YANMAR ViO20 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD
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YANMAR ViO20 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 ViO20 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work ………………………………………………………………………………………………………………………………………………………1-1
1-2 Safety Precautions ………………………………………………………………………………………………………………………………………………1-1
1-3 Preparations……………………………………………………………………………………………………………………………………………………….1-1
1-4 Cautions for Disassembly and Reassembly…………………………………………………………………………………………………………….1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ………………………………………………………………………………….1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping…………………………………………………………………………………………1-2
1-7 Cautions for Handling Seals………………………………………………………………………………………………………………………………….1-3
1-8 Correct Installation of Hydraulic Hose…………………………………………………………………………………………………………………….1-3
1-9 Specifications of Hydraulic Hose……………………………………………………………………………………………………………………………1-6
1-10 Air Release of Hydraulic Equipment……………………………………………………………………………………………………………………1-11
CHAPTER 2
TECHNICAL DATA
2-1 Specifications …………………………………………………………………………………………………………………………………………………. 2-1-1
2-2 Outline Drawing and Working Area……………………………………………………………………………………………………………………. 2-2-1
2-3 Weight List of Main Parts …………………………………………………………………………………………………………………………………. 2-3-1
2-4 Lifting Capacity List …………………………………………………………………………………………………………………………………………. 2-4-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance ……………………………………………………………………………………………………………………………………… 3-1-1
3-2 Engine …………………………………………………………………………………………………………………………………………………………… 3-2-1
3-3 Undercarriage ………………………………………………………………………………………………………………………………………………… 3-3-1
3-3-1 Rubber Crawler Specifications ………………………………………………………………………………………………………………….. 3-3-1
3-3-2 Steel Crawler Specifications……………………………………………………………………………………………………………………… 3-3-2
3-3-3 Common Specifications of Steel & Rubber Crawlers ……………………………………………………………………………………. 3-3-3
3-4 Controls…………………………………………………………………………………………………………………………………………………………. 3-4-1
3-5 Hydraulic Equipment ……………………………………………………………………………………………………………………………………….. 3-5-1
3-5-1 Hydraulic Cylinders …………………………………………………………………………………………………………………………………. 3-5-1
3-6 Implement ……………………………………………………………………………………………………………………………………………………… 3-6-1
3-6-1 Front Attachments …………………………………………………………………………………………………………………………………… 3-6-1
3-6-2 Blade Moving Device……………………………………………………………………………………………………………………………….. 3-6-2
3-6-3 Bucket Teeth ………………………………………………………………………………………………………………………………………….. 3-6-2
3-7 List of Tightening Torque …………………………………………………………………………………………………………………………………. 3-7-1
3-7-1 Machine…………………………………………………………………………………………………………………………………………………. 3-7-1
3-7-2 Engine …………………………………………………………………………………………………………………………………………………… 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts…………………………………………………………………………………………….. 3-7-4
CHAPTER 4
ENGINE
4-1 Measurement, Inspection and Adjustment ………………………………………………………………………………………………………….. 4-1-1
4-1-1 Measuring the Compression Pressure ……………………………………………………………………………………………………….. 4-1-1
4-1-2 Adjusting the Valve Clearance ………………………………………………………………………………………………………………….. 4-1-2
4-1-3 Checking the V-belt Tension …………………………………………………………………………………………………………………….. 4-1-3
4-1-4 Checking the Fuel Injection Valve……………………………………………………………………………………………………………… 4-1-3
4-1-5 Checking and adjusting the Fuel Injection Timing………………………………………………………………………………………… 4-1-5
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed……………………………………………………………………………………… 4-1-7
4-1-7 Checking the Cooling Water System and Radiator for Water Leakage …………………………………………………………… 4-1-7
4-1-8 Checking the Sensors ……………………………………………………………………………………………………………………………… 4-1-8
4-2 Measurement Procedure, Service Data and Corrective Action………………………………………………………………………………. 4-2-1
4-2-1 Cylinder Head…………………………………………………………………………………………………………………………………………. 4-2-1
4-2-2 Cylinder Block ………………………………………………………………………………………………………………………………………… 4-2-6
4-2-3 Valve Rocker Arm …………………………………………………………………………………………………………………………………… 4-2-8
4-2-4 Piston and Piston Rings …………………………………………………………………………………………………………………………. 4-2-10
4-2-5 Connecting Rod…………………………………………………………………………………………………………………………………….. 4-2-13
4-2-6 Cam shaft …………………………………………………………………………………………………………………………………………….. 4-2-16
4-2-7 Crank shaft …………………………………………………………………………………………………………………………………………… 4-2-17
4-2-8 Gears…………………………………………………………………………………………………………………………………………………… 4-2-20
4-2-9 Trochoid Pump……………………………………………………………………………………………………………………………………… 4-2-21
4-3 Precautions for Reassembly …………………………………………………………………………………………………………………………….. 4-3-1
4-4 Fuel Injection System………………………………………………………………………………………………………………………………………. 4-4-1
4-4-1 Fuel Injection Pump…………………………………………………………………………………………………………………………………. 4-4-1
4-4-2 Fuel Injection Valve…………………………………………………………………………………………………………………………………. 4-4-1
4-4-3 Governor Mechanism………………………………………………………………………………………………………………………………. 4-4-2
4-4-4 Specifications of Fuel Injection Pump ………………………………………………………………………………………………………… 4-4-4
4-5 Electrical Equipment ……………………………………………………………………………………………………………………………………….. 4-5-1
4-5-1 Starter Motor ………………………………………………………………………………………………………………………………………….. 4-5-1
4-5-2 Alternator……………………………………………………………………………………………………………………………………………….. 4-5-2
4-5-3 Glow Plug ………………………………………………………………………………………………………………………………………………. 4-5-3
CHAPTER 5
HYDRAULIC SYSTEM
5-1 Outline…………………………………………………………………………………………………………………………………………………………… 5-1-1
5-1-1 Control Valve Operation …………………………………………………………………………………………………………………………… 5-1-4
5-1-2 Additional Operation of Control Valve ………………………………………………………………………………………………………… 5-1-6
5-2 Hydraulic Circuit Schematic ……………………………………………………………………………………………………………………………… 5-2-1
5-2-1 Quick Coupler…………………………………………………………………………………………………………………………………………. 5-2-1
5-2-2 W/O Quick Coupler Type …………………………………………………………………………………………………………………………. 5-2-2
5-3 Circuit Operation …………………………………………………………………………………………………………………………………………….. 5-3-1
5-3-1 Boom…………………………………………………………………………………………………………………………………………………….. 5-3-1
5-3-2 Arm……………………………………………………………………………………………………………………………………………………….. 5-3-3
5-3-3 Bucket …………………………………………………………………………………………………………………………………………………… 5-3-5
5-3-4 Swing…………………………………………………………………………………………………………………………………………………….. 5-3-7
5-3-5 Boom Swing …………………………………………………………………………………………………………………………………………… 5-3-9
5-3-6 Blade …………………………………………………………………………………………………………………………………………………… 5-3-11
5-3-7 Travel ………………………………………………………………………………………………………………………………………………….. 5-3-13
5-3-8 Non-Deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation)…………………………………………………… 5-3-15
5-3-9 Simultaneous Operation of Boom Up and Arm Retract……………………………………………………………………………….. 5-3-17
5-3-10 Simultaneous Operation of Boom Up and Bucket…………………………………………………………………………………….. 5-3-19
5-3-11 Simultaneous Operation of Arm and Bucket ……………………………………………………………………………………………. 5-3-21
5-3-12 Simultaneous Operation of Boom Up and Swing ……………………………………………………………………………………… 5-3-23
5-3-13 Hydraulic P.T.O. …………………………………………………………………………………………………………………………………. 5-3-25
5-3-14 Quick Coupler……………………………………………………………………………………………………………………………………… 5-3-27
5-4 Pressure Adjustment ……………………………………………………………………………………………………………………………………….. 5-4-1
5-4-1 Relief Valves ………………………………………………………………………………………………………………………………………….. 5-4-1
5-4-2 Swing Brake Valve ………………………………………………………………………………………………………………………………….. 5-4-3
5-4-3 Cut-Off Valve………………………………………………………………………………………………………………………………………….. 5-4-4
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump………………………………………………………………………………………………………………………………………………. 6-1-1
6-2 Control Valve………………………………………………………………………………………………………………………………………………….. 6-2-1
6-3 Pilot Valve ……………………………………………………………………………………………………………………………………………………… 6-3-1
6-4 Swing Motor …………………………………………………………………………………………………………………………………………………… 6-4-1
6-5 Travel Motor …………………………………………………………………………………………………………………………………………………… 6-5-1
6-6 Pilot Check Valve (Quick Coupler Type)…………………………………………………………………………………………………………….. 6-6-1
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electrical Equipment of Machine and Engine………………………………………………………………………………………………………. 7-1-1
7-1-1 Parts Layout of Electrical Equipment …………………………………………………………………………………………………………. 7-1-1
7-1-2 Monitor and Alarm Systems ……………………………………………………………………………………………………………………… 7-1-2
7-1-3 Wiring Diagram……………………………………………………………………………………………………………………………………….. 7-1-5
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging ……………………………………………………………….. 7-1-6
7-1-5 Removal and Reinstallation of Engine ……………………………………………………………………………………………………….. 7-1-8
7-1-6 Removal and Reassembly of Starter Motor ………………………………………………………………………………………………. 7-1-14
7-1-7 Removal and Reinstallation of Fuel Injection Pump……………………………………………………………………………………. 7-1-15
7-2 Undercarriage ………………………………………………………………………………………………………………………………………………… 7-2-1
7-2-1 Outline …………………………………………………………………………………………………………………………………………………… 7-2-1
7-2-2 Major Parts …………………………………………………………………………………………………………………………………………….. 7-2-1
7-2-3 Points of Reassembly (Rubber Crawler Models) …………………………………………………………………………………………. 7-2-2
7-2-4 Removal and Reinstallation of Crawler ………………………………………………………………………………………………………. 7-2-3
7-2-5 Disassembly and Reassembly of Idler ……………………………………………………………………………………………………….. 7-2-6
7-2-6 Disassembly and Reassembly of Track Roller…………………………………………………………………………………………….. 7-2-8
7-3 Controls…………………………………………………………………………………………………………………………………………………………. 7-3-1
7-3-1 Control Train…………………………………………………………………………………………………………………………………………… 7-3-1
7-3-2 Mechanical Control Linkage ……………………………………………………………………………………………………………………… 7-3-2
7-3-3 Adjustment of Travel Levers……………………………………………………………………………………………………………………… 7-3-4
7-3-4 Adjustment of Boom Swing Pedal ……………………………………………………………………………………………………………… 7-3-5
7-3-5 Adjustment of Blade Control Lever…………………………………………………………………………………………………………….. 7-3-5
7-3-6 Adjustment of Lock Lever …………………………………………………………………………………………………………………………. 7-3-6
7-3-7 Adjustment Procedure of Travel Alarm Switch…………………………………………………………………………………………….. 7-3-7
7-3-8 Adjustment Procedure of P.T.O. Pedal ………………………………………………………………………………………………………. 7-3-8
7-3-9 Adjustment Procedure of P.T.O. Pedal Lock……………………………………………………………………………………………….. 7-3-8
7-3-10 Adjustment of Accelerator Lever ……………………………………………………………………………………………………………… 7-3-9
7-4 Swing Bearing ………………………………………………………………………………………………………………………………………………… 7-4-1
7-5 Hydraulic Equipment ……………………………………………………………………………………………………………………………………….. 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump …………………………………………………………………………………………… 7-5-1
7-5-2 Removal and Reinstallation of Control Valve ………………………………………………………………………………………………. 7-5-3
7-5-3 Removal and Reinstallation of Swing Motor………………………………………………………………………………………………… 7-5-6
7-5-4 Removal and Reinstallation of Swivel Join………………………………………………………………………………………………….. 7-5-8
7-5-5 Disassembly and Reassembly of Swivel Joint …………………………………………………………………………………………… 7-5-11
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders ………………………………………………………………………………… 7-5-14
7-5-7 Hydraulic Oil Tank …………………………………………………………………………………………………………………………………. 7-5-18
7-5-8 Piping Layout………………………………………………………………………………………………………………………………………… 7-5-25
7-6 Work Implements ……………………………………………………………………………………………………………………………………………. 7-6-1
7-6-1 Removal and Reinstallation of Work Implements…………………………………………………………………………………………. 7-6-1
7-6-2 Quick Coupler…………………………………………………………………………………………………………………………………………. 7-6-8
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing…………………………………………………………………………………………………………………8-1
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended……………………………………………………………………………………………………………….9-1
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns…………………………………………………………………………………………………………………………………………. 10-1-1
10-1-1 Natural Release of Bucket…………………………………………………………………………………………………………………….. 10-1-1
10-1-2 Discontinuous Arm Movement ………………………………………………………………………………………………………………. 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation ……………………………………………………………………………….. 10-1-2
10-1-4 Thermal Shock of Travel Motor ……………………………………………………………………………………………………………… 10-1-3
10-1-5 Elongation of Boom Swing Cylinder on 75 degrees Swing ………………………………………………………………………… 10-1-4
10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position ………………………………………… 10-1-5
10-1-7 Time Lag on Travel Speed Switching……………………………………………………………………………………………………… 10-1-6
10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change…………………………………………………. 10-1-7
10-1-9 Operation of Quick Coupler Cylinder (for Quick Coupler Type) ………………………………………………………………….. 10-1-8
10-2 Troubleshooting ………………………………………………………………………………………………………………………………………….. 10-2-1
10-2-1 Machine and Engine…………………………………………………………………………………………………………………………….. 10-2-1
10-2-2 Electrical Equipment on Panel …………………………………………………………………………………………………………….. 10-2-23
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment…………………………………………………………………………………………………………………………….11-1
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Gregory –
Very nice! Thanks!