YANMAR SV05 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

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YANMAR SV05 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD 

YANMAR SV05 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD:

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YANMAR SV05 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 SV05 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD 

COVER..........................................................................................  1
FOREWORD.......................................................................................  2
CONTENTS.......................................................................................  3
CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK................................................  7
	1. General Cautions for Maintenance Work...................................................  8
		1-1 Correct Work.......................................................................  8
		1-2 Safety Precautions.................................................................  8
		1-3 Preparations.......................................................................  8
		1-4 Cautions for Disassembly and Reassembly............................................  8
		1-5 Cautions for Removal and Installation of Hydraulic Equipment.......................  9
		1-6 Cautions for Removal and Installation of Hydraulic Piping..........................  9
		1-7 Cautions for Handling Seals........................................................ 10
		1-8 Correct Installation of Hydraulic Hose............................................. 10
		1-9 Specifications of Hydraulic Hose................................................... 13
		1-10 Air Release of Hydraulic Equipment................................................ 18
CHAPTER 2 TECHNICAL DATA....................................................................... 19
	2. Technical Data.......................................................................... 20
		2-1 Specifications..................................................................... 20
		2-2 Outline Drawing and Working Area................................................... 27
		2-3 Weight List of Main Parts.......................................................... 28
		2-4 Lifting Capacity List.............................................................. 29
CHAPTER 3 SERVICE STANDARDS.................................................................... 30
	3. Service Standards....................................................................... 31
		3-1 Machine Performance................................................................ 31
		3-2 Engine............................................................................. 35
		3-3 Undercarriage...................................................................... 38
			3-3-1 Rubber Crawler Specifications................................................ 38
		3-4 Controls........................................................................... 40
		3-5 Hydraulic Equipment................................................................ 41
			3-5-1 Hydraulic Cylinders.......................................................... 41
		3-6 Implement.......................................................................... 42
			3-6-1 Front Attachments............................................................ 42
			3-6-2 Blade Moving Device.......................................................... 43
			3-6-3 Bucket Teeth................................................................. 43
		3-7 List of Tightening Torque.......................................................... 44
			3-7-1 Machine...................................................................... 44
			3-7-2 Engine....................................................................... 46
			3-7-3 Tightening Torque for General Bolts and Nuts................................. 46
CHAPTER 4 ENGINE............................................................................... 47
	4. Engine.................................................................................. 48
		4-1 Measurement, Inspection and Adjustment............................................. 48
			4-1-1 Measuring the Compression Pressure........................................... 48
			4-1-2 Adjusting the Valve Clearance................................................ 49
			4-1-3 Checking the V-belt Tension.................................................. 50
			4-1-4 Checking the Fuel Injection Valve............................................ 50
			4-1-5 Checking and Adjusting the Fuel Injection Timing (FID)....................... 53
			4-1-6 Adjusting the Maximum (or Minimum) Idling Speed.............................. 54
			4-1-7 Checking the Cooling Water System and Radiator for Water Leakage............. 54
			4-1-8 Checking the Sensors......................................................... 55
		4-2 Measurement Procedure, Service Data and Corrective Action.......................... 56
			4-2-1 Cylinder Head................................................................ 56
			4-2-2 Cylinder Block............................................................... 61
			4-2-3 Valve Rocker Arm............................................................. 63
			4-2-4 Piston and Piston Rings...................................................... 65
			4-2-5 Connecting Rod............................................................... 68
			4-2-6 Camshaft..................................................................... 71
			4-2-7 Crankshaft................................................................... 72
			4-2-8 Gears........................................................................ 75
			4-2-9 Trochoid Pump................................................................ 76
		4-3 Precautions for Reassembly......................................................... 77
		4-4 Fuel Oil Injection System.......................................................... 80
			4-4-1 Fuel Oil Injection Pump...................................................... 80
			4-4-2 Disassembling Procedures..................................................... 81
			4-4-3 Reassembling Procedures...................................................... 82
		4-5 Electrical Equipment............................................................... 83
			4-5-1 Starter Motor................................................................ 83
			4-5-2 Alternator................................................................... 89
			4-5-3 Glow Plug.................................................................... 91
			4-5-4 Stop Solenoid................................................................ 92
CHAPTER 5 HYDRAULIC SYSTEM..................................................................... 93
	5. Hydraulic System........................................................................ 94
		5-1 Outline............................................................................ 94
			5-1-1 Control Valve Operation...................................................... 97
		5-2 Hydraulic Oil Circuit Schematic.................................................... 99
		5-3 Circuit Operation..................................................................100
			5-3-1 Boom.........................................................................100
			5-3-2 Arm..........................................................................102
			5-3-3 Bucket.......................................................................104
			5-3-4 Swing........................................................................106
			5-3-5 Boom Swing...................................................................108
			5-3-6 Blade........................................................................110
			5-3-7 Travel.......................................................................112
			5-3-8 Simultaneous Operation of Travel and Blade...................................114
			5-3-9 Simultaneous Operation of Boom Up and Bucket.................................116
			5-3-10 Hydraulic P.T.O.............................................................118
		5-4 Pressure Adjustment................................................................120
			5-4-1 System Relief Valves.........................................................120
			5-4-2 Circuit Relief Valves........................................................121
			5-4-3 Swing Combination Valve (Brake Valve)........................................122
CHAPTER 6 HYDRAULIC EQUIPMENT..................................................................123
	6. Hydraulic Equipment.....................................................................124
		6-1 Hydraulic Pump.....................................................................124
		6-2 Control Valve......................................................................135
		6-3 Swing Motor........................................................................155
		6-4 Travel Motor.......................................................................169
CHAPTER 7 ADJUSTMENT AND REPAIR................................................................194
	7. Adjustment and Repair...................................................................195
		7-1 Electrical Equipment and Engine of Machine.........................................195
			7-1-1 Parts Layout of Electrical Equipment.........................................195
			7-1-2 Monitor and Alarm Systems....................................................196
			7-1-3 Wiring Diagram...............................................................201
			7-1-4 Circuit Description of Engine Start and Stop, and Battery Charge.............202
			7-1-5 Removal and Reinstallation of Engine.........................................204
			7-1-6 Removal and Reinstallation of Starter Motor..................................208
			7-1-7 Removal and Reinstallation of Fuel Tank......................................209
			7-1-8 Removal and Reinstallation of Radiator.......................................210
			7-1-9 Removal and Reinstallation of Muffler........................................212
		7-2 Undercarriage......................................................................213
			7-2-1 Outline......................................................................213
			7-2-2 Points of Reassembly.........................................................214
			7-2-3 Removal and Reinstallation of Crawler........................................215
			7-2-4 Disassembly and Reassembly of Idler..........................................217
			7-2-5 Disassembly and Reassembly of Track Roller...................................219
		7-3 Controls...........................................................................221
			7-3-1 Control Train................................................................221
			7-3-2 Removal and Reinstallation of Control Levers.................................222
			7-3-3 Adjustment of Control Levers.................................................225
			7-3-4 Adjustment of Boom Swing Pedal...............................................226
			7-3-5 Adjustment of P.T.O. Pedal...................................................226
			7-3-6 Adjustment of Accelerator Lever (Adjustment of Engine Idling Speed)..........227
		7-4 Swing Bearing......................................................................228
			7-4-1 Removal and Reinstallation of Swing Bearing..................................228
		7-5 Hydraulic Equipment................................................................230
			7-5-1 Removal and Reinstallation of Hydraulic Pump.................................230
			7-5-2 Removal and Reinstallation of Control Valve..................................232
			7-5-3 Removal and Reinstallation of Swing Motor....................................234
			7-5-4 Removal and Reinstallation of Swivel Joint...................................236
			7-5-5 Disassembly and Reassembly of Swivel Joint...................................239
			7-5-6 Disassembly and Reassembly of Hydraulic Cylinders............................242
			7-5-7 Removal and Reinstallation of Hydraulic Oil Tank.............................246
			7-5-8 Piping Layout................................................................250
		7-6 Implement..........................................................................256
			7-6-1 Removal and Reinstallation of Implement......................................256
CHAPTER 8 PERIODIC INSPECTION AND SERVICING....................................................263
	8. Periodic Inspection and Servicing.......................................................264
		8-1 List of Periodic Inspection and Servicing..........................................264
CHAPTER 9 FUEL, LUBE OIL AND GREASE RECOMMENDED................................................266
	9. Fuel, Lube Oil and Grease Recommended...................................................267
CHAPTER 10 TROUBLESHOOTING.....................................................................268
	10. Troubleshooting........................................................................269
		10-1 Non-Breakdowns....................................................................269
			10-1-1 Natural Release of Bucket...................................................269
			10-1-2 Discontinuous Arm Movement..................................................269
			10-1-3 Drifting of Upperstructure on Quick Travel Operation........................270
			10-1-4 Thermal Shock of Travel Motor...............................................271
			10-1-5 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change....272
		10-2 Troubleshooting...................................................................273
			10-2-1 Machine and Engine..........................................................273
			10-2-2 Electrical Equipment on Panel...............................................292
CHAPTER 11 REFERENCE DATA......................................................................297
	11. Reference Data.........................................................................298
		11-1 Specifications for Attachment.....................................................298
COLOPHON.......................................................................................299
SPINE TITLE....................................................................................300

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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