Yanmar SV100-1 Excavator Service Manual

Description

• Model List:
  • SV100-1 Excavator

• 1. SPINE TITLE
• 2. CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK
• 2.1. General Cautions for Maintenance Work
• 2.1.1. Correct Work
• 2.1.2. Safety Precautions
• 2.1.3. Preparations
• 2.1.4. Cautions for Disassembly and Reassembly
• 2.1.5. Cautions for Removal and Installation of Hydraulic Equipment
• 2.1.6. Cautions for Removal and Installation of Hydraulic Piping
• 2.1.7. Cautions for Handling Seals
• 2.1.8. Correct Installation of Hydraulic Hose
• 2.1.9. Specifications of Hydraulic Hose
• 2.1.10. Air Release of Hydraulic Equipment
• 3. CHAPTER 2 TECHNICAL DATA
• 3.1. Technical Data
• 3.1.1. Specifications
• 3.1.2. Outline Drawing and Working Area
• 3.1.2.1. Quick coupler
• 3.1.2.2. W/O Quick coupler
• 3.1.3. Weight List of Main Parts
• 3.1.4. Lifting Capacity List
• 3.1.4.1. SV100-1 Quick Coupler
• 3.1.4.2. SV100-1 W/O Quick Coupler
• 4. CHAPTER 3 SERVICE STANDARDS
• 4.1. Service Standards
• 4.1.1. Machine Performance
• 4.1.2. Engine
• 4.1.3. Undercarriage
• 4.1.3.1. Rubber Crawler Specifications
• 4.1.3.2. Steel Crawler Specifications
• 4.1.3.3. Common Specifications of Steel Rubber Crawlers
• 4.1.4. Controls
• 4.1.5. Hydraulic Equipment
• 4.1.5.1. Hydraulic Cylinders
• 4.1.6. Implement
• 4.1.6.1. Front Attachments
• 4.1.6.2. Blade Moving Device
• 4.1.6.3. Bucket Teeth
• 4.1.7. List of Tightening Torque
• 4.1.7.1. Machine
• 4.1.7.2. Engine
• 4.1.7.3. Tightening Torque for General Bolts and Nuts
• 4.1.7.4. Hydraulic Fitting
• 5. CHAPTER 4 ENGINE
• 5.1. Engine
• 5.1.1. Engine
• 5.1.1.1. Safety Precautions
• 5.1.1.2. Introduction
• 5.1.1.3. Special Service Tools
• 5.1.1.4. Measuring Instruments
• 5.1.1.5. Valve Cylinder Head
• 5.1.1.6. Measuring and Adjusting Valve Clearance
• 5.1.1.7. Crankshaft and Camshaft Components
• 5.1.1.8. EGR System
• 5.1.2. Fuel System
• 5.1.2.1. Before You Begin Servicing
• 5.1.2.2. Introduction
• 5.1.2.3. Special Service Tools
• 5.1.2.4. Measuring Instruments
• 5.1.2.5. Fuel System Diagram
• 5.1.2.6. Fuel System Components
• 5.1.2.7. Fuel Injection Pump
• 5.1.2.8. Fuel Injectors
• 5.1.3. Cooling System
• 5.1.3.1. Before You Begin Servicing
• 5.1.3.2. Introduction
• 5.1.3.3. Cooling System Diagram
• 5.1.3.4. Engine Coolant Pump Components
• 5.1.3.5. Engine Coolant System Check
• 5.1.3.6. Engine Coolant Pump
• 5.1.4. Lubrication System
• 5.1.4.1. Before You Begin Servicing
• 5.1.4.2. Introduction
• 5.1.4.3. Lubrication System Diagram
• 5.1.4.4. Checking Engine Oil Pressure
• 5.1.4.5. Trochoid Oil Pump
• 5.1.5. Turbocharger
• 5.1.5.1. Before You Begin Servicing
• 5.1.5.2. Introduction
• 5.1.5.3. Specifications
• 5.1.5.4. Troubleshooting
• 5.1.5.5. Turbocharger Components
• 5.1.5.6. Turbocharger Component Functions
• 5.1.5.7. Washing Procedure
• 5.1.5.8. Periodic Inspection
• 5.1.6. Starter Motor
• 5.1.6.1. Before You Begin Servicing
• 5.1.6.2. Introduction
• 5.1.6.3. Starter Motor Specifications
• 5.1.6.4. Starter Motor Troubleshooting
• 5.1.6.5. Starter Motor Components
• 5.1.6.6. Starter Motor
• 5.1.7. Alternator
• 5.1.7.1. Before You Begin Servicing
• 5.1.7.2. Introduction
• 5.1.7.3. Alternator Specifications
• 5.1.7.4. Alternator Troubleshooting
• 5.1.7.5. Alternator Components
• 5.1.7.6. Alternator Wiring Diagram
• 5.1.7.7. Alternator Standard Output
• 5.1.7.8. Alternator
• 5.1.8. Electronic Control System
• 5.1.8.1. Engines Available with the Electronic Control System
• 5.1.8.2. Before You Begin Servicing
• 5.1.8.3. Main Electronic Control Components and Features
• 5.1.9. Electric Wiring
• 5.1.9.1. Electric Wiring Precautions
• 5.1.10. Failure Diagnosis
• 5.1.10.1. Special Service Tools
• 5.1.10.2. Troubleshooting By Measuring Compression Pressure
• 6. CHAPTER 5 HYDRAULIC SYSTEM
• 6.1. Hydraulic System
• 6.1.1. Outline
• 6.1.1.1. Control Valve Operation
• 6.1.1.2. Additional Operation of Control Valve
• 6.1.2. Hydraulic Circuit Schematic
• 6.1.2.1. US spec.
• 6.1.2.2. AS/NZ spec.
• 6.1.2.3. AYR spec.
• 6.1.3. Circuit Operation
• 6.1.3.1. Boom
• 6.1.3.2. Arm
• 6.1.3.3. Bucket
• 6.1.3.4. Swing
• 6.1.3.5. Boom Swing
• 6.1.3.6. Blade
• 6.1.3.7. Travel
• 6.1.3.8. Non-deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation)
• 6.1.3.9. Simultaneous Operation of Boom Up and Arm Retract
• 6.1.3.10. Simultaneous Operation of Boom Up and Bucket
• 6.1.3.11. Simultaneous Operation of Boom Up and Swing
• 6.1.3.12. Simultaneous Operation of Arm and Bucket
• 6.1.3.13. Hydraulic P.T.O.
• 6.1.3.14. Travel Alarm
• 6.1.3.15. h P.T.O.
• 6.1.3.16. Quick Coupler
• 6.1.3.17. Auto Deceleration
• 6.1.4. Pressure Adjustment
• 6.1.4.1. Relief Valves
• 6.1.4.2. Swing Brake Valve
• 6.1.4.3. Cut-off Valve
• 7. CHAPTER 6 HYDRAULIC EQUIPMENT
• 7.1. Hydraulic Equipment
• 7.1.1. Hydraulic Pump
• 7.1.2. Control Valve
• 7.1.2.1. Main Control Valve
• 7.1.2.2. Disassembly
• 7.1.2.3. Cleaning
• 7.1.2.4. Checking
• 7.1.2.5. Reassembly
• 7.1.2.6. Servicing Procedure for Relief Valve
• 7.1.2.7. Installation
• 7.1.2.8. Running
• 7.1.2.9. Troubleshooting
• 7.1.3. Pilot Valve
• 7.1.3.1. Remote Control Valve
• 7.1.3.2. Travel Pilot Valve
• 7.1.3.3. Blade and Boom Swing Pilot Valve
• 7.1.4. Swing Motor
• 7.1.4.1. Overview
• 7.1.4.2. Description of Functions and Operation
• 7.1.4.3. Precautions for Handling
• 7.1.4.4. Troubleshooting
• 7.1.4.5. Employment Tool
• 7.1.4.6. Disassembly Procedure
• 7.1.4.7. Assembly Procedure
• 7.1.4.8. Quality Check After Reassembly.
• 7.1.5. Travel Motor
• 7.1.5.1. Product Overview
• 7.1.5.2. External Dimensions and Circuit Diagram
• 7.1.5.3. Basic Configuration and Drawing
• 7.1.5.4. Operating Description
• 7.1.5.5. Troubleshooting
• 7.1.5.6. Service outline
• 7.1.5.7. Disassembly
• 7.1.5.8. Service criteria
• 7.1.5.9. Assembly
• 7.1.5.10. Performance Confirmation Test
• 7.1.6. Cutoff Valve
• 7.1.7. Solenoid Valve
• 7.1.8. Quick Coupler Solenoid Valve
• 7.1.9. Pilot Check Valve (Quick Coupler spec.)
• 7.1.10. Holding Valve (AS/NZ spec.)
• 8. CHAPTER 7 ADJUSTMENT AND REPAIR
• 8.1. Adjustment and Repair
• 8.1.1. Electric Equipment of the Machine
• 8.1.1.1. Parts Layout of Electrical Equipment
• 8.1.1.2. Monitor and Alarm Systems
• 8.1.1.3. Wiring Diagram
• 8.1.1.4. Circuit Description of Engine Start, Stop and Battery Charging
• 8.1.1.5. Electronic Control
• 8.1.1.6. Removal and Reinstallation of Engine
• 8.1.1.7. Removal and Reinstallation of Starter Motor
• 8.1.1.8. Removal and Reinstallation of Radiator and Oil cooler
• 8.1.1.9. Removal and Reinstallation of Fan Belt and Compressor Driving Belt
• 8.1.1.10. Removal and Reinstallation of Fuel Injection Pump
• 8.1.1.11. Removal and Reinstallation of ECU
• 8.1.2. Undercarriage
• 8.1.2.1. Outline
• 8.1.2.2. Compatibility of Main Parts
• 8.1.2.3. Points of Reassembly (Rubber Crawler Type)
• 8.1.2.4. Points of Reassembly (Steel Crawler Type)
• 8.1.2.5. Removal and Reinstallation of Crawler
• 8.1.2.6. Disassembly and Reassembly of Steel Crawler
• 8.1.2.7. Disassembly and Reassembly of Front Idler
• 8.1.2.8. Removal and Reinstallation of Adjusting Cylinder
• 8.1.2.9. Disassembly and Reassembly of Track Roller
• 8.1.2.10. Installation of Floating Seal
• 8.1.2.11. Disassembly and Reassembly of Carrier Roller
• 8.1.3. Controls
• 8.1.3.1. Control Lever
• 8.1.3.2. Travel Lever
• 8.1.3.3. Adjustment of Lock Lever
• 8.1.4. Swing Bearing
• 8.1.4.1. Removal and Reinstallation of Swing Bearing
• 8.1.5. Hydraulic Equipment
• 8.1.5.1. Removal and Reinstallation of Hydraulic Pump
• 8.1.5.2. Removal and Reinstallation of Control Valve
• 8.1.5.3. Removal and Reinstallation of Remote Control Valves
• 8.1.5.4. Removal and Reinstallation of Blade Pilot Valve
• 8.1.5.5. Removal and Reinstallation of Travel Pilot Valve
• 8.1.5.6. Removal and Reinstallation of Boom Swing Pilot Valve
• 8.1.5.7. Removal and Reinstallation of Solenoid Valve
• 8.1.5.8. Removal and Reinstallation of P.T.O. Solenoid Valve
• 8.1.5.9. Removal and Reinstallation of Line Filter
• 8.1.5.10. Removal and Reinstallation of Accumulator
• 8.1.5.11. Removal and Reinstallation of Swing Motor
• 8.1.5.12. Removal and Reinstallation of Swivel Joint
• 8.1.5.13. Disassembly and Reassembly of Swivel Joint
• 8.1.5.14. Disassembly and Reassembly of Hydraulic Cylinders
• 8.1.5.15. Hydraulic Oil Tank
• 8.1.5.16. Piping Layout
• 8.1.6. Implement
• 8.1.6.1. Removal and Reinstallation of Implement
• 8.1.6.2. Quick Coupler
• 8.1.7. Cabin
• 8.1.7.1. Removal and Reinstallation of Cabin
• 8.1.7.2. Disassembly and Reassembly of Cabin
• 8.1.7.3. Removal and Reinstall of Cabin Glasses
• 8.1.8. Air Conditioner
• 8.1.8.1. Removal and Reinstallation of Air Conditioner
• 9. CHAPTER 8 PERIODIC INSPECTION AND SERVICING
• 9.1. Periodic Inspection and Servicing
• 10. CHAPTER 9 FUEL, LUBE OIL AND GREASE RECOMMENDED
• 10.1. Fuel, Lube Oil and Grease Recommended
• 11. CHAPTER 10 TROUBLESHOOTING
• 11.1. Troubleshooting
• 11.1.1. Non-breakdowns
• 11.1.1.1. Natural Release of Bucket
• 11.1.1.2. Discontinuous Arm Movement
• 11.1.1.3. Thermal Shock of Travel Motor
• 11.1.1.4. Elongation of Boom Swing Cylinder on 60 degrees Swing
• 11.1.1.5. Time Lag on Travel Speed Switching
• 11.1.1.6. Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change
• 11.1.1.7. Operation of Quick Coupler Cylinder
• 11.1.2. Troubleshooting
• 11.1.2.1. Machine and Engine
• 11.1.2.2. Electrical Equipment on Panel
• 12. CHAPTER 11 REFERENCE DATA
• 12.1. Reference Data
• 12.1.1. Specifications for Attachment