Yanmar V7, V7HW Wheel Loader Service Manual

Description

• Model List:
  • V7, V7HW Wheel Loader

• 1. FOREWORD
• 2. CONTENTS
• 3. CHAPTER 1 – 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 System
• 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. CHAPTER 2 – Technical Data
• 4.1. Specifications
• 4.2. Outline Drawing and Working Area
• 4.3. Weight List of Main Parts
• 4.4. Lifting Capacity List
• 4.5. Periodic Inspection and Servicing
• 4.6. Fuel, Lube Oil and Grease Recommended
• 4.7. Hydraulic Circuit Schematic
• 4.8. Wiring Diagram
• 4.8.1. _PF3_V7_Serie_EN
• 5. CHAPTER 3 – Service
• 5.1. Machine Performance
• 5.2. Engine
• 5.3. Undercarriage
• 5.3.1. Wheel specifications
• 5.4. Controls
• 5.5. Hydraulic Equipment
• 5.5.1. Hydraulic Cylinders
• 5.6. Implement
• 5.6.1. Front Attachments
• 5.6.2. Steering Attachments
• 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
• 5.7.5. Hydromatik tightening values
• 5.8. Pressure Adjustment
• 5.8.1. Relief Valves
• 6. CHAPTER 4 – Engine
• 6.1. INTRODUCTION
• 6.2. YANMAR WARRANTIES
• 6.2.1. YANMAR LIMITED WARRANTY
• 6.2.2. EMISSION SYSTEM WARRANTY
• 6.2.3. YANMAR POWER TECHNOLOGY CO., LTD. LIMITED EMISSION CONTROL SYSTEMWARRANTY
• 6.3. SAFETY
• 6.3.1. SAFETY STATEMENTS
• 6.3.2. SAFETY PRECAUTIONS
• 6.4. GENERAL SERVICE INFORMATION
• 6.4.1. COMPONENT IDENTIFICATION
• 6.4.2. LOCATION OF LABELS
• 6.4.3. EMISSION CONTROL REGULATIONS
• 6.4.4. EMISSION CONTROL LABELS
• 6.4.5. ENGINE FAMILY
• 6.4.6. FUNCTION OF MAJOR ENGINE COMPONENTS
• 6.4.7. FUNCTION OF COOLING SYSTEM COMPONENTS
• 6.4.8. MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
• 6.4.9. INSTALLATION POSITION OF SENSORS
• 6.4.10. DIESEL FUEL
• 6.4.11. ENGINE LUBRICATING OIL
• 6.4.12. ENGINE COOLANT
• 6.4.13. SPECIFICATIONS
• 6.4.14. PRINCIPAL ENGINE SPECIFICATIONS
• 6.4.15. ENGINE SERVICE STANDARDS
• 6.4.16. TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
• 6.4.17. ABBREVIATIONS AND SYMBOLS
• 6.4.18. UNIT CONVERSIONS
• 6.5. PERIODIC MAINTENANCE
• 6.5.1. BEFORE YOU BEGIN SERVICING
• 6.5.2. INTRODUCTION
• 6.5.3. PERIODIC MAINTENANCE SCHEDULE
• 6.5.4. PERIODIC MAINTENANCE PROCEDURES
• 6.6. ENGINE
• 6.6.1. BEFORE YOU BEGIN SERVICING
• 6.6.2. INTRODUCTION
• 6.6.3. CYLINDER HEAD SPECIFICATIONS
• 6.6.4. CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS
• 6.6.5. CRANKSHAFT AND PISTON SPECIFICATIONS
• 6.6.6. CYLINDER BLOCK SPECIFICATIONS
• 6.6.7. SPECIAL TORQUE CHART
• 6.6.8. SPECIAL SERVICE TOOLS
• 6.6.9. MEASURING INSTRUMENTS
• 6.6.10. CYLINDER HEAD
• 6.6.11. MEASURING AND ADJUSTING VALVE CLEARANCE
• 6.6.12. CRANKSHAFT AND CAMSHAFT COMPONENTS
• 6.6.13. EGR SYSTEM
• 6.6.14. INTAKE THROTTLE
• 6.6.15. EXHAUST THROTTLE
• 6.7. FUEL SYSTEM
• 6.7.1. BEFORE YOU BEGINSERVICING
• 6.7.2. SYSTEM STRUCTURE
• 6.7.3. FUEL SYSTEM SPECIFICATIONS
• 6.7.4. FUEL SYSTEM DIAGRAM
• 6.7.5. FUEL SYSTEM COMPONENTS
• 6.8. COOLING SYSTEM
• 6.8.1. BEFORE YOU BEGINSERVICING
• 6.8.2. INTRODUCTION
• 6.8.3. COOLING SYSTEM DIAGRAM
• 6.8.4. ENGINE COOLANT PUMP COMPONENTS
• 6.8.5. ENGINE COOLANT SYSTEM CHECK
• 6.8.6. ENGINE COOLANT PUMP
• 6.9. LUBRICATION SYSTEM
• 6.9.1. BEFORE YOU BEGINSERVICING
• 6.9.2. INTRODUCTION
• 6.9.3. OIL PUMP SERVICE INFORMATION
• 6.9.4. LUBRICATION SYSTEM DIAGRAM
• 6.9.5. CHECKING ENGINELUBRICATING OIL PRESSURE
• 6.9.6. OIL PUMP COMPONENTS
• 6.10. TURBOCHARGER
• 6.10.1. BEFORE YOU BEGIN SERVICING
• 6.10.2. INTRODUCTION
• 6.10.3. SPECIFICATIONS
• 6.10.4. TROUBLESHOOTING
• 6.10.5. TURBOCHARGER COMPONENTS
• 6.10.6. TURBOCHARGER COMPONENT FUNCTIONS
• 6.10.7. PERIODIC INSPECTION
• 6.10.8. REMOVAL AND INSTALLATION OF TURBOCHARGER
• 6.10.9. CLEANING PROCEDURE
• 6.11. STARTER MOTOR
• 6.11.1. BEFORE YOU BEGINSERVICING
• 6.11.2. INTRODUCTION
• 6.11.3. STARTER MOTOR INFORMATION
• 6.11.4. STARTER MOTOR SPECIFICATIONS
• 6.11.5. STARTER MOTOR TROUBLESHOOTING
• 6.11.6. STARTER MOTOR COMPONENTS
• 6.11.7. STARTER MOTOR
• 6.12. ALTERNATOR
• 6.12.1. BEFORE YOU BEGIN SERVICING
• 6.12.2. INTRODUCTION
• 6.12.3. ALTERNATOR SPECIFICATIONS
• 6.12.4. ALTERNATOR TROUBLESHOOTING
• 6.12.5. ALTERNATOR COMPONENTS
• 6.12.6. ALTERNATOR WIRING DIAGRAM
• 6.12.7. ALTERNATOR STANDARD OUTPUT
• 6.12.8. ALTERNATOR
• 6.13. ELECTRONIC CONTROL SYSTEM
• 6.13.1. BEFORE YOU BEGINSERVICING
• 6.13.2. INTRODUCTION
• 6.13.3. SYSTEM STRUCTURE
• 6.13.4. HOW TO REMOVE AND REATTACH THE DIESEL PARTICULATE FILTER (DPF)
• 6.13.5. SF AND DPF MAINTENANCE KIT
• 6.13.6. TROUBLESHOOTING OF ELECTRONIC CONTROL SYSTEM
• 6.13.7. SMARTASSIST-DIRECT (SA-D)
• 6.13.8. REPLACEMENT OF COMPONENTS
• 6.13.9. HARDWARE MODIFICATION FOR DE-TIER
• 6.13.10. ELECTRONIC CONTROL HARNESS CONNECTIONS
• 6.14. ELECTRIC WIRING
• 6.14.1. ELECTRIC WIRING PRECAUTIONS
• 6.14.2. ELECTRICAL WIRE RESISTANCE
• 6.14.3. BATTERY CABLE RESISTANCE
• 6.14.4. ELECTRICAL WIRE SIZES – VOLTAGE DROP
• 6.14.5. CONVERSION OF AWG TO EUROPEAN STANDARDS
• 6.15. FAILURE DIAGNOSIS
• 6.15.1. SPECIAL SERVICE TOOLS
• 6.15.2. TROUBLESHOOTING BY MEASURING
• 6.15.3. COMPRESSION PRESSURE
• 6.15.4. MEASURED VALUE AND TROUBLESHOOTING
• 6.15.5. QUICK REFERENCE TABLE FOR TROUBLESHOOTING
• 7. CHAPTER 5 – Electric System
• 7.1. Electric Equipment of Machine
• 7.1.1. Parts Layout of Electrical Equipment
• 7.2. Circuit Description of Engine Start and Stop
• 7.2.1. Engine Start and Stop
• 7.2.2. Battery charge
• 7.3. Battery
• 7.3.1. Generality
• 7.3.2. Maintenance
• 8. CHAPTER 6 – Hydraulic System
• 8.1. Outline
• 8.1.1. Description of operation
• 8.1.2. Description of operation
• 8.2. Circuit Operation
• 8.2.1. Drive
• 8.2.2. Steering
• 8.2.3. Arm
• 8.2.4. Bucket
• 8.2.5. PTO1
• 8.2.6. PTO2 (Option)
• 8.2.7. Loader quick coupling
• 8.2.8. Loader Vibration damping (Option)
• 8.3. Drive Hydraulic Pump
• 8.3.1. Functional description
• 8.3.2. Removing controller
• 8.3.3. Sealing controller
• 8.3.4. Installing the controller
• 8.4. Work Hydraulic Pump
• 8.4.1. Outline
• 8.4.2. Names of Parts
• 8.4.3. Model descriptions
• 8.4.4. Specification
• 8.4.5. Installation
• 8.4.6. Piping
• 8.4.7. Piping
• 8.4.8. Maintenance/Inspection
• 8.4.9. Gear pump troubleshooting
• 8.5. Control Valve
• 8.5.1. Standard control valve
• 8.5.2. Control valve with PTO2 (optional)
• 8.6. Drive Motor
• 8.6.1. Performance description
• 8.6.2. Product description
• 8.6.3. Axial piston unit layout
• 8.6.4. Functional description
• 8.6.5. Transport with lifting devices
• 8.6.6. Troubleshooting
• 9. CHAPTER 7 – 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 Generator
• 9.1.4. Removal and Reinstallation of Fuel Injection Pump
• 9.1.5. Removal and Reinstallation of Fuel Tank
• 9.2. Carriages
• 9.2.1. Transmission
• 9.2.2. Front Axle
• 9.2.3. Rear Axle
• 9.3. Controls
• 9.3.1. Adjustment of Park Brake Lever cable
• 9.4. Frame Axis
• 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 Steering Cylinder
• 9.5.4. Disassembly and Reassembly of Hydraulic Cylinders
• 9.5.5. Removal and Reinstallation of Drive Motor
• 9.5.6. Removal and Reinstallation of Hydraulic Oil Tank
• 9.5.7. Removal and Reinstallation of Radiator
• 9.5.8. Piping Layout
• 9.6. Work Implements
• 9.6.1. Removal and Reinstallation of Implement
• 9.7. Cabin
• 9.7.1. Removal and Reinstallation of Cabin
• 9.7.2. Removal and Reinstallation of windows of the cabin
• 9.7.3. Removal and Reinstallation of the heater or air conditioning
• 10. CHAPTER 8 – Troubleshooting
• 10.1. Reading the charts
• 10.2. Troubleshooting trees