disassembly and assembly engine and cooling system · disassembly and assembly engine and cooling...

DISASSEMBLY AND ASSEMBLY ENGINE AND COOLING SYSTEM

PC360/390LC-10 50-135 C

4. Remove the flywheel housing according to the following procedure.

A. Place blocks under the engine oil pan to float flywheel housing(4).

B. Remove engine mounting brackets (5) and (6) from flywheelhousing (4).

C. Set slings to flywheel housing (4).

D. Remove mounting bolts (7).

E. Sling and remove flywheel housing (4).

5. Remove the engine rear oil seal according to the following procedure.

A. Remove rear cover (8).★ When separating rear cover (8) and engine oil pan gasket,

take care not to damage the engine oil pan gasket.★ Insert a feeler gauge etc. between the bottom of rear cover

(8) and engine oil pan gasket and move it back and forth toseparate the gasket.

★ When engine oil pan gasket is damaged. [*3]

i. Drain the engine oil from the engine oil pan.

ii. Remove engine oil pan (9).★ Replace the engine oil pan gasket.

iii. Remove dust seal (10).

B. Remove engine rear oil seal (11) from rear cover (8).

Flywheel housing: 60 kg {132 lbs}

Engine oil pan: 35 l {9.25 gal}


50-136 C PC360/390LC-10

Installation

1. Clean, degrease, and dry the gasket contact surface of the rear coverand cylinder block.

2. Clean, degrease, and dry the engine rear oil seal contact surface ofthe crankshaft.

3. Apply neutral detergent to the periphery of engine rear oil seal (11).★ Since plastic pilot [2] inside the rear oil seal (11) is used as a

guide for the crankshaft in installation, do not remove it fromthe rear oil seal.

4. Install engine rear oil seal (11) to rear cover (8).

5. By using alignment tool [3], push engine rear oil seal (11) intoproper depth of rear cover (8).★ Alignment tool [3] (positioning tool) is attached to the engine

rear oil seal.

6. Remove alignment tool [3].


PC360/390LC-10 50-137 C

7. Apply liquid gasket according to the following procedure.

A. Apply liquid gasket to bold-line portion (a) of the underside ofrear cover (8).

B. Apply liquid gasket thickly to two hatched areas (b) in the following figure.

8. Install guide pin [4] to the cylinder block.

9. While positioning with guide pin [4], install gasket (12).

10. Place pilot [2] to the crankshaft and push it together with rear cover(8) with the hand.★ Cut gasket (12) so that its protrusion (c) from the engine oil

pan is as follows.Protrusion dimension (c): Max. 0.25 mm {0.010 in}

11. Remove pilot [2].

12. Install alignment tool [3] again and check that engine rear oil seal(11) is pushed in to proper depth.★ Do not remove alignment tool [3] but keep it installed.

13. Remove guide pin [4] mentioned above.

Apply a bead of liquid gasket 3 mm {0.118 in} in diameter to bold-line portion (a) of underside of rear cover (8): Liquid gasket (LG-7)

Hatched area (b): Liquid gasket (LG-7)


50-138 C PC360/390LC-10

14. Loosely tighten four oil pan mounting bolts (indicated by thearrows).

15. Tighten the eight mounting bolts of rear cover (8) in the ordershown in the figure to the right.

16. Tighten four oil pan mounting bolts (indicated with arrows) to thespecified torque.

17. Remove alignment tool [3].

18. Install dust seal (10)

19. Install flywheel housing (4).

★ Tighten the mounting bolts in the order shown to the right.

Rear cover (8) mounting bolt: 12.7 ± 2.0 Nm {112 ± 18 lbf in}

Mounting bolt: 24 ± 4 Nm {18 ± 3 lbf ft}

Flywheel housing: 60 kg {132 lbs}

Bead line 1 - 3 mm {0.039 - 0.118 in} in diameter around mounting bolt hole on cylinder block: Liquid gasket (LG-6)

Flywheel housing mounting bolt (3): 77 ± 12 Nm {57 ± 9 lbf ft}


PC360/390LC-10 50-139 C

20. After installing the flywheel housing, measure the radial runout and facial runout with dial gauge [5].★ Radial runout: Max. 0.20 mm {0.008 in}★ Facial runout: Max. 0.20 mm {0.008 in}

Measuring Radial Runout

A. Install dial gauge [5] to the end face of the crankshaft.

B. Place the probe of dial gauge [5] at a right angle to the spigotjoint portion of the flywheel housing.

C. Set the pointer of dial gauge [5] to “0”, rotate the crankshaft byone turn, and measure the difference of the maximum readingof the pointer of dial gauge [5].★ After rotating the crankshaft by one turn, check that the

pointer of the dial gauge [5] reads the value at the start of rotation.

Measuring Facial Runout

A. Similarly to the measurement of the radial runout, place theprobe of dial gauge [5] at a right angle to the end face of theflywheel housing.★ When measuring, move the crankshaft to either front or

rear end to eliminate error caused by the end play.

B. Set the pointer of dial gauge [5] to “0”, rotate the crankshaft byone turn, and measure the difference of the maximum readingof the pointer of dial gauge [5].


50-140 C PC360/390LC-10

Carry Out the Rest of Installation in the Reverse Order to Removal.

[*1]

[*2]★ By using guide bolts [1], sling and install flywheel assembly (3).

★ Fix the flywheel and flywheel housing with bar [6].

★ Tighten the mounting bolts in the following order shown to theright.

Damper assembly mounting bolt: Adhesive (LT-2)

Spline of damper: Molybdenum disulfide anti-friction lubricant (LM-G)

Flywheel assembly (3): 40 kg {88 lbs}

Flywheel mounting bolt: Engine oil (EO15W-40)

Flywheel mounting bolt: 137 ± 7 Nm {101 ± 5 lbf ft}


PC360/390LC-10 50-141 C

★ Measure the facial runout and radial runout of the flywheel.• Radial runout: max. 0.13 mm {0.005 in}• Facial runout: max. 0.02 mm {0.001 in}

Measurement of Radial Runout

1. Install dial gauge [5] to the flywheel housing.

2. Place the probe of dial gauge [5] at a right angle to spigot joint portion (d) or periphery of the flywheel.

3. Set the pointer of dial gauge [5] to “0”.

4. Rotate the crankshaft by one turn and measure the difference of the maximum reading of the pointer of dial gauge [5].★ After rotating the crankshaft by one turn, check that the pointer of the dial gauge [5] reads the value at the start of

rotation.

Measuring Facial Runout

1. Similarly to the measurement of the radial runout, place the probe of dial gauge [5] at a right angle to end face (e) of theperiphery of the flywheel.★ When measuring, push the crankshaft to the front or rear so that an error is not caused by the end play.

2. Set the pointer of dial gauge [5] to “0”.

3. Rotate the crankshaft by one turn and measure the difference of the maximum reading of the pointer of dial gauge [5].

[*3]★ If the engine oil pan was removed, install it according to the following procedure.1. Apply liquid gasket to portion ( ) of the cylinder block.

2. Install the gasket to the bottom of the cylinder block.★ Apply liquid gasket to neither side of the gasket.

3. Install bed plate (14) to cylinder block (13).★ Apply liquid gasket to neither side of the bed plate.

Portion ( ) of cylinder block: Liquid gasket (LG-7)


50-142 C PC360/390LC-10

4. Apply liquid gasket to hatched areas (j) of the bed plate side of gasket (15).

★ Do not apply liquid gasket to the oil pan.

5. Install gasket (16) to the end flange and install suction tube (17).

6. Apply liquid gasket to hatched area (k) of the mounting face ofengine oil pan (9).

7. Install engine oil pan (9) to the cylinder block.

Hatched areas (j) on bed plate side of gasket (15): Liquid gasket (LG-7)

End flange: Liquid gasket (LG-7)

Flange mounting bolt (18): 7.8 ± 2 Nm {69 ± 18 lbf in}

Hatched area (k) of mounting face of engine oil pan (9): Liquid gasket (LG-7)


PC360/390LC-10 50-143 C

8. Tighten the mounting bolts in the numerical order shown in the figure to the right.

• Refilling with oil (engine oil pan)Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check theoil level again.

• Bleeding air (fuel system) Bleed air from the fuel circuit.

Mounting bolt of engine oil pan (9): 24 ± 4 Nm {18 ± 3 lbf ft}

Engine oil pan (engine oil): 35 l {9.25 gal}


50-144 C PC360/390LC-10

Fuel Tank Assembly

Removal

1. Remove undercovers (1) and (2).

2. Open the right side cover and open fuel tank drain valve (3) to drainthe fuel.

3. Remove mirror (5) from handrail (4).

WARNING! Park the machine on a level place, swing the upper structure by 45°, lower the work equipment to the ground stably, and stop the engine.

WARNING! Set the lock lever in the LOCK position.

WARNING! Turn the battery disconnect switch to the OFF position and remove the key.

Fuel tank (when full): 605 l {159.8 gal}

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