Yanmar V3-5, V4-5, V4-5HL (US) Wheel Loader Service Manual

Description

• Model List:
  • V3-5, V4-5, V4-5HL (US) Wheel Loader

• 1. FOREWORD
• 2. CONTENTS
• 3. CHAPTER 1 GENERAL CAUTIONS FOR MAINTENANCE WORK
• 3.1. Correct Work
• 3.2. Safety Precautions
• 3.3. Preparations
• 3.4. Cautions for Disassembly and Reassembly
• 3.5. Cautions for Removal and Installation of Hydraulic Equipment
• 3.6. Cautions for Removal and Installation of Hydraulic Piping
• 3.7. Cautions for Handling Seals
• 3.8. Correct Installation of Hydraulic Hose
• 3.9. Specifications of Hydraulic Hose
• 3.10. Air Release of Hydraulic Equipment
• 4. CHAPTER 2 TECHNICAL DATA
• 4.1. Specifications
• 4.2. External Drawings and Working Area
• 4.2.1. Canopy type
• 4.2.2. Cabin type
• 4.3. Hydraulic Circuit Diagram
• 4.4. Wiring Diagram
• 4.5. Mass List of Main Parts
• 5. CHAPTER 3 SERVICE STANDARDS
• 5.1. Machine Performance
• 5.2. Engine Specifications
• 5.3. Controls
• 5.4. Undercarriage
• 5.5. Hydraulic Equipment
• 5.6. Implement
• 5.6.1. Front Implements
• 5.7. Tightening Torque List for Bolts and Nuts
• 5.7.1. Machine Side
• 5.7.2. Engine Side
• 5.7.3. general Bolts and Nuts
• 6. CHAPTER 4 ENGINE
• 6.1. Outline
• 6.1.1. Structural Drawing (Direct Injection Engine)
• 6.1.2. Cooling Water, Lubricating Oil and Fuel
• 6.1.3. Fuel Injection System
• 6.2. Troubleshooting
• 6.2.1. Quick Reference Table for Troubleshooting
• 6.2.2. Troubleshooting through Measurement of Compression Pressure
• 6.3. Measurement, Inspection and Adjustment
• 6.3.1. Measuring Compression Pressure
• 6.3.2. Adjusting Valve Clearance
• 6.3.3. Checking V-belt Tension
• 6.3.4. Checking Fuel Injection Valve
• 6.3.5. Checking and Adjusting Fuel Injection Timing
• 6.3.6. Adjusting No-load Maximum (or Minimum) Engine Speed
• 6.3.7. Checking Cooling Water System and Radiator for Water Leakage
• 6.3.8. Checking Sensors
• 6.3.9. Checking Oil Cooler
• 6.3.10. Checking Piston Cooling Nozzle
• 6.4. Measuring Procedure, Service Data and Correctve Action
• 6.4.1. Cylinder Head
• 6.4.2. Cylinder Block
• 6.4.3. Valve Rocker Arm
• 6.4.4. Oiston and Piston Ring
• 6.4.5. Connecting Rod
• 6.4.6. Camshaft
• 6.4.7. Crankshaft
• 6.4.8. Gears
• 6.4.9. Trochoid Pump
• 6.5. Precautions for Reassembly
• 6.6. Electrical Equipment
• 6.6.1. Starter Motor
• 6.6.2. Alternator
• 6.6.3. Air Heater
• 6.7. Specifications and Service Data
• 6.7.1. Specifications of Fuel Injection Pump
• 6.7.2. Adjustment Service Data for Fuel Injection System
• 6.8. Turbocharger
• 6.8.1. Structure and Function
• 6.8.2. Exploded View
• 6.8.3. Tightening Torqus
• 6.8.4. Service Standards
• 6.8.5. Periodic Inspection
• 6.8.6. Disassembly Procedure
• 6.8.7. Cleaning and Inspection Procedures
• 6.8.8. Reassembly Procedure
• 6.8.9. Handling of Turbocharger after Disassmbly and Reassembly
• 6.8.10. Troubleshooting
• 6.8.11. Servicing Procedure for Waste Gate
• 7. CHAPTER 5 STRUCTURE AND OPERATION
• 7.1. Outline
• 7.2. Component Parts
• 7.3. Power Transmission Device
• 7.3.1. Arrangement Drawing
• 7.3.2. Flow of Oil
• 7.3.3. Power Train
• 7.3.4. Sectional View of Axles and Component Parts
• 7.4. Steering System
• 7.5. Electrical Equipment
• 7.5.1. Arrangement of Electrical Equipment
• 7.5.2. Wiring
• 7.5.3. Engine Start/Stop Circuit
• 7.5.4. Charging Circuit
• 8. CHAPTER 6 HYDRAULIC EQUIPMENT
• 8.1. Hydraulic Pump (H.S.T.)
• 8.2. Hydraulic Motor (H.S.T.)
• 8.3. Troubleshooting for Hydraulic Pump and Motor (H.S.T.)
• 8.4. Control Valve
• 8.5. Orbit Roll
• 8.6. Hydraulic Cylinders
• 9. CHAPTER 7 ADJUSTMENT AND REPAIR
• 9.1. Machine
• 9.1.1. Layout of Electrical Equipment
• 9.1.2. Monitor and Alarm System
• 9.1.3. Engine Controls
• 9.1.4. Fuel Tank System
• 9.1.5. Replacement of Tire
• 9.2. Hydraulic Pump (H.S.T.)
• 9.2.1. Removal and Installation of Hydraulic Pump
• 9.3. Front and Rear Axles
• 9.3.1. Removal and Installation of Front and Rear Axles
• 9.3.2. Disassembly and Reassembly of Front and Rear Axles and Associated Parts
• 9.4. Controls
• 9.4.1. Adjustment of Accelerator pedal
• 9.4.2. Adjustment of Parking Brake
• 9.4.3. Adjustment of Inching Brake
• 9.4.4. Adjustment of Loader Link Cabie
• 9.4.5. Adjustment of Auto Leveler
• 9.5. Adjustment of Pressure
• 9.5.1. Hydraulic Circuit Diagram
• 9.5.2. Pressure Measurement of Hydraulic Pump (H.S.T.)
• 9.5.3. Control Valve
• 9.5.4. Orbit Roll
• 9.6. Loader Towing at Hydraulic Power Source Failure
• 9.7. Cabin
• 9.7.1. Cabin Sevicing Procedure
• 10. CHAPTER 8 PERIODIC INSPECTION AND SERVICING
• 10.1. List of Periodic Inspection and Servicing
• 11. CHAPTER 9 FUEL, LUBE OIL AND GREASE RECOMMENDED
• 12. CHAPTER 10 TROUBLESHOOTING
• 12.1. Troubleshooting
• 13. SPINE TITLE