Yanmar SV20 (EP) Excavator Service Manual

Description

• Model List:
  • SV20 (EP) Excavator

• 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
• 2. Technical Data
• 2.1. Specifications
• 2.2. Outline Drawing and Working Area
• 2.3. Weight List of Main Parts
• 2.4. Lifting Capacity List
• 3. Service Standards
• 3.1. Machine Performance
• 3.2. Engine
• 3.3. Undercarriage
• 3.3.1. Rubber Crawler Specifications
• 3.3.2. 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
• 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
• 4. Engine
• 4.1. General
• 4.1.1. Engine External Views
• 4.2. Measurement, Inspection and Adjustment
• 4.2.1. Measuring the Compression Pressure
• 4.2.2. Adjusting the Valve Clearance
• 4.2.3. Checking the V-belt Tension
• 4.2.4. Checking the Fuel Injection Valve
• 4.2.5. Checking and adjusting the Fuel Injection Timing
• 4.2.6. Adjusting the Maximum (or Minimum) Idling Speed
• 4.2.7. Checking the Cooling Water System and Radiator for Water Leakage
• 4.2.8. Checking the Sensors
• 4.3. Measurement Procedure, Service Data and Corrective Action
• 4.3.1. Cylinder Head
• 4.3.2. Cylinder Block
• 4.3.3. Valve Rocker Arm
• 4.3.4. Piston and Piston Rings
• 4.3.5. Connecting Rod
• 4.3.6. Cam Shaft
• 4.3.7. Crank Shaft
• 4.3.8. Gears
• 4.3.9. Trochoid Pump
• 4.4. Precautions for Reassembly
• 4.5. Fuel Injection System
• 4.5.1. Introduction
• 4.5.2. Fuel Injection Pump
• 4.5.3. Governor Mechanism
• 4.5.4. Specifications of Fuel Injection Pump
• 4.6. Electrical Equipment
• 4.6.1. Starter Motor
• 4.6.2. Alternator
• 4.6.3. Glow Plug
• 5. Hydraulic System
• 5.1. Outline
• 5.2. Hydraulic Circuit Schematic
• 6. Hydraulic Equipment
• 6.1. Hydraulic Pump
• 6.2. Control Valve
• 6.3. Pilot Valve
• 6.4. Swing Motor
• 6.5. Travel Motor
• 6.5.1. Malfunction of equipment other than motor, counter balance valve and reduction gear.
• 6.5.2. Escape of pressure oil due to excessive wear of motors sliding parts.
• 6.5.3. Malfunction due to breakage of motors sliding parts. (In this case, motor makes an abnormal sound).
• 6.5.4. Relief valve operates due to too much load applied to motor.
• 6.5.5. Specified volume of oil is not being supplied to motor due to failure of hydraulic pump, system relief valve, etc.
• 6.5.6. Specified speed is not obtained due to drop of motors displacement.
• 6.5.7. A large volume of high pressure oil leaks and flows out from drain port due to wear of motors parts, causing a large drop and fluctuation in motor revolutions. The fluctuation is also caused by worn bearing.
• 6.5.8. Breakage of oil seals or O-rings.
• 6.5.9. Plunger is not moved.
• 6.5.10. Plunger does not return.
• 6.5.11. Plunger does not move smoothly.
• 6.5.12. Plunger is quick to return.
• 6.5.13. Plunger does not return.
• 6.5.14. Seat of check valve is defective.
• 6.5.15. Sticking of check valve
• 6.5.16. Spool does not move.
• 6.5.17. Oil leak due to excessive wear of high speed control piston.
• 6.5.18. High speed control piston is not installed.
• 6.5.19. Excessive wear of steel ball.
• 7. Adjustment and Repair
• 7.1. Electric Equipment of Machine
• 7.1.1. Parts Layout of Electrical Equipment
• 7.1.2. Monitor and Alarm Systems
• 7.1.3. Wiring Diagram
• 7.1.4. Circuit Description of Engine Start and Stop, and Battery Charging
• 7.1.5. Removal and Reinstallation of Engine
• 7.1.6. Removal and Reinstallation of Starter Motor
• 7.1.7. Removal and Reinstallation of Fuel Injection Pump
• 7.1.8. Removal and Reinstallation of Fuel Tank
• 7.1.9. Removal and Reinstallation of Radiator
• 7.2. Undercarriage
• 7.2.1. Outline
• 7.2.2. Major Parts
• 7.2.3. Points of Reassembly
• 7.2.4. Removal and Reinstallation of Crawler
• 7.2.5. Disassembly and Reassembly of Idler
• 7.2.6. Disassembly and Reassembly of Track 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 (Track Gauge Change Lever)
• 7.3.6. Adjustment of Lock Lever Switch
• 7.3.7. Adjustment of Accelerator Lever
• 7.3.8. Adjustment of P.T.O. Pedal
• 7.4. 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. Work Implements
• 7.6.1. Removal and Reinstallation of Work Implements
• 8. Periodic Inspection and Servicing
• 8.1. List of Periodic Inspection and Servicing
• 9. Fuel, Lube Oil and Grease Recommended
• 10. Troubleshooting
• 10.1. Non-Breakdowns
• 10.1.1. Natural Release of Bucket
• 10.1.2. Discontinuous Arm Movement
• 10.1.3. Drifting of Upperstructure on Quick Travel Operation
• 10.1.4. Thermal Shock of Travel Motor
• 10.1.5. Elongation of Boom Swing Cylinder on 75 degrees Swing
• 10.1.6. Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position
• 10.1.7. Time Lag on Travel Speed Switching
• 10.1.8. Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
• 10.2. Troubleshooting
• 10.2.1. Machine and Engine
• 10.2.2. Electrical Equipment on Panel
• 11. Reference Data
• 11.1. Specifications for Attachment