Be sure to follow the general precautions given be- low when performing removal or installation (disas- sembly or assembly) of units.
1. Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of ade- quate size to catch the oil.
• Confirm the match marks showing the installa- tion position, and make match marks in the nec- essary places before removal to prevent any mistake when assembling.
• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wiring, hold onto the connectors when dis- connecting them.
• Fasten tags to wires and hoses to identify and show their installation position and help prevent any mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
• When using forcing screws to remove any com- ponents, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering after removal.
★ Precautions when handling piping during disas- sembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
Nominal number Part Number Dimensions
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
Precautions when performing operation DISASSEMBLY AND ASSEMBLY
2. Precautions when carrying out installation work
• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interfer- ence.
• Replace all gaskets, O-rings, cotter pins and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uni- formly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs or rust.
• Coat rotating parts and sliding parts with en- gine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After installing snap rings, check that the snap ring is installed securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt or water then connect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them in fully and align in the direction of the hook.
• When tightening split flanges, tighten uni- formly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for re- pair, bleed the air as follows:
1. Start the engine and run it at low idle.
2. Operate the work equipment control lever to op- erate the hydraulic cylinders, 4 - 5 times, stop- ping the cylinders 100 mm from the end of their stroke.
3. Next operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same proce- dure.
3. Precautions when completing the operations
• If the engine coolant water has been drained, tighten the drain valve and add coolant water to the specified level. Run the engine to circulate the coolant water through the system. Then check the coolant water level again.
• If the hydraulic equipment has been re- moved and installed again, add hydraulic oil to the specified level. Run the engine to cir- culate the oil through the system. Then check the hydraulic oil level again.
• If the piping or hydraulic equipment, have been removed for repair, bleed the air from the system after reassembling the parts.
• For details, see TESTING AND ADJUST- ING, Bleeding air.Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel supply pump assembly
Removal and installation of fuel supply pump assembly
Removal
Disconnect the cable from the negative (-) termi- nal of the battery.
1. Close fuel stop valve (1) under the fuel tank.
2. Open the engine hood.
3. Disconnect clamp (3) of fuel hose (2) from brack- et (4).
★ When loosening the bolt, fix the nut with wrench so that the hose will not be twisted.
(If the hose is dragged and twisted, an ex- cessive force is applied to the connector and the inside of the connector may be broken.) 4. Remove clamp bracket (4).
5. Disconnect fuel return hose connector (5) con- nected to the supply pump. [*1]
★ When removing a connector of quick coupler type, observe the following points.
• Remove mud from each hose joint in ad- vance (since the lock may be stuck in the mud).
• Never use pliers or a screwdriver to dis- connect the connector.
• Pull out lock (L) of each hose joint straight (in direction [a]) while pressing it from both sides.
(If the connector is disconnected forcibly by twisting or bending it to the right and left, its inside may be broken.)
• Put plugs in the adapters of the discon- nected hoses to prevent fuel from flow- ing out.
(Do not use wooden plugs since chips may enter the fuel line.)
6. Disconnect fuel return hose (6).
7. Disconnect hose (7) connected to the fuel filter.
★ Before disconnecting hose (7), be sure to perform steps 3 to 5.
8. Disconnect wiring connector (8).
9. Disconnect hose (9) connected to the prefilter.
[*2]
10. Disconnect hose (10) connected to the fuel filter.
1
Removal and installation of fuel supply pump assembly DISASSEMBLY AND ASSEMBLY
11. Remove 2 high-pressure pipe bellows (11) from common rail (12) and fuel supply pump (13). [*3]
12. Disconnect 2 high-pressure pipe clamps (14) be- tween the common rail (12) and fuel supply pump (13). [*4]
★ Since each clamps are divided two, take care not to drop them in the end cover when removing.
13. Disconnect high-pressure pipe (15) from fuel supply pump (13). [*5]
★ Loosen the sleeve nut on the common rail side in advance.
14. Remove the 3 fuel supply pump mounting nuts and fuel supply pump assembly (7). (Locations of nuts: [A]) [*6]
Installation
• Carry out installation in the reverse order to re- moval.
[*1]
When installing a connector of quick coupler type, observe the following points.
★ Replace the connector with new one in the following cases.
1] The connector was removed with pliers or a screwdriver or by bending it to the right and left.
2] There is damage or deformation in the
★ Check that mud or dirt is not sticking to the hose adapter in advance.
★ Press and insert the connector straight (in di- rection [b]) without bending it to the right or left.
(If it is difficult to insert the connector, do not push it in forcibly but pull it out. Then, check the convex and concave parts for abnormali- ty and mud.)
[*2]
Joint bolt
19.6 - 29.4 Nm (2.0 - 3.0 kgm) [*3]
★ Install each bellows with the slits out and down.
★ The bellows are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason.
[*4]
Clamp mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*5]
★ Temporarily tighten the high-pressure pipe sleeve nuts on the common rail side and fuel supply pump side and then tighten them to the specified torque in the order of the pump side and common rail side.
Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.36 kgm}
[*6]
If too much grease is applied to an O-ring at as- sembly, it will ooze out during operation.
Accordingly, do not apply grease too much. (Ap-
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel supply pump assembly
When the supply pump mounting stud bolts of the gear housing were removed, apply adhesive to thier root side and mount them.
Stud bolt: Adhesive (LT-2) Stud bolt:
12 ± 2 Nm {1.22 ± 0.2 kgm}
Fuel supply pump mounting nut 24 ± 4 Nm {2.45 ± 0.41 kgm}
Removal and installation of fuel injector assembly DISASSEMBLY AND ASSEMBLY
Removal and installation of fuel injector assembly
Special tools
Removal
Disconnect the cable from the negative (-) termi- nal of the battery.
1. Close fuel stop valve (1) under the fuel tank.
2. Remove blow-by duct (2) mounting bolts and dis- connect blow-by duct (2). [*1]
3. Remove cylinder head cover mounting bolts (3) and remove cylinder head cover (4). [*2]
4. Referring to Testing and adjusting, "Adjusting valve clearance", set the No. 1 and 4 cylinders to the top dead center.
6. Disconnect bracket (6).
7. Remove high-pressure pipe bellows (7) from the cylinder head and common rail. [*3]
8. Remove high-pressure pipe (8). [*4]
9. Remove retaining nut (9) and then remove inlet connector (10) .
★ Tool A3 is prepared for remove the inlet con- nector (10).
★ Check that the inlet connector is free from flaw and dirt.
10. Disconnect wiring (11).
★ Since different cylinders have different wiring
Symbol Part No. Part name
Necessity Q'ty New/Remodel Sketch
A
1 795-799-6700 Puller 1
2 795-799-1131 Gear 1
3 795-799-8150 Remover 1
1
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly
11. Loosen locknut (12) and then loosen adjustment screw (13) thoroughly.
12. Remove rocker arm (14).
13. Remove crosshead (15).
★ Since the shapes of holes [a] and [b] of the crosshead are different, record the installed position of the crosshead.
14. Remove fuel injector assembly mounting bolt (16).
15. Using tool A1, remove fuel injector assembly (17).
★ Cover injector sleeve with cloth after remov- ing fuel injector assembly for free from flaw and dirt.
Removal and installation of fuel injector assembly DISASSEMBLY AND ASSEMBLY
Installation
1. Fuel injector assembly
★ Check that fuel injector sleeve (18) is free from flaw and dirt.
a. Fit O-ring (20) and gasket (21) to fuel injector (19).
★ Replace O-ring and gasket with new one.
b. Apply engine oil (EO15W-40) to the O-ring of the fuel injector (19) and the mounting hole on the head.
c. While setting the concave and convex (A), install holder (22) to fuel injector (19).