Manitou Yanmar V65 Wheel Loader Service Manual – PDF DOWNLOAD
DESCRIPTION:
Manitou Yanmar V65 Wheel Loader Service Manual – PDF DOWNLOAD
Introduction / user notice :
The individual assemblies of the manufacturer machine program and the functions of and adjustments to the installed units are described in this service manual. The hydraulics and electrics diagrams and sectional representations combined with the operating instructions and spare parts list should make maintenance and repair work easier. Descriptions of work procedures and assembly steps were consciously omitted, because big repairs are generally performed by qualified and experienced workshop personnel, who are masters at this routine work.
- Safety and cleanliness at the workstation is the highest priority when performing repairs. Using tools in perfect condition and generally replacing sealing components during each repair should be a matter of course.
- Provided no special values are specified, screw connections are to be fastened with the usual tightening torques. This service manual has been issued by the customer service department with the aim of jointly improving the servicing of manufacturer machines. The service messages we send out for information can serve as a supplement. We keep this manual up to date with continuous additions.
- This document may be copied and transmitted to third parties neither wholly nor in excerpts without our consent. The division of the main groups can be seen in the table of contents. The accident prevention regulations of the responsible employer’s liability insurance association are to be strictly observed. Attentiveness when performing repairs is the best way of preventing accidents.
- We therefore recommend studying the relevant instructions concerning the intended repair in detail. Maintenance and repair work on machines in the field may only begin once the work equipment has been placed on the ground, the engine is turned off, the machine is secured against rolling away, and the hydraulic system has been relieved of pressure. If repair work is performed by qualified personnel in the workshop, the relevant accident prevention regulations apply here too.
Safety and accident prevention
1 Introductory remarks:
- Read the operating instructions thoroughly and follow the notes on safe operation before starting up the earth-moving machine. National safety regulations – e.g. the Accident Prevention Regulations, “Earth-Moving Machinery” (VBG 40) and “Vehicles” (VBG 12) in the Federal Republic of Germany – must also be complied with when operating the earth-moving machine.
- In addition to the operating instructions, legal regulations governing road safety and accident prevention measures must also be observed. Such requirements could also apply with respect to the handling of hazardous goods or the wearing of personal safety gear, for example. Furthermore, safety requirements governing work in particular locations (tunnels, adits, quarries, pontoons, contaminated areas, etc.) must likewise be observed.
2 Intended use :
The earth-moving machine with standard bucket equipment is intended solely for work which is suitable for the function of the machine and its work attachments. Such work involves loosening, taking up, transporting and dumping soil, rock, or other materials as well as loading these materials on trucks, conveyor belts, or other means of transport, when the transport of the material is normally done by positioning the earth-moving machine.
- The assembly of special work attachments – such as multi-purpose bucket, side-dump bucket, broom, fork lift attachment, etc. – makes corresponding applications possible. Any usage above and beyond that specified here – e.g. the transport of persons or the usage of the lift equipment as a work platform – is regarded as improper use. The supplier cannot be held responsible for any damage resulting from improper use.
- The risk is borne by the user alone. Strict compliance with the operating and maintenance instructions and the performance of maintenance work, as well as adherence to the maintenance intervals is also part of intended use.
TABLE OF CONTENTS:
Manitou Yanmar V65 Wheel Loader Service Manual – PDF DOWNLOAD
V65 - Cover - TL0065_1063 ► XXXX ........................................................................ 1 List of Contents..................................................................................... 2 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 Technische Daten................................................................................. 49 Drift values..................................................................................... 57 03 Diesel Engine..................................................................................... 59 Operation manual DEUTZ D/TD/TCD2011.............................................................. 61 Notes........................................................................................ 62 Foreword..................................................................................... 63 Contents..................................................................................... 64 General...................................................................................... 65 Engine description........................................................................... 67 Type..................................................................................... 67 Engine Illustrations..................................................................... 69 Lubricating oil schematic................................................................ 73 Fuel schematic........................................................................... 78 Coolant schematic........................................................................ 79 Exhaust gas recirculation................................................................ 81 Electrics/Electronics.................................................................... 83 Operation.................................................................................... 84 Ambient conditions....................................................................... 84 Initial commissioning.................................................................... 85 Start procedure.......................................................................... 87 Operation monitoring..................................................................... 88 Stop procedure........................................................................... 90 Operating media.............................................................................. 91 Lubricating oil ......................................................................... 91 Fuel..................................................................................... 93 Coolant.................................................................................. 94 Maintenance.................................................................................. 95 Maintenance schedule..................................................................... 95 Care and maintenance work.................................................................... 98 Lubricating oil system................................................................... 98 Fuel system..............................................................................100 Cooling system...........................................................................104 Engine cleaning..........................................................................106 Suction system...........................................................................107 Belt drives..............................................................................111 Electrical system........................................................................113 Faults.......................................................................................115 Fault table..............................................................................115 Engine management........................................................................120 Transport and storage........................................................................122 Transport ...............................................................................122 Protecting the engine against corrosion..................................................123 Technical data...............................................................................125 Engine and setting data..................................................................125 Tools....................................................................................130 Workshop manual DEUTZ D/TD/TCD 2011..............................................................135 Table of contents............................................................................137 1 Foreword...............................................................................139 2 General................................................................................143 3 User notes.............................................................................147 4 Technical data.........................................................................155 4.1Testing and setting data..........................................................155 4.2 Tightening specifications........................................................157 5 Job card overview......................................................................161 5.1Sorted alphabetically.............................................................161 5.2 Sorted numerically...............................................................165 6 Job cards..............................................................................169 Checking the compression pressure............................................................171 Mounting engine on assembly block and demounting.............................................177 Setting valve clearance......................................................................183 Removing and installing the rocker arm and rocker arm bracket................................189 Disassembling, assembling and checking the rocker arm and rocker arm bracket.................193 Removing and installing cylinder head........................................................199 Checking piston overhang.....................................................................207 Removing and installing the crankcase bleeding...............................................213 Removing and installing the exhaust line.....................................................217 Removing and install the charge air line.....................................................221 Removing and installing the turbocharger.....................................................225 Removing and installing the intake manifold..................................................233 Removing and installing the exhaust gas return valve.........................................237 Removing and installing the exhaust gas return pipe..........................................245 Removing and installing the exhaust gas collection pipe (Exhaust gas recirculationl..........253 Removing and installing the lifting magnet (Start amount release)............................259 Renewing the injection lines.................................................................263 Removing and installing the fuelinjectors....................................................267 Removing and installing the lifting magnet (charge air pressure-dependent full load stop)....273 Installing and removing charge air pressure-dependent full load stop.........................277 Removing and installing fuel pipes...........................................................281 Removing and installing the fuel filter console..............................................289 Removing and installing the fuel supply pump.................................................295 Removing and installing the lubricating oil cooler...........................................301 Removing and installing the oil filter console...............................................305 Removing and installing the oil pressure switch..............................................311 Removing and installing the thermostat (Lubricating oil cooler)..............................315 Removing and installing the control line.....................................................319 Removing and installing the coolant pump.....................................................323 Checking the thermostat (in the removed state)...............................................327 Removing and installing the thermostat.......................................................331 Removing and installing the thermostat housing...............................................335 Removing and installing temperature transmitter..............................................341 Removing and installing the lifting magnet (Engine shutdown).................................345 Removing and installing the V-belt pulley....................................................349 Renew V-belts, check V-belt tension..........................................................353 Removing and installing the flywheel.........................................................361 Removing and installing the hydraulic pump...................................................365 Removing and installing the generator........................................................369 Removing and installing the starter..........................................................373 Removing and installing the heating plugs....................................................377 Removing and installing the glow plug........................................................381 7 Standard tools.............................................................................385 8 Special tools .............................................................................393 04 Hydraulics........................................................................................401 Hydraulic circuit diagram: Parallel-Kinematic Standard ..........................................403 Hydraulic circuit diagram:Z-Kinematic Standard...................................................404 Hydraulic circuit diagram: Parallel-Kinematic – Additional circuit and options...................405 Hydraulic circuit diagram: Z-Kinematic – Additional circuit and options..........................406 05 Setting Instructions..............................................................................407 General setting instructions.....................................................................409 Hydromatik tightening values.....................................................................411 Travel hydraulics – setting instructions.........................................................413 Valve description HDM19WL........................................................................429 Service- and parking brake.......................................................................431 06 Functional Description............................................................................445 Saug - Rücklauffilter............................................................................447 Vorsteuergerät 4TH6..............................................................................449 07 Electrics.........................................................................................451 Kabel- und Stecker Farben........................................................................453 Verknüpfungen in Elektoschaltplänen lesen........................................................455 Verknüpfungen am Steuermodul und Display.........................................................456 Stromlaufplan Blatt 1............................................................................457 Stromlaufplan Blatt 2............................................................................458 Stromlaufplan Blatt 3............................................................................459 Stromlaufplan Blatt 4............................................................................460 Stromlaufplan Blatt 5............................................................................461 Stromlaufplan Blatt 6............................................................................462 Stromlaufplan Blatt 7............................................................................463 Sicherungs- und Relaisbelegung...................................................................464 08 Maintenance.......................................................................................465 Betriebsstoffspezifikation.......................................................................467 Inspektionsplan..................................................................................471 09 Operation.........................................................................................475 Betätigung proportional - 3. Hydrauliksteuerkreis................................................477 10 Options...........................................................................................481 Steuerblock - Lastschwingungsdämpfung............................................................483 11 Repair Instructions...............................................................................485 Fitting hydraulic screw connections..............................................................487 Adhesive kit – cab windows.......................................................................499 12 Diagnosis / Tools.................................................................................501 Special tools - purchased parts..................................................................503 Beschreibung der BDE-Software....................................................................511 Home to List of Contents................................................................................. 2
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