Yanmar SV100 Crawler Excavators Service Manuals

Yanmar SV100 Crawler Excavators Service Manuals
Size : 43.9 MB
Format : PDF
Language : English
Make: Yanmar
Machine: Crawler Excavators
Document: Service Manual, Electric and Hydraulic Diagrams
Model: Yanmar SV100
Part Number: 4990505
Page: 546 Pages

Detail Contents:
CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK

• 1-1 Correct Work
  1-2 Safety Precautions
  1-3 Preparations
  1-4 Cautions for Disassembly and Reassembly
  1-5 Cautions for Removal and Installation of Hydraulic Equipment
  1-6 Cautions for Removal and Installation of Hydraulic Piping
  1-7 Cautions for Handling Seals
  1-8 Correct Installation of Hydraulic Hose
  1-9 Specifications of Hydraulic Hose
  1-10 Air Release of Hydraulic Equipment

CHAPTER 2 TECHNICAL DATA

• 2-1 Specifications
  2-2 Outline Drawing and Working Area
  2-2-1 Quick coupler
  2-2-2 W/O Quick coupler
  2-3 Weight List of Main Parts
  2-4 Lifting Capacity List
  2-4-1 SV100

CHAPTER 3 SERVICE STANDARDS

• 3-1 Machine Performance
  3-2 Engine
  3-3 Undercarriage
  3-3-1 Rubber Crawler Specifications
  3-3-2 Steel Crawler Specifications
  3-3-3 Common Specifications of Steel & Rubber Crawlers
  3-4 Controls
  3-5 Hydraulic Equipment
  3-5-1 Hydraulic Cylinders
  3-6 Implement
  3-6-1 Front Attachments (Quick Coupler Type)
  3-6-2 Blade Moving Device
  3-6-3 Bucket Teeth
  3-7 List of Tightening Torque
  3-7-1 Machine
  3-7-2 Engine
  3-7-3 Tightening Torque for General Bolts and Nuts

CHAPTER 4 ENGINE

• 4-1 General
  4-1-1 How to Read This Manual
  4-1-2 Precautions for Service Work
  4-1-3 Engine External Views
  4-1-4 Structural Description
  4-1-5 Exhaust Gas Emission Regulation
  4-2 Troubleshooting
  4-2-1 Quick Reference Table for Troubleshooting
  4-2-2 Troubleshooting by Measuring Compression Pressure
  4-3 Inspection and Adjustment
  4-3-1 Oil Inspection
  4-3-2 Cooling Water Inspection
  4-3-3 Inspecting Water Leak from Cooling Water System and Radiator
  4-3-4 Fan Belt Tension Inspection and Adjustment
  4-3-5 Adjusting the Valve Clearance
  4-3-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern
  4-3-7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment
  4-3-8 Sensor Inspection
  4-3-9 Battery Inspection
  4-3-10 Adjusting Operation
  4-3-11 Long Storage
  4-3-12 Periodic Maintenance Schedule
  4-4 Engine Body
  4-4-1 Introduction
  4-4-2 Cylinder Head
  4-4-3 Gear Train and Camshaft
  4-4-4 Cylinder Block
  4-5 Lubrication System
  4-5-1 Lubrication System Diagram
  4-5-2 Trochoid Pump Components
  4-5-3 Disassembly (Reverse the Procedure Below for Assembly)
  4-5-4 Servicing Points
  4-5-5 Parts Inspection and Measurement
  4-6 Cooling System
  4-6-1 Cooling Water System
  4-6-2 Cooling Water Pump Components
  4-6-3 Disassembly (Reverse the Procedure Below for Assembly)
  4-6-4 Servicing Points
  4-7 Fuel Injection Pump / Governor
  4-7-1 Introduction
  4-7-2 Fuel Injection Pump
  4-8 Turbocharger : Disassembly, Inspection and Reassembly
  4-8-1 Structure and Functions
  4-8-2 Service Standards and Tightening Torque
  4-8-3 Periodic Inspection Procedure
  4-8-4 Disassembly Procedure
  4-8-5 Washing and Inspection procedure
  4-8-6 Reassembly Procedure
  4-8-7 Handling after Disassembly and Reassembly
  4-8-8 Troubleshooting
  4-9 Starting motor
  4-9-1 Specifications
  4-9-2 Configuration Drawing
  4-9-3 Troubleshooting
  4-9-4 Component Names and Disassembly Procedure
  4-9-5 Disassembly Procedure
  4-9-6 Inspection and Maintenance
  4-9-7 Assembly
  4-9-8 Adjustment
  4-9-9 Service Standards
  4-10 Alternator
  4-10-1 Specifications
  4-10-2 Section View
  4-10-3 Troubleshooting
  4-10-4 Parts Names and Disassembly Procedure
  4-10-5 Inspection and Overhaul
  4-10-6 Assembly
  4-10-7 Service Standards
  4-10-8 Performance Test
  4-11 Special Service Tools
  4-11-1 Special Tools
  4-11-2 Measuring Instruments
  4-12 Service Standards
  4-12-1 Engine Turning
  4-12-2 Engine Body
  4-12-3 Lubricating Oil System (Trochoid Pump)
  4-12-4 Tightening Torques for Main Parts

CHAPTER 5 HYDRAULIC SYSTEM

• 5-1 Outline (Quick Coupler Type)
  5-1-1 Control Valve Operation
  5-1-2 Additional Operation of Control Valve
  5-2 Hydraulic Circuit Schematic
  5-3 Circuit Operation
  5-3-1 Boom
  5-3-2 Arm
  5-3-3 Bucket
  5-3-4 Swing
  5-3-5 Boom Swing
  5-3-6 Blade
  5-3-7 Travel
  5-3-8 Non-deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation)
  5-3-9 Simultaneous Operation of Boom Up and Arm Retract
  5-3-10 Simultaneous Operation of Boom Up and Bucket
  5-3-11 Simultaneous Operation of Boom Up and Swing
  5-3-12 Simultaneous Operation of Arm and Bucket
  5-3-13 Hydraulic P
  5-3-14 Travel Alarm
  5-3-15 Quick Coupler
  5-3-16 2nd P
  5-4 Pressure Adjustment
  5-4-1 Relief Valves
  5-4-2 Swing Brake Valve
  5-4-3 Cut-off Valve

CHAPTER 6 HYDRAULIC EQUIPMENT

• 6-1 Hydraulic Pump
  6-2 Control Valve
  6-2-1 Hydraulic Circuit Schematic and Parts Name
  6-2-2 Operation of Each Spool Section
  6-2-3 Relief Valves
  6-3 Pilot Valve
  6-4 Swing Motor
  6-5 Travel Motor
  6-5-1 Specifications
  6-5-2 Model Labeling
  6-5-3 External Dimensions
  6-5-4 Basic Configuration and Drawing
  6-5-5 Operating Description
  6-5-6 Troubleshooting
  6-5-7 Disassembly
  6-5-8 Service Preparations
  6-5-9 Assembly
  6-5-10 Performance Congirmation Test
  6-5-11 Clearance Adjustment Parts Dimensions Table
  6-6 Pilot Check Valve (Quick Coupler Type)

CHAPTER 7 ADJUSTMENT AND REPAIR

• 7-1 Electric Equipment of the Machine
  7-1-1 Parts Layout of Electrical Equipment
  7-1-2 Monitor and Alarm Systems
  7-1-3 Wiring Diagram
  7-1-4 Stop Motor Operation
  7-1-5 Removal and Reinstallation of Engine
  7-1-6 Removal and Reinstallation of Starter Motor
  7-1-7 Removal and Reinstallation of Radiator
  7-1-8 Removal and Reinstallation of Fan Belt and Compressor Driving Belt
  7-1-9 Removal and Reinstallation of Fuel Injection Pump
  7-2 Undercarriage
  7-2-1 Outline
  7-2-2 Compatibility of Main Parts
  7-2-3 Points of Reassembly (Rubber Crawler Type)
  7-2-4 Points of Reassembly (Steel Crawler Type)
  7-2-5 Removal and Reinstallation of Crawler
  7-2-6 Disassembly and Reassembly of Steel Crawler
  7-2-7 Disassembly and Reassembly of Front Idler
  7-2-8 Disassembly and Reassembly of Track Roller
  7-2-9 Installation of Floating Seal
  7-2-10 Disassembly and Reassembly of Carrier Roller
  7-3 Controls
  7-3-1 Control Train
  7-3-2 Mechanical Control Linkage
  7-3-3 Adjustment of Travel Levers
  7-3-4 Adjustment of Boom Swing Pedal
  7-3-5 Adjustment of Blade Lever
  7-3-6 Adjustment of Lock Lever
  7-3-7 Adjustment Procedure of P
  7-3-8 Adjustment Procedure of P
  7-3-9 Adjustment of Accelerator Lever
  7-4 Swing Bearing
  7-4-1 Removal and Reinstallation of Swing Bearing
  7-5 Hydraulic Equipment
  7-5-1 Removal and Reinstallation of Hydraulic Pump
  7-5-2 Removal and Reinstallation of Control Valve
  7-5-3 Removal and Reinstallation of Swing Motor
  7-5-4 Removal and Reinstallation of Swivel Joint
  7-5-5 Disassembly and Reassembly of Swivel Joint
  7-5-6 Disassembly and Reassembly of Hydraulic Cylinders
  7-5-7 Hydraulic Oil Tank
  7-5-8 Piping Layout
  7-6 Implement
  7-6-1 Removal and Reinstallation of Implement
  7-6-2 Quick Coupler
  7-7 Air Conditioner
  7-7-1 Removal and Reinstallation of Air Conditioner

CHAPTER 8 PERIODIC INSPECTION AND SERVICING

• 8-1 List of Periodic Inspection and Servicing

CHAPTER 9 FUEL, LUBE OIL AND GREASE RECOMMENDED
CHAPTER 10 TROUBLESHOOTING

• 10-1 Non-breakdowns
  10-1-1 Natural Release of Bucket
  10-1-2 Discontinuous Arm Movement
  10-1-3 Thermal Shock of Travel Motor
  10-1-4 Elongation of Boom Swing Cylinder on 68 degrees Swing
  10-1-5 Time Lag on Travel Speed Switching
  10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change
  10-1-7 Operation of Quick Coupler Cylinder
  10-2 Troubleshooting
  10-2-1 Machine and Engine
  10-2-2 Electrical Equipment on Panel

CHAPTER 11 REFERENCE DATA
11-1 Specifications for Attachment

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