SERVICE MANUAL
E45B SR / E50B SR / E55B
Mini Excavator
Part number 47574277B
English March 2014
Copyright © 2014 CNH Industrial Italia S.p.A. All Rights Reserved.
SER VICE MANUAL E45B SR E50B SR E55B 47574277B 24/03/2014
control valve
Hydraulic hand control Hydraulic foot control
Hydraulic swing system
Hydraulic travel system Hydraulic central joint
Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] V alve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Crankshaft and flywheel Fuel tanks [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.250] T urbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.254] Intake and exhaust manifolds and muf fler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 1 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic
Reservoir
Main
systems
, cooler , and filters V ariable displacement pump
Boom hydraulic
Dipper hydraulic system 1 47574277B 24/03/2014
system
Excavator and backhoe bucket hydraulic system
Hammer and rotating bucket hydraulic system
Swing arm hydraulic system
Dozer blade cylinders
Frames and ballasting
Upper frame
Swing ring assembly
Ballasts and supports
T racks and track suspension
T rack frame and driving wheels
T racks
T rack tension units
T rack rollers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system Harnesses and connectors [55.015] Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.01 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 platform harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 1 Booms, dippers, and buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47574277B 24/03/2014
Cab climate control
14] Boom pivoting support Boom Dipper arm Bucket Dozer blade and arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [86.1 10] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1 Platform, cab, bodywork, and decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab 10] Operator platform less cab 14] Operator protections [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.1 16] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 47574277B 24/03/2014
INTRODUCTION 47574277B 24/03/2014 1
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed this manual must carried out only qualified dealership strictly complying with the instructions and whenever the special
Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent
The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer
The information this manual - - date the date the the policy the manufacturer for continuous Some information could not updated due modifications a technical commercial type, changes the laws and regulations dif ferent countries.
case refer your NEW HOLLAND CONSTRUCTION Sales and Service
47574277B 24/03/2014
INTRODUCTION
3
INTRODUCTION
Safety rules
Personal safety
This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury
Throughout this manual you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation not will result death serious injury
W
ARNING indicates a hazardous situation not could result death serious injury
CAUTION indicates a hazardous situation not could result minor moderate injury
F AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .
Machine safety
NOTICE: Notice indicates a situation that, not avoided, could result machine property damage.
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property damage. The word Notice used address practices not related personal safety .
Information
NOTE: Note indicates additional information that clarifies other information this
Throughout this manual you will find the word Note followed additional information about a step, other information the The word Note not intended address personal safety property
47574277B 24/03/2014 4
Personal safety
NOTICE: The proper and safe lubrication and maintenance for this recommended Manufacturer , are outlined the OPERA T OR’S MANUAL for the Improper performance lubrication maintenance procedures are dangerous and could result injury Read and understand the MANUAL before performing any lubrication
The serviceman mechanic may unfamiliar with many the systems this machine. This makes a careful use the systems very important when performing maintenance Sound knowledge the system and components important before the removal disassembly any
Because the size some the machine the serviceman mechanic should check the weights noted this Use proper lifting procedures when removing any W eight components table shown this
The following a list basic precautions that must always
Read and understand all W arning plates and decals the machine before Maintaining Repairing this
Always wear protective glasses and protective shoes when working around particular , wear tive glasses when using punches drifts any part the machine Use welders gloves, hood / goggles, apron and the protective clothing appropriate the welding job being performed. not wear loose fitting torn Remove all rings from loose jewellery , confine long hair and loose ing before working this machinery
Disconnect the battery and hang a tag the operator ’ s Remove starter key make all repairs with the machine parked a level and firm Block the machine does not roll while working under the machine. Hang a tag the operator ’ s seat. not work any machine that supported only jacks a Always use blocks stops for the jack before carrying out any disassembly operation.
NOTICE: not operate this machine unless you have read and understood all instructions contained this manual. Improper machine operation dangerous and could result injury
Relieve all pressure air , oil water systems before any lines, fittings related items are disconnected Always make sure all raised components are blocked correctly and alert for possible pressure when disconnecting any device from a system under
Lower the dozer other attachments the ground before performing any work the this cannot make sure the blade other attachment blocked correctly prevent from dropping unexpectedly .
Use steps and grab handles when mounting dismounting a Remove any debris mud from walkways work platforms before using Always face the machine when using ladders and When not possible use the designed access provide scaf platforms perform safe repair
T o avoid back injury , use a hoist when lifting components which weigh lb) Make sure all are good condition and are the correct capacity sure hooks are positioned correctly Lifting eyes are not side loaded during a lifting
T o avoid alert for hot parts and surfaces immediately after stopping the machine such hot fluids tubes and compartment
1 careful when removing cover Gradually back f the last two capscrews nuts located opposite ends the cover device and carefully pry the cover loose relieve any spring other before removing the last two capscrews nuts completely .
Be careful when removing filler breathers and plugs the Hold a rag over the cap plug prevent being sprayed splashed liquids under Danger even greater the machine has just been liquids might boiling
Always use the proper tools that are good condition and that are suited for the job sure you understand how use them before performing any service
Reinstall all clamps with the same spare part number not use clamps inferior quality replacement necessary . 47574277B
INTRODUCTION
24/03/2014 5
Repairs which require welding should performed only with the benefit the appropriate reference tion and personnel adequately trained and skilled welding
Determine the type metal being welded and select the correct welding procedure and rods wires provide a metal weld strength least equivalent that the parent Make sure disconnect the battery before any welding operation performed.
not damage wiring during removal Reinstall the wiring not damaged nor will damaged operation the machine contacting sharp rubbing against some object hot not connect wiring a line containing sure all protective including guards and are properly installed and functioning correctly before starting a repair . a guard shield must removed perform the repair work, use extra caution and replace the guard shield after repair
18. Performing maintenance and repair operations while the bucket lifted dangerous, because there the sibility a device not fail lower such device and place the bucket the ground before starting the
Loose dirty lubrication and hydraulic pipes and hoses may cause not bend strike high - pressure not install bent damaged Inspect tubes and hoses carefully not check for leaks with your hands. V ery small (pinhole) leaks can result a high velocity oil jet that will invisible close the This oil can penetrate the skin and cause personal injury Use card - board paper locate pinhole
T ighten connections the correct Make sure that all protections against the clamps and the ator ’ s protective devices are correctly installed order prevent excessive vibrations rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components event a tube seal failure must installed correctly
not operate a machine any rotating part damaged contacts any other part during Any high speed rotating component that has been damaged altered should checked for balance before careful when servicing separating the Chips can fly when removing installing a track W ear safety glasses and long sleeve protective T racks can unroll very quickly when Keep away from front and rear The machine can move unexpectedly when both tracks (crawlers) are disengaged from the Block the machine prevent from
INTRODUCTION
47574277B 24/03/2014 6
Part identification
INTRODUCTION
TULI12EXN8006GB 1 Engine 14. Safety lever 27. Rubber crawler Oil filter Canopy Dozer Radiator Operating lever Dozer cylinder Reservoir tank Dozer control lever Boom Air cleaner Throttle lever Boom cylinder Muf fler Gauge cluster Arm cylinder Fuel tank Battery Light Hydraulic oil tank Swivel joint Arm Hydraulic pumps T ravel motor Rod and idler link Slewing motor Slewing ring Bucket cylinder 1 Swing cylinder Idler adjuster Bucket Control valve Lower roller T ravel lever Upper roller 47574277B 24/03/2014
Engine E45B E50B E55B 47574277B 24/03/2014
SER VICE MANUAL
1
Engine - External view
Filler port (engine oil)
T urbocharger
Engine - Engine and crankcase
Air intake port (from air cleaner , optional)
Lifting eye
Coolant pump
Fan
V - belt
Crankshaft V - pulley
Filler port (engine oil)
Drain plug (engine oil)
Engine oil cooler (4TNV98T , 4TNV106 and 4TNV106T)
Engine oil filter
Dipstick (engine oil)
Fuel injection pump
Governor lever
Fuel filter
Fuel cock
17.
Fuel filter mounting
19. Lifting eye
Engine name plate
21. Rocker arm cover
Flywheel
23. Starter motor
Exhaust manifold
Generator
NOTE: This illustration shows the 4TNV98T engine (with
The drain plug (engine oil) location depends the engine installed the machine unit the fuel injection pump side (above illustration) starter motor
TULI12EXN4782CA 1
47574277B 24/03/2014 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Static description
Emission reduction
New fuel injection pressure
• Mono plunger
• Higher injection pressure
• Injection speed timer , load timer , cold start timer control
Noise reduction
Higher stif fness cylinder block
Higher stif fness gear - case
Emission reduction
Injection nozzle
• Low suck volume
• Multi injection holes
Emission reduction
Cylinder head
• Optimal nozzle angle
• Optimal swirl ratio
• Optional valve timing
Emission reduction
Piston
• New combustion chamber
Noise reduction
New lube oil pan
• Change rotor shape for low pulsation
• Driven crankshaft directly
Emission reduction
Cylinder head
• 4 valve / cylinder (intake - exhaust -
• Optimal installation the injection nozzle vertical installation and location the centre cylinder
• Optimal valve timing
47574277B 24/03/2014 10.1 [10.001] /
TULI12EXN4783CB 1
Emission reduction
New fuel injection nozzle
• Low suck volume
• Multi injection holes
Emission reduction
New fuel injection pump
• Mono plunger
• Higher injection pressure
• Mechanical control injection timing, speed timer , load timer , cold start timer
Emission reduction
Piston
• New combustion chamber
Noise reduction (only applied for 4TNV84T)
New lube oil pan
• Change rotor shape for low pulsation
• Driven crankshaft directly
Engine - Engine and crankcase
47574277B 24/03/2014 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Service instruction
Periodic maintenance schedule
The engine periodic inspection timing hard determine varies with the load qualities the fuel and lubricating oils used and handling General rules are described here.
:
Maintenance period Classification Piece Daily Every h Every 250 h 3 months Every 500 h 6 months Inspection every 1000 h one year Every 2000 h two years Whole V isual
the machine Fuel
Fuel
W ater separator (Option)
Fuel system bleeding W ater separator cleaning Fuel system Fuel filter element replacement Lube oil level check and replenishment Lube oil replacement Lubricating oil system Lube oil filter replacement 1 s t time 2 n d time and after Coolant level check and replenishment Radiator fin cleaning V - belt tension check 1 s t time 2 n d time and after Coolant change Coolant pump Coolant / water path flushing and maintenance Rubber hose Fuel pipe and coolant pipe inspection and maintenance Injection governor Inspection and adjustment governor lever and accelerator 47574277B 24/03/2014 10.1 [10.001] /
: User - maintenance : Parts replacement
Shop - inspection
check around
tank level check and fuel supply
tank drain
draining
Air intake system
cleaner cleaning and element replacement
Diaphragm assy inspection
T urbocharger blower
W arning lamp and instruments function check Electrical system Battery electrolyte
level check and battery recharging
Intake / exhaust valve
Cylinder
head
head clearance adjustment
Intake / exhaust valve
seat lapping
Fuel injection nozzle pressure inspection
Fuel injection pump and nozzle
Fuel injection timing adjustment
Fuel injection pump
inspection and adjustment
*EP A allows servicing the emission related parts every 1500 - 3000 h
- Engine
Maintenance period tion Piece Daily Every h Every 250 h 3 months Every 500 h 6 months tion every 1000 h one year Every 2000 h two years
Engine
and crankcase
Air
years)
47574277B 24/03/2014 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Inspect - Daily Inspection
sure check the following points before starting engine every day:
No. Inspection item
V isual 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 governor lever and accelerator
W arning lamp and instruments function check
W ater separator draining
V isual check around the machine any problem not use before the engine pairs have been
• Oil leak from the lubrication system
• Fuel leak from the fuel system
• Coolant leak from the water cooling system
• Damaged parts
• Loosened lost screws
• radiator rubber cracked V - loosened clamp
Fuel tank level check and fuel supply
Check the remaining fuel oil level the fuel tank and refuel the recommended fuel necessary
47574277B 24/03/2014 10.1 [10.001] /
Lube oil level check and replenishment
(a) Checking oil level
Check the lubricating oil level with the dipstick (A) , after adjusting the position the machine that the engine
Insert the dipstick fully and check the oil The oil shall not contaminated heavily and have priate viscosity
coolant water diesel fuel shall
When lube oil supplied after the engine has been check the lube oil level after about min after the engine shutdown that the lube oil has filled the oil
The level shall between the upper (AU) and lower (AL) limit lines the dipstick (A)
Lube oil capacity may dif fer from the above volume pending engine installed a machine
(b) Replenishing oil pan with lube oil
the remaining engine oil level low , remove the filler port cap (B) and fill the oil pan with the specified engine oil the specified level through the filler port (C)
NOTE: The oil should not overfilled exceed the per limit Otherwise a naturally - aspirated engine may intake lube oil the combustion chamber during the operthen white oil hummer urgent rotation may occur , because the blow - gas reduced the suction air flow case turbocharged engine oil may jet out from the breather the engine may become faulty
Engine - Engine and crankcase
TULI12EXN4788BB 1
Model T otal volume Effective volume 3TNV82A 5.5 l ( 1.45 gal ) 1.9 l ( 0.50 gal ) 3TNV84(T) 6.7 l ( 1.77 gal ) 2.8 l ( 0.74 gal ) 4TNV84(T) l ( gal ) l ( gal ) 4TNV94L98(T) 10.5 l ( 2.77 gal ) 4.5 l ( 1.19 gal ) 4TNV106(T) (CL class) 14.0 l ( 3.70 gal ) 9.0 l ( 2.38 gal ) 4TNV106(T) (VM class) 14.0 l ( 3.70 gal ) 7.5 l ( 1.98 gal )
47574277B 24/03/2014 10.1 [10.001] /
Coolant check
Daily inspection coolant water should done only coolant recovery
NOTICE: Never open the radiator filler cap (R) while the engine and radiator are still Steam and hot water will spurt out and seriously burn W ait until the radiator cooled down after the engine has stopped, wrap the filler cap with a rag piece and turn the cap slowly gently lease the pressure inside the radiator
Securely tighten the filler port plug (R) after checking the diator Steam can spurt out during engine tightening loose.
(a) Checking coolant water volume
Check the coolant level the expansion tank (C) the water level close the LOW mark, open the coolant expansion tank plug (H) and replenish the tank with soft clean water the FULL
The level shall between the upper and lower limit lines the
(b) Replenishing radiator with water
the coolant recovery tank water level lower than the LOW open the radiator cap (R) and check the coolant water level the radiator
Replenish the radiator with the level low
• Check the coolant level while the engine Checking when the engine hot And the water volume expanded due the
• Daily coolant level check and replenishing shall done only from the expansion
Usually not open the radiator cap check
T T ighten Loosen
NOTICE: the coolant water runs short quickly when the radiator runs short water with the coolant expansion tank level water may leaking the air tightness may lost. Increase the coolant expansion tank ter level during operation not The increased water the coolant expansion tank returns the radiator when the engine cooled the water level normal the coolant expansion tank but low the radiator , check loosened clamping the rubber hose between the radiator and coolant recovery tank tear the
Engine: The radiator shall filled
Engine - Engine and crankcase
TULI12EXN4789AB 2
Model Coolant water volume engine 3TNV82A 1.8 l ( 0.48 gal ) 3TNV84(T) 3TNV88 l ( gal ) 4TNV84(T) 4TNV88 2.7 l ( 0.71 gal ) 4TNV94L 4TNV98(T) 4.2 l ( 1.1 1 gal ) 4TNV106(T) 6.0 l ( 1.59 gal ) 47574277B 24/03/2014 10.1 [10.001] /
Engine coolant water capacity may dif fer from the above volume depending engine installed a machine
Fuel pipe and coolant pipe inspection and maintenance
Check the rubber hoses for fuel and coolant water pipes
the cracked hose replace with new Check the loosened tighten
Inspection and adjustment governor lever and accelerator
Make sure the accelerator the machine unit can ated smoothly before starting the feels heavy lubricate the accelerator cable joints and ots. Adjust the accelerator cable there a dislocation excessive play between the accelerator and the governor lever Refer Engine - Inspect – Every 250 hours 3 months
W arning lamp and instruments function check
Before and after starting the check see that the alarm function normally Failure alarm cannot warn the lack the engine oil the coolant water Make a rule check the alarm operation before and after starting gine every day . Refer each manual for machine units
W ater separator draining
Drain f the water separator (W) whenever there a lot drain collected the water separator the bottom the cup (C) even the time for periodic inspection has not elapsed The cup the water separator (C) made semi - transparent material and, the cup itself, the red colored floating ring (FR) which rises the surface the drain installed visualize the amount A level sensor connected a warning device the gauge cluster provided optional
Drain f the water separator the following manner: Prepare a waste oil container collecting waste oil.
Close the fuel cock (FC)
Loosen the drain cock (DC) the bottom the water separator , and drain f any water collected
T ighten the drain cock (DC) manually
Air bleeding from fuel
NOTE: drain drips when the drain cock loosen the air bleeding bolt (A) the top the water arator turning counterclockwise 2 - 3 times using driver . (This may occur case the water separator sition higher than the fuel oil level the fuel
After sure tighten the air bleeding bolt (A)
Engine - Engine and crankcase
TULI12EXN4795AB 3 47574277B 24/03/2014 10.1 [10.001] /
Engine - Engine and crankcase
necessary , adjust the V - belt tension
T o adjust the V - belt loosen the setscrew (S) and move the alternator (A) tighten the Vbelt.
(Adjust the V - belt tension inserting a bar
After replacing with a new V - belt and adjusting run the engine for 5 min and readjust the deflection the value the table
After replacing with a new V - belt and adjusting it, run the engine for 5 min and readjust the deflection the value the table
V isually check the V - belt for oiliness wear any , replace the V - belt with new
Direction A B C For used V - belt - ( 0.390.55 ) 7 - ( 0.280.39 ) 9 - ( 0.350.51 ) For new V - belt 8 - ( - ) 5 - 8 ( - ) 7 - 1 1 ( - )
TULI12EXN4793AB 7 47574277B 24/03/2014 10.1 [10.001] /
Engine - Inspect – Every hours
sure check the following points before starting engine every day .
No.
Fuel tank drain
Fuel system bleeding
Inspection item
Battery electrolyte level check and battery recharging
Fuel tank drain
Prepare a waste oil container collecting waste
Remove the drain plug (D) the fuel tank (F) drain (water , from the fuel tank
Drain until fuel with water and dust flow
Then tighten the drain plug firmly
Fuel system bleeding
Bleed the fuel system according the following
When there air the fuel the fuel jection pump (FI) will not able
Check the fuel oil level the fuel Refuel insuf
Open the cock (FC) the water separator (W)
Loosen the air bleeding bolt (A) the water rator turning counterclockwise 2 - 3 times using a screwdriver a spanner .
When the fuel coming out clear and not mixed with any tighten the air bleeding bolt (A)
Feed fuel with the fuel priming pump (FP) tro - magnetic fuel feed
• case the engine uses the electro - magnetic fuel feed
T urn the starter switch the “ON” position and hold the position for - s operate the fuel feed
• case the engine uses the electro - magnetic fuel feed pump (FP)
The priming pump the top the fuel filter
Move the priming pump and down feed fuel until feel your hand slightly heavy .
• W ater separator (W)
(Installed the pipe line)
• Fuel filter (FF)
(Mounting with fuel priming pump) (option)
Engine - Engine and crankcase
TULI12EXN4794AB 1
TULI12EXN4796BB 2 47574277B 24/03/2014 10.1 [10.001] /
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Battery electrolyte level check and battery recharging
W ARNING
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result severe irritation and Always wear splash - proof goggles and protective clothing (gloves and W ash hands after handling.
Failure comply could result death serious injury
W ARNING
Battery acid causes burns. Batteries contain sulfuric acid.
A void contact with eyes Antidote (external): Flush with water Antidote (eyes): flush with water for minutes and seek medical attention immediately . Antidote (internal): Drink large quantities water milk. not induce vomiting. Seek medical attention immediately .
Failure comply could result death serious injury
NOTICE: Make sure turn off the battery switch disconnect the negative cable ( before inspecting the electrical Failure could cause short - circuiting and Always disconnect the ( Negative battery cable first before disconnecting the battery cables from battery dental - may cause fire and personal injury
And remember connect the ( Negative battery cable (back onto the battery) LAST
NOTICE: Keep the area around the battery well paying attention keep away any fire During operation hydrogen gas generated from the battery and can easily
Engine - Engine and crankcase
W0006A
W01 1
Battery structure Anode plate BC. Battery case Cap Cover Cathode plate Glass mat Separator T T erminal TULI12EXN4797AB 3 47574277B 24/03/2014 10.1 [10.001] /
Electrolyte level
• Check the electrolyte level (EL) the battery When the amount fluid nears the lower limit (LL) , fill with battery fluid (available the market) the upper limit (UL) operation continues with insuf ficient battery the battery life and the battery may overheat and
• Battery fluid tends evaporate more quickly the summer , and the fluid level should checked lier than the specified
• the engine cranking speed slow that the gine does not start recharge the battery
• the engine still will not start after replace the battery
• Remove the battery from the battery mounting the machine unit after daily use letting the machine unit leave the place that the ambient temperature could drop ( ) And store the battery a warm place until the next use the unit start the engine easily low ambient
Battery charge
Use a battery tester hydrometer and check the battery the battery recharge
Measurement with a battery tester (BT)
When checking the battery with the batter tester , connect the red clip the tester the battery positive (+) terminal and black clip the battery negative ( terminal ing them securely , and judge the battery charge level from the indicator position.
Green zone: Normal
Y ellow zone: Slightly discharged
Red zone: Defective much discharged
Measurement with hydrometer
When using a hydrometer , the measured specific gravity must corrected according the temperature the time
- Engine and crankcase
Engine
TULI12EXN4798AB 4
TULI12EXN4799AB 5
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Engine - Engine and crankcase
The specific gravity battery electrolyte defined with ( ) the
Since the specific gravity increases decreases when the temperature varies 1 ( ) correct the value according the equation below
S20 = St + 0.007(t - 20)
t = Electrolyte temperature measurement
= Specific gravity measurement S20 = Converted specific gravity ( )
T erminals
Clean corroded
Mounting bracket
Repair replace
Retighten
Battery appearance
Replace the battery cracked
Clean with fresh water
TULI12EXN4800AA 6
Specific gravity and
Specific gravity ( ( ) ) Discharged quantity electricity Remaining charge 100% 10% 90% 20% 80% 25% 75% Float Glass tube (RB). Rubber bulb TULI12EXN4801AB 7
remaining battery charge
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Engine - Inspect – Every 250 hours 3 months
sure check the following points every 250 h 3 months operation, whichever comes first.
No. Inspection item
Lube oil and filter replacement
Radiator fin cleaning
V - belt tension check
Inspection and adjustment governor lever and accelerator
Air cleaner cleaning and element replacement
W ater separator cleaning
Lube oil and filter replacement (The second replacement and after)
Replace the engine oil every 250 h operation from 2 n d time and Replace the engine oil filter the same
Radiator fin cleaning
NOTICE: Beware dirt from air
W ear protective equipment such goggles protect your eyes when blowing compressed air Dust flying debris can hurt eyes.
Dirt and dust “DD” adhering the radiator fins (RF) reduce the cooling causing Make a rule check the radiator fins daily and clean
• Blow f dirt and dust from fins and periphery with compressed air ( 0.19 MPa ( psi ) less order not damage the fins).
• contaminated heavily , apply thoroughly clean and rinse with tap water shower
NOTICE: Never use high pressure water air from close fins never attempt clean using a wire Radiator fins (RF) can
V - belt tension check (The second time and after)
Check and adjust the V - belt tension.
Engine - Engine and crankcase
TULI12EXN4803AB 1
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Inspection and adjustment governor lever and accelerator
The governor lever (GL) and accelerating devices erating lever , the machine unit are nected accelerating wire rod. the wire becomes stretched the connections the deviation the position may result and make operation Check the wire periodically and adjust necessary not strongly move the accelerating wire accelerating pedal. may deform the governor lever stretch the wire cause irregular engine speed
Checking and adjusting procedure are follows:
• Check that the governor lever (GL) the engine makes uniform contact with the high idling (H) and low idling (LI) limiting screws when the ing devices are the high idling speed low idling speed
• either the high the low idling speed side does not make contact with the limiting screw , adjust the accelerating Loosen the accelerating wire fastening screw (AF) and just the wire contact with the limiting screw
NOTICE: Never loosen the limiting will impair the safety and performance the product and functions and result shorter engine
Air cleaner cleaning and element replacement
NOTICE: Beware dirt from air W ear protective equipment such goggles protect your eyes when blowing compressed air Dust flying debris can hurt
The engine performance adversely fected when the air cleaner element (E) clogged periodical cleaning after disassembly
• Undo the clamps (L) the dust pan (DP) and move the dust
• Loosen the wing nut the element and pull out the element (E)
Engine - Engine and crankcase
TULI12EXN4804BB 2
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• Blow air ( 0.290.49 MPa ( - psi ) ) from inside the element blow dust f shown the figure the Apply the air blowing pressure low possible not damage the element (OE) having the air cleaner with double never remove and clean the inner element (IE) . The purpose installing the inner element (IE) tecting the engine from the penetration dust during gine operation when leaving the outer element (OE) nonreinstalled after removing when damaging the outer element unexpectedly during engine operation.
• Replace the element with a new one, the element excessively dirty oily
• Remove the inside dust cover the dust pan (DP) , and clean the inside the dust
• Reinstall the element (OE) with a new wing screw (do not drop the Reattach the inside dust cover the dust pan (DP) and install the dust pan the air cleaner case (AC) directing the T mark (AM)
NOTICE: When the engine operated dusty clean the element more frequently not run the engine with removed air cleaner this may cause foreign material enter and damage the
Engine - Engine and crankcase
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