Yanmar ViO80-1A Installation guide

USER OPERATION AND
MAINTENANCE MANUAL
EXCAVATOR
ViO80 -1A
Original manual
MUB11ENMA00202
12/01/2016

YANMAR CONSTRUCTION EQUIPMENT EUROPE
S.A.S. THANK YOU FOR PURCHASING A YANMAR
MACHINE
Read this manual carefully to find out how to use and maintain your machine correctly.
If the safety rules are not respected, injury may be caused or the equipment may be damaged.
This manual must be considered as a permanent part of your machine and must not be separated
from the machine when you sell it.
This machine has been designed metrically. The measurements contained in this manual are also
metric.
Only use metric equipment and tools.
The right and left hand sides are determined by facing the forward movement direction.
The warranty is a part of the YANMAR product support programme for customers who use and
maintain their equipment as described in this manual. If the equipment has been used incorectly
or modifications have been made to transform its perfomances beyond the original factory speci-
fications, the warranty expires and the improvements on site under warranty are rejected. The
use of fuel beyond the specifications required or boosting the machines' engines will cancel the
warranty.
All the information, illustrations and specifications contained in this manual are based on the lat-
est product information available on publication. YANMAR reserves the right to modify the in-
formation and illustrations in this manual without notice. For any further information, please
contact your approved YANMAR dealer.
The images that appear in this booklet are provided for information purposes and may vary ac-
cording to each model.
WARNING
Never try to run or use this machine without having read and understood all the applicable
security messages contained in this manual.
Injury may be caused if the safety messages are not respected.
To ensure that this manual remains available for other users, always put it back in its com-
partment when it is not being used.

DECLARATION OF CONFORMITY
The undersigned YANMAR C.E. Europe SAS, 25 rue de la Tambourine, 52115 ST-Dizier FRANCE states that the
designated machine:
Description - Generic name - Function - Model - Type - Serial number - Trade name
VIO801AXX – VIO80–1A – EXCAVATORS – VIO80–1A – VIO – XXXXXXXX – VIO80–1A
Special equipment:
–XXXX
–XXXX
* complies with the provisions of the following European directivesand the national legislations implementing them.
• 2006/42 CE
• 2004/108 CE
• 2000/14 CE + 2005/88 CE
Procedures applied for conformity assessment are: NF EN ISO 3744;
NF ISO 6395
produced by: SNCH, 11, route de Luxembourg L-5230 Sandweiler
LUXEMBOURG
Net power output: 39,3 kW * 1900 rpm
Measured sound pressure 97,8 dBA
Guaranteed sound pressure 98 dBA
Name and address of the person established in the European community, authorized to compile the technical file and
transmit it in whole or part to the public authorities in response to a reasonable request:
Jean Marc REYNAUD, Directeur Général, YANMAR C.E. Europe SAS – 25, rue de la Tambourine 52115 SAINT DIZIER
CEDEX –FRANCE
* The following documents were used in the design of the machine:
- Harmonised standards:
EN 474–1; EN 474–5;
Done at Saint-Dizier, the
Jean-Marc REYNAUD, Directeur Général
XX/XX/XXXX

REFERENCE INFORMATION
Note information about your YANMAR machine here.
Always use these references for everything to do with your YANMAR machine.
Model name :
Machine serial number :
Serial number of the engine :
Your YANMAR dealer :
Address :
Telephone :

INTRODUCTION
This User and Maintenance Manual has been designed to provide you with important informa-
tion and the suggestions you need for safe and effective use of the machine.Read the manual be-
fore you use the machine to familiarise yourself with the operation, verification and
maintenance procedures and instructions.A serious accident may be caused if you do not respect
the precautions contained in this user manual or use any procedures that are not recommended.
DANGER
Incorrect use of the machine may cause serious injury or even death. Personnel involved
in using and maintaining the machine must familiarise themselves with the content of
this manual before carrying out a task.
• Do not start the machine before you have familiarised yourself with the content of this
manual.
• The personnel responsible for using the machine must keep this manual within easy reach
and consult it from time to time.
• If you lose or damage the manual, order a new one immediately from your dealer.
• When you sell the machine to another user, do not forget to pass on the manual at the same
time.
• YANMAR provides its customers with products that conform to the regulations and indus-
trial standards that apply in their respective countries. If you are using a YANMAR machine
that you have bought from a foreign company, you should be aware that certain safety mecha-
nisms may be missing from the machine. Consult your dealer to find out whether your ma-
chine complies with the regulations and industrial standards that apply in your country.
• Some of the machine's specifications may differ from those described in the manual be-
cause the machine's design and performances have been improved. If you have any comments
to make concerning the content of the manual, do not hesitate to consult your dealer.
• The important safety instructions are presented in this manual in sections:
–1 Basic precautions , page 65
–2 Usage precautions , page 70
Consult these pages and respect these safety instructions before starting up the machine.
• In this manual, the main product sections are designated as follows :
(1) Machine = whole product
(2) Equipment = part including the arm, the boom, the
bucket or any other accessory
(3) Basic machine = part comprising the upper structure
and the lower frame

SAFETY SIGNALS
The following signals are used in this manual to indicate the severity of the risks that may be en-
countered if the warnings concerning the product are not respected :
DANGER Dangerous situation imminent that may cause death or serious
injury.
WARNING Potentially dangerous situation likely to cause death or serious
injury.
CAUTION Potentially dangerous situation likely to cause slight or me-
dium-seriousness injury .
IMPORTANT Remarks or instructions to be respected to ensure the com-
pletely safe operation and maintenance of the machine.
WARNING
The operator of this machine must be competent and trained in its use.
WARNING
Never try to operate or repair the machine if you have not read and understood all the ap-
plicable warnings and usage instructions contained in this manual and on the safety signals
on this machine. Physical injury may be caused if the safety instructions are not respected.
WARNING
Never modify the design of the machine or its engine.
Never remove or deactivate the protections or safety mechanisms installed.
Any unauthorised modification to the design or use of unauthorised accessories may cause
physical damage.
In addition, in that these actions would constitute an explicit violation of the terms of the YAN-
MAR Product Warranty, the applicable warranty would also become null and void.

TABLE OF CONTENT
A Description and illustration of the machine ........................................................ 1
1 Applications and regulations ................................................................... 3
1.1 Applications................................................................................ 3
1.2 Warranty ................................................................................... 3
1.3 Driving permits............................................................................ 3
1.4 Lifting....................................................................................... 3
2 Identification plates .............................................................................. 4
2.1 Machine serial number plate ........................................................... 4
2.2 Engine serial number plate ............................................................. 4
2.3 EPA information plate ................................................................... 4
2.4 Spare parts order and intervention request ........................................... 5
3 Warning labels ..................................................................................... 6
3.1 Location of the warning adhesive labels .............................................. 7
3.2 Explanation of the warning adhesive labels .......................................... 9
4 Identification of important parts ............................................................. 13
4.1 General view of the machine ......................................................... 13
4.2 Commands and switches .............................................................. 14
5 Description of the driving position .......................................................... 15
5.1 Operator display station ................................................................ 15
5.1.1 Indicator lights ................................................................. 15
5.1.2 Diesel gauge .................................................................... 17
5.1.3 Cooling fluid temperature indicator ......................................... 17
5.1.4 Time counter ................................................................... 18
5.1.5 Displaying the fuel consumption ............................................ 18
5.1.6 Navigation keys ................................................................ 18
5.1.7 Information and error icons................................................... 19
5.2 Switches ................................................................................. 20
5.2.1 Start key ......................................................................... 21
5.2.2 Headlight switch ............................................................... 21
5.2.3 Horn.............................................................................. 22
5.2.4 Windscreen wiper switch and windscreen wiper .......................... 22
5.2.5 Engine rate setting ............................................................. 22
5.2.6 Side movement switch ........................................................ 22
5.2.7 Engine slow down switch .................................................... 23
5.2.8 Eco mode switch ............................................................... 23
5.2.9 Engine stop switch............................................................. 23
5.2.10 Interior lighting switch ........................................................ 23
5.2.11 Manual regeneration ............................................................ 24
5.3 Joysticks and pedals .................................................................... 24
5.3.1 Locking lever ................................................................... 25
5.3.2 Right command lever .......................................................... 25
5.3.3 3rd hydraulic circuit control (P.T.O. 1)....................................... 26
5.3.4 Left command lever ............................................................ 27
5.3.5 4th hydraulic circuit control (P.T.O. 2)....................................... 28
5.3.6 Travel levers and pedals........................................................ 29
5.3.7 Blade lever ...................................................................... 30
5.3.8 Protection of pedals............................................................. 31
5.3.9 Boom rotation pedal ............................................................ 31
5.4 Power socket ............................................................................ 31
5.5 Driver's seat ............................................................................ 32

5.6 Location for the tools and user manual ............................................. 33
5.6.1 Toolkit ........................................................................... 33
5.6.2 User manual .................................................................... 33
5.7 Fuses ..................................................................................... 34
5.7.1 Fusebox........................................................................... 35
5.8 Cabin .................................................................................... 37
5.8.1 Cab side door .................................................................... 37
5.8.2 Upper windscreen .............................................................. 38
5.8.3 Lower windscreen .............................................................. 39
5.8.4 Right hand cab window ....................................................... 40
5.9 Headlights ............................................................................... 40
6 Operation of the air conditioning ............................................................ 41
7 Covers ........................................................................................... 43
7.1 Bonnet ................................................................................... 43
7.2 Cover B ................................................................................. 44
7.3 Cover R ................................................................................. 44
8 Using the electric fuel filling pump ......................................................... 45
9 Options ........................................................................................... 46
9.1 Long arm ................................................................................. 46
9.2 Additional counterweights ............................................................. 46
9.3 Lifting Kit ............................................................................... 46
9.3.1 Lifting ring ...................................................................... 46
9.3.2 Safety valves .................................................................... 47
9.3.3 Overload box .................................................................... 47
9.3.4 Lifting Tables .................................................................................. 47
9.4 FOPS 2 protection grill for demolition work. ....................................... 48
9.5 Cab headlight ........................................................................... 48
9.6 Plug-in flashing light ................................................................... 49
9.7 Keypad immobilizer .................................................................... 49
9.8 Immobilizer with coded key ........................................................... 50
9.9 Anti-starter with key .................................................................... 50
9.10 Fleet management system .............................................................. 51
9.11 SMART-ASSIST......................................................................... 51
9.12 Radio ...................................................................................... 52
9.13 Quick hitch ............................................................................... 52
9.14 Centralized greasing system............................................................ 53
9.15 Mechanical quick hitch ................................................................. 54
9.15.1 Mechanical quick hitch ARDEN EQUIPMENT ........................ 55
9.15.2 Mechanical quick hitch RETROMATIC MORIN ...................... 57
9.15.3 Mechanical quick hitch CSERI ............................................. 58
9.16 Quick hydraulic hitch CSERI....................................................... 59
9.16.1 Dismantling the accessory ................................................... 60
9.16.2 Mounting the accessory ...................................................... 61
B Operating instructions .............................................................................. 63
1 Basic precautions ............................................................................... 65
1.1 Comply with your workplace's safety rules ........................................ 65
1.2 Put the safety mechanisms in place ................................................. 65
1.3 Wear suitable clothing and protective equipment ................................. 65
1.4 Do not drive under the influence of alcohol, drugs or medication............... 66
1.5 Provide adequate ventilation when working in an enclosed space .............. 66
1.6 Protect plants from hot air and exhaust fumes ..................................... 66
1.7 Keep fuel and oil away from sparks ................................................. 67
1.8 Avoid removing the caps when the temperatures are high ....................... 67

1.9 Avoid crush injuries due to accessories ............................................. 67
1.10 Have an extinguisher and a first aid kit ............................................ 68
1.11 Avoid any unauthorised modifications ............................................. 68
1.12 Precautions for optional parts and tools ............................................ 68
1.13 Warning concerning the cab windows .............................................. 69
1.14 Cabin's emergency exit ............................................................... 69
2 Usage precautions .............................................................................. 70
2.1 Precautions before starting the engine .............................................. 70
2.1.1 Make sure that your workplace is safe ...................................... 70
2.1.2 Clean the machine ............................................................. 70
2.1.3 Check the safety structures ................................................... 71
2.1.4 Check the position of the blade ............................................. 71
2.1.5 Accessing the machine ........................................................ 72
2.1.6 Fasten your safety belt and adjust the rearview mirror(s) ................ 72
2.2 Movement precautions ................................................................. 73
2.2.1 Machine's Danger Zone ....................................................... 73
2.2.2 Movement and accessories ................................................... 73
2.2.3 Driving the machine on a slope .............................................. 74
2.3 Working precautions .................................................................. 75
2.3.1 Precautions for using the equipment ........................................ 75
2.3.2 Dangerous tasks ............................................................... 77
2.3.3 Working near electricity lines ................................................ 77
2.3.4 Working near obstacles ....................................................... 78
2.3.5 Emergency stop and securing the machine ................................. 78
2.3.6 Working on a slope ............................................................ 78
2.3.7 Working in an area covered with snow ..................................... 78
2.3.8 Working on unstable ground ................................................. 79
2.3.9 Working in a submerged area ................................................ 79
2.3.10 Working in a muddy area ..................................................... 79
2.3.11 Working in an area with reduced visibility ................................. 80
2.4 Parking precautions .................................................................... 81
2.5 Precautions for the accessories ...................................................... 82
2.6 Precautions for using optional accessories ......................................... 82
2.7 Precautions for the battery ........................................................... 83
3 Precautions for the engine...................................................................... 84
4 Checks before starting the machine .......................................................... 85
4.1 Overall visual inspection ............................................................. 85
4.2 Checking and topping up the level of cooling fluid ............................... 86
4.3 Checking and topping up the engine oil level ..................................... 87
4.4 Checking and topping up the fuel level ............................................. 88
4.5 Checking and topping up the hydraulic oil level .................................. 89
5 Checks after start-up ........................................................................... 91
6 Checks after use ................................................................................. 93
7 operator LCD display station interfaces ..................................................... 94
7.1 Indication of functions.................................................................. 94
7.2 User Interface............................................................................ 95
7.3 Maintenance interface .................................................................. 95
7.4 Machine usage management interface................................................ 96
7.5 Configuration interface................................................................. 97
8 Using the machine in cold weather .......................................................... 98
8.1 Preparation for use in cold weather ................................................. 98
8.2 Starting in cold weather ............................................................... 98
8.3 Precautions after use .................................................................. 99

8.4 When cold weather is over ........................................................... 99
9 Rubber tracks ................................................................................... 100
9.1 Correct use of rubber tracks ......................................................... 100
9.2 Rubber track warranty ............................................................... 100
9.3 Precautions for using rubber tracks ................................................ 101
9.4 Track maintenance .................................................................... 102
9.5 Track replacement .................................................................... 102
10 Handling the bucket ......................................................................... 103
10.1 Machine stability when using with a bucket or an accessory .................. 103
10.2 Compatible accessories ............................................................. 105
10.3 Operation of the retro bucket ...................................................... 107
10.4 Digging trenches .................................................................... 107
10.5 Loading ............................................................................... 108
11 Handling of accessories ...................................................................... 109
11.1 Hydraulic hammer SOCOMEC..................................................... 109
12 Accessory change by direct coupling ...................................................... 111
12.1 Dismantling the accessory ......................................................... 111
12.2 Mounting the accessory ............................................................ 112
12.2.1 Loading bucket .............................................................. 114
13 Load lifting .................................................................................... 115
14 Implementing the 3rd hydraulic circuit ................................................... 116
14.1 Description ............................................................................ 116
14.1.1 3rd circuit selector .......................................................... 117
14.2 Mounting the accessory ............................................................ 117
14.3 Precautions for using the accessory ............................................... 117
15 Using the particle filter....................................................................... 119
15.1 Auto-regeneration .................................................................... 119
15.2 Assisted regeneration................................................................. 119
15.3 Launching the regeneration ......................................................... 120
15.4 Manual regeneration of the particulate filter ...................................... 120
16 Transporting the machine .................................................................. 122
16.1 Loading/unloading the machine ................................................... 122
16.1.1 Precautions for loading/unloading the machine ......................... 122
16.1.2 Procedure ..................................................................... 123
16.2 Immobilising the machine on the truck .......................................... 124
16.3 Tying down the machine ........................................................... 125
16.4 Slinging the machine ............................................................... 126
17 Detecting anomalies ......................................................................... 127
17.1 Phenomena that do not constitute faults .......................................... 127
17.2 Detecting anomalies ................................................................ 127
17.2.1 Engine ........................................................................ 128
17.2.2 Electrical equipment ........................................................ 129
17.2.3 Machine structure............................................................ 130
18 If the battery is discharged ................................................................. 131
18.1 Precautions for connecting and disconnecting the starter cables ............. 131
18.2 Connecting the starter cables ...................................................... 131
18.3 Starting the engine .................................................................. 132
18.4 Disconnecting the starter cables ................................................... 132
18.5 Charging the battery ................................................................ 133
19 Towing the machine ......................................................................... 134
C Periodic maintenance programme ................................................................ 135
1 Periodic inspections and upkeeps ............................................................ 137
2 Maintenance precautions ...................................................................... 139

2.1 Precautions before maintenance ..................................................... 139
2.1.1 Removing the residual pressure............................................. 139
2.1.2 Place a warning label ........................................................ 139
2.1.3 Establish a safety perimeter ................................................. 140
2.1.4 Keep the machine clean ..................................................... 140
2.2 Precautions during maintenance .................................................... 140
2.2.1 Oil and grease ................................................................. 140
2.2.2 Tools ............................................................................ 141
2.2.3 Parts ............................................................................ 141
2.2.4 Dismantling the accessory .................................................. 141
2.2.5 Working under the machine ................................................. 141
2.2.6 Lighting ........................................................................ 142
2.2.7 Battery ......................................................................... 142
2.2.8 Hoses ........................................................................... 142
2.2.9 Radiator ventilator ............................................................ 142
2.2.10 Soldering ....................................................................... 143
2.2.11 Waste processing .............................................................. 143
3 Recommended greases and fluids ........................................................... 144
4First maintenance .............................................................................. 145
4.1 After the first 50 hours of service ................................................... 145
5 List of periodic inspections and maintenance operations ................................ 146
6 Maintenance by the operator ................................................................ 150
6.1 Daily maintenance .................................................................... 150
6.1.1 Checking the machine before use .......................................... 150
6.1.2 Checks after using the machine ............................................ 150
6.1.3 Checking the commands ..................................................... 150
6.1.4 Checking the seat ............................................................. 150
6.1.5 Greasing points ............................................................... 151
6.1.6 Using the centralized greasing system ..................................... 152
6.1.7 Cleaning the separator/decanter ............................................ 152
6.1.8 Purging the fuel tank ......................................................... 153
6.1.9 Checking the hydraulic hoses ............................................... 153
6.1.10 Visual inspection of the fuel hoses ......................................... 154
6.2 Maintenance every 50 hours ......................................................... 154
6.2.1 Greasing the pin and rotation crown ....................................... 154
6.3 Maintenance every 15 days .......................................................... 154
6.3.1 Checking the air conditioning/heating system ............................ 154
6.4 Non periodic maintenance ............................................................ 155
6.4.1 Fuse replacement ............................................................. 155
6.4.2 Replacing a bulb .............................................................. 155
6.4.3 Top up the windscreen washer fluid. ...................................... 156
6.4.4 Replacing the windscreen wiper ........................................... 156
6.5 Rubber track maintenance ........................................................... 156
6.5.1 Checking the condition of the tracks ....................................... 156
6.5.2 Track replacement ............................................................ 157
6.5.3 Tension check ................................................................. 158
6.5.4 Increasing the tension ........................................................ 159
6.5.5 Releasing the tension ......................................................... 160
6.6 Steel track maintenance .............................................................. 161
6.6.1 Checking the condition of the tracks ....................................... 161
6.6.2 Track replacement ............................................................ 161
6.6.3 Tension check ................................................................. 161
6.6.4 Increasing the tension ........................................................ 162
6.6.5 Releasing the tension ......................................................... 163

7 Maintenance by the dealer ................................................................... 164
7.1 Maintenance of the particle filter .................................................... 165
D Conservation and storage .......................................................................... 167
1 Conservation ................................................................................... 169
2 Storage .......................................................................................... 170
3Recommissioning .............................................................................. 171
E Technical data ....................................................................................... 173
1 Specifications .................................................................................. 175
2Working dimensions .......................................................................... 176
3 Noise emitted by the machine ............................................................... 177
4 Vibrations emitted by the machine ......................................................... 178
F Lifting capacities .................................................................................... 179
1 Lifting ViO80-1A .............................................................................. 181
2 Lifting ViO80–1A With rear counterweight ................................................ 182
Appendices ................................................................................................ 183
AList of error codes displayed on the operator display station .......................... 184
B Control sheets to be photocopied ........................................................... 187
C Notes ........................................................................................... 192
DLashing record ................................................................................ 193
Index........................................................................................................ 195

1
A Description and illustration
of the machine
CHAPTERS COVERED IN THIS PART:
1 APPLICATIONS AND REGULATIONS
2 IDENTIFICATION PLATES
3 WARNING LABELS
4 IDENTIFICATION OF IMPORTANT PARTS
5 DESCRIPTION OF THE DRIVING POSITION
6 OPERATION OF THE AIR CONDITIONING
7 COVERS
8 USING THE ELECTRIC FUEL FILLING PUMP
9 OPTIONS

2

1 APPLICATIONS AND REGULATIONS
1.1 Applications
The machine is designed to carry out the following tasks :
• excavation
• ground levelling
• shovelling
• trench digging and ridging
• loading
• lifting (optional)
CAUTION
The machine must not be used for any tasks that are not covered.
CAUTION
It is forbidden to transport or lift people with the machine.
1.2 Warranty
Refer to the maintenance book.
1.3 Driving permits
Before using this machine, check the requirements applicable to its use concerning the driving
permits. Respect all applicable laws. See your dealer for questions about usage permits.
1.4 Lifting
• Using the machine as a hoist is subject to the Machinery Directive 2006/42/EC for mem-
bers of the European Community, and to the legislations specific to each country for states
outside the EC. YANMAR CONSTRUCTION EQUIPMENT EUROPE S.A.S. declines all
responsibility for any use of the machine that does not respect the instructions in this
regulation.
• Consult your YANMAR dealer for more information about the lifting function.
CAUTION
It is forbidden to transport or lift people with the machine.
3