Yanmar SV05-A, SV05-B Excavator Service Manual

Description

• Model List:
  • SV05-A, SV05-B Excavator

• 1. SPINE TITLE
• 2. FOREWORD
• 3. CONTENTS
• 4. General Cautions for Maintenance Work
• 4.1. Correct Work
• 4.2. Safety Precautions
• 4.3. Preparations
• 4.4. Cautions for Disassembly and Reassembly
• 4.5. Cautions for Removal and Installation of Hydraulic Equipment
• 4.6. Cautions for Removal and Installation of Hydraulic Piping
• 4.7. Cautions for Handling Seals
• 4.8. Correct Installation of Hydraulic Hose
• 4.9. Specifications of Hydraulic Hose
• 4.10. Air Release of Hydraulic Equipment
• 5. Technical Data
• 5.1. Specifications
• 5.1.1. Machine Body
• 5.1.2. Engine
• 5.2. Outline Drawing and Working Area
• 5.2.1. W/O ROPS spec.
• 5.2.2. ROPS spec.
• 5.3. Weight List of Main Parts
• 5.4. Lifting Capacity List
• 5.4.1. W/O ROPS spec.
• 5.4.2. ROPS spec.
• 6. Service Standards
• 6.1. Machine Performance
• 6.2. Engine
• 6.2.1. SV05-A (2TE67-BV2)
• 6.2.2. SV05-B (2TE67L-XBV3)
• 6.3. Undercarriage
• 6.3.1. Rubber Crawler Specifications
• 6.4. Controls
• 6.5. Hydraulic Equipment
• 6.5.1. Hydraulic Cylinders
• 6.6. Implement
• 6.6.1. Front Attachments
• 6.6.2. Blade Moving Device
• 6.6.3. Bucket Teeth
• 6.7. List of Tightening Torque
• 6.7.1. Machine
• 6.7.2. Engine
• 6.7.3. Tightening Torque for General Bolts and Nuts (Engine)
• 6.7.4. Tightening Torque for General Bolts and Nuts (Machine)
• 6.7.5. Hydraulic Hose Joint
• 7. Engine
• 7.1. SV05-A (2TE67-BV2)
• 7.1.1. Measurement, Inspection and Adjustment
• 7.1.1.1. Measuring the Compression Pressure
• 7.1.1.2. Adjusting the Valve Clearance
• 7.1.1.3. Checking the V-belt Tension
• 7.1.1.4. Checking the Fuel Injection Valve
• 7.1.1.5. Checking and Adjusting the Fuel Injection Timing (FID)
• 7.1.1.6. Adjusting the Maximum (or Minimum) Idling Speed
• 7.1.1.7. Checking the Cooling Water System and Radiator for Water Leakage
• 7.1.1.8. Checking the Sensors
• 7.1.2. Measurement Procedure, Service Data and Corrective Action
• 7.1.2.1. Cylinder Head
• 7.1.2.2. Cylinder Block
• 7.1.2.3. Valve Rocker Arm
• 7.1.2.4. Piston and Piston Rings
• 7.1.2.5. Connecting Rod
• 7.1.2.6. Camshaft
• 7.1.2.7. Crankshaft
• 7.1.2.8. Gears
• 7.1.2.9. Trochoid Pump
• 7.1.3. Precautions for Reassembly
• 7.1.4. Fuel Oil Injection System
• 7.1.4.1. Fuel Oil Injection Pump
• 7.1.4.2. Disassembling Procedures
• 7.1.4.3. Reassembling Procedures
• 7.1.5. Electrical Equipment
• 7.1.5.1. Starter Motor
• 7.1.5.2. Alternator
• 7.1.5.3. Glow Plug
• 7.1.5.4. Stop Solenoid
• 7.2. SV05-B (2TE67L-XBV3)
• 7.2.1. Disassembly of Engine
• 7.2.1.1. Removing the Nozzle and Glow Plug
• 7.2.1.2. Removing the Cylinder Head Cover
• 7.2.1.3. Removing the Oil Pipe
• 7.2.1.4. Removing the Water Pump Assembly
• 7.2.1.5. Removing the Rocker Arm and Push Rods
• 7.2.1.6. Removing the Exhaust Manifold
• 7.2.1.7. Removing the Cylinder Head
• 7.2.1.8. Removing the Tappets
• 7.2.1.9. Removing the Injection Pump Assembly
• 7.2.1.10. Removing the Crankshaft Pulley
• 7.2.1.11. Removing the Timing Gear Case Assembly
• 7.2.1.12. Removing the Idle Gear and Oil Pump Assembly
• 7.2.1.13. Removing the Camshaft Assembly
• 7.2.1.14. Removing the Suction Filter and Pipe
• 7.2.1.15. Removing the Connecting Rods and Pistons
• 7.2.1.16. Removing the Crankshaft Assembly
• 7.2.2. Disassembly, Inspection and Reassembly of Main Component Parts
• 7.2.2.1. Cylinder Head
• 7.2.2.2. Rocker Arm
• 7.2.2.3. Cylinder Block
• 7.2.2.4. Piston and Piston Rings
• 7.2.2.5. Connecting Rod
• 7.2.2.6. Connecting Rod Metal
• 7.2.2.7. Bearing Holder
• 7.2.2.8. Crankshaft Bearing
• 7.2.2.9. Crankshaft
• 7.2.2.10. Timing Gears and Camshaft Assembly
• 7.2.2.11. Lubrication Oil Pump
• 7.2.2.12. Thermostat
• 7.2.2.13. Nozzle and Holder Assembly
• 7.2.2.14. Flywheel and Ring Gear
• 7.2.3. Reassembly of Engine
• 7.2.3.1. Crankshaft and Bearing Holder Assembly
• 7.2.3.2. Oil Seal and Flywheel Cover (Rear Plate)
• 7.2.3.3. Flywheel
• 7.2.3.4. Pistons and Connecting Rods
• 7.2.3.5. Suction Pipe and Suction Filter
• 7.2.3.6. Oil Pan and Front Plate
• 7.2.3.7. Camshaft Assembly and Plate
• 7.2.3.8. Idle Gear and Oil Pump Assembly
• 7.2.3.9. Timing Gear Case
• 7.2.3.10. Crankshaft Pulley
• 7.2.3.11. Injection Pump Assembly
• 7.2.3.12. Oil filter and Oil Pipe
• 7.2.3.13. Tappets
• 7.2.3.14. Cylinder Head Assembly and Cylinder Head Gasket
• 7.2.3.15. Caps, Push Rods and Rocker Arm Assembly
• 7.2.3.16. Adjusting the valve clearance
• 7.2.3.17. Cylinder Head Cover
• 7.2.3.18. Water Pump Assembly
• 7.2.3.19. Oil Pressure Switch
• 7.2.3.20. Nozzle and Holder Assembly
• 7.2.3.21. Return Pipes and Injection Pipes
• 7.2.3.22. V-belt
• 7.2.4. Electrical Equipment
• 7.2.4.1. Starter Motor
• 7.2.4.2. Alternator
• 7.2.4.3. Glow Plug
• 7.2.4.4. Stop Solenoid
• 7.2.5. Troubleshooting
• 8. Hydraulic System
• 8.1. Outline
• 8.1.1. Control Valve Operation
• 8.2. Hydraulic Oil Circuit Schematic
• 8.3. Circuit Operation
• 8.3.1. Boom
• 8.3.2. Arm
• 8.3.3. Bucket
• 8.3.4. Swing
• 8.3.5. Boom Swing
• 8.3.6. Blade
• 8.3.7. Travel
• 8.3.8. Simultaneous Operation of Travel and Blade
• 8.3.9. Simultaneous Operation of Boom Up and Bucket
• 8.3.10. Hydraulic P.T.O.
• 8.4. Pressure Adjustment
• 8.4.1. System Relief Valves
• 8.4.2. Circuit Relief Valves
• 8.4.3. Swing Combination Valve (Brake Valve)
• 9. Hydraulic Equipment
• 9.1. Hydraulic Pump
• 9.2. Control Valve
• 9.3. Swing Motor
• 9.4. Travel Motor
• 10. Adjustment and Repair
• 10.1. Electrical Equipment and Engine of Machine
• 10.1.1. Parts Layout of Electrical Equipment
• 10.1.2. Monitor and Alarm Systems
• 10.1.3. Wiring Diagram
• 10.1.4. Circuit Description of Engine Start and Stop, and Battery Charge
• 10.1.5. Removal and Reinstallation of Engine
• 10.1.6. Removal and Reinstallation of Starter Motor
• 10.1.7. Removal and Reinstallation of Fuel Tank
• 10.1.8. Removal and Reinstallation of Radiator
• 10.1.9. Removal and Reinstallation of Muffler
• 10.2. Undercarriage
• 10.2.1. Outline
• 10.2.2. Points of Reassembly
• 10.2.3. Removal and Reinstallation of Crawler
• 10.2.4. Disassembly and Reassembly of Idler
• 10.2.5. Disassembly and Reassembly of Track Roller
• 10.3. Controls
• 10.3.1. Control Train
• 10.3.2. Removal and Reinstallation of Control Levers
• 10.3.3. Adjustment of Control Levers
• 10.3.4. Adjustment of Boom Swing Pedal
• 10.3.5. Adjustment of P.T.O. Pedal
• 10.3.6. Adjustment of Accelerator Lever (Adjustment of Engine Idling Speed)
• 10.4. Swing Bearing
• 10.4.1. Removal and Reinstallation of Swing Bearing
• 10.5. Hydraulic Equipment
• 10.5.1. Removal and Reinstallation of Hydraulic Pump
• 10.5.2. Removal and Reinstallation of Control Valve
• 10.5.3. Removal and Reinstallation of Swing Motor
• 10.5.4. Removal and Reinstallation of Swivel Joint
• 10.5.5. Disassembly and Reassembly of Swivel Joint
• 10.5.6. Disassembly and Reassembly of Hydraulic Cylinders
• 10.5.7. Removal and Reinstallation of Hydraulic Oil Tank
• 10.5.8. Piping Layout
• 10.6. Implement
• 10.6.1. Removal and Reinstallation of Implement
• 11. Periodic Inspection and Servicing
• 11.1. List of Periodic Inspection and Servicing
• 12. Fuel, Lube Oil and Grease Recommended
• 13. Troubleshooting
• 13.1. Non-Breakdowns
• 13.1.1. Natural Release of Bucket
• 13.1.2. Discontinuous Arm Movement
• 13.1.3. Drifting of Upperstructure on Quick Travel Operation
• 13.1.4. Thermal Shock of Travel Motor
• 13.1.5. Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
• 13.2. Troubleshooting
• 13.2.1. Machine and Engine
• 13.2.2. Electrical Equipment on Panel
• 14. Reference Data
• 14.1. Specifications for Attachment