YANMAR SV20 EP EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD
VIDEO PREVIEW:
IMAGE PREVIEW:
DESCRIPTION:
YANMAR SV20 EP 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 SV20 EP EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD
1. General Cautions for Maintenance Work....................................................................................................................................................................................... 11 1-1 Correct Work........................................................................................................................................................................................................... 11 1-2 Safety Precautions..................................................................................................................................................................................................... 11 1-3 Preparations........................................................................................................................................................................................................... 11 1-4 Cautions for Disassembly and Reassembly................................................................................................................................................................................ 11 1-5 Cautions for Removal and Installation of Hydraulic Equipment........................................................................................................................................................... 12 1-6 Cautions for Removal and Installation of Hydraulic Piping.............................................................................................................................................................. 12 1-7 Cautions for Handling Seals............................................................................................................................................................................................ 13 1-8 Correct Installation of Hydraulic Hose................................................................................................................................................................................. 13 1-9 Specifications of Hydraulic Hose....................................................................................................................................................................................... 16 1-10 Air Release of Hydraulic Equipment.................................................................................................................................................................................... 21 2. Technical Data.............................................................................................................................................................................................................. 25 2-1 Specifications......................................................................................................................................................................................................... 25 2-2 Outline Drawing and Working Area....................................................................................................................................................................................... 32 2-3 Weight List of Main Parts.............................................................................................................................................................................................. 33 2-4 Lifting Capacity List.................................................................................................................................................................................................. 34 3. Service Standards........................................................................................................................................................................................................... 37 3-1 Machine Performance.................................................................................................................................................................................................... 37 3-2 Engine................................................................................................................................................................................................................. 41 3-3 Undercarriage.......................................................................................................................................................................................................... 45 3-3-1 Rubber Crawler Specifications.................................................................................................................................................................................... 45 3-3-2 Common Specifications of Steel & Rubber Crawlers................................................................................................................................................................. 46 3-4 Controls............................................................................................................................................................................................................... 47 3-5 Hydraulic Equipment.................................................................................................................................................................................................... 48 3-5-1 Hydraulic Cylinders.............................................................................................................................................................................................. 48 3-6 Implement.............................................................................................................................................................................................................. 49 3-6-1 Front Attachments................................................................................................................................................................................................ 49 3-6-2 Blade Moving Device.............................................................................................................................................................................................. 50 3-6-3 Bucket Teeth..................................................................................................................................................................................................... 50 3-7 List of Tightening Torque.............................................................................................................................................................................................. 51 3-7-1 Machine.......................................................................................................................................................................................................... 51 3-7-2 Engine........................................................................................................................................................................................................... 54 3-7-3 Tightening Torque for General Bolts and Nuts..................................................................................................................................................................... 54 4. Engine...................................................................................................................................................................................................................... 57 4-1 General................................................................................................................................................................................................................ 57 4-1-1 Engine External Views............................................................................................................................................................................................ 57 4-2 Measurement, Inspection and Adjustment................................................................................................................................................................................. 58 4-2-1 Measuring the Compression Pressure............................................................................................................................................................................... 58 4-2-2 Adjusting the Valve Clearance.................................................................................................................................................................................... 59 4-2-3 Checking the V-belt Tension...................................................................................................................................................................................... 60 4-2-4 Checking the Fuel Injection Valve................................................................................................................................................................................ 60 4-2-5 Checking and adjusting the Fuel Injection Timing................................................................................................................................................................. 62 4-2-6 Adjusting the Maximum (or Minimum) Idling Speed.................................................................................................................................................................. 64 4-2-7 Checking the Cooling Water System and Radiator for Water Leakage................................................................................................................................................. 64 4-2-8 Checking the Sensors............................................................................................................................................................................................. 65 4-3 Measurement Procedure, Service Data and Corrective Action.............................................................................................................................................................. 66 4-3-1 Cylinder Head.................................................................................................................................................................................................... 66 4-3-2 Cylinder Block................................................................................................................................................................................................... 71 4-3-3 Valve Rocker Arm................................................................................................................................................................................................. 73 4-3-4 Piston and Piston Rings.......................................................................................................................................................................................... 75 4-3-5 Connecting Rod................................................................................................................................................................................................... 78 4-3-6 Cam Shaft........................................................................................................................................................................................................ 81 4-3-7 Crank Shaft...................................................................................................................................................................................................... 82 4-3-8 Gears............................................................................................................................................................................................................ 85 4-3-9 Trochoid Pump.................................................................................................................................................................................................... 86 4-4 Precautions for Reassembly............................................................................................................................................................................................. 87 4-5 Fuel Injection System.................................................................................................................................................................................................. 90 4-5-1 Introduction..................................................................................................................................................................................................... 90 4-5-2 Fuel Injection Pump.............................................................................................................................................................................................. 90 4-5-3 Governor Mechanism............................................................................................................................................................................................... 92 4-5-4 Specifications of Fuel Injection Pump............................................................................................................................................................................ 94 4-6 Electrical Equipment................................................................................................................................................................................................... 95 4-6-1 Starter Motor.................................................................................................................................................................................................... 95 4-6-2 Alternator....................................................................................................................................................................................................... 96 4-6-3 Glow Plug........................................................................................................................................................................................................ 97 5. Hydraulic System............................................................................................................................................................................................................101 5-1 Outline................................................................................................................................................................................................................101 5-2 Hydraulic Circuit Schematic............................................................................................................................................................................................102 6. Hydraulic Equipment.........................................................................................................................................................................................................105 6-1 Hydraulic Pump.........................................................................................................................................................................................................105 6-2 Control Valve..........................................................................................................................................................................................................120 6-3 Pilot Valve............................................................................................................................................................................................................142 6-4 Swing Motor............................................................................................................................................................................................................152 6-5 Travel Motor...........................................................................................................................................................................................................154 1) Malfunction of equipment other than motor, counter balance valve and reduction gear.................................................................................................................................193 2) Escape of pressure oil due to excessive wear of motor’s sliding parts...............................................................................................................................................193 3) Malfunction due to breakage of motor’s sliding parts. (In this case, motor makes an abnormal sound).................................................................................................................193 4) Relief valve operates due to too much load applied to motor.........................................................................................................................................................193 1) Specified volume of oil is not being supplied to motor due to failure of hydraulic pump, system relief valve, etc...................................................................................................193 2) Specified speed is not obtained due to drop of motor’s displacement.................................................................................................................................................193 1) A large volume of high pressure oil leaks and flows out from drain port due to wear of motor’s parts, causing a large drop and fluctuation in motor revolutions. The fluctuation is also caused by worn bearing.....193 1) Breakage of oil seals or O-rings....................................................................................................................................................................................193 1) Plunger is not moved................................................................................................................................................................................................194 1) Plunger does not return.............................................................................................................................................................................................194 1) Plunger does not move smoothly......................................................................................................................................................................................194 1) Plunger is quick to return..........................................................................................................................................................................................194 1) Plunger does not return.............................................................................................................................................................................................194 1) Seat of check valve is defective....................................................................................................................................................................................195 1) Sticking of check valve.............................................................................................................................................................................................195 1) Spool does not move.................................................................................................................................................................................................196 2) Oil leak due to excessive wear of high speed control piston.........................................................................................................................................................196 3) High speed control piston is not installed..........................................................................................................................................................................196 4) Excessive wear of steel ball........................................................................................................................................................................................196 7. Adjustment and Repair.......................................................................................................................................................................................................199 7-1 Electric Equipment of Machine..........................................................................................................................................................................................199 7-1-1 Parts Layout of Electrical Equipment.............................................................................................................................................................................199 7-1-2 Monitor and Alarm Systems........................................................................................................................................................................................200 7-1-3 Wiring Diagram...................................................................................................................................................................................................203 7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging...............................................................................................................................................204 7-1-5 Removal and Reinstallation of Engine.............................................................................................................................................................................207 7-1-6 Removal and Reinstallation of Starter Motor......................................................................................................................................................................214 7-1-7 Removal and Reinstallation of Fuel Injection Pump................................................................................................................................................................215 7-1-8 Removal and Reinstallation of Fuel Tank..........................................................................................................................................................................217 7-1-9 Removal and Reinstallation of Radiator...........................................................................................................................................................................219 7-2 Undercarriage..........................................................................................................................................................................................................221 7-2-1 Outline..........................................................................................................................................................................................................221 7-2-2 Major Parts......................................................................................................................................................................................................221 7-2-3 Points of Reassembly.............................................................................................................................................................................................222 7-2-4 Removal and Reinstallation of Crawler............................................................................................................................................................................223 7-2-5 Disassembly and Reassembly of Idler..............................................................................................................................................................................224 7-2-6 Disassembly and Reassembly of Track Roller.......................................................................................................................................................................226 7-3 Controls...............................................................................................................................................................................................................228 7-3-1 Control Train....................................................................................................................................................................................................228 7-3-2 Mechanical Control Linkage.......................................................................................................................................................................................229 7-3-3 Adjustment of Travel Levers......................................................................................................................................................................................231 7-3-4 Adjustment of Boom Swing Pedal...................................................................................................................................................................................232 7-3-5 Adjustment of Blade Lever (Track Gauge Change Lever).............................................................................................................................................................232 7-3-6 Adjustment of Lock Lever Switch..................................................................................................................................................................................233 7-3-7 Adjustment of Accelerator Lever..................................................................................................................................................................................234 7-3-8 Adjustment of P.T.O. Pedal.......................................................................................................................................................................................235 7-4 Swing Bearing..........................................................................................................................................................................................................236 7-5 Hydraulic Equipment....................................................................................................................................................................................................238 7-5-1 Removal and Reinstallation of Hydraulic Pump.....................................................................................................................................................................238 7-5-2 Removal and Reinstallation of Control Valve......................................................................................................................................................................240 7-5-3 Removal and Reinstallation of Swing Motor........................................................................................................................................................................243 7-5-4 Removal and Reinstallation of Swivel Joint.......................................................................................................................................................................246 7-5-5 Disassembly and Reassembly of Swivel Joint.......................................................................................................................................................................249 7-5-6 Disassembly and Reassembly of Hydraulic Cylinders................................................................................................................................................................252 7-5-7 Hydraulic Oil Tank...............................................................................................................................................................................................256 7-5-8 Piping Layout....................................................................................................................................................................................................260 7-6 Work Implements........................................................................................................................................................................................................267 7-6-1 Removal and Reinstallation of Work Implements....................................................................................................................................................................267 8. Periodic Inspection and Servicing...........................................................................................................................................................................................277 8-1 List of Periodic Inspection and Servicing..............................................................................................................................................................................277 9. Fuel, Lube Oil and Grease Recommended.......................................................................................................................................................................................281 10. Troubleshooting............................................................................................................................................................................................................285 10-1 Non-Breakdowns........................................................................................................................................................................................................285 10-1-1 Natural Release of Bucket.......................................................................................................................................................................................285 10-1-2 Discontinuous Arm Movement......................................................................................................................................................................................285 10-1-3 Drifting of Upperstructure on Quick Travel Operation............................................................................................................................................................286 10-1-4 Thermal Shock of Travel Motor...................................................................................................................................................................................287 10-1-5 Elongation of Boom Swing Cylinder on 75 degrees Swing...........................................................................................................................................................288 10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position...................................................................................................................................289 10-1-7 Time Lag on Travel Speed Switching..............................................................................................................................................................................290 10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change........................................................................................................................................291 10-2 Troubleshooting.......................................................................................................................................................................................................292 10-2-1 Machine and Engine..............................................................................................................................................................................................292 10-2-2 Electrical Equipment on Panel...................................................................................................................................................................................313 11. Reference Data.............................................................................................................................................................................................................325 11-1 Specifications for Attachment.........................................................................................................................................................................................325
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]