YANMAR SV100-1 SERVICE MANUAL – PDF DOWNLOADYANMAR SV100-1 SERVICE MANUAL – PDF DOWNLOAD
DESCRIPTION:
YANMAR SV100-1 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 SV100-1 SERVICE MANUAL – PDF DOWNLOAD
COVER
......................................................................................... 1
SPINE TITLE.................................................................................... 2
CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK................................................ 11
1. General Cautions for Maintenance Work................................................... 13
1-1 Correct Work....................................................................... 13
1-2 Safety Precautions................................................................. 13
1-3 Preparations....................................................................... 13
1-4 Cautions for Disassembly and Reassembly............................................ 13
1-5 Cautions for Removal and Installation of Hydraulic Equipment....................... 14
1-6 Cautions for Removal and Installation of Hydraulic Piping.......................... 14
1-7 Cautions for Handling Seals........................................................ 15
1-8 Correct Installation of Hydraulic Hose............................................. 15
1-9 Specifications of Hydraulic Hose................................................... 18
1-10 Air Release of Hydraulic Equipment................................................ 23
CHAPTER 2 TECHNICAL DATA....................................................................... 25
2. Technical Data.......................................................................... 27
2-1 Specifications..................................................................... 27
2-2 Outline Drawing and Working Area................................................... 34
2-2-1 Quick coupler................................................................ 34
2-2-2 W/O Quick coupler............................................................ 35
2-3 Weight List of Main Parts.......................................................... 36
2-4 Lifting Capacity List.............................................................. 37
2-4-1 SV100-1 Quick Coupler........................................................ 37
2-4-2 SV100-1 W/O Quick Coupler.................................................... 39
CHAPTER 3 SERVICE STANDARDS.................................................................... 41
3. Service Standards....................................................................... 43
3-1 Machine Performance................................................................ 43
3-2 Engine............................................................................. 47
3-3 Undercarriage...................................................................... 52
3-3-1 Rubber Crawler Specifications................................................ 52
3-3-2 Steel Crawler Specifications................................................. 53
3-3-3 Common Specifications of Steel & Rubber Crawlers............................. 54
3-4 Controls........................................................................... 55
3-5 Hydraulic Equipment................................................................ 56
3-5-1 Hydraulic Cylinders.......................................................... 56
3-6 Implement.......................................................................... 57
3-6-1 Front Attachments............................................................ 57
3-6-2 Blade Moving Device.......................................................... 58
3-6-3 Bucket Teeth................................................................. 58
3-7 List of Tightening Torque.......................................................... 59
3-7-1 Machine...................................................................... 59
3-7-2 Engine....................................................................... 62
3-7-3 Tightening Torque for General Bolts and Nuts................................. 63
3-7-4 Hydraulic Fitting............................................................ 64
CHAPTER 4 ENGINE............................................................................... 65
4. Engine.................................................................................. 67
4-1 Engine............................................................................. 67
4-1-1 Safety Precautions........................................................... 67
4-1-2 Introduction................................................................. 87
4-1-3 Special Service Tools........................................................ 88
4-1-4 Measuring Instruments........................................................ 91
4-1-5 4-Valve Cylinder Head........................................................ 93
4-1-6 Measuring and Adjusting Valve Clearance......................................108
4-1-7 Crankshaft and Camshaft Components...........................................112
4-1-8 EGR System...................................................................139
4-2 Fuel System........................................................................146
4-2-1 Before You Begin Servicing...................................................146
4-2-2 Introduction.................................................................151
4-2-3 Special Service Tools........................................................154
4-2-4 Measuring Instruments........................................................154
4-2-5 Fuel System Diagram..........................................................155
4-2-6 Fuel System Components.......................................................156
4-2-7 Fuel Injection Pump..........................................................158
4-2-8 Fuel Injectors...............................................................173
4-3 Cooling System.....................................................................178
4-3-1 Before You Begin Servicing...................................................178
4-3-2 Introduction.................................................................180
4-3-3 Cooling System Diagram.......................................................180
4-3-4 Engine Coolant Pump Components...............................................181
4-3-5 Engine Coolant System Check..................................................182
4-3-6 Engine Coolant Pump..........................................................182
4-4 Lubrication System.................................................................187
4-4-1 Before You Begin Servicing...................................................187
4-4-2 Introduction.................................................................189
4-4-3 Lubrication System Diagram...................................................189
4-4-4 Checking Engine Oil Pressure.................................................190
4-4-5 Trochoid Oil Pump............................................................190
4-5 Turbocharger.......................................................................194
4-5-1 Before You Begin Servicing...................................................194
4-5-2 Introduction.................................................................196
4-5-3 Specifications...............................................................196
4-5-4 Troubleshooting..............................................................197
4-5-5 Turbocharger Components......................................................199
4-5-6 Turbocharger Component Functions.............................................200
4-5-7 Washing Procedure............................................................202
4-5-8 Periodic Inspection..........................................................203
4-6 Starter Motor......................................................................206
4-6-1 Before You Begin Servicing...................................................206
4-6-2 Introduction.................................................................208
4-6-3 Starter Motor Specifications.................................................208
4-6-4 Starter Motor Troubleshooting................................................209
4-6-5 Starter Motor Components.....................................................210
4-6-6 Starter Motor................................................................211
4-7 Alternator.........................................................................221
4-7-1 Before You Begin Servicing...................................................221
4-7-2 Introduction.................................................................224
4-7-3 Alternator Specifications....................................................224
4-7-4 Alternator Troubleshooting...................................................225
4-7-5 Alternator Components........................................................226
4-7-6 Alternator Wiring Diagram....................................................227
4-7-7 Alternator Standard Output...................................................228
4-7-8 Alternator...................................................................229
4-8 Electronic Control System..........................................................234
4-8-1 Engines Available with the Electronic Control System.........................234
4-8-2 Before You Begin Servicing...................................................234
4-8-3 Main Electronic Control Components and Features..............................237
4-9 Electric Wiring....................................................................238
4-9-1 Electric Wiring Precautions..................................................238
4-10 Failure Diagnosis.................................................................243
4-10-1 Special Service Tools.......................................................243
4-10-2 Troubleshooting By Measuring Compression Pressure...........................244
CHAPTER 5 HYDRAULIC SYSTEM.....................................................................247
5. Hydraulic System........................................................................249
5-1 Outline............................................................................249
5-1-1 Control Valve Operation......................................................251
5-1-2 Additional Operation of Control Valve........................................252
5-2 Hydraulic Circuit Schematic........................................................253
5-2-1 US spec......................................................................253
5-2-2 AS/NZ spec...................................................................254
5-2-3 AYR spec.....................................................................255
5-3 Circuit Operation..................................................................256
5-3-1 Boom.........................................................................256
5-3-2 Arm..........................................................................258
5-3-3 Bucket.......................................................................259
5-3-4 Swing........................................................................260
5-3-5 Boom Swing...................................................................261
5-3-6 Blade........................................................................262
5-3-7 Travel.......................................................................263
5-3-8 Non-deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation)........265
5-3-9 Simultaneous Operation of Boom Up and Arm Retract............................266
5-3-10 Simultaneous Operation of Boom Up and Bucket................................267
5-3-11 Simultaneous Operation of Boom Up and Swing.................................268
5-3-12 Simultaneous Operation of Arm and Bucket....................................269
5-3-13 Hydraulic P.T.O.............................................................270
5-3-14 Travel Alarm................................................................271
5-3-15 4th P.T.O...................................................................272
5-3-16 Quick Coupler...............................................................273
5-3-17 Auto Deceleration...........................................................274
5-4 Pressure Adjustment................................................................275
5-4-1 Relief Valves................................................................275
5-4-2 Swing Brake Valve............................................................277
5-4-3 Cut-off Valve................................................................278
CHAPTER 6 HYDRAULIC EQUIPMENT..................................................................279
6. Hydraulic Equipment.....................................................................281
6-1 Hydraulic Pump.....................................................................281
6-2 Control Valve......................................................................312
6-2-1 Main Control Valve...........................................................312
6-2-2 Disassembly..................................................................321
6-2-3 Cleaning.....................................................................332
6-2-4 Checking.....................................................................332
6-2-5 Reassembly...................................................................332
6-2-6 Servicing Procedure for Relief Valve.........................................337
6-2-7 Installation.................................................................341
6-2-8 Running......................................................................341
6-2-9 Troubleshooting..............................................................342
6-3 Pilot Valve........................................................................343
6-3-1 Remote Control Valve.........................................................343
6-3-2 Travel Pilot Valve...........................................................352
6-3-3 Blade and Boom Swing Pilot Valve.............................................374
6-4 Swing Motor........................................................................389
6-4-1 Overview.....................................................................389
6-4-2 Description of Functions and Operation.......................................390
6-4-3 Precautions for Handling.....................................................402
6-4-4 Troubleshooting..............................................................403
6-4-5 Employment Tool..............................................................409
6-4-6 Disassembly Procedure........................................................412
6-4-7 Assembly Procedure...........................................................425
6-4-8 Quality Check After Reassembly...............................................442
6-5 Travel Motor.......................................................................443
6-5-1 Product Overview.............................................................443
6-5-2 External Dimensions and Circuit Diagram......................................444
6-5-3 Basic Configuration and Drawing..............................................446
6-5-4 Operating Description........................................................451
6-5-5 Troubleshooting..............................................................463
6-5-6 Service outline..............................................................465
6-5-7 Disassembly..................................................................471
6-5-8 Service criteria.............................................................487
6-5-9 Assembly.....................................................................489
6-5-10 Performance Confirmation Test...............................................505
6-6 Cutoff Valve.......................................................................506
6-7 P.T.O. Solenoid Valve..............................................................515
6-8 Quick Coupler Solenoid Valve.......................................................517
6-9 Pilot Check Valve (Quick Coupler spec.)............................................523
6-10 Holding Valve (AS/NZ spec.).......................................................531
CHAPTER 7 ADJUSTMENT AND REPAIR................................................................541
7. Adjustment and Repair...................................................................543
7-1 Electric Equipment of the Machine..................................................543
7-1-1 Parts Layout of Electrical Equipment.........................................543
7-1-2 Monitor and Alarm Systems....................................................548
7-1-3 Wiring Diagram...............................................................559
7-1-4 Circuit Description of Engine Start, Stop and Battery Charging...............563
7-1-5 Electronic Control...........................................................565
7-1-6 Removal and Reinstallation of Engine.........................................574
7-1-7 Removal and Reinstallation of Starter Motor..................................581
7-1-8 Removal and Reinstallation of Radiator and Oil cooler........................582
7-1-9 Removal and Reinstallation of Fan Belt and Compressor Driving Belt...........585
7-1-10 Removal and Reinstallation of Fuel Injection Pump...........................586
7-1-11 Removal and Reinstallation of ECU...........................................588
7-2 Undercarriage......................................................................589
7-2-1 Outline......................................................................589
7-2-2 Compatibility of Main Parts..................................................589
7-2-3 Points of Reassembly (Rubber Crawler Type)...................................590
7-2-4 Points of Reassembly (Steel Crawler Type)....................................591
7-2-5 Removal and Reinstallation of Crawler........................................592
7-2-6 Disassembly and Reassembly of Steel Crawler..................................595
7-2-7 Disassembly and Reassembly of Front Idler....................................597
7-2-8 Removal and Reinstallation of Adjusting Cylinder.............................599
7-2-9 Disassembly and Reassembly of Track Roller...................................600
7-2-10 Installation of Floating Seal...............................................602
7-2-11 Disassembly and Reassembly of Carrier Roller................................603
7-3 Controls...........................................................................605
7-3-1 Control Lever................................................................605
7-3-2 Travel Lever.................................................................606
7-3-3 Adjustment of Lock Lever.....................................................607
7-4 Swing Bearing......................................................................608
7-4-1 Removal and Reinstallation of Swing Bearing..................................608
7-5 Hydraulic Equipment................................................................610
7-5-1 Removal and Reinstallation of Hydraulic Pump.................................610
7-5-2 Removal and Reinstallation of Control Valve..................................613
7-5-3 Removal and Reinstallation of Remote Control Valves..........................615
7-5-4 Removal and Reinstallation of Blade Pilot Valve..............................617
7-5-5 Removal and Reinstallation of Travel Pilot Valve.............................618
7-5-6 Removal and Reinstallation of Boom Swing Pilot Valve.........................619
7-5-7 Removal and Reinstallation of Solenoid Valve.................................620
7-5-8 Removal and Reinstallation of P.T.O. Solenoid Valve..........................621
7-5-9 Removal and Reinstallation of Line Filter....................................622
7-5-10 Removal and Reinstallation of Accumulator...................................623
7-5-11 Removal and Reinstallation of Swing Motor...................................624
7-5-12 Removal and Reinstallation of Swivel Joint..................................626
7-5-13 Disassembly and Reassembly of Swivel Joint..................................629
7-5-14 Disassembly and Reassembly of Hydraulic Cylinders...........................632
7-5-15 Hydraulic Oil Tank..........................................................660
7-5-16 Piping Layout...............................................................664
7-6 Implement..........................................................................675
7-6-1 Removal and Reinstallation of Implement......................................675
7-6-2 Quick Coupler................................................................683
7-7 Cabin..............................................................................686
7-7-1 Removal and Reinstallation of Cabin..........................................686
7-7-2 Disassembly and Reassembly of Cabin..........................................688
7-7-3 Removal and Reinstall of Cabin Glasses.......................................701
7-8 Air Conditioner....................................................................711
7-8-1 Removal and Reinstallation of Air Conditioner................................711
CHAPTER 8 PERIODIC INSPECTION AND SERVICING....................................................727
8. Periodic Inspection and Servicing.......................................................729
CHAPTER 9 FUEL, LUBE OIL AND GREASE RECOMMENDED................................................731
9. Fuel, Lube Oil and Grease Recommended...................................................733
CHAPTER 10 TROUBLESHOOTING.....................................................................735
10. Troubleshooting........................................................................737
10-1 Non-breakdowns....................................................................737
10-1-1 Natural Release of Bucket...................................................737
10-1-2 Discontinuous Arm Movement..................................................737
10-1-3 Thermal Shock of Travel Motor...............................................738
10-1-4 Elongation of Boom Swing Cylinder on 60 degrees Swing.......................739
10-1-5 Time Lag on Travel Speed Switching..........................................740
10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change....741
10-1-7 Operation of Quick Coupler Cylinder.........................................742
10-2 Troubleshooting...................................................................743
10-2-1 Machine and Engine..........................................................743
10-2-2 Electrical Equipment on Panel...............................................765
CHAPTER 11 REFERENCE DATA......................................................................775
11. Reference Data.........................................................................777
11-1 Specifications for Attachment.....................................................777
PLEASE NOTE:
This is the SAME MANUAL used by the dealerships to diagnose your vehicle
No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
SK
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
