Yanmar ViO80-1A Hydraulic Excavator Service Manual

Description

• Model List:
  • ViO80-1A Hydraulic Excavator

• 1. General Cautions for Maintenance Work
• 1.1. Correct Work
• 1.2. Safety Precautions
• 1.3. Preparations
• 1.4. Cautions for Disassembly and Reassembly
• 1.5. Cautions for Removal and Installation of Hydraulic Equipment
• 1.6. Cautions for Removal and Installation of Hydraulic Piping
• 1.7. Cautions for Handling Seals
• 1.8. Correct Installation of Hydraulic Hose
• 1.9. Specifications of Hydraulic Hose
• 1.10. Air Release of Hydraulic Equipment
• 2. Technical Data
• 2.1. Specifications
• 2.2. Outline Drawing and Working Area
• 2.3. Weight List of Main Parts
• 2.4. Lifting Capacity List
• 2.5. Specifications for Attachment
• 2.6. Periodic Inspection and Servicing
• 2.7. Fuel, Lube Oil and Grease Recommended
• 2.8. Hydraulic Circuit Schematic
• 2.9. Wiring Diagram
• 3. Service Standards
• 3.1. Machine Performance
• 3.2. Engine
• 3.3. Undercarriage
• 3.3.1. Rubber Crawler Specifications
• 3.3.2. Steel Crawler Specifications
• 3.3.3. Common Specifications of Steel Rubber Crawlers
• 3.4. Controls
• 3.5. Hydraulic Equipment
• 3.5.1. Hydraulic Cylinders
• 3.6. Implement
• 3.6.1. Front Attachments
• 3.6.2. Blade Moving Device
• 3.7. List of Tightening Torque
• 3.7.1. Machine
• 3.7.2. Engine
• 3.7.3. Tightening Torque for General Bolts and Nuts
• 3.7.4. Hydraulic Fitting
• 3.8. Pressure Adjustment
• 3.8.1. Relief Valves
• 3.8.2. Swing Brake Valve
• 3.8.3. Cut-off Valve
• 4. Engine
• 4.1. Safety
• 4.1.1. Safety Statements
• 4.1.2. Safety Precautions
• 4.2. Engine
• 4.2.1. Before You Begin Servicing
• 4.2.2. Special Service Tools
• 4.2.3. Measuring Instruments
• 4.2.4. Cylinder Head
• 4.2.5. Measuring and Adjusting Valve Clearance
• 4.2.6. Crankshaft and Camshaft Components
• 4.2.7. EGR System
• 4.3. Fuel System
• 4.3.1. Before You Begin Servicing
• 4.3.2. System Structure
• 4.3.3. Fuel System Diagram
• 4.3.4. Fuel System Components
• 4.4. Cooling System
• 4.4.1. Before You Begin Servicing
• 4.4.2. Introduction
• 4.4.3. Cooling System Diagram
• 4.4.4. Engine Coolant Pump Components
• 4.4.5. Engine Coolant System Check
• 4.4.6. Engine Coolant Pump
• 4.5. Lubrication System
• 4.5.1. Before You Begin Servicing
• 4.5.2. Introduction
• 4.5.3. Lubrication System Diagram
• 4.5.4. Checking Engine Oil Pressure
• 4.5.5. Oil Pump Components
• 4.6. Starter Motor
• 4.6.1. Before You Begin Servicing
• 4.6.2. Introduction
• 4.6.3. Starter Motor Specifications
• 4.6.4. Starter Motor Troubleshooting
• 4.6.5. Starter Motor Components
• 4.6.6. Starter Motor
• 4.7. Alternator
• 4.7.1. Before You Begin Servicing
• 4.7.2. Introduction
• 4.7.3. Alternator Specifications
• 4.7.4. Alternator Troubleshooting
• 4.7.5. Alternator Components
• 4.7.6. Alternator Wiring Diagram
• 4.7.7. Alternator Standard Output
• 4.7.8. Alternator
• 4.8. Electronic Control System
• 4.8.1. Before You Begin Servicing
• 4.8.2. System Structure
• 4.8.3. Electronic Engine Speed Control
• 4.8.4. Diesel Particulate Filter (DPF)
• 4.8.5. Troubleshooting of electronic control system
• 4.8.6. SMARTASSIST DIRECT (SA-D)
• 4.8.7. Replacement of Components
• 4.8.8. Installation Position of Sensors
• 4.9. Electric Wiring
• 4.9.1. Electric Wiring Precautions
• 4.10. Failure Diagnosis
• 4.10.1. Special Service Tools
• 4.10.2. Tier 4 (BOSCH) Compression Inspection Procedures
• 4.10.3. Measured Value and Troubleshooting
• 4.10.4. Quick Reference Table for Troubleshooting
• 5. Electric System
• 5.1. Electric Equipment of Machine
• 5.1.1. Parts Layout of Electrical Equipment
• 5.1.2. LCD Monitor and Alarm Systems
• 5.2. Circuit Description of Engine Start and Stop
• 5.3. Engine ECU (engine controller)
• 5.3.1. Outline
• 5.3.2. Control Functions
• 5.4. Hydraulic ECU (Controller)
• 5.4.1. Outline
• 5.4.2. Engine Control
• 5.4.3. Speed Sensing Horsepower Limit Control
• 5.5. Error Code
• 6. Hydraulic System
• 6.1. Outline
• 6.1.1. Control Valve Operation
• 6.1.2. Additional Operation of Control Valve
• 6.2. Circuit Operation
• 6.2.1. Boom A
• 6.2.2. Arm
• 6.2.3. Bucket
• 6.2.4. Swing
• 6.2.5. Boom Swing
• 6.2.6. Blade
• 6.2.7. Travel
• 6.2.8. Non-deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation)
• 6.2.9. Simultaneous Operation of Boom Up and Arm Retract
• 6.2.10. Simultaneous Operation of Boom Up and Bucket
• 6.2.11. Simultaneous Operation of Boom Up and Swing
• 6.2.12. Simultaneous Operation of Arm and Bucket
• 6.2.13. Hydraulic P.T.O.
• 6.2.14. Travel Alarm
• 6.2.15. Auto Deceleration
• 6.2.16.
• 6.2.17. Boom B (Arti-boom Cylinder)
• 6.3. Hydraulic Pump
• 6.3.1. Structure and Theory of Operation
• 6.3.2. Troubleshooting
• 6.3.3. Disassembly and Reassembly
• 6.3.4. Service Standards
• 6.4. Control Valve
• 6.4.1. Main Control Valve
• 6.4.2. Disassembly
• 6.4.3. Cleaning
• 6.4.4. Checking
• 6.4.5. Reassembly
• 6.4.6. Servicing Procedure for Relief Valve
• 6.4.7. Installation
• 6.4.8. Running
• 6.4.9. Troubleshooting
• 6.5. Pilot Valve
• 6.5.1. Remote Control Valve
• 6.5.2. Travel Pilot Valve
• 6.5.3. Blade and Boom Swing Pilot Valve
• 6.6. Swing Motor
• 6.6.1. Overview
• 6.6.2. Description of Functions and Operation
• 6.6.3. Precautions for Handling
• 6.6.4. Troubleshooting
• 6.6.5. Employment Tool
• 6.6.6. Disassembly Procedure
• 6.6.7. Assembly Procedure
• 6.6.8. Quality Check After Reassembly.
• 6.7. Travel Motor
• 6.7.1. Product Overview
• 6.7.2. External Dimensions
• 6.7.3. Basic Configuration and Drawing
• 6.7.4. Operating Description
• 6.7.5. Troubleshooting
• 6.7.6. Service outline
• 6.7.7. Disassembly
• 6.7.8. Service Standard
• 6.7.9. Assembly
• 6.7.10. Performance Confirmation Test
• 6.8. ESS Proportional Solenoid Valve
• 6.9. Cutoff Valve
• 6.10. Arti-boom check valve
• 6.11. Articulate Boom Cylinder and P.T.O.2 Circuit Control Valve
• 6.11.1. Main Valve
• 6.11.2. Disassembly
• 6.11.3. Cleaning
• 6.11.4. Checking
• 6.11.5. Reassembly
• 6.11.6. Installation
• 6.11.7. Running
• 6.11.8. Troubleshooting
• 6.12. Hold Valve (for the boom and arm cylinders)
• 6.13. Control Pilot Valve
• 7. Adjustment and Repair
• 7.1. Engine and Electric Equipment
• 7.1.1. Removal and Reinstallation of Engine
• 7.1.2. Removal and Reinstallation of Starter Motor
• 7.1.3. Removal and Reinstallation of Radiator and Oil cooler
• 7.1.4. Removal and Reinstallation of Fan Belt and Compressor Driving Belt
• 7.1.5. Removal and Reinstallation of Engine ECU
• 7.1.6. Removal and Reinstallation of Hydraulic ECU
• 7.1.7. Removal and Reinstallation of Diesel Particulate Filter (DPF)
• 7.2. Undercarriage
• 7.2.1. Outline
• 7.2.2. Compatibility of Main Parts
• 7.2.3. Points of Reassembly (Rubber Crawler Type)
• 7.2.4. Points of Reassembly (Steel Crawler Type)
• 7.2.5. Removal and Reinstallation of Crawler
• 7.2.6. Disassembly and Reassembly of Steel Crawler
• 7.2.7. Removal and Reinstallation of Travel Motor
• 7.2.8. Disassembly and Reassembly of Idler
• 7.2.9. Disassembly and Reassembly of Track Roller
• 7.2.10. Disassembly and Reassembly of Carrier Roller
• 7.2.11. Installation of Floating Seal
• 7.2.12. Drawings of Jigs
• 7.3. Controls
• 7.3.1. Control Lever
• 7.3.2. Travel Lever
• 7.3.3. Adjustment of Lock Lever
• 7.4. Swing Bearing
• 7.4.1. Removal and Reinstallation of Swing Bearing
• 7.5. Hydraulic Equipment
• 7.5.1. Removal and Reinstallation of Hydraulic Pump
• 7.5.2. Removal and Reinstallation of Control Valve
• 7.5.3. Removal and Reinstallation of Arti-Boom Cylinder and PTO 2 Circuit Control Valve
• 7.5.4. Removal and Reinstallation of Remote Control Valves
• 7.5.5. Removal and Reinstallation of Blade Pilot Valve
• 7.5.6. Removal and Reinstallation of Travel Pilot Valve
• 7.5.7. Removal and Reinstallation of Boom Swing Pilot Valve
• 7.5.8. Removal and Reinstallation of Solenoid Valve
• 7.5.9. Removal and Reinstallation of P.T.O.1 Solenoid Valve
• 7.5.10. Removal and Reinstallation of P.T.O.2 Solenoid Valve
• 7.5.11. Removal and Reinstallation of ESS Solenoid Valve
• 7.5.12. Removal and Reinstallation of Boom Holding Valve
• 7.5.13. Removal and Reinstallation of Arm Holding Valve
• 7.5.14. Removal and Reinstallation of Line Filter
• 7.5.15. Removal and Reinstallation of Accumulator
• 7.5.16. Removal and Reinstallation of Swing Motor
• 7.5.17. Removal and Reinstallation of Swivel Joint
• 7.5.18. Disassembly and Reassembly of Swivel Joint
• 7.5.19. Disassembly and Reassembly of Hydraulic Cylinders
• 7.5.20. Hydraulic Oil Tank
• 7.5.21. Piping Layout
• 7.6. Implement
• 7.6.1. Removal and Reinstallation of Implement
• 7.7. Cabin
• 7.7.1. Removal and Reinstallation of Cabin
• 7.8. Air Conditioner
• 7.8.1. Removal and Reinstallation of Air Conditioner
• 8. Troubleshooting
• 8.1. Non-breakdowns
• 8.1.1. Natural Release of Bucket
• 8.1.2. Discontinuous Arm Movement
• 8.1.3. Thermal Shock of Travel Motor
• 8.1.4. Elongation of Boom Swing Cylinder on 60 degrees Swing
• 8.1.5. Time Lag on Travel Speed Switching
• 8.1.6. Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change
• 8.2. Quick Reference Table for Troubleshooting