YANMAR SV120 2PB SERVICE MANUAL – PDF DOWNLOADYANMAR SV120 2PB SERVICE MANUAL – PDF DOWNLOAD
DESCRIPTION:
YANMAR SV120 2PB SERVICE MANUAL – PDF DOWNLOAD
The individual assemblies of the manufacturer machine program and the functions of and adjustments to the installed units are described in this service manual. The hydraulics and electrics diagrams and sectional representations combined with the operating instructions and spare parts list should make maintenance and repair work easier.
Descriptions of work procedures and assembly steps were consciously omitted, because big repairs are generally performed by qualified and experienced workshop personnel, who are masters at this routine work.
Safety and cleanliness at the workstation is the highest priority when performing repairs. Using tools in perfect condition and generally replacing sealing components during each repair should be a matter of course.
Provided no special values are specified, screw connections are to be fastened with the usual tightening torques. This service manual has been issued by the customer service department with the aim of jointly improving the servicing of manufacturer machines.
The service messages we send out for information can serve as a supplement. We keep this manual up to date with continuous additions. This document may be copied and transmitted to third parties neither wholly nor in excerpts without our consent.
The division of the main groups can be seen in the table of contents. The accident prevention regulations of the responsible employer’s liability insurance association are to be strictly observed.
Attentiveness when performing repairs is the best way of preventing accidents. We therefore recommend studying the relevant instructions concerning the intended repair in detail. Maintenance and repair work on machines in the field may only begin once the work equipment has been placed on the ground, the engine is turned off, the machine is secured against rolling away, and the hydraulic system has been relieved of pressure. If repair work is performed by qualified personnel in the workshop, the relevant accident prevention regulations apply here too.
TABLE OF CONTENTS:
YANMAR SV120 2PB SERVICE MANUAL – PDF DOWNLOAD
SV120 2PB - Cover.............................................................................................. 1
List of Contents............................................................................................... 2
01 General..................................................................................................... 3
Technical data................................................................................................. 45
03 Engine...................................................................................................... 55
03.67.02 Operating manual TD - TCD 3.6L4 .................................................................. 57
Notes.................................................................................................. 58
Foreword............................................................................................... 59
Table of contents...................................................................................... 61
General................................................................................................ 62
Engine description..................................................................................... 64
Model.............................................................................................. 64
Engine illustration................................................................................ 67
Lubricating oil plan............................................................................... 73
Fuel system plan................................................................................... 74
Coolant plan....................................................................................... 75
Exhaust gas recirculation.......................................................................... 76
Exhaust gas aftertreatment......................................................................... 77
Electrics/Electronics.............................................................................. 79
Operation.............................................................................................. 81
Ambient conditions................................................................................. 81
Initial commissioning.............................................................................. 83
Start process...................................................................................... 86
Operation monitoring............................................................................... 87
Exhaust gas aftertreatment system.................................................................. 91
Passive regeneration............................................................................... 96
Stopping process................................................................................... 99
Operating media........................................................................................101
Lubricating oil....................................................................................101
Fuel...............................................................................................103
Coolant............................................................................................104
SCR reduction agent................................................................................106
Maintenance............................................................................................107
Maintenance schedule...............................................................................107
Service and maintenance work...........................................................................110
Lubricating oil system.............................................................................110
Fuel system........................................................................................112
SCR (Selective Catalytic Reduction)................................................................115
Cooling system.....................................................................................116
Suction system.....................................................................................118
Belt drives........................................................................................120
Engine cleaning....................................................................................122
Electrical system..................................................................................123
Faults.................................................................................................124
Fault table........................................................................................124
Engine management..................................................................................129
Transport and storage..................................................................................132
Transport..........................................................................................132
Engine corrosion protection........................................................................133
Technical data.........................................................................................136
Engine and setting data............................................................................136
Tools..............................................................................................138
03.67.12 Workshop Manual TD / TCD 3.6 L4...................................................................143
Table of contents......................................................................................145
1 Foreword.........................................................................................147
2 General..........................................................................................151
3 Safety information / User iformation.............................................................155
5 Job card overview................................................................................165
5.1 Sorted alphabetically..........................................................................165
5.2 Sorted numerically.............................................................................171
6 Job cards........................................................................................177
Renewing the crankshaft sealing ring {flywheel side)...................................................179
Removing and installing the gasket housing ............................................................183
Removing and installing the transfer line..............................................................187
Removing and installing the oil pressure regulating valve..............................................191
Closing parts..........................................................................................195
Oil measuring device...................................................................................197
Line...................................................................................................199
Removing and installing the lubricating oil pan........................................................201
Closing parts..........................................................................................209
Drain valve............................................................................................211
Oil filling............................................................................................213
Removing and installing the V-belt pulley / V-ribbed pulley............................................215
Removing and installing the flywheel (Fastening parts).................................................227
Removing and installing the sensor wheel...............................................................231
V-belt pulley..........................................................................................235
Checking the compression pressure (when injectors are removed).........................................237
Removing and installing the cylinder head cover........................................................245
Renewing the crankshaft sealing ring (opposite side to flywheel).......................................251
Cover..................................................................................................255
Removing and installing the control valve..............................................................257
Removing and installing the lubricating oil cooler.....................................................261
Installing the lubricating oil filter..................................................................265
Removing and installing the oil suction pipe...........................................................267
Removing and installing the lubricating oil line (exhaust turbocharger)................................271
Removing and installing the lubricating oil return line (exhaust turbocharger).........................275
Lubricating oil line...................................................................................281
Removing and installing the high-pressure pump.........................................................283
Removing and installing the injector...................................................................291
Fastening parts........................................................................................299
Fuel pre-filter........................................................................................301
Fuel filter............................................................................................303
Supply pump (Fuel).....................................................................................305
Removing and installing the rail.......................................................................307
Removing and installing the fuel line (injector, rail, high-pressure pump).............................317
Removing and install the charge air line...............................................................323
Intake nozzle (exhaust turbocharger)...................................................................327
Charge air manifold....................................................................................329
Removing and installing the coolant pump...............................................................331
Drive components.......................................................................................337
V-rib belt pulley......................................................................................339
Removing and installing the thermostat.................................................................341
Checking the thermostat (in the removed state).........................................................345
Line ..................................................................................................349
Line...................................................................................................351
Suction fan............................................................................................353
Pressure fan...........................................................................................355
Adapter................................................................................................357
Removing and installing the exhaust line...............................................................359
Removing and installing the flutter valve..............................................................363
Removing and installing the cooler.....................................................................367
Removing and installing the exhaust gas return valve...................................................371
Removing and installing the exhaust gas return pipe....................................................379
Removing and installing the Venturi tube...............................................................385
Removing and installing the temperature sensor.........................................................391
Removing and installing the pressure transmitter.......................................................395
Connection (Crankcase housing, exhaust gas circulation, coolant line)..................................401
Screw plug (Thermostat housing, exhaust gas circulation, coolant line).................................403
Holder.................................................................................................405
Holder.................................................................................................407
Holder.................................................................................................409
Compensator structure (Exhaust line)...................................................................411
Line (Crankcase housing, exhaust gas circulation, coolant line)........................................413
Line (Thermostat housing, exhaust gas circulation, coolant line).......................................415
Removing and installing the turbocharger...............................................................417
Removing and installing the belt tensioner (V-rib belt)................................................421
Removing and installing the console (V-rib belt, level 1)..............................................425
Removing and installing the Starter....................................................................429
Fastening parts........................................................................................433
Generator .............................................................................................435
Engine mounting .......................................................................................437
Engine mounting .......................................................................................439
Engine mounting .......................................................................................441
Engine mounting .......................................................................................443
Removing and installing the pressure/temperature sensor (charge air)...................................445
Fastening parts........................................................................................449
Fastening parts........................................................................................451
Fastening parts........................................................................................453
Fastening parts........................................................................................455
Relay..................................................................................................457
Removing and installing turning gear/ locking device...................................................459
Impulse transmitter (crankshaft).......................................................................463
Impulse transmitter (camshaft).........................................................................465
Installing the pressure sensor (oil pressure)..........................................................467
Removing and installing the connection housing.........................................................469
Connection housing.....................................................................................473
Removing and installing the glow plugs.................................................................475
Removing and installing the sensor (NOx)...............................................................479
Removing and installing pressure sensor (exhaust back pressure) SCR (Selective Catalytic Reduction)....483
Removing and installing the dosing device SCR {Selective Catalytic Reduction)..........................487
Removing and installing temperature transmitter (before diesel oxidation catalyst).....................491
Removing and installing the compensator (exhaust turbocharger).........................................495
Holder.................................................................................................499
Holder.................................................................................................501
Exhaust back pressure sensor (mixing pipe) SCR (Selective Catalytic Reduction).........................503
Temperature sensor (air intake temperature, ambient air temperature)...................................505
Coolant line SCR (Selective Catalytic Reduction).......................................................507
Catalytic converter DOC (Diesel Oxidation Catalist) / DPF (Diesel Particle Filter).....................509
Catalytic converter SCR (Selective Catalytic Reduction)...............................................511
Supply pump SCR (Selective Catalytic Reduction)........................................................513
Console................................................................................................515
Tank SCR (Selective Catalytic Reduction)...............................................................517
Mixing pipe (Screw connection).........................................................................519
Removing and installing the coolant compressor.........................................................521
Fastening parts........................................................................................527
Removing and installing hydraulic pump drive...........................................................529
8 Special tools........................................................................................533
04 Hydraulics..................................................................................................557
05 Setting instructions........................................................................................563
06 Function description........................................................................................597
07 Electrics...................................................................................................611
Instructional film - E3.viewer............................................................................. 0
E3.viewer - Vehicle electrics; Project: SCRT_V0.1.2 from Serial-NO.: TC12540105 to TC1254XXXX ............. 0
07.65.12 Vehicle electrics; Project: SCRT_V0.1.2 from Serial-NO.: TC12540105 to TC1254XXXX................615
2 | 6304540002.........................................................................................616
3 | 6304540003.....................................................................................617
4 | 6304540004.....................................................................................618
5 | 6304540005.....................................................................................619
02 Schematic circuit diagram...........................................................................620
10 | 6304541010....................................................................................620
11 | 6304541011....................................................................................621
12 | 6304541012....................................................................................622
13 | 6304541013....................................................................................623
14 | 6304541014....................................................................................624
15 | 6304541015....................................................................................625
16 | 6304541016....................................................................................626
17 | 6304541017....................................................................................627
18 | 6304541018....................................................................................628
19 | 6304541019....................................................................................629
20 | 6304541020....................................................................................630
21 | 6304541021....................................................................................631
22 | 6304541022....................................................................................632
23 | 6304541023....................................................................................633
24 | 6304541024....................................................................................634
25 | 6304541025....................................................................................635
26 | 6304541026....................................................................................636
27 | 6304541027....................................................................................637
28 | 6304541028....................................................................................638
29 | 6304541029....................................................................................639
30 | 6304541030....................................................................................640
31 | 6304541031....................................................................................641
32 | 6304541032....................................................................................642
03 Cable harness.......................................................................................643
101 +1 | 6304542011................................................................................643
102 +1 | 6304542012................................................................................644
103 +1 | 6304542013................................................................................645
104 +2 | 6304543011................................................................................646
105 +2 | 6304543012................................................................................647
106 +3 | 6293543030................................................................................648
107 +2.2 | 6303740011..............................................................................649
108 +2.3 | 6303740121..............................................................................650
109 +7 | 6303543020................................................................................651
110 +6 | 6293043040................................................................................652
111 +8 | 6293240031................................................................................653
112 +8.1 | 6291608530..............................................................................654
114 +1.2 | 6293042040..............................................................................655
120 +5 | 6303544010................................................................................656
121 +5 | 6303544020................................................................................657
122 +5 | 6293044050................................................................................658
123 +5 | 6293044060................................................................................659
124 +5 | 6303544070................................................................................660
125 +5 | 6303544030................................................................................661
04 overview............................................................................................662
201 | 6291540006...................................................................................662
202 | 6304542022...................................................................................663
203 | 6304542023...................................................................................664
204 | 6291542024...................................................................................665
205 | 6291543021...................................................................................666
206 | 6291542025...................................................................................667
207 +1 | 6304542021................................................................................668
08 Maintenance.................................................................................................695
09 Operation...................................................................................................707
10 Options.....................................................................................................745
11 Repair instructions.........................................................................................761
12 Diagnosis / tools...........................................................................................777
Home to List of Contents....................................................................................... 2
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