Part of the Yanmar Repair Manuals.
Set a gauge on the P1 port of an SV100-1 with a soft boom and you need one number before anything else: the relief pressure the pump is supposed to hit. That figure, along with valve clearances, crawler wear limits, and torque tables, is what this 780-page Yanmar factory service manual (publication 0BKB6-G10102) puts in front of you.
It covers the SV100-1 excavator built from 2010 to 2011 with the 4TNV98T-ZSBV1 engine, in dedicated sections for the engine, the hydraulic system and hydraulic equipment, service standards for both rubber and steel crawlers, adjustment and repair, and troubleshooting.
Every hour this machine sits with weak breakout force or a slipping track is an hour the crew stands around it. With 262 bookmarks and a searchable text layer, the PDF takes you from symptom to spec to the correct part the first time, on a shop screen or printed at the bench.
What's Inside This Yanmar SV100-1 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Cautions for Maintenance Work | 11-24 | Correct Work, Safety Precautions, Preparations, Cautions for Disassembly and Reassembly, Cautions for Removal and Installation of Hydraulic Equipment |
| Technical Data | 25-40 | Specifications, Outline Drawing and Working Area (Quick Coupler, W/O Quick Coupler), Weight List of Main Parts, Lifting Capacity List (SV100-1: Quick Coupler |
| Service Standards | 41-64 | Machine Performance, Engine, Undercarriage (Rubber Crawler Specifications, Steel Crawler Specifications, Common Specifications of Steel & Rubber Crawlers), Controls |
| Engine | 65-246 | - |
| Hydraulic System | 247-278 | - |
| Hydraulic Equipment | 279-540 | - |
| Adjustment and Repair | 541-726 | - |
| Periodic Inspection and Servicing | 727-730 | - |
| Fuel, Lube Oil and Grease Recommended | 731-734 | Fuel, Lube Oil and Grease Recommended |
| Troubleshooting | 735-774 | - |
| Reference Data | 775-780 | - |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for Travel motor × Track frame bolts | 195.3 to 224.2 ft•lbf (264.8 to 304 N•m) | p. 60 |
| Tightening torque for Swing motor × Turning frame bolts | 195.3 to 224.2 ft•lbf (264.8 to 304 N•m) | p. 60 |
| Tightening torque for parallel pipe thread G (PF) 1/8 | 10.1 to 12.3 ft•lbf (13.7 to 16.7 N•m) | p. 64 |
| Tightening torque for Cooling water hose (Hose clip 48) | 1.8 to 2.5 ft•lbf (2.5 to 3.4 N•m) | p. 59 |
| System relief set pressure (P1, P2) | 3982 PSI (27.5 MPa) | p. 28 |
| Engine Rated Output | 73.3 HP/2200 rpm (54.7 kW/2200 rpm) | p. 31 |
| Engine Compression Pressure | 497.7 PSI (3.4 MPa) at 250 rpm | p. 31 |
| Intake Valve Clearance (Cold engine) | 0.0059 to 0.0098 in. (0.15 to 0.25 mm) | p. 32 |
| Fuel Injection Valve Opening Pressure | 3132 to 3277 PSI (21.6 to 22.6 MPa) | p. 51 |
| Hydraulic Oil Tank Capacity | 30.38 Gals (115 L) | p. 30 |
| Control Valve System Relief Set Pressure (P1, P2) | 3982 PSI (27.5 MPa) | p. 28 |
| Swing Speed | 9.2 rpm | p. 28 |
Yanmar SV100-1 Common Problems This Manual Covers
Weak digging power and slow hydraulics
When the bucket loses breakout force or functions lag, low relief pressure, contamination, or pump wear is the usual suspect. The Hydraulic System section lays out the circuits so you can test against the 3982 PSI (27.5 MPa) relief setting instead of swapping parts on a guess.
Manual Section: Hydraulic System p. 247Track tension loss and crawler wear
Sagging or slipping tracks on this class of machine usually trace back to worn undercarriage components or incorrect tension. The Service Standards section gives wear limits for rubber and steel crawlers, including the 1.30 in. (33 mm) rubber crawler lug height, so you can measure instead of eyeball.
Manual Section: Service Standards p. 41Overheating from cooling system buildup
Dust and water scale collect in the cooling system over hard hours and end in repeated shutdowns on hot days. The Engine section covers the 4TNV98T-ZSBV1 in detail so you can service the cooling side before a warm gauge becomes a lost day.
Manual Section: Engine p. 65Boom drift and leaking cylinder seals
A boom that settles overnight or a rod wet with oil means seals are done. The Hydraulic Equipment section covers the machine's hydraulic components so cylinder teardown and reassembly happen in the right order with the right parts.
Manual Section: Hydraulic Equipment p. 279Spongy controls after hydraulic hose work
Air left in the circuit after a hose or component swap makes controls feel vague and can damage equipment. The General Cautions for Maintenance Work section covers removal and installation of hydraulic equipment and piping, plus the air release procedure to finish the job properly.
Manual Section: General Cautions for Maintenance Work p. 11Swing or travel motor bolts loosening
Abnormal noise or movement at the swing bearing or final drives sometimes comes down to mounting hardware, and guessing the torque makes it worse. The manual specifies 195.3 to 224.2 ft-lbf (264.8 to 304 N-m) for both the travel motor and swing motor bolts, with repair procedures in the Adjustment and Repair section.
Manual Section: Adjustment and Repair p. 541Frequently Asked Questions
Which machine and engine does this manual cover?
It is the Yanmar factory service manual for the SV100-1 excavator, 2010 to 2011, with the 4TNV98T-ZSBV1 engine. Publication number 0BKB6-G10102, 780 pages, in English.
Does it include the hydraulic pressure specs for diagnosing weak functions?
Yes. The Technical Data section lists the control valve relief set pressure for P1 and P2 at 3982 PSI (27.5 MPa), and the Hydraulic System section covers the circuits, so you can put a gauge on it and compare against factory numbers. p. 25
Are undercarriage wear limits covered for both rubber and steel tracks?
Yes. The Service Standards section has separate specifications for rubber crawlers, steel crawlers, and items common to both, including wear limits such as the 1.30 in. (33 mm) rubber crawler lug height, plus track roller torque values. p. 41
Can I use it for engine work like valve adjustment?
Yes. The Engine section covers the 4TNV98T-ZSBV1, and the manual lists specs such as intake valve clearance of 0.0059 to 0.0098 in. (0.15 to 0.25 mm) cold and cylinder head bolt torque of 76 to 83 ft-lbf. p. 65
What format is this manual in?
Instant PDF download. You get the full 780-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print this manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Does this Yanmar SV100-1 Service Manual cover the hydraulic system?
Full hydraulic system diagrams are included, covering circuits, valve locations, and hydraulic component specs for the Yanmar SV100-1.
Reviews
There are no reviews yet.