All 754 pages of this Yanmar V120 Service Manual zero in on one machine: the V120 Wheel Loader, covering everything from TD/TCD 3.6L4 Stage IV & V engine workshop procedures to hydraulic circuits and full electrical diagnostics. Inside you get hydraulic circuit diagrams for Standard, Options, and High Flow configurations, complete wiring schematics with fuse assignments, relay assignments, and connector pinouts that trace every circuit in the machine. Open the Diagnosis section and you'll find a complete error code library for Dashboard software variants V1 and V4, SerDia 2010 SPN/FMI fault tables, and setting instructions for the A4VG085DA1 variable displacement pump and A6VM115DA motor. Set the oil drain plug to 55 Nm, then walk the V-belt tightening sequence at 30-42-30 Nm: exact, factory-verified numbers. Your machine is down. Pull up the PDF on your tablet, bookmarked and searchable, and get back to work.
What's Inside This Yanmar V120 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 3-46 | Introduction / User Notice, Safety and Accident Prevention, Symbol and Hazard Descriptions, Tightening Torques for Pistons or Piston Nuts, Tightening Torques for Guide Bushings |
| Technical Data | 47-56 | Drift Values |
| Engine | 57-406 | Operating Manual Td - Tcd 3.6L4 Eu Stage Iv & V _ 06/2018 En, Workshop Manual TD_TCD 3.6 L4 Stage Iv & V _ 2018/07 En, Bleeding the Fuel System, AdBlue – DEF Installation |
| Hydraulics | 407-412 | Hydraulic Circuit Diagram - Standard, Hydraulic Circuit Diagram - Options, Hydraulic Circuit Diagram - High Flow |
| Setting Instructions | 413-438 | Hydromatik Tightening Values, Valve Description - HDM19WL, Variable Displacement Pump A4VG085DA1, Variable Displacement Motor A6VM115DA, Travel Hydraulics – Setting Instructions |
| Functional Description | 439-442 | Pilot Control Device 4TH6 with Handle Options |
| Electrics | 443-534 | Cable Colors Overview, Vehicle Electrics 0102-V02, Fuse Assignment, Relay Assignment, Diesel Engine Control Unit Structural Diagram, Fan Control Unit Structural Diagram |
| Maintenance | 535-544 | Specification for Fuels, Lubricants, And Coolants, Unbenannt |
| Operation | 545-618 | Keypad Operation, Instructions for Using the Combo-Tool |
| Options | 619-628 | Exhaust Gas After-Treatment System – Diesel Particle Filter Replacement |
| Repair Instructions | 629-652 | Fitting Hydraulic Screw Connections, Adhesive Kit – Cab Windows, Ride Control System - "Rcs" |
| Diagnosis / Tools | 653-754 | Special Tools - Purchased Parts, Diagnostic Messaging Specification, Error Codes: Dashboard - Software Variants, SerDia 2010 - Diagnoses- and Error Codes Spn / Fmi |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for lubricating oil drain plug | 55 Nm | p. 112 |
| Tightening torque for V-belt (Screw 1) | 30 Nm | p. 122 |
| Tightening torque for starter mounting screws | 42.5 Nm | p. 336 |
| Starter power | 12 V / 3.2 kW | p. 50 |
| Tightening torque for relay (Heating flange, starter, glow plugs) hexagon nut | 4.5 - 5.5 Nm | p. 345 |
| Tightening torque for relay holder (Starter) hexagon head screw | 13 Nm | p. 420 |
| Fuse for ignition lock | 7.5 A | p. 522 |
| Ground strap size | 50mm², 300mm, M10 | p. 506 |
| Battery cable size (positive terminal) | M10 70 mm² | p. 499 |
| Battery cable size (negative terminal) | 70mm² | p. 502 |
| Measuring hoses (mini measurement) lengths | 2000 mm, 3200 mm, 5000 mm, 6000 mm | p. 35 |
| Tightening torque for DKO hose fittings (M12 x 1.5) | 18 Nm | p. 420 |
Yanmar V120 Common Problems This Manual Covers
Yanmar V120 wheel loader cranks but won't start unless starter solenoid is jumped, key does nothing p. 443
Check the 7.5 A ignition lock fuse (page 522) first. Verify all ground connections: the main ground strap is 50mm², 300mm, M10 (page 506) and positive battery cable is 70mm² M10 (page 499). If fuse and grounds are good, test the starter relay and solenoid circuit before replacing components. Torque starter mounting screws to 42.5 Nm (page 336).
Manual Section: ElectricsHydrostatic drive feels weak or loader refuses to move when pushing into material under load p. 413
Check hydraulic fluid level and condition first; contaminated fluid is the most common cause of premature pump wear. Measure main relief valve pressure at high idle with oil temperature at 60°C: spec is 260 +5 max. bar (page 52). For travel circuit calibration, consult the Setting Instructions section (page 413) for variable displacement pump and motor adjustment procedures.
Manual Section: Setting InstructionsEngine shuts down unexpectedly mid-shift or won't restart after key-on, battery and grounds test good
Check the combo-tool for active fault codes before pulling any connectors. Inspect the relay assignment chart in the Electrics section (page 443) for the control circuit relay. Verify the ignition lock fuse reads 7.5 A and is seated (page 522). Probe harness connectors for intermittent opens; wiggling wires while cranking often isolates the fault faster than swapping parts.
Manual Section: OperationActive error codes on the display panel with no clear description of what system or sensor failed
Inspect the error code tables to identify your DTC format: ACTIA, dashboard software variant, or SerDia 2010. Confirm battery is 12 V / 100 Ah (page 50) before chasing electrical codes. Match FMI to fault type first: open circuit, range violation, and plausibility failure each require a different test path.
Manual Section: Diagnosis / ToolsHydraulic hose connections leaking after replacement, fittings won't seal even with new O-rings installed p. 629
Inspect the pipe end for burrs, scratches, or deformation before assembly. Follow fitting procedures in Repair Instructions (page 629): clean the sealing cone, seat the O-ring dry, hand-tighten before torquing. DKO hose fittings (M12 x 1.5) torque to 18 Nm (page 420); seal-lock flange nuts (M6) torque to 10 Nm (page 418). Never re-use a deformed olive.
Manual Section: Repair InstructionsFrequently Asked Questions
How to reset the YANMAR V120 error code?
For general error codes, rectifying the issue and switching off the ignition for 30 seconds may clear the diagnostics lamp. For specific issues like DPF soot and ash content, the data stored in the ECU must be reset using the service tool (SERDIA).
How to reset the DPF regeneration on a YANMAR V120?
If the DPF is overloaded to an impermissible level, regeneration can only be performed via DEUTZ service. After replacing the DPF filter, the soot and ash content stored in the ECU must be reset using the service tool (SERDIA).
How to clear fault codes on a YANMAR V120 wheel loader?
For general fault codes, rectifying the issue and switching off the ignition for 30 seconds may clear the diagnostics lamp. For specific issues like DPF soot and ash content, the data stored in the ECU must be reset using the service tool (SERDIA).
What are the hydraulic pressure settings for a YANMAR V120?
Key hydraulic pressure settings include: Steering pressure (high idle) at 175 +3-5 bar, Shock valves at 240 bar each, High pressure (relief valve) at 500 bar, and Main relief valve (high idle, 60°C) at max. 260 +5 bar. Secondary pressures for raising/tilting the lifting frame backward are 280 +10 bar, while for tilting forward it is 130 +10 bar. Pilot pressure (supply pressure) is 30 ±1 bar.
What do I get after purchasing this Yanmar V120 manual?
Immediate download of the complete 754-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Am I able to print pages from this manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
Are there wiring harness diagrams in this Yanmar V120 manual?
Yes. You'll find full electrical schematics with wire routing diagrams, connector identification, and circuit descriptions.
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