YANMAR ViO75-A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

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YANMAR ViO75-A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

YANMAR VIO75-A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD:

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YANMAR ViO75-A 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 ViO75-A EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD

COVER
............................................................................................  1
SPINE TITLE
......................................................................................  2
FOREWORD
.........................................................................................  3
CONTENTS 
........................................................................................  5
1. General Cautions for Maintenance Work.......................................................... 11
	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
2. Technical Data................................................................................. 25
	2-1 Specifications............................................................................ 27
	2-2 Outline Drawing and Working Area.......................................................... 34
		2-2-1 Cabin Type.......................................................................... 34
	2-3 Weight List of Main Parts................................................................. 35
	2-4 Lifting Capacity List..................................................................... 36
3. Service Standards.............................................................................. 39
	3-1 Machine Performance....................................................................... 41
	3-2 Engine.................................................................................... 45
	3-3 Undercarriage............................................................................. 49
		3-3-1 Rubber Crawler Specifications....................................................... 49
		3-3-2 Steel Crawler Specifications........................................................ 50
		3-3-3 Common Specifications of Steel & Rubber Crawlers.................................... 51
	3-4 Controls.................................................................................. 52
	3-5 Hydraulic Equipment....................................................................... 53
		3-5-1 Hydraulic Cylinders................................................................. 53
	3-6 Implement................................................................................. 54
		3-6-1 Front Attachments................................................................... 54
		3-6-2 Blade Moving Device................................................................. 55
		3-6-3 Bucket Teeth........................................................................ 55
	3-7 List of Tightening Torque................................................................. 56
		3-7-1 Machine............................................................................. 56
		3-7-2 Engine.............................................................................. 59
		3-7-3 Tightening Torque for General Bolts and Nuts........................................ 59
4. Engine......................................................................................... 61
	4-1 General................................................................................... 63
		4-1-1 How to Read This Manual............................................................. 63
		4-1-2 Precautions for Service Work........................................................ 65
		4-1-3 Engine External Views............................................................... 66
		4-1-4 Structural Description.............................................................. 66
		4-1-5 Exhaust Gas Emission Regulation..................................................... 67
	4-2 Troubleshooting........................................................................... 71
		4-2-1 Quick Reference Table for Troubleshooting........................................... 71
		4-2-2 Troubleshooting by Measuring Compression Pressure................................... 75
	4-3 Inspection and Adjustment................................................................. 77
		4-3-1 Oil Inspection...................................................................... 77
		4-3-2 Cooling Water Inspection............................................................ 77
		4-3-3 Inspecting Water Leak from Cooling Water System and Radiator........................ 77
		4-3-4 Fan Belt Tension Inspection and Adjustment.......................................... 78
		4-3-5 Adjusting the Valve Clearance....................................................... 79
		4-3-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern............ 81
		4-3-7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment.... 85
		4-3-8 Sensor Inspection................................................................... 88
		4-3-9 Battery Inspection.................................................................. 89
		4-3-10 Adjusting Operation................................................................ 91
		4-3-11 Long Storage....................................................................... 92
		4-3-12 Periodic Maintenance Schedule...................................................... 93
	4-4 Engine Body............................................................................... 94
		4-4-1 Introduction........................................................................ 94
		4-4-2 Cylinder Head....................................................................... 95
	4-5 Lubrication System........................................................................124
		4-5-1 Lubrication System Diagram..........................................................124
		4-5-2 Trochoid Pump Components............................................................124
		4-5-3 Disassembly (Reverse the Procedure Below for Assembly)..............................124
		4-5-4 Servicing Points....................................................................125
	4-6 Cooling System............................................................................126
		4-6-1 Cooling Water System................................................................126
		4-6-2 Cooling Water Pump Components.......................................................126
		4-6-3 Disassembly (Reverse the Procedure Below for Assembly)..............................127
		4-6-4 Servicing Points....................................................................127
	4-7 Fuel Injection Pump / Governor............................................................128
		4-7-1 Introduction........................................................................128
		4-7-2 Fuel Injection Pump.................................................................128
	4-8 Starting motor............................................................................132
		4-8-1 Specifications......................................................................132
		4-8-2 Components..........................................................................133
		4-8-3 Troubleshooting.....................................................................134
	4-9 Alternator................................................................................135
		4-9-1 Components..........................................................................135
		4-9-2 Specifications......................................................................137
		4-9-3 Wiring diagram......................................................................137
		4-9-4 Standard output characteristics.....................................................138
		4-9-5 Troubleshooting.....................................................................139
	4-10 Air Heater...............................................................................140
5. Hydraulic System...............................................................................141
	5-1 Outline...................................................................................143
		5-1-1 Control Valve Operation.............................................................146
		5-1-2 Additional Operation of Control Valve...............................................148
	5-2 Hydraulic Circuit Schematic...............................................................149
		5-2-1 For Standard Type Machines..........................................................149
	5-3 Circuit Operation.........................................................................150
		5-3-1 Boom................................................................................150
		5-3-2 Arm.................................................................................152
		5-3-3 Bucket..............................................................................154
		5-3-4 Swing...............................................................................156
		5-3-5 Boom Swing..........................................................................158
		5-3-6 Blade...............................................................................160
		5-3-7 Travel..............................................................................162
		5-3-8 Non-deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation)...............164
		5-3-9 Simultaneous Operation of Boom Up and Arm Retract...................................166
		5-3-10 Simultaneous Operation of Boom Up and Bucket.......................................168
		5-3-11 Simultaneous Operation of Boom Up and Swing........................................170
		5-3-12 Simultaneous Operation of Arm and Bucket...........................................172
		5-3-13 Hydraulic P.T.O....................................................................174
		5-3-14 Travel Alarm.......................................................................176
		5-3-15 4th P.T.O..........................................................................178
		5-3-16 Quick Coupler......................................................................179
	5-4 Pressure Adjustment.......................................................................181
		5-4-1 Relief Valves.......................................................................181
		5-4-2 Swing Brake Valve...................................................................183
		5-4-3 Cut-off Valve.......................................................................184
6. Hydraulic Equipment............................................................................185
	6-1 Hydraulic Pump............................................................................187
	6-2 Control Valve.............................................................................231
	6-3 Pilot Valve...............................................................................285
	6-4 Swing Motor...............................................................................295
	6-5 Travel Motor..............................................................................328
		6-5-1 Product Overview....................................................................328
		6-5-2 Model Labeling......................................................................328
		6-5-3 External Dimensions.................................................................329
		6-5-4 Basic Configuration and Drawing.....................................................330
		6-5-5 Operating Description...............................................................333
		6-5-6 Precautions for Use.................................................................339
		6-5-7 Maintenance and Inspection..........................................................341
		6-5-8 Troubleshooting.....................................................................344
		6-5-9 GM Motor Storage....................................................................345
		6-5-10 Disposal...........................................................................345
		6-5-11 Service Outline....................................................................346
		6-5-12 Disassembly........................................................................359
		6-5-13 Service Preparations...............................................................378
		6-5-14 Assembly...........................................................................379
		6-5-15 Performance Congirmation Test......................................................401
		6-5-16 Clearance Adjustment Parts Dimensions Table........................................402
	6-6 Pilot Check Valve.........................................................................403
7. Adjustment and Repair..........................................................................411
	7-1 Electric Equipment of the Machine.........................................................413
		7-1-1 Parts Layout of Electrical Equipment................................................413
		7-1-2 Monitor and Alarm Systems...........................................................416
		7-1-3 Wiring Diagram......................................................................419
		7-1-4 Stop Motor Operation................................................................421
		7-1-5 Removal and Reinstallation of Engine................................................423
		7-1-6 Removal and Reinstallation of Starter Motor.........................................433
		7-1-7 Removal and Reinstallation of Radiator..............................................434
		7-1-8 Removal and Reinstallation of Fan Belt and Compressor Driving Belt..................437
		7-1-9 Removal and Reinstallation of Fuel Injection Pump...................................438
	7-2 Undercarriage.............................................................................440
		7-2-1 Outline.............................................................................440
		7-2-2 Compatibility of Main Parts.........................................................440
		7-2-3 Points of Reassembly (Rubber Crawler Type)..........................................441
		7-2-4 Points of Reassembly (Steel Crawler Type)...........................................442
		7-2-5 Removal and Reinstallation of Crawler...............................................443
		7-2-6 Disassembly and Reassembly of Steel Crawler.........................................446
		7-2-7 Disassembly and Reassembly of Front Idler...........................................448
		7-2-8 Disassembly and Reassembly of Track Roller..........................................450
		7-2-9 Installation of Floating Seal.......................................................452
		7-2-10 Drawings of Jigs...................................................................453
		7-2-11 Disassembly and Reassembly of Carrier Roller.......................................455
	7-3 Controls..................................................................................457
		7-3-1 Control Train.......................................................................457
		7-3-2 Mechanical Control Linkage..........................................................458
		7-3-3 Adjustment of Travel Levers.........................................................460
		7-3-4 Adjustment of Boom Swing Pedal......................................................461
		7-3-5 Adjustment of Blade Lever...........................................................461
		7-3-6 Adjustment of Lock Lever............................................................462
		7-3-7 Adjustment Procedure of P.T.O. Pedal................................................463
		7-3-8 Adjustment Procedure of P.T.O. Pedal Lock...........................................463
		7-3-9 Adjustment of Accelerator Lever.....................................................464
	7-4 Swing Bearing.............................................................................465
		7-4-1 Removal and Reinstallation of Swing Bearing.........................................465
	7-5 Hydraulic Equipment.......................................................................467
		7-5-1 Removal and Reinstallation of Hydraulic Pump........................................467
		7-5-2 Removal and Reinstallation of Control Valve.........................................471
		7-5-3 Removal and Reinstallation of Swing Motor...........................................474
		7-5-4 Removal and Reinstallation of Swivel Joint..........................................476
		7-5-5 Disassembly and Reassembly of Swivel Joint..........................................479
		7-5-6 Disassembly and Reassembly of Hydraulic Cylinders...................................482
		7-5-7 Hydraulic Oil Tank..................................................................486
		7-5-8 Piping Layout.......................................................................492
	7-6 Implement.................................................................................500
		7-6-1 Removal and Reinstallation of Implement.............................................500
		7-6-2 Quick Coupler.......................................................................508
	7-7 Cabin.....................................................................................511
		7-7-1 Cabin...............................................................................511
	7-8 Air Conditioner...........................................................................525
		7-8-1 Removal and Reinstallation of Air Conditioner.......................................525
8. Periodic Inspection and Servicing..............................................................533
	8-1 List of Periodic Inspection and Servicing.................................................535
9. Fuel, Lube Oil and Grease Recommended..........................................................537
10. Troubleshooting...............................................................................541
	10-1 Non-breakdowns...........................................................................543
		10-1-1 Natural Release of Bucket..........................................................543
		10-1-2 Discontinuous Arm Movement.........................................................543
		10-1-3 Thermal Shock of Travel Motor......................................................544
		10-1-4 Elongation of Boom Swing Cylinder on 68 degrees Swing..............................545
		10-1-5 Time Lag on Travel Speed Switching.................................................546
		10-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change...........547
	10-2 Troubleshooting..........................................................................548
		10-2-1 Machine and Engine.................................................................548
		10-2-2 Electrical Equipment on Panel......................................................569
11. Reference Data................................................................................579
	11-1 Specifications for Attachment............................................................581
COLOPHON
.........................................................................................583

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