YANMAR B55W-1 SHOP MANUAL – PDF DOWNLOADYANMAR B55W-1 SHOP MANUAL – PDF DOWNLOAD
DESCRIPTION:
YANMAR B55W-1 SHOP MANUAL – PDF DOWNLOAD
The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact Yanmar for proper installation and application.
Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading. DO NOT use the machine for activities for which it was not intended.
DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration. Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
LIFTING CAPACITY RATING CONFIGURATION Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration. Loads must be balanced and supported evenly.
Use taglines to keep the load steady if wind conditions and large surface area are a problem. Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made .
TABLE OF CONTENTS:
YANMAR B55W-1 SHOP MANUAL – PDF DOWNLOAD
Table Of Contents................................................................................................... 5
Safety.............................................................................................................. 7
Wheel Excavator Safety.......................................................................................... 9
To the Operator of a Yanmar Excavator....................................................................... 11
Learn the Signal Words Used with the Safety Alert Symbol................................................ 13
General Safety Essentials................................................................................... 14
Accessory Applications.................................................................................. 14
Lifting Capacity Rating Configuration................................................................... 14
Location of Safety Labels................................................................................... 14
Summary of Safety Precautions for Lifting in Digging Mode................................................... 15
Unauthorized Modifications.................................................................................. 16
General Hazard Information.................................................................................. 16
Safety Rules............................................................................................ 16
Safety Features......................................................................................... 16
Inside Operator's Compartment........................................................................... 17
Clothing and Personal Protective Items.................................................................. 18
Breathing Masks, Ear Protection May be Required......................................................... 18
Mounting and Dismounting................................................................................ 19
Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 20
Precautions When Handling Fluids at High Temperature.................................................... 20
Asbestos Dust Hazard Prevention......................................................................... 21
Injury from Work Equipment.............................................................................. 21
Fire Extinguisher and First Aid Kit..................................................................... 22
Protection from Falling or Flying Objects............................................................... 22
Attachment Precautions.................................................................................. 23
Accumulator............................................................................................. 23
Indoor Ventilation...................................................................................... 24
Emergency Exit.......................................................................................... 24
Before Starting Engine...................................................................................... 25
Work Site Precautions................................................................................... 25
Checks Before Starting Engine........................................................................... 26
Engine Starting......................................................................................... 27
Before Operating Machine................................................................................ 27
Machine Operation........................................................................................... 28
When Swinging or Changing Direction of Travel........................................................... 28
Travel Precautions...................................................................................... 28
Traveling on Slopes..................................................................................... 29
Prohibited Operations................................................................................... 30
Precautions for Operation............................................................................... 30
Avoid High-voltage Cables............................................................................... 31
Operate Carefully on Snow, Ice and in Very Cold Temperatures............................................ 31
Operations on Slopes.................................................................................... 32
Parking Machine......................................................................................... 32
Never Let Anyone Ride on Attachment..................................................................... 32
Maintenance................................................................................................. 33
Warning Tag............................................................................................. 33
Clean Before Inspection or Maintenance.................................................................. 33
Proper Tools............................................................................................ 34
Use of Lighting......................................................................................... 34
Fire Prevention and Explosion Prevention................................................................ 34
Burn Prevention......................................................................................... 35
Welding Repairs......................................................................................... 36
Warning for Counterweight and Front Attachment Removal.................................................. 36
Precautions for Removal, Installation, and Storage of Attachments....................................... 37
Precautions when Working on Machine..................................................................... 37
Lock Inspection Covers.................................................................................. 37
Crushing Prevention and Cutting Prevention.............................................................. 37
Supports and Blocking for Work Equipment................................................................ 38
Action When Abnormally Is Found During Inspection....................................................... 39
Precautions with High Pressure Line, Tubes and Hoses.................................................... 39
Waste Materials......................................................................................... 40
Battery..................................................................................................... 41
Battery Hazard Prevention............................................................................... 41
Boost Starting or Charging Engine Batteries............................................................. 42
Towing...................................................................................................... 43
Precautions When Towing................................................................................. 43
Shipping and Transportation................................................................................. 44
Obey State and Local Over-the-Road Regulations.......................................................... 44
Lifting With Sling.......................................................................................... 44
Specifications...................................................................................................... 45
Specifications for B55W-1....................................................................................... 47
General Description......................................................................................... 49
Component Locations......................................................................................... 50
General Dimensions.......................................................................................... 52
Working Range............................................................................................... 54
General Specifications...................................................................................... 56
Weight Table................................................................................................ 57
Working Attachments......................................................................................... 58
Pin and Bushing Wear Limits............................................................................. 58
Measuring Cylinder Drift................................................................................ 60
Measuring Speed......................................................................................... 61
General Maintenance................................................................................................. 63
General Maintenance Procedures.................................................................................. 65
Welding Precautions and Guidelines.......................................................................... 67
Hydraulic System - General Precautions...................................................................... 68
Maintenance Service and Repair Procedure.................................................................... 69
General Precautions..................................................................................... 69
Hydraulic System Cleanliness and Oil Leaks.................................................................. 70
Maintenance Precautions for Hydraulic System Service.................................................... 70
Oil Leakage Precautions................................................................................. 70
Cleaning and Inspection..................................................................................... 71
General Guidelines...................................................................................... 71
Bearing inspection...................................................................................... 72
Standard Torques................................................................................................ 79
Torque Values for Standard Metric Fasteners................................................................. 81
Torque Values for Standard U.S. Fasteners................................................................... 82
Type 8 Phosphate Coated Hardware............................................................................ 84
Torque Values for Hose Clamps............................................................................... 85
Torque Values for Split Flanges............................................................................. 86
Torque Wrench Extension Tools............................................................................... 87
Torque Multiplication................................................................................... 87
Other Uses for Torque Wrench Extension Tools............................................................ 88
Tightening Torque Specifications (Metric)............................................................... 88
Upper Structure..................................................................................................... 91
Counterweight................................................................................................... 93
General..................................................................................................... 95
Removal..................................................................................................... 96
Installation................................................................................................ 98
Fuel Transfer Pump.............................................................................................. 99
General Description.........................................................................................101
Theory of Operation.....................................................................................101
Troubleshooting.............................................................................................102
Replacement of Rotor and Vane...............................................................................102
Replacement of Rear Cover...................................................................................103
Replacement of Armature.....................................................................................104
Swing Bearing...................................................................................................105
Swing Bearing Maintenance...................................................................................107
Operating Recommendation................................................................................107
Measuring Swing Bearing Axial Play......................................................................107
Measuring Bearing Lateral Play..........................................................................107
Swing Bearing Basic Operation...........................................................................108
Rebuilding Swing Bearing................................................................................108
Swing Reduction Gearbox.........................................................................................111
General Description.........................................................................................113
Theory of Operation.....................................................................................113
Parts List..............................................................................................114
Special Tools and Materials.................................................................................116
Special Tools...........................................................................................116
Troubleshooting, Testing and Adjustment.....................................................................117
Removal.....................................................................................................118
Disassembly.................................................................................................120
Reassembly..................................................................................................122
Installation................................................................................................124
Lower Structure and Chassis.........................................................................................125
Ram Lock Valve Operation........................................................................................127
Theory of Operation.........................................................................................129
Engine and Drive Train..............................................................................................131
Drive Axle...................................................................................................... 0
Introduction................................................................................................ 0
Introductory Statement.................................................................................. 0
Special Tool................................................................................................ 0
Trouble Shooting............................................................................................ 0
Clark-Hurth Axle Identification............................................................................. 0
Data Plate.............................................................................................. 0
Maintenance Points...................................................................................... 0
Maintenance Intervals................................................................................... 0
Conversion Tables....................................................................................... 0
Tightening Torques...................................................................................... 0
Brakes.................................................................................................. 0
Safety Brake............................................................................................ 0
Wheel Hub............................................................................................... 0
Wheel Hub onto Axle Housing............................................................................. 0
Epycicloidal Reduction 4.25............................................................................. 0
Epycicloidal Reduction 5.25............................................................................. 0
Articulation 271-278.................................................................................... 0
Steering Cylinder....................................................................................... 0
Bevel Pinion Support.................................................................................... 0
Adjustments of Bevel Gear Set........................................................................... 0
Taper roller bearings of differential................................................................... 0
Disassembling of Differential........................................................................... 0
Assembling of the Differential.......................................................................... 0
Self Locking Differential............................................................................... 0
Nospin.................................................................................................. 0
Hydraulic Differential Lock............................................................................. 0
Air Conditioner................................................................................................. 0
General Description......................................................................................... 0
Refrigerant Circulation..................................................................................... 0
Air-conditioning System Circuit Diagram..................................................................... 0
Troubleshooting............................................................................................. 0
Weight of R134a Gas Used In Machines........................................................................ 0
Refrigerant System Repairs.................................................................................. 0
Refrigerant Safe Handling Procedures.................................................................... 0
Repair and Replacement Procedure........................................................................ 0
Refrigerant Recovery.................................................................................... 0
Vacuuming Refrigerant System............................................................................ 0
Leakage Check........................................................................................... 0
Refrigerant Charging.................................................................................... 0
Inspecting System for Leakage........................................................................... 0
Transmission.................................................................................................... 0
Introduction................................................................................................ 0
Introductory Remarks.................................................................................... 0
Maintenance and Lubricant................................................................................... 0
Maintenance Points...................................................................................... 0
Data Plate.............................................................................................. 0
Maintenance Intervals................................................................................... 0
Conversion Tables....................................................................................... 0
Tightening Torques...................................................................................... 0
Diagrams of Reduction Unit and Exploded Views............................................................... 0
Diagram................................................................................................. 0
Reduction gear.......................................................................................... 0
First gear.............................................................................................. 0
Second gear............................................................................................. 0
Disassembly of Directly Flanged Reduction Gear 357.......................................................... 0
Removal of hydraulic gear control........................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357.......................................................... 0
Assembly of Directly Flanged Reduction Gear 357............................................................. 0
Installation of Hydraulic Gear Control...................................................................... 0
Drive Coupling (Main Pump)...................................................................................... 0
Drive Coupling.............................................................................................. 0
Special Tools............................................................................................... 0
Kawasaki / Tong Myung Pump Tool......................................................................... 0
Uchida Pump Tool........................................................................................ 0
Drive Coupling Installation................................................................................. 0
Installation Procedure.................................................................................. 0
Hydraulics.......................................................................................................... 0
Hydraulic System Troubleshooting, Testing and Adjustment........................................................ 0
Hydraulic System............................................................................................ 0
Outline................................................................................................. 0
Major Components........................................................................................ 0
Hydraulic Schematic (B55W-1)............................................................................ 0
Control Valve Operation................................................................................. 0
Circuit Operation....................................................................................... 0
Accumulator..................................................................................................... 0
General Description......................................................................................... 0
Specifications.......................................................................................... 0
Center Joint (Swivel)........................................................................................... 0
General Description......................................................................................... 0
Parts List.............................................................................................. 0
Troubleshooting, Testing and Adjustment..................................................................... 0
Inspection.............................................................................................. 0
Testing................................................................................................. 0
Disassembly................................................................................................. 0
Reassembly.................................................................................................. 0
Cylinders....................................................................................................... 0
General Description......................................................................................... 0
Theory of Operation..................................................................................... 0
Parts List.............................................................................................. 0
Special Tools and Materials................................................................................. 0
Piston Nut.............................................................................................. 0
Piston Jig.............................................................................................. 0
Steel bush Jig.......................................................................................... 0
Dust Wiper Jig.......................................................................................... 0
Slipper Seal Jig........................................................................................ 0
Slipper Seal Straightening Jig.......................................................................... 0
Disassembly................................................................................................. 0
Assembly.................................................................................................... 0
Travel Motor.................................................................................................... 0
Sectional View.............................................................................................. 0
Seal Kits and Component Groups.............................................................................. 0
Seal Kits and Component groups / Replace Seal Nut........................................................... 0
Sealing the Drive Shaft..................................................................................... 0
Sealing of the Control Parts................................................................................ 0
Sealing of the Relief Valve / Counter- Balance Valve........................................................ 0
Spare Parts List Counter-Balance Valve...................................................................... 0
Spare Parts List Brake Release Valve (Pos. 50).............................................................. 0
Shuttle Valve (Pos. 25)................................................................................. 0
Disassembly of the Port Plate............................................................................... 0
Remove of the Positioning Piston............................................................................ 0
Remove Rotary Group......................................................................................... 0
Exchanging of the rotary group.............................................................................. 0
Complete Rotary Group................................................................................... 0
Rotary Group............................................................................................ 0
Inspection Notes............................................................................................ 0
Rotary Group Assembly....................................................................................... 0
Rotary Group Adjustment (see service information)........................................................... 0
Assembly of the Port Plate.................................................................................. 0
Tightening Torques.......................................................................................... 0
Safety Regulations.......................................................................................... 0
General Advice.......................................................................................... 0
Before starting......................................................................................... 0
Start................................................................................................... 0
Hydraulic Equipment..................................................................................... 0
Swing Motor..................................................................................................... 0
Swing Motor................................................................................................. 0
Motor................................................................................................... 0
Valve Casing............................................................................................ 0
Relief Valve............................................................................................ 0
Troubleshooting............................................................................................. 0
Main Pump....................................................................................................... 0
General Description......................................................................................... 0
Description of Ports.................................................................................... 0
Operation Principle and Function of Components.............................................................. 0
Components of the Pump.................................................................................. 0
Operation Principle..................................................................................... 0
Adjustment.................................................................................................. 0
Installation................................................................................................ 0
Driving..................................................................................................... 0
Hydraulic Oil............................................................................................... 0
Procedures for Test Operation............................................................................... 0
Maintenance and Protection.................................................................................. 0
Checking Filters............................................................................................ 0
Filter Replacement.......................................................................................... 0
Replacement of Hydraulic Oil................................................................................ 0
Hydraulic Fluid Leakage Check............................................................................... 0
Diagnosis of Troubles and Actions to be Taken............................................................... 0
Diagnosis of Troubles with the Pump..................................................................... 0
Disassembling and Reassembling hydraulic pump............................................................... 0
Necessary Tools and Jigs................................................................................ 0
Reminders for Disassembly and Assembly.................................................................. 0
Disassembling Procedure................................................................................. 0
Standard Values for Maintenance......................................................................... 0
Reassembly Procedure.................................................................................... 0
Main Control Valve.............................................................................................. 0
Specifications.............................................................................................. 0
Internal Construction....................................................................................... 0
Construction of Relief and Make-Up Valves................................................................... 0
Relief Valve............................................................................................ 0
Make-up Valve........................................................................................... 0
Overload Relief Valve................................................................................... 0
Operation................................................................................................... 0
Operation in Neutral Position........................................................................... 0
Actuation of Relief Valve (MRV)......................................................................... 0
Actuation of Overload Relief Valve (ORV)................................................................ 0
Function and Operation of Make-up Valve................................................................. 0
Detail Views of Major Components........................................................................ 0
Disassembly................................................................................................. 0
Valve Handling Guide.................................................................................... 0
Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anti- cavitation Valve (ACV)........ 0
Check Valve Disassembly................................................................................. 0
Pressure Relief Load Check Valve Disassembly............................................................ 0
Anti-cavitation Valve Disassembly....................................................................... 0
Relief Valve Disassembly................................................................................ 0
Overload Relief Valve Disassembly....................................................................... 0
Other Components Disassembly............................................................................ 0
Joint Body Disassembly.................................................................................. 0
Disassembly Precautions................................................................................. 0
Assembly.................................................................................................... 0
Assembly Precautions.................................................................................... 0
Guide for Assembly of Each Part......................................................................... 0
Criteria for Maintenance.................................................................................... 0
Inspection of Spare Parts............................................................................... 0
Troubleshooting and Remedies............................................................................ 0
Control Valve........................................................................................... 0
Relief Valve............................................................................................ 0
Pilot Control Valve (Work Lever / Joystick)..................................................................... 0
General Description......................................................................................... 0
Theory of Operation..................................................................................... 0
Parts List.............................................................................................. 0
Specifications.......................................................................................... 0
Hydraulic Specifications................................................................................ 0
Special Tools............................................................................................... 0
Disassembly................................................................................................. 0
Reassembly.................................................................................................. 0
Hydraulic Schematic (B55W-1).................................................................................... 0
General Description......................................................................................... 0
B55W-1...................................................................................................... 0
Electrical System................................................................................................... 0
Electrical System............................................................................................... 0
Overview.................................................................................................... 0
Electric Supply System...................................................................................... 0
Engine Starting Circuit..................................................................................... 0
Operation During Starting Process....................................................................... 0
Operation After Start Process........................................................................... 0
Engine Preheating System.................................................................................... 0
Engine Stop System.......................................................................................... 0
Charging System............................................................................................. 0
Instrument System........................................................................................... 0
Instrument Panel........................................................................................ 0
Function Check.......................................................................................... 0
Operation............................................................................................... 0
Circuit Diagram of Instrument Panel..................................................................... 0
Circuit Diagram of Control Unit......................................................................... 0
Control Unit............................................................................................ 0
Electrical Schematic (B55W-1)................................................................................... 0
General Description......................................................................................... 0
B55W-1...................................................................................................... 0
Attachments......................................................................................................... 0
Bucket.......................................................................................................... 0
Bucket Tooth Inspection and Replacement..................................................................... 0
Type 1.................................................................................................. 0
Type 2.................................................................................................. 0
Type 3.................................................................................................. 0
Bucket O-ring Replacement................................................................................... 0
Type 1.................................................................................................. 0
Type 2.................................................................................................. 0
Bucket Shimming Procedures.................................................................................. 0
New Bucket Installation................................................................................. 0
Type 1.................................................................................................. 0
Type 2.................................................................................................. 0
Bucket Attachment, Removal and Reversal..................................................................... 0
Detaching the Bucket.................................................................................... 0
Attaching The bucket.................................................................................... 0
Reversing the Bucket.................................................................................... 0
sm b55w-1 (c).pdf................................................................................................... 0
Table Of Contents............................................................................................... 5
Safety.......................................................................................................... 7
Wheel Excavator Safety...................................................................................... 9
To the Operator of a Yanmar Excavator................................................................... 11
Learn the Signal Words Used with the Safety Alert Symbol............................................ 13
General Safety Essentials............................................................................... 14
Accessory Applications.............................................................................. 14
Lifting Capacity Rating Configuration............................................................... 14
Location of Safety Labels............................................................................... 14
Summary of Safety Precautions for Lifting in Digging Mode............................................... 15
Unauthorized Modifications.............................................................................. 16
General Hazard Information.............................................................................. 16
Safety Rules........................................................................................ 16
Safety Features..................................................................................... 16
Inside Operator's Compartment....................................................................... 17
Clothing and Personal Protective Items.............................................................. 18
Breathing Masks, Ear Protection May be Required..................................................... 18
Mounting and Dismounting............................................................................ 19
Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20
Precautions When Handling Fluids at High Temperature................................................ 20
Asbestos Dust Hazard Prevention..................................................................... 21
Injury from Work Equipment.......................................................................... 21
Fire Extinguisher and First Aid Kit................................................................. 22
Protection from Falling or Flying Objects........................................................... 22
Attachment Precautions.............................................................................. 23
Accumulator......................................................................................... 23
Indoor Ventilation.................................................................................. 24
Emergency Exit...................................................................................... 24
Before Starting Engine.................................................................................. 25
Work Site Precautions............................................................................... 25
Checks Before Starting Engine....................................................................... 26
Engine Starting..................................................................................... 27
Before Operating Machine............................................................................ 27
Machine Operation....................................................................................... 28
When Swinging or Changing Direction of Travel....................................................... 28
Travel Precautions.................................................................................. 28
Traveling on Slopes................................................................................. 29
Prohibited Operations............................................................................... 30
Precautions for Operation........................................................................... 30
Avoid High-voltage Cables........................................................................... 31
Operate Carefully on Snow, Ice and in Very Cold Temperatures........................................ 31
Operations on Slopes................................................................................ 32
Parking Machine..................................................................................... 32
Never Let Anyone Ride on Attachment................................................................. 32
Maintenance............................................................................................. 33
Warning Tag......................................................................................... 33
Clean Before Inspection or Maintenance.............................................................. 33
Proper Tools........................................................................................ 34
Use of Lighting..................................................................................... 34
Fire Prevention and Explosion Prevention............................................................ 34
Burn Prevention..................................................................................... 35
Welding Repairs..................................................................................... 36
Warning for Counterweight and Front Attachment Removal.............................................. 36
Precautions for Removal, Installation, and Storage of Attachments................................... 37
Precautions when Working on Machine................................................................. 37
Lock Inspection Covers.............................................................................. 37
Crushing Prevention and Cutting Prevention.......................................................... 37
Supports and Blocking for Work Equipment............................................................ 38
Action When Abnormally Is Found During Inspection................................................... 39
Precautions with High Pressure Line, Tubes and Hoses................................................ 39
Waste Materials..................................................................................... 40
Battery................................................................................................. 41
Battery Hazard Prevention........................................................................... 41
Boost Starting or Charging Engine Batteries......................................................... 42
Towing.................................................................................................. 43
Precautions When Towing............................................................................. 43
Shipping and Transportation............................................................................. 44
Obey State and Local Over-the-Road Regulations...................................................... 44
Lifting With Sling...................................................................................... 44
Specifications.................................................................................................. 45
Specifications for B55W-1................................................................................... 47
General Description..................................................................................... 49
Component Locations..................................................................................... 50
General Dimensions...................................................................................... 52
Working Range........................................................................................... 54
General Specifications.................................................................................. 56
Weight Table............................................................................................ 57
Working Attachments..................................................................................... 58
Pin and Bushing Wear Limits......................................................................... 58
Measuring Cylinder Drift............................................................................ 60
Measuring Speed..................................................................................... 61
General Maintenance............................................................................................. 63
General Maintenance Procedures.............................................................................. 65
Welding Precautions and Guidelines...................................................................... 67
Hydraulic System - General Precautions.................................................................. 68
Maintenance Service and Repair Procedure................................................................ 69
General Precautions................................................................................. 69
Hydraulic System Cleanliness and Oil Leaks.............................................................. 70
Maintenance Precautions for Hydraulic System Service................................................ 70
Oil Leakage Precautions............................................................................. 70
Cleaning and Inspection................................................................................. 71
General Guidelines.................................................................................. 71
Bearing inspection.................................................................................. 72
Standard Torques............................................................................................ 79
Torque Values for Standard Metric Fasteners............................................................. 81
Torque Values for Standard U.S. Fasteners............................................................... 82
Type 8 Phosphate Coated Hardware........................................................................ 84
Torque Values for Hose Clamps........................................................................... 85
Torque Values for Split Flanges......................................................................... 86
Torque Wrench Extension Tools........................................................................... 87
Torque Multiplication............................................................................... 87
Other Uses for Torque Wrench Extension Tools........................................................ 88
Tightening Torque Specifications (Metric)........................................................... 88
Upper Structure................................................................................................. 91
Counterweight............................................................................................... 93
General................................................................................................. 95
Removal................................................................................................. 96
Installation............................................................................................ 98
Fuel Transfer Pump.......................................................................................... 99
General Description.....................................................................................101
Theory of Operation.................................................................................101
Troubleshooting.........................................................................................102
Replacement of Rotor and Vane...........................................................................102
Replacement of Rear Cover...............................................................................103
Replacement of Armature.................................................................................104
Swing Bearing...............................................................................................105
Swing Bearing Maintenance...............................................................................107
Operating Recommendation............................................................................107
Measuring Swing Bearing Axial Play..................................................................107
Measuring Bearing Lateral Play......................................................................107
Swing Bearing Basic Operation.......................................................................108
Rebuilding Swing Bearing............................................................................108
Swing Reduction Gearbox.....................................................................................111
General Description.....................................................................................113
Theory of Operation.................................................................................113
Parts List..........................................................................................114
Special Tools and Materials.............................................................................116
Special Tools.......................................................................................116
Troubleshooting, Testing and Adjustment.................................................................117
Removal.................................................................................................118
Disassembly.............................................................................................120
Reassembly..............................................................................................122
Installation............................................................................................124
Lower Structure and Chassis.....................................................................................125
Ram Lock Valve Operation....................................................................................127
Theory of Operation.....................................................................................129
Engine and Drive Train..........................................................................................131
Drive Axle.................................................................................................. 0
Introduction............................................................................................ 0
Introductory Statement.............................................................................. 0
Special Tool............................................................................................ 0
Trouble Shooting........................................................................................ 0
Clark-Hurth Axle Identification......................................................................... 0
Data Plate.......................................................................................... 0
Maintenance Points.................................................................................. 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Brakes.............................................................................................. 0
Safety Brake........................................................................................ 0
Wheel Hub........................................................................................... 0
Wheel Hub onto Axle Housing......................................................................... 0
Epycicloidal Reduction 4.25......................................................................... 0
Epycicloidal Reduction 5.25......................................................................... 0
Articulation 271-278................................................................................ 0
Steering Cylinder................................................................................... 0
Bevel Pinion Support................................................................................ 0
Adjustments of Bevel Gear Set....................................................................... 0
Taper roller bearings of differential............................................................... 0
Disassembling of Differential....................................................................... 0
Assembling of the Differential...................................................................... 0
Self Locking Differential........................................................................... 0
Nospin.............................................................................................. 0
Hydraulic Differential Lock......................................................................... 0
Air Conditioner............................................................................................. 0
General Description..................................................................................... 0
Refrigerant Circulation................................................................................. 0
Air-conditioning System Circuit Diagram................................................................. 0
Troubleshooting......................................................................................... 0
Weight of R134a Gas Used In Machines.................................................................... 0
Refrigerant System Repairs.............................................................................. 0
Refrigerant Safe Handling Procedures................................................................ 0
Repair and Replacement Procedure.................................................................... 0
Refrigerant Recovery................................................................................ 0
Vacuuming Refrigerant System........................................................................ 0
Leakage Check....................................................................................... 0
Refrigerant Charging................................................................................ 0
Inspecting System for Leakage....................................................................... 0
Transmission................................................................................................ 0
Introduction............................................................................................ 0
Introductory Remarks................................................................................ 0
Maintenance and Lubricant............................................................................... 0
Maintenance Points.................................................................................. 0
Data Plate.......................................................................................... 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Diagrams of Reduction Unit and Exploded Views........................................................... 0
Diagram............................................................................................. 0
Reduction gear...................................................................................... 0
First gear.......................................................................................... 0
Second gear......................................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Removal of hydraulic gear control....................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Assembly of Directly Flanged Reduction Gear 357......................................................... 0
Installation of Hydraulic Gear Control.................................................................. 0
Drive Coupling (Main Pump).................................................................................. 0
Drive Coupling.......................................................................................... 0
Special Tools........................................................................................... 0
Kawasaki / Tong Myung Pump Tool..................................................................... 0
Uchida Pump Tool.................................................................................... 0
Drive Coupling Installation............................................................................. 0
Installation Procedure.............................................................................. 0
Hydraulics...................................................................................................... 0
Hydraulic System Troubleshooting, Testing and Adjustment.................................................... 0
Hydraulic System........................................................................................ 0
Outline............................................................................................. 0
Major Components.................................................................................... 0
Hydraulic Schematic (B55W-1)........................................................................ 0
Control Valve Operation............................................................................. 0
Circuit Operation................................................................................... 0
Accumulator................................................................................................. 0
General Description..................................................................................... 0
Specifications...................................................................................... 0
Center Joint (Swivel)....................................................................................... 0
General Description..................................................................................... 0
Parts List.......................................................................................... 0
Troubleshooting, Testing and Adjustment................................................................. 0
Inspection.......................................................................................... 0
Testing............................................................................................. 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Cylinders................................................................................................... 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Special Tools and Materials............................................................................. 0
Piston Nut.......................................................................................... 0
Piston Jig.......................................................................................... 0
Steel bush Jig...................................................................................... 0
Dust Wiper Jig...................................................................................... 0
Slipper Seal Jig.................................................................................... 0
Slipper Seal Straightening Jig...................................................................... 0
Disassembly............................................................................................. 0
Assembly................................................................................................ 0
Travel Motor................................................................................................ 0
Sectional View.......................................................................................... 0
Seal Kits and Component Groups.......................................................................... 0
Seal Kits and Component groups / Replace Seal Nut....................................................... 0
Sealing the Drive Shaft................................................................................. 0
Sealing of the Control Parts............................................................................ 0
Sealing of the Relief Valve / Counter- Balance Valve.................................................... 0
Spare Parts List Counter-Balance Valve.................................................................. 0
Spare Parts List Brake Release Valve (Pos. 50).......................................................... 0
Shuttle Valve (Pos. 25)............................................................................. 0
Disassembly of the Port Plate........................................................................... 0
Remove of the Positioning Piston........................................................................ 0
Remove Rotary Group..................................................................................... 0
Exchanging of the rotary group.......................................................................... 0
Complete Rotary Group............................................................................... 0
Rotary Group........................................................................................ 0
Inspection Notes........................................................................................ 0
Rotary Group Assembly................................................................................... 0
Rotary Group Adjustment (see service information)....................................................... 0
Assembly of the Port Plate.............................................................................. 0
Tightening Torques...................................................................................... 0
Safety Regulations...................................................................................... 0
General Advice...................................................................................... 0
Before starting..................................................................................... 0
Start............................................................................................... 0
Hydraulic Equipment................................................................................. 0
Swing Motor................................................................................................. 0
Swing Motor............................................................................................. 0
Motor............................................................................................... 0
Valve Casing........................................................................................ 0
Relief Valve........................................................................................ 0
Troubleshooting......................................................................................... 0
Main Pump................................................................................................... 0
General Description..................................................................................... 0
Description of Ports................................................................................ 0
Operation Principle and Function of Components.......................................................... 0
Components of the Pump.............................................................................. 0
Operation Principle................................................................................. 0
Adjustment.............................................................................................. 0
Installation............................................................................................ 0
Driving................................................................................................. 0
Hydraulic Oil........................................................................................... 0
Procedures for Test Operation........................................................................... 0
Maintenance and Protection.............................................................................. 0
Checking Filters........................................................................................ 0
Filter Replacement...................................................................................... 0
Replacement of Hydraulic Oil............................................................................ 0
Hydraulic Fluid Leakage Check........................................................................... 0
Diagnosis of Troubles and Actions to be Taken........................................................... 0
Diagnosis of Troubles with the Pump................................................................. 0
Disassembling and Reassembling hydraulic pump........................................................... 0
Necessary Tools and Jigs............................................................................ 0
Reminders for Disassembly and Assembly.............................................................. 0
Disassembling Procedure............................................................................. 0
Standard Values for Maintenance..................................................................... 0
Reassembly Procedure................................................................................ 0
Main Control Valve.......................................................................................... 0
Specifications.......................................................................................... 0
Internal Construction................................................................................... 0
Construction of Relief and Make-Up Valves............................................................... 0
Relief Valve........................................................................................ 0
Make-up Valve....................................................................................... 0
Overload Relief Valve............................................................................... 0
Operation............................................................................................... 0
Operation in Neutral Position....................................................................... 0
Actuation of Relief Valve (MRV)..................................................................... 0
Actuation of Overload Relief Valve (ORV)............................................................ 0
Function and Operation of Make-up Valve............................................................. 0
Detail Views of Major Components.................................................................... 0
Disassembly............................................................................................. 0
Valve Handling Guide................................................................................ 0
Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anti- cavitation Valve (ACV).... 0
Check Valve Disassembly............................................................................. 0
Pressure Relief Load Check Valve Disassembly........................................................ 0
Anti-cavitation Valve Disassembly................................................................... 0
Relief Valve Disassembly............................................................................ 0
Overload Relief Valve Disassembly................................................................... 0
Other Components Disassembly........................................................................ 0
Joint Body Disassembly.............................................................................. 0
Disassembly Precautions............................................................................. 0
Assembly................................................................................................ 0
Assembly Precautions................................................................................ 0
Guide for Assembly of Each Part..................................................................... 0
Criteria for Maintenance................................................................................ 0
Inspection of Spare Parts........................................................................... 0
Troubleshooting and Remedies........................................................................ 0
Control Valve....................................................................................... 0
Relief Valve........................................................................................ 0
Pilot Control Valve (Work Lever / Joystick)................................................................. 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Specifications...................................................................................... 0
Hydraulic Specifications............................................................................ 0
Special Tools........................................................................................... 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Hydraulic Schematic (B55W-1)................................................................................ 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Electrical System............................................................................................... 0
Electrical System........................................................................................... 0
Overview................................................................................................ 0
Electric Supply System.................................................................................. 0
Engine Starting Circuit................................................................................. 0
Operation During Starting Process................................................................... 0
Operation After Start Process....................................................................... 0
Engine Preheating System................................................................................ 0
Engine Stop System...................................................................................... 0
Charging System......................................................................................... 0
Instrument System....................................................................................... 0
Instrument Panel.................................................................................... 0
Function Check...................................................................................... 0
Operation........................................................................................... 0
Circuit Diagram of Instrument Panel................................................................. 0
Circuit Diagram of Control Unit..................................................................... 0
Control Unit........................................................................................ 0
Electrical Schematic (B55W-1)............................................................................... 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Attachments..................................................................................................... 0
Bucket...................................................................................................... 0
Bucket Tooth Inspection and Replacement................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Type 3.............................................................................................. 0
Bucket O-ring Replacement............................................................................... 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Shimming Procedures.............................................................................. 0
New Bucket Installation............................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Attachment, Removal and Reversal................................................................. 0
Detaching the Bucket................................................................................ 0
Attaching The bucket................................................................................ 0
Reversing the Bucket................................................................................ 0
sm b55w-1 (d).pdf................................................................................................... 0
Table Of Contents............................................................................................... 5
Safety.......................................................................................................... 7
Wheel Excavator Safety...................................................................................... 9
To the Operator of a Yanmar Excavator................................................................... 11
Learn the Signal Words Used with the Safety Alert Symbol............................................ 13
General Safety Essentials............................................................................... 14
Accessory Applications.............................................................................. 14
Lifting Capacity Rating Configuration............................................................... 14
Location of Safety Labels............................................................................... 14
Summary of Safety Precautions for Lifting in Digging Mode............................................... 15
Unauthorized Modifications.............................................................................. 16
General Hazard Information.............................................................................. 16
Safety Rules........................................................................................ 16
Safety Features..................................................................................... 16
Inside Operator's Compartment....................................................................... 17
Clothing and Personal Protective Items.............................................................. 18
Breathing Masks, Ear Protection May be Required..................................................... 18
Mounting and Dismounting............................................................................ 19
Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20
Precautions When Handling Fluids at High Temperature................................................ 20
Asbestos Dust Hazard Prevention..................................................................... 21
Injury from Work Equipment.......................................................................... 21
Fire Extinguisher and First Aid Kit................................................................. 22
Protection from Falling or Flying Objects........................................................... 22
Attachment Precautions.............................................................................. 23
Accumulator......................................................................................... 23
Indoor Ventilation.................................................................................. 24
Emergency Exit...................................................................................... 24
Before Starting Engine.................................................................................. 25
Work Site Precautions............................................................................... 25
Checks Before Starting Engine....................................................................... 26
Engine Starting..................................................................................... 27
Before Operating Machine............................................................................ 27
Machine Operation....................................................................................... 28
When Swinging or Changing Direction of Travel....................................................... 28
Travel Precautions.................................................................................. 28
Traveling on Slopes................................................................................. 29
Prohibited Operations............................................................................... 30
Precautions for Operation........................................................................... 30
Avoid High-voltage Cables........................................................................... 31
Operate Carefully on Snow, Ice and in Very Cold Temperatures........................................ 31
Operations on Slopes................................................................................ 32
Parking Machine..................................................................................... 32
Never Let Anyone Ride on Attachment................................................................. 32
Maintenance............................................................................................. 33
Warning Tag......................................................................................... 33
Clean Before Inspection or Maintenance.............................................................. 33
Proper Tools........................................................................................ 34
Use of Lighting..................................................................................... 34
Fire Prevention and Explosion Prevention............................................................ 34
Burn Prevention..................................................................................... 35
Welding Repairs..................................................................................... 36
Warning for Counterweight and Front Attachment Removal.............................................. 36
Precautions for Removal, Installation, and Storage of Attachments................................... 37
Precautions when Working on Machine................................................................. 37
Lock Inspection Covers.............................................................................. 37
Crushing Prevention and Cutting Prevention.......................................................... 37
Supports and Blocking for Work Equipment............................................................ 38
Action When Abnormally Is Found During Inspection................................................... 39
Precautions with High Pressure Line, Tubes and Hoses................................................ 39
Waste Materials..................................................................................... 40
Battery................................................................................................. 41
Battery Hazard Prevention........................................................................... 41
Boost Starting or Charging Engine Batteries......................................................... 42
Towing.................................................................................................. 43
Precautions When Towing............................................................................. 43
Shipping and Transportation............................................................................. 44
Obey State and Local Over-the-Road Regulations...................................................... 44
Lifting With Sling...................................................................................... 44
Specifications.................................................................................................. 45
Specifications for B55W-1................................................................................... 47
General Description..................................................................................... 49
Component Locations..................................................................................... 50
General Dimensions...................................................................................... 52
Working Range........................................................................................... 54
General Specifications.................................................................................. 56
Weight Table............................................................................................ 57
Working Attachments..................................................................................... 58
Pin and Bushing Wear Limits......................................................................... 58
Measuring Cylinder Drift............................................................................ 60
Measuring Speed..................................................................................... 61
General Maintenance............................................................................................. 63
General Maintenance Procedures.............................................................................. 65
Welding Precautions and Guidelines...................................................................... 67
Hydraulic System - General Precautions.................................................................. 68
Maintenance Service and Repair Procedure................................................................ 69
General Precautions................................................................................. 69
Hydraulic System Cleanliness and Oil Leaks.............................................................. 70
Maintenance Precautions for Hydraulic System Service................................................ 70
Oil Leakage Precautions............................................................................. 70
Cleaning and Inspection................................................................................. 71
General Guidelines.................................................................................. 71
Bearing inspection.................................................................................. 72
Standard Torques............................................................................................ 79
Torque Values for Standard Metric Fasteners............................................................. 81
Torque Values for Standard U.S. Fasteners............................................................... 82
Type 8 Phosphate Coated Hardware........................................................................ 84
Torque Values for Hose Clamps........................................................................... 85
Torque Values for Split Flanges......................................................................... 86
Torque Wrench Extension Tools........................................................................... 87
Torque Multiplication............................................................................... 87
Other Uses for Torque Wrench Extension Tools........................................................ 88
Tightening Torque Specifications (Metric)........................................................... 88
Upper Structure................................................................................................. 91
Counterweight............................................................................................... 93
General................................................................................................. 95
Removal................................................................................................. 96
Installation............................................................................................ 98
Fuel Transfer Pump.......................................................................................... 99
General Description.....................................................................................101
Theory of Operation.................................................................................101
Troubleshooting.........................................................................................102
Replacement of Rotor and Vane...........................................................................102
Replacement of Rear Cover...............................................................................103
Replacement of Armature.................................................................................104
Swing Bearing...............................................................................................105
Swing Bearing Maintenance...............................................................................107
Operating Recommendation............................................................................107
Measuring Swing Bearing Axial Play..................................................................107
Measuring Bearing Lateral Play......................................................................107
Swing Bearing Basic Operation.......................................................................108
Rebuilding Swing Bearing............................................................................108
Swing Reduction Gearbox.....................................................................................111
General Description.....................................................................................113
Theory of Operation.................................................................................113
Parts List..........................................................................................114
Special Tools and Materials.............................................................................116
Special Tools.......................................................................................116
Troubleshooting, Testing and Adjustment.................................................................117
Removal.................................................................................................118
Disassembly.............................................................................................120
Reassembly..............................................................................................122
Installation............................................................................................124
Lower Structure and Chassis.....................................................................................125
Ram Lock Valve Operation....................................................................................127
Theory of Operation.....................................................................................129
Engine and Drive Train..........................................................................................131
Drive Axle.................................................................................................. 0
Introduction............................................................................................ 0
Introductory Statement.............................................................................. 0
Special Tool............................................................................................ 0
Trouble Shooting........................................................................................ 0
Clark-Hurth Axle Identification......................................................................... 0
Data Plate.......................................................................................... 0
Maintenance Points.................................................................................. 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Brakes.............................................................................................. 0
Safety Brake........................................................................................ 0
Wheel Hub........................................................................................... 0
Wheel Hub onto Axle Housing......................................................................... 0
Epycicloidal Reduction 4.25......................................................................... 0
Epycicloidal Reduction 5.25......................................................................... 0
Articulation 271-278................................................................................ 0
Steering Cylinder................................................................................... 0
Bevel Pinion Support................................................................................ 0
Adjustments of Bevel Gear Set....................................................................... 0
Taper roller bearings of differential............................................................... 0
Disassembling of Differential....................................................................... 0
Assembling of the Differential...................................................................... 0
Self Locking Differential........................................................................... 0
Nospin.............................................................................................. 0
Hydraulic Differential Lock......................................................................... 0
Air Conditioner............................................................................................. 0
General Description..................................................................................... 0
Refrigerant Circulation................................................................................. 0
Air-conditioning System Circuit Diagram................................................................. 0
Troubleshooting......................................................................................... 0
Weight of R134a Gas Used In Machines.................................................................... 0
Refrigerant System Repairs.............................................................................. 0
Refrigerant Safe Handling Procedures................................................................ 0
Repair and Replacement Procedure.................................................................... 0
Refrigerant Recovery................................................................................ 0
Vacuuming Refrigerant System........................................................................ 0
Leakage Check....................................................................................... 0
Refrigerant Charging................................................................................ 0
Inspecting System for Leakage....................................................................... 0
Transmission................................................................................................ 0
Introduction............................................................................................ 0
Introductory Remarks................................................................................ 0
Maintenance and Lubricant............................................................................... 0
Maintenance Points.................................................................................. 0
Data Plate.......................................................................................... 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Diagrams of Reduction Unit and Exploded Views........................................................... 0
Diagram............................................................................................. 0
Reduction gear...................................................................................... 0
First gear.......................................................................................... 0
Second gear......................................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Removal of hydraulic gear control....................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Assembly of Directly Flanged Reduction Gear 357......................................................... 0
Installation of Hydraulic Gear Control.................................................................. 0
Drive Coupling (Main Pump).................................................................................. 0
Drive Coupling.......................................................................................... 0
Special Tools........................................................................................... 0
Kawasaki / Tong Myung Pump Tool..................................................................... 0
Uchida Pump Tool.................................................................................... 0
Drive Coupling Installation............................................................................. 0
Installation Procedure.............................................................................. 0
Hydraulics...................................................................................................... 0
Hydraulic System Troubleshooting, Testing and Adjustment.................................................... 0
Hydraulic System........................................................................................ 0
Outline............................................................................................. 0
Major Components.................................................................................... 0
Hydraulic Schematic (B55W-1)........................................................................ 0
Control Valve Operation............................................................................. 0
Circuit Operation................................................................................... 0
Accumulator................................................................................................. 0
General Description..................................................................................... 0
Specifications...................................................................................... 0
Center Joint (Swivel)....................................................................................... 0
General Description..................................................................................... 0
Parts List.......................................................................................... 0
Troubleshooting, Testing and Adjustment................................................................. 0
Inspection.......................................................................................... 0
Testing............................................................................................. 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Cylinders................................................................................................... 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Special Tools and Materials............................................................................. 0
Piston Nut.......................................................................................... 0
Piston Jig.......................................................................................... 0
Steel bush Jig...................................................................................... 0
Dust Wiper Jig...................................................................................... 0
Slipper Seal Jig.................................................................................... 0
Slipper Seal Straightening Jig...................................................................... 0
Disassembly............................................................................................. 0
Assembly................................................................................................ 0
Travel Motor................................................................................................ 0
Sectional View.......................................................................................... 0
Seal Kits and Component Groups.......................................................................... 0
Seal Kits and Component groups / Replace Seal Nut....................................................... 0
Sealing the Drive Shaft................................................................................. 0
Sealing of the Control Parts............................................................................ 0
Sealing of the Relief Valve / Counter- Balance Valve.................................................... 0
Spare Parts List Counter-Balance Valve.................................................................. 0
Spare Parts List Brake Release Valve (Pos. 50).......................................................... 0
Shuttle Valve (Pos. 25)............................................................................. 0
Disassembly of the Port Plate........................................................................... 0
Remove of the Positioning Piston........................................................................ 0
Remove Rotary Group..................................................................................... 0
Exchanging of the rotary group.......................................................................... 0
Complete Rotary Group............................................................................... 0
Rotary Group........................................................................................ 0
Inspection Notes........................................................................................ 0
Rotary Group Assembly................................................................................... 0
Rotary Group Adjustment (see service information)....................................................... 0
Assembly of the Port Plate.............................................................................. 0
Tightening Torques...................................................................................... 0
Safety Regulations...................................................................................... 0
General Advice...................................................................................... 0
Before starting..................................................................................... 0
Start............................................................................................... 0
Hydraulic Equipment................................................................................. 0
Swing Motor................................................................................................. 0
Swing Motor............................................................................................. 0
Motor............................................................................................... 0
Valve Casing........................................................................................ 0
Relief Valve........................................................................................ 0
Troubleshooting......................................................................................... 0
Main Pump................................................................................................... 0
General Description..................................................................................... 0
Description of Ports................................................................................ 0
Operation Principle and Function of Components.......................................................... 0
Components of the Pump.............................................................................. 0
Operation Principle................................................................................. 0
Adjustment.............................................................................................. 0
Installation............................................................................................ 0
Driving................................................................................................. 0
Hydraulic Oil........................................................................................... 0
Procedures for Test Operation........................................................................... 0
Maintenance and Protection.............................................................................. 0
Checking Filters........................................................................................ 0
Filter Replacement...................................................................................... 0
Replacement of Hydraulic Oil............................................................................ 0
Hydraulic Fluid Leakage Check........................................................................... 0
Diagnosis of Troubles and Actions to be Taken........................................................... 0
Diagnosis of Troubles with the Pump................................................................. 0
Disassembling and Reassembling hydraulic pump........................................................... 0
Necessary Tools and Jigs............................................................................ 0
Reminders for Disassembly and Assembly.............................................................. 0
Disassembling Procedure............................................................................. 0
Standard Values for Maintenance..................................................................... 0
Reassembly Procedure................................................................................ 0
Main Control Valve.......................................................................................... 0
Specifications.......................................................................................... 0
Internal Construction................................................................................... 0
Construction of Relief and Make-Up Valves............................................................... 0
Relief Valve........................................................................................ 0
Make-up Valve....................................................................................... 0
Overload Relief Valve............................................................................... 0
Operation............................................................................................... 0
Operation in Neutral Position....................................................................... 0
Actuation of Relief Valve (MRV)..................................................................... 0
Actuation of Overload Relief Valve (ORV)............................................................ 0
Function and Operation of Make-up Valve............................................................. 0
Detail Views of Major Components.................................................................... 0
Disassembly............................................................................................. 0
Valve Handling Guide................................................................................ 0
Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anti- cavitation Valve (ACV).... 0
Check Valve Disassembly............................................................................. 0
Pressure Relief Load Check Valve Disassembly........................................................ 0
Anti-cavitation Valve Disassembly................................................................... 0
Relief Valve Disassembly............................................................................ 0
Overload Relief Valve Disassembly................................................................... 0
Other Components Disassembly........................................................................ 0
Joint Body Disassembly.............................................................................. 0
Disassembly Precautions............................................................................. 0
Assembly................................................................................................ 0
Assembly Precautions................................................................................ 0
Guide for Assembly of Each Part..................................................................... 0
Criteria for Maintenance................................................................................ 0
Inspection of Spare Parts........................................................................... 0
Troubleshooting and Remedies........................................................................ 0
Control Valve....................................................................................... 0
Relief Valve........................................................................................ 0
Pilot Control Valve (Work Lever / Joystick)................................................................. 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Specifications...................................................................................... 0
Hydraulic Specifications............................................................................ 0
Special Tools........................................................................................... 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Hydraulic Schematic (B55W-1)................................................................................ 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Electrical System............................................................................................... 0
Electrical System........................................................................................... 0
Overview................................................................................................ 0
Electric Supply System.................................................................................. 0
Engine Starting Circuit................................................................................. 0
Operation During Starting Process................................................................... 0
Operation After Start Process....................................................................... 0
Engine Preheating System................................................................................ 0
Engine Stop System...................................................................................... 0
Charging System......................................................................................... 0
Instrument System....................................................................................... 0
Instrument Panel.................................................................................... 0
Function Check...................................................................................... 0
Operation........................................................................................... 0
Circuit Diagram of Instrument Panel................................................................. 0
Circuit Diagram of Control Unit..................................................................... 0
Control Unit........................................................................................ 0
Electrical Schematic (B55W-1)............................................................................... 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Attachments..................................................................................................... 0
Bucket...................................................................................................... 0
Bucket Tooth Inspection and Replacement................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Type 3.............................................................................................. 0
Bucket O-ring Replacement............................................................................... 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Shimming Procedures.............................................................................. 0
New Bucket Installation............................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Attachment, Removal and Reversal................................................................. 0
Detaching the Bucket................................................................................ 0
Attaching The bucket................................................................................ 0
Reversing the Bucket................................................................................ 0
sm b55w-1 (e).pdf................................................................................................... 0
Table Of Contents............................................................................................... 5
Safety.......................................................................................................... 7
Wheel Excavator Safety...................................................................................... 9
To the Operator of a Yanmar Excavator................................................................... 11
Learn the Signal Words Used with the Safety Alert Symbol............................................ 13
General Safety Essentials............................................................................... 14
Accessory Applications.............................................................................. 14
Lifting Capacity Rating Configuration............................................................... 14
Location of Safety Labels............................................................................... 14
Summary of Safety Precautions for Lifting in Digging Mode............................................... 15
Unauthorized Modifications.............................................................................. 16
General Hazard Information.............................................................................. 16
Safety Rules........................................................................................ 16
Safety Features..................................................................................... 16
Inside Operator's Compartment....................................................................... 17
Clothing and Personal Protective Items.............................................................. 18
Breathing Masks, Ear Protection May be Required..................................................... 18
Mounting and Dismounting............................................................................ 19
Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20
Precautions When Handling Fluids at High Temperature................................................ 20
Asbestos Dust Hazard Prevention..................................................................... 21
Injury from Work Equipment.......................................................................... 21
Fire Extinguisher and First Aid Kit................................................................. 22
Protection from Falling or Flying Objects........................................................... 22
Attachment Precautions.............................................................................. 23
Accumulator......................................................................................... 23
Indoor Ventilation.................................................................................. 24
Emergency Exit...................................................................................... 24
Before Starting Engine.................................................................................. 25
Work Site Precautions............................................................................... 25
Checks Before Starting Engine....................................................................... 26
Engine Starting..................................................................................... 27
Before Operating Machine............................................................................ 27
Machine Operation....................................................................................... 28
When Swinging or Changing Direction of Travel....................................................... 28
Travel Precautions.................................................................................. 28
Traveling on Slopes................................................................................. 29
Prohibited Operations............................................................................... 30
Precautions for Operation........................................................................... 30
Avoid High-voltage Cables........................................................................... 31
Operate Carefully on Snow, Ice and in Very Cold Temperatures........................................ 31
Operations on Slopes................................................................................ 32
Parking Machine..................................................................................... 32
Never Let Anyone Ride on Attachment................................................................. 32
Maintenance............................................................................................. 33
Warning Tag......................................................................................... 33
Clean Before Inspection or Maintenance.............................................................. 33
Proper Tools........................................................................................ 34
Use of Lighting..................................................................................... 34
Fire Prevention and Explosion Prevention............................................................ 34
Burn Prevention..................................................................................... 35
Welding Repairs..................................................................................... 36
Warning for Counterweight and Front Attachment Removal.............................................. 36
Precautions for Removal, Installation, and Storage of Attachments................................... 37
Precautions when Working on Machine................................................................. 37
Lock Inspection Covers.............................................................................. 37
Crushing Prevention and Cutting Prevention.......................................................... 37
Supports and Blocking for Work Equipment............................................................ 38
Action When Abnormally Is Found During Inspection................................................... 39
Precautions with High Pressure Line, Tubes and Hoses................................................ 39
Waste Materials..................................................................................... 40
Battery................................................................................................. 41
Battery Hazard Prevention........................................................................... 41
Boost Starting or Charging Engine Batteries......................................................... 42
Towing.................................................................................................. 43
Precautions When Towing............................................................................. 43
Shipping and Transportation............................................................................. 44
Obey State and Local Over-the-Road Regulations...................................................... 44
Lifting With Sling...................................................................................... 44
Specifications.................................................................................................. 45
Specifications for B55W-1................................................................................... 47
General Description..................................................................................... 49
Component Locations..................................................................................... 50
General Dimensions...................................................................................... 52
Working Range........................................................................................... 54
General Specifications.................................................................................. 56
Weight Table............................................................................................ 57
Working Attachments..................................................................................... 58
Pin and Bushing Wear Limits......................................................................... 58
Measuring Cylinder Drift............................................................................ 60
Measuring Speed..................................................................................... 61
General Maintenance............................................................................................. 63
General Maintenance Procedures.............................................................................. 65
Welding Precautions and Guidelines...................................................................... 67
Hydraulic System - General Precautions.................................................................. 68
Maintenance Service and Repair Procedure................................................................ 69
General Precautions................................................................................. 69
Hydraulic System Cleanliness and Oil Leaks.............................................................. 70
Maintenance Precautions for Hydraulic System Service................................................ 70
Oil Leakage Precautions............................................................................. 70
Cleaning and Inspection................................................................................. 71
General Guidelines.................................................................................. 71
Bearing inspection.................................................................................. 72
Standard Torques............................................................................................ 79
Torque Values for Standard Metric Fasteners............................................................. 81
Torque Values for Standard U.S. Fasteners............................................................... 82
Type 8 Phosphate Coated Hardware........................................................................ 84
Torque Values for Hose Clamps........................................................................... 85
Torque Values for Split Flanges......................................................................... 86
Torque Wrench Extension Tools........................................................................... 87
Torque Multiplication............................................................................... 87
Other Uses for Torque Wrench Extension Tools........................................................ 88
Tightening Torque Specifications (Metric)........................................................... 88
Upper Structure................................................................................................. 91
Counterweight............................................................................................... 93
General................................................................................................. 95
Removal................................................................................................. 96
Installation............................................................................................ 98
Fuel Transfer Pump.......................................................................................... 99
General Description.....................................................................................101
Theory of Operation.................................................................................101
Troubleshooting.........................................................................................102
Replacement of Rotor and Vane...........................................................................102
Replacement of Rear Cover...............................................................................103
Replacement of Armature.................................................................................104
Swing Bearing...............................................................................................105
Swing Bearing Maintenance...............................................................................107
Operating Recommendation............................................................................107
Measuring Swing Bearing Axial Play..................................................................107
Measuring Bearing Lateral Play......................................................................107
Swing Bearing Basic Operation.......................................................................108
Rebuilding Swing Bearing............................................................................108
Swing Reduction Gearbox.....................................................................................111
General Description.....................................................................................113
Theory of Operation.................................................................................113
Parts List..........................................................................................114
Special Tools and Materials.............................................................................116
Special Tools.......................................................................................116
Troubleshooting, Testing and Adjustment.................................................................117
Removal.................................................................................................118
Disassembly.............................................................................................120
Reassembly..............................................................................................122
Installation............................................................................................124
Lower Structure and Chassis.....................................................................................125
Ram Lock Valve Operation....................................................................................127
Theory of Operation.....................................................................................129
Engine and Drive Train..........................................................................................131
Drive Axle.................................................................................................. 0
Introduction............................................................................................ 0
Introductory Statement.............................................................................. 0
Special Tool............................................................................................ 0
Trouble Shooting........................................................................................ 0
Clark-Hurth Axle Identification......................................................................... 0
Data Plate.......................................................................................... 0
Maintenance Points.................................................................................. 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Brakes.............................................................................................. 0
Safety Brake........................................................................................ 0
Wheel Hub........................................................................................... 0
Wheel Hub onto Axle Housing......................................................................... 0
Epycicloidal Reduction 4.25......................................................................... 0
Epycicloidal Reduction 5.25......................................................................... 0
Articulation 271-278................................................................................ 0
Steering Cylinder................................................................................... 0
Bevel Pinion Support................................................................................ 0
Adjustments of Bevel Gear Set....................................................................... 0
Taper roller bearings of differential............................................................... 0
Disassembling of Differential....................................................................... 0
Assembling of the Differential...................................................................... 0
Self Locking Differential........................................................................... 0
Nospin.............................................................................................. 0
Hydraulic Differential Lock......................................................................... 0
Air Conditioner............................................................................................. 0
General Description..................................................................................... 0
Refrigerant Circulation................................................................................. 0
Air-conditioning System Circuit Diagram................................................................. 0
Troubleshooting......................................................................................... 0
Weight of R134a Gas Used In Machines.................................................................... 0
Refrigerant System Repairs.............................................................................. 0
Refrigerant Safe Handling Procedures................................................................ 0
Repair and Replacement Procedure.................................................................... 0
Refrigerant Recovery................................................................................ 0
Vacuuming Refrigerant System........................................................................ 0
Leakage Check....................................................................................... 0
Refrigerant Charging................................................................................ 0
Inspecting System for Leakage....................................................................... 0
Transmission................................................................................................ 0
Introduction............................................................................................ 0
Introductory Remarks................................................................................ 0
Maintenance and Lubricant............................................................................... 0
Maintenance Points.................................................................................. 0
Data Plate.......................................................................................... 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Diagrams of Reduction Unit and Exploded Views........................................................... 0
Diagram............................................................................................. 0
Reduction gear...................................................................................... 0
First gear.......................................................................................... 0
Second gear......................................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Removal of hydraulic gear control....................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Assembly of Directly Flanged Reduction Gear 357......................................................... 0
Installation of Hydraulic Gear Control.................................................................. 0
Drive Coupling (Main Pump).................................................................................. 0
Drive Coupling.......................................................................................... 0
Special Tools........................................................................................... 0
Kawasaki / Tong Myung Pump Tool..................................................................... 0
Uchida Pump Tool.................................................................................... 0
Drive Coupling Installation............................................................................. 0
Installation Procedure.............................................................................. 0
Hydraulics...................................................................................................... 0
Hydraulic System Troubleshooting, Testing and Adjustment.................................................... 0
Hydraulic System........................................................................................ 0
Outline............................................................................................. 0
Major Components.................................................................................... 0
Hydraulic Schematic (B55W-1)........................................................................ 0
Control Valve Operation............................................................................. 0
Circuit Operation................................................................................... 0
Accumulator................................................................................................. 0
General Description..................................................................................... 0
Specifications...................................................................................... 0
Center Joint (Swivel)....................................................................................... 0
General Description..................................................................................... 0
Parts List.......................................................................................... 0
Troubleshooting, Testing and Adjustment................................................................. 0
Inspection.......................................................................................... 0
Testing............................................................................................. 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Cylinders................................................................................................... 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Special Tools and Materials............................................................................. 0
Piston Nut.......................................................................................... 0
Piston Jig.......................................................................................... 0
Steel bush Jig...................................................................................... 0
Dust Wiper Jig...................................................................................... 0
Slipper Seal Jig.................................................................................... 0
Slipper Seal Straightening Jig...................................................................... 0
Disassembly............................................................................................. 0
Assembly................................................................................................ 0
Travel Motor................................................................................................ 0
Sectional View.......................................................................................... 0
Seal Kits and Component Groups.......................................................................... 0
Seal Kits and Component groups / Replace Seal Nut....................................................... 0
Sealing the Drive Shaft................................................................................. 0
Sealing of the Control Parts............................................................................ 0
Sealing of the Relief Valve / Counter- Balance Valve.................................................... 0
Spare Parts List Counter-Balance Valve.................................................................. 0
Spare Parts List Brake Release Valve (Pos. 50).......................................................... 0
Shuttle Valve (Pos. 25)............................................................................. 0
Disassembly of the Port Plate........................................................................... 0
Remove of the Positioning Piston........................................................................ 0
Remove Rotary Group..................................................................................... 0
Exchanging of the rotary group.......................................................................... 0
Complete Rotary Group............................................................................... 0
Rotary Group........................................................................................ 0
Inspection Notes........................................................................................ 0
Rotary Group Assembly................................................................................... 0
Rotary Group Adjustment (see service information)....................................................... 0
Assembly of the Port Plate.............................................................................. 0
Tightening Torques...................................................................................... 0
Safety Regulations...................................................................................... 0
General Advice...................................................................................... 0
Before starting..................................................................................... 0
Start............................................................................................... 0
Hydraulic Equipment................................................................................. 0
Swing Motor................................................................................................. 0
Swing Motor............................................................................................. 0
Motor............................................................................................... 0
Valve Casing........................................................................................ 0
Relief Valve........................................................................................ 0
Troubleshooting......................................................................................... 0
Main Pump................................................................................................... 0
General Description..................................................................................... 0
Description of Ports................................................................................ 0
Operation Principle and Function of Components.......................................................... 0
Components of the Pump.............................................................................. 0
Operation Principle................................................................................. 0
Adjustment.............................................................................................. 0
Installation............................................................................................ 0
Driving................................................................................................. 0
Hydraulic Oil........................................................................................... 0
Procedures for Test Operation........................................................................... 0
Maintenance and Protection.............................................................................. 0
Checking Filters........................................................................................ 0
Filter Replacement...................................................................................... 0
Replacement of Hydraulic Oil............................................................................ 0
Hydraulic Fluid Leakage Check........................................................................... 0
Diagnosis of Troubles and Actions to be Taken........................................................... 0
Diagnosis of Troubles with the Pump................................................................. 0
Disassembling and Reassembling hydraulic pump........................................................... 0
Necessary Tools and Jigs............................................................................ 0
Reminders for Disassembly and Assembly.............................................................. 0
Disassembling Procedure............................................................................. 0
Standard Values for Maintenance..................................................................... 0
Reassembly Procedure................................................................................ 0
Main Control Valve.......................................................................................... 0
Specifications.......................................................................................... 0
Internal Construction................................................................................... 0
Construction of Relief and Make-Up Valves............................................................... 0
Relief Valve........................................................................................ 0
Make-up Valve....................................................................................... 0
Overload Relief Valve............................................................................... 0
Operation............................................................................................... 0
Operation in Neutral Position....................................................................... 0
Actuation of Relief Valve (MRV)..................................................................... 0
Actuation of Overload Relief Valve (ORV)............................................................ 0
Function and Operation of Make-up Valve............................................................. 0
Detail Views of Major Components.................................................................... 0
Disassembly............................................................................................. 0
Valve Handling Guide................................................................................ 0
Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anti- cavitation Valve (ACV).... 0
Check Valve Disassembly............................................................................. 0
Pressure Relief Load Check Valve Disassembly........................................................ 0
Anti-cavitation Valve Disassembly................................................................... 0
Relief Valve Disassembly............................................................................ 0
Overload Relief Valve Disassembly................................................................... 0
Other Components Disassembly........................................................................ 0
Joint Body Disassembly.............................................................................. 0
Disassembly Precautions............................................................................. 0
Assembly................................................................................................ 0
Assembly Precautions................................................................................ 0
Guide for Assembly of Each Part..................................................................... 0
Criteria for Maintenance................................................................................ 0
Inspection of Spare Parts........................................................................... 0
Troubleshooting and Remedies........................................................................ 0
Control Valve....................................................................................... 0
Relief Valve........................................................................................ 0
Pilot Control Valve (Work Lever / Joystick)................................................................. 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Specifications...................................................................................... 0
Hydraulic Specifications............................................................................ 0
Special Tools........................................................................................... 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Hydraulic Schematic (B55W-1)................................................................................ 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Electrical System............................................................................................... 0
Electrical System........................................................................................... 0
Overview................................................................................................ 0
Electric Supply System.................................................................................. 0
Engine Starting Circuit................................................................................. 0
Operation During Starting Process................................................................... 0
Operation After Start Process....................................................................... 0
Engine Preheating System................................................................................ 0
Engine Stop System...................................................................................... 0
Charging System......................................................................................... 0
Instrument System....................................................................................... 0
Instrument Panel.................................................................................... 0
Function Check...................................................................................... 0
Operation........................................................................................... 0
Circuit Diagram of Instrument Panel................................................................. 0
Circuit Diagram of Control Unit..................................................................... 0
Control Unit........................................................................................ 0
Electrical Schematic (B55W-1)............................................................................... 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Attachments..................................................................................................... 0
Bucket...................................................................................................... 0
Bucket Tooth Inspection and Replacement................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Type 3.............................................................................................. 0
Bucket O-ring Replacement............................................................................... 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Shimming Procedures.............................................................................. 0
New Bucket Installation............................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Attachment, Removal and Reversal................................................................. 0
Detaching the Bucket................................................................................ 0
Attaching The bucket................................................................................ 0
Reversing the Bucket................................................................................ 0
sm b55w-1 (f).pdf................................................................................................... 0
Table Of Contents............................................................................................... 5
Safety.......................................................................................................... 7
Wheel Excavator Safety...................................................................................... 9
To the Operator of a Yanmar Excavator................................................................... 11
Learn the Signal Words Used with the Safety Alert Symbol............................................ 13
General Safety Essentials............................................................................... 14
Accessory Applications.............................................................................. 14
Lifting Capacity Rating Configuration............................................................... 14
Location of Safety Labels............................................................................... 14
Summary of Safety Precautions for Lifting in Digging Mode............................................... 15
Unauthorized Modifications.............................................................................. 16
General Hazard Information.............................................................................. 16
Safety Rules........................................................................................ 16
Safety Features..................................................................................... 16
Inside Operator's Compartment....................................................................... 17
Clothing and Personal Protective Items.............................................................. 18
Breathing Masks, Ear Protection May be Required..................................................... 18
Mounting and Dismounting............................................................................ 19
Fuel, Oil and Hydraulic Fluid Fire Hazards.......................................................... 20
Precautions When Handling Fluids at High Temperature................................................ 20
Asbestos Dust Hazard Prevention..................................................................... 21
Injury from Work Equipment.......................................................................... 21
Fire Extinguisher and First Aid Kit................................................................. 22
Protection from Falling or Flying Objects........................................................... 22
Attachment Precautions.............................................................................. 23
Accumulator......................................................................................... 23
Indoor Ventilation.................................................................................. 24
Emergency Exit...................................................................................... 24
Before Starting Engine.................................................................................. 25
Work Site Precautions............................................................................... 25
Checks Before Starting Engine....................................................................... 26
Engine Starting..................................................................................... 27
Before Operating Machine............................................................................ 27
Machine Operation....................................................................................... 28
When Swinging or Changing Direction of Travel....................................................... 28
Travel Precautions.................................................................................. 28
Traveling on Slopes................................................................................. 29
Prohibited Operations............................................................................... 30
Precautions for Operation........................................................................... 30
Avoid High-voltage Cables........................................................................... 31
Operate Carefully on Snow, Ice and in Very Cold Temperatures........................................ 31
Operations on Slopes................................................................................ 32
Parking Machine..................................................................................... 32
Never Let Anyone Ride on Attachment................................................................. 32
Maintenance............................................................................................. 33
Warning Tag......................................................................................... 33
Clean Before Inspection or Maintenance.............................................................. 33
Proper Tools........................................................................................ 34
Use of Lighting..................................................................................... 34
Fire Prevention and Explosion Prevention............................................................ 34
Burn Prevention..................................................................................... 35
Welding Repairs..................................................................................... 36
Warning for Counterweight and Front Attachment Removal.............................................. 36
Precautions for Removal, Installation, and Storage of Attachments................................... 37
Precautions when Working on Machine................................................................. 37
Lock Inspection Covers.............................................................................. 37
Crushing Prevention and Cutting Prevention.......................................................... 37
Supports and Blocking for Work Equipment............................................................ 38
Action When Abnormally Is Found During Inspection................................................... 39
Precautions with High Pressure Line, Tubes and Hoses................................................ 39
Waste Materials..................................................................................... 40
Battery................................................................................................. 41
Battery Hazard Prevention........................................................................... 41
Boost Starting or Charging Engine Batteries......................................................... 42
Towing.................................................................................................. 43
Precautions When Towing............................................................................. 43
Shipping and Transportation............................................................................. 44
Obey State and Local Over-the-Road Regulations...................................................... 44
Lifting With Sling...................................................................................... 44
Specifications.................................................................................................. 45
Specifications for B55W-1................................................................................... 47
General Description..................................................................................... 49
Component Locations..................................................................................... 50
General Dimensions...................................................................................... 52
Working Range........................................................................................... 54
General Specifications.................................................................................. 56
Weight Table............................................................................................ 57
Working Attachments..................................................................................... 58
Pin and Bushing Wear Limits......................................................................... 58
Measuring Cylinder Drift............................................................................ 60
Measuring Speed..................................................................................... 61
General Maintenance............................................................................................. 63
General Maintenance Procedures.............................................................................. 65
Welding Precautions and Guidelines...................................................................... 67
Hydraulic System - General Precautions.................................................................. 68
Maintenance Service and Repair Procedure................................................................ 69
General Precautions................................................................................. 69
Hydraulic System Cleanliness and Oil Leaks.............................................................. 70
Maintenance Precautions for Hydraulic System Service................................................ 70
Oil Leakage Precautions............................................................................. 70
Cleaning and Inspection................................................................................. 71
General Guidelines.................................................................................. 71
Bearing inspection.................................................................................. 72
Standard Torques............................................................................................ 79
Torque Values for Standard Metric Fasteners............................................................. 81
Torque Values for Standard U.S. Fasteners............................................................... 82
Type 8 Phosphate Coated Hardware........................................................................ 84
Torque Values for Hose Clamps........................................................................... 85
Torque Values for Split Flanges......................................................................... 86
Torque Wrench Extension Tools........................................................................... 87
Torque Multiplication............................................................................... 87
Other Uses for Torque Wrench Extension Tools........................................................ 88
Tightening Torque Specifications (Metric)........................................................... 88
Upper Structure................................................................................................. 91
Counterweight............................................................................................... 93
General................................................................................................. 95
Removal................................................................................................. 96
Installation............................................................................................ 98
Fuel Transfer Pump.......................................................................................... 99
General Description.....................................................................................101
Theory of Operation.................................................................................101
Troubleshooting.........................................................................................102
Replacement of Rotor and Vane...........................................................................102
Replacement of Rear Cover...............................................................................103
Replacement of Armature.................................................................................104
Swing Bearing...............................................................................................105
Swing Bearing Maintenance...............................................................................107
Operating Recommendation............................................................................107
Measuring Swing Bearing Axial Play..................................................................107
Measuring Bearing Lateral Play......................................................................107
Swing Bearing Basic Operation.......................................................................108
Rebuilding Swing Bearing............................................................................108
Swing Reduction Gearbox.....................................................................................111
General Description.....................................................................................113
Theory of Operation.................................................................................113
Parts List..........................................................................................114
Special Tools and Materials.............................................................................116
Special Tools.......................................................................................116
Troubleshooting, Testing and Adjustment.................................................................117
Removal.................................................................................................118
Disassembly.............................................................................................120
Reassembly..............................................................................................122
Installation............................................................................................124
Lower Structure and Chassis.....................................................................................125
Ram Lock Valve Operation....................................................................................127
Theory of Operation.....................................................................................129
Engine and Drive Train..........................................................................................131
Drive Axle.................................................................................................. 0
Introduction............................................................................................ 0
Introductory Statement.............................................................................. 0
Special Tool............................................................................................ 0
Trouble Shooting........................................................................................ 0
Clark-Hurth Axle Identification......................................................................... 0
Data Plate.......................................................................................... 0
Maintenance Points.................................................................................. 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Brakes.............................................................................................. 0
Safety Brake........................................................................................ 0
Wheel Hub........................................................................................... 0
Wheel Hub onto Axle Housing......................................................................... 0
Epycicloidal Reduction 4.25......................................................................... 0
Epycicloidal Reduction 5.25......................................................................... 0
Articulation 271-278................................................................................ 0
Steering Cylinder................................................................................... 0
Bevel Pinion Support................................................................................ 0
Adjustments of Bevel Gear Set....................................................................... 0
Taper roller bearings of differential............................................................... 0
Disassembling of Differential....................................................................... 0
Assembling of the Differential...................................................................... 0
Self Locking Differential........................................................................... 0
Nospin.............................................................................................. 0
Hydraulic Differential Lock......................................................................... 0
Air Conditioner............................................................................................. 0
General Description..................................................................................... 0
Refrigerant Circulation................................................................................. 0
Air-conditioning System Circuit Diagram................................................................. 0
Troubleshooting......................................................................................... 0
Weight of R134a Gas Used In Machines.................................................................... 0
Refrigerant System Repairs.............................................................................. 0
Refrigerant Safe Handling Procedures................................................................ 0
Repair and Replacement Procedure.................................................................... 0
Refrigerant Recovery................................................................................ 0
Vacuuming Refrigerant System........................................................................ 0
Leakage Check....................................................................................... 0
Refrigerant Charging................................................................................ 0
Inspecting System for Leakage....................................................................... 0
Transmission................................................................................................ 0
Introduction............................................................................................ 0
Introductory Remarks................................................................................ 0
Maintenance and Lubricant............................................................................... 0
Maintenance Points.................................................................................. 0
Data Plate.......................................................................................... 0
Maintenance Intervals............................................................................... 0
Conversion Tables................................................................................... 0
Tightening Torques.................................................................................. 0
Diagrams of Reduction Unit and Exploded Views........................................................... 0
Diagram............................................................................................. 0
Reduction gear...................................................................................... 0
First gear.......................................................................................... 0
Second gear......................................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Removal of hydraulic gear control....................................................................... 0
Disassembly of Directly Flanged Reduction Gear 357...................................................... 0
Assembly of Directly Flanged Reduction Gear 357......................................................... 0
Installation of Hydraulic Gear Control.................................................................. 0
Drive Coupling (Main Pump).................................................................................. 0
Drive Coupling.......................................................................................... 0
Special Tools........................................................................................... 0
Kawasaki / Tong Myung Pump Tool..................................................................... 0
Uchida Pump Tool.................................................................................... 0
Drive Coupling Installation............................................................................. 0
Installation Procedure.............................................................................. 0
Hydraulics...................................................................................................... 0
Hydraulic System Troubleshooting, Testing and Adjustment.................................................... 0
Hydraulic System........................................................................................ 0
Outline............................................................................................. 0
Major Components.................................................................................... 0
Hydraulic Schematic (B55W-1)........................................................................ 0
Control Valve Operation............................................................................. 0
Circuit Operation................................................................................... 0
Accumulator................................................................................................. 0
General Description..................................................................................... 0
Specifications...................................................................................... 0
Center Joint (Swivel)....................................................................................... 0
General Description..................................................................................... 0
Parts List.......................................................................................... 0
Troubleshooting, Testing and Adjustment................................................................. 0
Inspection.......................................................................................... 0
Testing............................................................................................. 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Cylinders................................................................................................... 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Special Tools and Materials............................................................................. 0
Piston Nut.......................................................................................... 0
Piston Jig.......................................................................................... 0
Steel bush Jig...................................................................................... 0
Dust Wiper Jig...................................................................................... 0
Slipper Seal Jig.................................................................................... 0
Slipper Seal Straightening Jig...................................................................... 0
Disassembly............................................................................................. 0
Assembly................................................................................................ 0
Travel Motor................................................................................................ 0
Sectional View.......................................................................................... 0
Seal Kits and Component Groups.......................................................................... 0
Seal Kits and Component groups / Replace Seal Nut....................................................... 0
Sealing the Drive Shaft................................................................................. 0
Sealing of the Control Parts............................................................................ 0
Sealing of the Relief Valve / Counter- Balance Valve.................................................... 0
Spare Parts List Counter-Balance Valve.................................................................. 0
Spare Parts List Brake Release Valve (Pos. 50).......................................................... 0
Shuttle Valve (Pos. 25)............................................................................. 0
Disassembly of the Port Plate........................................................................... 0
Remove of the Positioning Piston........................................................................ 0
Remove Rotary Group..................................................................................... 0
Exchanging of the rotary group.......................................................................... 0
Complete Rotary Group............................................................................... 0
Rotary Group........................................................................................ 0
Inspection Notes........................................................................................ 0
Rotary Group Assembly................................................................................... 0
Rotary Group Adjustment (see service information)....................................................... 0
Assembly of the Port Plate.............................................................................. 0
Tightening Torques...................................................................................... 0
Safety Regulations...................................................................................... 0
General Advice...................................................................................... 0
Before starting..................................................................................... 0
Start............................................................................................... 0
Hydraulic Equipment................................................................................. 0
Swing Motor................................................................................................. 0
Swing Motor............................................................................................. 0
Motor............................................................................................... 0
Valve Casing........................................................................................ 0
Relief Valve........................................................................................ 0
Troubleshooting......................................................................................... 0
Main Pump................................................................................................... 0
General Description..................................................................................... 0
Description of Ports................................................................................ 0
Operation Principle and Function of Components.......................................................... 0
Components of the Pump.............................................................................. 0
Operation Principle................................................................................. 0
Adjustment.............................................................................................. 0
Installation............................................................................................ 0
Driving................................................................................................. 0
Hydraulic Oil........................................................................................... 0
Procedures for Test Operation........................................................................... 0
Maintenance and Protection.............................................................................. 0
Checking Filters........................................................................................ 0
Filter Replacement...................................................................................... 0
Replacement of Hydraulic Oil............................................................................ 0
Hydraulic Fluid Leakage Check........................................................................... 0
Diagnosis of Troubles and Actions to be Taken........................................................... 0
Diagnosis of Troubles with the Pump................................................................. 0
Disassembling and Reassembling hydraulic pump........................................................... 0
Necessary Tools and Jigs............................................................................ 0
Reminders for Disassembly and Assembly.............................................................. 0
Disassembling Procedure............................................................................. 0
Standard Values for Maintenance..................................................................... 0
Reassembly Procedure................................................................................ 0
Main Control Valve.......................................................................................... 0
Specifications.......................................................................................... 0
Internal Construction................................................................................... 0
Construction of Relief and Make-Up Valves............................................................... 0
Relief Valve........................................................................................ 0
Make-up Valve....................................................................................... 0
Overload Relief Valve............................................................................... 0
Operation............................................................................................... 0
Operation in Neutral Position....................................................................... 0
Actuation of Relief Valve (MRV)..................................................................... 0
Actuation of Overload Relief Valve (ORV)............................................................ 0
Function and Operation of Make-up Valve............................................................. 0
Detail Views of Major Components.................................................................... 0
Disassembly............................................................................................. 0
Valve Handling Guide................................................................................ 0
Disassembly of Relief Valve (MRV), Overload Relief Valve (ORV), and Anti- cavitation Valve (ACV).... 0
Check Valve Disassembly............................................................................. 0
Pressure Relief Load Check Valve Disassembly........................................................ 0
Anti-cavitation Valve Disassembly................................................................... 0
Relief Valve Disassembly............................................................................ 0
Overload Relief Valve Disassembly................................................................... 0
Other Components Disassembly........................................................................ 0
Joint Body Disassembly.............................................................................. 0
Disassembly Precautions............................................................................. 0
Assembly................................................................................................ 0
Assembly Precautions................................................................................ 0
Guide for Assembly of Each Part..................................................................... 0
Criteria for Maintenance................................................................................ 0
Inspection of Spare Parts........................................................................... 0
Troubleshooting and Remedies........................................................................ 0
Control Valve....................................................................................... 0
Relief Valve........................................................................................ 0
Pilot Control Valve (Work Lever / Joystick)................................................................. 0
General Description..................................................................................... 0
Theory of Operation................................................................................. 0
Parts List.......................................................................................... 0
Specifications...................................................................................... 0
Hydraulic Specifications............................................................................ 0
Special Tools........................................................................................... 0
Disassembly............................................................................................. 0
Reassembly.............................................................................................. 0
Hydraulic Schematic (B55W-1)................................................................................ 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Electrical System............................................................................................... 0
Electrical System........................................................................................... 0
Overview................................................................................................ 0
Electric Supply System.................................................................................. 0
Engine Starting Circuit................................................................................. 0
Operation During Starting Process................................................................... 0
Operation After Start Process....................................................................... 0
Engine Preheating System................................................................................ 0
Engine Stop System...................................................................................... 0
Charging System......................................................................................... 0
Instrument System....................................................................................... 0
Instrument Panel.................................................................................... 0
Function Check...................................................................................... 0
Operation........................................................................................... 0
Circuit Diagram of Instrument Panel................................................................. 0
Circuit Diagram of Control Unit..................................................................... 0
Control Unit........................................................................................ 0
Electrical Schematic (B55W-1)............................................................................... 0
General Description..................................................................................... 0
B55W-1.................................................................................................. 0
Attachments..................................................................................................... 0
Bucket...................................................................................................... 0
Bucket Tooth Inspection and Replacement................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Type 3.............................................................................................. 0
Bucket O-ring Replacement............................................................................... 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Shimming Procedures.............................................................................. 0
New Bucket Installation............................................................................. 0
Type 1.............................................................................................. 0
Type 2.............................................................................................. 0
Bucket Attachment, Removal and Reversal................................................................. 0
Detaching the Bucket................................................................................ 0
Attaching The bucket................................................................................ 0
Reversing the Bucket................................................................................ 0
PLEASE NOTE:
This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
Require some other service manual or have any queries: please WRITE to us at [email protected]
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