All 780 pages of this Yanmar SV100-1 service manual PDF cover your 2010-2011 excavator from engine teardown to full hydraulic equipment rebuild. You get wiring diagrams with complete circuit routing, hydraulic schematics showing every flow path, and a dedicated troubleshooting section that walks you through weak implement response, slow swing, and pressure loss without guesswork. Inside: page after page of torque tables covering track frame hardware, hydraulic fittings, and swing motor mounting, plus exploded views and step-by-step adjustment and repair procedures spanning engine, hydraulic system, and hydraulic equipment. Set your travel motor and track frame bolt torque to 264.8-304 N•m, then confirm system relief pressure at 27.5 MPa (3982 PSI) before closing up. Every idle hour on a down machine costs money. Bookmarked and keyword-searchable: find the spec, fix the excavator.
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
Yanmar SV100-1 weak digging power, slow implement response, and loss of hydraulic pressure during heavy lifting. p. 28
Test the main hydraulic system and check page 28 to verify the control valve system relief set pressure. Adjust the P1 and P2 valves to 3982 PSI (27.5 MPa). Inspect the hydraulic hoses for leaks and confirm the tank is filled to its 30.38 Gals (115 L) capacity.
Manual Section: Technical DataEngine runs poorly, overheats repeatedly, and shuts down during continuous operation in high ambient temperatures. p. 59
Inspect the cooling system for severe dust and water scale buildup. Torque the cooling water hose clips to 1.8 to 2.5 ft•lbf (2.5 to 3.4 N•m) as detailed on page 59. Drain degraded coolant and replace the primary cooling system hoses if cracks or leaks are visible.
Manual Section: Service StandardsRubber tracks slip continuously on slight gradients and the machine feels unstable while traveling across side slopes. p. 52
Measure the rubber crawler lug height and replace the tracks if they fall below the 1.30 in. (33 mm) specification found on page 52. Verify track tension components are intact. Torque the M20 track roller bolts to 325.4 to 361.6 ft•lbf (441.2 to 490.2 N•m) to prevent shifting.
Manual Section: Service StandardsEngine turns over slowly, produces excessive exhaust smoke, and suffers from a noticeable lack of power. p. 31
Test the engine compression pressure at 250 rpm to confirm it reaches 497.7 PSI (3.4 MPa) as indicated on page 31. Remove the valve cover and adjust the cold engine intake valve clearance to 0.0059 to 0.0098 in. (0.15 to 0.25 mm). Replace the fuel/water separator element.
Manual Section: Technical DataFrequently Asked Questions
What does the YANMAR SV100-1 error code mean?
The manual provides a 'Detected failure list' that links 'Lamp Number of flash' (error codes) to specific 'Failure detection conditions' and 'Operation when failure occurs'. For example, a 'Lamp Number of flash' of 4 indicates a 'Coolant temperature sensor failure' with conditions like sensor voltage being 4.8 V or more, or 0.2 V or less.
How do I reset the YANMAR SV100-1 after a hydraulic or engine fault?
Recovery from engine faults, such as ECU failures, often involves turning the key off, as indicated in the 'Detected failure list' on page 85. For hydraulic faults, the troubleshooting tables suggest corrective actions like repairing or replacing specific parts, implying that the system recovers once the underlying issue is resolved, rather than requiring a manual reset procedure.
YANMAR SV100-1 torque specs for track motor bolts
For the YANMAR SV100-1, the tightening torque for the 'Travel motor × Track frame' bolts (M16) is specified as 195.3 to 224.2 ft·lbf (264.8 to 304 N·m), and Loctite 262 adhesive should be applied.
What are the replacement specifications for air cleaner element?
The air cleaner element should be replaced every 250 hours as part of periodic servicing. Additionally, it must be cleaned or replaced if the maximum air intake restriction exceeds 0.90 psi (6.23 kPa; 635 mmAq).
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.
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