All 719 pages of this Yanmar ViO80-1A service manual PDF (OEM #0BKB3-G00200) cover a single compact excavator end-to-end, from engine EGR teardown to swing motor rebuild. You get full hydraulic circuit schematics showing pilot valve and ESS proportional solenoid valve routing, a complete wiring diagram covering both the engine ECU and hydraulic controller circuits, torque tables for machine bolts, engine fasteners, and hydraulic fittings, plus an error code section with a quick-reference troubleshooting chart. Torque the M20x40 track roller mounting bolts to 441.2-490.2 N-m; travel motor-to-track-frame bolts (M16x45) spec out at 167-206 N-m. Every hour your machine sits costs money. Download now, pull it up on any device, and let the bookmarks take you straight to the section you need.
What's Inside This Yanmar ViO80-1A Manual
| System | Pages | Key Topics |
|---|---|---|
| General Cautions for Maintenance Work | 13-24 | Correct Work, Safety Precautions, Preparations, Cautions for Disassembly and Reassembly, Cautions for Removal and Installation of Hydraulic Equipment, Cautions for Handling Seals |
| Technical Data | 25-52 | Specifications, Outline Drawing and Working Area (W/O Quick Coupler), Weight List of Main Parts, Lifting Capacity List (W/O Quick Coupler), Specifications for Attachment |
| Service Standards | 53-80 | Machine Performance, Engine, Undercarriage (Rubber Crawler Specifications, Steel Crawler Specifications, Common Specifications of Steel & Rubber Crawlers), Controls |
| Engine | 81-240 | 4-1 Safety, 4-2 Engine, 4-3 Fuel System, 4-4 Cooling System, 4-5 Lubrication System, 4-6 Starter Motor, 4-7 Alternator, 4-8 Electronic Control System |
| Electric System | 241-294 | 5-1 Electric Equipment of Machine, 5-2 Circuit Description of Engine Start and Stop, 5-3 Engine ECU (Engine Controller), 5-4 Hydraulic ECU (Controller), 5-5 Error Code |
| Hydraulic System | 295-566 | 6-1 Outline, 6-2 Circuit Operation, 6-3 Hydraulic Pump, 6-4 Control Valve, 6-5 Pilot Valve, 6-6 Swing Motor, 6-7 Travel Motor, 6-8 Ess Proportional Solenoid Valve |
| Adjustment and Repair | 567-706 | 7-1 Engine and Electric Equipment, 7-2 Undercarriage, 7-3 Controls, 7-4 Swing Bearing, 7-5 Hydraulic Equipment, 7-6 Implement, 7-7 Cabin, 7-8 Air Conditioner |
| Troubleshooting | 707-716 | 8-1 Non-Breakdowns, 8-2 Quick Reference Table for Troubleshooting |
| Appendix | 717-719 | ViO80-1A (Ycee) Wiring Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Track roller mounting bolts (M20 × 40) | 325.4 to 361.6 ft•lbf (441.2 to 490.2 N•m) | p. 70 |
| Travel motor × Track frame mounting bolts (M16 × 45) | 123.2 to 151.9 ft•lbf (167 to 206 N•m) | p. 70 |
| Idler seal cover × Crawler adjust spring mounting bolts (M14 × 60) | 87.0 to 108.4 ft•lbf (118 to 147 N•m) | p. 70 |
| Fuel filter element replacement interval | Every 250 hrs | p. 38 |
| Fuel filter filtration area | 310 sq.in. (2000 sq.cm) | p. 30 |
| Suction filter cleaning interval | Every 1000 hrs | p. 38 |
| Return filter replacement interval | Every 1000 hrs | p. 38 |
| Air cleaner cleaning interval | Every 250 hrs | p. 38 |
| Air cleaner element replacement interval | Every 500 hrs | p. 38 |
| Radiator fins cleaning interval | Every 250 hrs | p. 38 |
| Radiator cap pressure | 12.80 PSI (0.09 MPa) | p. 31 |
| Grease-up positions check and grease interval | Daily | p. 38 |
Yanmar ViO80-1A Common Problems This Manual Covers
Yanmar ViO80-1A excavator loses hydraulic power under heavy load and bucket becomes completely unresponsive p. 26
Check the system relief set pressure on page 26 to verify it reaches 3698 PSI (25.5 MPa). Inspect the main pump flow and clean the suction filter screen. Verify the hydraulic tank contains 29.6 Gals (112 L) of fluid before replacing worn pump components.
Manual Section: Technical DataEngine cranks normally but will not start or turn over fully in cold weather conditions p. 30
Measure engine compression pressure to ensure it meets the 493 PSI (3.4 MPa) at 250 rpm specification listed on page 30. Drain water from the fuel filter housing and bleed air from the injector lines. Inspect the glow plug circuit if cold starting issues persist.
Manual Section: Technical DataCoolant temperature gauge reads high during continuous operation and machine suddenly shuts down under load p. 27
Inspect the radiator fins for blockages and clean them thoroughly. Test the radiator cap check pressure on page 27 to confirm it holds 10.8 - 14.8 psi (75 - 105 kPa). Replace the cap if it fails the pressure test and verify coolant levels are correct.
Manual Section: EngineBoom slowly drops overnight and hydraulic cylinder lacks holding strength during heavy lifting operations p. 66
Torque the boom cylinder rod nut to 2098 to 2171 ft•lbf (2845 to 2943 N•m) as specified on page 66. Inspect the internal cylinder seals for tearing or excessive wear. Drain the hydraulic fluid and rebuild the cylinder assembly to restore normal load holding capacity.
Manual Section: Service StandardsExcavator travel motor feels extremely weak and machine constantly pulls sharply to the left side p. 70
Verify the track roller mounting bolts are torqued to 325.4 to 361.6 ft·lbf.
Manual Section: Service StandardsFrequently Asked Questions
How do I reset the hydraulic system on a YANMAR ViO80-1A?
To release air from the hydraulic system after disassembly or parts replacement, run the engine at low idling speed for 5 to 10 minutes, then check and supply hydraulic oil to the specified level. For hydraulic cylinders, extend and retract them 4 to 5 times up to 1.97 to 3.9 inches (50 to 100 mm) from each stroke end slowly, then fully extend and retract 3 or 4 times. For the hydraulic oil tank, replace the oil supply cap with a vacuuming cap, connect it to a vacuum compressor, and vacuum the air in the tank.
How do I reset fault codes on a YANMAR ViO80-1A?
To reset fault codes, connect the SMARTASSIST DIRECT (SA-D) tool to the engine wire harness. From the SA-D interface, select "Diagnostic Codes" and then "Defect History." Press the "All Clear" button to clear the error information from the Defect History.
What does error code mean on a YANMAR ViO80-1A excavator?
Error codes on the YANMAR ViO80-1A excavator indicate specific malfunctions detected by the ECU. For example, error code 00 000051.03 signifies an Intake throttle position sensor malfunction: High voltage, meaning the sensor voltage is higher than 4.8 V when the engine is not cranking. The manual provides a comprehensive list of error codes, their descriptions, detection conditions, causes, and corrective measures.
What are the replacement specifications for Fuel filters?
The fuel filter is a filter paper with an automatic air release device, with a filtration area of 310 square inches (2000 sq.cm). The periodic inspection and servicing schedule recommends replacing the fuel filter element at the first 100 hours of operation, and then every 250 hours thereafter.
How will I receive this Service Manual?
Immediate download of the complete 719-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?
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 ViO80-1A manual?
Yes. The manual includes hydraulic circuit diagrams, system schematics, and component specifications with pressure ratings.
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