Yanmar SV60-B Excavator Service Manual

Description

• Model List:
  • SV60-B Excavator

• 1. FOREWORD
• 2. GENERAL CAUTIONS FOR MAINTENANCE WORK
• 2.1. Correct Work
• 2.2. Safety Precautions
• 2.3. Preparations
• 2.4. Cautions for Disassembly and Reassembly
• 2.5. Cautions for Removal and Installation of Hydraulic Equipment
• 2.6. Cautions for Removal and Installation of Hydraulic Piping
• 2.7. Cautions for Handling Seals
• 2.8. Correct Installation of Hydraulic Hose
• 2.9. Specification of Hydraulic Hose
• 2.10. Air Release of Hydraulic Equipment
• 3. TECHNICAL DATA
• 3.1. Specifications
• 3.2. Outline Drawing and Working Area
• 3.3. Weight List of Main Parts
• 3.4. Lifting Capacity List
• 3.5. Specifications for Attachment
• 3.6. Periodic Inspection and Servicing
• 3.7. Fuel, Lube Oil and Grease Recommended
• 3.8. Hydraulic Circuit Schematic
• 3.9. Wiring Diagram
• 4. SERVICE STANDARDS
• 4.1. Machine Performance
• 4.2. Engine
• 4.2.1. Nominal and Allowable Values
• 4.3. Undercarriage
• 4.3.1. Rubber Crawler Specifications
• 4.3.2. Steel Crawler Specifications
• 4.3.3. Common Specifications of Steel Rubber Crawlers
• 4.4. Controls
• 4.5. Hydraulic Equipment
• 4.5.1. Hydraulic Cylinders
• 4.6. Implement
• 4.6.1. Front Attachments
• 4.6.2. Blade Moving Device
• 4.6.3. Bucket Teeth
• 4.7. List of Tightening Torque
• 4.7.1. Machine
• 4.7.2. Engine
• 4.7.3. Tightening Torque for General Bolts and Nuts
• 4.7.4. Hydraulic Fitting
• 4.8. Pressure Adjustment
• 4.8.1. Relief Valves
• 4.8.2. Swing Brake Valve
• 4.8.3. Cut-Off Valve
• 5. ENGINE
• 5.1. Safety
• 5.1.1. Safety Statements
• 5.1.2. Safety Precautions
• 5.2. Engine
• 5.2.1. Before You Begin Servicing
• 5.2.2. Introduction
• 5.2.3. Special Service Tools
• 5.2.4. Measuring Instruments
• 5.2.5. Cylinder Head
• 5.2.6. Measuring and Adjusting Valve Clearance
• 5.2.7. Crankshaft and Camshaft Components
• 5.2.8. EGR System
• 5.2.9. Intake Throttle
• 5.3. Fuel System
• 5.3.1. Before You Begin Servicing
• 5.3.2. System Structure
• 5.3.3. Fuel System Specifications
• 5.3.4. Fuel System Diagram
• 5.3.5. Fuel System Components
• 5.4. Cooling System
• 5.4.1. Before You Begin Servicing
• 5.4.2. Introduction
• 5.4.3. Cooling System Diagram
• 5.4.4. Engine Coolant Pump Components
• 5.4.5. Engine Coolant System Check
• 5.4.6. Engine Coolant Pump
• 5.5. Lubrication System
• 5.5.1. Before You Begin Servicing
• 5.5.2. Introduction
• 5.5.3. Lubrication System Diagram
• 5.5.4. Checking Engine Oil Pressure
• 5.5.5. Oil Pump Components
• 5.6. Turbocharger
• 5.6.1. Before You Begin Servicing
• 5.6.2. Introduction
• 5.6.3. Specifications
• 5.6.4. Troubleshooting
• 5.6.5. Turbocharger Components
• 5.6.6. Turbocharger Component Functions
• 5.6.7. Washing Procedure
• 5.6.8. Periodic Inspection
• 5.7. Starter Motor
• 5.7.1. Before You Begin Servicing
• 5.7.2. Introduction
• 5.7.3. Starter Motor Specifications
• 5.7.4. Starter Motor Troubleshooting
• 5.7.5. Starter Motor Components
• 5.7.6. Starter Motor
• 5.8. Alternator
• 5.8.1. Before You Begin Servicing
• 5.8.2. Introduction
• 5.8.3. Alternator Specifications
• 5.8.4. Alternator Troubleshooting
• 5.8.5. Alternator Components
• 5.8.6. Alternator Wiring Diagram
• 5.8.7. Alternator Standard Output
• 5.8.8. Alternator
• 5.9. Electronic Control System
• 5.9.1. Before You Begin Servicing
• 5.9.2. Introduction
• 5.9.3. System Structure
• 5.9.4. How to Remove and Reattach the Diesel Particulate Filter (DPF)
• 5.9.5. SF and DPF Maintenance Kit
• 5.9.6. Troubleshooting of Electronic Control System
• 5.9.7. Replacement of Components
• 5.9.8. Installation Position of Sensors
• 5.10. Electric Wiring
• 5.10.1. Electric Wiring Precautions
• 5.11. Failure Diagnosis
• 5.11.1. Special Service Tools
• 5.11.2. Troubleshooting By Measuring Compression Pressure
• 5.12. Troubleshooting
• 5.12.1. Quick Reference Table for Troubleshooting
• 6. ELECTRIC SYSTEM
• 6.1. Electric Equipment of Machine
• 6.1.1. Parts Layout of Electrical Equipment
• 6.1.2. LCD Monitor and Alarm Systems
• 6.2. Circuit Description of Engine Start and Stop
• 6.3. Engine ECU (engine controller)
• 6.3.1. Engine ECU
• 6.3.2. Circuit Description of Auto Deceleration Mode
• 6.3.3. Circuit Description of Eco Mode
• 6.3.4. Control Functions
• 6.4. Battery
• 6.5. Error Code List
• 7. HYDRAULIC SYSTEM
• 7.1. Outline
• 7.1.1. Control Valve Operation
• 7.1.2. Additional Operation of Control Valve
• 7.2. Circuit Operation
• 7.2.1. Boom
• 7.2.2. Arm
• 7.2.3. Bucket
• 7.2.4. Swing
• 7.2.5. Boom Swing
• 7.2.6. Blade
• 7.2.7. Travel
• 7.2.8. Non-Deviation Travel (with Boom, Arm orBoom Swing Operation)
• 7.2.9. Non-Deviation Travel (with Bucket Operation)
• 7.2.10. Simultaneous Operation of Boom Upand Arm Retract
• 7.2.11. Simultaneous Operation of Boom Upand Bucket
• 7.2.12. Simultaneous Operation of Boom Upand Swing
• 7.2.13. Simultaneous Operation of Arm andBucket
• 7.2.14. Hydraulic P.T.O. 1
• 7.2.15. Hydraulic P.T.O. 2 (Optional)
• 7.2.16. Travel Alarm
• 7.2.17. Auto Deceleration
• 7.3. Hydraulic Pump
• 7.4. Control Valve
• 7.5. Pilot Valve
• 7.6. Swing Motor
• 7.7. Travel Motor
• 7.8. Proportional solenoid valve for P.T.O.
• 8. ADJUSTMENT AND REPAIR
• 8.1. Engine and Electric Equipment
• 8.1.1. Removal and Reinstallation of Engine
• 8.1.2. Removal and Reinstallation of Starter Motor
• 8.1.3. Removal and Reinstallation of Radiator and Oil Cooler
• 8.1.4. Removal and Reinstallation of Fan Belt and Compressor Driving Belt
• 8.1.5. Removal and Reinstallation of Engine ECU
• 8.1.6. Removal and Reinstallation of Diesel Particulate Filter (DPF)
• 8.2. Undercarriage
• 8.2.1. Outline
• 8.2.2. Main Parts
• 8.2.3. Points of Reassembly (Rubber Track)
• 8.2.4. Points of Reassembly (Steel Track)
• 8.2.5. Removal and Reinstallation of Crawler
• 8.2.6. Removal and Reinstallation of Travel Motor
• 8.2.7. Disassembly and Reassembly of Idler
• 8.2.8. Disassembly and Reassembly of Track Roller
• 8.2.9. Disassembly and Reassembly of Carrier Roller
• 8.2.10. Installation of Floating Seal
• 8.2.11. Drawings of Jig
• 8.3. Controls
• 8.3.1. Mechanical Control Linkage
• 8.3.2. Adjustment of Travel Levers
• 8.3.3. Adjustment of Boom Swing Pedal
• 8.3.4. Adjustment of Blade Lever
• 8.3.5. Adjustment of Lock Lever
• 8.4. Swing Bearing
• 8.5. Hydraulic Equipment
• 8.5.1. Removal and Reinstallation of Hydraulic Pump
• 8.5.2. Removal and Reinstallation of Control Valve
• 8.5.3. Removal and Reinstallation of Pilot Valves (L and R)
• 8.5.4. Removal and Reinstallation of Swing Motor
• 8.5.5. Removal and Reinstallation of Swivel Joint
• 8.5.6. Disassembly and Reassembly of Swivel Joint
• 8.5.7. Disassembly and Reassembly of Hydraulic Cylinder
• 8.5.8. Removal and Reinstallation of Fuel Tank
• 8.5.9. Removal and Reinstallation of Hydraulic Oil Tank
• 8.5.10. Piping Layout
• 8.6. Work Implements
• 8.6.1. Removal and Reinstallation of Work Implements
• 8.7. Cabin
• 8.7.1. Removal and Reinstallation of Cabin
• 8.7.2. Disassembly and Reassembly of Cabin
• 8.8. Air Conditioner
• 8.8.1. Removal and Reinstallation of Air Conditioner
• 9. TROUBLESHOOTING
• 9.1. Non-Breakdowns
• 9.1.1. Natural Release of Bucket
• 9.1.2. Discontinuous Arm Movement
• 9.1.3. Drifting of Upperstructure on Quick Travel Operation
• 9.1.4. Thermal Shock of Travel Motor
• 9.1.5. Elongation of Boom Swing Cylinder on 68 degrees Swing
• 9.1.6. Time Lag on Travel Speed Switching
• 9.1.7. Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
• 9.2. Quick Reference Table for Troubleshooting