Part of the Yanmar Repair Manuals.
When a ViO80 starts swinging slower than it did last month, the real question is whether the main relief is drifting or the pump is wearing out, and guessing wrong costs the crew a full day. This service manual, Yanmar publication 0BKB3-G80002, covers the ViO80 excavator with the 4TNV98-ZWBV1 diesel and walks that diagnosis step by step, from pressure adjustment in the Hydraulic System chapter to pump teardown in Hydraulic Equipment.
Across 776 pages it works through engine service (valve clearance, the EGR system, fuel injection pump removal), the control valve, travel and swing motors, undercarriage service standards, electrical wiring diagrams, and a full troubleshooting chapter. Service standards give wear limits and tightening torques, so you can measure a part and know whether it stays or goes.
The PDF carries 247 bookmarks for fast navigation, and you can print the pages you need and let them get dirty at the bench while the clean copy stays on your laptop.
What's Inside This Yanmar ViO80 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Cautions for Maintenance Work | 11-24 | Correct Work, Safety Precautions, Preparations, Cautions for Disassembly and Reassembly, Cautions for Removal and Installation of Hydraulic Equipment |
| Technical Data | 25-42 | Specifications, Outline Drawing and Working Area (Quick Coupler, W/O Quick Coupler), Weight List of Main Parts |
| Service Standards | 43-66 | Machine Performance, Engine, Undercarriage (Rubber Crawler Specifications, Steel Crawler Specifications, Common Specifications of Steel & Rubber Crawlers), Controls |
| Engine | 67-242 | Safety Precautions, Introduction, Special Service Tools, Measuring Instruments, 4-Valve Cylinder Head, Measuring and Adjusting Valve Clearance, Crankshaft and Camshaft Components |
| Hydraulic System | 243-276 | Outline (Control Valve Operation, Additional Operation of Control Valve), Hydraulic Circuit Schematic (Us Spec., AS/NZ Spec., Kr Spec., Ayr Spec.) |
| Hydraulic Equipment | 277-534 | Hydraulic Pump, Control Valve (Main Control Valve, Disassembly, Cleaning, Checking, Reassembly, Servicing Procedure for Relief Valve, Installation, Running, Troubleshooting) |
| Adjustment and Repair | 535-722 | Electric Equipment of the Machine (Parts Layout of Electrical Equipment, Monitor and Alarm Systems, Wiring Diagram, Circuit Description of Engine Start, Stop and Battery Charging, Electronic Control, Removal and Reinstallation of Engine, Removal and Reinstallation of Starter Motor, Removal and Reinstallation of Radiator and Oil Cooler, Removal and Reinstallation of Fan Belt and Compressor Driving Belt, Removal and Reinstallation of Fuel Injection Pump, Removal and Reinstallation of ECU) |
| Periodic Inspection and Servicing | 723-726 | List of Periodic Inspection and Servicing |
| Fuel, Lube Oil and Grease Recommended | 727-730 | Fuel, Lube Oil and Grease Recommended, Mixture Ratio of Cooling Water and Antifreeze |
| Troubleshooting | 731-770 | Non-Breakdowns, Natural Release of Bucket, Discontinuous Arm Movement, Thermal Shock of Travel Motor, Time Lag on Travel Speed Switching, Operation of Quick Coupler Cylinder, Machine and Engine, How to Use the Charts |
| Reference Data | 771-776 | Specifications for Attachment, ViO80 Service Manual (Published by, Edited by, Finished by) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine mount vibroisolating rubber M16 tightening torque | 195.3 to 224.2 ft•lbf (264.8 to 304 N•m) | p. 60 |
| Return filter Filtration accuracy | 10 µ | p. 30 |
| Fuel filter filtration area | 775 (5000) sq.in. (sq.cm) | p. 32 |
| Air cleaner Filtration area | 11.8 (1.1) sq.ft. (sq.m) | p. 33 |
| Cooling water hose clip 48 tightening torque | 1.8 to 2.5 ft•lbf (2.5 to 3.4 N•m) | p. 60 |
| SAE J517, 100R1 Hose dia. 02 working pressure | 2489 (17.2) PSI (MPa) | p. 19 |
| Track roller & shaft A wear limit | Ø1.56 (Ø39.5) in. (mm) | p. 55 |
| Hydraulic pump insufficient discharge volume corrective action | Replace | p. 743 |
| Engine Model | 4TNV98-ZWBV1 | p. 31 |
| Rated Output / Engine Speed | 54.6 HP / 2000 rpm | p. 31 |
| Hydraulic Oil Tank Capacity | 29.59 Gals | p. 30 |
| System Relief Set Pressure (P1, P2) | 3698 PSI | p. 29 |
Yanmar ViO80 Common Problems This Manual Covers
Weak or slow hydraulics under load
Fading digging power or sluggish travel can trace to low or contaminated oil, a clogged return filter, air in the circuit, or a pump losing discharge volume. The troubleshooting chapter works through the causes in order and tells you when the pump has to be replaced rather than adjusted.
Manual Section: Troubleshooting p. 731Hard starting and stalling under load
Water in the fuel or a restricted fuel supply will make the 4TNV98-ZWBV1 crank long, stall, or fall flat under load. The Engine chapter covers the fuel system and failure diagnosis, so you can trace the problem from tank to injection pump instead of swapping parts.
Manual Section: Engine p. 67Overheating and coolant loss
Temperature warnings usually mean low coolant, a plugged radiator core, or a tired hose. The Engine chapter covers the cooling system, and the manual includes removal and reinstallation procedures for the radiator and oil cooler when cleaning alone will not fix it.
Manual Section: Engine p. 67Machine pulls to one side traveling
When one track lags the other, the fault is usually in a travel motor or a sticking control valve spool. The Hydraulic Equipment chapter carries disassembly, cleaning, checking, and reassembly procedures for both, along with the swing motor and pilot valve.
Manual Section: Hydraulic Equipment p. 277Loose tracks and worn undercarriage
Track rollers, idlers, and chains wear down quietly until the track starts derailing or the ride goes rough. The Service Standards chapter gives undercarriage wear limits for both rubber and steel crawler specifications, so you can measure and decide instead of guessing.
Manual Section: Service Standards p. 43Electrical faults and charging problems
A machine that will not crank, a battery that will not stay charged, or a monitor throwing alarms all come back to the electrical system. The Adjustment and Repair chapter includes the electrical parts layout, wiring diagram, and circuit descriptions for engine start, stop, and battery charging.
Manual Section: Adjustment and Repair p. 535Frequently Asked Questions
Which machine does this manual cover?
The Yanmar ViO80 excavator with the 4TNV98-ZWBV1 diesel engine. It is Yanmar publication 0BKB3-G80002, and the hydraulic circuit schematics include US, AS/NZ, Kr, and Ayr specifications, so regional variants are addressed.
Does it cover engine repair on the 4TNV98-ZWBV1?
Yes. The Engine chapter runs from the 4-valve cylinder head and measuring and adjusting valve clearance through the crankshaft and camshaft components, with the special service tools and measuring instruments listed up front. p. 67
Are wiring diagrams included?
Yes. The Adjustment and Repair chapter includes the parts layout of the electrical equipment, the wiring diagram, monitor and alarm systems, and circuit descriptions for engine start, stop, and battery charging, plus removal and reinstallation of the starter motor and ECU. p. 535
Can I test and adjust hydraulic pressures with it?
Yes. The Hydraulic System chapter covers circuit operation and pressure adjustment, and the manual lists the system relief set pressure of 3698 PSI for the P1 and P2 circuits, so you know what a healthy gauge reading looks like before you touch a relief valve. p. 243
Is this Service Manual a digital download?
A 776-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Is this Yanmar ViO80 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 ViO80 manual include wiring diagrams?
Yes, full electrical schematics are included with wire colors, connector locations, and circuit descriptions.
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