow rate : 10 l/min (3 US gpm)

TULI12EXN6098BA

TULI12EXN4670AA

TULI12EXN4671AA

SW-1 Starter switch

SW-2, 28 Switch Working light and Swing selector switch

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Electrical systems - Electrical system

SW-3 Switch Travel 1, 2 speed

TULI12EXN4672AA

TULI12EXN4673AA

TULI12EXN4674AA

TULI12EXN4675AA

SW-4 Switch Wiper / washer 1. Auto return 2. Washing A. Windshield wiper motor B. Washer, motor Insulation resistance : 1M Ω or more / 500 V Megger SW-5 Sensor Engine water temperature Operating temperature : ON: 107 - 113 °C (225 - 235 °F) , OFF : 100 °C (212 °F) or lower Electric capacity : DC 12 V 1 A Insulation resistance : 100M Ω or more / 500 V Megger Tightening torque : 27 N·m (20 lb ft) SW-6 Sensor Engine oil pressure Rated voltage : DC 6 V, 12 V, 24 V Nominal load : 5 W (Lamp load) Operating pressure : 48 - 50 kPa (7 - 7 psi)

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Electrical systems - Electrical system

SW-7 Horn switch Type : OFF-(ON) momentary Nominal : 125 V 3 A (AC) Insulation resistance : 100M Ω or more / 500 V Megger

TULI12EXN4676AA

TULI12EXN4677AA

TULI12EXN4678AA

TULI12EXN4679AA

SW-9 Lever lock switch Rated voltage : 12 V DC Nominal current : 15 A Insulation resistance : 1M Ω or more Stroke : Switch ON: 1 - 3 mm (0.04 - 0.12 in)

SW-10 Heater switch (opt) 1. Connector 2. Cap

SW-11 Deceleration switch (opt) 1. Free 2. Push Rated voltage : 12 V DC (MAXIMUM: 16 V DC) Insulation resistance : 1M Ω or more / 500 V Megger

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Electrical systems - Electrical system

SW-35 Hydraulic nibbler activation slider A. Hydraulic breaker activation push-button B. SW-35, hydraulic nibbler activation slider

TULI12EXN6209BB

TULI12EXN4681AA

TULI12EXN4682AA

SW-39 Overload pressure switch Max voltage : 250 V Max current : 3 A Setting ( CX35B): 11.5 - 12.0 MPa (1668 - 1740.6 psi) Setting ( CX39B): 14.5 - 15.0 MPa (2103 - 2175.8 psi) Max static pressure : 60 MPa (8703 psi) Operating temperature : 55 - 60 °C (131 - 140 °F) SW-40 Overload switch 1. Symbol mark 2. Connector (with lock) 3. Red (R) 4. Red / White 5. Switch 6. Terminal

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Electrical systems - Electrical system

Electrical system - Electrical schema Group

Diode

Electrical system Fittings

Lights

Engine

Relay

Sensors

Code D-1 D-2 D-3 D-4 D-12 D-13 D-14 D-18 E-1 E-2 E-3 E-4 E-6 E-7 E-8 E-10 E-9 E-11 E-12 E-13 E-14 E-17 E-18 E-26 E-32 L-1 L-2 L-5 M-1 M-2 M-3 M-4 M-6 R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 R-22 R-23 R-26 R-31 SE-1 SE-2

Part name Diode Diode Diode Diode Diode Diode Diode Diode Fuse box Generator (alternator) Horn Fusible link (45A) Gauge cluster Power socket Air heater Radio (opt) Fuse Overload buzzer Heater (opt) Battery Sequence box Engine condenser Compressor Hour counter Fuse Room lamp Boom working light Cab/canopy working light Starter motor Wiper motor (cab) Washer motor (cab) Deceleration motor Fuel pump Battery relay Safety relay Deceleration relay Timer unit Engine stop relay Charge indicator relay Cab/canopy working light relay Slew/swing select relay Switch selector relay Swivel swing selector relay Rotary light relay Horn relay Fuel sensor Engine thermo sensor

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Electrical systems - Electrical system

Group

Solenoid

Switch

Code SV-1 SV-2 SV-3 SV-5 SV-12 PSV-D PSV-E PSV-F PSV-G SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-9 SW-10 SW-11 SW-28 SW-30 SW-31 SW-35 SW-37 SW-39 SW-40

Part name Lever lock solenoid 2-speed select solenoid Engine stop solenoid Power shifting solenoid (Radiator specifications) Swing selector solenoid Nibbler open proportional solenoid (right slide) Nibbler close proportional solenoid (left slide) Revolution left (A1) Revolution right (A2) Key switch Working lights switch 2nd speed selector switch Wiper washer switch Engine coolant temperature switch Engine oil pressure switch Horn switch Lever lock switch Heater switch (opt) Deceleration switch Swing select switch Swing lever pressure switch left Swing lever pressure switch right Hydraulic nibbler activation slider Revolution switch (A1, A2) Overload pressure switch Overload switch

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Electrical systems - Electrical system

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Electrical systems - Electrical system

TULI12EXN9281JA

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Electrical systems - Electrical system

SMIL13MEX0158JA

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Electrical systems - Electrical system

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Electrical systems - Electrical system

TULI12EXN9283JA

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Electrical systems - Electrical system

Harness and cable list Code H-1 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 H-11 H-12

Name Inst Main Harness Engine wiring harness Starter cable (+) Battery ground cable (-) Engine ground cable Boom harness Key switch harness Canopy work light harness Boom work light extension wiring harness Wiring harness for connection with cab Heater Harness

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Observations

(opt) (opt)

Electrical systems - Electrical system

Electrical system - Overview 1. Wiring of starter must be observed as follows otherwise it causes miss starting or damage of startermotor. • Total electric resistance of battery cable (1) + (2) should be less than 2/1000 Ω. Reference: AV 15: ≤ 1.4 m (4.6 ft), AV 20: ≤ 2.2 m (7.2 ft) AV 30: ≤ 3.8 m (12.5 ft), AV 40: ≤ 4.6 m (15.1 ft) • Total electric resistance of wiring for starter (3)~(6) should be less than 5/100 Ω. Reference of terminal resistance: 15/1000 Ω per coupler 0 Ω per screw setting • Battery earth cable (1) connection on shall be ensured. Painted surface may not be used (for earthing) avoiding the miss contact. 2. Battery treatment must be observed as follows. Otherwise it may cause burning of electric equipment or components. Alternator (diodes) burning caused by battery cable connection reversely is not warranted. • Battery should be fixed by fitting. (not to move). • Battery cable length should be adjusted properly and clamped not to be connected reversely. • Not loose the battery cable terminal, nor turn the battery switch “OFF” during the engine running. 3. Only the specified load should be applied on the alternator (L) and (P) line. 4. Check any surge current or voltage occurred under normal operations and erroneous operations, and confirm the circuit no surge occurs. Especially provide the flywheel diode for (C-LOAD) and diode for (L-LOAD). Mark B W R L G Y Br Lg Sb O P Gr R/W

Color Black White Red Blue Green Yellow Brown Light green Sky blue Orange Pink Gray Red/White

NOTE: Engine stop solenoids. 1.

Permissible resistance of solenoide circuit should be less than 0.07 Ω to guarantee permissible lowest voltage 9 V to work solenoid (pull coil). (terminal resistance: 15/1000 Ω per coupler 0 Ω per screw setting Coupler resistance of solenoid doesn’t need to be counted). Reference: AV2 ( 0.0088 Ω/m): ≤ 8 m (26 ft), without terminal resistance AV3 ( 0.0056 Ω/m): ≤ 12.5 m (41.0 ft), same as above When you exceed permissible resistance, adopt the circuit impressed from the power supply to the solenoid directly using a relay. Refer to #

High temperature parts, such as an exhaust pipe, should not approach for the pull power fall of solenoid, and heating prevention of inner coil temperature. (permissible ambient temperature: -30 - 100 °C (-22 - 212 °F))

Install fuse to protect the harness against trouble such as short circuit or continuous drive of pull-coil.

The power supply of solenoid may not be common with the line of alternator initial excitator as shown in Fig. 1. (Otherwise, solenoid may loose stop function due to the power supply from alternator L terminal).

In case of waterproof connect or application, connector should be fixed by fitting to prevent lead wire break. 47574272B 24/03/2014

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Electrical systems - Electrical system

In case of emergency stop of machine for safety will be applied, switch location should be shown as “a”.

In case of the solenoid circuit resistance would be limit, # wiring is applicable.

For 4TNV84 (T), 88 starter motor DC 12 V 1.4 kW (1.9 Hp)

For 3TNV82A, 84 (T), 88 starter motor DC 12 V 1.2 kW (1.6 Hp)

10. Battery DC 12 V 11. Fusible link 12. Generator CC 12 V- 40 A 13. Timer 13.5 - 16.5 s 14. Pre-heat lamp (after 15 s “OFF”) less than 3.4 W 15. Air heater DC 12 V- 400 W 16. Charge lamp DC 12 V 3.4 W 17. Safety relay 18. 20 A fuse 19. 5 A fuse 20. Pilot lamp DC 12 V less than 3.4 W 21. 22. Electrical feed pump DC 12 V 1.5 A 23. Lubricating oil pressure switch CC 12 V 1 A 0.5 Kg/cm² (7 psi) “OFF” 24. C.W. temp switch DC 12 V 0.4 A 110 °C (230 °F) “ON” 25. Solenoid DC 12 V hold 0.49 A pull 36.5 A 26. Timer -0.5 - 2.5 s 27. Relay DC 12 V 40 A 28. Solenoid DC 12 V hold 0.49 A pull 36.5 A 29. Diode 600 V, 1.1 A Mark B W R L G Y Br Lg Sb O P Gr R/W

Color Black White Red Blue Green Yellow Brown Light green Sky blue Orange Pink Gray Red/White

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Electrical systems - Electrical system

TULI12EXN5292HB

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Electrical systems - Electrical system

Precaution on electric wiring Generator In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user. 1. When the battery cable can be connected backwards. The alternator diode will be damaged and recharging made impossible if the plus and minus ends of the battery cable are confused. The stator coil will also be burned as a result. To prevent this, supply the user with a cable of such a length or structure that the plus and minus ends cannot be confused. Also warn the user not to connect the cable backwards. 2. When charging output voltage is used for control purposes. The engine speed at starting is not proportional to the output voltage of the alternator, so this output voltage must not be used for any control systems. It is especially wrong to use it for the control signal of the safety relay for cutting the starter motor because this will damage the starter motor and cause engine starting failure. 3. When the L line is used for control purposes. Consult with Dealer first before connecting any load other than the charge lamp to the L line. Damage to the alternator and related equipment will not be warranted without such prior consultation. 4. Non-use of wiring diagram. Use without prior consultation of any wiring diagram other than that provided by Dealer removes any breakdown of any electrical equipment from the warranty. 5. Regarding lamp control. Once the charge lamp goes out after the start of charging, it does not come on again even if the engine speed falls and charging is insufficient. The lamp will not light again if the charging circuit is normal. The lamp only comes on during operation if the alternator itself is broken or the drive V-belt breaks. However, when an LED is used for the charge lamp, the LED will shine faintly even during normal operation. This is due to the control system for the alternator lamp and is not an abnormality. 6. Use of a non-specified V-belt. Use of a non-specified V-belt will cause inadequate charging and shorten the life of the belt. Use a belt of the specified type. 7. Direct high pressure washing is prohibited. Water will enter the brush if the alternator is washed directly at high pressure, causing inadequate charging. Warn users not to use direct, high-pressure washing. 8. Use of agricultural or other chemicals (direct contact or airborne). Adhesion of agricultural and other chemicals, especially those with high sulphur content, to the IC regulator corrodes the conductor on the substrate, leading to over-charging (battery boiling) and charging malfunctions. Consult with Yanmar prior to use in such an environment. Use without prior consultation removes any breakdown from the warranty.

Starter motor In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user. 1. Starting performance in the case of using an untested battery. The starting performance of the engine is closely dependent on the battery capacity. This battery capacity is itself affected by the climate and the type of equipment installation. The details regarding ambient temperature and equipment installation vary depending on the OEM, so Dealer cannot decide the battery capacity on its own. Confer with Dealer in advance after checking these conditions and fix the battery capacity on the basis of confirmatory tests. 2. When the resistance of the battery cable exceeds the specified value. The combined total resistance of the battery cable in both directions between the starting motor and battery should be within the value indicated on the wiring diagram. The starting motor will malfunction or break down if the resistance is higher than the specified value. 3. When the resistance of the starter circuit exceeds the specified value. The combined total resistance of the wiring between the starting motor and key switch (or power relay or safety relay, depending on the application) should be within the value indicated on the wiring diagram. Engine starting 47574272B 24/03/2014

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will be difficult if the resistance is higher than the specified value. This can also blow the magnetic switch at the point of contact and consequently burn the rotor coil. 4. When there is no safety relay. Over-running (when the electric current flows for too long) is a major cause of starting failure. This burns the rotor and the clutch. Excessive work and failure of the key switch to return properly are the main causes of over-running. The user must be given sufficient warning about this. Be sure to use the safety relay to prevent over-running. This safety relay is supplied as an option. Consult Yanmar first when planning to install a safety relay at your own company. In the case of failure to consult with Yanmar, our warranty will not be applied to all the electrical equipment. 5. When there is too much rust due to the entry of water. The water-proofing of the starting motor is equivalent to R2 of JIS D 0203. This guarantees that there will be no damage from the sort of exposure encountered in rain or when water is poured on from a bucket. You should, however, avoid the use of high-pressure washing and steeping in water. 6. Regarding the heat resistance of the starter motor. The starter motor has heat resistance for an ambient temperature of 80° and surface temperature of 100°. Insulators must be installed to prevent overheating when used near high temperature parts such as the exhaust system. 7. Corrosion of magnet switch contact point by corrosive gas.

Current limiter In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user. 1. When an over-discharged battery is used. Use of booster starting with an over-discharged battery (when the voltage has dropped to 8 V or less) will destroy other electrical equipment by generating an abnormally high voltage. A specialized battery charger should be used to recharge such an over-discharged battery (when the voltage has dropped to 8 V or less). 2. When checks for malfunctioning are not performed. When high voltage noise from other electrical equipment is impressed on the current limiter upon turning Off the key switch, the current limiter can be damaged and cause loss of control over the output voltage. Other electrical equipment may also be damaged if this happens, so surge killers should be fitted to the electrical equipment whenever necessary. Be sure to check prior to mass production whether electrical noise might damage the current limiter by turning the key switch and other electrical equipment On and Off while the engine is running, using F both the vehicle and the wire harness that will be used in mass production. 3. Removal of the battery cable during operation. The current limiter may malfunction if the battery cable and/or battery are removed during operation, depending on the kind of electrical equipment being used, causing loss of control over the output voltage. In such cases, the current limiter and other electrical equipment will be damaged by the generation of a continuous high voltage of 24 - 43 V (for 5000 RPM dynamo). All electrical equipment falls outside the scope of the warranty under these circumstances. Be sure to warn the user not to remove the battery cable and/or battery during operation. 4. If the battery cable can be attached in reverse. The current limiter’s SCR diode will be destroyed if the plus and minus ends of the battery cable are connected the wrong way around. This causes charging malfunctioning and burns the harness. Give the user a cable of such a length that it cannot be connected the wrong way and warn the user against connecting the cable backwards. 5. Non-use of wiring diagram. Use without prior consultation of any wiring diagram other than that provided by Dealer removes any breakdown of any electrical equipment from the warranty. 6. Installation environment Observe the following when installing the current limiter: • Do not install it on the engine. • Place it in a well-ventilated place with an ambient temperature of 65 °C (149 °F) or less. • Ensure that the cooling air flows in the right direction for the current limiter’s cooling fins. • Do not use the earth wire of the current limiter to earth any other electrical equipment.

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Section area and resistance of electric wire 1. Allowable maximum cable length (Terminal resistance is not included). Cable size (mm2) 3 5 8 15 20 30 40 50 60 85 100

Cable construction Element No. Cable diameter ø 0.32 mm 41 (0.01 in) ø 0.32 mm 65 (0.01 in) ø 0.45 mm 50 (0.02 in) ø 0.45 mm 84 (0.02 in) ø 0.80 mm 41 (0.03 in) 0.80 mm 70 (0.03 in) 0.80 mm 85 (0.03 in) 0.80 mm 108 (0.03 in) 0.80 mm 127 (0.03 in) 0.80 mm 169 (0.03 in) 0.80 mm 217 (0.03 in)

Resistance (/m) 0.005590 Ω 0.003520 Ω 0.002320 Ω 0.001380 Ω 0.000887 Ω 0.000520 Ω 0.000428 Ω 0.000337 Ω 0.000287 Ω 0.000215 Ω 0.000168 Ω

2 m Ω Note1

20 m ΩRef.

50 m ΩNote 2

0.36 m (14.17 in) 0.57 m (22.44 in) 0.86 m (33.86 in) 1.45 m (57.09 in) 2.25 m (88.58 in) 3.85 m (151.57 in) 4.67 m (183.86 in) 5.93 m (233.46 in) 6.97 m (274.41 in) 9.3 m (366.14 in) 11.9 m (468.5 in)

3.58 m (140.94 in) 5.68 m (223.62 in) 8.62 m (339.37 in) 14.49 m (570.47 in) 22.55 m (887.8 in) 38.46 m (1514.17 in) 46.73 m (1839.76 in) 59.35 m (2336.61 in) 69.69 m (2743.7 in) 93.02 m (3662.2 in) 119.05 m (4687.01 in)

8.94 m (351.97 in) 14.20 m (559.06 in) 21.55 m (848.43 in) 36.23 m (1426.38 in) 56.37 m (2219.29 in) 96.15 m (14.17 in) 116.82 m (4599.21 in) 148.37 m (5841.34 in) 174.22 m (6859.06 in) 232.56 m (9155.91 in) 297.52 m (11713.39 in)

NOTE: Allowable maximum resistance of Battery cable. NOTE: Allowable maximum resistance of Starting motor circuit. 2. Terminal resistance Generally, a terminal resistance is 15m Ω per coupler and 0 Ω per screw setting. This resistance should be included in allowable maximum resistance when the cable length is planned.

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Electrical system - Service instruction – Troubleshooting RefClassifi- ercation ence No. (1) (2)

(3)

General 1 (4)

(5)

(6)

Attachment operation 2 (1)

Travel operation 3 (1)

Deceleration 4 (1)

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

Causes

Electrical equipment

Sensors

Solenoid

Switch

Relay

Others

10 11 12 13 14 15 16 17 18 19 20 1* 2* 3* 4* 5* 6* 7* 8* 9* 21* Defect * * * * * * * * * * * Engine does not Ο Ο Ο Ο Ο Ο start. Horn does Ο Ο Ο not sound. Working light does Ο Ο Ο not light up. Hourmeter does Ο Ο Ο Ο not actuate. Fuel gauge Ο Ο Ο does not actuate. Water temperature meter Ο Ο Ο does not actuate. All controls does not function. (ExΟ Ο Ο cluding swing operations) Travel 1 and 2 speed can Ο Ο Ο Ο not be changed.. Deceleration switching Ο Ο Ο Ο can not be carried out..

Gauge cluster Generator Working light Deceleration motor Horn Coolant temp sensor Fuel level sensor Travel 1, 2 speed solenoid Lever lock solenoid For engine stop solenoid Horn switch

12* 13* 14* 15* 16* 17* 18* 19* 20* 21*

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Working light switch Travel 1, 2 speed switch Lever lock switch/limit switch Deceleration switch Engine stop solenoid relay Charge indicator relay Safety relay Timer Travel holding circuit control unit Fuse, disconnect, short circuit, looseness

Electrical systems - Electrical system

Abbreviations Decel: Deceleration SOL: Solenoid

General Engine does not start

TULI12EXN4504GA

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TULI12EXN4523GA

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The horn does not sound

TULI12EXN4524FA

TULI12EXN4525FA

Work light does not turn On

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Hourmeter does not actuate

TULI12EXN4526FA

TULI12EXN4527FA

The fuel gauge does not actuate

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Water temperature meter does not actuate

TULI12EXN4528FA

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Attachment operation All controls do not function (excluding swing operations)

TULI12EXN4529FA

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Travel operation Travel speed does not switch from 1st speed to 2nd speed

TULI12EXN4530GC

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Deceleration Deceleration operation cannot be carried out

TULI12EXN4531GA

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Index Electrical systems - 55 Electrical system - 000 Electrical system - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical system - Service instruction â&#x20AC;&#x201C; Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Electrical systems - 55 Harnesses and connectors - 100

CX35B CX39B

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Harnesses and connectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wiring schema â&#x20AC;&#x201C; Upper frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wiring schema - Additional auxiliary line (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuse and relay box Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Harnesses and connectors Replace - Object handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Overview How to read circuit diagram and harness connection Electric circuit diagram NOTE: For the electric circuit diagram, refer to Electrical system - Electrical schema (55.000). In the diagram, the number, size and colour of wires are shown on the wiring line. The size of the wire is to be 0.5625 mm (0.022 in) unless otherwise specified. Symbol B G L R W Y P

Colour Black Green Blue Red White Yellow Pink

Symbol O Br Lg Gr Sb V

Colour Orange Brown Light green Gray Sky blue Violet

1. Red wire 2. Wire size 4 mm (0.2 in) 3. Wire no. 6

TULI12EXN4044AA

TULI12EXN4043AB

Harness connection Indication for connector 1. The numbers of the connector appears by placing the lock (1) (pin) onto the upper part, as seen from the mounting side. 2. The numbers on the connectors indicate the wire number (3), and the letters indicate the wire colour (2). 3. On the side of connector, the connector name (4) and serial number (5) are indicated. 4. At the place indicated as “DOUBLE SPLICE”, two wires are connected together.

The connector is to be connected with engaging the male (M) and female (F) connectors of the same number. Example: CN-101M and CN-101F Where: M means for male, and F for female. the mark here to the side indicates the connector with the diode. The direction for diode is shown by the arrow. The AVSS wires must be used for sizes between 0.75 2.00 mm² (0.81 - 2.06 in²), the AVS wires for sizes between 3.00 mm² (3.06 in²) and 5.00 mm² (5.06 in²), and AV wires in all other cases, unless otherwise specified. The wire size is 0.75 mm² (0.81 in²) unless otherwise specified.

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Electrical systems - Harnesses and connectors

Wiring harnesses are to be treated as follows: 1.

: After roughly applying the tape, the wires are installed in a corrugated tube.

: Harness taping by two plies.

: No harness treatment for connection.

The length for the above (6)- (3) must be 20 - 40 mm (0.8 1.6 in), and the length includes the total length of the wire as shown in the diagram.

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Wiring schema – Upper frame

TULI12EXN6101FB

Fairlead

2. 3.

Fix ground connector with ring terminal To canopy light

4. 5.

Starter cable Battery ground cable

6. 7.

To boom Tightening torque 9.6 - 11.8 N·m (7.1 - 8.7 lb ft) (Tighten after checking no paint) Tightening torque 46.1 N·m (34.0 lb ft) Tightening torque 11 - 13 N·m (8.1 - 9.6 lb ft)

8. 9.

10. Tightening torque 46.1 N·m (34.0 lb ft) (Tighten after checking no paint) 11. Connect with fuel sensor 12. Capscrew tightening torque 21.54 - 25.46 N·m (15.89 - 18.78 lb ft) 13. To engine wiring harness 14. Connect to the heater relay assy. In case of heaterless, it is bundled and put into relay assy 15. Connect to two-speed selector switch 16. Fix optional harness

NOTE: Tightening torque of battery terminal to be 4.4 N·m (3.2 lb ft) Grounding tightening torque 46.1 N·m (34.0 lb ft).

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TULI12EXN6102GB

1. 2. 3. 4. 5. 6. 7.

Connect to boom light wiring harness Fasten it so that connection is directed downwards Hourmeter Tightening torque 8.8 - 10.8 NÂˇm (6.5 - 8.0 lb ft) To boom Tightening torque 46.1 NÂˇm (34.0 lb ft) Clip

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TULI12EXN6103FB

1. 2. 3. 4. 5.

Horn Deceleration switch Key switch Light assy Wiper switch

6 7 8 9

Heater switch Working light switch Connect to lever lock switch Fix lever lock harness to horn harness using a hole

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TULI12EXN6104HB

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Electrical systems - Harnesses and connectors

Tightening torque 41.2 - 51 NÂˇm (30.4 - 37.6 lb ft) (tighten after checking no paint)

Tighten after checking no paint

Tightening torque 9.6 - 11.8 NÂˇm (7.1 - 8.7 lb ft). Fix with taping part. Fix with ring terminal for a ground Put the clip before connect ground connector with ring terminal. Tighten after checking no paint

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TULI12EXN6105HB

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1. 2. 3. 4. 5.

To engine brake WG (+) P (-) Fix the maintenance harness Fix the wiring to the radiator support in order not to use the clip during cabin installation

6. 7.

TULI12EXN6106GB

A. B.

Detail of hoses bracket position Detail of hoses rubber protection

1. 2. 3. 4. 5. 6.

Connect with boom light harness Fix in 100 mm (3.9 in) pitch Fix to the hose for boom cylinder Fix to 180 mm (7.1 in) from boom hose end Fix boom light harness to boom hose Ful tank air breather

To canopy lights Fix harness to joint of solenoid valve T port

9. Connect main harness to cab harness 10. Tightening torque 21.54 - 25.46 NÂˇm (15.89 18.78 lb ft) 11. Nibbler and breaker - supply 12. Harness 13. Nibbler and breaker - return 14. Bucket cylinder - return 15. Boom cylinder - return 16. Arm cylinder - return

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Electrical systems - Harnesses and connectors

7. 8.

Fix so that harness is not swell to the tank air breather Fix harness so that it is not straddled by plate

17. Arm cylinder - supply 18. Boom cylinder - supply 19. Bucket cylinder - supply

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Harnesses and connectors - Wiring schema - Additional auxiliary line (AUX2)

SMIL13MEX0191FB

1. Selector switch for boom swing/attachment rotation.

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SMIL13MEX0192FB

1. Connected to the auxiliary solenoid valve CN-204 2. Harness 3. Connected to the main harness CN-315 4. Connected to the main harness CN-42 5. Connected with the selector switch 6. Harness 7. Harness 8. Connected to the main harness CN-117F

2AUX electrical schema

SMIL13MEX0193EB

1. Selector switch for boom swing/attachment rotation 2. Auxiliary solenoid valve

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Fuse and relay box - Component localisation Fuse box 1. Wiper, heater - AUX 2 selection - 30 A 2. Relay, solenoid - 30 A 3. Work lights - 30 A 4. Horn, dome light - 10 A 5. Engine stop solenoid - 30 A 6. Battery relay, gauge cluster - 10 A

LELI11E0481BB

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Relays 1. R-2, Safety relay - 40 A 2. R-9, Working light relay 3. R-1, Battery relay - 70 A 4. R-7, Engine stop relay - 70 A 5. R-6, Timer unit 6. R-8, Charge indicator relay - 50 A 7. R-3, Decel relay - 50 A

SMIL13MEX0006BB

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Harnesses and connectors - Replace - Object handling Switch for activation of anti-tipping sensor 1. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position. 2. Remove all the screws (K). Raise the control panel (J) and remove the switch (20).

TULI12EXN9229AB

TULI12EXN9230AB

3. From the upper part of the control panel (J), remove the switch (20). From the lower part, disconnect the electric cable (21) on one side to the switch (20) and on the other side to the cabâ&#x20AC;&#x2122;s electric wiring harness (W). 4. Install the new switch (20) and connect the electric cable (21). 5. Install the control panel (J) with the new switch (20) and attach it by means of the screws (K).

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Acoustic alarm (buzzer) 1. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position. 2. Remove the protection caps (X), loosen the fastening screws and disassemble the two half caps (AA) of the left-hand control lever.

TULI12EXN9231AB

TULI12EXN9232AB

TULI12EXN9233AB

TULI12EXN9234AB

3. Remove the buzzer (18), disconnect the electric cable and remove screws, washers and nuts. Install the new buzzer (18) and fasten it by means of the hex. M4 X 20 screws (15), the D=4 washers (16) and (17) and the M4 nuts (19).

4. Connect the electric cable (22) to the buzzer (18).

5. Install the two half caps (AA) of the left-hand control lever and install the protection caps (X).

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Index Electrical systems - 55 Harnesses and connectors - 100 Fuse and relay box - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Harnesses and connectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Harnesses and connectors - Replace - Object handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Harnesses and connectors - Wiring schema - Additional auxiliary line (AUX2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Harnesses and connectors - Wiring schema â&#x20AC;&#x201C; Upper frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - 55 Engine control system - 015

CX35B CX39B

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Contents Electrical systems - 55 Engine control system - 015

FUNCTIONAL DATA Engine wire harness Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine wire harness - Wiring schema

TULI12EXN6107HB

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Electrical systems - Engine control system

Tightening torque 7.4 - 9.8 NÂˇm (5.5 - 7.2 lb ft)

Connect with engine harness, directing the connector to the opposite side of fan

Install the engine sensor and tighten to a torque of 34.2 - 44.2 NÂˇm (25.2 - 32.6 lb ft) Fix with taping part

Connect with main harness

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Electrical systems - Engine control system

TULI12EXN6108HB

1. 2.

Fix perpendicularly. Tightening torque 5.9 9.8 NÂˇm (4.4 - 7.2 lb ft) Harness must pass below alternator

Fix with taping part

Ground harness for engine stop solenoid

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Electrical systems - Engine control system

3. 4.

Alternator Fix the clip with a bolt of alternator bracket. Fix with taping part

Fix connector to bracket

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Index Electrical systems - 55 Engine control system - 015 Engine wire harness - Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine starting system - 201

CX35B CX39B

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starter General specification – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Service limits – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service limits – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Engine starter Component identification – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component identification – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exploded view – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Exploded view – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Engine starter Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Service instruction – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Test – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Service instruction – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassemble – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Inspect – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Assemble - 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Adjust – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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Electrical systems - Engine starting system

Engine starter - General specification – 4TNV94L/98 Manufacturer’s model (Hitachi) Rated output Weight Revolution direction (as viewed from pinion) Engagement system Terminal voltage/current No-load Revolution Terminal voltage/current Load Torque Clutch system Pinion projection voltage (at 100 °C (212 °F) Pinion DP or module/number of teeth Difference (O-ring, oil seal) Application

S13-204 2.3 kW (3 Hp) 5.5 kg (0.01 ton) Right Magnetic shift 11 V/ 140 A or less 4100 RPM or more 2.5 V/ 1050 A or less 24.5 N·m (18 lb ft) or more Overload 8.6 V or less M3/9 Dry (none) Standard value

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S13-205 ← ← ← ← ← ← ← ← ← ← ← Wet (with) Option

Electrical systems - Engine starting system

Engine starter - General specification – 4TNV106(T) Manufacturer’s model (Hitachi) Yanmar code Rated voltage Rated output Serviceability limit Revolution direction (as viewed from pinion) Clutch system Engagement system Pinion: Module/number of teeth Weight Pinion projection voltage (at 100 °C (212 °F)) Terminal voltage/current No-load Revolution Terminal voltage/current Load Torque Revolution

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S13-138 – 12 V 3.0 kW (4 Hp) 30 s Right Roller clutch Magnetic shift M3/9 7.3 kg (16 lb) 8 V or less 12 V / 180 A or less 3000 RPM or more 9 V / 500 A 16.7 N·m (12 lb ft) or more 1270 RPM or more

Electrical systems - Engine starting system

Engine starter - Service limits – 4TNV94L/98 Maintenance standard Spring force Brush

Standard height/wear limit

Magnetic switch resistance, series coil/shunt coil (at 20 °C (68 °F)) Standard diameter/limit diameter Commutator

Difference between maximum and minimum diameter

Repair limit/repair accuracy

Mica undercut depth chips

Repair limit/repair accuracy

Armature front Armature rear Bearing type Pinion front Pinion rear “L” dimension (pinion projection length)

Nominal number

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35 N (8 lb) 15 mm (0.59 in) / 9 mm (0.35 in) 0.27 Ω/ 0.60 Ω 36.5 mm (1.44 in) / 35.5 mm (1.40 in) 0.2 mm (0.0079 in) / 0.03 mm (0.0012 in) 0.2 mm (0.0079 in) / 0.5 - 0.8 mm (0.02 - 0.03 in) 6903DDU 608DDU 60004DDU 6904DDU 0.3 - 1.5 mm (0.01 - 0.06 in)

Electrical systems - Engine starting system

Engine starter - Service limits – 4TNV106(T) Maintenance standard Spring force Brush

Standard/limit height Standard value Limit value Limit value Correction accuracy Limit value

Outside diameter Commutator

Bending Depth of insulation mica Armature shaft diameter

Correction accuracy Front Rear Gear shaft diameter

Bearing on gear case side Standard dimensions

Hole diameter Shaft diameter Sliding portion of pinion Hole diameter

Ball bearing

Rotor

Front Rear

Length “L” (pinion projection length)

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31.4 N (7 lb) 18 mm (0.71 in)/ 6 mm (0.24 in) 37 mm (1.46 in) 36 mm (1.42 in) 0.2 mm (0.01 in) 0.05 mm (0.002 in) 0.2 mm (0.01 in) 0.5 - 0.8 mm (0.02 - 0.03 in) 25 mm (0.98 in) 12 mm (0.47 in) 13.95 - 13.968 mm (0.5492 - 0.5499 in) 14.00 - 14.018 mm (0.5512 - 0.5519 in) 13.95 - 13.968 mm (0.5492 - 0.5499 in) 14.03 - 14.05 mm (0.5524 - 0.5531 in) 6905DDU 6001DDU 0.3 - 1.5 mm (0.01 - 0.06 in)

Electrical systems - Engine starting system

Engine starter - Component identification â&#x20AC;&#x201C; 4TNV94L/98

TULI12EXN4683HB

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Electrical systems - Engine starting system

3. 4. 5. 6. 7. 9. 11.

Through bolt Rear cover Brush Field coil Rotor Magnetic switch Shift lever

13. 14. 18. 19. 20. 21.

Bearing retainer Gear case Pinion shaft Clutch assy O-ring Oil seal

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Electrical systems - Engine starting system

Engine starter - Component identification â&#x20AC;&#x201C; 4TNV106(T)

TULI12EXN5217FB

1. 2. 3. 4. 5. 6. 7. 8. 9.

Gear case Magnetic switch Rear cover Gear shaft Pinion stopper Shift lever Needle bearing Pinion Ball bearing

10. 11. 12. 13. 14. 15. 16. 17.

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Oil seal Rotor Yoke Through bolt Terminal E O-ring Brush Ball bearing

Electrical systems - Engine starting system

Engine starter - Exploded view â&#x20AC;&#x201C; 4TNV94L/98 Names of parts and disassembly procedure Disassembling order

TULI12EXN4685FB

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Nut M8 (disconnect the connecting wire). See the disassembly drawing Screw M4 (2) Through bolt M5 (2) Rear cover Brush holder Yoke assy. Rotor Bolt M6 (2) Magnetic switch Dust cover

11.

Shift lever

12. 13. 14. 15. 16. 17. 18. 19.

Screw M4 (3) Bearing retainer Gear case Pinion stopper clip Pinion stopper Return spring Pinion shaft Clutch assy.

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Electrical systems - Engine starting system

Engine starter - Exploded view â&#x20AC;&#x201C; 4TNV106(T) 1. Disassembly procedure 2. Disassembly diagram

TULI12EXN5219FB

1. 2. 3. 4.

Disconnect the lead Remove the magnetic switch Remove the rear cover Remove the brush holder

5. 6. 7. 8.

Disassemble the gear case and center bracket Remove the shift lever pin Remove the gear case dust cover Remove the pinion

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Electrical systems - Engine starting system

Engine starter - Prepare 1. Remove the floor cover. 2. Remove the seat and the front stand cover, loosen four M8 X 20 sems-bolts (15), and remove the seat assembly (7) and the front stand cover (14) in one piece. : 13 mm Tightening torque: 23.5 NÂˇm (17.3 lb ft) 3. Disconnect the negative side terminal of the battery.

TULI12EXN4986AB

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Electrical systems - Engine starting system

Engine starter - Remove 1. Remove the M8 nut for the terminal B of the starter. : 13 mm 2. Disconnect connector on the terminal S of the starter (M1). 3. Loosen two fastening bolts (1) to remove the starter. : 19 mm M8 nut for terminal B tightening torque 7.4 9.8 NÂˇm (5 - 7 lb ft)

TULI12EXN6331FB

B. Terminal B H-4. Starter cable M-1. Starter motor

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Electrical systems - Engine starting system

Engine starter - Install Install starter in reverse order of the removal.

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Electrical systems - Engine starting system

Engine starter - Service instruction â&#x20AC;&#x201C; 4TNV94L/98 Troubleshooting

TULI12EXN4684HA

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Electrical systems - Engine starting system

Engine starter - Disassemble – 4TNV94L/98 • Nut M8 Remove the magnetic switch nut M8 ( 12 mm) (1) and disconnect the connecting wire (22).

TULI12EXN4686AB

TULI12EXN4687AB

TULI12EXN4688AA

TULI12EXN4689AB

• Screw M4 (2) • Through bolt M5 (2) • Rear cover Remove the M4 screw fastening the brush holder and remove through bolt M5 for rear cover removal.

• Brush holder Pull the brush spring up with the brush spring puller. On the negative (-) side, bring the brush spring into contact with the side of the brush for lifting from the commutator surface. On the positive (+) side, extract the brush from the brush holder.

• Yoke assy. • Rotor Remove the brush holder. The armature and yoke assy. can now be removed.

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Electrical systems - Engine starting system

• Bolt M6 (2) • Magnetic switch Remove bolt M6 ( 10 mm), and the magnetic switch can be removed.

TULI12EXN4690AB

TULI12EXN4691AB

TULI12EXN4692AB

TULI12EXN4693AB

• Dust cover • Shift lever Take the dust cover out from the gear case. The shift lever can be removed.

• Screw M4 (3) • Bearing retainer • Gear case Remove screw M4, and the bearing retainer and clutch assy can be removed.

• Pinion stopper clip Remove the bearing retainer at the edge and the bearing, and shift the pinion stopper toward the pinion. Use a plain screwdriver and pry to remove the pinion stopper clip.

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Electrical systems - Engine starting system

• Pinion stopper • Return spring • Pinion shaft • Clutch assy Remove the pinion stopper clip. The pinion stopper, return spring, pinion shaft and bearing retainer can be removed. Disassembly is completed now.

TULI12EXN4694AB

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Electrical systems - Engine starting system

Engine starter - Inspect â&#x20AC;&#x201C; 4TNV94L/98 Rotor Commutator outside diameter Measure the commutator outside diameter and replace the commutator if the measured value is less than the limit. Standard value: 36.5 mm (1.44 in) Limit value: 35.5 mm (1.40 in)

TULI12EXN4695AA

TULI12EXN4696AB

TULI12EXN4697AB

Armature coil continuity test Check continuity between commutator segments with a multimeter (M). Good if continuity exists. In case of no continuity (coil disconnection), replace the armature.

Armature coil insulation test Inspect the continuity between a commutator segment and the shaft or core with a multimeter (M). Good if no continuity exists. If continuity exists (coil short circuit), replace the armature.

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Electrical systems - Engine starting system

Armature and commutator run-out Use a dial gauge and measure the armature core runout and commutator run-out. Correct or replace if the limit is exceeded. Armature standard value: 0.03 mm (0.0012 in) Armature limit value: 0.2 mm (0.008 in) Commutator standard value: 0.03 mm (0.0012 in) Commutator limit value: 0.2 mm (0.008 in)

TULI12EXN4698AA

TULI12EXN4699AA

TULI12EXN4700AB

Commutator surface inspection If the commutator surface is roughened, grind with 500 to 600 emery cloth grain.

Commutator insulation depth Measure the depth of the insulating material between commutator segments, and correct it if it is less than the limit. A. Abnormal C. Commutator CS. Commutator segment H. Hack-saw IM. Insulating material N. Normal Armature standard value: 0.5 - 0.8 mm (0.02 - 0.03 in) Armature limit value: 0.2 mm (0.008 in)

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Electrical systems - Engine starting system

Field coil Field coil continuity test Check continuity between field coil terminals. Good if continuity exists. If there is no continuity (coil disconnection), replace the field coil.

TULI12EXN5201AB

TULI12EXN5202AB

TULI12EXN5203AB

Field coil insulation test Check continuity between field coil terminal and yoke. Good if no continuity exists. If continuity exists (coil short circuit), replace the armature.

Brush Measure the length of the brush (B). Replace with a good one if the length is less than the limit. Standard value: 15 mm (0.6 in) Limit value: 9 mm (0.4 in)

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Electrical systems - Engine starting system

Brush holder Brush holder insulation test Check the continuity between the brush holder (+ side) and base (- side) with a multimeter (M). Good if no continuity exists. If continuity exists (insulation defect), replace the brush holder.

TULI12EXN5204AB

TULI12EXN5205AA

TULI12EXN5206AB

Brush spring inspection Inspect the brush spring pressure. Standard spring force: 31 - 39 N (7 - 9 lb)

Magnetic switch When the starting motor is wetted with water, always replace the magnetic switch with a new even if the function is normal.

Shunt coil continuity test Check the continuity between the S terminal and the switch body. Good if continuity exists. If there is no continuity (coil disconnection), replace the magnetic switch.

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Electrical systems - Engine starting system

Series coil continuity test Check continuity between the S and (M) terminals. Good if continuity exists. If there is no continuity (coil disconnection), replace the magnetic switch.

TULI12EXN5207AB

TULI12EXN5208AB

TULI12EXN5209AA

Contact continuity test Depress the magnetic switch with the plunger at the bottom. Check continuity between the B and (M) terminals with a multimeter (M). Good if continuity exists. If there is no continuity (coil continuity defect), replace the magnetic switch.

Pinion clutch Pinion inspection Manually rotate the pinion. Inspect if it is rotated smoothly in the driving direction, and is locked in the opposite direction. Replace the pinion clutch if abnormal.

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Electrical systems - Engine starting system

Pinion sliding inspection Check if the pinion slide smoothly in the axial direction. If damaged, rusted or heavy in sliding, repair it. If grease is applied too much on the pinion shaft, sliding becomes heavy.

TULI12EXN5210AA

TULI12EXN5211AA

Ball bearing inspection Rotate the ball bearing while holding the outer race with fingertips. Inspect if it is sticking or it there is play.

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Electrical systems - Engine starting system

Engine starter - Assemble – 4TNV94L/98 The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following points: 1. Grease application points • Gears in the gear case • Shift lever operating portion • Pinion sliding portion • Magnetic switch plunger sliding portion Use the specified grease as below table at all points. Pinion and magnetic switch plunger sliding portions Gears Shift lever operating portion

AKCELA Moly grease

2. Magnetic switch assembly • Install the shift lever on the magnetic switch with the torsion spring in-between.

TULI12EXN5212AA

TULI12EXN5213AA

TULI12EXN5214AA

• For installation on the gear case, install the magnet-ic switch with the shift lever on the gear case after pulling the pinion out. Fix the magnetic switch by tightening a built-in bolt M6. Do not forget to install the dust cover (adjusting shim).

3. Pinion projection length Connect the positive (+) lead from the battery to ter-minal S and negative (-) lead to terminal M. Turn the switch On and measure the pinion moving distance L in the thrust direction. Perform this test within 10 s.

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Electrical systems - Engine starting system

Standard value 0.3 - 1.5 mm (0.012 - 0.059 in)

NOTE: Before measuring the dimension, pull the pinion out lightly in the direction of the arrow. If the measured L dimension is outside the standard range, either insert or remove the dust cover (adjusting shim 0.5 mm (0.02 in), 0.8 mm (0.03 in) for adjustment.

TULI12EXN5215AB

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Electrical systems - Engine starting system

Engine starter - Test â&#x20AC;&#x201C; 4TNV94L/98 Since the characteristics can be checked roughly by means of a simple no-load test as explained below. NOTE: Complete the test quickly since the rating of the starting motor is 30 s.

No load test Fix the starting motor on a test bench and connect wiring as shown in Fig. 1. When the switch is closed, a current flows in the starting motor, which is rotated at no-load. Measure the current, voltage and number of revolutions then and check if they satisfy the specified characteristics.

TULI12EXN5216FB

A. B.

Ammeter Battery

Voltmeter

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Electrical systems - Engine starting system

Engine starter - Service instruction â&#x20AC;&#x201C; 4TNV106(T) Troubleshooting

TULI12EXN5218HA

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Electrical systems - Engine starting system

Engine starter - Disassemble â&#x20AC;&#x201C; 4TNV106(T) Disconnect the lead Loosen the M8 nut ( 12 mm) of the magnetic switch and disconnect the lead.

TULI12EXN5220BA

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Electrical systems - Engine starting system

Removing magnet switch Remove the M6 bolts ( 10 mm x 2).

TULI12EXN5221AA

TULI12EXN5222AA

TULI12EXN5223AA

TULI12EXN5224AA

Removal of rear cover Remove the brush holder tightening screws ( 4 mm Ă&#x2DC; x 2) and the M5 through bolts (x 2). Then, disconnect the rear cover from the yoke using a minus screwdriver.

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Electrical systems - Engine starting system

Removal of brush holder For the negative (â&#x20AC;&#x201C;) brush, bring the brush spring into contact with the side of the brush for lifting from the commutator surface. For the positive (+) brush, extract the pull out the brush from the brush holder. After the brush holder is removed, the armature and yoke can be disassembled.

TULI12EXN5225AA

TULI12EXN5226AA

TULI12EXN5227AA

TULI12EXN5228AA

Separating gear case from center bracket Remove three M6 bolts ( 10 mm) fastening the gear case to the center bracket. After removal of the M6 bolts, the centre bracket and oil seal can be removed.

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Electrical systems - Engine starting system

Removal of shift lever pin Remove the M6 nut ( 10 mm) and pull out the shift lever pin. Now the dust cover, shift lever, gear case and gear shaft can be removed.

TULI12EXN5229AA

TULI12EXN5230AA

TULI12EXN5231AA

TULI12EXN5232AA

Removal of gear case dust cover Remove the two M5 bolts (using 4 mm hexagon wrench) to disassemble the dust cover from the gear case.

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Electrical systems - Engine starting system

Removal of pinion Slide the pinion stopper towards the pinion and remove the pinion stopper clip using a minus screwdriver.

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TULI12EXN5233AA

TULI12EXN5234AA

Electrical systems - Engine starting system

Engine starter - Inspect – 4TNV106(T) Rotor • Check the commutator for rough surface. If so, smooth the surface using 500 to 600 emery cloth grain. If the outside periphery of the commutator has been deflected over 0.2 mm (0.008 in), repair by a lathe.

TULI12EXN5235AA

TULI12EXN5082AA

• Measure the depth of the insulating material between commutator segments, and correct if it is less than 0.2 mm (0.008 in).

Armature coil continuity and earth tests Test type Continuity test Earth test

Measurement point Across commutator Between commutator and shaft or armature

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Normal Yes

Abnormal (cause) None (open circuit)

None

Yes (short-circuiting)

Electrical systems - Engine starting system

Replace if needed.

TULI12EXN5083AA

TULI12EXN5084AA

Field coil Field coil continuity and earth tests Test type Continuity test Earth test

Measurement point Across commutator Between commutator and shaft or armature

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Normal Yes

Abnormal (cause) None (open circuit)

None

Yes (short-circuiting)

Electrical systems - Engine starting system

Replace if needed.

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TULI12EXN5085AA

TULI12EXN5086AA

Electrical systems - Engine starting system

Brush â&#x20AC;¢ Check wear of the brush and the brush spring force. L. Limit N. New U. Used

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TULI12EXN5087AA

TULI12EXN5088BA

Electrical systems - Engine starting system

â&#x20AC;˘ Check of brush movement If the brush does not move smoothly, inspect the brush holder for bending and the brush holder sliding surface for dirt. Repair or clean as needed. â&#x20AC;˘ Check the continuity between the insulated brush holder (positive (+)) and the brush holder base (negative (-)). If they are electrically continuous, replace since the holder is grounded.

TULI12EXN5089BA

Magnetic switch continuity test Test type Shunt coil Series coil

Measurement point Between C and ground C and M

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Normal Yes None

Abnormal (cause) None (open circuit) Yes (short-circuiting)

Electrical systems - Engine starting system

Replace if needed.

S13-138 Resistance (at 20 °C (68 °F)) 0.6 Ω 0.218 Ω

Shunt coil Series coil

Pinion • Check the pinion teeth for wear and damage. Replace with a new element if necessary. • Check if the pinion slides smoothly. If it is damaged or rusted or does not slide smoothly, repair. • Check springs for damage, and replace if necessary. • Ball bearing If abnormalities such as irregular noises are detected to the ball bearing, replace with a new one.

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TULI12EXN5090AA

TULI12EXN5091AA

TULI12EXN5092AA

Electrical systems - Engine starting system

Engine starter - Assemble - 4TNV106(T) The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following points: 1. Apply grease as instructed below: Greasing point Sliding portions and head of plunger Pinion metal and metal portions of gear case Spline portions of pinion Sliding portions of shift lever Deceleration gear

Grease type

AKCELA Moly grease

2. Armature thrust No adjustments are needed for the thrust. 3. Gear shaft thrust Some thrust washers of 1.0 mm (0.04 in) and 0.25 mm (0.01 in) thickness are provided between the center bracket and gear shaft supporting surface. Make sure to check them at reassembly. If washers are deformed or worn, replace them with new ones. The thrust washer is correct if its thickness is between 0.05 mm (0.002 in) and 0.3 mm (0.01 in). If it exceeds 0.3 mm (0.01 in), make sure the thrust is not zero.

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Electrical systems - Engine starting system

Engine starter - Adjust – 4TNV106(T) Pinion projection length “L” by magnetic switch.

TULI12EXN5093AA

TULI12EXN5094AA

TULI12EXN5095AB

Measure the pinion moving distance “L” ( 0.3 - 1.5 mm (0.012 - 0.059 in)) in the thrust direction when the pinion is protruded by the magnetic switch. If the distance “L” is outside the standard range, adjust by the dust cover as shown below. B. Battery S. Switch

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Index Electrical systems - 55 Engine starting system - 201 Engine starter - Adjust – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Engine starter - Assemble - 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Engine starter - Assemble – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Engine starter - Component identification – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine starter - Component identification – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine starter - Disassemble – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine starter - Disassemble – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine starter - Exploded view – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine starter - Exploded view – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine starter - General specification – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine starter - General specification – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starter - Inspect – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Engine starter - Inspect – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine starter - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine starter - Service instruction – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine starter - Service instruction – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine starter - Service limits – 4TNV106(T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine starter - Service limits – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine starter - Test – 4TNV94L/98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Electrical systems - 55 Alternator - 301

CX35B CX39B

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Alternator Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - Alternator

Alternator - General specification Standard output characteristics The standard output characteristics of this alternator are shown in the Fig. 1. ( 13.5 V constant) (Ambient temperature: 25 °C (77 °F)) A.

Output current

Cold

Hot Alternator speed (x 10³ RPM)

TULI12EXN5099BA

Manufacturer’s model (Hitachi) Serviceability limit Battery voltage Nominal output ( 13.5 V heat) Rating speed Operating revolution Grounding characteristics Direction of revolution (viewed from pulley) Integrated regulator Weight Pulley (outside diameter) Belt shape

ACFA68 Continuous 12 V 40 A 5000 RPM 1350 - 18000 RPM Minus side grounding Right IC regulator 2.8 kg (6 lb) 69.2 mm (2.72 in) Type A

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Alternator - Component identification The 40 A alternator for 3TNV84 and other models Parts related to the alternator. 1. Joint 2. V-belt adjuster 3. Generator 4. Gear case

TULI12EXN5096AB

Alternator components of the disassembly and assembly.

TULI12EXN5097FB

5. 6. 7. 8. 9. 10.

Nut Spring washer Washer Rear bracket Spacer Stator

11. 12. 13. 14. 15. 16.

Front bracket Cover Bearing Coupler Bearing Pulley

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Electrical systems - Alternator

Alternator - Electrical schema

TULI12EXN5098FB

B. K. L.

Battery Key switch Load

La. Charge lamp (max. 3.4 W) R. IC regulator T. Alternator assy

• Don’t do miss-wiring and short-circuit of each terminal. • Don’t short-circuit between IG and L (connect through the charge lamp). • Don’t connect a load between L and E. • Don’t remove a battery terminal and a B terminal when rotating. • Shut out a battery switch during the alternator stop. • Tightening torque of each terminal: 1.7 - 2.3 N·m (1 - 2 lb ft).

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Electrical systems - Alternator

Alternator - Inspect 1. V belt inspection • Inspect the matter whether there are not crack, stickiness and wear on the belt visually. Check that a belt doesn’t touch the bottom part of the pulley groove. If necessary, replace the V belt set. • V belt tension: (Refer to Engine - Inspect - Daily Inspection (10.001) ) D. Defect E. Clearance N. Normal TULI12EXN5100AA

2. Visual check of wiring and check of unusual sound. • Confirm whether wiring is right or there is no looseness of the terminal part. • Confirm that there is no unusual sound from the alternator during the engine operation. 3. Inspection of charge lamp circuit. • Move a start switch to the position of On. Confirm lighting of the charge lamp. • Start an engine, and confirm the lights-out of the lamp. Repair a charge lamp circuit when a lamp doesn’t work.

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Electrical systems - Alternator

Alternator - Service instruction Troubleshooting

TULI12EXN5291HA

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Electrical systems - Alternator

Alternator - Prepare 1. Remove the cover at the lower right of the seat. 2. Disconnect the negative side terminal of the battery.

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Electrical systems - Alternator

Alternator - Remove 1. Disconnect the connector and remove the M6 nut for the terminal B. 2. Loosen the screws (1) and (3) and the nut (2). : 13 mm 3. Remove the V-belt and the alternator.

TULI12EXN4942AB

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Electrical systems - Alternator

Alternator - Install 1. Assemble the alternator in reverse order of the disassembly. 2. Belt tension. Check the tension of the belt by applying a load of 19 N (4 lb) and make sure that the arrow does not exceed 4 mm (0.16 in). To adjust the belt tension, loosen slightly the nut (2), and adjust the tension by turning the screw (3). Tighten the nut (1). After adjustment, start the engine and idle it at low speed for about 5 min. And recheck the belt tension. A. M6 nut for terminal B tightening torque 5.9 9.8 NÂˇm (4 - 7 lb ft)

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TULI12EXN6317AB

TULI12EXN4942AB

Index Electrical systems - 55 Alternator - 301 Alternator - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alternator - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Alternator - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - 55 Battery - 302

CX35B CX39B

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Contents Electrical systems - 55 Battery - 302

SERVICE Battery Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Battery

Battery - Prepare 1. Remove the floor mats (5) and (8). 2. Remove cover (4). 3. Remove the cover assembly (5) of the lower left side.

TULI12EXN4217AB

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Electrical systems - Battery

Battery - Remove 1. Disconnect the negative side terminal of the cable. 2. Then, disconnect the positive side terminal of the cable. : 12 mm NOTICE: Follow the removal procedure of battery cable. Firstly disconnect the grounding side cable. Connect the grounding side finally. Failure to do so may result in dangerous situation due to spark. 3. Loosen the M8 nut (7) to remove the plate (5) and the rod (4). : 13 mm 4. Take out the battery (1) holding the straps attached to it.

TULI12EXN4218BB

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Electrical systems - Battery

Battery - Install Install the battery in reverse order of the removal. Nut (7) M8: : 13 mm Tightening torque: 3.5 NÂˇm (2.58 lb ft)

TULI12EXN4218BB

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Index Electrical systems - 55 Battery - 302 Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Fuel tank system - 011

CX35B CX39B

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Contents Electrical systems - 55 Fuel tank system - 011

FUNCTIONAL DATA Fuel tank system Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Fuel tank system

Fuel tank system - Wiring schema

TULI12EXN6110HB

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Electrical systems - Fuel tank system

1. 2.

Tightening torque 11.0 N·m (8.1 lb ft) Fuel tank

Tightening torque 2.94 N·m (2.17 lb ft)

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Electrical systems - Fuel tank system

TULI12EXN6111FB

1. 2. 3.

Fuel pump Fuel tank Fuel filter

4. 5. 6.

Inlet Return Water separator

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Index Electrical systems - 55 Fuel tank system - 011 Fuel tank system - Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine oil system - 013

CX35B CX39B

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Contents Electrical systems - 55 Engine oil system - 013

SERVICE Engine oil system Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine oil system

Engine oil system - Inspect Oil pressure switch Continuity test Disconnect the connector from the oil pressure switch (O). Keep the voltmeter probes (T) in contact with the switch terminal and cylinder block (C) while operating the engine. It is abnormal if circuit is closed.

TULI12EXN4835AB

TULI12EXN4836AB

Thermo switch Place the thermo switch in a container filled with “H” antifreeze or oil. Heat it while measuring the fluid temperature (Thermometer (TH)). The switch (TS) is normal if the voltmeter shows continuity when the fluid temperature is 107 113 °C (225 - 235 °F).

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Index Electrical systems - 55 Engine oil system - 013 Engine oil system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Cab controls - 512

CX35B CX39B

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Contents Electrical systems - 55 Cab controls - 512

SERVICE Cab controls Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Cab controls

Cab controls - Replace Selector switch for boom swing/attachment rotation 1. Remove screws that fix the panel (1).

SMIL13MEX0194AB

SMIL13MEX0195AB

SMIL13MEX0196BB

2. Disconnect the connector (2).

3. Pull out the knob (3). 4. Remove the nut (5). 5. Remove the washer with O-ring (6). 6. Remove the selector switch from the cover assembly (4).

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Electrical systems - Cab controls

7. Install the selector switch in the reverse order.

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Index Electrical systems - 55 Cab controls - 512 Cab controls - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 External lighting - 404

CX35B CX39B

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Contents Electrical systems - 55 External lighting - 404

FUNCTIONAL DATA External lighting Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - External lighting

External lighting - Wiring schema Boom work light

TULI12EXN6115GB

7. 8.

1. 2.

Connect to main harness Rest of harness is fixed with clips

3. 4. 5.

9. Harness is fixed under the hose To boom light A. Electrical harness fixed on work light side is fixed B. so that water may not enter Fix eyebolt with bolt

Fix corrugated hose to the harness Fix the ground terminal and work light harness to the main harness Harness is fixed between hose and boom with clip CX35B CX39B

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Electrical systems - External lighting

Cab work light

TULI12EXN6116FB

Connect with cable terminal of harness cab assy

Tightening torque 16.7 - 21.6 N·m (12.3 - 15.9 lb 5. ft) Install light 40° lower from ground level. Tightening 6. torque 7 - 8 N·m (5 - 6 lb ft)

Deform the hose after connection of cable terminals Fix to the light bracket 20 mm (0.8 in) of opening from hole

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Electrical systems - External lighting

Canopy work light

TULI12EXN6117FB

Connect harness to upper frame slide

2. 3.

5. Pass through internal part of canopy pillar Install light 40° lower from ground level. Tightening torque 7 - 8 N·m (5 - 6 lb ft)

Tightening torque 16.7 - 21.6 N·m (12.3 - 15.9 lb ft) Fix to the clip

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Index Electrical systems - 55 External lighting - 404 External lighting - Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Cab or platform harnesses and connectors - 510

CX35B CX39B

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Contents Electrical systems - 55 Cab or platform harnesses and connectors - 510

FUNCTIONAL DATA Cab or platform harnesses and connectors Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wiring schema â&#x20AC;&#x201C; Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Cab or platform harnesses and connectors

Cab or platform harnesses and connectors - Wiring schema

TULI12EXN6112FB

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Electrical systems - Cab or platform harnesses and connectors

TULI12EXN6113HB

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Electrical systems - Cab or platform harnesses and connectors

1. 2. 3.

Fix to the main harness Fix harness and connectors to the bracket with a clip Tightening torque: 4.5 - 5.5 NÂˇm (3.3 - 4.1 lb ft)

4. 5.

Horn relay Put white tape positioned on the plate

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Electrical systems - Cab or platform harnesses and connectors

TULI12EXN6114HB

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Electrical systems - Cab or platform harnesses and connectors

A. B. 1. 2. 3. 4. 5.

Detail of left control lever stand Detail of right control lever stand Connection for nibbler and breaker connector. Switch for nibbler opening/closing Fuse Put white tape positioned on gasket Fixed on main harness Horn switch

6. 7. 8.

For main harness of horn connector Horn push-button Hydraulic breaker activation push-button

9. 10. 11.

Pass along the right hand side of the valve Fix harness to the hole of plate Put white tape positioned on clip of main harness

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Electrical systems - Cab or platform harnesses and connectors

Cab or platform harnesses and connectors - Wiring schema â&#x20AC;&#x201C; Cab

TULI12EXN6118GB

1. 2. 3. 4. 5.

Connect to cabin side harness Clip cab side harness Tightening torque 21.5 - 25.5 NÂˇm (15.9 - 18.8 lb ft). Fix ground terminal Connect to the cabin work light harness Connect to the installation main harness

6. 7. 8.

Connect main harness with wiper harness Label attachment Clip

Washer motor

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Index Electrical systems - 55 Cab or platform harnesses and connectors - 510 Cab or platform harnesses and connectors - Wiring schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cab or platform harnesses and connectors - Wiring schema â&#x20AC;&#x201C; Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47574272B 24/03/2014 EN

SERVICE MANUAL Booms, dippers, and buckets CX35B CX39B

47574272B 24/03/2014

Contents Booms, dippers, and buckets - 84

[84.114] Boom pivoting support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1 [84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2 [84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3 [84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.4

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CX35B CX39B

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Contents Booms, dippers, and buckets - 84 Boom pivoting support - 114

TECHNICAL DATA Boom pivoting support Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Booms, dippers, and buckets - Boom pivoting support

Boom pivoting support - Dimension Swing bracket

TULI12EXN6038GA

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Booms, dippers, and buckets - Boom pivoting support

No. A B C D E F F1 F2 G H J d1 d2 d3 d4

Name Distance between swing centre pin and boom foot pin Distance between boom foot pin and boom cylinder pin Distance between boom foot pin and boom cylinder pin Distance between swing centre pin and swing cylinder pin Distance between swing centre pin and swing cylinder pin Inside width of swing centre Inside width of swing centre Inside width of swing centre Inside width of boom foot Inside width for installing boom cylinder Inside width for installing swing cylinder Pin diameter of swing center Pin diameter of boom foot pin Pin diameter of boom cylinder Pin diameter of swing cylinder

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Size 96 mm (3.78 in) 176.8 mm (6.96 in) 266.9 mm (10.51 in) R 264 mm (10.39 in) 257 mm (10.12 in) 303.7 mm (11.96 in) 75.7 mm (2.98 in) 73.5 mm (2.89 in) 178 mm (7.01 in) 61 mm (2.40 in) 67 mm (2.64 in) ø 65 mm (2.56 in) ø 45 mm (1.77 in) ø 45 mm (1.77 in) ø 45 mm (1.77 in)

Booms, dippers, and buckets - Boom pivoting support

Boom pivoting support - Service limits Clearance of pin and bushing

TULI12EXN6039FB

Ref.

Piece

Swing cylinder (Rod side) Swing cylinder (Bottom side) Swing center (Upper side) Swing center (Lower side)

Standard dimension Tolerance on Tolerance Pin bushing on pin diameter bore diameter diameter 0.2 0.05 mm (0.008 0.002 in)

Ă¸ 45 mm (1.77 in) -0.02 -0.05 mm (-0.001 -0.002 in) Ă¸ 65 mm (2.56 in)

Tolerance Standard value

Standard Servicevalue for ability limit repair

0.07 0.25 mm (0.0028 0.01 in) 0.7 mm (0.03 in)

0.07 0.02 mm (0.0028 0.001 in)

Remedy

1.0 mm (0.04 in)

0.04 0.12 mm (0.0016 0.005 in)

NOTE: The tolerance for bushing inside diameter means the dimension after fitting of it into place. The part number for pins may be changed owing to improvement, use them only for reference.

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Replace bushing or pin

Booms, dippers, and buckets - Boom pivoting support

Clearance in thrust direction on swing bracket and cylinder installation section

SMIL13MEX0377GB

1. Washer ( 2.3 mm (0.09 in)) - to be installed by directing the groove to the lower side. 2. Shim - to be installed in order to have the total clearance between 0.5 - 0.9 mm (0.02 - 0.04 in).

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Booms, dippers, and buckets - Boom pivoting support

Standard value Dimension Sec.

Piece No.

A-A

B-B

Swing cylinder (Rod side)

Swing cylinder (Bottom side)

Cylinder L1 Bracket

Cylinder L2 Upper frame

Upper frame C-C D-D

Swing center

L3 Bracket

Dimensions 64.5 65 mm (2.54 2.56 in) 67 69 mm (2.6 2.72 in) 64.5 65 mm (2.54 2.56 in) 67 68 mm (2.64 2.68 in) 300.5 - 3 00.8 mm (11.83 11.84 in) 303.5 - 3 03.9 mm (11.95 11.96 in)

Clearance X adjusted with shim (total of both sides) StanService- Remedy Standard ability dard value for limit value repair

0.5 0.9 mm (0.02 0.04 in)

1.5 mm (0.06 in)

—

Pin length

No.

Dimensions

PL1

123 mm (4.84 in)

PL2

139 mm (5.47 in)

PL3

153. 5 mm (6.04 in)

PL4

134 mm (5.28 in)

Adjust with shim 0.1 0.5 mm (0.004 0.02 in)

0.5 0.9 mm (0.02 0.04 in)

1.0 mm (0.04 in)

1.5 mm (0.06 in)

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—

Replace washer, adjust with shim

Index Booms, dippers, and buckets - 84 Boom pivoting support - 114 Boom pivoting support - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Boom pivoting support - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Booms, dippers, and buckets - 84 Boom - 910

CX35B CX39B

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Contents Booms, dippers, and buckets - 84 Boom - 910

TECHNICAL DATA Boom Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Boom Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Booms, dippers, and buckets - Boom

Boom - Dimension

TULI12EXN4101GA

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Booms, dippers, and buckets - Boom

Dimensions

No.

Name

A B C D E F

Boom length Distance between pins and bushings Distance between pins of bracket Height of boom cylinder rod pin Height of arm cylinder pin (bottom side) Boom width Inner width of bracket for boom cylinder (rod side) mounting Boom end inner width Boom end outer width Inner width of bracket for dipper cylinder (bottom side) Boom pin diameter [Bushing outer diameter] Boom cylinder (rod side) pin diameter Dipper end pin diameter Dipper cylinder (bottom side) pin diameter

G H J K d1 d2 d3 d4

CX35B 2300 mm (90.55 in) R 1217.5 mm (47.93 in) R 1130.5 mm (44.51 in) 420.5 mm (16.56 in) 764 mm (30.08 in) 178 mm (7.01 in)

CX39B 2500 mm (98.43 in) R 1210 mm (47.64 in) R 1157 mm (45.55 in) 385.5 mm (15.18 in) 708 mm (27.87 in) ←

61 mm (2.4 in)

←

150 mm (5.91 in) 235 mm (9.25 in) 61 mm (2.4 in) ø 45 mm (1.77 in) [ø 55 mm (2.17 in)] ø 45 mm (1.77 in) ø 45 mm (1.77 in) ø 45 mm (1.77 in)

← ← ← ←

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← ← ←

Booms, dippers, and buckets - Boom

Boom - Service limits Clearance of pin and bushing on boom section

TULI12EXN4102FB

Locat ion

Piece

Boom Boom cylinder (Bottom side) Boom cylinder (Rod side) Arm cylinder (Bottom side)

Standard dimensions Tolerance Tolerance on bushing Pin on pin bore diameter diameter diameter -0.02 0.05 -0.05 mm 0.1 mm (0.00 (0.00 0.00 in) 0.00 in) -0.02 0.06 -0.08 mm 0.12 mm (0.00 (0.00 Ă¸ 45 mm 0.00 in) 0.00 in) (1.77 in) -0.02 -0.05 mm (0.00 0.00 in)

0.07 0.13 mm (0.00 0.01 in)

Tolerance Standard value 0.07 0.15 mm (0.00 0.01 in) 0.08 0.20 mm (0.00 0.01 in)

Standard value for repair

Serviceability limit

0.7 mm (0.03 in)

1.0 mm (0.04 in)

0.09 0.23 mm (0.00 0.01 in)

NOTE: The tolerance for bushing inside diameter means the dimension after fitting of it into place. The part number for pins may be changed owing to improvement, use them only for reference.

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Remedy

Replace bushing or pin

Booms, dippers, and buckets - Boom

Clearance in thrust direction on boom and cylinder installation section

TULI12EXN6030HA

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Booms, dippers, and buckets - Boom

Clearance X adjusted with shim Remedy (total of both sides) Standard ServiceStandard value for ability No. Dimensions value repair limit 177.6 177.8 mm 0.2 (6.99 - 7 in) 0.6 mm L1 178 (0.01 178.2 mm 0.02 in) (7.01 7.02 in) 59.5 - 60 mm (2.34 0.1 2.36 in) 0.5 mm L2 (0.00 61 - 63 mm 0.02 in) (2.40 Adjusted 1.0 mm 1.5 mm 2.48 in) with (0.04 in) (0.06 in) shim 59.5 - 60 mm (2.34 0.5 2.36 in) 0.9 mm L3 (0.02 61 - 62 mm 0.04 in) (2.40 2.44 in) 59.5 - 60 mm (2.34 0.1 2.36 in) 0.5 mm L4 (0.00 61 - 62 mm 0.02 in) (2.40 2.44 in) Standard dimensions

Sec.

Piece

Boom A-A Boom Swing bracket

Boom cylinder B-B (Bottom side)

Boom cylinder C-C (Rod side)

Arm cylinder D-D (Bottom side)

Boom cylinder Swing Bracket Boom cylinder Boom Arm cylinder Boom

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Pin length No.

Dimensions

PL1

297 mm (11.69 in)

PL2

302 mm (11.89 in)

PL3

151 mm (5.94 in)

PL4

151 mm (5.94 in)

Booms, dippers, and buckets - Boom

Boom - Remove 1. Get down the boom from which the arm was removed, and support the boom end with a stable stand. 2. Disconnect all hoses from the bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all the openings. : 22 mm 3. Disconnect the wiring for working light at the connector.

TULI12EXN4070AC

TULI12EXN4071AB

TULI12EXN4072AC

TULI12EXN4073AC

4. Removal of boom cylinder 1.

Temporarily lift up the boom cylinder with a nylon sling to prevent the boom cylinder from falling down.

Removing the capscrew and nuts that are preventing the rod pin (C) from coming out, remove the pin (C). : 17 mm

Retract the rod, then put the cylinder on a stable stand.

Removing the capscrew that is preventing the head pin (B) from coming out, remove the pin (B).

Remove the boom cylinder. Weight: 35 kg (77 lb)

5. Removal of boom 1.

Temporarily lift up the boom assembly in order not to exert any load to the boom foot pin (A). Weight of arm assembly: approx. 170 kg (375 lb) - CX35B 184 kg (406 lb) - CX39B

Removing the capscrew that is preventing the boom foot pin (A) from coming out, pull off the pin (A).

Applying a sling to the boom assembly, remove the boom assembly.

6. Removal of arm cylinder 1.

Removing the capscrew and nuts that are preventing the head pin (D) from coming out, remove the pin (D). : 17 mm

Applying a nylon sling to the tube of arm cylinder, remove the arm cylinder. Weight: 31 kg (68 lb) - CX35B 34 kg (75 lb) - CX39B

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Booms, dippers, and buckets - Boom

Boom - Install Installation is performed in the reverse order of removal, including the following. NOTICE: At the alignment of pin positions, never insert your finger into the pin holes. Make sure to align them with visual confirmation. 1. Make the welded area clean to inspect any cracks there. 2. Check the dust seal (Q) for damages, and replace the faulty dust seal to new one (referring to Fig. 1 for the installing procedures). 3. Referring to Boom - Dimension (84.910) of Specifications, replace the worn-out pin and bushing to new ones. 4. Before installing the pin, apply grease to the shaft area. 5. Referring to Fig. 2, install the capscrew and nuts to prevent the pin from coming out. TULI12EXN6220AB

: 17 mm 6. Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 2. 7. For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

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Booms, dippers, and buckets - Boom

TULI12EXN4074GC

Total clearance must be between 0.5 - 0.9 mm (0.02 - 0.04 in) after adjusting the shims

S. Z.

Total clearance must be between after adjusting the shims Apply LOCTITEÂ® 262

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Index Booms, dippers, and buckets - 84 Boom - 910 Boom - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Boom - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Boom - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Boom - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Booms, dippers, and buckets - 84 Dipper arm - 912

CX35B CX39B

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Contents Booms, dippers, and buckets - 84 Dipper arm - 912

TECHNICAL DATA Dipper arm Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Dipper arm Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Booms, dippers, and buckets - Dipper arm

Dipper arm - Dimension

TULI12EXN4104GA

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Booms, dippers, and buckets - Dipper arm

No.

Name Arm 1.18 m (3.87 ft)

A B C D E F G H J K L M N D1 D2 D3 d1 d2 d3 d4 d5

Arm length

1180 mm (46.46 in)

Distance between R 304.5 mm (11.99 in) pins Distance between R 1036 mm (40.79 in) pins Distance between R 190 mm (7.48 in) pins Distance between 332 mm (13.07 in) pins Distance between 180 mm (7.09 in) pins Distance between 8 mm (0.31 in) pins 140 mm (5.51 in) Bosses width 150 mm (5.91 in) Hub width 56 mm (2.20 in) Bracket inner width 61 mm (2.40 in) Bracket inner width 310 mm (12.20 in) Idler link dimension 285 mm (11.22 in) Bucket link dimension ø 50 mm (1.97 in) O.D. of boss ø 50 mm (1.97 in) Hub O.D. ø 55 mm (2.17 in) Hub O.D. ø 40 mm (1.57 in) Pin diameter ø 40 mm (1.57 in) Pin diameter ø 45 mm (1.77 in) Pin diameter ø 40 mm (1.57 in) Pin diameter ø 45 mm (1.77 in) Pin diameter

Dimensions Arm 1.47 m Arm 1.32 m (4.33 ft) (4.82 ft) 1470 mm 1320 mm (51.97 in) (57.87 in) R 309 mm R 314 mm (12.36 in) (12.17 in)

Arm 1.59 m (5.22 ft) 1590 mm (62.60 in) R 317 mm (12.48 in)

←

R 1036 mm (40.79 in)

←

R 190 mm (7.48 in)

←

332 mm (13.07 in)

←

185.5 mm (7.30 in)

149.5 mm (5.89 in)

155.5 mm (6.12 in)

←

8 mm (0.31 in)

←

← ← ← ← ← ← ← ← ← ← ← ← ← ←

140 mm (5.51 in) 150 mm (5.91 in) 56 mm (2.20 in) 61 mm (2.40 in) 310 mm (12.20 in) 285 mm (11.22 in) ø 50 mm (1.97 in) ø 50 mm (1.97 in) ø 55 mm (2.17 in) ø 40 mm (1.57 in) ø 40 mm (1.57 in) ø 45 mm (1.77 in) ø 40 mm (1.57 in) ø 45 mm (1.77 in)

← ← ← ← ← ← ← ← ← ← ← ← ← ←

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Booms, dippers, and buckets - Dipper arm

Dipper arm - Service limits Clearance of pin and bushing

TULI12EXN4105FB

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Booms, dippers, and buckets - Dipper arm

CX35B

Location

Piece

Dipper point (Connected part of bucket) Bucket connecting rod (Bucket side) Bucket link (Connected part of dipper) Bucket connecting rod (Idler link side)

D’

Bucket cylinder (Rod side)

Bucket cylinder (Bottom side)

Dipper foot (Connection with boom)

Arm cylinder (Rod side)

Standard dimensions Tolerance Tolerance on bushing Pin on pin bore diameter diameter diameter 0.06 0.11 mm (0.00 0.00 in) 0.05 0.11 mm (0.00 0.00 in) 0.03 0.08 mm (0.00 0.00 in) ø 40 mm (1.57 in) 0.03 0.09 mm (0.00 -0.02 -0.05 mm 0.00 in) (0.00 0.05 0.00 in) 0.25 mm (0.00 0.01 in) 0.07 0.13 mm (0.00 0.01 in) 0.05 0.1 mm (0.00 0.00 in) ø 45 mm (1.77 in) 0.07 0.13 mm (0.00 0.01 in)

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Tolerance StanServiceStandard dard valability ues for value limit repair 0.08 0.16 mm (0.00 0.01 in) 0.07 0.16 mm (0.00 0.01 in) 0.05 0.13 mm (0.00 0.01 in) 0.05 0.14 mm (0.00 0.01 in) 0.7 mm 1.0 mm (0.03 in) (0.04 in) 0.07 0.30 mm (0.00 0.01 in) 0.09 0.18 mm (0.00 0.01 in) 0.07 0.15 mm (0.00 0.01 in) 0.09 0.18 mm (0.00 0.01 in)

Remedy

Replace bushing or pin

Booms, dippers, and buckets - Dipper arm

CX39B

Location

Piece

Dipper point (Connected part of bucket) Bucket connecting rod (Bucket side) Bucket link (Connected part of dipper) Bucket connecting rod (Idler link side)

D’

Bucket cylinder (Rod side)

Bucket cylinder (Bottom side)

Dipper foot (Connection with boom)

Arm cylinder (Rod side)

NOTE: The tolerance for bushing inside diameter means the dimension after fitting of it into place. The part number for pins may be changed owing to improvement, use them only for reference.

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Remedy

Replace bushing or pin

Booms, dippers, and buckets - Dipper arm

Clearance in thrust direction on dipper and cylinder installation section

TULI12EXN6033HA

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Booms, dippers, and buckets - Dipper arm

CX35B Standard dimensions Piece

Sec.

No.

Arm A-A

Dipper point

L1 Bucket

Link side Bucket B-B connecting rod

L2 Bucket

Bucket Arm link (ConC-C nected part of Link side dipper) Bucket Rod side connecting rod (Rod Link side side) Bucket connecting rod Bucket link

140 mm (5.51 in) 140.3 141.7 mm (5.52 5.58 in) 139.6 139.8 mm (5.50 5.50 in) 140.3 141.7 mm (5.52 5.58 in) 140 mm (5.51 in)

L3 –

D-D Bucket connecting rod (Idler link side)

Dimensions

Clearance X adjusted with shim (total of both sides) StanSerdard viceStandard value for ability value repair limit

0.5 - 2.1 mm (0.02 0.08 in)

0.1 - 0.5 mm (0.00 0.02 in)

Pin length Remedy No.

Dimensions

PL1

278 mm (10.94 in)

PL2

278 mm (10.94 in)

PL3

204. 5 mm (8.05 in)

PL5

204. 5 mm (8.05 in)

See “NOTE”

–

54.5 - 55 mm (2.15 Less than 1.5 2.17 in) 1.0 mm 0.5 mm mm (0. (0.04 in) 55.5 - 56 mm (0.02 in) 06 in) (2.19 2.20 in) 139.6 139.8 mm 0.1 - 0.5 mm (5.50 – (0.00 5.50 in) 0.02 in) -

Adjusted with shim

NOTE: Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

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Booms, dippers, and buckets - Dipper arm

CX35B Standard dimensions Piece

Sec.

No.

Bucket cylinder E-E (Bottom side)

Bottom side L6 Arm

Arm F-F

Dipper foot

L7 Boom

Arm cylinder G-G (Rod side)

Rod side L8 Arm

Dimensions

Clearance X adjusted with shim (total of both sides) StanSerdard viceStandard value for ability value repair limit

Pin length Remedy

54.5 - 55 mm (2.15 Less than 2.17 in) 0.5 - 0.9 mm (0.02 56 - 57 mm 0.04 in) (2.20 2.24 in) 149.6 149.8 mm (5.89 1.5 Less than 5.90 in) 1.0 mm Adjusted mm (0. 0.5 mm (0.04 in) with shim 150 06 in) (0.02 in) 150.5 mm (5.91 5.93 in) 59.5 - 60 mm (2.34 0.5 - 0.9 mm 2.36 in) (0.02 61 - 62 mm 0.04 in) (2.40 2.44 in)

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No.

Dimensions

PL6

153 mm (6.02 in)

PL7

234. 5 mm (9.23 in)

PL8

151 mm (5.94 in)

Booms, dippers, and buckets - Dipper arm

CX39B Standard dimensions Piece

Sec.

No.

Arm A-A

Dipper point

L1 Bucket

Link side Bucket B-B connecting rod

L2 Bucket

Bucket Arm link (ConC-C nected part of Link side dipper) Bucket Rod side connecting rod (Rod Link side side) Bucket connecting rod Bucket link

140 mm (5.51 in) 140.3 141.7 mm (5.52 5.58 in) 139.6 139.8 mm (5.50 5.50 in) 140.3 141.7 mm (5.52 5.58 in) 140 mm (5.51 in)

L3 –

D-D Bucket connecting rod (Idler link side)

Dimensions

Clearance X adjusted with shim (total of both sides) StanSerdard viceStandard value for ability value repair limit

0.5 - 2.1 mm (0.02 0.08 in)

0.1 - 0.5 mm (0.00 0.02 in)

Pin length Remedy No.

Dimensions

PL1

278 mm (10.94 in)

PL2

278 mm (10.94 in)

PL3

204. 5 mm (8.05 in)

PL5

204. 5 mm (8.05 in)

See “NOTE”

–

54.5 - 55 mm (2.15 Less than 1.5 2.17 in) 1.0 mm 0.5 mm mm (0. (0.04 in) 55.5 - 56 mm (0.02 in) 06 in) (2.19 2.20 in) 139.6 139.8 mm 0.1 - 0.5 mm (5.50 – (0.00 5.50 in) 0.02 in) -

Adjusted with shim

NOTE: Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

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Booms, dippers, and buckets - Dipper arm

CX39B Standard dimensions Piece

Sec.

No.

Bucket cylinder E-E (Bottom side)

Bottom side L6 Arm

Arm F-F

Dipper foot

L7 Boom

Arm cylinder G-G (Rod side)

Rod side L8 Arm

Dimensions

Clearance X adjusted with shim (total of both sides) StanSerdard viceStandard value for ability value repair limit

54.5 - 55 mm (2.15 Less than 2.17 in) 0.5 - 0.9 mm (0.02 56 - 57 mm 0.04 in) (2.20 2.24 in) 149.6 149.8 mm (5.89 1.5 Less than 5.90 in) 1.0 mm mm (0. 0.5 mm (0.04 in) 150 06 in) (0.02 in) 150.5 mm (5.91 5.93 in) 59.5 - 60 mm (2.34 0.5 - 0.9 mm 2.36 in) (0.02 61 - 62 mm 0.04 in) (2.40 2.44 in)

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Pin length Remedy No.

Dimensions

PL6

157 mm (6.18 in)

PL7

234. 5 mm (9.23 in)

PL8

160 mm (6.30 in)

Booms, dippers, and buckets - Dipper arm

Dipper arm - Remove 1. Making the arm cylinder and bucket cylinder (1) to the most retracting conditions, get touch the arm tip with the ground. 2. Shut-off the engine and operate the arm control lever several times at the same moment, and the pressure in circuit is released. Then put the safety lock lever in the “Locked” position, and depress the air breather on the hydraulic oil tank, release the pressure in the tank. 3. Disconnect the 2 hoses connected to the bucket cylinder (1). Then apply plugs to the openings. : 22 mm

TULI12EXN4064AB

TULI12EXN4065BC

TULI12EXN4066AB

4. Lift up the arm cylinder body with a nylon sling in order not to exert any load to the pin (E). 5. Remove the capscrew and nuts that are preventing the pin (E) from coming out. Then remove the pin (E) and shims. : 17 mm 6. Placing a square timber under the arm cylinder, get down the cylinder. 7. Install the pin (E) to the original position, and install the capscrew and nuts that prevents the pin (E) from coming out. Applying a rope to the pin (E) and the arm tip, slightly lift it up in order not to exert any load to the pin (F). 8. Remove the capscrew that is preventing the pin (F) connecting the arm and boom, from coming out. Then pull off the pin (F). : 24 mm 9. Remove the arm assembly paying attention to the stability of arm. Weight of arm assembly: approx. • 120 kg (265 lb) - CX35B [Arm 1.47 m (4.82 ft)] • 140 kg (309 lb) - CX39B [Arm 1.59 m (5.22 ft)]

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Booms, dippers, and buckets - Dipper arm

10. Removal of bucket cylinder (1) 1.

Remove the capscrew that is preventing the rod pin (H) from coming out, then pull off the pin (H). : 24 mm

Remove the capscrew and nuts that are preventing the head pin (G) from coming out, then pull off the pin (G). : 17 mm

Apply a nylon sling to the tube of bucket cylinder, and remove the cylinder. Weight: approx. 22 kg (49 lb)

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TULI12EXN6219AB

Booms, dippers, and buckets - Dipper arm

Dipper arm - Install Installation is performed in the reverse order of removal, including the following workings. NOTICE: At the alignment of pin positions, never insert your finger into the pin holes. Make sure to align them with visual confirmation. 1. Make the welded area clean to inspect any cracks there. 2. Check the dust seal (Q) for damages, and replace the faulty dust seal to new one (referring to Fig. 1 for the installing procedures). 3. Replace the worn-out pin and bushing to new ones. 4. Before installing the pin, apply grease to the shaft area. 5. Referring to Fig. 2, install the capscrews and nuts to prevent the pin from coming out. : 17 mm

TULI12EXN6220AB

6. Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 2. 7. For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

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Booms, dippers, and buckets - Dipper arm

TULI12EXN6221FB

K. J.

Total clearance must be between 0.5 - 0.9 mm (0.02 - 0.04 in) after adjusting the shims Total clearance must be lower than 0.5 mm (0.02 in) after adjusting the shims

W. Z.

Total clearance must be between 0.5 - 0.9 mm (0.02 - 0.04 in) after adjusting the shims Apply LOCTITEÂŽ 262

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Index Booms, dippers, and buckets - 84 Dipper arm - 912 Dipper arm - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dipper arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Dipper arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Dipper arm - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Booms, dippers, and buckets - 84 Bucket - 100

CX35B CX39B

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Contents Booms, dippers, and buckets - 84 Bucket - 100

TECHNICAL DATA Bucket General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Bucket Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Booms, dippers, and buckets - Bucket

Bucket - General specification Width

Capacity ISO 7451

350 mm (13.8 in)

0.05 m³ (1.8 ft³)

450 mm (17.7 in)

0.07 m³ (2.5 ft³)

500 mm (19.7 in)

0.09 m³ (3.2 ft³)

600 mm (23.6 in)

0.11 m³ (3.9 ft³)

700 mm (27.6 in)

0.12 m³ (4.2 ft³)

Weight 62 kg (136.7 lb) 69 kg (152.1 lb) 72 kg (158.7 lb) 78 kg (172.0 lb) 84 kg (185.2 lb)

Number of teeth

Type

* = Generic digging; for digging and sand loading operations, gravel, clay, earth in general, etc., the specific weight of material should not be higher than 1400 kg/m³ (2359.8 lb/yd³) Standard bucket: • 500 mm (19.7 in) for CX35B models • 600 mm (23.6 in) for CX39B models

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Booms, dippers, and buckets - Bucket

Bucket - Dimension Bucket dimensional drawings

TULI12EXN6034FA

No.

Model Heaped capacity

Distance between pin and bracket

Distance between bucket pin and tooth end

Inner width of bucket top end

Inner width of lug

Bracket inner width

Outer width of side cutter

Outer width of bucket bottom plate

Outer tooth distance

Pitch between teeth

d1 d2

Pin diameter Pin diameter

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CX35B 0.09 m³ (3.18 ft³) 192 mm (7.56 in) R 694 mm (27.32 in) 428 mm (16.85 in) 191 mm (7.52 in) 141 mm (5.55 in) 543 mm (21.38 in) 387 mm (15.24 in) 360 mm (14.17 in) 120 mm (4.72 in) 120 mm (4.72 in) ø40 ø40

CX39B 0.11 m³ (3.88 ft³) ← ← 528 mm (20.79 in) ← ← 643 mm (25.31 in) 487 mm (19.17 in) 460 mm (18.1 in) 153 mm (6.02 in) 153 mm (6.02 in) ← ←

Booms, dippers, and buckets - Bucket

Detail dimensional drawings of lug section

TULI12EXN6035FA

Part Dimensions

Plate outer diameter øA

Boss thickness B

ø 85 mm (3.35 in)

25 mm (0.98 in)

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Pin bore diameter Lug plate thickness øC D 40 - 40.15 mm (1.57 15 mm (0.59 in) 1.58 in)

Booms, dippers, and buckets - Bucket

Bucket - Remove 1. Operate the operating lever and place the bucket on the ground, so the bucket and arm connecting pins are not loaded. 2. Move the O-rings (3) toward the bucket bosses using a spatula. 3. In order to remove pin (K) which links arm and bucket, remove the ring (2) and the pin (1) by means of straight driver, and draw out pin (K). • If the pin does not come off easily, the pin is loaded. Take off the load by manipulating the operating lever. • Take care so the dust (4) seal between the arm and the bucket bosses is not damaged.

TULI12EXN4061AB

TULI12EXN4062BB

4. Adjust the bucket by manipulating the operating lever so the pin (J) between the bucket link and the bucket is not loaded. 5. Remove the ring (2) and pin (1) then pull out the pin (J). 6. Remove bucket assembly. Weight: 81 kg (179 lb) - CX35B 89 kg (196 lb) - CX39B • Fig. 2: Assembly of pin (A-A)

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Booms, dippers, and buckets - Bucket

Bucket - Install Installation is performed in the reverse order of removal, including the following workings: NOTICE: When aligning the pin position, do not put your finger in the pin holes in any circumstances, but align them visually. 1. Clean the welded part of the structures and check that there is no crack on the part. 2. Check that the dust seal is not damaged, and replace a faulty one if necessary. 3. Replace the worn pins and bushings. 4. When inserting the pin, coat the shaft with grease. â&#x20AC;˘ The bucket is mounted more easily if the bucket connecting rod is installed first.

TULI12EXN4063AA

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Index Booms, dippers, and buckets - 84 Bucket - 100 Bucket - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bucket - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bucket - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bucket - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47574272B 24/03/2014 EN

SERVICE MANUAL Dozer blade and arm CX35B CX39B

47574272B 24/03/2014

Contents Dozer blade and arm - 86

[86.110] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1

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Dozer blade and arm - 86 Dozer blade - 110

CX35B CX39B

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Contents Dozer blade and arm - 86 Dozer blade - 110

TECHNICAL DATA Dozer blade Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Dozer blade Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Dozer blade and arm - Dozer blade

Dozer blade - Dimension

TULI12EXN4109GA

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Dozer blade and arm - Dozer blade

Dimensions

No.

Name

A B

Dozer width Dozer height Distance from dozer attaching pin center to cutting edge end Inner width of dozer attaching bracket Width of dozer attaching bracket Distance from dozer attaching pin center to attaching pin on dozer cylinder bottom side Attaching bracket inner width on dozer cylinder bottom side Horizontal distance from dozer attaching pin centre to edge end Vertical distance from dozer attaching pin center to edge end Dozer attaching pin diameter Attaching pin diameter on dozer cylinder bottom side

C D E F G H J d1 d2

CX35B 1550 mm (61 in) 346 mm (14 in)

CX39B 1700 mm (67 in) 345 mm (14 in)

R 1187 mm (47 in)

R 1232 mm (49 in)

500 mm (20 in) 60 mm (2 in)

← ←

R 608 mm (24 in)

R 626 mm (25 in)

62 mm (2 in)

←

1144 mm (45 in)

1192 mm (47 in)

315 mm (12 in)

310 mm (12 in)

ø 40 mm (2 in) ø 45 mm (2 in)

← ←

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Dozer blade and arm - Dozer blade

Dozer blade - Service limits

TULI12EXN6037GB

A-B-C = Pin

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Dozer blade and arm - Dozer blade

Clearance of pin and bushing

Ref.

Standard dimension Tolerance on Tolerance Pin bushing on pin diameter bore diameter diameter

Piece

Dozer cylinder (Bottom side) Dozer cylinder (Rod side)

Ă¸ 45 mm (1.77 in)

Dozer foot

Ă¸ 40 mm (1.57 in)

Tolerance Standard value

-0.06 -0.11 mm (0.00 0.00 in)

0.05 0.20 mm (0.00 0.01 in)

0.11 0.31 mm (0.00 0.01 in)

-0.06 -0.09 mm (0.00 0.00 in)

0.12 0.22 mm (0.00 0.01 in)

0.18 0.31 mm (0.01 0.01 in)

Standard Servicevalue for ability limit repair

0.7 mm (0.03 in)

1.0 mm (0.04 in)

Remedy

Replace bushing or pin

NOTE: The tolerance for bushing inside diameter means the dimension after fitting of it into place. The part number for pins may be changed owing to improvement, use them only for reference.

Clearance in thrust direction on the dozer and cylinder installation section

Piece

Ref.

Dozer cylinder (Bottom side)

Dozer cylinder (Rod side)

Bottom side

Dozer

Rod side

Lower frame

Dozer C

Dozer foot Lower frame

Standard dimensions Clearance X adjusted with shim DimenNo. (total sions of both sides) 59.5 60 mm (2.34 2.36 in) L1 62 - 63 mm 0.6 (2.44 2.0 mm 2.48 in) (0.08 0.14 in) 59.5 After shim 60 mm adjustment (2.34 2.36 in) L2 62 - 63 mm (2.44 2.48 in) 59.7 60.3 mm 1.7 (2.35 3.3 mm 2.37 in) L3 (0.07 62 - 63 mm 0.13 in) (2.44 2.48 in)

Pin length

Remedy

When clearance X exceeds 3.5 mm (0.14 in) adjust it with shim

When clearance X exceeds the upper limit. adjust it with shim

No.

Dimensions

PL1

137 mm (5.39 in)

PL2

137 mm (5.39 in)

PL3

127 mm (5.00 in)

NOTE: Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

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Dozer blade and arm - Dozer blade

Dozer blade - Remove 1. Put a support (1) of appropriate height under the mounting side of dozer body, and make the dozer at a stable condition not to exert any load to the pin (P). 2. Disconnect the hydraulic hoses and apply a plug to the connecting portions. : 22 mm 3. Apply a nylon sling to the dozer cylinder (C1), and lift it up slightly not to exert any load to the pin (Q) of rod side. 4. Remove the capscrew (C3) and nuts (C4) that are preventing the pin (Q) from coming out, of rod side. Remove the pin (Q), and support (1) the cylinder (C1) with a wood block, etc. : 17 mm 5. Remove the capscrew (B2) and nuts (B3) that are preventing the dozer body fixing pin (P) from coming out, and remove the two pins (P). 6. Gradually move the machine to backward to remove the dozer. Weight of blade: 145 kg (320 lb) for CX35B models 155 kg (342 lb) for CX39B models 7. If necessary, remove the dozer cylinder by means of removing the pin (R) of head side. Weight of dozer cylinder: 27 kg (60 lb)

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TULI12EXN4079AB

Dozer blade and arm - Dozer blade

Dozer blade - Install The installation is carried out with the reverse order of the removal paying attention for the following. 1. Replace the worn-out pin and bushing to new ones. 2. Before installing pin (P), (Q) and (R), apply grease to their shaft area. 3. Install the nuts (2) for capscrew (3) to prevent the pin from coming out. : 17 mm

TULI12EXN6234AB

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Index Dozer blade and arm - 86 Dozer blade - 110 Dozer blade - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dozer blade - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dozer blade - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dozer blade - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47574272B 24/03/2014 EN

SERVICE MANUAL Platform, cab, bodywork, and decals CX35B CX39B

47574272B 24/03/2014

Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.110] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

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Platform, cab, bodywork, and decals - 90 Cab - 150

CX35B CX39B

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab and platform Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Cab guard Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Platform, cab, bodywork, and decals - Cab

Cab and platform - Prepare 1. Remove the floor mats (6) and (7). 2. Removing cab harness connector. â&#x20AC;˘ Respectively disconnect 6P connectors of cab harness and cab connecting harness, 2P connector of washer motor, 3P connector of radio (optional) and so on.

TULI12EXN8287AB

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Platform, cab, bodywork, and decals - Cab

Cab and platform - Remove 1. Remove the fuel filler cap (A2) and rubber cover (20). 2. Removing cover installed on rear of cab. Loosen three sems-screws M6 X 25 (12) for installing the cover (13). : plus screwdriver 3. Removing cab mounting screws. screws for mounting the cab. Two capscrews (1) M16 X 100 One capscrew (2) M16 X 50 Three capscrews (3) M12 X 50

Loosen six cap-

: 19 mm and 24 mm An extension tool about 1 m (3.28 ft) long is required for removing the capscrew item (1) (with mark *).

TULI12EXN6278BB

TULI12EXN8289AB

TULI12EXN4205AB

Lifting cab 1.

Loosen the sems-screws M10 X 20 (C6) to remove the seat belt assembly (C2) in advance to prevent it from interfering with the cab during lifting. : 17 mm

Put slings through the lifting eyes on the cab top and lift up. Cab weight: 220 kg (485 lb) D. Adjust the clearance between guard and cab rear bracket with shims (t1.2, 2.0, 3.2).

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Platform, cab, bodywork, and decals - Cab

Cab and platform - Install Install the cab in reverse order of the removal. In the fastening position of the capscrew (3), it is necessary to adjust the clearance with shims as shown in Cab and platform - Remove (90.150). Tighten screws to the torque specified below. M6: T = 4.4 N路m (3 lb ft) M10: T = 46 N路m (34 lb ft) M12: T = 79 N路m (58 lb ft) M16: T = 191 N路m (141 lb ft) TULI12EXN8289AB

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Platform, cab, bodywork, and decals - Cab

Cab guard - Remove 1. Use a suitable hoist to support the front guard (1). Approximate operating mass: 19 kg (42 lb)

SMIL13MEX0202FB

2. Remove four screw M12x30 (2) and washers (2). : 19 mm 3. Remove the front guard to the frame.

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Platform, cab, bodywork, and decals - Cab

Cab guard - Install 1. Use a suitable hoist to support the front guard (1). Approximate operating mass: 19 kg (42 lb)

SMIL13MEX0202FB

2. Use four screw M12x30 (2) and washers (2) to attach the front guard to the frame. 3. Torque screws to 85 - 95 NÂˇm (63 - 70 lb ft). : 19 mm

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab and platform - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cab and platform - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cab and platform - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cab guard - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cab guard - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110

CX35B CX39B

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90.2 [90.110] / 1

Contents Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110

SERVICE Operator platform less cab Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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90.2 [90.110] / 2

Platform, cab, bodywork, and decals - Operator platform less cab

Operator platform less cab - Prepare 1. Remove the canopy and the handrail. 2. Remove the floor covers, and the plates. 3. Remove the covers for the guards, and the bonnet. 4. Remove the counterweight. 5. Disconnect the negative side terminal of the battery.

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Platform, cab, bodywork, and decals - Operator platform less cab

Operator platform less cab - Disassemble 1. Removing the air cleaner. 2. Removing throttle cable (15) 1.

Pull out the pin (10) and remove the pin (8).

Loosen the adjusting nut ( M8) to remove the cable.

3. Removing deceleration motor (option) 1.

Disconnect the connector.

Loosen the adjusting nut ( M8) to remove the cable.

Loosen three M8 X 20 sems-bolts (13) to remove the deceleration motor (16). TULI12EXN6319AB

TULI12EXN6320AB

TULI12EXN4947AB

: 13 mm 4. Removing filler neck (fuel supply port) 1.

Pull out the hose (C4) connected to the fuel tank.

Loosen two M8 X 16 capscrews to remove the filler neck (C1). : 13 mm

5. Disconnect the air bleed hose (A3) for the fuel tank (A1).

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Platform, cab, bodywork, and decals - Operator platform less cab

6. Pilot valve removal for dozer 1.

Disconnecting hoses. Disconnect all the hoses connected to the pilot valve (10). Then attach a plug and a tag recording the connecting port to each of their openings.

Removing pilot valve. Loosen two M8 X 20 capscrews (11) to remove the pilot valve.

TULI12EXN6322BB

TULI12EXN4949AB

TULI12EXN4950AB

7. Removing seat and front stand cover. Loosen four M8 X 20 sems-bolts (15) to remove the seat assembly (7) and the front stand cover (14) in one piece. : 13 mm

8. Removing heat insulation cover. Loosen two M8 X 20 sems-bolts (24) to remove the cover (5). : 13 mm

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Platform, cab, bodywork, and decals - Operator platform less cab

9. Disconnecting pilot hose 1. Disconnect the hose of the right pilot valve (R) under the pilot valve. 2. Disconnect the hose of the left pilot valve (L) from the control valve and solenoid (B1) valve (B1) sections . • When a multi-control valve (option) is equipped, disconnect hose at the multi-control valve section.

TULI12EXN4951BB

TULI12EXN4952AB

10. Removing heater hose (option). Remove the engine side clip (5) to disconnect the heater hoses (1) and (6). • Four M8 X 16 sems-bolts (12) for fastening heater (2). : 13 mm Tightening torque: 23.5 N·m (17.3 lb ft)

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Platform, cab, bodywork, and decals - Operator platform less cab

11. Disconnecting harness. See below drawing to disconnect the harness connected to the instrument harness and main harness.

TULI12EXN6327GB

1. 2. 3. 4. 5.

To boom To canopy light Connect with fuel sensor Battery ground cable Starter cable

E-3. Horn SV-1. Lock lever solenoid SV-2. Two-speed selection solenoid

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Platform, cab, bodywork, and decals - Operator platform less cab

12. Removing control stand. Remove M8 (A1), M10 (19) and M12 (20) sems-bolts for fastening the stand in addition to the sems-bolts already removed to disassemble the canopy and floor covers. sems-bolts for fastening the stand in addition to the sems-bolts already removed to disassemble the canopy and floor covers. : 13 mm, 17 mm and 19 mm Weight of removed stand: Approximately 55 kg (121.3 lb) â&#x20AC;˘ Before lifting the control stand, ensure that harnesses and hoses are already disconnected. 13. Removing support 1.

Loosen two M6 X 20 sems-screws (A9) to remove the reserve tank (A5). : 10 mm

2. Remove the M8 X 16 capscrew (A10) for the clamp (A6) of the oil cooler hose (A2). : 13 mm 3. Loosen two M12 X 50 (26) and two M16 X 50 (23) capscrews to remove the support (7). : 19 mm and 24 mm Weight: 39 kg (86 lb)

TULI12EXN6329BB

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Platform, cab, bodywork, and decals - Operator platform less cab

Operator platform less cab - Assemble 1. Install the control stand in reverse order of the removal. Tighten the capscrews and sems-bolts at the torque specified below: Thread size M6 M8 M10 M12 M16 Thread size PF 1/4 PF 3/8

Tool 10 mm 13 mm 17 mm 19 mm 24 mm Spanner used 19 mm 22 mm

Tightening torque 4.4 N·m (3.2 lb ft) 23.5 N·m (17.3 lb ft) 46.1 N·m (34 lb ft) 79.4 N·m (58.6 lb ft) 191 N·m (140.9 lb ft) O-ring type fitting 36.3 N·m (26.8 lb ft) –

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30°flare type fitting 29.4 N·m (21.7 lb ft) 49 N·m (36.1 lb ft)

Index Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110 Operator platform less cab - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operator platform less cab - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator platform less cab - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - 90 Operator protections - 114

CX35B CX39B

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90.3 [90.114] / 1

Contents Platform, cab, bodywork, and decals - 90 Operator protections - 114

SERVICE Roll Over Protective Structure (ROPS) frame canopy Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Platform, cab, bodywork, and decals - Operator protections

Roll Over Protective Structure (ROPS) frame canopy - Remove 1. Remove the floor mats (5) and (8). 2. Removing handrail (A4). Loosen sems-screws M10 X 40 (A9) and M16 X 100 (A6) to remove the handrail (A4). : 17 mm and 19 mm 3. Removing canopy assembly. 1.

Disconnect the light harness (B1) that runs inside the support (A2) and is connected to the main harness with a connector.

Loosen one screw M16 X 65 (A5) and four screws M12 X 55 (A8) to remove the canopy.

TULI12EXN8285AB

TULI12EXN4202BC

: 19 mm and 24 mm Canopy weight: 70 kg (154 lb) C. Harness outlet

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Platform, cab, bodywork, and decals - Operator protections

Roll Over Protective Structure (ROPS) frame canopy - Install Install the canopy in reverse order of the removal. Tighten the capscrews at the torque specified below: M10: 46 N·m (33.9 lb ft) M12: 79 N·m (58.3 lb ft) M16: 191 N·m (140.9 lb ft) C. Harness outlet

TULI12EXN8286BB

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Index Platform, cab, bodywork, and decals - 90 Operator protections - 114 Roll Over Protective Structure (ROPS) frame canopy - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Roll Over Protective Structure (ROPS) frame canopy - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

CX35B CX39B

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90.4 [90.105] / 1

Contents Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

SERVICE Machine shields and guards Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Platform, cab, bodywork, and decals - Machine shields and guards

Machine shields and guards - Remove Fig. 1 shows the method for removing the cover of the canopy.

TULI12EXN6281BB

TULI12EXN6282AB

TULI12EXN6283AB

1. Removing bonnet assembly (2) Unlock and open the bonnet assembly (2). Loosen two sems-bolts M12 X 30 (37) of the hinge section (2-8) to remove the bonnet (2). : 19 mm

2. Removing cover assembly (3) Loosen three M8 X 20 sems-screws (21) to remove the cover assembly (3). : 13 mm

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Platform, cab, bodywork, and decals - Machine shields and guards

3. Removing cover assembly (4) Loosen three sems-screws M10 X 30 (19) to remove the cover assembly (4). : 17 mm 4. Removing cover assembly (5) Loosen four sems-screws M10 X 30 (19) to remove the cover assembly (5). : 17 mm TULI12EXN6284AB

TULI12EXN6285AB

5. Removing cover assembly (1) 1.

Unlock the cover (1-3) to open the cover assembly (1).

Loosen four M12 capscrews (31) to remove the cover assembly (1).

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Platform, cab, bodywork, and decals - Machine shields and guards

Machine shields and guards - Install Install the guards in reverse order of the removal. Tighten the capscrews to the torque specified below: M8: T = 24 N路m (18 lb ft) M10: T = 46 N路m (34 lb ft) M12: T = 79 N路m (58 lb ft) M16: T = 191 N路m (141 lb ft)

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Index Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105 Machine shields and guards - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Machine shields and guards - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - 90 Fenders and guards - 116

CX35B CX39B

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90.5 [90.116] / 1

Contents Platform, cab, bodywork, and decals - 90 Fenders and guards - 116

SERVICE Platform guard Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Platform, cab, bodywork, and decals - Fenders and guards

Platform guard - Prepare Remove floor plate together with the travel pilot valve assembly and the swing pedal in one piece. 1. Remove the floor mats (5) and (8). 2. Remove the canopy or cab. 3. Remove the covers (2) and (4) as well as the plates (3). : 13 mm 4. Remove the cover assembly (5) of the deck under the floor.

TULI12EXN8801AB

TULI12EXN8802BB

5. Disconnect electrical wiring for travel 2-speed selector switch from the connector portion. NOTICE: In advance, disconnect the minus terminal of the battery to prevent danger of short circuit, etc. 6. Removing travel pilot piping (prior to this work, release the pressure in the piping) Disconnect hoses of the travel pilot valve (A10) at the valve side position marked with * and then plug their openings. • Attach a tag recording the valve connecting port to each of the disconnected hoses. For installation, tighten the hose fittings at the following torque:

Tightening torque Thread size PF 1/4

Spanner used 19 mm (0.75 in)

O-ring type fitting 26.5 N·m (19.55 lb ft)

NOTE: Take care of the tightening torque as the pilot valve is made of aluminum.

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30° flare type fitting 29.4 N·m (21.68 lb ft)

Platform, cab, bodywork, and decals - Fenders and guards

7. Removing cable of swing pedal 1.

Loosen four M8 X 20 sems-screws (B11) to pull out the support (B1) upward. : 13 mm

Pull out the pin (B6) and loosen the adjusting nut (B2) to disconnect the control cable (B4) .

TULI12EXN8803AB

TULI12EXN8804AB

8. Removing of nibbler and breaker piping from solenoid valve (prior to this work, release the pressure in the piping) Disconnect hoses of the solenoid valve (1) at the valve side position marked with * and then plug their openings. • Attach a tag recording the valve connecting port to each of the disconnected hoses. For installation, tighten the hose fittings at the following torque:

Tightening torque Thread size PF 1/4

Spanner used 19 mm (0.75 in)

O-ring type fitting 36.3 N·m (26.77 lb ft)

NOTE: Take care of the tightening torque as the pilot valve is made of aluminum.

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30° flare type fitting 29.4 N·m (21.68 lb ft)

Platform, cab, bodywork, and decals - Fenders and guards

Platform guard - Remove 1. Remove the M8 X 20 sems-bolts (6). : 13 mm 2. Remove the floor plate assembly (1).

TULI12EXN4216AB

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Platform, cab, bodywork, and decals - Fenders and guards

Platform guard - Install Assemble the floor plate in reverse order of the disassembly. Sems-screws (6) M8: : 13 mm Tightening torque: 23.5 NÂˇm (17.33 lb ft)

TULI12EXN4216AB

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Index Platform, cab, bodywork, and decals - 90 Fenders and guards - 116 Platform guard - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Platform guard - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Platform guard - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47574272B 24/03/2014 EN

SPECIAL TOOL INDEX Genuine 380000303 [Cylinder Liner Pressure Check Kit]

Reference Engine - Special tools

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CNH Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 SERVICE - Technical Publications & Tools

47574272B 24/03/2014 EN