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 |
