YANMAR ViO40-1 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

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YANMAR ViO40-1 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD 

YANMAR VIO40-1 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD:

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YANMAR ViO40-1 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 ViO40-1 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD 

FOREWORD.........................................................................................  2
CONTENTS.........................................................................................  3
 1 GENERAL CAUTIONS FOR MAINTENANCE WORK.........................................................  6
	1-1 Correct Work.............................................................................  7
	1-2 Safety Precautions ......................................................................  7
	1-3 Preparations.............................................................................  7
	1-4 Cautions for Disassembly and Reassembly..................................................  7
	1-5 Cautions for Removal and Installation of Hydraulic Equipment.............................  8
	1-6 Cautions for Removal and Installation of Hydraulic Piping................................  8
	1-7 Cautions for Handling Seals..............................................................  8
	1-8 Correct Installation of Hydraulic Hose...................................................  9
	1-9 Specifications of Hydraulic Hose......................................................... 11
	1-10 Air Release of Hydraulic Equipment...................................................... 15
2 TECHNICAL DATA................................................................................. 16
	2-1 Specifications........................................................................... 17
	2-2 Machine Dimensions and Working Ranges.................................................... 24
		2-2-1 Canopy Type........................................................................ 24
		2-2-2 Cabin Type......................................................................... 25
	2-3 Compoment Weights........................................................................ 26
	2-4 Lifting Capacities....................................................................... 27
3 SERVING STANDARDS.............................................................................. 28
	3-1 Machine Performance...................................................................... 29
	3-2 Engine................................................................................... 33
	3-3 Undercarriage............................................................................ 36
		3-3-1 Rubber Crawler Specifications...................................................... 36
		3-3-2 Steel Crawler Specifications....................................................... 37
		3-3-3 Common Specifications of Steel & Rubber Crawlers................................... 38
	3-4 Controls Devices......................................................................... 39
	3-5 Hydraulic Equipment...................................................................... 40
		3-5-1 Hydraulic Cylinder................................................................. 40
	3-6 Work Implements.......................................................................... 41
		3-6-1 Front Attachments.................................................................. 41
		3-6-2 Blade Moving Device................................................................ 42
	3-7 List of Tightening Torque ............................................................... 43
		 3-7-1 Machine........................................................................... 43
		3-7-2 Engine............................................................................. 45
		3-7-3 Tightening Torque for General Bolts and Nuts....................................... 45
4 ENGINE......................................................................................... 46
	4-1 Cylinder Block........................................................................... 47
	4-2 Cylinder Head............................................................................ 52
	4-3 Piston and Piston Pin.................................................................... 59
	4-4 Connecting Rod........................................................................... 63
	4-5 Crankshaft and Main Bearing.............................................................. 66
	4-6 Camshaft and Tappets..................................................................... 69
	4-7 Timig Gear............................................................................... 72
	4-8 Service Data............................................................................. 74
	4-9 Cooling System........................................................................... 77
	4-10 Lubrication System...................................................................... 83
	4-11 Fuel Supply System...................................................................... 91
	4-12 Starter Motor...........................................................................144
	4-13 Alternator..............................................................................155
	4-14 Starting Aids...........................................................................164
	4-15 Adjustment of Engine Output.............................................................165
5 HYDRAULIC SYSTEM...............................................................................167
	5-1 Outline..................................................................................168
		5-1-1 Control Valve Operation............................................................171
		5-1-2 Additional Operation of Control Valve..............................................173
	5-2 Hydaulic Circuit Schematic...............................................................174
		5-2-1 Standard Specifications............................................................174
	5-3 Circuit Operation........................................................................175
		5-3-1 Boom...............................................................................175
		5-3-2 Arm................................................................................177
		5-3-3 Bucket.............................................................................179
		5-3-4 Swing..............................................................................181
		5-3-5 Boom Swing.........................................................................183
		5-3-6 Blade..............................................................................185
		5-3-7 Travel.............................................................................187
		5-3-8 Simultaneous Operation of Travel and Boom/Bucket...................................189
		5-3-9 Simultaneous Operation of Travel and Arm/Boom Swing................................191
		5-3-10 Simultaneous Operation of Boom Up and Arm Retract.................................193
		5-3-11 Simultaneous Operation of Boom Up and Bucket......................................195
		5-3-12 Simultaneous Operation of Boom Up and Swing.......................................197
		5-3-13 Simultaneous Operation of Arm  and Bucket.........................................199
		5-3-14 Hydraulic P.T.O...................................................................201
	5-4 Pressure Adjustment......................................................................203
		5-4-1 Relief Valves......................................................................203
		5-4-2 Swing Brake Valve..................................................................205
		5-4-3 Cut-off Valve......................................................................206
6 HYDRAULIC EQUIPMENT............................................................................208
	6-1 Hydraulic Pump...........................................................................209
	6-2 Control Valve............................................................................230
	6-3 Pilot Valve..............................................................................275
	6-4 Swing Motor..............................................................................282
	6-5 Travel Motor.............................................................................312
7 ADJUSTMENT AND REPAIR..........................................................................354
	7-1 Electric Equipment of the Machine........................................................355
		7-7-1 Parts Layout of Electrical Equipment and Heater....................................355
		7-1-2 Monitor and Alarm Systemes.........................................................358
		7-1-3 Wiring Diagram.....................................................................362
	7-2 Undercarriage............................................................................364
		7-2-1 Outline............................................................................364
		7-2-2 Major Parts........................................................................364
		7-2-3 Points of Reassembly (Rubber Crawler Models).......................................365
		7-2-4 Points of Reassembly (Steel Crawler Models)........................................366
		7-2-5 Disassembly and Reassembly of Ideler...............................................368
		7-2-6 Disassembly and Reassembly of Track Roller.........................................371
		7-2-7 Disassembly and Reassembly of Carrier Roller.......................................373
		7-2-8 Installation of Floating Seal......................................................374
		7-2-9 Drawings of Jigs...................................................................375
	7-3 Controls.................................................................................377
		7-3-1 Control Train......................................................................377
		7-3-2 Mechanical Control Linkage.........................................................378
		7-3-3 Adjustment of Implement Control Levers.............................................380
		7-3-4 Adjustment of Travel Levers........................................................382
		7-3-5 Adjustment of 2-Speed Pedal .......................................................383
		7-3-6 Adjustment of Boom Swing Pedal.....................................................384
		7-3-7 Adjustment of Blade Control Lever..................................................385
		7-3-8 Adjustment of Lock Lever...........................................................386
		7-3-9 Adjustment of Accelerator Lever....................................................387
	7-4 Swing Bearing............................................................................388
	7-5 Hydraulic Equipmennt.....................................................................390
		7-5-1 Removal and Reinstallation (R&R) of Hydraulic Pump.................................390
		7-5-2 Disassembly and Reassembly of Hydraulic Cylinder ..................................395
		7-5-3 Swivel Joint.......................................................................396
		7-5-4 Hydraulic Oil Tank.................................................................400
		7-5-5 Piping Layout......................................................................402
	7-6 Engine Hoodand Cabin.....................................................................409
		7-6-1 Engine Hood........................................................................409
		7-6-2 Cabin..............................................................................410
8 PERIODIC INSPECTION AND SERVICING..............................................................422
	8 List of Periodic Inspection and Servincing ................................................423
9 FUEL, LUBE OIL AND GREASE RECOMMENDED..........................................................425
	9 Fuel, Lube Oil and Grease Recommneded by Yanmar............................................426
10 TROUBLESHOOTING...............................................................................427
	10-1 Non-breakdowns..........................................................................428
		10-1-1 Natural Release of Bucket.........................................................428
		10-1-2 Discontinuous Arm Movement........................................................428
		10-1-3 Drifting of Upperstructure on Quick Travel Operation..............................429
		10-1-4 Thermal Shock of Travel Motor.....................................................430
		10-1-5 Elongation of Boom Swing Cylinder on 70 degrees Swing.............................431
		10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position ....432
		10-1-7 Time Lag on Travel Speed Swichting................................................433
		10-1-8 Fluctuation in Oil Level Hydraulic Oil Tank Due to temperature Change.............434
	10-2 Troubleshooting.........................................................................435
		10-2-1 Machine and Engine................................................................435
		10-2-2 Electrical Equipment on Panel.....................................................456
11 REFERENCE DATA................................................................................464
	11-1 Specifications for Attachment...........................................................465

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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