YANMAR V80 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
YANMAR V80 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD:
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YANMAR V80 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOADYANMAR V80 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
DESCRIPTION:
YANMAR V80 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 V80 WHEEL LOADER SERVICE WORKSHOP MANUAL – PDF DOWNLOAD
V80 _ 0103 ► XXXX Cover 01/25/2019............................................................................................................. 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 Diesel Engine........................................................................................................................... 57
Operating manual D_TD_TCD 2.9 L4 - 12_2018............................................................................................. 59
Notes.............................................................................................................................. 60
Foreword........................................................................................................................... 63
Table of contents.................................................................................................................. 65
General............................................................................................................................ 66
Engine description................................................................................................................. 68
Model.......................................................................................................................... 68
Engine illustration............................................................................................................ 72
Lubricating oil plan........................................................................................................... 80
Fuel system plan............................................................................................................... 81
Coolant plan................................................................................................................... 82
Exhaust gas recirculation...................................................................................................... 83
Exhaust gas aftertreatment..................................................................................................... 85
Electrics/Electronics.......................................................................................................... 88
Operation.......................................................................................................................... 90
Ambient conditions............................................................................................................. 90
Initial commissioning.......................................................................................................... 92
Start process.................................................................................................................. 95
Operation monitoring........................................................................................................... 96
Exhaust gas aftertreatment system..............................................................................................100
Regeneration Stage V / Tier 4..................................................................................................105
Regeneration Stage IIIA, IIIB and Tier 4i, 4...................................................................................108
Stopping process...............................................................................................................111
Operating media....................................................................................................................112
Lubricating oil................................................................................................................112
Fuel...........................................................................................................................115
Coolant........................................................................................................................116
SCR reduction agent............................................................................................................119
Maintenance........................................................................................................................120
Maintenance schedule...........................................................................................................120
Service and maintenance work.......................................................................................................123
Lubricating oil system.........................................................................................................123
Fuel system....................................................................................................................126
SCR (Selective Catalytic Reduction)............................................................................................129
Cooling system.................................................................................................................130
Engine cleaning................................................................................................................132
Suction system.................................................................................................................133
Belt drives....................................................................................................................135
Electrical system..............................................................................................................137
Faults.............................................................................................................................138
Fault table....................................................................................................................138
Engine management..............................................................................................................144
Transport and storage..............................................................................................................146
Transport......................................................................................................................146
Engine corrosion protection....................................................................................................147
Technical data.....................................................................................................................150
Engine and setting data........................................................................................................150
Tools..........................................................................................................................152
Workshop Manual TCD 2.9 L4Tier 4 - 2018_09_08..........................................................................................157
Table of contents..................................................................................................................159
General............................................................................................................................162
Safety informatin / User information...............................................................................................163
Special tools......................................................................................................................170
Job cards..........................................................................................................................183
01 Crankcase / front cover.....................................................................................................183
W 01-00-01 Check crankcase pressure........................................................................................183
W 01-17-01 Removing and installing the controlvalve........................................................................188
W 01-90-01 Sealing parts (crankcase,oilfiller neck)........................................................................191
W 01-90-23 Oilmeasuring device.............................................................................................192
W 01-90-32 Line (crankcase breather).......................................................................................193
02 Oilpan......................................................................................................................195
W 02-01-01 Removing and installing the lubricating oilpan..................................................................195
05 Crankshaft/Torsionalvibration damper........................................................................................201
W 05-02-03 Removing and installing the drive flange........................................................................201
W 05-03-01 Removing and installing the flywheel(f astening parts)..........................................................208
W 05-90-05 Fastening parts (Pulley - drive flange).........................................................................210
08 Cylinder head...............................................................................................................211
W 08-00-01 Checking the compression pressure (when injectors are removed)..................................................211
W 08-01-01Removing and installing the cylinder head cover..................................................................217
09 Gear case / Gear drive......................................................................................................219
W 09-01-01Replacing the crankshaft sealing ring (flywheelside).............................................................219
W 09-02-03 Removing and installing the sealing cover.......................................................................222
W 09-03-01Removing and fitting the front cover (f astening parts)..........................................................224
W 09-04-01Replacing the crankshaft sealing ring (opposite side to flywheel)................................................228
W 09-90-63 Oilpressure controlvalve........................................................................................231
15 Lubricating oilcooler / Lubricating oilfilter...............................................................................232
W 15-02-01Removing and installing the lubricating oilcooler................................................................232
W 15-90-38 Lubricating oilfilter installation..............................................................................234
16 Lubricating oilpipe.........................................................................................................235
W 16-01-01Removing and installing the oilsuction pipe......................................................................235
17 lnjection pump/High pressure pump...........................................................................................237
W 17-01-04 Removing and installing the high-pressure pump..................................................................237
19 Fuelinjector / ]njector.....................................................................................................245
W 19-01-01Removing and installing the injector.............................................................................245
20 Fuelfilter / Fuelpump.......................................................................................................252
W 20-90-16 Fuelpre-filter..................................................................................................252
W 20-90-17 Fuelfilter......................................................................................................254
W 20-90-20 Pressure sensor installation (fuelpressure).....................................................................256
W 20-90-40 Levelsensor (f uelpre-filter)...................................................................................258
W 20-90-47 Fuelsupplv pump (electric)......................................................................................259
21 Fuel pipes..................................................................................................................261
W 21-04-01 Removing and installing the rail................................................................................261
W 21-04-03 Removing and installing the pressure relief valve (Rail)........................................................266
W 21-04-05 Removing and installing the railpressure sensor.................................................................270
W 21-05-05 Removing and installing the fuelline (injector,rail,high-pressure pump)........................................273
W 21-90-30 Fuelline (Quick coupling).......................................................................................278
22 Air filter / Suction pipe / Charge air line.................................................................................280
W 22-01-01 Removing and installing the charge air line.....................................................................280
W 22-90-35Intake nozzle (Exhaust turbocharger).............................................................................284
W 22-90-54 Charge air manifold.............................................................................................285
37 Coolant pump................................................................................................................286
W 37-03-01 Removing and installing the coolant pump........................................................................286
W 37-90-13 V-belt pulley (f astening parts,coolant pump)...................................................................290
38 Coolant pipes / Thermostat housing..........................................................................................291
W 38-01-01 Removing and installing the thermostat..........................................................................291
W 38-01-02 Checking the thermostat (when removed)..........................................................................294
41 Exhaust pipe / Exhaust gas recirculation....................................................................................296
W 41-01-01 Removing and installing the exhaust pipe........................................................................296
W 41-05-01 Removing and installing the flutter valve.......................................................................298
W 41-05-02 Removing and installing the exhaust gas recirculation module....................................................302
W 41-05-03 a Removing and installing exhaust gas recirculation valve.......................................................306
W 41-05-03 b Removing and installing exhaust gas recirculation valve.......................................................311
43 Exhaust gas turbocharger....................................................................................................312
W 43-01-01Removing and installing the exhaust gas turbocharger.............................................................312
W 43-04-01 Removing and installing the lubricating oil line (Exhaust turbocharger).........................................315
W 43-05-01 Removing and installing the lubricating oil return line (upper partial section) (Exhaust turbocharger)..........319
W 43-05-02 Removing and installing the lubricating oil return line (lower partial se tion) (Exhaust turbocharger)..........322
44 Generator / Starter.........................................................................................................326
W 44-02-01 Removing and installing the generator...........................................................................326
W 44-90-42 Generator.......................................................................................................329
W 44-90-90 Starter.........................................................................................................330
48 Electric....................................................................................................................331
W 48-90-05 Fastening parts (Cable harness, transfer connector, crankcase)..................................................331
W 48-90-20 Pressure sensor installation (f uel pressure/ lubricating oil pressure).........................................332
W 48-90-68 Cable harness ..................................................................................................334
49 Tools/Special tools.........................................................................................................335
W 49-01-03 Check cooling system for leaks..................................................................................335
W 49-02-01Removing and installing turning gear/locking device..............................................................338
51 Measuring instruments.......................................................................................................340
W 51-02-01 Removing and installing the speed sensor (Crankshaft)...........................................................340
W 51-02-03 Removing and installing the speed sensor (Camshaft).............................................................342
W 51-08-01 a Removing and installing pressure/temperature sensor (Charge air)..............................................344
W 51-08-01 b Removing and installing pressure/temperature sensor (Charge air)..............................................346
W 51-09-01 Removing and installing the temperature sensor (Charge air).....................................................350
W 51-90-20 Pressure sensor installation (Lubrication oil pressure).........................................................353
W 51-90-20 Temperature sensor (Coolant) ...................................................................................354
52 Connection housing..........................................................................................................355
W 52-01-01Installing and removing the connection housing...................................................................355
71 Exhaust gas treatment.......................................................................................................357
W 71-10-01 Order of assembly (lnstalling catalyst) DOC (Diesel Oxidation Catalyst), SCR (Selective Catalytic Reduction)....357
W 71-90-09 Holder (Module size 13")........................................................................................363
W 71-90-09 Holder (Module size 5.66")......................................................................................364
W 71-90-09 Holder (Module size 8.5").......................................................................................365
W 71-90-09 Holder (Module size 9.5").......................................................................................366
Bleeding the fuel system...............................................................................................................367
04 Hydraulics..............................................................................................................................369
Hydraulic circuit diagram: Parallel-Kinematic Standard.................................................................................371
Hydraulic circuit diagram: Z-Kinematic Standard........................................................................................372
Hydraulic circuit diagram: Parallel-Kinematic – Additional circuit and Options.........................................................373
Hydraulic circuit diagram: Z-Kinematic – Additional circuit and Options................................................................374
Hydraulic circuit diagram: Parallel-Kinematic – 4th control circuit with high flow.....................................................375
Hydraulic circuit diagram: Z-Kinematic – 4th control circuit with high flow............................................................376
05 Setting Instructions....................................................................................................................377
General setting instructions..........................................................................................................379
Hydromatik tightening values...........................................................................................................381
HDM19WL valve description..............................................................................................................383
Displacement pump – A4VG045DA1.........................................................................................................385
Displacement motor – A6VM DA...........................................................................................................391
Travel hydraulics – setting instructions...............................................................................................395
06 Functional Description..................................................................................................................403
Pilot control device 4TH6 with handle options..........................................................................................405
07 Electrics...............................................................................................................................407
Cable colors overview..................................................................................................................409
07 26 11 Vehicle electrics project-TL80-100 CRT_103.pdf................................................................................411
01 Cover sheet.....................................................................................................................411
1 | 6436040501.................................................................................................................411
2 | 6436040502.................................................................................................................412
3 | 6436040503.................................................................................................................413
4 | 6436040504.................................................................................................................414
5 | 6436040505.................................................................................................................415
02 Schematic circuit diagram.......................................................................................................416
10 | 6436041510................................................................................................................416
11 | 6436041511................................................................................................................417
12 | 6436041512................................................................................................................418
13 | 6436041513................................................................................................................419
14 | 6436041514................................................................................................................420
15 | 6436041515................................................................................................................421
16 | 6436041516................................................................................................................422
17 | 6436041517................................................................................................................423
18 | 6436041518................................................................................................................424
19 | 6436041519................................................................................................................425
20 | 6436041520................................................................................................................426
21 | 6436041521................................................................................................................427
22 | 6436041522................................................................................................................428
23 | 6436041523................................................................................................................429
24 | 6436041524................................................................................................................430
25 | 6436041525................................................................................................................431
26 | 6436041526................................................................................................................432
27 | 6436041527................................................................................................................433
28 | 6436041528................................................................................................................434
29 | 6436041529................................................................................................................435
30 | 6436041530................................................................................................................436
31 | 6436041531................................................................................................................437
32 | 6436041532................................................................................................................438
33 | 6436041534................................................................................................................439
03 Cable harness...................................................................................................................440
101 +1 | 6407043010............................................................................................................440
102 +3 | 6437543041............................................................................................................441
103 +3 | 6437543042............................................................................................................442
104 +3.1 | 6451245521..........................................................................................................443
105 +3.4 | 6436241020..........................................................................................................444
106 +3.5 | 6436242020..........................................................................................................445
107 +3.9 | 6293042040..........................................................................................................446
108 +6 | 6436042030............................................................................................................447
109 +6.1 | 6436268122..........................................................................................................448
110 +6.2 | 6407284010..........................................................................................................449
111 +7 | 6406149011............................................................................................................450
112 +7.1 | 6436267021..........................................................................................................451
113 +7.2 | 6436268121..........................................................................................................452
114 +7.3 | 6451327024..........................................................................................................453
115 +7.4 | 6451327025..........................................................................................................454
116 +7.5 | 6407266021..........................................................................................................455
117 +7.11 | 6436111120.........................................................................................................456
130 +5 | 6436044010............................................................................................................457
131 +5 | 6436044030............................................................................................................458
132 +5 | 6436044040............................................................................................................459
133 +5 | 6436044060............................................................................................................460
134 +5 | 6436044070............................................................................................................461
135 +5 | 6436044080............................................................................................................462
136 +5 | 5653246956............................................................................................................463
04 overview........................................................................................................................464
201 | 6437543048...............................................................................................................464
202 | 6437543044...............................................................................................................465
203 | 6437543045...............................................................................................................466
204 | 6437541011...............................................................................................................467
205 | 6437541012...............................................................................................................468
206 | 6437541013...............................................................................................................469
207 | 6407043091...............................................................................................................470
208 | 6436149011...............................................................................................................471
209 | 6436149012...............................................................................................................472
210 | 6407277021...............................................................................................................473
290 | 6437541010...............................................................................................................474
05 Documentation...................................................................................................................475
220 +3 | 64070xxxxx............................................................................................................475
221 +7.........................................................................................................................476
07 26 15 Vehicle electrics project-TL80-100 DOC_103.pdf................................................................................477
01 Cover sheet.....................................................................................................................477
1 | 6436040001.................................................................................................................477
2 | 6436040002.................................................................................................................478
3 | 6436040003.................................................................................................................479
4 | 6436040004.................................................................................................................480
5 | 6436040005.................................................................................................................481
02 Schematic circuit diagram.......................................................................................................482
10 | 6436041010................................................................................................................482
11 | 6436041011................................................................................................................483
12 | 6436041012................................................................................................................484
13 | 6436041013................................................................................................................485
14 | 6436041014................................................................................................................486
15 | 6436041015................................................................................................................487
16 | 6436041016................................................................................................................488
17 | 6436041017................................................................................................................489
18 | 6436041018................................................................................................................490
19 | 6436041019................................................................................................................491
20 | 6436041020................................................................................................................492
21 | 6436041021................................................................................................................493
22 | 6436041022................................................................................................................494
23 | 6436041023................................................................................................................495
24 | 6436041024................................................................................................................496
25 | 6436041025................................................................................................................497
26 | 6436041026................................................................................................................498
27 | 6436041027................................................................................................................499
28 | 6436041028................................................................................................................500
29 | 6436041029................................................................................................................501
30 | 6436041030................................................................................................................502
31 | 6436041031................................................................................................................503
32 | 6436041032................................................................................................................504
03 Cable harness...................................................................................................................505
101 +1 | 6407043010............................................................................................................505
102 +3 | 6437543041............................................................................................................506
103 +3 | 6437543042............................................................................................................507
104 +3.1 | 6451245521..........................................................................................................508
105 +3.4 | 6436241020..........................................................................................................509
106 +3.5 | 6436242020..........................................................................................................510
107 +3.9 | 6293042040..........................................................................................................511
108 +6 | 6436042030............................................................................................................512
109 +6.1 | 6436268122..........................................................................................................513
110 +6.2 | 6407284010..........................................................................................................514
111 +7 | 6436042111............................................................................................................515
112 +7 | 6436042112............................................................................................................516
113 +7.1 | 6436267021..........................................................................................................517
114 +7.2 | 6436268121..........................................................................................................518
115 +7.3 | 6451327024..........................................................................................................519
116 +7.4 | 6451327025..........................................................................................................520
117 +7.5 | 6407266021..........................................................................................................521
118 +7.11 | 6436111120.........................................................................................................522
130 +5 | 6436044010............................................................................................................523
131 +5 | 6436044030............................................................................................................524
132 +5 | 6436044040............................................................................................................525
133 +5 | 6436044060............................................................................................................526
134 +5 | 6436044070............................................................................................................527
135 +5 | 6436044080............................................................................................................528
136 +5 | 5653246956............................................................................................................529
04 overview........................................................................................................................530
201 | 6437543048...............................................................................................................530
202 | 6437543044...............................................................................................................531
203 | 6437543045...............................................................................................................532
204 | 6437541011...............................................................................................................533
205 | 6437541012...............................................................................................................534
206 | 6437541013...............................................................................................................535
207 | 6407043091...............................................................................................................536
208 | 6436149011...............................................................................................................537
209 | 6436149012...............................................................................................................538
210 | 6407277021...............................................................................................................539
290 | 6437541010...............................................................................................................540
05 Documentation...................................................................................................................541
220 +3 | 64070xxxxx............................................................................................................541
221 +7.........................................................................................................................542
Fuse assignment........................................................................................................................543
Relay assignment.......................................................................................................................549
Diesel engine control unit structural diagram..........................................................................................553
Electrical components structural diagram...............................................................................................554
Electrical components structural diagram...............................................................................................555
08 Maintenance.............................................................................................................................557
Specification for fuels, lubricants, and coolants......................................................................................559
Inspection plan........................................................................................................................563
09 Operation...............................................................................................................................567
Keypad operation.......................................................................................................................569
Instructions for using the combo-tool (display)........................................................................................575
10 Options.................................................................................................................................635
Exhaust gas after-treatment system –
diesel particle filter (DPF) replacement.........................................................637
11 Repair Instructions.....................................................................................................................645
Fitting hydraulic screw connections....................................................................................................647
Adhesive kit – cab windows.............................................................................................................659
Ride control system - "RCS"............................................................................................................661
12 Diagnosis / Tools.......................................................................................................................669
Special tools - purchased parts........................................................................................................671
ACTIA - Diagnostic Messaging Specification.............................................................................................679
Error Codes: Dashboard - Software variants (V1 / V4)...................................................................................701
SerDia 2010 - Diagnoses- and Error Codes SPN / FMI.....................................................................................723
Diagnostics and programming port - purchased parts.....................................................................................769
Home to List of Contents................................................................................................................... 2
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