Yanmar B55W-1 Wheel Excavator Shop Manual

Description

• Model List:
  • B55W-1 Wheel Excavator

• 1. Table Of Contents
• 1.1. Wheel Excavator Safety
• 1.1.1. To the Operator of a Yanmar Excavator
• 1.1.2. General Safety Essentials
• 1.1.3. Location of Safety Labels
• 1.1.4. Summary of Safety Precautions for Lifting in Digging Mode
• 1.1.5. Unauthorized Modifications
• 1.1.6. General Hazard Information
• 1.1.7. Before Starting Engine
• 1.1.8. Machine Operation
• 1.1.9. Maintenance
• 1.1.10. Battery
• 1.1.11. Shipping and Transportation
• 1.1.12. Lifting With Sling
• 2. Specifications
• 2.1. Specifications for B55W-1
• 2.1.1. General Description
• 2.1.2. Component Locations
• 2.1.3. General Dimensions
• 2.1.4. Working Range
• 2.1.5. General Specifications
• 2.1.6. Weight Table
• 2.1.7. Working Attachments
• 3. General Maintenance
• 3.1. General Maintenance Procedures
• 3.1.1. Welding Precautions and Guidelines
• 3.1.2. Hydraulic System – General Precautions
• 3.1.3. Maintenance Service and Repair Procedure
• 3.1.4. Hydraulic System Cleanliness and Oil Leaks
• 3.1.5. Cleaning and Inspection
• 3.2. Standard Torques
• 3.2.1. Torque Values for Standard Metric Fasteners
• 3.2.2. Torque Values for Standard U.S. Fasteners
• 3.2.3. Type 8 Phosphate Coated Hardware
• 3.2.4. Torque Values for Hose Clamps
• 3.2.5. Torque Values for Split Flanges
• 3.2.6. Torque Wrench Extension Tools
• 4. Upper Structure
• 4.1. Counterweight
• 4.1.1. General
• 4.1.2. Removal
• 4.1.3. Installation
• 4.2. Fuel Transfer Pump
• 4.2.1. General Description
• 4.2.2. Troubleshooting
• 4.2.3. Replacement of Rotor and Vane
• 4.2.4. Replacement of Rear Cover
• 4.2.5. Replacement of Armature
• 4.3. Swing Bearing
• 4.3.1. Swing Bearing Maintenance
• 4.4. Swing Reduction Gearbox
• 4.4.1. General Description
• 4.4.2. Special Tools and Materials
• 4.4.3. Troubleshooting, Testing and Adjustment
• 4.4.4. Removal
• 4.4.5. Disassembly
• 4.4.6. Reassembly
• 4.4.7. Installation
• 5. Lower Structure and Chassis
• 5.1. Ram Lock Valve Operation
• 5.1.1. Theory of Operation
• 6. Engine and Drive Train
• 6.1. Drive Axle
• 6.1.1. Introduction
• 6.1.2. Special Tool
• 6.1.3. Trouble Shooting
• 6.1.4. Clark-Hurth Axle Identification
• 6.2. Air Conditioner
• 6.2.1. General Description
• 6.2.2. Refrigerant Circulation
• 6.2.3. Air-conditioning System Circuit Diagram
• 6.2.4. Troubleshooting
• 6.2.5. Weight of R134a Gas Used In Machines
• 6.2.6. Refrigerant System Repairs
• 6.3. Transmission
• 6.3.1. Introduction
• 6.3.2. Maintenance and Lubricant
• 6.3.3. Diagrams of Reduction Unit and Exploded Views
• 6.3.4. Disassembly of Directly Flanged Reduction Gear 357
• 6.3.5. Removal of hydraulic gear control
• 6.3.6. Disassembly of Directly Flanged Reduction Gear 357
• 6.3.7. Assembly of Directly Flanged Reduction Gear 357
• 6.3.8. Installation of Hydraulic Gear Control
• 6.4. Drive Coupling (Main Pump)
• 6.4.1. Drive Coupling
• 6.4.2. Special Tools
• 6.4.3. Drive Coupling Installation
• 7. Hydraulics
• 7.1. Hydraulic System Troubleshooting, Testing and Adjustment
• 7.1.1. Hydraulic System
• 7.2. Accumulator
• 7.2.1. General Description
• 7.3. Center Joint (Swivel)
• 7.3.1. General Description
• 7.3.2. Troubleshooting, Testing and Adjustment
• 7.3.3. Disassembly
• 7.3.4. Reassembly
• 7.4. Cylinders
• 7.4.1. General Description
• 7.4.2. Special Tools and Materials
• 7.4.3. Disassembly
• 7.4.4. Assembly
• 7.5. Travel Motor
• 7.5.1. Sectional View
• 7.5.2. Seal Kits and Component Groups
• 7.5.3. Seal Kits and Component groups / Replace Seal Nut
• 7.5.4. Sealing the Drive Shaft
• 7.5.5. Sealing of the Control Parts
• 7.5.6. Sealing of the Relief Valve / Counter- Balance Valve
• 7.5.7. Spare Parts List Counter-Balance Valve
• 7.5.8. Spare Parts List Brake Release Valve (Pos. 50)
• 7.5.9. Disassembly of the Port Plate
• 7.5.10. Remove of the Positioning Piston
• 7.5.11. Remove Rotary Group
• 7.5.12. Exchanging of the rotary group
• 7.5.13. Inspection Notes
• 7.5.14. Rotary Group Assembly
• 7.5.15. Rotary Group Adjustment (see service information)
• 7.5.16. Assembly of the Port Plate
• 7.5.17. Tightening Torques
• 7.5.18. Safety Regulations
• 7.6. Swing Motor
• 7.6.1. Swing Motor
• 7.6.2. Troubleshooting
• 7.7. Main Pump
• 7.7.1. General Description
• 7.7.2. Operation Principle and Function of Components
• 7.7.3. Adjustment
• 7.7.4. Installation
• 7.7.5. Driving
• 7.7.6. Hydraulic Oil
• 7.7.7. Procedures for Test Operation
• 7.7.8. Maintenance and Protection
• 7.7.9. Checking Filters
• 7.7.10. Filter Replacement
• 7.7.11. Replacement of Hydraulic Oil
• 7.7.12. Hydraulic Fluid Leakage Check
• 7.7.13. Diagnosis of Troubles and Actions to be Taken
• 7.7.14. Disassembling and Reassembling hydraulic pump
• 7.8. Main Control Valve
• 7.8.1. Specifications
• 7.8.2. Internal Construction
• 7.8.3. Construction of Relief and Make-Up Valves
• 7.8.4. Operation
• 7.8.5. Disassembly
• 7.8.6. Assembly
• 7.8.7. Criteria for Maintenance
• 7.9. Pilot Control Valve (Work Lever / Joystick)
• 7.9.1. General Description
• 7.9.2. Special Tools
• 7.9.3. Disassembly
• 7.9.4. Reassembly
• 7.10. Hydraulic Schematic (B55W-1)
• 7.10.1. General Description
• 8. Electrical System
• 8.1. Electrical System
• 8.1.1. Overview
• 8.1.2. Electric Supply System
• 8.1.3. Engine Starting Circuit
• 8.1.4. Engine Preheating System
• 8.1.5. Engine Stop System
• 8.1.6. Charging System
• 8.1.7. Instrument System
• 8.2. Electrical Schematic (B55W-1)
• 8.2.1. General Description
• 9. Attachments
• 9.1. Bucket Tooth Inspection and Replacement
• 9.2. Bucket O-ring Replacement
• 9.3. Bucket Shimming Procedures
• 9.4. New Bucket Installation
• 9.5. Bucket Attachment, Removal and Reversal
• 9.6. Detaching the Bucket
• 9.7. Attaching The bucket
• 9.8. Reversing the Bucket
• 10. sm b55w-1 (c).pdf
• 10.1. Table Of Contents
• 10.1.1. Wheel Excavator Safety
• 10.2. Specifications
• 10.2.1. Specifications for B55W-1
• 10.3. General Maintenance
• 10.3.1. General Maintenance Procedures
• 10.3.2. Standard Torques
• 10.4. Upper Structure
• 10.4.1. Counterweight
• 10.4.2. Fuel Transfer Pump
• 10.4.3. Swing Bearing
• 10.4.4. Swing Reduction Gearbox
• 10.5. Lower Structure and Chassis
• 10.5.1. Ram Lock Valve Operation
• 10.6. Engine and Drive Train
• 10.6.1. Drive Axle
• 10.6.2. Air Conditioner
• 10.6.3. Transmission
• 10.6.4. Drive Coupling (Main Pump)
• 10.7. Hydraulics
• 10.7.1. Hydraulic System Troubleshooting, Testing and Adjustment
• 10.7.2. Accumulator
• 10.7.3. Center Joint (Swivel)
• 10.7.4. Cylinders
• 10.7.5. Travel Motor
• 10.7.6. Swing Motor
• 10.7.7. Main Pump
• 10.7.8. Main Control Valve
• 10.7.9. Pilot Control Valve (Work Lever / Joystick)
• 10.7.10. Hydraulic Schematic (B55W-1)
• 10.8. Electrical System
• 10.8.1. Electrical System
• 10.8.2. Electrical Schematic (B55W-1)
• 10.9. Attachments
• 10.9.1. Bucket Tooth Inspection and Replacement
• 10.9.2. Bucket O-ring Replacement
• 10.9.3. Bucket Shimming Procedures
• 10.9.4. New Bucket Installation
• 10.9.5. Bucket Attachment, Removal and Reversal
• 10.9.6. Detaching the Bucket
• 10.9.7. Attaching The bucket
• 10.9.8. Reversing the Bucket
• 11. sm b55w-1 (d).pdf
• 11.1. Table Of Contents
• 11.1.1. Wheel Excavator Safety
• 11.2. Specifications
• 11.2.1. Specifications for B55W-1
• 11.3. General Maintenance
• 11.3.1. General Maintenance Procedures
• 11.3.2. Standard Torques
• 11.4. Upper Structure
• 11.4.1. Counterweight
• 11.4.2. Fuel Transfer Pump
• 11.4.3. Swing Bearing
• 11.4.4. Swing Reduction Gearbox
• 11.5. Lower Structure and Chassis
• 11.5.1. Ram Lock Valve Operation
• 11.6. Engine and Drive Train
• 11.6.1. Drive Axle
• 11.6.2. Air Conditioner
• 11.6.3. Transmission
• 11.6.4. Drive Coupling (Main Pump)
• 11.7. Hydraulics
• 11.7.1. Hydraulic System Troubleshooting, Testing and Adjustment
• 11.7.2. Accumulator
• 11.7.3. Center Joint (Swivel)
• 11.7.4. Cylinders
• 11.7.5. Travel Motor
• 11.7.6. Swing Motor
• 11.7.7. Main Pump
• 11.7.8. Main Control Valve
• 11.7.9. Pilot Control Valve (Work Lever / Joystick)
• 11.7.10. Hydraulic Schematic (B55W-1)
• 11.8. Electrical System
• 11.8.1. Electrical System
• 11.8.2. Electrical Schematic (B55W-1)
• 11.9. Attachments
• 11.9.1. Bucket Tooth Inspection and Replacement
• 11.9.2. Bucket O-ring Replacement
• 11.9.3. Bucket Shimming Procedures
• 11.9.4. New Bucket Installation
• 11.9.5. Bucket Attachment, Removal and Reversal
• 11.9.6. Detaching the Bucket
• 11.9.7. Attaching The bucket
• 11.9.8. Reversing the Bucket
• 12. sm b55w-1 (e).pdf
• 12.1. Table Of Contents
• 12.1.1. Wheel Excavator Safety
• 12.2. Specifications
• 12.2.1. Specifications for B55W-1
• 12.3. General Maintenance
• 12.3.1. General Maintenance Procedures
• 12.3.2. Standard Torques
• 12.4. Upper Structure
• 12.4.1. Counterweight
• 12.4.2. Fuel Transfer Pump
• 12.4.3. Swing Bearing
• 12.4.4. Swing Reduction Gearbox
• 12.5. Lower Structure and Chassis
• 12.5.1. Ram Lock Valve Operation
• 12.6. Engine and Drive Train
• 12.6.1. Drive Axle
• 12.6.2. Air Conditioner
• 12.6.3. Transmission
• 12.6.4. Drive Coupling (Main Pump)
• 12.7. Hydraulics
• 12.7.1. Hydraulic System Troubleshooting, Testing and Adjustment
• 12.7.2. Accumulator
• 12.7.3. Center Joint (Swivel)
• 12.7.4. Cylinders
• 12.7.5. Travel Motor
• 12.7.6. Swing Motor
• 12.7.7. Main Pump
• 12.7.8. Main Control Valve
• 12.7.9. Pilot Control Valve (Work Lever / Joystick)
• 12.7.10. Hydraulic Schematic (B55W-1)
• 12.8. Electrical System
• 12.8.1. Electrical System
• 12.8.2. Electrical Schematic (B55W-1)
• 12.9. Attachments
• 12.9.1. Bucket Tooth Inspection and Replacement
• 12.9.2. Bucket O-ring Replacement
• 12.9.3. Bucket Shimming Procedures
• 12.9.4. New Bucket Installation
• 12.9.5. Bucket Attachment, Removal and Reversal
• 12.9.6. Detaching the Bucket
• 12.9.7. Attaching The bucket
• 12.9.8. Reversing the Bucket
• 13. sm b55w-1 (f).pdf
• 13.1. Table Of Contents
• 13.1.1. Wheel Excavator Safety
• 13.2. Specifications
• 13.2.1. Specifications for B55W-1
• 13.3. General Maintenance
• 13.3.1. General Maintenance Procedures
• 13.3.2. Standard Torques
• 13.4. Upper Structure
• 13.4.1. Counterweight
• 13.4.2. Fuel Transfer Pump
• 13.4.3. Swing Bearing
• 13.4.4. Swing Reduction Gearbox
• 13.5. Lower Structure and Chassis
• 13.5.1. Ram Lock Valve Operation
• 13.6. Engine and Drive Train
• 13.6.1. Drive Axle
• 13.6.2. Air Conditioner
• 13.6.3. Transmission
• 13.6.4. Drive Coupling (Main Pump)
• 13.7. Hydraulics
• 13.7.1. Hydraulic System Troubleshooting, Testing and Adjustment
• 13.7.2. Accumulator
• 13.7.3. Center Joint (Swivel)
• 13.7.4. Cylinders
• 13.7.5. Travel Motor
• 13.7.6. Swing Motor
• 13.7.7. Main Pump
• 13.7.8. Main Control Valve
• 13.7.9. Pilot Control Valve (Work Lever / Joystick)
• 13.7.10. Hydraulic Schematic (B55W-1)
• 13.8. Electrical System
• 13.8.1. Electrical System
• 13.8.2. Electrical Schematic (B55W-1)
• 13.9. Attachments
• 13.9.1. Bucket Tooth Inspection and Replacement
• 13.9.2. Bucket O-ring Replacement
• 13.9.3. Bucket Shimming Procedures
• 13.9.4. New Bucket Installation
• 13.9.5. Bucket Attachment, Removal and Reversal
• 13.9.6. Detaching the Bucket
• 13.9.7. Attaching The bucket
• 13.9.8. Reversing the Bucket