Yanmar V8 Wheel Loader Service Manual – PDF DOWNLOAD
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Yanmar V8 Wheel Loader Service Manual – PDF DOWNLOAD
- Correct work means the quickest possible completion of according to the correct procedures and the specified standards. It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions to watch out for.
- (1) Never attempt servicing while engine is running or immediately after stopping operation. (2) Wear work cloths, safety shoes and helmet. (3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools. (4) When working together with other persons, allocate everyone’s share of job, arrange the signals and act in concert with the other persons.
- (5) The operation of the crane and slinging work must be performed by qualified persons. (6) Do not enter or pass under the raised load. (7) Lift and support the massive parts by crane before removing the installation bolts. (8) Disconnect cables from battery before repairing the electric system. (9) Remove the battery when welding the machine.
- (1) Check the service record of the machine. (That is, check how many months or hours the machine has been used since the preceding overhaul, what was the trouble then and what parts were replaced.) (2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), containers, oil & grease, etc.
- (3) Have the service literature (operation manual, parts catalog, etc.) ready. (1) Clean the machine before disassembly. (2) Check and record the condition of the machine before disassembly : • Model, machine number, operation hours • Reasons for repair, history of repair •
- Contamination of filters • Fuel and oil condition • Damage to parts, etc. (3) Place alignment marks on the necessary parts to facilitate reassembly. (4) Clean all the removed parts and new replacement parts and put them in order. (5) Use new seals, split pins, etc. for reassembly.
TABLE OF CONTENTS:
Yanmar V8 Wheel Loader Service Manual – PDF DOWNLOAD
1-1 Correct Work ………………………………………………………………………………………………………………………………………………………1-1
1-2 Safety Precautions ………………………………………………………………………………………………………………………………………………1-1
1-3 Preparations……………………………………………………………………………………………………………………………………………………….1-1
1-4 Cautions for Disassembly and Reassembly…………………………………………………………………………………………………………….1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ………………………………………………………………………………….1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping…………………………………………………………………………………………1-2
1-7 Cautions for Handling Seals………………………………………………………………………………………………………………………………….1-3
1-8 Correct Installation of Hydraulic Hose…………………………………………………………………………………………………………………….1-3
1-9 Specifications of Hydraulic Hose……………………………………………………………………………………………………………………………1-6
1-10 Air Release of Hydraulic Equipment……………………………………………………………………………………………………………………..1-8
2-1 Specifications …………………………………………………………………………………………………………………………………………………. 2-1-1
2-2 Outline Drawing and Working Area……………………………………………………………………………………………………………………. 2-2-1
2-3 Lifting Capacity List …………………………………………………………………………………………………………………………………………. 2-3-1
2-4 Periodic Inspection and Servicing ……………………………………………………………………………………………………………………… 2-4-1
2-5 Fuel, Lube Oil and Grease Recommended…………………………………………………………………………………………………………. 2-5-1
2-6 Hydraulic Circuit Schematic ……………………………………………………………………………………………………………………………… 2-6-1
2-7 Electrical Diagram……………………………………………………………………………………………………………………………………………. 2-7-1
3-1 Machine Performance ……………………………………………………………………………………………………………………………………… 3-1-1
4-1 Safety ……………………………………………………………………………………………………………………………………………………………. 4-1-1
4-1-1 Safety Statements …………………………………………………………………………………………………………………………………… 4-1-1
4-1-2 Safety Precautions ………………………………………………………………………………………………………………………………….. 4-1-2
4-2 Engine …………………………………………………………………………………………………………………………………………………………… 4-2-1
4-2-1 Before You Begin Servicing ……………………………………………………………………………………………………………………… 4-2-1
4-2-2 Special Service Tools………………………………………………………………………………………………………………………………. 4-2-2
4-2-3 Measuring Instruments…………………………………………………………………………………………………………………………….. 4-2-4
4-2-4 Cylinder Head…………………………………………………………………………………………………………………………………………. 4-2-6
4-2-5 Measuring and Adjusting Valve Clearance ……………………………………………………………………………………………….. 4-2-20
4-2-6 Crankshaft and Camshaft Components ……………………………………………………………………………………………………. 4-2-23
4-3 Fuel System …………………………………………………………………………………………………………………………………………………… 4-3-1
4-3-1 Before You Begin Servicing ……………………………………………………………………………………………………………………… 4-3-1
4-3-2 Introduction…………………………………………………………………………………………………………………………………………….. 4-3-2
4-3-3 Special Service Tools……………………………………………………………………………………………………………………………….4-3-
4-3-4 Measuring Instruments……………………………………………………………………………………………………………………………..4-3-
4-3-5 Fuel System Diagram……………………………………………………………………………………………………………………………….4-3-
4-3-6 Fuel System Components…………………………………………………………………………………………………………………………4-3-
4-3- Fuel Injection Pump……………………………………………………………………………………………………………………………....4-3-
4-3- Checking and Adjusting Fuel Injection Timing……………………………………………………………………………………………4-3-
4-3- Fuel Injectors………………………………………………………………………………………………………………………………………4-3-
4-4 Cooling System………………………………………………………………………………………………………………………………………………. 4-4-1
4-4-1 Before You Begin Servicing ……………………………………………………………………………………………………………………… 4-4-1
4-4-2 Introduction…………………………………………………………………………………………………………………………………………….. 4-4-2
4-4-3 Cooling System Diagram………………………………………………………………………………………………………………………….. 4-4-2
4-4-4 Engine Coolant Pump Components …………………………………………………………………………………………………………… 4-4-3
4-4-5 Engine Coolant System Check………………………………………………………………………………………………………………….. 4-4-4
4-4-6 Engine Coolant Pump ……………………………………………………………………………………………………………………………… 4-4-4
4-5 Lubrication System………………………………………………………………………………………………………………………………………….. 4-5-1
4-5-1 Before You Begin Servicing ……………………………………………………………………………………………………………………… 4-5-1
4-5-2 Introduction…………………………………………………………………………………………………………………………………………….. 4-5-2
4-5-3 Lubrication System Diagram…………………………………………………………………………………………………………………….4-5-
4-5-4 Checking Engine Oil Pressure…………………………………………………………………………………………………………………4-5-
4-5-5 Trochoid Oil Pump…………………………………………………………………………………………………………………………………..4-5-
4-6 Starter Motor ………………………………………………………………………………………………………………………………………………….. 4-6-1
4-6-1 Before You Begin Servicing ……………………………………………………………………………………………………………………… 4-6-1
4-6-2 Introduction…………………………………………………………………………………………………………………………………………….. 4-6-2
4-6-3 Starter Motor Information …………………………………………………………………………………………………………………………. 4-6-2
4-6-4 Starter Motor Troubleshooting…………………………………………………………………………………………………………………… 4-6-3
4-6-5 Starter Motor Components ……………………………………………………………………………………………………………………….. 4-6-4
4-7 Alternator……………………………………………………………………………………………………………………………………………………….. 4-7-1
4-7-1 Before You Begin Servicing ……………………………………………………………………………………………………………………… 4-7-1
4-7-2 Introduction…………………………………………………………………………………………………………………………………………….. 4-7-2
4-7-3 Alternator Specifications…………………………………………………………………………………………………………………………… 4-7-2
4-7-4 Alternator Troubleshooting ……………………………………………………………………………………………………………………….. 4-7-3
4-7-5 Alternator Components ……………………………………………………………………………………………………………………………. 4-7-4
4-7-6 Alternator Wiring Diagram………………………………………………………………………………………………………………………… 4-7-5
4-7-7 Alternator Standard Output ………………………………………………………………………………………………………………………. 4-7-6
4-7-8 Alternator ……………………………………………………………………………………………………………………………………………….. 4-7-7
4-8 Electric Wiring ……………………………………………………………………………………………………………………………………………….. 4-8-1
4-8-1 Electric Wiring Precautions ……………………………………………………………………………………………………………………… 4-8-1
4-9 Troubleshooting ……………………………………………………………………………………………………………………………………………… 4-9-1
4-9-1 Special Service Tools………………………………………………………………………………………………………………………………. 4-9-1
4-9-2 Troubleshooting By Measuring Compression Pressure ………………………………………………………………………………… 4-9-2
4-9-3 Quick Reference Table For Troubleshooting ………………………………………………………………………………………………. 4-9-4
5-1 Electric Equipment of Machine………………………………………………………………………………………………………………………….. 5-1-1
5-1-1 Localisation of fuse and relays ………………………………………………………………………………………………………………….. 5-1-1
5-1-2 Identification of fuses……………………………………………………………………………………………………………………………….5-1-2
5-1-3 Identification of relays ………………………………………………………………………………………………………………………………. 5-1-3
5-1-4 Identification of connectors……………………………………………………………………………………………………………………….5-1-4
5-2 Electric diagram ………………………………………………………………………………………………………………………………………………. 5-2-1
5-2-1 Steering column ……………………………………………………………………………………………………………………………………… 5-2-1
5-2-2 Engine line……………………………………………………………………………………………………………………………………………..5-2-1
6-1 Hydraulic Circuit ……………………………………………………………………………………………………………………………………………… 6-1-1
6-1-1 Valve setting chart…………………………………………………………………………………………………………………………………..6-1-1
6-1-2 Pressure outlets………………………………………………………………………………………………………………………………………6-1-1
6-2 Circuit Operation …………………………………………………………………………………………………………………………………………….. 6-2-1
6-2-1 Loader …………………………………………………………………………………………………………………………………………………… 6-2-1
6-2-2 Steering …………………………………………………………………………………………………………………………………………………6-2-2
6-2-3 6-2-3 Loader quick-coupling (optional)……………………………………………………………………………………………………….6-2-3
6-3 Hydrostatic Transmission…………………………………………………………………………………………………………………………………6-3-1
6-3-1 Valve setting chart………………………………………………………………………………………………………………………………….6-3-1
6-3-2 Description of operation…………………………………………………………………………………………………………………………6-3-2
5-2-3 Cabine line …………………………………………………………………………………………………………………………………………….. 5-2-3
5-2-4 Electric system description………………………………………………………………………………………………………………………..5-2-4
6-3-3 Hydrostatic balancing ……………………………………………………………………………………………………………………………… 6-3-3
6-3-4 Hydrostatic pump …………………………………………………………………………………………………………………………………… 6-3-4
6-3-5 Working pressure control ………………………………………………………………………………………………………………………… 6-3-5
6-3-6 Pressure relief control valves …………………………………………………………………………………………………………………… 6-3-6
6-3-7 Towing procedure with hydrostatic moto …………………………………………………………………………………………………… 6-3-7
6-3-8 Overfeeding pressure control ………………………………………………………………………………………………………………….. 6-3-8
6-3-9 Idling adjustment ……………………………………………………………………………………………………………………………………. 6-3-8
6-3-10 Control valve operation and start point setting …………………………………………………………………………………………. 6-3-9
6-3-11 Control valve diagram …………………………………………………………………………………………………………………………. 6-3-10
6-3-12 Hydrostatic motor ……………………………………………………………………………………………………………………………….. 6-3-11
6-3-13 Checking the hydrostatic motor displacement change …………………………………………………………………………….. 6-3-12
6-4 Troubleshooting ……………………………………………………………………………………………………………………………………………… 6-4-1
6-4-1 Pump / Motor ………………………………………………………………………………………………………………………………………… 6-4-1
6-4-2 Equipment …………………………………………………………………………………………………………………………………………….. 6-4-2
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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