All 568 pages of this Yanmar ViO45-5, ViO55-5 Service Manual PDF are built around one job: returning your compact excavators to factory spec. Inside you get full hydraulic circuit schematics covering boom, arm, bucket, swing, and travel operation, plus wiring diagrams for every electrical circuit on the machine. A complete troubleshooting section, page after page of tightening torque tables, and step-by-step rebuild procedures for the hydraulic pump, control valve, swing motor, and travel motor fill out the remaining pages. Torque the M16 engine mount rubber to 206-235 N·m; set the swivel joint-to-track frame M10 fasteners to 44.1-58.8 N·m with Loctite 262. No more chasing faults blind. Bookmarked and keyword-searchable, this PDF opens on any device and puts the right number in front of you in seconds.
What's Inside This Yanmar ViO45-5, ViO55-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| Spine Title | 2 | - |
| General Cautions for Maintenance Work | 13-26 | 1-1 Correct Work, 1-2 Safety Precautions, 1-3 Preparations, 1-4 Cautions for Disassembly and Reassembly, 1-5 Cautions for Removal and Installation of Hydraulic Equipment |
| Technical Data | 27-50 | 2-1 Specifications, 2-2 Outline Drawing and Working Area, 2-3 Weight List of Main Parts, 2-4 Lifting Capacity List |
| Service Standards | 51-72 | 3-1 Machine Performance, 3-2 Engine, 3-3 Undercarriage, 3-4 Controls, 3-5 Hydraulic Equipment, 3-6 Implement, 3-7 List of Tightening Torque |
| Engine | 73-148 | 4-1 General, 4-3 Inspection and Adjustment, 4-4 Engine Body, 4-5 Lubrication System, 4-6 Cooling System, 4-7 Fuel Injection Pump / Governor, 4-8 Electrical Equipment |
| Hydraulic System | 149-192 | Outline (Control Valve Operation, Additional Operation of Control Valve), Hydraulic Circuit Schematic |
| Hydraulic Equipment | 193-398 | 6-1 Hydraulic Pump, 6-2 Control Valve, 6-3 Pilot Valve, 6-4 Swing Motor, 6-5 Travel Motor, 6-6 Blade Control Pilot Valve, 6-7 Solenoid Valve for P.T.O. Operation |
| Adjustment and Repair | 399-512 | 7-1 Electric Equipment of Machine, 7-2 Undercarriage, 7-3 Controls, 7-4 Swing Bearing, 7-5 Hydraulic Equipment, 7-6 Work Implements, 7-7 Cabin |
| Periodic Inspection and Servicing | 513-516 | 8-1 List of Periodic Inspection and Servicing |
| Fuel, Lube Oil and Grease Recommended | 517-520 | Fuel, Engine Oil, Hydraulic Oil, Travel Reduction Gear Oil, Grease, Antifreeze |
| Troubleshooting | 521-562 | 10-1 Non-Breakdowns, 10-2 Troubleshooting |
| Reference Data | 563-568 | 11-1 Dimensions and Specifications for Attachment |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine mount vibroisolating rubber (M16) tightening torque | 155.0 to 170.0 ft·lbf (206 to 235 N·m) | p. 66 |
| Swivel joint × Track frame (M10) tightening torque | 32.6 to 43.4 ft·lbf (44.1 to 58.8 N·m) | p. 67 |
| Solenoid valve spool clearance | 0.03 mm or less | p. 387 |
| Return filter bypass valve opening pressure | 21.3 PSI (0.147 MPa) | p. 150 |
| Fan belt tension (deflection) | 0.39 to 0.59 in. (10 to 15 mm) / 72.3 lbf. (98 N) | p. 88 |
| Heater hose clip (Hose clip 22) tightening torque | 1.6 to 1.8 ft·lbf (2.16 to 2.45 N·m) | p. 417 |
| Travel alarm switch clearance | 0.02 in. (0.5 mm) or less | p. 442 |
| Hydraulic cylinder extension and retraction stroke for air release | 1.97 to 3.9 in. (50 to 100 mm) from each stroke end | p. 23 |
| Engine Oil Capacity (Total) | 9.4 Qts (8.9 L) | p. 87 |
| Hydraulic Oil Tank Capacity (Total) | 16.9 Gals (64 L) | p. 30 |
| Cooling Water Capacity (Total) | 7.1 Qts (6.7 L) | p. 517 |
| Intake Valve Clearance (Cold Engine) | 0.0059 to 0.0098 in (0.15 to 0.25 mm) | p. 37 |
Yanmar ViO45-5, ViO55-5 Common Problems This Manual Covers
Yanmar ViO45-5 hydraulic functions become weak, erratic, or slow requiring repeated air bleeding after regular service. p. 23
Bleed the hydraulic circuit as detailed on page 23. Extend and retract the hydraulic cylinders, stopping 1.97 to 3.9 in. (50 to 100 mm) from each stroke end. Repeat this process until all trapped air escapes the system and cylinder movement smooths out completely.
Manual Section: General Cautions for Maintenance WorkEngine turns over at normal speed but will not start or produces heavy black smoke under load. p. 38
Test the fuel delivery system and verify fuel injection pressure reaches 2844 to 2986 PSI (19.6 to 20.6 MPa). Inspect the injection pump components shown on page 38. Adjust the valve clearances if compression is low and replace any fouled injectors to restore proper starting.
Manual Section: EngineCoolant temperature gauge spikes into the red zone rapidly and alternator warning lamp stays illuminated. p. 88
Inspect the engine cooling system and verify fan belt tension deflection measures exactly 0.39 to 0.59 in (10 to 15 mm) when pressed. Follow the adjustment procedures on page 88 to correct the tension. Replace the belt if it shows signs of cracking or glazing.
Manual Section: EngineTravel alarm fails to sound when operating the travel levers during routine safety and operation checks. p. 442
Inspect the travel alarm switch wiring and verify the switch clearance measures 0.02 in. (0.5 mm) or less. Adjust the mounting bracket on page 442 to achieve the correct gap. Clean the connector terminals and test the circuit for continuity if the alarm still fails.
Manual Section: Adjustment and RepairFrequently Asked Questions
What are the torque specs for YANMAR ViO45-5 / ViO55-5 track rollers, idlers, and sprockets?
For the YANMAR ViO45-5 / ViO55-5, the tightening torque for the sprocket bolts (M14) is 137.4 to 151.9 ft·lbf (186.3 to 205.9 N·m) with Three Bond 1324 adhesive. Idler plugs (R (PT) 1/8) require 6.5 to 7.2 ft·lbf (8.8 to 9.8 N·m) with Loctite 572. Track roller tightening nuts (Cap nut M16) should be tightened to 151.9 to 180.8 ft·lbf (205.9 to 245.2 N·m) with Loctite 262.
What are the replacement specifications for Hydraulic hoses?
Hydraulic hoses are categorized by Yanmar Standard Type, with specifications including hose material code, type code, nominal length, and nominal diameter. For example, a SAE J517, 100R1 hose with a 02 diameter has an inner diameter of 0.25 in. (6.3 mm) and a working pressure of 2489 PSI (17.2 MPa). When installing, ensure ample slackness as hose length can change by +2% to -4% under high pressure, and use proper adapters to prevent twisting.
What are the replacement specifications for Seals?
When disassembling hydraulic equipment, removed seals and O-rings must be replaced with new ones in principle. For floating seals, completely wipe off oil from the O-ring and housing, apply a little gear oil to the matching face before installation, and turn the seals two or three times to break them in. Oil seals should have grease applied to their lips to prevent wear, and should be inspected for flaws, distortion, or excessive wear (e.g., oil seal 30 on page 364) and replaced if damaged.
How do you fix yanmar ViO45-5 hydraulic functions become weak, erratic, or slow requiring repeated air bleeding after regular service?
Bleed the hydraulic circuit as detailed on page 23. Extend and retract the hydraulic cylinders, stopping 1.97 to 3.9 in. (50 to 100 mm) from each stroke end. Repeat this process until all trapped air escapes the system and cylinder movement smooths out completely.
What format is this manual in?
You get a 568-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Can I print specific sections of this Service Manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Are electrical wiring diagrams included in this Yanmar ViO45-5, ViO55-5 manual?
Included. The Yanmar ViO45-5, ViO55-5 Service Manual covers complete wiring harness diagrams, electrical circuits, and connector pinouts.
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