All 770 pages of this Yanmar V80 Wheel Loader Service Manual cover every system on your compact loader: the full embedded Deutz TCD 2.9 L4 workshop manual, travel hydraulics setting instructions, and a complete electrics section with cable colors, fuse assignments, and relay charts. You get hydraulic circuit diagrams for both Parallel-Kinematic and Z-Kinematic configurations, full vehicle wiring schematics, and a diagnosis section packed with SerDia 2010 SPN/FMI error codes. Inside the setting instructions: A4VG045DA1 displacement pump specs, A6VM DA motor calibration, and Hydromatik tightening values for the entire travel hydraulic system. Torque the M68x2 guide bushing on the 63mm cylinder to 290-335 Nm; M8 headless screws get 25 Nm. Your machine doesn't care about guesses. Bookmarked for instant navigation: pull it up on your tablet, jump to the schematic, and start turning wrenches.
What's Inside This Yanmar V80 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 |
| Diesel Engine | 57-368 | Operating Manual D_TD_TCD 2.9 L4 - 12_2018, Workshop Manual Tcd 2.9 L4Tier 4 - 2018_09_08, Bleeding the Fuel System |
| Hydraulics | 369-376 | Hydraulic Circuit Diagram: Parallel-Kinematic Standard, Hydraulic Circuit Diagram: Z-Kinematic Standard |
| Setting Instructions | 377-402 | Hydromatik Tightening Values, HDM19WL Valve Description, Displacement Pump – A4VG045DA1, Displacement Motor – A6VM Da, Travel Hydraulics – Setting Instructions |
| Functional Description | 403-406 | Pilot Control Device 4TH6 with Handle Options |
| Electrics | 407-556 | Cable Colors Overview, 26 11 Vehicle Electrics project-TL80-100 CRT_103.pdf, 26 15 Vehicle Electrics project-TL80-100 DOC_103.pdf, Fuse Assignment, Relay Assignment |
| Maintenance | 557-566 | Specification for Fuels, Lubricants, And Coolants, Inspection Plan |
| Operation | 567-634 | Keypad Operation, Instructions for Using the Combo-Tool |
| Options | 635-644 | Exhaust Gas After-Treatment System – Diesel Particle Filter Replacement |
| Repair Instructions | 645-668 | Fitting Hydraulic Screw Connections, Adhesive Kit – Cab Windows, Ride Control System - "Rcs" |
| Diagnosis / Tools | 669 | Special Tools - Purchased Parts, Actia - 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 hydraulic cylinder ∅ 63, thread M68x2 (guide bushing) | 290 - 335 Nm | p. 26 |
| Tightening torque for hydraulic cylinder ∅ 125, thread M130x2 (guide bushing) | 690 - 795 Nm | p. 26 |
| Hydraulic oil filter replacement interval | Every time the lubricating oil is changed | p. 121 |
| Fuel filter replacement interval (filter size 0.9 L) | E40 | p. 121 |
| Fuel pre-filter replacement interval | E40 | p. 121 |
| Maximum angle for sawing pipe | ± 1° | p. 647 |
| Cutting ring shoulder throw-up coverage | approx. 80% | p. 649 |
| V-belt AVX 13 (width: 13 mm) pre-load tension | 650±50 N | p. 49 |
| V-belt AVX 13 (width: 13 mm) re-load tension | 400±50 N | p. 49 |
| Coolant pH value | 6.5 - 8.5 | p. 116 |
| Coolant chlorine (Cl) content | - 100 mg/l | p. 116 |
| Steering pressure (high idle) | 175 bar | p. 50 |
Yanmar V80 Common Problems This Manual Covers
Yanmar V80 loses drive power under load, machine slows or stops after warming up p. 395
Check hydraulic oil level and fluid condition first. Measure travel hydraulic supply pressure following the calibration procedure on page 395, including pressure cut-off and high-pressure valve readings. If pressure is low, adjust travel pump neutral position and verify diesel engine reduction speed. Drain and refill if fluid appears milky, dark, or smells burnt.
Manual Section: Travel Hydraulics Setting and AdjustmentBoom lifts slowly or won't reach full height, bucket movement weak or jerky under load p. 52
Check hydraulic oil level and replace filters on schedule, every oil change per page 121. Measure main relief valve pressure at high idle with the machine warm: it must read max. 250+5 bar (page 52). Also verify pilot supply pressure reaches 30 ±1 bar (page 51). Low readings point to pump wear or a stuck relief valve.
Manual Section: HydraulicsEngine won't start, cranks slowly in cold weather, or shuts down unexpectedly during operation
Check battery and fuel system first. The electrical system runs on 12 V nominal (page 50), so load-test the battery under crank before condemning the engine. Replace fuel pre-filter and main filter at E40 service intervals, torquing the pre-filter cartridge to 17-18 Nm (page 128). Bleed fuel lines after any filter service. For recurring shutdowns, work through the fault tree.
Manual Section: Engine Faults and Corrective MeasuresCoolant temperature climbs into red during heavy work or warm-weather operation, machine overheats p. 116
Inspect the radiator and cooler pack for debris buildup and clean thoroughly. Verify coolant pH is 6.5-8.5 and chlorine content below 100 mg/l (page 116); drain and refill if out of spec. After coolant service, torque the system locking screw to 26 Nm (page 130). Check engine oil pressure at high idle: the spec is 2.3 bar (page 49).
Manual Section: MaintenanceSteering becomes heavy or delayed, extra effort needed to turn at low travel speeds p. 50
Measure steering pressure at high idle: it must reach 175 bar (page 50). Check hydraulic oil level first, then inspect the gear pump, which is rated at 30.0 cm³ per revolution. Shock valves should hold 240 bar each; if one has failed, steering effort spikes under turn loads. Trace the steering circuit using the hydraulic schematic on page 371.
Manual Section: Technical DataHydraulic hose fitting leaks after field repair, fluid seeps from freshly installed cutting-ring connection p. 647
Saw the pipe at no more than ±1° from square (page 647). For diameters up to 18 mm, tighten the cutting ring 1 1/2 rotations past hand-tight; for 20 mm and above, 1 1/4 rotations (page 648). Confirm the cutting ring shoulder throw-up covers approximately 80% before final assembly (page 649). Never reuse a previously deformed cutting ring.
Manual Section: Repair InstructionsFrequently Asked Questions
How do I reset the warning light on a YANMAR V80?
The diagnostics lamp, which indicates a warning, goes out when all errors are rectified. For some errors, it is necessary to switch off the ignition, wait 30 seconds, and then switch it back on. If the fault display is ignored, the engine may switch off automatically after a certain period.
How do I reset the service reminder on a YANMAR V80?
The manual indicates that the daily operating hours counter can be reset to 0.0 hours. This is done by selecting the desired display field (orange display border) and confirming with OK in the 'Parameter reset of main control unit data' submenu. For DPF regeneration, the counter is reset automatically after a standstill regeneration.
What does the error code mean on a YANMAR V80?
The meaning of error codes can be found in the DTC Code List Software Variants (V1 / V4) document. This list is available in the '12 Diagnosis / Tools' section of the manual, starting from page 681. For the latest information, refer to the Yanmar Construction Portal.
How do I clear fault codes on a YANMAR V80?
Fault codes typically clear when the underlying error is rectified. For some errors, switching off the ignition, waiting 30 seconds, and then switching it back on may clear the diagnostics lamp. For specific components like the diesel particle filter, soot and ash content must be reset using the SERDIA service tool after replacement.
Is this Service Manual a digital download?
Instant PDF download. You get the full 770-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Is this Yanmar V80, Wheel Loader Service Manual printable?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
Does this Yanmar V80, Wheel Loader manual include wiring diagrams?
Yes. You'll find full electrical schematics with wire routing diagrams, connector identification, and circuit descriptions.
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