Yanmar ViO82 Hydraulic Excavator Service Manual

Description

• Model List:
  • ViO82 Hydraulic Excavator

• 1. Foreword
• 2. Contents
• 3. General Cautions for Maintenance Work
• 3.1. Correct Work
• 3.2. Safety Precautions
• 3.3. Preparations
• 3.4. Cautions for Disassembly and Reassembly
• 3.5. Cautions for Removal and Installation of Hydraulic Equipment
• 3.6. Cautions for Removal and Installation of Hydraulic Piping
• 3.7. Cautions for Handling Seals
• 3.8. Correct Installation of Hydraulic Hose
• 3.9. Specifications of Hydraulic Hose
• 3.10. Air Release of Hydraulic Equipment
• 4. Technical Data
• 4.1. Specifications
• 4.1.1. Standard arm type
• 4.1.2. Long arm type
• 4.2. Outline Drawing and Working Area
• 4.2.1. Standard arm type
• 4.2.2. Long arm type
• 4.3. Weight List of Main Parts
• 4.4. Lifting Capacity List
• 4.4.1. Standard arm type
• 4.4.2. Long arm type
• 4.5. Specifications for Attachment
• 4.6. Periodic Inspection and Servicing
• 4.7. Fuel, Lube Oil and Grease Recommended
• 4.8. Hydraulic Circuit Schematic
• 4.9. Wiring Diagram
• 5. Service Standards
• 5.1. Machine Performance
• 5.2. Engine
• 5.3. Undercarriage
• 5.3.1. Rubber Crawler Specifications
• 5.3.2. Steel Crawler Specifications
• 5.3.3. Common Specifications of Steel Rubber Crawlers
• 5.4. Controls
• 5.5. Hydraulic Equipment
• 5.5.1. Hydraulic Cylinders
• 5.6. Implement
• 5.6.1. Front Attachments
• 5.6.2. Blade Moving Device
• 5.7. List of Tightening Torque
• 5.7.1. Machine
• 5.7.2. Engine
• 5.7.3. Tightening Torque for General Bolts and Nuts
• 5.7.4. Hydraulic Fitting
• 5.8. Pressure Adjustment
• 5.8.1. Relief Valves
• 5.8.2. Swing Brake Valve
• 5.8.3. Cut-off Valve
• 6. Engine
• 6.1. Safety
• 6.1.1. Safety Statements
• 6.1.2. Safety Precautions
• 6.2. Engine
• 6.2.1. Before You Begin Servicing
• 6.2.2. Special Service Tools
• 6.2.3. Measuring Instruments
• 6.2.4. Cylinder Head
• 6.2.5. Measuring and Adjusting Valve Clearance
• 6.2.6. Crankshaft and Camshaft Components
• 6.2.7. EGR System
• 6.3. Fuel System
• 6.3.1. Before You Begin Servicing
• 6.3.2. System Structure
• 6.3.3. Fuel System Diagram
• 6.3.4. Fuel System Components
• 6.4. Cooling System
• 6.4.1. Before You Begin Servicing
• 6.4.2. Introduction
• 6.4.3. Cooling System Diagram
• 6.4.4. Engine Coolant Pump Components
• 6.4.5. Engine Coolant System Check
• 6.4.6. Engine Coolant Pump
• 6.5. Lubrication System
• 6.5.1. Before You Begin Servicing
• 6.5.2. Introduction
• 6.5.3. Lubrication System Diagram
• 6.5.4. Checking Engine Oil Pressure
• 6.5.5. Trochoid Oil Pump
• 6.6. Starter Motor
• 6.6.1. Before You Begin Servicing
• 6.6.2. Introduction
• 6.6.3. Starter Motor Specifications
• 6.6.4. Starter Motor Troubleshooting
• 6.6.5. Starter Motor Components
• 6.6.6. Starter Motor
• 6.7. Alternator
• 6.7.1. Before You Begin Servicing
• 6.7.2. Introduction
• 6.7.3. Alternator Specifications
• 6.7.4. Alternator Troubleshooting
• 6.7.5. Alternator Components
• 6.7.6. Alternator Wiring Diagram
• 6.7.7. Alternator Standard Output
• 6.7.8. Alternator
• 6.8. Electronic Control System
• 6.8.1. Before You Begin Servicing
• 6.8.2. System Structure
• 6.8.3. Electronic Engine Speed Control
• 6.8.4. Diesel Particulate Filter (DPF)
• 6.8.5. SMARTASSIST DIRECT (SA-D)
• 6.8.6. Replacement of Components
• 6.8.7. Installation Position of Sensors
• 6.9. Electric Wiring
• 6.9.1. Electric Wiring Precautions
• 6.10. Failure Diagnosis
• 6.10.1. Special Service Tools
• 6.10.2. Tier 4 (BOSCH) Compression Inspection Procedures
• 6.10.3. Measured Value and Troubleshooting
• 6.10.4. Quick Reference Table for Troubleshooting
• 7. Electric System
• 7.1. Electric Equipment of Machine
• 7.1.1. Parts Layout of Electrical Equipment
• 7.1.2. LCD Monitor and Alarm Systems
• 7.2. Circuit Description of Engine Start and Stop
• 7.3. Engine ECU (engine controller)
• 7.3.1. Outline
• 7.3.2. Control Functions
• 7.4. Pump ECU (Pump Controller)
• 7.4.1. Outline
• 7.4.2. Engine Control
• 7.4.3. Speed Sensing Horsepower Limit Control
• 7.4.4. Load Sensing Gain Control (Pump Flow Rate Control)
• 7.4.5. Implement-limiting Control During Travel
• 7.5. Error Code
• 8. Hydraulic System
• 8.1. Outline
• 8.2. Hydraulic Pump
• 8.2.1. Main Specifications and Appearance
• 8.2.2. Basic Configuration and Operation Theory
• 8.2.3. Part Names
• 8.2.4. Disassembly and Reassembly
• 8.2.5. Service Standards
• 8.2.6. Troubleshooting
• 8.3. Control Valve
• 8.4. Pilot Valve
• 8.4.1. Remote Control Valve
• 8.4.2. Travel Pilot Valve
• 8.4.3. Blade and Boom Swing Pilot Valve
• 8.5. Swing Motor
• 8.5.1. Overview
• 8.5.2. Description of Functions and Operation
• 8.5.3. Precautions for Handling
• 8.5.4. Troubleshooting
• 8.5.5. Employment Tool
• 8.5.6. Disassembly Procedure
• 8.5.7. Assembly Procedure
• 8.5.8. Quality Check After Reassembly.
• 8.6. Travel Motor
• 8.6.1. Product Overview
• 8.6.2. External Dimensions
• 8.6.3. Basic Configuration and Drawing
• 8.6.4. Operating Description
• 8.6.5. Troubleshooting
• 8.6.6. Service outline
• 8.6.7. Disassembly
• 8.6.8. Service Standard
• 8.6.9. Assembly
• 8.6.10. Performance Confirmation Test
• 8.7. Pump Control Proportional Solenoid Valve
• 8.8. Cutoff Valve
• 8.9. Quick Coupler Solenoid Valve
• 8.10. Pilot Check Valve (Quick Coupler)
• 8.11. Travel Priority Proportional Solenoid Valve
• 9. Adjustment and Repair
• 9.1. Engine and Electric Equipment
• 9.1.1. Removal and Reinstallation of Engine
• 9.1.2. Removal and Reinstallation of Starter Motor
• 9.1.3. Removal and Reinstallation of Radiator and Oil cooler
• 9.1.4. Removal and Reinstallation of Fan Belt and Compressor Driving Belt
• 9.1.5. Removal and Reinstallation of Engine ECU
• 9.1.6. Removal and Reinstallation of Pump ECU
• 9.1.7. Removal and Reinstallation of Diesel Particulate Filter (DPF)
• 9.2. Undercarriage
• 9.2.1. Outline
• 9.2.2. Compatibility of Main Parts
• 9.2.3. Points of Reassembly (Rubber Crawler Type)
• 9.2.4. Points of Reassembly (Steel Crawler Type)
• 9.2.5. Removal and Reinstallation of Crawler
• 9.2.6. Disassembly and Reassembly of Steel Crawler
• 9.2.7. Removal and Reinstallation of Travel Motor
• 9.2.8. Disassembly and Reassembly of Idler
• 9.2.9. Disassembly and Reassembly of Track Roller
• 9.2.10. Disassembly and Reassembly of Carrier Roller
• 9.2.11. Installation of Floating Seal
• 9.2.12. Drawings of Jigs
• 9.3. Controls
• 9.3.1. Control Lever
• 9.3.2. Travel Lever
• 9.3.3. Adjustment of Lock Lever
• 9.4. Swing Bearing
• 9.4.1. Removal and Reinstallation of Swing Bearing
• 9.5. Hydraulic Equipment
• 9.5.1. Removal and Reinstallation of Hydraulic Pump
• 9.5.2. Removal and Reinstallation of Control Valve
• 9.5.3. Removal and Reinstallation of Remote Control Valves
• 9.5.4. Removal and Reinstallation of Blade Pilot Valve
• 9.5.5. Removal and Reinstallation of Travel Pilot Valve
• 9.5.6. Removal and Reinstallation of Boom Swing Pilot Valve
• 9.5.7. Removal and Reinstallation of Solenoid Valve
• 9.5.8. Removal and Reinstallation of P.T.O. 1 Solenoid Valve
• 9.5.9. Removal and Reinstallation of P.T.O. 2 Solenoid Valve
• 9.5.10. Removal and Reinstallation of Pump Control Proportional Solenoid Valve
• 9.5.11. Removal and Reinstallation of Travel Priority Proportional Solenoid Valve
• 9.5.12. Removal and Reinstallation of Line Filter
• 9.5.13. Removal and Reinstallation of Accumulator
• 9.5.14. Removal and Reinstallation of Swing Motor
• 9.5.15. Removal and Reinstallation of Swivel Joint
• 9.5.16. Disassembly and Reassembly of Swivel Joint
• 9.5.17. Disassembly and Reassembly of Hydraulic Cylinders
• 9.5.18. Hydraulic Oil Tank
• 9.5.19. Piping Layout
• 9.6. Implement
• 9.6.1. Removal and Reinstallation of Implement
• 9.6.2. Quick Coupler
• 9.7. Cabin
• 9.7.1. Removal and Reinstallation of Cabin
• 9.7.2. Disassembly and Reassembly of Cabin
• 9.7.3. Window/Door Glass Replacement Procedure
• 9.8. Air Conditioner
• 9.8.1. Removal and Reinstallation of Air Conditioner
• 10. Troubleshooting
• 10.1. Non-breakdowns
• 10.1.1. Natural Release of Bucket
• 10.1.2. Discontinuous Arm and Bucket Movement
• 10.1.3. Thermal Shock of Travel Motor
• 10.1.4. Elongation of Boom Swing Cylinder on 60 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. Quick Reference Table for Troubleshooting
• 11. Colophon
• 12. Appendix