YANMAR ViO35-6A Excavator Repair Service Manual (OBKB3-U00100 )
Complete service repair manual with Electrical Wiring Diagrams for YANMAR ViO35-6A Excavator, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
YANMAR ViO35-6A Excavator workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 686 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
OBKB3-U00100 - YANMAR ViO35-6A Excavator Service Manual.pdf
MAIN SECTIONS
TABLE OF CONTENTS
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
2-2-1 Canopy type .. 2-2-1
2-2-2 Cabin type .. 2-2-2
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 Track Specifications .. 3-3-1
3-3-2 Steel Track Specifications .. 3-3-2
3-3-3 Common Specifications of Steel & Rubber Tracks .. 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.. 3-7-4CHAPTER 4
ENGINE
4-1 General .. 4-1-1
4-1-1 How to Read This Manual .. 4-1-1
4-1-2 Precautions for Service Work.. 4-1-3
4-1-3 Engine External Views .. 4-1-4
4-1-4 Structural Description .. 4-1-4
4-1-5 Exhaust Gas Emission Regulation .. 4-1-5
4-2 Troubleshooting .. 4-2-1
4-2-1 Quick Reference Table for Troubleshooting.. 4-2-1
4-2-2 Troubleshooting by Measuring Compression Pressure .. 4-2-4
4-3 Inspection and Adjustment ..4-1
4-3-1 Oil Inspection.. 4-3-1
4-3-2 Cooling Water Inspection .. 4-3-1
4-3-3 Inspecting Water Leak from Cooling Water System and Radiator .. 4-3-1
4-3-4 Fan Belt Tension Inspection and Adjustment.. 4-3-2
4-3-5 Adjusting the Valve Clearance .. 4-3-3
4-3-6 Inspecting the Fuel Injection Valve Injection Pressure and Spray Pattern.. 4-3-5
4-3-7 Fuel Injection Timing Adjustment / Fuel Injection Pump Inspection and Adjustment .. 4-3-9
4-3-8 Sensor Inspection.. 4-3-12
4-3-9 Battery Inspection.. 4-3-13
4-3-10 Adjusting Operation.. 4-3-15
4-3-11 Long Storage.. 4-3-16
4-3-12 Periodic Maintenance Schedule.. 4-3-17
4-4 Engine Body.. 4-4-1
4-4-1 Introduction.. 4-4-1
4-4-2 Cylinder Head.. 4-4-2
4-4-3 Gear Train and Camshaft.. 4-4-11
4-4-4 Cylinder Block .. 4-4-16
4-5 Lubrication System.. 4-5-1
4-5-1 Lubrication System Diagram .. 4-5-1
4-5-2 Trochoid Pump Components.. 4-5-1
4-5-3 Disassembly (Reverse the Procedure Below for Assembly) .. 4-5-1
4-5-4 Servicing Points.. 4-5-2
4-5-5 Parts Inspection and Measurement.. 4-5-2
4-6 Cooling System .. 4-6-1
4-6-1 Cooling Water System.. 4-6-1
4-6-2 Cooling Water Pump Components.. 4-6-1
4-6-3 Disassembly (Reverse the Procedure Below for Assembly) .. 4-6-2
4-6-4 Servicing Points.. 4-6-2
4-7 Fuel Injection Pump / Governor.. 4-7-1
4-7-1 Introduction.. 4-7-1
4-7-2 Fuel Injection Pump.. 4-7-1
4-8 Electrical Equipment .. 4-8-1
4-8-1 Starter Motor .. 4-8-1
4-8-2 Alternator.. 4-8-3
4-8-3 Air Heater .. 4-8-6CHAPTER 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 .. 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 or Boom Swing Operation).. 5-3-15
5-3-9 Non-Deviation Travel (with Bucket Operation) .. 5-3-17
5-3-10 Simultaneous Operation of Boom Up and Arm Retract.. 5-3-19
5-3-11 Simultaneous Operation of Boom Up and Bucket.. 5-3-21
5-3-12 Simultaneous Operation of Boom Up and Swing .. 5-3-23
5-3-13 Simultaneous Operation of Arm and Bucket .. 5-3-25
5-3-14 Hydraulic P.T.O. .. 5-3-27
5-3-15 Quick Coupler.. 5-3-29
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 Blade Control Pilot Valve .. 6-6-1
6-7 Solenoid Valve for P.T.O. Operation .. 6-7-1
6-8 Pilot Check Valve (For Quick Coupler Circuit) .. 6-8-1CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electric Equipment of Machine.. 7-1-1
7-1-1 Parts Layout of Electrical Equipment .. 7-1-1
7-1-2 Monitor and Alarm Systems .. 7-1-3
7-1-3 Wiring Diagram.. 7-1-6
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging .. 7-1-7
7-1-5 Removal and Reinstallation of Engine .. 7-1-9
7-1-6 Removal and Reassembly of Starter Motor .. 7-1-18
7-1-7 Removal and Reassembly of Drive Belts for Generator and Compressor .. 7-1-19
7-2 Undercarriage .. 7-2-1
7-2-1 Outline .. 7-2-1
7-2-2 Main Parts .. 7-2-1
7-2-3 Points of Reassembly (Rubber Track) .. 7-2-2
7-2-4 Points of Reassembly (Steel Track) .. 7-2-3
7-2-5 Removal and Reinstallation of Track.. 7-2-4
7-2-6 Removal and Reinstallation of Steel Track .. 7-2-5
7-2-7 Disassembly and Reassembly of Front Idler .. 7-2-8
7-2-8 Disassembly and Reassembly of Track Roller .. 7-2-10
7-2-9 Installation of Floating Seal .. 7-2-12
7-2-10 Drawings of Jigs .. 7-2-13
7-2-11 Disassembly and Reassembly of Carrier Roller.. 7-2-15
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 Lock Lever.. 7-3-6
7-3-6 Adjustment Procedure of Travel Alarm Switch .. 7-3-7
7-3-7 Adjustment Procedure of P.T.O. Pedal .. 7-3-8
7-3-8 Adjustment Procedure of P.T.O. Pedal Lock.. 7-3-8
7-3-9 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 Joint.. 7-5-9
7-5-5 Disassembly and Reassembly of Swivel Joint .. 7-5-13
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders .. 7-5-16
7-5-7 Hydraulic Oil Tank .. 7-5-20
7-5-8 Piping Layout.. 7-5-26
7-6 Work Implements .. 7-6-1
7-6-1 Removal and Reinstallation of Work Implements.. 7-6-1
7-6-2 Quick Coupler.. 7-6-107-7 Cabin.. 7-7-1
7-7-1 Cabin .. 7-7-1
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 70 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 Dimensions and Specifications for Attachment ..11-1
TABLE OF CONTENTS
COVER...1
FOREWORD...2
CONTENTS...3
1. General Cautions for Maintenance Work...9
1-1 Correct Work...9
1-2 Safety Precautions...9
1-3 Preparations...9
1-4 Cautions for Disassembly and Reassembly...9
1-5 Cautions for Removal and Installation of Hydraulic Equipment...10
1-6 Cautions for Removal and Installation of Hydraulic Piping...10
1-7 Cautions for Handling Seals...11
1-8 Correct Installation of Hydraulic Hose...11
1-9 Specifications of Hydraulic Hose...14
1-10 Air Release of Hydraulic Equipment...16
2. Technical Data...19
2-1 Specifications...19
2-2 Outline Drawing and Working Area...27
2-3 Weight List of Main Parts...31
2-4 Lifting Capacity List...32
2-5 Specifications for Attachment...34
2-6 Periodic Inspection and Servicing...35
2-7 Fuel, Lube Oil and Grease Recommended...37
2-8 Hydraulic Circuit Schematic...38
2-9 Wiring Diagram...39
3. Service Standards...46
3-1 Machine Performance...46
3-2 Engine...50
3-3 Undercarriage...55
3-3-1 Rubber Crawler Specifications...55
3-3-2 Steel Crawler Specifications...56
3-3-3 Common Specifications of Steel & Rubber Crawlers...57
3-4 Controls...58
3-5 Hydraulic Equipment...59
3-5-1 Hydraulic Cylinders...59
3-6 Implement...60
3-6-1 Front Attachments...60
3-6-2 Blade Moving Device...61
3-6-3 Bucket Teeth...61
3-7 List of Tightening Torque...62
3-7-1 Machine...62
3-7-2 Engine...67
3-7-3 Tightening Torque for General Bolts and Nuts...68
3-7-4 Hydraulic Fitting...69
3-8 Pressure Adjustment...70
3-8-1 Relief Valves...70
3-8-2 Swing Brake Valve...73
3-8-3 Cut-Off Valve...74
4. Engine...76
4-1 Engine...76
4-1-1 Safety Precautions...76
4-1-2 Introduction...96
4-1-3 Special Service Tools...97
4-1-4 Measuring Instruments...99
4-1-5 2-Valve Cylinder Head...101
4-1-6 Measuring and Adjusting Valve Clearance...116
4-1-7 Crankshaft and Camshaft Components...118
4-1-8 EGR System...145
4-2 Fuel System...151
4-2-1 Before You Begin Servicing...151
4-2-2 Introduction...156
4-2-3 Special Service Tools...159
4-2-4 Measuring Instruments...159
4-2-5 Fuel System Diagram...160
4-2-6 Fuel System Components...161
4-2-7 Fuel Injection Pump...163
4-2-8 Fuel Injectors...179
4-3 Cooling System...186
4-3-1 Before You Begin Servicing...186
4-3-2 Introduction...188
4-3-3 Cooling System Diagram...188
4-3-4 Engine Coolant Pump Components...189
4-3-5 Engine Coolant System Check...190
4-3-6 Engine Coolant Pump...190
4-4 Lubrication System...195
4-4-1 Before You Begin Servicing...195
4-4-2 Introduction...197
4-4-3 Lubrication System Diagram...197
4-4-4 Checking Engine Oil Pressure...198
4-4-5 Trochoid Oil Pump...198
4-5 Starter Motor...202
4-5-1 Before You Begin Servicing...202
4-5-2 Introduction...204
4-5-3 Starter Motor Specifications...204
4-5-4 Starter Motor Troubleshooting...205
4-5-5 Starter Motor Components...206
4-5-6 Starter Motor...207
4-6 Alternator...217
4-6-1 Before You Begin Servicing...217
4-6-2 Introduction...220
4-6-3 Alternator Specifications...220
4-6-4 Alternator Troubleshooting...221
4-6-5 Alternator Components...222
4-6-6 Alternator Wiring Diagram...223
4-6-7 Alternator Standard Output...224
4-6-8 Alternator...225
4-7 Electronic Control System...230
4-7-1 Engines available with the electronic control system...230
4-7-2 Before You Begin Servicing...230
4-7-3 Main Electronic Control Components and Features...233
4-8 Electric Wiring...235
4-8-1 Electric Wiring Precautions...235
4-9 Failure Diagnosis...236
4-9-1 Special Service Tools...236
4-9-2 Troubleshooting By Measuring Compression Pressure...237
5. Electric System...245
5-1 Electric Equipment of Machine...245
5-1-1 Parts Layout of Electrical Equipment...245
5-1-2 LCD Monitor and Alarm Systems...250
5-2 Electronic Control System...256
5-2-1 Start/Stop Control...256
5-2-2 Circuit Description of Engine Start, Stop and Battery Charging...257
5-3 Engine ECU (engine controller)...260
5-3-1 Engine ECU...260
5-3-2 Circuit Description of Auto Deceleration Mode...261
5-3-3 Circuit Description of Eco Mode...263
5-3-4 Engine Speed and Output Control...265
5-4 Hydraulic ECU (Controller)...266
5-5 Error Code List...268
6. Hydraulic System...276
6-1 Outline...276
6-1-1 Control Valve Operation...278
6-1-2 Additional Operation of Control Valve...279
6-2 Circuit Operation...280
6-2-1 Boom...280
6-2-2 Arm...281
6-2-3 Bucket...282
6-2-4 Swing...283
6-2-5 Boom Swing...284
6-2-6 Blade...285
6-2-7 Travel...286
6-2-8 Non-Deviation Travel (with Boom, Arm or Boom Swing Operation)...287
6-2-9 Non-Deviation Travel (with Bucket Operation)...288
6-2-10 Simultaneous Operation of Boom Up and Arm Retract...289
6-2-11 Simultaneous Operation of Boom Up and Bucket...290
6-2-12 Simultaneous Operation of Boom Up and Swing...291
6-2-13 Simultaneous Operation of Arm and Bucket...292
6-2-14 Hydraulic P.T.O...293
6-2-15 Quick Coupler (Quick coupler spec.)...294
6-2-16 Travel Alarm...295
6-2-17 Auto Deceleration...296
6-3 Hydraulic Pump...297
6-4 Control Valve...334
6-5 Pilot Valve...402
6-6 Swing Motor...416
6-7 Travel motor...447
6-8 Proportional solenoid valve...495
6-8-1 Proportional Solenoid Valve for P.T.O. (Without Air Conditioner spec.)...495
6-8-2 Proportional Solenoid Valve for P.T.O. and Engine Speed Sensing (Air Conditioner spec.)...501
6-9 Pilot Check Valve (For Quick Coupler Circuit)...507
6-10 2-way valve...515
7. Adjustment and Repair...518
7-1 Engine and Electric Equipment...518
7-1-1 Removal and Reinstallation of Engine...518
7-1-2 Removal and Reinstallation of Starter Motor...531
7-1-3 Removal and Reinstallation of Radiator and Oil Cooler...533
7-1-4 Removal and Reinstallation of Fan Belt and Compressor Driving Belt...538
7-1-5 Removal and Reinstallation of Engine ECU...541
7-1-6 Removal and Reinstallation of Hydraulic ECU (Air conditioner spec.)...543
7-2 Undercarriage...544
7-2-1 Outline...544
7-2-2 Main Parts...544
7-2-3 Points of Reassembly (Rubber Track)...545
7-2-4 Points of Reassembly (Steel Track)...546
7-2-5 Removal and Reinstallation of Crawler...548
7-2-6 Removal and Reinstallation of Travel Motor...550
7-2-7 Disassembly and Reassembly of Idler...552
7-2-8 Disassembly and Reassembly of Track Roller...555
7-2-9 Disassembly and Reassembly of Carrier Roller...558
7-2-10 Installation of Floating Seal...560
7-2-11 Drawings of Jigs...561
7-3 Controls...562
7-3-1 Mechanical Control Linkage...562
7-3-2 Adjustment of Travel Levers...564
7-3-3 Adjustment of Boom Swing Pedal...565
7-3-4 Adjustment of Blade Lever...565
7-3-5 Adjustment of Lock Lever...566
7-4 Swing Bearing...567
7-5 Hydraulic Equipment...569
7-5-1 Removal and Reinstallation of Hydraulic Pump...569
7-5-2 Removal and Reinstallation of Control Valve...571
7-5-3 Removal and Reinstallation of Pilot Valves (L and R)...575
7-5-4 Removal and Reinstallation of Swing Motor...577
7-5-5 Removal and Reinstallation of Swivel Joint...579
7-5-6 Disassembly and Reassembly of Swivel Joint...583
7-5-7 Disassembly and Reassembly of Hydraulic Cylinder...586
7-5-8 Removal and Reinstallation of Hydraulic Oil Tank...591
7-5-9 Piping Layout...600
7-6 Work Implements...607
7-6-1 Removal and Reinstallation of Work Implements...607
7-6-2 Quick Coupler...617
7-7 Cabin...620
7-7-1 Removal and Reinstallation of Cabin...620
7-7-2 Disassembly and Reassembly of Cabin...624
7-8 Air Conditioner...656
7-8-1 Removal and Reinstallation of Air Conditioner...656
8. Troubleshooting...673
8-1 Non-Breakdowns...673
8-1-1 Natural Release of Bucket...673
8-1-2 Discontinuous Arm Movement...673
8-1-3 Drifting of Upperstructure on Quick Travel Operation...674
8-1-4 Thermal Shock of Travel Motor...675
8-1-5 Elongation of Boom Swing Cylinder on 65 degrees Swing...676
8-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position...677
8-1-7 Time Lag on Travel Speed Switching...678
8-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change...679
8-1-9 Operation of Quick Coupler Cylinder (for Quick Coupler Type)...680
8-2 Quick Reference Table for Troubleshooting...681
APPENDIX ViO35-6A Wiring Diagram...686
