YANMAR V120 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
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YANMAR V120 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 V120 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
V120 _ 0103 ► XXXX Cover 02/22/2019..................................................................................................... 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..................................................................................................................... 55 03 Engine............................................................................................................................ 57 Operating manual TD - TCD 3.6L4 EU Stage IV & V _ 06/2018 en..................................................................... 59 Notes........................................................................................................................ 60 Foreword..................................................................................................................... 61 Table of contents............................................................................................................ 63 General...................................................................................................................... 64 Engine description........................................................................................................... 66 Model.................................................................................................................... 66 Engine illustration...................................................................................................... 69 Lubricating oil plan..................................................................................................... 75 Fuel system plan......................................................................................................... 76 Coolant plan............................................................................................................. 77 Exhaust gas recirculation................................................................................................ 78 Exhaust gas aftertreatment............................................................................................... 79 Electrics/Electronics.................................................................................................... 81 Operation.................................................................................................................... 83 Ambient conditions....................................................................................................... 83 Initial commissioning.................................................................................................... 85 Start process............................................................................................................ 88 Operation monitoring..................................................................................................... 89 Exhaust gas aftertreatment system........................................................................................ 93 Passive regeneration..................................................................................................... 98 Stopping process.........................................................................................................101 Operating media..............................................................................................................103 Lubricating oil..........................................................................................................103 Fuel.....................................................................................................................105 Coolant..................................................................................................................106 SCR reduction agent......................................................................................................108 Maintenance..................................................................................................................109 Maintenance schedule.....................................................................................................109 Service and maintenance work.................................................................................................112 Lubricating oil system...................................................................................................112 Fuel system..............................................................................................................114 SCR (Selective Catalytic Reduction)......................................................................................117 Cooling system...........................................................................................................118 Suction system...........................................................................................................120 Belt drives..............................................................................................................122 Engine cleaning..........................................................................................................124 Electrical system........................................................................................................125 Faults.......................................................................................................................126 Fault table..............................................................................................................126 Engine management........................................................................................................131 Transport and storage........................................................................................................134 Transport................................................................................................................134 Engine corrosion protection..............................................................................................135 Technical data...............................................................................................................138 Engine and setting data..................................................................................................138 Tools....................................................................................................................140 Workshop manual TD_TCD 3.6 L4 Stage IV & V _ 2018/07 en.........................................................................145 Table of contents............................................................................................................147 General......................................................................................................................150 Safety informatin / User information.........................................................................................151 Special tools................................................................................................................158 Job cards....................................................................................................................173 01 Crankcase/Front cover.................................................................................................173 W 01-00-01 Check crankcase pressure..................................................................................173 W 01-02-0 1Replacing the crankshaft sealing ring (flywheel side).....................................................178 W 01-03-01 Removing and installing the gasket housing................................................................181 W 01-07-05 Removing and installing the transfer line.................................................................184 W 01-90-01 Sealing parts (Crankcase).................................................................................187 W 01-90-23 Oil measuring device......................................................................................188 W 01-90-32 Line (crankcase breather).................................................................................189 W 01-90-63 Oil pressure control valve (gate valve)...................................................................190 02 Oil pan...............................................................................................................191 W 02-01-01Removing and installing the lubricating oil pan............................................................191 W 02-90-01Sealing parts..............................................................................................197 W 02-90-24 Oil filling...............................................................................................198 05 Crankshaft/Torsional vibration damper.................................................................................199 W 05-01-01 Removing and installing the V-belt pulley / V-ribbed pulley...............................................199 W 05-03-01 Removing and installing the flywheel(fastening parts).....................................................210 W 05-90-13 V-belt pulley.............................................................................................212 08 Cylinder head.........................................................................................................213 W O8-00-01 Checking the compression pressure (when injectors are removed)............................................213 W O8-01-01 Removing and installing the cylinder head cover...........................................................219 09 Gear case/Gear drive..................................................................................................222 W 09-01-01 Replacing the crankshaft sealing ring (opposite side to flywheel).........................................222 W 09-17-01 Removing and _installing the control valve................................................................225 15 Lubricating oil cooler/Lubricating oil filter.........................................................................228 W 15-02-01Removing and installing the lubricating oil cooler.........................................................228 W 15-90-38 Lubricating oil filter installation (Crankcase)...........................................................230 16 Lubricating oil pipe..................................................................................................231 W 16-01-01 Removing and installing the oil suction pipe..............................................................231 W 16-04-01 Removing and installing the lubricating oil line (Exhaust turbocharger)...................................233 W 16-05-01 Removing and installing the lubricating oil return line (upper partial section) (Exhaust turbocharger)....236 W 16-05-02 Removing and installing the lubricating oil return line (lower partial section) (Exhaust turbocharger)....239 17 Injection pump/High pressure pump.....................................................................................243 W 17-01-04 Removing and installing the high-pressure pump............................................................243 9 Fuelinjector/Injector..................................................................................................250 W 19-01-01 Removing and installing the injector......................................................................250 20 Fuel filter/Fuel pump.................................................................................................257 W 20-90-16 Fuel pre-filter...........................................................................................257 W 20-90-17 Fuel filter...............................................................................................259 W 20-90-20 Pressure s:ensor installation (fuel pressure).............................................................261 W 20-90-40 Level sensor (fuel pre-filter)............................................................................263 W 20-90-47 Fuel supply pump (electric)...............................................................................264 21 Fuel pipes............................................................................................................266 W 21-04-01 Removing and installing the rail..........................................................................266 W 21-04-03 Removing and installing the pressure relief valve (Rail)..................................................272 W 21-04-05 Removing and installing the rail pressure sensor..........................................................276 W 21-05-05 Removing and installing the fuel line (injector, rail, high-pressure pump)................................279 22 Air filter/Suction pipe/Charge air line...............................................................................284 W 22-01-01 Removing and installing the charge air line...............................................................284 W 22-13-01 Removing and installing pressure/temperature sensor (Charge air)..........................................286 W 22-90-89 Throttle valve............................................................................................288 37 Coolant pump..........................................................................................................289 W 37-03-01 Removing and installing the coolant pump..................................................................289 W 37-90-13 V-belt pulley (fastening parts, coolant pump).............................................................293 38 Coolant pipes/Thermostat housing......................................................................................294 W 38-01-01 Removing and installing the thermostat....................................................................294 W 38-01-02 Checking the thermostat (when removed)....................................................................297 W 38-90-32 Coolant line (Cooler - coolant pump)......................................................................299 W 38-90-32 Hose line (Thermostat housing - crankcase)................................................................300 41 Exhaust pipe/Exhaust gas recirculation................................................................................302 W 41-01-01 Removing and installing the exhaust pipe..................................................................302 W 41-05-01 Removing and installing the flutter valve.................................................................304 W 41-05-02 Removing and installing the cooler........................................................................307 W 41-05-03 Removing and installing exhaust gas recirculation valve...................................................311 W 41-05-10 Removing and installing the Venturi tube..................................................................317 W 41-90-02 Locking screw (Coolant pipe, cooler- thermostat housing)..................................................321 W 41-90-21 Compensator installation (Exhaust line)...................................................................322 W 41-90-32 Coolant line (Cooler - Crankcase).........................................................................324 W 41-90-32 Coolant line (Thermostat housing - cooler)................................................................325 43 Exhaust gas turbocharger..............................................................................................327 W 43-01-01Removing and installing the exhaust gas turbocharger.......................................................327 44 Generator/Starter.....................................................................................................330 W 44-02-01 Removing and installing the generator (Clamping latch)....................................................330 W 44-02-06 Removing and installing the console (Generator)...........................................................333 W 44-03-01 Removing and installing the starter.......................................................................335 W 44-90-07 Cover cap (Generator).....................................................................................337 W 44-90-42 Generator.................................................................................................338 48 Electric..............................................................................................................339 W 48-90-05 Fastening parts (Cable harness, transfer connector).......................................................339 W 48-90-10 Holder (glow plugs relay) (on charge air line)............................................................340 W 48-90-10 Holder (glow plugs relay) (on charge air line)............................................................341 W 48-90-19 Temperature sensor (Coolant)..............................................................................342 W 48-90-20 Pressure sensor installation (fuel pressure / lubricating oil pressure)...................................343 W 48-90-20 Relay (Heating flange, starter, glow plugs)...............................................................345 W 48-90-20 Relay, holder (Starter)...................................................................................346 W 48-90-20 Relay, holder (heating plugs).............................................................................347 W 48-90-68 Cable harness (fastening parts)...........................................................................348 W 48-90-88 Protective caps (Connection line, relay- starter).........................................................350 49 Tools/Special tools...................................................................................................351 W 49 -01-03 Check cooling system for leaks...........................................................................351 W 49 -02-01 Removing and installing turning gear/locking device......................................................354 51 Measuring instruments.................................................................................................356 W 51-90-20 Pressure sensor installation (lubricating oil pressure)...................................................356 W 51-90-20 Speed sensor (Camshaft)...................................................................................357 W 51-90-20 Speed sensor (Camshaft)...................................................................................358 52 Connection housing....................................................................................................359 W 52-01-01 Installing and removing the connection housing............................................................359 63 Start aid.............................................................................................................361 W 63-90-02 locking screw (heating plugs).............................................................................361 71 Exhaust gas treatment.................................................................................................362 W 71-05-04 Removing and installing the sensor (NOx)..................................................................362 W 71-05-05 Removing and installing the pressure sensor (Exhaust gas back pressure)...................................365 W 71-06-02 Removing and installing the metering unit SCR (Selective Catalytic Reduction).............................369 W 71-06-06 Flush the supply pump SCR (Selective Catalytic Reduction).................................................372 W 71-06-07 Flush/test metering unit SCR (Selective Catalytic Reduction)..............................................375 W 71-06-08 Flush the line (supply pump - metering unit) SCR (Selective Catalytic Reduction)..........................379 W 71-90-02 locking screw, SCR catalytic converter (NOx sensor).......................................................382 W 71-90-02 locking screw, diesel oxidation catalytic converter (Temperature sensor)..................................383 W 71-90-20 Temperature sensor (Air intake temperature, Ambient air temperature)......................................384 W 71-90-20 Temperature sensor (before SCR catalytic converter).......................................................385 W 71-90-20 Temperature sensor (before and after diesel oxidation catalyst)...........................................388 W 71-90-47 Supply pump SCR (Selective Catalytic Reduction)...........................................................391 W 71-90-80 Mixing pipe (Screw connection)............................................................................393 Bleeding the fuel system.........................................................................................................395 AdBlue – DEF Installation........................................................................................................397 04 Hydraulics........................................................................................................................407 Hydraulic circuit diagram - Standard.............................................................................................409 Hydraulic circuit diagram - Options..............................................................................................410 Hydraulic circuit diagram - High flow............................................................................................411 05 Setting Instructions..............................................................................................................413 General setting instructions.....................................................................................................415 Hydromatik tightening values.....................................................................................................417 Valve description - HDM19WL......................................................................................................419 Variable displacement pump A4VG085DA1............................................................................................421 Variable displacement motor A6VM115DA............................................................................................427 Travel hydraulics – setting instructions.........................................................................................431 06 Functional Description............................................................................................................439 Pilot control device 4TH6 with handle options....................................................................................441 07 Electrics.........................................................................................................................443 Cable colors overview............................................................................................................445 Vehicle electrics 0102-V02.......................................................................................................447 1 | 6437540001...............................................................................................................447 2 | 6437540002...........................................................................................................448 3 | 6437540003...........................................................................................................449 4 | 6437540004...........................................................................................................450 5 | 6437540005...........................................................................................................451 02 Schematic circuit diagram.................................................................................................452 10 | 6437541010..........................................................................................................452 11 | 6437541011..........................................................................................................453 12 | 6437541012..........................................................................................................454 13 | 6437541013..........................................................................................................455 14 | 6437541014..........................................................................................................456 15 | 6437541015..........................................................................................................457 16 | 6437541016..........................................................................................................458 17 | 6437541017..........................................................................................................459 18 | 6437541018..........................................................................................................460 19 | 6437541019..........................................................................................................461 20 | 6437541020..........................................................................................................462 21 | 6437541021..........................................................................................................463 22 | 6437541022..........................................................................................................464 23 | 6437541023..........................................................................................................465 24 | 6437541024..........................................................................................................466 25 | 6437541025..........................................................................................................467 26 | 6437541026..........................................................................................................468 27 | 6437541027..........................................................................................................469 28 | 6437541028..........................................................................................................470 29 | 6437541029..........................................................................................................471 30 | 6437541030..........................................................................................................472 31 | 6437541031..........................................................................................................473 32 | 6437541032..........................................................................................................474 33 | 6437541033..........................................................................................................475 34 | 6437541034..........................................................................................................476 35 | 6437541035..........................................................................................................477 36 | 6407041036..........................................................................................................478 03 Cable harness.............................................................................................................479 101 +1 | 6407043010......................................................................................................479 102 +3 | 6437543041......................................................................................................480 103 +3 | 6437543042......................................................................................................481 104 +3.1 | 6451245521....................................................................................................482 105 +3.4 | 6436241020....................................................................................................483 106 +3.5 | 6436242020....................................................................................................484 107 +3.9 | 6293042040....................................................................................................485 120 +3.10 | 6435847005...................................................................................................486 108 +6 | 6436042030......................................................................................................487 109 +6.1 | 6436268122....................................................................................................488 110 +6.2 | 6407284010....................................................................................................489 111 +7 | 6437542010......................................................................................................490 112 +7.1 | 6436267021....................................................................................................491 113 +7.2 | 6436268121....................................................................................................492 114 +7.3 | 6451327024....................................................................................................493 115 +7.4 | 6451327025....................................................................................................494 116 +7.5 | 6407266021....................................................................................................495 117 +7.6 | 6407042020....................................................................................................496 118 +7.7 | 6437507040....................................................................................................497 119 +7.9 | 6437611021....................................................................................................498 130 +5 | 6437544010......................................................................................................499 131 +5 | 6437544030......................................................................................................500 132 +5 | 6293044050......................................................................................................501 133 +5 | 6437544060......................................................................................................502 134 +5 | 6437544070......................................................................................................503 135 +5 | 6437544080......................................................................................................504 136 +5 | 6437544090......................................................................................................505 137 +5 | 5653246956......................................................................................................506 04 overview..................................................................................................................507 201 | 6437543048.........................................................................................................507 202 | 6437543044.........................................................................................................508 203 | 6437543045.........................................................................................................509 204 | 6437541011.........................................................................................................510 205 | 6437541012.........................................................................................................511 206 | 6437541013.........................................................................................................512 207 | 6437543050.........................................................................................................513 208 | 6437542013.........................................................................................................514 209 | 6407277021.........................................................................................................515 290 | 6437541010.........................................................................................................516 05 Documentation.............................................................................................................517 220 +3 | 64070xxxxx......................................................................................................517 221 +7...................................................................................................................518 Fuse assignment..................................................................................................................519 Relay assignment.................................................................................................................525 Diesel engine control unit structural diagram....................................................................................529 Fan control unit structural diagram..............................................................................................531 Electrical components structural diagram.........................................................................................533 Diagnostics and programming connection...........................................................................................534 08 Maintenance.......................................................................................................................535 Specification for fuels, lubricants, and coolants................................................................................537 Unbenannt........................................................................................................................541 09 Operation.........................................................................................................................545 Keypad operation.................................................................................................................547 Instructions for using the combo-tool (display)..................................................................................553 10 Options...........................................................................................................................619 Exhaust gas after-treatment system – diesel particle filter (DPF) replacement...................................................621 11 Repair Instructions...............................................................................................................629 Fitting hydraulic screw connections..............................................................................................631 Adhesive kit – cab windows.......................................................................................................643 Ride control system - "RCS"......................................................................................................645 12 Diagnosis / Tools.................................................................................................................653 Special tools - purchased parts..................................................................................................655 Diagnostic Messaging Specification...............................................................................................663 Error Codes: Dashboard - Software variants (V1 / V4).............................................................................685 SerDia 2010 - Diagnoses- and Error Codes SPN / FMI...............................................................................707 Diagnostics and programming port - purchased parts...............................................................................753 Home to List of Contents................................................................................................................. 2
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