YANMAR V120 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
YANMAR V120 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD:
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YANMAR V120 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOADYANMAR V120 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
DESCRIPTION:
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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