YANMAR V100 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
YANMAR V100 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD:
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YANMAR V100 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOADYANMAR V100 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
DESCRIPTION:
YANMAR V100 WHEEL LOADER SERVICE WORKSHOP 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.
TABLE OF CONTENTS:
YANMAR V100 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
V100 _ 0103 ► XXXX Cover 01/31/2019............................................................................................................ 1
01 General................................................................................................................................. 3
Introduction / user notice............................................................................................................. 5
Safety and accident prevention......................................................................................................... 7
Symbol and hazard descriptions......................................................................................................... 19
Tightening torques for pistons or piston nuts.......................................................................................... 25
Tightening torques for guide bushings.................................................................................................. 26
Pictograms............................................................................................................................. 27
Measuring connections.................................................................................................................. 35
Units and conversion tables............................................................................................................ 37
02 Technical Data.......................................................................................................................... 47
Technical data......................................................................................................................... 49
Drift values........................................................................................................................... 57
03 Diesel Engine........................................................................................................................... 59
Operating manual D_TD_TCD 2.9 L4 – 12_2018............................................................................................. 61
Notes.............................................................................................................................. 62
Foreword........................................................................................................................... 65
Table of contents.................................................................................................................. 67
General............................................................................................................................ 68
Engine description................................................................................................................. 70
Model.......................................................................................................................... 70
Engine illustration............................................................................................................ 74
Lubricating oil plan........................................................................................................... 82
Fuel system plan............................................................................................................... 83
Coolant plan................................................................................................................... 84
Exhaust gas recirculation...................................................................................................... 85
Exhaust gas aftertreatment..................................................................................................... 87
Electrics/Electronics.......................................................................................................... 90
Operation.......................................................................................................................... 92
Ambient conditions............................................................................................................. 92
Initial commissioning.......................................................................................................... 94
Start process.................................................................................................................. 97
Operation monitoring........................................................................................................... 98
Exhaust gas aftertreatment system..............................................................................................102
Regeneration Stage V / Tier 4..................................................................................................107
Regeneration Stage IIIA, IIIB and Tier 4i, 4...................................................................................110
Stopping process...............................................................................................................113
Operating media....................................................................................................................114
Lubricating oil................................................................................................................114
Fuel...........................................................................................................................117
Coolant........................................................................................................................118
SCR reduction agent............................................................................................................121
Maintenance........................................................................................................................122
Maintenance schedule...........................................................................................................122
Service and maintenance work.......................................................................................................125
Lubricating oil system.........................................................................................................125
Fuel system....................................................................................................................128
SCR (Selective Catalytic Reduction)............................................................................................131
Cooling system.................................................................................................................132
Engine cleaning................................................................................................................134
Suction system.................................................................................................................135
Belt drives....................................................................................................................137
Electrical system..............................................................................................................139
Faults.............................................................................................................................140
Fault table....................................................................................................................140
Engine management..............................................................................................................146
Transport and storage..............................................................................................................148
Transport......................................................................................................................148
Engine corrosion protection....................................................................................................149
Technical data.....................................................................................................................152
Engine and setting data........................................................................................................152
Tools..........................................................................................................................154
Workshop manual TCD 2.9 L4Tier 4 - 2018_06.............................................................................................159
Table of contents..................................................................................................................161
General............................................................................................................................164
Safety informatin / User information...............................................................................................165
Special tools......................................................................................................................172
Job cards..........................................................................................................................185
01 Crankcase / front cover.....................................................................................................185
W 01-00-01 Check crankcase pressure........................................................................................185
W 01-17-01 Removing and installing the controlvalve........................................................................190
W 01-90-01 Sealing parts (crankcase,oilfiller neck)........................................................................193
W 01-90-23 Oilmeasuring device.............................................................................................194
W 01-90-32 Line (crankcase breather).......................................................................................195
02 Oilpan......................................................................................................................197
W 02-01-01 Removing and installing the lubricating oilpan..................................................................197
05 Crankshaft/Torsionalvibration damper........................................................................................203
W 05-02-03 Removing and installing the drive flange........................................................................203
W 05-03-01 Removing and installing the flywheel(f astening parts)..........................................................210
W 05-90-05 Fastening parts (Pulley - drive flange).........................................................................212
08 Cylinder head...............................................................................................................213
W 08-00-01 Checking the compression pressure (when injectors are removed)..................................................213
W 08-01-01Removing and installing the cylinder head cover..................................................................219
09 Gear case / Gear drive......................................................................................................221
W 09-01-01Replacing the crankshaft sealing ring (flywheelside).............................................................221
W 09-02-03 Removing and installing the sealing cover.......................................................................224
W 09-03-01Removing and fitting the front cover (f astening parts)..........................................................226
W 09-04-01Replacing the crankshaft sealing ring (opposite side to flywheel)................................................230
W 09-90-63 Oilpressure controlvalve........................................................................................233
15 Lubricating oilcooler / Lubricating oilfilter...............................................................................234
W 15-02-01Removing and installing the lubricating oilcooler................................................................234
W 15-90-38 Lubricating oilfilter installation..............................................................................236
16 Lubricating oilpipe.........................................................................................................237
W 16-01-01Removing and installing the oilsuction pipe......................................................................237
17 lnjection pump/High pressure pump...........................................................................................239
W 17-01-04 Removing and installing the high-pressure pump..................................................................239
19 Fuelinjector / ]njector.....................................................................................................247
W 19-01-01Removing and installing the injector.............................................................................247
20 Fuelfilter / Fuelpump.......................................................................................................254
W 20-90-16 Fuelpre-filter..................................................................................................254
W 20-90-17 Fuelfilter......................................................................................................256
W 20-90-20 Pressure sensor installation (fuelpressure).....................................................................258
W 20-90-40 Levelsensor (f uelpre-filter)...................................................................................260
W 20-90-47 Fuelsupplv pump (electric)......................................................................................261
21 Fuel pipes..................................................................................................................263
W 21-04-01 Removing and installing the rail................................................................................263
W 21-04-03 Removing and installing the pressure relief valve (Rail)........................................................268
W 21-04-05 Removing and installing the railpressure sensor.................................................................272
W 21-05-05 Removing and installing the fuelline (injector,rail,high-pressure pump)........................................275
W 21-90-30 Fuelline (Quick coupling).......................................................................................280
22 Air filter / Suction pipe / Charge air line.................................................................................282
W 22-01-01 Removing and installing the charge air line.....................................................................282
W 22-90-35Intake nozzle (Exhaust turbocharger).............................................................................286
W 22-90-54 Charge air manifold.............................................................................................287
37 Coolant pump................................................................................................................288
W 37-03-01 Removing and installing the coolant pump........................................................................288
W 37-90-13 V-belt pulley (f astening parts,coolant pump)...................................................................292
38 Coolant pipes / Thermostat housing..........................................................................................293
W 38-01-01 Removing and installing the thermostat..........................................................................293
W 38-01-02 Checking the thermostat (when removed)..........................................................................296
41 Exhaust pipe / Exhaust gas recirculation....................................................................................298
W 41-01-01 Removing and installing the exhaust pipe........................................................................298
W 41-05-01 Removing and installing the flutter valve.......................................................................300
W 41-05-02 Removing and installing the exhaust gas recirculation module....................................................304
W 41-05-03 a Removing and installing exhaust gas recirculation valve.......................................................308
W 41-05-03 b Removing and installing exhaust gas recirculation valve.......................................................313
43 Exhaust gas turbocharger....................................................................................................314
W 43-01-01Removing and installing the exhaust gas turbocharger.............................................................314
W 43-04-01 Removing and installing the lubricating oil line (Exhaust turbocharger).........................................317
W 43-05-01 Removing and installing the lubricating oil return line (upper partial section) (Exhaust turbocharger)..........321
W 43-05-02 Removing and installing the lubricating oil return line (lower partial se tion) (Exhaust turbocharger)..........324
44 Generator / Starter.........................................................................................................328
W 44-02-01 Removing and installing the generator...........................................................................328
W 44-90-42 Generator.......................................................................................................331
W 44-90-90 Starter.........................................................................................................332
48 Electric....................................................................................................................333
W 48-90-05 Fastening parts (Cable harness, transfer connector, crankcase)..................................................333
W 48-90-20 Pressure sensor installation (f uel pressure/ lubricating oil pressure).........................................334
W 48-90-68 Cable harness ..................................................................................................336
49 Tools/Special tools.........................................................................................................337
W 49-01-03 Check cooling system for leaks..................................................................................337
W 49-02-01Removing and installing turning gear/locking device..............................................................340
51 Measuring instruments.......................................................................................................342
W 51-02-01 Removing and installing the speed sensor (Crankshaft)...........................................................342
W 51-02-03 Removing and installing the speed sensor (Camshaft).............................................................344
W 51-08-01 a Removing and installing pressure/temperature sensor (Charge air)..............................................346
W 51-08-01 b Removing and installing pressure/temperature sensor (Charge air)..............................................348
W 51-09-01 Removing and installing the temperature sensor (Charge air).....................................................352
W 51-90-20 Pressure sensor installation (Lubrication oil pressure).........................................................355
W 51-90-20 Temperature sensor (Coolant) ...................................................................................356
52 Connection housing..........................................................................................................357
W 52-01-01Installing and removing the connection housing...................................................................357
71 Exhaust gas treatment.......................................................................................................359
W 71-10-01 Order of assembly (lnstalling catalyst) DOC (Diesel Oxidation Catalyst), SCR (Selective Catalytic Reduction)....359
W 71-90-09 Holder (Module size 13")........................................................................................365
W 71-90-09 Holder (Module size 5.66")......................................................................................366
W 71-90-09 Holder (Module size 8.5").......................................................................................367
W 71-90-09 Holder (Module size 9.5").......................................................................................368
Bleeding the fuel system...............................................................................................................369
04 Hydraulics..............................................................................................................................371
0103 ► 0659 Hydraulic circuit diagram Standard.........................................................................................373
0660 ► XXXX Hydraulic circuit diagram Standard........................................................................................374
0103 ► 0659 Hydraulic circuit diagram Z-kinematics Standard............................................................................375
0660 ► XXXX Hydraulic circuit diagram Z-kinematics Standard............................................................................376
0103 ► 0659 Hydraulic circuit diagram 4th control circuit and options..................................................................377
0660 ► XXXX Hydraulic circuit diagram 4th control circuit and options..................................................................378
0103 ► 0659 Hydraulic circuit diagram Z-kinematics 4th control circuit and options.....................................................379
0660 ► XXXX Hydraulic circuit diagram Z-kinematics 4th control circuit and options.....................................................380
0103 ► 0659 Hydraulic circuit diagram 4th control circuit with High flow...............................................................381
0660 ► XXXX Hydraulic circuit diagram 4th control circuit with High flow...............................................................382
0103 ► 0659 Hydraulic circuit diagram Z-kinematics 4th control circuit with High flow..................................................383
0660 ► XXXX Hydraulic circuit diagram Z-kinematics 4th control circuit with High flow..................................................384
05 Setting Instructions....................................................................................................................385
General setting instructions...........................................................................................................387
Hydromatik tightening values...........................................................................................................389
HDM19WL valve description..............................................................................................................391
A4VG065DA1 displacement pump...........................................................................................................393
Displacement motor – A6VM..............................................................................................................399
Travel hydraulics – setting instructions...............................................................................................403
06 Functional Description..................................................................................................................411
Pilot control device 4TH6 with handle options..........................................................................................413
07 Electrics...............................................................................................................................415
Cable colors overview..................................................................................................................417
07.26.11 Vehicle electrics - project: TL80-100 CRT_103.pdf.............................................................................419
01 Cover sheet.....................................................................................................................419
1 | 6436040501.................................................................................................................419
2 | 6436040502.................................................................................................................420
3 | 6436040503.................................................................................................................421
4 | 6436040504.................................................................................................................422
5 | 6436040505.................................................................................................................423
02 Schematic circuit diagram.......................................................................................................424
10 | 6436041510................................................................................................................424
11 | 6436041511................................................................................................................425
12 | 6436041512................................................................................................................426
13 | 6436041513................................................................................................................427
14 | 6436041514................................................................................................................428
15 | 6436041515................................................................................................................429
16 | 6436041516................................................................................................................430
17 | 6436041517................................................................................................................431
18 | 6436041518................................................................................................................432
19 | 6436041519................................................................................................................433
20 | 6436041520................................................................................................................434
21 | 6436041521................................................................................................................435
22 | 6436041522................................................................................................................436
23 | 6436041523................................................................................................................437
24 | 6436041524................................................................................................................438
25 | 6436041525................................................................................................................439
26 | 6436041526................................................................................................................440
27 | 6436041527................................................................................................................441
28 | 6436041528................................................................................................................442
29 | 6436041529................................................................................................................443
30 | 6436041530................................................................................................................444
31 | 6436041531................................................................................................................445
32 | 6436041532................................................................................................................446
33 | 6436041534................................................................................................................447
03 Cable harness...................................................................................................................448
101 +1 | 6407043010............................................................................................................448
102 +3 | 6437543041............................................................................................................449
103 +3 | 6437543042............................................................................................................450
104 +3.1 | 6451245521..........................................................................................................451
105 +3.4 | 6436241020..........................................................................................................452
106 +3.5 | 6436242020..........................................................................................................453
107 +3.9 | 6293042040..........................................................................................................454
108 +6 | 6436042030............................................................................................................455
109 +6.1 | 6436268122..........................................................................................................456
110 +6.2 | 6407284010..........................................................................................................457
111 +7 | 6406149011............................................................................................................458
112 +7.1 | 6436267021..........................................................................................................459
113 +7.2 | 6436268121..........................................................................................................460
114 +7.3 | 6451327024..........................................................................................................461
115 +7.4 | 6451327025..........................................................................................................462
116 +7.5 | 6407266021..........................................................................................................463
117 +7.11 | 6436111120.........................................................................................................464
130 +5 | 6436044010............................................................................................................465
131 +5 | 6436044030............................................................................................................466
132 +5 | 6436044040............................................................................................................467
133 +5 | 6436044060............................................................................................................468
134 +5 | 6436044070............................................................................................................469
135 +5 | 6436044080............................................................................................................470
136 +5 | 5653246956............................................................................................................471
04 overview........................................................................................................................472
201 | 6437543048...............................................................................................................472
202 | 6437543044...............................................................................................................473
203 | 6437543045...............................................................................................................474
204 | 6437541011...............................................................................................................475
205 | 6437541012...............................................................................................................476
206 | 6437541013...............................................................................................................477
207 | 6407043091...............................................................................................................478
208 | 6436149011...............................................................................................................479
209 | 6436149012...............................................................................................................480
210 | 6407277021...............................................................................................................481
290 | 6437541010...............................................................................................................482
05 Documentation...................................................................................................................483
220 +3 | 64070xxxxx............................................................................................................483
221 +7.........................................................................................................................484
07.26.15 Vehicle electrics - project: TL80-100 DOC_103.pdf.............................................................................485
01 Cover sheet.....................................................................................................................485
1 | 6436040001.................................................................................................................485
2 | 6436040002.................................................................................................................486
3 | 6436040003.................................................................................................................487
4 | 6436040004.................................................................................................................488
5 | 6436040005.................................................................................................................489
02 Schematic circuit diagram.......................................................................................................490
10 | 6436041010................................................................................................................490
11 | 6436041011................................................................................................................491
12 | 6436041012................................................................................................................492
13 | 6436041013................................................................................................................493
14 | 6436041014................................................................................................................494
15 | 6436041015................................................................................................................495
16 | 6436041016................................................................................................................496
17 | 6436041017................................................................................................................497
18 | 6436041018................................................................................................................498
19 | 6436041019................................................................................................................499
20 | 6436041020................................................................................................................500
21 | 6436041021................................................................................................................501
22 | 6436041022................................................................................................................502
23 | 6436041023................................................................................................................503
24 | 6436041024................................................................................................................504
25 | 6436041025................................................................................................................505
26 | 6436041026................................................................................................................506
27 | 6436041027................................................................................................................507
28 | 6436041028................................................................................................................508
29 | 6436041029................................................................................................................509
30 | 6436041030................................................................................................................510
31 | 6436041031................................................................................................................511
32 | 6436041032................................................................................................................512
03 Cable harness...................................................................................................................513
101 +1 | 6407043010............................................................................................................513
102 +3 | 6437543041............................................................................................................514
103 +3 | 6437543042............................................................................................................515
104 +3.1 | 6451245521..........................................................................................................516
105 +3.4 | 6436241020..........................................................................................................517
106 +3.5 | 6436242020..........................................................................................................518
107 +3.9 | 6293042040..........................................................................................................519
108 +6 | 6436042030............................................................................................................520
109 +6.1 | 6436268122..........................................................................................................521
110 +6.2 | 6407284010..........................................................................................................522
111 +7 | 6436042111............................................................................................................523
112 +7 | 6436042112............................................................................................................524
113 +7.1 | 6436267021..........................................................................................................525
114 +7.2 | 6436268121..........................................................................................................526
115 +7.3 | 6451327024..........................................................................................................527
116 +7.4 | 6451327025..........................................................................................................528
117 +7.5 | 6407266021..........................................................................................................529
118 +7.11 | 6436111120.........................................................................................................530
130 +5 | 6436044010............................................................................................................531
131 +5 | 6436044030............................................................................................................532
132 +5 | 6436044040............................................................................................................533
133 +5 | 6436044060............................................................................................................534
134 +5 | 6436044070............................................................................................................535
135 +5 | 6436044080............................................................................................................536
136 +5 | 5653246956............................................................................................................537
04 overview........................................................................................................................538
201 | 6437543048...............................................................................................................538
202 | 6437543044...............................................................................................................539
203 | 6437543045...............................................................................................................540
204 | 6437541011...............................................................................................................541
205 | 6437541012...............................................................................................................542
206 | 6437541013...............................................................................................................543
207 | 6407043091...............................................................................................................544
208 | 6436149011...............................................................................................................545
209 | 6436149012...............................................................................................................546
210 | 6407277021...............................................................................................................547
290 | 6437541010...............................................................................................................548
05 Documentation...................................................................................................................549
220 +3 | 64070xxxxx............................................................................................................549
221 +7.........................................................................................................................550
Fuse assignment........................................................................................................................551
Relay assignment.......................................................................................................................557
Diesel engine control unit structural diagram..........................................................................................561
Electrical components structural diagram...............................................................................................562
Diagnostics and programming connection.................................................................................................563
08 Maintenance.............................................................................................................................565
Specification for fuels, lubricants, and coolants......................................................................................567
Inspection plan........................................................................................................................571
09 Operation...............................................................................................................................575
Keypad operation.......................................................................................................................577
Instructions for using the combo-tool (display)........................................................................................583
10 Options.................................................................................................................................643
Exhaust gas after-treatment system –
diesel particle filter (DPF) replacement.........................................................645
11 Repair Instructions.....................................................................................................................653
Fitting hydraulic screw connections....................................................................................................655
Adhesive kit – cab windows.............................................................................................................667
Ride control system - “RCS”............................................................................................................669
12 Diagnosis / Tools.......................................................................................................................677
Special tools - purchased parts........................................................................................................679
ACTIA - Diagnostic Messaging Specification.............................................................................................687
Error Codes: Dashboard - Software variants (V1 / V4)...................................................................................709
SerDia 2010 - Diagnoses- and Error Codes SPN / FMI.....................................................................................731
Diagnostics and programming port - purchased parts.....................................................................................777
Home to List of Contents................................................................................................................... 2
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