YANMAR B55W-1 Operation and Maintenance Manual – PDF DOWNLOAD

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YANMAR B55W-1 Operation and Maintenance Manual – PDF DOWNLOAD 

YANMAR B55W-1 OPERATION AND MAINTENANCE MANUAL – PDF DOWNLOAD:

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YANMAR B55W-1 Operation and Maintenance Manual – PDF DOWNLOAD 

• Any modification made without authorization or written approval from Yanmar can create a safety hazard, for which the machine owner must be held responsible.
• For safety’s sake, replace all OEM parts with the correct authorized or genuine Yanmar part. For example, not taking the time to replace fasteners, bolts or nuts with the correct replacement parts could lead to a condition in which the safety of critical assemblies is dangerously compromised.
• GENERAL HAZARD INFORMATION SAFETY RULES Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
• Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems.
• These problems will interfere with your sense of judgement in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used.
• Always observe strictly any other rules related to safety. SAFETY FEATURES Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged.
• Be sure that you understand the method of use of safety features such as safety lock lever and the seat belt, and use them properly. Never remove any safety features. Always keep them in good operating condition.
• Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious bodily injury.

TABLE OF CONTENTS:

YANMAR B55W-1 Operation and Maintenance Manual – PDF DOWNLOAD 

Safety..........................................................................................................  7
	To the Operator of a YANMAR Excavator.......................................................................  7
		Learn the Signal Words Used with the Safety Alert Symbol................................................  9
	Location of Safety Labels................................................................................... 10
		1. Warnings for operation, inspection and maintenance (190-00688, 190-00092)............................ 11
		2. Warnings for High Voltage (190-00689, 190-00096)..................................................... 11
		3. Warnings When Opening a Front Window (190-00690, 190-01082).......................................... 12
		4. Warnings for front attachments (190-00652)........................................................... 12
		5. keep out of the swing area (2190-3379, 190-00090).................................................... 13
		6. WARNINGs FOR Leaving Operator’s Seat (190-00693, 190-00094).......................................... 13
		7. Warnings for Batteries Maintenance (2190-2533A, 190-00100)........................................... 14
		8. Warnings for Handling an Accumulator (190-00703, 190-00099).......................................... 14
		9. Warnings for Hot Coolant (190-00692, 190-00097)...................................................... 14
		10. 11. Warnings For Rotating Parts (190-00694, 190-00095, 190-00557)................................... 15
		12. Warning for a Hot Surface (19000648)............................................................... 15
		13. Warning Tag - Used When Inspection and Maintenance (190-00695, 190-00098)........................... 16
		14. Caution for Gear Shift (190-00156).................................................................. 16
	Summary of Safety Precautions for Lifting in Digging Mode................................................... 17
	Unauthorized Modifications.................................................................................. 18
	General Hazard Information.................................................................................. 18
		Safety Rules............................................................................................ 18
		Safety Features......................................................................................... 18
		Inside Operator's Compartment........................................................................... 19
		Clothing and Personal Protective Items.................................................................. 19
		Breathing Masks, Ear Protection May Be Required......................................................... 19
		Mounting and Dismounting................................................................................ 20
		Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 21
		Precautions When Handling Fluids at High Temperature.................................................... 21
		Asbestos Dust Hazard Prevention......................................................................... 22
		Injury from Work Equipment.............................................................................. 22
		Fire Extinguisher and First Aid Kit..................................................................... 23
		Protection from Falling or Flying Objects............................................................... 23
		Attachment Precautions.................................................................................. 24
		Accumulator............................................................................................. 24
		Indoor Ventilation...................................................................................... 25
		Emergency Exit.......................................................................................... 25
	Before Starting Engine...................................................................................... 26
		Work Site Precautions................................................................................... 26
		Checks Before Starting Engine........................................................................... 27
		Engine Starting......................................................................................... 28
		Before Operating Machine................................................................................ 28
	Machine Operation........................................................................................... 29
		When Swinging or Changing Direction of Travel........................................................... 29
		Travel Precautions...................................................................................... 29
		Traveling on Slopes..................................................................................... 30
		Prohibited Operations................................................................................... 31
		Precautions for Operation............................................................................... 31
		Avoid High-voltage Cables............................................................................... 32
		Operate Carefully on Snow, Ice and in Very Cold Temperatures............................................ 32
		Operations on Slopes.................................................................................... 33
		Parking Machine......................................................................................... 33
		Never Let Anyone Ride on Attachment..................................................................... 33
	Maintenance................................................................................................. 34
		Warning Tag............................................................................................. 34
		Clean Before Inspection or Maintenance.................................................................. 34
		Proper Tools............................................................................................ 35
		Use of Lighting......................................................................................... 35
		Fire Prevention and Explosion Prevention................................................................ 35
		Burn Prevention......................................................................................... 36
		Welding Repairs......................................................................................... 37
		Warning for Counterweight and Front Attachment Removal.................................................. 37
		Precautions for Removal, Installation, and Storage of Attachments....................................... 38
		Precautions when Working on Machine..................................................................... 38
		Lock Inspection Covers.................................................................................. 38
		Crushing Prevention and Cutting Prevention.............................................................. 38
		Supports and Blocking for Work Equipment................................................................ 39
		Action When Abnormally Is Found During Inspection....................................................... 40
		Precautions with High Pressure Line, Tubes and Hoses.................................................... 40
		Waste Materials......................................................................................... 41
	Battery..................................................................................................... 42
		Battery Hazard Prevention............................................................................... 42
		Boost Starting or Charging Engine Batteries............................................................. 43
	Towing...................................................................................................... 44
		Precautions When Towing................................................................................. 44
	Shipping and Transportation................................................................................. 45
		Obey State and Local Over-the-Road Regulations.......................................................... 45
	Excavator Rated Lift Capacity Tables........................................................................ 46
		Lifting Capacity (Without Dozer)........................................................................ 48
		Lifting Capacity (With Dozer)........................................................................... 49
Operating Controls.............................................................................................. 51
	Component Locations......................................................................................... 52
	Operator’s Area............................................................................................. 54
	Operational Controls and Panels............................................................................. 55
		1. Digital Clock........................................................................................ 56
		2. Instrument Panel..................................................................................... 56
		3. Travel Speed Change Lever............................................................................ 57
		4. Hazard Warning Light Switch.......................................................................... 57
		5. Work Light Switch.................................................................................... 58
		6. Warning Light Switch (Optional)...................................................................... 58
		7. Stereo............................................................................................... 58
		8. Cigar Lighter........................................................................................ 59
		9. Starter Switch....................................................................................... 59
		10. Dozer Blade Control Lever........................................................................... 60
		11. Right Hand Work Lever (Joystick).................................................................... 60
		12. Horn Switch (Right Hand Work Lever)................................................................. 60
		13. Two way Switch...................................................................................... 61
		14. Boom Swing Selector Switch.......................................................................... 61
		15. Left Hand Work Lever................................................................................ 62
		16. Engine Speed Control Lever.......................................................................... 62
		17. Heater and Air Conditioner Control Panel............................................................ 63
		18. Safety Lever........................................................................................ 63
		19. Steering Console.................................................................................... 63
		20. Steering Tilt Lever................................................................................. 63
	Steering Console............................................................................................ 64
		1. Combination Switch................................................................................... 65
		2. Working Lamp Indicator Light......................................................................... 66
		3. 8. Directional / Hazard Indicator Light.............................................................. 67
		4. Travel Indicator Light............................................................................... 67
		5. High Beam Indicator Light............................................................................ 67
		6. Brake Oil Pressure Warning Light..................................................................... 68
		7. Parking Brake Warning Light.......................................................................... 68
		9. Boom Swing Indicator Light........................................................................... 68
		10. Transmission Selector Switch........................................................................ 69
		11. Headlight Switch.................................................................................... 69
		12. Ram Lock Switch..................................................................................... 69
		13. Travel/Work/Park Selector Switch.................................................................... 69
	Instrument Panel............................................................................................ 71
		Inspection of the controls for operation................................................................ 71
		1. Preheat Completion Indicator Light................................................................... 72
		2. Fuel Level Warning Light............................................................................. 72
		3. Air Cleaner Clogging Warning Light................................................................... 72
		4. Engine Overheat Warning Light........................................................................ 73
		5. Battery Charge Warning Light......................................................................... 73
		6. Engine Oil Pressure Warning Light.................................................................... 73
		7 Engine Coolant Temperature Gauge...................................................................... 74
		8. Fuel Gauge........................................................................................... 74
		9. Hour Meter........................................................................................... 74
	Heating and Air-conditioning System......................................................................... 75
		Location of Vents....................................................................................... 75
		Control Switches........................................................................................ 75
		Additional Operating Instructions....................................................................... 77
	Stereo (If Equipped)........................................................................................ 78
		Security and Area Code Setting.......................................................................... 78
		Order to Set Up Security and Area Code.................................................................. 78
		Front Panel............................................................................................. 79
		1. Power/Volume Control Knob............................................................................ 79
		2. Sound Mode Selection Button.......................................................................... 79
		3. Band Selection Switch................................................................................ 80
		4. Tuning Up/Down....................................................................................... 80
		5 & 6. Auto Memory and Preset Scan Button / Preset Station Button....................................... 81
		7. Tape Slot............................................................................................ 81
		8. Tape Ejection Button................................................................................. 81
		9. Cassette and Program Buttons......................................................................... 82
		10. Security Warning LED................................................................................ 82
		11. Scan................................................................................................ 82
		12. LCD................................................................................................. 83
		Care of Stereo.......................................................................................... 83
	Miscellaneous Electrical Devices............................................................................ 85
		1. Room Light........................................................................................... 85
		2. Pilot Cutoff Switch.................................................................................. 85
		3. Circuit Breaker...................................................................................... 85
		4. Fusible Link......................................................................................... 86
	Fuse Box.................................................................................................... 87
	Seat Adjustment............................................................................................. 88
		1. Forward / Backward Adjustment (Figure 70)............................................................ 88
		2. Adjusting the Seat's Tilt and Seat Height (Figure 70)................................................ 88
		3. Weight Adjustment (Figure 70)........................................................................ 88
		4. Adjusting Reclining (Figure 70)...................................................................... 88
		5. Moving the Total Seat Setting Forward/Backward (Figure 70)........................................... 89
		6. Angle Adjustment of Armrest (Figure 71).............................................................. 89
		7. Headrest (Figure 71)................................................................................. 89
	Seat Belt................................................................................................... 90
		Seat Belt Locking and Unlocking......................................................................... 90
	Front Windows............................................................................................... 91
		Front Upper Window...................................................................................... 91
		Front Bottom Window..................................................................................... 92
	Door Side Latch............................................................................................. 92
	Cab Storage Compartments.................................................................................... 93
	Ashtray..................................................................................................... 94
	Upper Structure Swing Lock Pin.............................................................................. 94
	Boom Swing Lock............................................................................................. 95
	Wheel Chocks................................................................................................ 95
	Emergency Glass Breaking Tool............................................................................... 95
Operation....................................................................................................... 97
	To Handle a New Excavator................................................................................... 97
		Lubrication and filters................................................................................. 97
	Starting and Stopping The Engine............................................................................ 98
		Inspection Before Starting Engine....................................................................... 98
		Operational Checks Before Starting Engine............................................................... 98
		Engine Start............................................................................................100
		Cold Weather Starting...................................................................................102
		Starting Engine with a Booster cable....................................................................104
		Hydraulic System Warm-up................................................................................106
		Hydraulic System Warm-up - Cold Weather.................................................................107
		Engine Shutdown.........................................................................................109
		Check and Confirmation After Stopping Engine............................................................110
	Safety Lever................................................................................................111
	Travel......................................................................................................112
		Before Traveling........................................................................................112
		Over the Road Traveling Procedures......................................................................113
		Traveling On a Work Site................................................................................114
		Traveling On a Slope....................................................................................115
		Parking.................................................................................................116
		Travel Problems.........................................................................................118
	Operating Instructions......................................................................................119
		Engine Speed Control....................................................................................119
		Steering Wheel..........................................................................................120
		Accelerator Pedal.......................................................................................120
		Brake Pedal.............................................................................................120
		Work Lever (Joysticks) (ISO Style)......................................................................121
		Boom Swing Control......................................................................................122
		Dozer Blade Control Lever...............................................................................123
	Operating Precautions.......................................................................................124
		Working In Water........................................................................................127
		Grading.................................................................................................127
		Be careful of blade position............................................................................128
		Precautions for blade use...............................................................................128
		Use care when crowding (moving in) front attachment.....................................................128
		Be careful not to hit obstacles with blade..............................................................128
		Be careful of Lower Structure...........................................................................129
	Parking Excavator...........................................................................................129
	Towing Procedure............................................................................................131
	Hydraulic Breaker...........................................................................................132
		Selection of Hydraulic Breaker..........................................................................132
		Hydraulic Hoses and Tubing for Breaker..................................................................132
		Hydraulic Breaker Operation.............................................................................132
		To activate breaker.....................................................................................135
		To Activate The Actuator of Two Way Type................................................................135
		Hydraulic Oil and Filter Service Intervals..............................................................137
	Operating Techniques........................................................................................138
		Lifting.................................................................................................138
	Operation Under Unusual Conditions..........................................................................140
		Operation In Extreme Cold...............................................................................140
		Operation In Extreme Heat...............................................................................140
		Operation In Dusty or Sandy Areas.......................................................................141
		Operation In Rainy or Humid Conditions..................................................................142
		Operation In Salt Water Areas...........................................................................142
		Operation at High Altitudes.............................................................................142
Inspection, Maintenance and Adjustment..........................................................................143
	Serial Numbers..............................................................................................143
	Safety Precautions..........................................................................................143
	Preliminary Work Machine Setup for Maintenance..............................................................144
	Table of Recommended Lubricants.............................................................................146
	Fluid Capacities............................................................................................148
	Lubrication and Service Chart...............................................................................148
	Maintenance Intervals.......................................................................................150
		10 Hour / Daily Service.................................................................................150
		50 Hour / Weekly Service................................................................................150
		250 Hour / Monthly Service..............................................................................151
		500 Hour / 3 Month Service..............................................................................151
		1000 Hour / 6 Month Service.............................................................................151
		2000 Hour / Yearly Service..............................................................................151
		4000 Hour / Biennial Service............................................................................151
		12,000 Hour / Six Year Service..........................................................................152
	10 Hour / Daily Service.....................................................................................153
		Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear........................153
		Grease Dozer Blade Pins.................................................................................153
		Grease Boom, Arm and Front Attachment Pins..............................................................153
		Check Engine Oil Level..................................................................................153
		Check Level of Hydraulic Oil Tank.......................................................................154
		Check for Leaks in Hydraulic System.....................................................................155
		Check Fuel Level........................................................................................155
		Check Fuel Water Separator..............................................................................156
		Check for Leaks in Fuel System..........................................................................156
		Check Oil Level of Swing Reduction Device...............................................................157
		Check Cooling System and Refill as Required.............................................................158
		Check Level of Window Washer Liquid.....................................................................159
		Clean Dust Net in front of Radiator.....................................................................159
		Clean Engine Air Intake Precleaner......................................................................159
		Inspect Bucket Teeth and Side Cutters for Signs of Wear.................................................160
		Check Engine Fan Belt for Cracks, Wear and Correct Tension..............................................160
		Inspect Seat Belt for Proper Operation..................................................................161
		Inspect Structure for Cracks and Faulty Welds...........................................................161
		Check Operation of All Switches.........................................................................161
		Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights...........161
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operati.......161
		Check Operation of All Controls.........................................................................161
		Inspect for Any Loose or Missing Nuts and Bolts.........................................................161
	50 Hour / Weekly Service....................................................................................162
		Perform All 10 Hour / Daily Service Checks..............................................................162
		Grease Boom, Arm and Front Attachment Pins..............................................................162
		Grease Dozer Blade Pins.................................................................................165
		Grease Front Axle Pin...................................................................................165
		Grease Swing Bearing....................................................................................166
		Grease Boom Swing Cylinder Head.........................................................................166
		Change Engine Oil and Filter............................................................................166
		Drain Water and Sediment from Fuel Tank.................................................................166
		Clean Fuel Tank Strainer................................................................................167
		Drain and Refill Transmission Fluid (Drain and Refill after First 50 Hours).............................167
		Drain and Refill Hub Reduction Gear Oil.................................................................167
		Drain and Refill Front Axle Case Oil....................................................................167
		Drain and Refill Rear Axle Case Oil.....................................................................167
		Check Battery Fluid Level and Condition.................................................................167
	250 Hour / Monthly Service..................................................................................168
		Perform All 10 Hour / Daily and 50 Hour/Weekly Service Checks...........................................168
		Change Engine Oil.......................................................................................168
		Change Swing Reduction Device Oil (Drain and Refill after First 250 Hours)..............................168
		Drain Water and Sediment from Hydraulic Oil Tank........................................................169
		Change Pilot Filter.....................................................................................169
		Replace Hydraulic Oil Return Filter (After First 250 Hours).............................................170
		Clean Outer Element of Two Stage Air Cleaner............................................................170
		Inspect Pins and Bushings of Front End Attachments for Signs of Wear....................................170
		Inspect Fuel System Hose Clamps.........................................................................170
	500 Hour / 3 Month Service..................................................................................171
		Perform All 10 Hour / Daily, 50 Hour / Weekly, and 250 hour Service Checks..............................171
		Grease Swing Gear.......................................................................................171
		Grease Drive Shaft (6 Points)...........................................................................171
		Grease Front Axle Steering Knuckle (2 X 2 points, 4 points).............................................171
		Change Engine Oil and Filter............................................................................172
		Change Fuel Filter......................................................................................173
		Replace Hydraulic Oil Return Filter.....................................................................174
		Change Pilot Filter.....................................................................................175
		Replace Outer and Inner Air Cleaner Elements............................................................175
		Clean Radiator, Oil Cooler and Air Conditioner Condenser Coil...........................................176
	1000 Hour / 6 Month Service.................................................................................177
		Perform All 10 Hour / Daily, 50 Hour / Weekly, 250 hour and 500 hour Service Checks.....................177
		Grease Swing Reduction Gear.............................................................................177
		Change Swing Reduction Device Oil.......................................................................177
		Drain and Refill Transmission Fluid.....................................................................178
		Drain and Refill Front Axle Case Oil....................................................................179
		Drain and Refill Rear Axle Case Oil.....................................................................179
		Drain and Refill Hub Reduction Gear Oil.................................................................180
		Clean Fuel Tank Suction Strainer........................................................................180
		Clean Fuel Injection Priming Pump Strainer..............................................................181
		Check Air Conditioner Refrigerant.......................................................................181
	2000 Hour / Yearly Service..................................................................................183
		Perform All Daily, 50, 250, 500 and 1,000 Operating Hour Service Checks.................................183
		Change Radiator Coolant.................................................................................183
		Hydraulic Oil Exchange and Suction Strainer Cleaning....................................................184
		Check Alternator and Starter**..........................................................................186
		Check All Rubber Anti-vibration Shock Mounts............................................................186
		Perform and Record the Results of the Cycle Time Tests..................................................186
		Inspect Machine to Check for Cracked or Broken Welds or Other Structural Damage.........................186
	4000 Hour / Biennial Service................................................................................187
		Major Parts - Periodic Replacement......................................................................187
	12,000 Hour / Six Year Service..............................................................................188
		Hose In-service Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................188
	Venting and Priming Hydraulic System........................................................................189
		Main System Pump........................................................................................189
		Hydraulic Cylinders.....................................................................................189
		Swing Motor.............................................................................................190
		General Venting.........................................................................................190
	Handling of Accumulator.....................................................................................191
	Fuel Transfer Pump..........................................................................................192
	Electrical System...........................................................................................194
		Battery.................................................................................................194
		Fuse Box................................................................................................195
	Air Conditioning System.....................................................................................197
	Bucket......................................................................................................198
		Bucket Tooth Replacement................................................................................198
		Bucket O-ring Replacement...............................................................................199
	Bucket Shimming Procedures..................................................................................201
		New Bucket Installation.................................................................................201
		Shimming Procedures for Installed Bucket................................................................201
	Tires and Wheels............................................................................................202
		Check Tire For Damage...................................................................................203
		Tire Changing Procedure.................................................................................204
	Bolt and Nut Inspection.....................................................................................207
	Maintenance in Special Conditions...........................................................................208
	Long Term Storage...........................................................................................209
Transportation..................................................................................................211
	Short Distance Self-powered Travel..........................................................................212
	Trailer Loading/Unloading Procedures........................................................................213
		Dimensions for Transportation...........................................................................214
Troubleshooting.................................................................................................215
	Engine......................................................................................................215
	Hydraulic System............................................................................................216
	Swing System................................................................................................217
	Electrical System...........................................................................................218
	Travel System...............................................................................................218
	Steering....................................................................................................219
	Brakes......................................................................................................220
Specification...................................................................................................221
	Standard Specification......................................................................................221
	General Dimensions..........................................................................................222
	Working Range...............................................................................................223
	Approximate Weight of Workload Materials....................................................................224
Index...........................................................................................................227

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