Part of the Yanmar Repair Manuals.
The build plate on this machine starts at serial TC12540105, and that is exactly where this factory Yanmar service manual picks up. It is the workshop book Yanmar wrote for the SV120 2PB excavator, 858 pages that include the complete Deutz workshop manual for the TCD 3.6 L4f engine, not a summary of it.
That matters when the machine is down and there is no one standing next to you who knows the answer. Technical Data carries the relief pressures and cylinder drift limits you test against, Setting Instructions covers the travel drive and control valves, Electrics documents the wiring for this serial range, and Options walks through the DPF and SCR systems that put a machine into derate.
The PDF carries 236 bookmarks, so the route from download to the one procedure you need is a couple of clicks, whether you print a page for the bench or read it on a tablet beside the machine.
What's Inside This Yanmar SV120 2PB Manual
| System | Pages | Key Topics |
|---|---|---|
| SV120 2PB - Cover | 1 | Cover Page, Document Overview, Manual Identification |
| General | 3-44 | Foreword / User Instructions, Safety and Accident Prevention, Safety Signs, Tightening Torques of Pistons or Piston Nuts, Tightening Torques of Guide Bushings, Pictograms |
| Technical Data | 45-54 | Engine Type, Electrical System, Travel Drive, Working Hydraulics, Fluid Capacities, Drift Values |
| Engine | 55-556 | Operating Manual Td - Tcd 3.6L4, Workshop Manual Td / Tcd 3.6 L4 |
| Hydraulics | 557-562 | Variable Displacement Pump, Triple Gear Pump, Pilot-Operated Bloc, Control Valve, Hydraulic Cylinder, Rotary Transfer |
| Setting Instructions | 563-596 | General Setting Instructions, Hydromatik Tightening Values, Travel Drive Gft 17 T3, Control Valve SX14, Control Valve DPX100/5+1, Working Hydraulics |
| Function Description | 597-610 | Pilot Control Device 4TH5, Grip Options - Joystick, Pilot Control Unit 10989 |
| Electrics | 611-694 | Vehicle Electrics; Project: SCRT_V0.1.2 From Serial-NO.: TC12540105 to |
| Maintenance | 695-706 | Specification for Fuels, Lubricants and Coolants, Inspection Plan, Measurement Protocol |
| Operation | 707-744 | Keypad Operation, Engine Monitoring Icons, Machine Monitoring Icons, Menu Control, Submenu, Rear View Camera, Overload Warning |
| Options | 745-760 | Exhaust Gas After-Treatment System, Diesel Particle Filter (DPF) Replacement, Auto-Idling System, SCR System Warning Strategy, Power Reduction, Downtime Regeneration |
| Repair Instructions | 761 | Fitting Hydraulic Screw Connections, Adhesive Kit – Cab Windows, Principles of Pipe Connection Technology, Fitting Cutting Ring, Causes of Leaks |
| Operating manual TD - TCD 3.6L4 | 57-142 | Engine Start/Stop Procedures, Fuel System Operation, Coolant System, Engine Monitoring, Service Intervals |
| Hydraulics | 557-562 | - |
| Setting instructions | 563-596 | - |
| Function description | 597-610 | - |
| Electrics | 611-614 | - |
| Vehicle electrics; Project: SCRT_V0.1.2 from Serial-NO.: TC12540105 to | 615-777 | Wiring Diagrams, Electrical Schematics, Circuit Descriptions, Connector Locations, Fuse/Relay Layout |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| L6 (M12 x 1.5) hose line tightening torque | 18 Nm | p. 114 |
| Fuel pre-filter insert tightening torque | 17 Nm - 18 Nm | p. 114 |
| Engine oil filter tightening torque | 10 Nm - 12 Nm | p. 111 |
| Dry air filter replacement interval | Every 2 years | p. 109 |
| Coolant hose spring band clip tightening torque | 1.5 Nm | p. 772 |
| Working light, cab (optional) | H9_12V/65W | p. 48 |
| Engine output acc. to ISO 3046 | 85 kW | p. 47 |
| Rated engine speed | 2000 min⁻¹ | p. 47 |
| Boom cylinder (Mono) drift | 3.0 mm / min | p. 53 |
| Main pressure relief valve (Control valve 1 mono bloc boom) | 380 bar | p. 50 |
| Slewing pressure (valve on slewing motor) | 220 bar | p. 51 |
| Lube oil change volume (with filter) | 9 l | p. 137 |
Yanmar SV120 2PB Common Problems This Manual Covers
Boom drops with the controls centered
A boom or arm cylinder that creeps down under load usually means worn piston seals or a leaking holding circuit. The Hydraulics section covers the hydraulic cylinders, control valve, and variable displacement pump so you can trace where the oil is going before you pull anything apart.
Manual Section: Hydraulics p. 557DPF warnings and power reduction
The exhaust after-treatment on this machine will cut power and post warnings when regeneration is overdue or the SCR system flags a fault. The Options section explains the SCR warning strategy, power reduction stages, downtime regeneration, and DPF replacement.
Manual Section: Options p. 745Weak dig force on one circuit
When one function slows down while the rest of the machine works normally, the fix starts with pressure testing, not parts swapping. Setting Instructions gives the adjustment procedures for the working hydraulics, the SX14 and DPX100/5+1 control valves, and the GFT 17 T3 travel drive.
Manual Section: Setting Instructions p. 563Hard starting or water in fuel
Water collecting in the fuel pre-filter and neglected fuel system service are the usual reasons a Deutz-powered machine cranks but will not light off. The Engine section contains the full Deutz TD/TCD 3.6 L4 operating and workshop manuals, from routine filter service to fuel system repair.
Manual Section: Engine p. 55Warning icons and dead switches
An excavator that will not start, or lights up the display with faults, often comes down to wiring, fuses, or a switch rather than the component itself. The Electrics section documents the vehicle electrics specific to this serial range so you can follow the circuit instead of guessing.
Manual Section: Electrics p. 611Hydraulic fittings weep after service
A fitting that seeps after a hose change is usually an assembly problem, not a bad part. Repair Instructions covers fitting hydraulic screw connections, cutting ring installation, pipe connection principles, and the common causes of leaks.
Manual Section: Repair Instructions p. 761Engine runs hot under load
Overheating on a machine that works all day tends to trace back to coolant condition, plugged coolers, or missed inspection items. The Maintenance section sets out the coolant and lubricant specifications, the inspection plan, and a measurement protocol for tracking the machine's condition by the hour meter.
Manual Section: Maintenance p. 695Frequently Asked Questions
Which machines does this manual cover?
It covers the Yanmar SV120 2PB excavator with the Deutz TCD 3.6 L4f engine, for the serial number range TC12540105 to TC1254XXXX. Check the plate on your machine against that range before buying.
Does it include the Deutz engine workshop manual?
Yes. The Engine section runs from page 55 to 556 and contains both the Deutz TD/TCD 3.6 L4 operating manual and the full workshop manual, so engine service and repair are covered in the same PDF as the rest of the machine. p. 55
Are hydraulic pressure specs included?
Yes. The Technical Data section lists working hydraulics values including a main relief pressure of 380 bar on the boom mono bloc control valve, 220 bar slewing pressure at the slewing motor valve, and cylinder drift limits for testing. p. 45
Does it have wiring diagrams for the electrical system?
Yes. The Electrics section documents the vehicle electrics for machines from serial number TC12540105 onward, which is where to start when chasing display warnings, dead circuits, or starting problems that test out as electrical. p. 611
How will I receive this Service Manual?
You get a 858-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Are there any print restrictions on this manual?
There are no print restrictions. The PDF is DRM-free — print whatever sections you need for the shop. Standard letter or A4 paper works.
Are there hydraulic schematics in this Yanmar SV120 2PB manual?
Yes, this Yanmar SV120 2PB Service Manual includes hydraulic system diagrams, circuit schematics, and component specifications.
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