YANMAR B7-5 B7-5A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

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YANMAR B7-5 B7-5A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

YANMAR B7-5 B7-5A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD:

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YANMAR B7-5 B7-5A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

• Correct work means the quickest possible completion of according to the correct procedures and the specified standards.
• It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions to watch out for.
• (1) Never attempt servicing while engine is running or immediately after stopping operation. (2) Wear work cloths, safety shoes and helmet. (3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
• (4) When working together with other persons, allocate everyone’s share of job, arrange the signals and act in concert with the other persons. (5) The operation of the crane and slinging work must be performed by qualified persons.
• (6) Do not enter or pass under the raised load. (7) Lift and support the massive parts by crane before removing the installation bolts. (8) Disconnect cables from battery before repairing the electric system.
• (9) Remove the battery when welding the machine. (1) Check the service record of the machine. (That is, check how many months or hours the machine has been used since the preceding overhaul, what was the trouble then and what parts were replaced.)
• (2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), containers, oil & grease, etc. (3) Have the service literature (operation manual, parts catalog, etc.) ready.
• (1) Clean the machine before disassembly. (2) Check and record the condition of the machine before disassembly : • Model, machine number, operation hours • Reasons for repair, history of repair •
• Contamination of filters • Fuel and oil condition • Damage to parts, etc. (3) Place alignment marks on the necessary parts to facilitate reassembly. (4) Clean all the removed parts and new replacement parts and put them in order. (5) Use new seals, split pins, etc. for reassembly.

TABLE OF CONTENTS:

YANMAR B7-5 B7-5A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

1. General Cautions for Maintenance Work............................................................... 12
	1-1 Correct Work................................................................................... 12
	1-2 Safety Precautions............................................................................. 12
	1-3 Preparations................................................................................... 12
	1-4 Cautions for Disassembly and Reassembly........................................................ 12
	1-5 Cautions for Removal and Installation of Hydraulic Equipment................................... 13
	1-6 Cautions for Removal and Installation of Hydraulic Piping...................................... 13
	1-7 Cautions for Handling Seals.................................................................... 14
	1-8 Correct Installation of Hydraulic Hose......................................................... 14
	1-9 Specifications of Hydraulic Hose............................................................... 17
	1-10 Air Release of Hydraulic Equipment............................................................ 22
2. Technical Data...................................................................................... 26
	2-1 Specifications................................................................................. 26
		2-1-1 Machine Body............................................................................. 26
		2-1-2 Engine................................................................................... 31
	2-2 Outline Drawing and Working Area............................................................... 37
		2-2-1 B7-5, B7-5A.............................................................................. 37
	2-3 Weight List of Main Parts...................................................................... 38
	2-4 Lifting Capacity List.......................................................................... 39
3. Service Standards................................................................................... 44
	3-1 Machine Performance............................................................................ 44
	3-2 Engine......................................................................................... 48
	3-3 Undercarriage.................................................................................. 56
		3-3-1 Rubber Crawler Specifications............................................................ 56
		3-3-2 Steel Crawler Specifications............................................................. 57
		3-3-3 Common Specifications of Steel & Rubber Crawlers......................................... 58
	3-4 Controls....................................................................................... 59
	3-5 Hydraulic Equipment............................................................................ 60
		3-5-1 Hydraulic Cylinders...................................................................... 60
	3-6 Implement...................................................................................... 61
		3-6-1 Front Attachments........................................................................ 61
		3-6-2 Blade Moving Device...................................................................... 62
		3-6-3 Bucket Teeth............................................................................. 62
	3-7 List of Tightening Torque...................................................................... 63
		3-7-1 Machine.................................................................................. 63
		3-7-2 Engine................................................................................... 66
		3-7-3 Tightening Torque for General Bolts and Nuts............................................. 67
4. Engine.............................................................................................. 70
	B7-5 (4TNE98-EBVA)................................................................................. 70
		4-1 General.................................................................................... 70
			4-1-1 How to Read This Manual.............................................................. 70
			4-1-2 Precautions for Service Work......................................................... 72
		4-2 Troubleshooting............................................................................ 74
			4-2-1 Quick Reference Table for Troubleshooting............................................ 74
			4-2-2 Troubleshooting by Measuring Compression Pressure.................................... 78
		4-3 Inspection and Adjustment.................................................................. 80
			4-3-1 Oil Inspection....................................................................... 80
			4-3-2 Cooling Water Inspection............................................................. 80
			4-3-3 Inspecting Water Leak from Cooling Water System and Radiator......................... 80
			4-3-4 Fan Belt Tension Inspection and Adjustment........................................... 81
			4-3-5 Adjusting the Valve Clearance........................................................ 82
			4-3-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern............. 82
			4-3-7 Fuel Injection Timing Inspection and Adjustment...................................... 86
			4-3-8 Sensor Inspection.................................................................... 87
			4-3-9 Battery Inspection................................................................... 88
			4-3-10 Adjusting Operation................................................................. 90
			4-3-11 Long Storage........................................................................ 91
			4-3-12 Periodic Maintenance Schedule....................................................... 92
		4-4 Engine Body................................................................................ 93
			4-4-1 Introduction......................................................................... 93
			4-4-2 Cylinder Head........................................................................ 94
			4-4-3 Gear Train and Camshaft..............................................................102
			4-4-4 Cylinder Block.......................................................................107
		4-5 Lubrication System.........................................................................119
			4-5-1 Lubrication System Diagram...........................................................119
			4-5-2 Trochoid Pump Components.............................................................119
			4-5-3 Disassembly (Reverse the Procedure Below for Assembly)...............................120
			4-5-4 Servicing Points.....................................................................120
			4-5-5 Parts Inspection and Measurement.....................................................120
		4-6 Cooling System.............................................................................121
			4-6-1 Cooling Water System.................................................................121
			4-6-2 Cooling Water Pump Components........................................................121
			4-6-3 Disassembly (Reverse the Procedure Below for Assembly)...............................122
			4-6-4 Servicing Points.....................................................................122
		4-7 Fuel Injection Pump / Governor.............................................................123
			4-7-1 Introduction.........................................................................123
			4-7-2 Fuel Injection Pump..................................................................123
			4-7-3 Fuel Injection Valve.................................................................129
			4-7-4 Fuel Feed Pump.......................................................................129
			4-7-5 Governor.............................................................................130
			4-7-6 Special Service Tools for Disassembly / Assembly.....................................131
		4-8 Starting motor.............................................................................132
			4-8-1 Specifications.......................................................................132
			4-8-2 Configuration Drawing................................................................133
			4-8-3 Troubleshooting......................................................................134
			4-8-4 Component Names and Disassembly Procedure............................................135
			4-8-5 Disassembly Procedure................................................................136
			4-8-6 Inspection and Maintenance...........................................................138
			4-8-7 Assembly.............................................................................142
			4-8-8 Adjustment...........................................................................143
			4-8-9 Service Standards....................................................................144
		4-9 Alternator.................................................................................145
			4-9-1 Specifications.......................................................................145
			4-9-2 Section View.........................................................................146
			4-9-3 Troubleshooting......................................................................147
			4-9-4 Parts Names and Disassembly Procedure................................................148
			4-9-5 Inspection and Overhaul..............................................................151
			4-9-6 Assembly.............................................................................155
			4-9-7 Service Standards....................................................................156
			4-9-8 Performance Test.....................................................................157
		4-10 Special Service Tools.....................................................................158
			4-10-1 Special Tools.......................................................................158
			4-10-2 Measuring Instruments...............................................................160
		4-11 General...................................................................................163
			4-11-1 How to Read This Manual.............................................................163
			4-11-2 Precautions for Service Work........................................................165
			4-11-3 Engine External Views...............................................................166
			4-11-4 Structural Description..............................................................166
			4-11-5 Exhaust Gas Emission Regulation.....................................................167
		4-12 Troubleshooting...........................................................................172
			4-12-1 Quick Reference Table for Troubleshooting...........................................172
			4-12-2 Troubleshooting by Measuring Compression Pressure...................................176
		4-13 Inspection and Adjustment.................................................................178
			4-13-1 Oil Inspection......................................................................178
			4-13-2 Cooling Water Inspection............................................................178
			4-13-3 Inspecting Water Leak from Cooling Water System and Radiator........................178
			4-13-4 Fan Belt Tension Inspection and Adjustment..........................................179
			4-13-5 Adjusting the Valve Clearance.......................................................180
			4-13-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern............182
			4-13-7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment....186
			4-13-8 Sensor Inspection...................................................................189
			4-13-9 Battery Inspection..................................................................190
			4-13-10 Adjusting Operation................................................................192
			4-13-11 Long Storage.......................................................................193
			4-13-12 Periodic Maintenance Schedule......................................................194
		4-14 Engine Body...............................................................................195
			4-14-1 Introduction........................................................................195
			4-14-2 Cylinder Head.......................................................................196
			4-14-3 Gear Train and Camshaft.............................................................206
			4-14-4 Cylinder Block......................................................................211
		4-15 Lubrication System........................................................................225
			4-15-1 Lubrication System Diagram..........................................................225
			4-15-2 Trochoid Pump Components............................................................225
			4-15-3 Disassembly (Reverse the Procedure Below for Assembly)..............................225
			4-15-4 Servicing Points....................................................................226
			4-15-5 Parts Inspection and Measurement....................................................226
		4-16 Cooling System............................................................................227
			4-16-1 Cooling Water System................................................................227
			4-16-2 Cooling Water Pump Components.......................................................227
			4-16-3 Disassembly (Reverse the Procedure Below for Assembly)..............................228
			4-16-4 Servicing Points....................................................................228
		4-17 Fuel Injection Pump / Governor............................................................229
			4-17-1 Introduction........................................................................229
			4-17-2 Fuel Injection Pump.................................................................229
		4-18 Starting motor............................................................................233
			4-18-1 Specifications......................................................................233
			4-18-2 Components..........................................................................234
			4-18-3 Troubleshooting.....................................................................235
		4-19 Alternator................................................................................236
			4-19-1 Components..........................................................................236
			4-19-2 Specifications......................................................................238
			4-19-3 Wiring diagram......................................................................238
			4-19-4 Standard output characteristics.....................................................239
			4-19-5 Troubleshooting.....................................................................240
		4-20 Air Heater................................................................................241
5. Hydraulic System....................................................................................244
	5-1 Outline........................................................................................244
		5-1-1 Control Valve Operation..................................................................245
		5-1-2 Additional Operation of Control Valve....................................................247
	5-2 Hydraulic Circuit Schematic....................................................................248
		5-2-1 B7-5.....................................................................................248
		5-2-2 B7-5A....................................................................................249
	5-3 Circuit Operation..............................................................................250
		5-3-1 Boom.....................................................................................250
		5-3-2 Arm......................................................................................252
		5-3-3 Bucket...................................................................................254
		5-3-4 Swing....................................................................................256
		5-3-5 Boom Offset..............................................................................258
		5-3-6 Blade....................................................................................260
		5-3-7 Travel...................................................................................262
		5-3-8 Simultaneous Operation of Travel and Boom / Bucket.......................................264
		5-3-9 Simultaneous Operation of Travel and Arm / Boom Offset...................................266
		5-3-10 Simultaneous Operation of Boom Up and Arm Retract.......................................268
		5-3-11 Simultaneous Operation of Boom Up and Bucket............................................270
		5-3-12 Simultaneous Operation of Boom Up and Swing.............................................272
		5-3-13 Hydraulic P.T.O.........................................................................274
	5-4 Pressure Adjustment............................................................................276
		5-4-1 Relief Valves............................................................................276
		5-4-2 Swing Brake Valve........................................................................278
		5-4-3 Cut-off Valve............................................................................279
6. Hydraulic Equipment.................................................................................282
	6-1 Hydraulic Pump.................................................................................282
	6-2 Control Valve..................................................................................321
	6-3 Pilot Valve....................................................................................373
	6-4 Swing Motor....................................................................................384
	6-5 Travel Motor...................................................................................417
7. Adjustment and Repair...............................................................................490
	7-1 Electric Equipment of the Machine..............................................................490
		7-1-1 Parts Layout of Electrical Equipment.....................................................490
		7-1-2 Monitor and Alarm Systems................................................................493
		7-1-3 Wiring Diagram...........................................................................496
		7-1-4 Circuit Description of Engine Start, Stop and Battery Charging...........................499
		7-1-5 Removal and Reinstallation of Engine.....................................................504
		7-1-6 Removal and Reassembly of Starter Motor..................................................514
	7-2 Undercarriage..................................................................................517
		7-2-1 Outline..................................................................................517
		7-2-2 Compatibility of Main Parts..............................................................517
		7-2-3 Points of Reassembly (Rubber Crawler Type)...............................................518
		7-2-4 Points of Reassembly (Steel Crawler Type)................................................519
		7-2-5 Disassembly and Reassembly of Idler......................................................520
		7-2-6 Disassembly and Reassembly of Track Roller...............................................522
		7-2-7 Disassembly and Reassembly of Carrier Roller.............................................524
		7-2-8 Installation of Floating Seal............................................................525
		7-2-9 Drawings of Jigs.........................................................................526
	7-3 Controls.......................................................................................528
		7-3-1 Control Train............................................................................528
		7-3-2 Mechanical Control Linkage...............................................................529
		7-3-3 Adjustment of Implement Control Levers...................................................530
		7-3-4 Adjustment of Travel Levers..............................................................531
		7-3-5 Adjustment of Boom Offset Pedal..........................................................532
		7-3-6 Adjustment of Blade Control Lever........................................................532
		7-3-7 Adjustment of Lock Lever.................................................................534
		7-3-8 Adjustment of Accelerator Lever..........................................................535
	7-4 Swing Bearing..................................................................................537
	7-5 Hydraulic Equipment............................................................................539
		7-5-1 Removal and Reinstallation of Hydraulic Pump.............................................539
		7-5-2 Removal and Reinstallation of Control Valve..............................................544
		7-5-3 Removal and Reinstallation of Swing Motor................................................547
		7-5-4 Removal and Reinstallation of Swivel Joint...............................................549
		7-5-5 Disassembly and Reassembly of Swivel Joint...............................................551
		7-5-6 Disassembly and Reassembly of Hydraulic Cylinder.........................................554
		7-5-7 Hydraulic Oil Tank.......................................................................558
		7-5-8 Piping Layout............................................................................561
	7-6 Work Implements................................................................................570
		7-6-1 Removal and Reinstallation of Work Implements............................................570
	7-7 Cabin..........................................................................................578
		7-7-1 Cabin....................................................................................578
8. Periodic Inspection and Servicing...................................................................596
	8-1 List of Periodic Inspection and Servicing......................................................596
9. Fuel, Lube Oil and Grease Recommended...............................................................600
10. Troubleshooting....................................................................................604
	10-1 Non-breakdowns................................................................................604
		10-1-1 Natural Release of Bucket...............................................................604
		10-1-2 Discontinuous Arm Movement..............................................................604
		10-1-3 Extension or retraction of Boom Offset Cylinder when Excavating.........................605
		10-1-4 Thermal Shock of Travel Motor...........................................................606
		10-1-5 Time Lag on Travel Speed Switching......................................................607
		10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change................608
	10-2 Troubleshooting...............................................................................609
		10-2-1 Machine and Engine......................................................................609
		10-2-2 Electrical Equipment on Panel...........................................................630
11. Reference Data.....................................................................................642
	11-1 Specifications for Attachment.................................................................642
	11-2 Standard Bucket Specifications................................................................643

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