Yanmar SV86-7 SV100-7 Service Manual MMB69ENMA00200

Yanmar SV86-7 SV100-7 Service Manual MMB69ENMA00200

Size: 131.01 MB
Brand: Yanmar
Machine: Excavator
Document: Service Manual, Electrical and Hydraulic Diagrams
Machine Model: Yanmar SV86-7 SV100-7 Excavator
Part Number: MMB69ENMA00200
Page: 1009 Pages

Contents:

CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work
1-2 Safety Precautions
1-3 Preparations
1-4 Cautions for Disassembly and Reassembly
1-5 Cautions for Removal and Installation of Hydraulic Equipment
1-6 Cautions for Removal and Installation of Hydraulic Piping
1-7 Cautions for Handling Seals
1-8 Correct Installation of Hydraulic Hose
1-9 Specifications of Hydraulic Hose
1-10 Air Release of Hydraulic Equipment
CHAPTER 2
TECHNICAL DATA
2-1 Specifications
2-3 Weight List of Main Parts
2-4 Lifting Capacity List
2-4-1 SV86-7
2-4-2 SV100-7
2-5 Specifications for Attachment
2-6 Periodic Inspection and Servicing
2-7 Fuel, Lube Oil and Grease Recommended
2-8 Hydraulic Circuit Schematic
2-8-1 SV86-7
2-8-3 SV100-7
2-9 Wiring Diagram
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance
3-2 Engine
3-3 Undercarriage
3-3-1 Rubber Crawler Specifications
3-3-2 Steel Crawler Specifications
3-3-3 Common Specifications of Steel & Rubber Crawlers
2-1-1 Standard arm type
2-1-2 Long arm type
2-1-3 Arti-boom type
2-2 Outline Drawing and Working Area
2-2-1 Standard arm type
2-2-2 Long arm type
2-2-3 Arti-boom types
2-5-1 SV86-7
2-5-2 SV100-7
2-8-2 SV86-7 (Arti-boom spec.)
2-8-4 SV100-7 (Arti-boom spec.)
3-7-6 Breathers tightening torque
3-8 Pressure Adjustment
3-8-1 Relief Valves
3-8-2 Swing Brake Valve
3-8-4 Accumulator
CHAPTER 4
Engine
4-1 INTRODUCTION
4-2 YANMAR WARRANTIES
4-2-1 YANMAR LIMITED WARRANTY
4-2-2 EMISSION SYSTEM WARRANTY
4-3 SAFETY
4-3-1 SAFETY STATEMENTS
4-3-2 SAFETY PRECAUTIONS
4-4 PRODUCT OVERVIEW
4-4-1 YANMAR TNV/TN ENGINE FEATURES AND APPLICATIONS
4-4-2 COMPONENT IDENTIFICATION
4-4-3 LOCATION OF LABELS
4-4-4 EMISSION CONTROL REGULATIONS
4-4-5 EMISSION CONTROL LABELS
4-4-6 ENGINE FAMILY
4-4-7 FUNCTION OF MAJOR ENGINE COMPONENTS
4-4-8 FUNCTION OF COOLING SYSTEM COMPONENTS
4-4-9 ELECTRONIC CONTROL SYSTEM
4-4-10 Installation Position of Sensors for Electronic Control System
4-4-11 GAUGES AND INDICATORS
4-5-1 DIESEL FUEL
4-5-2 ENGINE LUBRICATING OIL
4-5-3 ENGINE COOLANT
4-5-4 DAILY CHECKS
3-8-3 Cut-off Valve
4-5 BEFORE YOU OPERATE
3-7-5 Solenoids tightening torque
3-7-4 Hydraulic Fitting
3-4 Controls
3-5 Hydraulic Equipment
3-5-1 Hydraulic Cylinders
3-6 Implement
3-6-1 Front Attachments
3-6-2 Blade Moving Device
3-7 List of Tightening Torque
3-7-1 Special management parts for main machine
3-7-2 Engine
3-7-3 Tightening Torque for General Bolts and Nuts
4-9-1 BEFORE YOU PLACE THE ENGINE IN LONG-TERM STORAGE
4-9 LONG-TERM STORAGE
4-9-2 RETURNING THE ENGINE TO SERVICE
4-10-2 PRINCIPAL ENGINE SPECIFICATIONS
CHAPTER 5
ELECTRIC SYSTEM
5-1 Electric Equipment of Machine
5-1-1 Parts Layout of Electrical Equipment
5-1-2 LCD Monitor and Alarm Systems
5-2 Circuit Description of Engine Start and Stop
5-3 Engine ECU (engine controller)
5-3-1 Outline
5-3-2 Control Functions
5-4 Hydraulic ECU (Pump Controller)
5-4-1 Outline
5-4-2 Engine Control
5-4-3 Speed Sensing Horsepower Limit Control
5-4-4 Load Sensing Gain Control (Pump Flow Rate Control)
5-5 Camera adjustment
5-6 Error Code
4-10-1 GENERAL
4-10 SPECIFICATIONS
5-7 Battery
5-7-1 Generality
5-7-2 Maintenance
CHAPTER 6
HYDRAULIC SYSTEM
6-1 Outline
6-1-1 Control Valve Operation
6-1-2 Additional Operation of Control Valve
4-6 ENGINE OPERATION
4-6-1 STARTING ENGINE
4-6-2 CHECKING THE ENGINE DURING OPERATION
4-6-3 SHUTTING DOWN THE ENGINE
4-7 PERIODIC MAINTENANCE
4-7-1 PRECAUTIONS
4-7-2 STANDARD TORQUE CHART
4-7-3 PERIODIC MAINTENANCE SCHEDULE
4-7-4 PERIODIC MAINTENANCE PROCEDURES
4-8 TROUBLESHOOTING
4-8-1 TROUBLESHOOTING CHART
4-8-2 TROUBLESHOOTING INFORMATION
4-8-3 TROUBLESHOOTING OF ELECTRONIC CONTROL SYSTEM
4-8-4 TROUBLESHOOTING FOR ELECTRONIC CONTROL SYSTEM
6-3-3 Part Names
6-3-4 Disassembly and Reassembly
6-3-5 Service Standards
6-3-6 Troubleshooting
6-4 Control Valve
6-5 Pilot Valve
6-5-1 Remote Control Valve
6-5-2 Travel Pilot Valve
6-5-3 Blade valve (Swing valve)
6-6 Swing Motor
6-6-1 Overview
6-6-2 Description of Functions and Operation
6-6-3 Precautions for Handling
6-6-4 Troubleshooting
6-6-5 Employment Tool
6-6-6 Disassembly Procedure
6-6-7 Assembly Procedure
6-6-8 Quality Check After Reassembly
6-7 Travel Motor (SV86-7)
6-7-1 Product Overview
6-7-2 External Dimensions
6-7-3 Basic Configuration and Drawing
6-7-4 Operating Description
6-7-5 Troubleshooting
6-7-6 Service outline
6-7-7 Disassembly
6-3 Hydraulic Pump
6-3-1 Main Specifications and Appearance
6-3-2 Basic Configuration and Operation Theory
6-2 Circuit Operation
6-2-1 Boom
6-2-2 Arm
6-2-3 Bucket
6-2-4 Simultaneous Implement Operations
6-2-5 Swing
6-2-6 Boom Swing
6-2-8 Blade
6-2-9 Travel
6-2-10 Non-deviation Travel
(Example: Simultaneous operation of traveling forward, boom raising, and arm excavation)
6-2-11 Hydraulic AUX1
6-2-12 Hydraulic AUX2
6-2-13Hydraulic AUX3 (AUX3 Spec.)
6-2-14 Auto Deceleration
6-2-15 Travel alarm
6-2-7 Arti-boom (Arti-boom spec.)
6-11 Solenoid Valve
6-12 Quick Coupler Solenoid Valve
6-13 AUX Solenoid
6-14 Safety Valve
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Hood and Weight
7-1-1 Removal and installation of hood
7-1-2 Removal and installation of additional weights (additional weights Spec.)
7-1-3 Removal and installation of weights
7-2 Engine and Electrical Components
7-2-1 Removal and installation of engine
7-2-2 Removal and installation of the starting motor
7-2-3 Removal and installation of the radiator and oil cooler
7-2-4 Removal and installation of the fan belt and compressor belt
7-2-5 Removal and installation of engine ECU
7-2-6 Removal and installation of hydraulic ECU
7-2-7 Removal and installation of diesel particulate filter (DPF)
6-9 Pump Control Proportional Solenoid Valve
6-15 High/Low switching Valve
6-16 Hydraulic tank breather
6-8 Travel Motor (SV100-7)
6-8-1 Product Overview
6-8-2 External Dimensions and Circuit Diagram
6-8-3 Basic Configuration and Drawing
6-8-4 Operating Description
6-8-5 Procedures for Replacement of Gear Oil
6-8-6 Troubleshooting
6-8-7 Storage of the Travel Unit
6-8-8 Disposal Methods
6-8-9 Outline of Services
6-8-10 Disassembly
6-8-11 Service Standard
6-8-12 Assembly
6-8-13 Performance Confirmation Test
6-10 Arti-boom check valve
6-7-8 Service Standard
6-7-9 Assembly
6-7-10 Performance Confirmation Test
7-6 Hydraulic device
7-6-1 Removal and installation of hydraulic pump
7-6-2 Removal and installation of control valves
7-6-3 Removal and installation of pilot valves (L, R)
7-6-4 Removal and installation of blade pilot valve
7-6-5 Removal and installation of travel pilot valve
7-6-6 Removal and installation of swing pilot valve
7-6-8 Removal and installation of cut-off valve and accumulator
7-6-9 Removal and Reinstallation of AUX Solenoid Valve
7-6-10 Removal and Reinstallation of AUX2 Solenoid Valve
7-6-11 Removal and Reinstallation of AUX3 Solenoid Valve (AUX3 Spec.)
7-6-12 Removal and installation of pump control proportional valve
7-6-13 Removal and installation of blade hold valve
7-6-14Removal and installation of line filter
7-6-15 Removal and installation of swing motor
7-6-16 Removal and Reinstallation of Swivel Joint
7-6-17 Disassembly and Reassembly of Swivel Joint
7-6-18 Hydraulic cylinder disassembly and assembly
7-6-19 Reservoir tank
7-6-20 Hydraulic piping diagram
7-7 Implement
7-7-1 Removal and installation of implements
7-8 Cabin
7-8-1 Removal and installation of cabin
7-8-2 Cabin disassembly and assembly
7-8-3 Procedures for replacement of bonded glass
7-9 Air conditioner
7-9-1 Removal and installation of air conditioner
7-6-7 Removal and installation of arti-boom pilot valve
7-7-2 Removal and Reinstallation of Implement (Arti-boom spec.)
7-3 Undercarriage
7-3-1 Outline
7-3-2 Main parts
7-3-3 Precautions for assembly
7-3-4 Removal and Reinstallation of Crawler
7-3-5 Disassembly and Reassembly of steel crawler
7-3-6 Removal and Reinstallation of Travel Motor
7-3-7 Disassembly and Reassembly of Idler
7-3-8 Disassembly and Reassembly of Track Roller
7-3-9 Disassembly and Reassembly of Carrier Roller
7-3-10 Installation of Floating Seal
7-5-1 Removal and Reinstallation of Swing Bearing
7-4 Control unit
7-4-1 Operation lever
7-4-2 Travel lever
7-5 Swing Bearing
CHAPTER 8
TROUBLESHOOTING
8-1 Non-breakdowns
8-1-1 Natural Release of Bucket
8-1-2 Discontinuous Arm and Bucket Movement
8-1-3 Thermal Shock of Travel Motor
8-1-4 Elongation of Boom Swing Cylinder on 60 degrees Swing
8-1-5 Time Lag on Travel Speed Switching
8-1-6 Fluctuation in Oil Level of Hydraulic Oil Tank due to Temperature Change
8-2 Quick Reference Table for Troubleshooting
APPENDIX
SV86-7, SV100-7 Wiring Diagram