Yanmar Vio45-5, Vio55-5 - Service Manual - Repair Manual - Wiring Diagrams

YANMAR VIO45-5, VIO55-5 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual, Repair Manual and Wiring Diagrams, for Yanmar Vio45-5, Vio55-5 Excavator.
 

CONTENTS:

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


2. Technical Data

- 2-1 Specifications
- 2-2 Outline Drawing and Working Area
-- 2-2-1 Canopy type
-- 2-2-2 Cabin type
- 2-3 Weight List of Main Parts
- 2-4 Lifting Capacity List


3. Service Standards

- 3-1 Machine Performance
- 3-2 Engine
- 3-3 Undercarriage
-- 3-3-1 Rubber Track Specifications
-- 3-3-2 Steel Track Specifications
-- 3-3-3 Common Specifications of Steel & Rubber Tracks
- 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
-- 3-6-3 Bucket Teeth
- 3-7 List of Tightening Torque
-- 3-7-1 Machine
-- 3-7-2 Engine
-- 3-7-3 Tightening Torque for General Bolts and Nuts


4. Engine

- 4-1 General
-- 4-1-1 How to Read This Manual
-- 4-1-2 Precautions for Service Work
-- 4-1-3 Engine External Views
-- 4-1-4 Structural Description
-- 4-1-5 Exhaust Gas Emission Regulation
- 4-2 Troubleshooting
-- 4-2-1 Quick Reference Table for Troubleshooting
-- 4-2-2 Troubleshooting by Measuring Compression Pressure
- 4-3 Inspection and Adjustment
-- 4-3-1 Oil Inspection
-- 4-3-2 Cooling Water Inspection
-- 4-3-3 Inspecting Water Leak from Cooling Water System and Radiator
-- 4-3-4 Fan Belt Tension Inspection and Adjustment
-- 4-3-5 Adjusting the Valve Clearance
-- 4-3-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern
-- 4-3-7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment
-- 4-3-8 Sensor Inspection
-- 4-3-9 Battery Inspection
-- 4-3-10 Adjusting Operation
-- 4-3-11 Long Storage
-- 4-3-12 Periodic Maintenance Schedule
- 4-4 Engine Body
-- 4-4-1 Introduction
-- 4-4-2 Cylinder Head
-- 4-4-3 Gear Train and Camshaft
-- 4-4-4 Cylinder Block
- 4-5 Lubrication System
-- 4-5-1 Lubrication System Diagram
-- 4-5-2 Trochoid Pump Components
-- 4-5-3 Disassembly (Reverse the Procedure Below for Assembly)
-- 4-5-4 Servicing Points
-- 4-5-5 Parts Inspection and Measurement
- 4-6 Cooling System
-- 4-6-1 Cooling Water System
-- 4-6-2 Cooling Water Pump Components
-- 4-6-3 Disassembly (Reverse the Procedure Below for Assembly)
-- 4-6-4 Servicing Points
- 4-7 Fuel Injection Pump / Governor
-- 4-7-1 Introduction
-- 4-7-2 Fuel Injection Pump
- 4-8 Electrical Equipment
-- 4-8-1 Starter Motor
-- 4-8-2 Alternator
-- 4-8-3 Air Heater


5. Hydraulic System

- 5-1 Outline
-- 5-1-1 Control Valve Operation
-- 5-1-2 Additional Operation of Control Valve
- 5-2 Hydraulic Circuit Schematic
- 5-3 Circuit Operation
-- 5-3-1 Boom
-- 5-3-2 Arm
-- 5-3-3 Bucket
-- 5-3-4 Swing
-- 5-3-5 Boom Swing
-- 5-3-6 Blade
-- 5-3-7 Travel
-- 5-3-8 Non-Deviation Travel (with Boom, Arm orBoom Swing Operation)
-- 5-3-9 Non-Deviation Travel (with Bucket Operation)
-- 5-3-10 Simultaneous Operation of Boom Upand Arm Retract
-- 5-3-11 Simultaneous Operation of Boom Upand Bucket
-- 5-3-12 Simultaneous Operation of Boom Upand Swing
-- 5-3-13 Simultaneous Operation of Arm andBucket
-- 5-3-14 Hydraulic P.T.O.
-- 5-3-15 Quick Coupler
- 5-4 Pressure Adjustment
-- 5-4-1 Relief Valves
-- 5-4-2 Swing Brake Valve
-- 5-4-3 Cut-Off Valve


6. Hydraulic Equipment

- 6-1 Hydraulic Pump
- 6-2 Control Valve
-- 1. Outline
-- 2. Operation
-- 3. Operation of Directional Control Valves
-- 4. Disassembly and Reassembly
-- 5. Disassembly and Reassembly of Relief Valves
-- 6. 2-way Valve
-- 7. Service Standard
-- 8. Troubleshooting
- 6-3 Pilot Valve
- 6-4 Swing Motor
- 6-5 Travel Motor
- 6-6 Blade Control Pilot Valve
- 6-7 Solenoid Valve for P.T.O. Operation
- 6-8 Pilot Check Valve (For Quick Coupler Circuit)


7. Adjustment and Repair

- 7-1 Electric Equipment of Machine
-- 7-1-1 Parts Layout of Electrical Equipment
-- 7-1-2 Monitor and Alarm Systems
-- 7-1-5 Removal and Reinstallation of Engine
-- 7-1-6 Removal and Reassembly of Starter Motor
-- 7-1-7 Removal and Reassembly of Drive Belts for Generator and Compressor
- 7-2 Undercarriage
-- 7-2-1 Outline
-- 7-2-2 Main Parts
-- 7-2-3 Points of Reassembly (Rubber Crawler)
-- 7-2-4 Points of Reassembly (Steel Crawler)
-- 7-2-5 Removal and Reinstallation of Crawler
-- 7-2-6 Removal and Reinstallation of Steel Crawler
-- 7-2-7 Disassembly and Reassembly of Front Idler
-- 7-2-8 Disassembly and Reassembly of Track Roller
-- 7-2-9 Installation of Floating Seal
-- 7-2-10 Drawings of Jigs
-- 7-2-11 Disassembly and Reassembly of Carrier Roller
- 7-3 Controls
-- 7-3-1 Control Train
-- 7-3-2 Mechanical Control Linkage
-- 7-3-3 Adjustment of Travel Levers
-- 7-3-4 Adjustment of Boom Swing Pedal
-- 7-3-5 Adjustment of Lock Lever
-- 7-3-6 Adjustment Procedure of Travel Alarm Switch
-- 7-3-7 Adjustment Procedure of P.T.O. Pedal
-- 7-3-8 Adjustment Procedure of P.T.O. Pedal Lock
-- 7-3-9 Adjustment of Accelerator Lever
- 7-4 Swing Bearing
- 7-5 Hydraulic Equipment
-- 7-5-1 Removal and Reinstallation of Hydraulic Pump
-- 7-5-2 Removal and Reinstallation of Control Valve
-- 7-5-3 Removal and Reinstallation of Swing Motor
-- 7-5-4 Removal and Reinstallation of Swivel Joint
-- 7-5-5 Disassembly and Reassembly of Swivel Joint
-- 7-5-6 Disassembly and Reassembly of Hydraulic Cylinders
-- 7-5-7 Hydraulic Oil Tank
-- 7-5-8 Piping Layout
- 7-6 Work Implements
-- 7-6-1 Removal and Reinstallation of Work Implements
-- 7-6-2 Quick Coupler
- 7-7 Cabin
-- 7-7-1 Cabin


8. Periodic Inspection and Servicing

- 8-1 List of Periodic Inspection and Servicing


9. Fuel, Lube Oil and Grease Recommended


10. Troubleshooting

- 10-1 Non-breakdowns
-- 10-1-1 Natural Release of Bucket
-- 10-1-2 Discontinuous Arm Movement
-- 10-1-3 Drifting of Upperstructure on Quick Travel Operation
-- 10-1-4 Thermal Shock of Travel Motor
-- 10-1-5 Elongation of Boom Swing Cylinder on 70 degrees Swing
-- 10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position
-- 10-1-7 Time Lag on Travel Speed Switching
-- 10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
-- 10-1-9 Operation of Quick Coupler Cylinder (for Quick Coupler Type)
- 10-2 Troubleshooting
-- 10-2-1 Machine and Engine
-- 10-2-2 Electrical Equipment on Panel


11. Reference Data

- 11-1 Dimensions and Specifications for Attachment