6. SAFETY
0-III5-15200 NA Issued 06-2008 Bur
GENERAL SAFETY INFORMATION
1. Most accidents, which occur during operation,
are due to neglect of precautionary measures
and safety rules. Sufficient care should be taken
to avoid these accidents. Erroneous operation,
lubrication or maintenance services are very
dangerous and may cause injury or death of
personnel. Therefore all precautionar y
measures, NOTES, DANGERS, WARNINGS
and CAUTIONS contained in the manual and on
the machine should be read and understood by
all personnel before starting any work with or on
the machine.
2. Operation, inspection, and maintenance should
be carefully carried out, and safety must be given
the first priority. Messages of safety are indicated
with marks. The safety information contained in
the manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
3. Messages of safety appear in the manual and on
the machine : All messages of safety are
identified by either word of DANGER, WARNING
and CAUTION.
DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury and is represented as follows:
WARNING- Indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used to
alert against possible damage to the machine
and its components and is represented as
follows:
4. It is very difficult to forecast every danger that
may occur during operation. However, safety can
be ensured by fully understanding proper
operating procedures for this machine according
to methods recommended by Manufacturer.
5. While operating the machine, be sure to perform
work with great care, so as not to damage the
machine, or allow accidents to occur.
6. Continue studying the manual until all Safety,
Operation and Maintenance procedures are
completely understood by all persons working
with the machine.
WARNING
Do not operate or perform any maintenance on this
machine until all instructions found in the
OPERATOR’S MANUAL and this MANUAL have been
thoroughly read and understood.
Improper operation or maintenance of this machine
may cause accidents and could result in serious
injury or death.
Always keep the manual in storage.
If it is missing or damaged, place an order with an
authorized our Distributor for a replacement.
If you have any questions, please consult an
authorized our Distributor.
DANGER
WARNING
CAUTION
7. 0-IV Issued 06-2008 Bur 5-15200 NA
SAFETY PRECAUTIONS
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service
work. A 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 compo-
nents, the serviceman or mechanic should check the
weights noted in this manual. Use proper lifting proce-
dures when removing any components. Weight of
components table is shown in the section ; SPECIFI-
CATIONS.
The following is a list of basic precautions that must
always be observed.
1. Read and understand all Warning plates and
decal 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 jewelry,
confine long hair and loose clothing before
working on this machinery.
3. Disconnect the battery and hang a Do Not
Operate tag in the Operators Compartment.
Remove ignition keys.
4. If possible, make all repairs with the machine
parked on a firm level surface. Block the machine
so it does not roll while working on or under the
machine. Hang a Do Not Operate tag in the
Operators Compartment.
5. Do not work on any machine that is supported
only by lift, jacks or a hoist. Always use blocks or
jack stands, capable of supporting the machine,
before performing any disassembly.
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 that utilizes pressure.
7. 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, dozer, ripper or other attachment is
blocked correctly to prevent it from dropping
unexpectedly.
8. Use steps and grab handles when mounting or
dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
using. Always face to 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.
9. To avoid back injury, use a hoist when lifting
components which weigh 20kg (45lbs) 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 on
machines which have just been stopped and hot
fluids in lines, tubes and compartments.
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 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. The danger is even
greater if the machine has just been stopped
because fluids can be hot.
WARNING
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.
WARNING
Do not operate this machine unless you have read
and understand the instructions in the OPERATOR’S
MANUAL. Improper machine operation is dangerous
and could result in injury or death.
8. SAFETY
0-V5-15200 NA Issued 06-2008 Bur
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. Install all fasteners with the same part number.
Do not use a lesser quality fastener if
replacements are necessary.
15. Repairs which require welding should be
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in
welding procedures. Determine type of metal
being welded and select correct welding
procedure and electrodes, rods or wire to provide
a weld metal strength equivalent at least to that
of the parent metal. Make sure to disconnect
battery before any welding procedures are
attempted.
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 completed.
18. The maintenance and repair work while holding
the bucket raised is dangerous due to the
possibility of a falling attachment. Don’t fail to
lower the attachment and place the bucket to the
ground before starting the work.
19. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. 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 stream 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 heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration 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 (crawlers). Chips can fly when removing
or installing a track (crawlers) pin. Wear safety
glasses and long sleeve protective clothing.
Tracks (crawlers) 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.
9. 5-1
DISASSEMBLY OF BASIC ENGINE
1. Disassembling and inspecting cylinder
head and valve mechanism ............5-2
1.1 Removing injector .................................... 5-3
1.2 Removing rocker shaft assembly............. 5-4
1.3 Disassembling rocker shaft assembly...... 5-4
1.4 Removing cylinder head bolt.................... 5-4
1.5 Removing cylinder head assembly .......... 5-5
1.6 Removing valve and valve spring ............ 5-5
1.7 Removing valve stem seal....................... 5-5
2. Disassembling and inspecting
flywheel ...........................................5-6
2.1 Removing flywheel................................... 5-7
2.2 Removing flywheel housing ..................... 5-7
3. Disassembling and inspecting gear
case, timing gear and camshaft ......5-8
3.1 Removing crankshaft pulley..................... 5-8
3.2 Removing timing gear case ..................... 5-9
3.3 Measuring timing gear backlash .............. 5-9
3.4 Measuring idler gear end play.................. 5-9
3.5 Removing idler gear............................... 5-10
3.6 Removing camshaft ............................... 5-10
3.7 Separating camshaft gear...................... 5-10
3.8 Installing camshaft gear and thrust plate5-11
3.9 Removing front plate.............................. 5-11
4. Disassembling and inspection
crankcase, crankshaft and piston..5-12
4.1 Removing connecting rod cap ............... 5-13
4.2 Removing carbon deposits from the upper part
of cylinder liner....................................... 5-13
4.3 Pulling out piston.................................... 5-13
4.4 Removing piston ring ............................. 5-14
4.5 Removing piston pin .............................. 5-14
4.6 Removing main bearing cap .................. 5-14
4.7 Removing crankshaft ............................. 5-15
10. DISASSEMBLY OF BASIC ENGINE
5-2
1. Disassembling and inspecting cylinder head and valve mechanism
Disassembling and inspecting cylinder head and valve mechanism
Disassembling sequence
1 Leak off hose 9 Eye bolt, oil pipe 17 Valve cap
2 Nozzle ground 10 Snap ring, spacer 18 Valve cotter
3 Injector 11 Rocker arm 19 Valve retainer
4 Rocker cover 12 Rocker shaft spring 20 Valve spring
5 Rocker cover gasket 13 Rocker shaft 21 Valve, valve seat
6 Adjusting screw 14 Cylinder head bolt 22 Valve guide, stem seal
7 Bolt (short) 15 Cylinder head 23 Push rod
8 Bolt (long) 16 Cylinder head gasket
13
14
1810
11
15
16
17
8
5
7
6
12
9
2
3
1
4
19
20
21
21
22
23
Replace
Replace
Wear, clogging
Fatigue, damage
Wear, damage,
bend
Local wear, damage,
fatigue, carbon depositLocal wear
Crack, damage,
water leak, oil leak,
carbon deposit,
scale deposit
Local wear
Fatigue, damage
Wear,
clogging
Wear, damage
Wear
11. DISASSEMBLY OF BASIC ENGINE
5-3
1.1 Removing injector
(1) Hold the injection connector by using a spanner, loosen
the injection pipe nut and remove the injection pipe.
(2) With pushing the pin on top of the injector, remove the
leak off hose.
(3) Disconnect the harness connector of main harness and
injector connector.
(4) Using the injector puller, remove the injector and the
nozzle ground at the same time.
(5) Remove the gasket from the cylinder head injector
insertion opening.
Removing injector
Pushing pin on top of injector
Pulling out injector
Injector
Nozzle
gland
Gasket
Injection pipe
Leak off hose
Injection connector
Pin
Leak off hose connector
Pin
Push
Injector
Injector puller
P/N:32G91-00100
Injector
12. DISASSEMBLY OF BASIC ENGINE
5-4
1.2 Removing rocker shaft assembly
Always loosen shorter bolts first. Failing to do so may
cause the damage to the rocker shaft bracket.
(1) Loosen the rocker arm adjusting screws by rotating
about one turn.
(2) Loosen the shorter rocker bracket bolts first.
(3) Then, loosen the longer rocker bracket bolts.
(4) Remove the rokcer bracket bolts, and remove the
rocker shaft assembly from the cylinder head.
(5) Remove push rods. Removing rocker shaft assembly
1.3 Disassembling rocker shaft assembly
(1) Remove eye bolt, oil pipe, and snap ring.
(2) Disassemble the rocker shaft assembly into the rocker
arms, brakets, rocker shaft springs and rocker shaft.
Note: (a) Be sure to arrange the parts of rocker shaft
assembly in the order of disassembly.
Reassemble the rocker shaft assembly in the
reverse order of disassembly by making sure of
the original combination of rocker arm and shaft
assembly so that the same clearance between the
rocker shaft and arms is restored when
reassembling.
(b) Do not remove the rocker bush when it is not
faulty, and its inside diameter is not exceed the
limit.
Disassembling rocker shaft assembly
1.4 Removing cylinder head bolt
Loosen cylinder head bolts in the numerical order as shown
in the illustration.
Removing cylinder head bolt
Adjusting screw
Rocker arm
Rocker bracket bolt
Rocker shaft
Rocker shaft spring
Bracket
Rocker arm
Oil pipe
Eye bolt
Snap ring
1212 4
5 1313
1616 8
9 1717
1515111173
6
1010
1414
12 4
5 13
16 8
1 9 17
151173
22
6
10
14
1
13. DISASSEMBLY OF BASIC ENGINE
5-5
1.5 Removing cylinder head assembly
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase surface
by tools such as a screwdriver.
(1) Remove the cylinder head bolt.
(2) Remove the cylinder head assembly by lifting it up.
Note: If the cylinder head assembly cannot be removed due
to crimping of the cylinder head gasket, tap the thick
area on the side of the cylinder head using a plastic
hammer to give a shock.
(3) Remove the gasket from the cylinder head.
Note: If there is a cylinder head problem, check the bolts for
tightness with a torque wrench before removing the
cylinder head bolts.
Removing cylinder head assembly
1.6 Removing valve and valve spring
Using a valve spring pusher, compress the valve spring
evenly and remove the valve cotters.
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original
positions. Do not mix valve seats with other valve
guides.
Removing valve and valve spring
1.7 Removing valve stem seal
Grab the stem seal with pliers and remove.
Note: Be sure to replace the stem seal with the new one
when reassembling the valve and valve spring.
Removing valve stem seal
Valve spring pusher
P/N:30691-04500
Stem seal
14. DISASSEMBLY OF BASIC ENGINE
5-6
2. Disassembling and inspecting flywheel
Disassembling and inspecting flywheel
Disassembling sequence
1 Flywheel 3 Oil seal 5 Speed/timing sensor (crankshaft
side), sensor bracket
2 Flywheel housing 4 Pick up
2
3
1
4
5
Replace
Replace
Wear, damage, aging
Wear, crack, damage
15. DISASSEMBLY OF BASIC ENGINE
5-7
2.1 Removing flywheel
(a) Be careful not to cut yourself with the ring gear
when pulling out the flywheel.
Be careful not to drop or hit the flywheel when
removing.
(b) The personnel who holds the pulley must pay due
attention to safety.
Also, personnel must stay in close contact with
each other during work.
(1) One personnel must firmly hold the pulley with a
wrench to prevent the flywheel from turning.
(2) Remove one bolt from the flywheel.
(3) Screw a guide bolt into the threaded hole of the bolt that
has been removed.
(4) Remove remaining bolts from the flywheel.
(5) Hold the flywheel firmly with both hands, and by
moving it back and forth, pull it out straight.
Note: The ring gear is shrink fitted to the flywheel. Do not
remove the ring gear unless it is defective.
Removing flywheel
2.2 Removing flywheel housing
Be careful not to damage the oil seal.
(1) Remove bolts from the flywheel housing.
(2) Remove the flywheel housing.
Removing flywheel housing
(Front) (Rear)
Crankshaft pulley
Guide bolt
16. DISASSEMBLY OF BASIC ENGINE
5-8
3. Disassembling and inspecting gear case, timing gear and camshaft
Disassembling and inspecting gear case, timing gear and camshaft
Disassembling sequence
3.1 Removing crankshaft pulley
The bar that stops the the crankshaft from turning may
come off. Pay due attention to safety.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Stick a bar across the guide bolts
to prevent the crankshaft from turning.
(2) Remove the crankshaft pulley.
(3) Take out the woodruff key of the crankshaft.
Removing crankshaft pulley
10
4
5 8
1
2
6
7
3
11
9
Replace
Replace
Wear
Wear
Wear
Flaking, contact, damage,
abnormality
Crack, dowel hole defect,
oil hole clogging
Oil hole clogging, wear
Wear, damage,
aging
Damage, wear
1 Crankshaft pulley 5 Idler gear 9 Tappet
2 Timing gear case 6 Thrust plate 10 Fuel pump gear,
Fuel pump idler gear
3 Oil seal 7 Camshaft
4 Thrust plate 8 Camshaft gear 11 Front plate
(Front) (Rear)
Guide bolt (M12×1.25mm)
Prevent crankshaft
from rotating
Crankshaft pulley
17. DISASSEMBLY OF BASIC ENGINE
5-9
3.2 Removing timing gear case
The front plate is bolted to the crankcase from inside
the gear case. Do not attempt to remove the front plate
together with the gear case by tapping.
(1) Remove bolts from the timing gear case.
(2) Remove the timing gear case.
Note: Bolts have different lengths. Pay attention to the
positions of bolts to ensure correct reassembling.
Removing timing gear case
3.3 Measuring timing gear backlash
Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the
dial gauge plunger applied to a tooth flank on the pitch
circle at a right angle to the tooth axis, or measure the
clearance between gears by inserting a feeler gauge between
the gears at the tooth-to-tooth contacting area. Replace the
faulty gear pair if the limit is exceeded.
Note: With the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump, install
the both gears to the front plate.
Measuring timing gear backlash
3.4 Measuring idler gear end play
Using a feeler gauge or dial gauge, measure the end play of
idler gear.
If the measured value exceeds the limit, replace the idler
gear with the new gear.
Measuring idler gear end play
Gasket
Timing gear case
Item Standard Limit
Backlash crankshaft gear and
idler gear
0.053 to 0.154 mm
[0.0021 to 0.0061 in.]
0.25 mm
[0.0098 in.]
Backlash camshaft gear and
idler gear
0.049 to 0.160 mm
[0.0019 to 0.0063 in.]
0.25 mm
[0.0098 in.]
Backlash Fuel injection pump
idler gear and idler gear
0.050 to 0.228 mm
[0.0020 to 0.0090 in.]
0.25 mm
[0.0098 in.]
Backlash fuel injection pump
idler gear and fuel injection
pump gear
0.044 to 0.163 mm
[0.0017 to 0.0064 in.]
0.25 mm
[0.0098 in.]
Item Standard Limit
End play
0.05 to 0.20 mm
[0.0020 to 0.0079 in.]
0.35 mm
[0.0138 in.]
Idler gear
18. DISASSEMBLY OF BASIC ENGINE
5-10
3.5 Removing idler gear
(1) Remove the thrust plate bolt.
(2) Remove the idler gear while turning the gear.
Removing idler gear
3.6 Removing camshaft
Be careful not to damage the cams of camshaft and
the bushings.
(1) Reverse the crankcase.
(2) Remove the thrust plate bolt.
(3) Remove the camshaft from the crankcase.
(4) Remove the tappet.
Removing camshaft
3.7 Separating camshaft gear
Using a puller, remove the camshaft gear and thrust plate
from the camshaft.
Note: Do not remove the camshaft gear from the camshaft
unless the camshaft gear or the thrust plate is
defective.
Separating camshaft gear
Idler gear
Thrust plate
Camshaft gear
Camshaft gear
Puller
P/N: 64309-12900
19. DISASSEMBLY OF BASIC ENGINE
5-11
3.8 Installing camshaft gear and thrust plate
(1) Install the woodruff key and the thrust plate on the
crankshaft.
Note: Be sure to install the thrust plate before installing the
camshaft gear.
(2) Heat the camshaft gear with a gear heater to a
temperature of about 250°C [482°F].
(3) Install the camshaft gear into the crankcase by tapping
with a plastic hammer.
Installing camshaft gear and thrust plate
3.9 Removing front plate
(1) Remove the front plate bolts.
(2) Remove the front plate from the crankcase.
Note: If it is difficult to remove the front plate, lightly tap it
with a plastic hammer.
Removing front plate
Thrust plate
Camshaft gear
Front plate
20. DISASSEMBLY OF BASIC ENGINE
5-12
4. Disassembling and inspection crankcase, crankshaft and piston
Disassembling and inspection crankcase, crankshaft and piston
Disassembling sequence
1 Nut 8 Piston pin 15 Main bearing (lower)
2 Connecting rod cap 9 Piston 16 Crankshaft
3 Connecting rod bearing 10 Connecting rod 17 Main bearing (upper)
4 No.1 compression ring 11 Main bearing cap bolt 18 Piston cooling nozzle
5 No.2 compression ring 12 Main bearing cap 19 Crankcase
6 Oil ring 13 Side seal
7 Snap ring 14 Thrust plate
18
19
16
12 13
11
17
15
14
10
4
5
6
8
7
3
2
1
9
Wear, damage
Wear, seizure,
flaking, damage
Wear
Crack
Fatigue
Scratch, crack, damage,
wear, carbon deposit
Scratch, crack, dent,
oil hole clogging, wear
Wear, scratch, rust
Wear, crack,
oil hole clogging
Wear, oil hole
clogging
Flaking,
local contact
Scratch, seizure,
flaking
Top surface distortion
Damage
Damage
Clogging
Replace
Scale deposit,
corrosion, flaking
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22. DISASSEMBLY OF BASIC ENGINE
5-13
4.1 Removing connecting rod cap
(1) Lay the engine by its side.
(2) Mark the cylinder number on the connecting rod and
connecting rod cap so that their combination is not
changed when reassembling.
(3) Remove the connecting rod caps.
Note: Mark the cylinder No. and upper/lower on connecting
rod bearings to ensure correct reassembling.
Removing connecting rod cap
4.2 Removing carbon deposits from the upper
part of cylinder liner
Be sure to remove carbon deposits from the upper part
of the cylinder liner before removing the piston, as they
could cause damage to the piston and piston ring.
Remove carbon deposits from the upper part of cylinder
liner using a cloth or oil paper.
Note: Be careful not to damage the inner surface of the
cylinder liner.
Removing carbon deposit from cylinder sleeve upper
area
4.3 Pulling out piston
(1) Turn the crankshaft to bring the piston to the top dead
center.
(2) Using a piece of wood such a hammer handle, push the
mating surface of the connecting rod cap, and pull the
piston and connecting rod upward from the cylinder.
Pulling out piston
Connecting rod cap
23. DISASSEMBLY OF BASIC ENGINE
5-14
4.4 Removing piston ring
Remove the piston rings using piston ring pliers.
Removing piston ring
4.5 Removing piston pin
(1) Using snap ring pliers, remove the snap ring.
(2) Remove the piston pin, and separate the piston from the
connecting rod.
Note: Heat the piston with a piston heater or in hot water if
the piston pin is stubborn.
Removing piston pin
4.6 Removing main bearing cap
(1) Reverse the engine.
(2) Remove the main bearing cap bolt.
(3) Remove the main bearing cap together with the lower
main bearing.
Use a sliding hammer to remove main bearing caps on
the front and rear ends.
Note: (a) Be careful not to damage main bearings.
(b) Mark each main bearing for its cylinder number.
Removing main bearing cap
Piston ring pliers
P/N:30091-07100
Snap ring pliers
Sliding hammer
Main bearing
cap bolt
24. DISASSEMBLY OF BASIC ENGINE
5-15
4.7 Removing crankshaft
Be careful not to damage bearings when removing the
crankshaft.
(1) Slowly lift the crankshaft straight up.
(2) Arrange the bearings in the order of disassembly so that
their original positions are restored when reassembling.
Note: (a) When raising the crankshaft, do not allow wire
chain to come into contact with the crankshaft.
To avoid damage to the crankshaft when raising,
use a cloth belt or pad.
(b) Mark the bearings for their cylinder numbers.
Removing crankshaft
