Yanmar SV86-7, SV100-7 Mini Excavator Service Manual

Description

• Model List:
  • SV86-7, SV100-7 Mini Excavator

• 1. SV86-7 SV100-7 SERVICE MANUAL.pdf
• 1.1. Foreword
• 1.2. CONTENTS
• 1.3. General Cautions for Maintenance Work
• 1.3.1. Correct Work
• 1.3.2. Safety Precautions
• 1.3.3. Preparations
• 1.3.4. Cautions for Disassembly and Reassembly
• 1.3.5. Cautions for Removal and Installation of Hydraulic Equipment
• 1.3.6. Cautions for Removal and Installation of Hydraulic Piping
• 1.3.7. Cautions for Handling Seals
• 1.3.8. Correct Installation of Hydraulic Hose
• 1.3.9. Specifications of Hydraulic Hose
• 1.3.10. Air Release of Hydraulic Equipment
• 1.4. Technical Data
• 1.4.1. Specifications
• 1.4.1.1. Standard arm type
• 1.4.1.2. Long arm type
• 1.4.1.3. Arti-boom type
• 1.4.2. Outline Drawing and Working Area
• 1.4.2.1. Standard arm type
• 1.4.2.2. Long arm type
• 1.4.2.3. Arti-boom type
• 1.4.3. Weight List of Main Parts
• 1.4.4. Lifting Capacity List
• 1.4.4.1. SV86-7
• 1.4.4.2. SV100-7
• 1.4.5. Specifications for Attachment
• 1.4.5.1. SV86-7
• 1.4.5.2. SV100-7
• 1.4.6. Periodic Inspection and Servicing
• 1.4.7. Fuel, Lube Oil and Grease Recommended
• 1.4.8. Hydraulic Circuit Schematic
• 1.4.8.1. SV86-7
• 1.4.8.2. SV86-7 (Arti-boom spec.)
• 1.4.8.3. SV100-7
• 1.4.8.4. SV100-7 (Arti-boom spec.)
• 1.4.9. Wiring Diagram
• 1.5. Service Standards
• 1.5.1. Machine Performance
• 1.5.2. Engine
• 1.5.3. Undercarriage
• 1.5.3.1. Rubber Crawler Specifications
• 1.5.3.2. Steel Crawler Specifications
• 1.5.3.3. Common Specifications of Steel Rubber Crawlers
• 1.5.4. Controls
• 1.5.5. Hydraulic Equipment
• 1.5.5.1. Hydraulic Cylinders
• 1.5.6. Implement
• 1.5.6.1. Front Attachments
• 1.5.6.2. Blade Moving Device
• 1.5.7. List of Tightening Torque
• 1.5.7.1. Special management parts for main machine
• 1.5.7.2. Engine
• 1.5.7.3. Tightening Torque for General Bolts and Nuts
• 1.5.7.4. Hydraulic Fitting
• 1.5.7.5. Solenoids tightening torque
• 1.5.7.6. Breathers tightening torque
• 1.5.8. Pressure Adjustment
• 1.5.8.1. Relief Valves
• 1.5.8.2. Swing Brake Valve
• 1.5.8.3. Cut-off Valve
• 1.5.8.4. Accumulator
• 1.6. Engine
• 1.6.1. INTRODUCTION
• 1.6.2. YANMAR WARRANTIES
• 1.6.2.1. YANMAR LIMITED WARRANTY
• 1.6.2.2. YANMAR POWER TECHNOLOGY CO., LTD. LIMITED EMISSION CONTROL SYSTEMWARRANTY
• 1.6.3. SAFETY
• 1.6.3.1. SAFETY STATEMENTS
• 1.6.3.2. SAFETY PRECAUTIONS
• 1.6.4. PRODUCT OVERVIEW
• 1.6.4.1. YANMAR TNV/TN ENGINE FEATURES AND APPLICATIONS
• 1.6.4.2. COMPONENT IDENTIFICATION
• 1.6.4.3. LOCATION OF LABELS
• 1.6.4.4. EMISSION CONTROL REGULATIONS
• 1.6.4.5. EMISSION CONTROL LABELS
• 1.6.4.6. ENGINE FAMILY
• 1.6.4.7. FUNCTION OF MAJOR ENGINE COMPONENTS
• 1.6.4.8. FUNCTION OF COOLING SYSTEM COMPONENTS
• 1.6.4.9. ELECTRONIC CONTROL SYSTEM
• 1.6.4.10. INSTALLATION POSITION OF SENSORS FOR ELECTRONIC CONTROL SYSTEM
• 1.6.4.11. GAUGES AND INDICATORS
• 1.6.5. BEFORE YOU OPERATE
• 1.6.5.1. DIESEL FUEL
• 1.6.5.2. ENGINE LUBRICATING OIL
• 1.6.5.3. ENGINE COOLANT
• 1.6.5.4. DAILY CHECKS
• 1.6.6. ENGINE OPERATION
• 1.6.6.1. STARTING ENGINE
• 1.6.6.2. CHECKING THE ENGINE DURING OPERATION
• 1.6.6.3. SHUTTING DOWN THE ENGINE
• 1.6.7. PERIODIC MAINTENANCE
• 1.6.7.1. PRECAUTIONS
• 1.6.7.2. STANDARD TORQUE CHART
• 1.6.7.3. PERIODIC MAINTENANCE SCHEDULE
• 1.6.7.4. PERIODIC MAINTENANCE PROCEDURES
• 1.6.8. TROUBLESHOOTING
• 1.6.8.1. TROUBLESHOOTING CHART
• 1.6.8.2. TROUBLESHOOTING INFORMATION
• 1.6.8.3. TROUBLESHOOTING OF ELECTRONIC CONTROL SYSTEM
• 1.6.8.4. TROUBLESHOOTING FOR ELECTRONIC CONTROL SYSTEM
• 1.6.9. LONG-TERM STORAGE
• 1.6.9.1. BEFORE YOU PLACE THE ENGINE IN LONG-TERM STORAGE
• 1.6.9.2. RETURNING THE ENGINE TO SERVICE
• 1.6.10. SPECIFICATIONS
• 1.6.10.1. GENERAL
• 1.6.10.2. PRINCIPAL ENGINE SPECIFICATIONS
• 1.7. Electric System
• 1.7.1. Electric Equipment of Machine
• 1.7.1.1. Parts Layout of Electrical Equipment
• 1.7.1.2. LCD Monitor and Alarm Systems
• 1.7.2. Circuit Description of Engine Start Stop and battery charge
• 1.7.3. Engine ECU (engine controller)
• 1.7.3.1. Outline
• 1.7.3.2. Control Functions
• 1.7.4. Hydraulic ECU (Pump Controller)
• 1.7.4.1. Outline
• 1.7.4.2. Engine Control
• 1.7.4.3. Speed Sensing Horsepower Limit Control
• 1.7.4.4. Load Sensing Gain Control (Pump Flow Rate Control)
• 1.7.5. Camera adjustment
• 1.7.6. Error Code
• 1.7.7. Battery
• 1.7.7.1. Generality
• 1.7.7.2. Maintenance
• 1.8. Hydraulic System
• 1.8.1. Outline
• 1.8.1.1. Control Valve Operation
• 1.8.1.2. Additional Operation of Control Valve
• 1.8.2. Circuit Operation
• 1.8.2.1. Boom
• 1.8.2.2. Arm
• 1.8.2.3. Bucket
• 1.8.2.4. Simultaneous Implement Operations
• 1.8.2.5. Swing
• 1.8.2.6. Boom Swing
• 1.8.2.7. Arti-boom (Arti-boom spec.)
• 1.8.2.8. Blade
• 1.8.2.9. Travel
• 1.8.2.10. Non-deviation Travel (Example Simultaneousoperation of traveling forward,boom raising, and arm excavation)
• 1.8.2.11. Hydraulic AUX1
• 1.8.2.12. Hydraulic AUX2
• 1.8.2.13. Hydraulic AUX3 (AUX3 Spec.)
• 1.8.2.14. Auto Deceleration
• 1.8.3. Hydraulic Pump
• 1.8.3.1. Main Specifications and Appearance
• 1.8.3.2. Basic Configuration and Operation Theory
• 1.8.3.3. Part Names
• 1.8.3.4. Disassembly and Reassembly
• 1.8.3.5. Service Standards
• 1.8.3.6. Troubleshooting
• 1.8.4. Control Valve
• 1.8.5. Pilot Valve
• 1.8.5.1. Remote Control Valve
• 1.8.5.2. Travel Pilot Valve
• 1.8.5.3. Blade valve (Swing valve)
• 1.8.6. Swing Motor
• 1.8.6.1. Overview
• 1.8.6.2. Description of Functions and Operation
• 1.8.6.3. Precautions for Handling
• 1.8.6.4. Troubleshooting
• 1.8.6.5. Employment Tool
• 1.8.6.6. Disassembly Procedure
• 1.8.6.7. Assembly Procedure
• 1.8.6.8. Quality Check After Reassembly.
• 1.8.7. Travel Motor (SV86-7)
• 1.8.7.1. Product Overview
• 1.8.7.2. External Dimensions
• 1.8.7.3. Basic Configuration and Drawing
• 1.8.7.4. Operating Description
• 1.8.7.5. Troubleshooting
• 1.8.7.6. Service outline
• 1.8.7.7. Disassembly
• 1.8.7.8. Service Standard
• 1.8.7.9. Assembly
• 1.8.7.10. Performance Confirmation Test
• 1.8.8. Travel Motor (SV100-7)
• 1.8.8.1. Product Overview
• 1.8.8.2. External Dimensions and Circuit Diagram
• 1.8.8.3. Basic Configuration and Drawing
• 1.8.8.4. Operating Description
• 1.8.8.5. Procedures for Replacement of Gear Oil
• 1.8.8.6. Troubleshooting
• 1.8.8.7. Storage of the Travel Unit
• 1.8.8.8. Disposal Methods
• 1.8.8.9. Outline of Services
• 1.8.8.10. Disassembly
• 1.8.8.11. Service Standard
• 1.8.8.12. Assembly
• 1.8.8.13. Performance Confirmation Test
• 1.8.9. Pump Control Proportional Solenoid Valve
• 1.8.10. Arti-boom check valve
• 1.8.11. Solenoid Valve
• 1.8.12. Quick Coupler Solenoid Valve
• 1.8.13. AUX Solenoid
• 1.8.14. Safety Valve
• 1.8.15. High/Low switching Valve
• 1.8.16. Hydraulic tank breather
• 1.9. Adjustment and Repair
• 1.9.1. Hood and Weight
• 1.9.1.1. Removal and installation of hood
• 1.9.1.2. Removal and installation of additional weights (additional weights Spec.)
• 1.9.1.3. Removal and installation of weights
• 1.9.2. Engine and Electrical Components
• 1.9.2.1. Removal and installation of engine
• 1.9.2.2. Removal and installation of the starting motor
• 1.9.2.3. Removal and installation of the radiator and oil cooler
• 1.9.2.4. Removal and installation of the fan belt and compressor belt
• 1.9.2.5. Removal and installation of engine ECU
• 1.9.2.6. Removal and installation of hydraulic ECU
• 1.9.2.7. Removal and installation of diesel particulate filter (DPF)
• 1.9.3. Undercarriage
• 1.9.3.1. Outline
• 1.9.3.2. Main parts
• 1.9.3.3. Precautions for assembly
• 1.9.3.4. Removal and Reinstallation of Crawler
• 1.9.3.5. Disassembly and Reassembly of steel crawler
• 1.9.3.6. Removal and Reinstallation of Travel Motor
• 1.9.3.7. Disassembly and Reassembly of Idler
• 1.9.3.8. Disassembly and Reassembly of Track Roller
• 1.9.3.9. Disassembly and Reassembly of Carrier Roller
• 1.9.3.10. Installation of Floating Seal
• 1.9.4. Control unit
• 1.9.4.1. Operation lever
• 1.9.4.2. Travel lever
• 1.9.5. Swing Bearing
• 1.9.5.1. Removal and Reinstallation of Swing Bearing
• 1.9.6. Hydraulic device
• 1.9.6.1. Removal and installation of hydraulic pump
• 1.9.6.2. Removal and installation of control valves
• 1.9.6.3. Removal and installation of pilot valves (L, R)
• 1.9.6.4. Removal and installation of blade pilot valve
• 1.9.6.5. Removal and installation of travel pilot valve
• 1.9.6.6. Removal and installation of swing pilot valve
• 1.9.6.7. Removal and installation of arti-boom pilot valve
• 1.9.6.8. Removal and installation of cut-off valve and accumulator
• 1.9.6.9. Removal and Reinstallation of AUX Solenoid Valve
• 1.9.6.10. Removal and Reinstallation of AUX2 Solenoid Valve
• 1.9.6.11. Removal and Reinstallation of AUX3 Solenoid Valve (AUX3 Spec.)
• 1.9.6.12. Removal and installation of pump control proportional valve
• 1.9.6.13. Removal and installation of blade hold valve
• 1.9.6.14. Removal and installation of line filter
• 1.9.6.15. Removal and installation of swing motor
• 1.9.6.16. Removal and Reinstallation of Swivel Joint
• 1.9.6.17. Disassembly and Reassembly of Swivel Joint
• 1.9.6.18. Hydraulic cylinder disassembly and assembly
• 1.9.6.19. Reservoir tank
• 1.9.6.20. Hydraulic piping diagram
• 1.9.7. Implement
• 1.9.7.1. Removal and installation of implements
• 1.9.7.2. Removal and Reinstallation of Implement (Arti-boom spec.)
• 1.9.8. Cabin
• 1.9.8.1. Removal and installation of cabin
• 1.9.8.2. Cabin disassembly and assembly
• 1.9.8.3. Procedures for replacement of bonded glass
• 1.9.9. Air conditioner
• 1.9.9.1. Removal and installation of air conditioner
• 1.10. Troubleshooting
• 1.10.1. Non-breakdowns
• 1.10.1.1. Natural Release of Bucket
• 1.10.1.2. Discontinuous Arm and Bucket Movement
• 1.10.1.3. Thermal Shock of Travel Motor
• 1.10.1.4. Elongation of Boom Swing Cylinder on 60 degrees Swing
• 1.10.1.5. Time Lag on Travel Speed Switching
• 1.10.1.6. Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change
• 1.10.2. Quick Reference Table for Troubleshooting
• 1.11. Colophon
• 1.12. APPENDIX