CONTENTS
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work ...........................................................................................................................................................................1-1
1-2 Safety Precautions ..................................................................................................................................................................1-1
1-3 Preparations ............................................................................................................................................................................1-1
1-4 Cautions for Disassembly and Reassembly ............................................................................................................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............................................................................................1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping......................................................................................................1-2
1-7 Cautions for Handling Seals ....................................................................................................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................................................................................................1-3
1-9 Specifications of Hydraulic Hose .............................................................................................................................................1-6
1-10 Air Release of Hydraulic Equipment....................................................................................................................................1-11
CHAPTER 2
TECHNICAL DATA
2-1 Specifications ...................................................................................................................................................................... 2-1-1
2-2 Outline Drawing and Working Area ..................................................................................................................................... 2-2-1
2-2-1 Canopy type ............................................................................................................................................................... 2-2-1
2-2-2 Cabin type .................................................................................................................................................................. 2-2-2
2-3 Weight List of Main Parts .................................................................................................................................................... 2-3-1
2-4 Lifting Capacity List ............................................................................................................................................................. 2-4-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance ......................................................................................................................................................... 3-1-1
3-2 Engine ................................................................................................................................................................................. 3-2-1
3-3 Undercarriage ..................................................................................................................................................................... 3-3-1
3-3-1 Rubber Crawler Specifications ................................................................................................................................... 3-3-1
3-3-2 Steel Crawler Specifications....................................................................................................................................... 3-3-2
3-3-3 Common Specifications of Steel & Rubber Crawlers ................................................................................................. 3-3-3
3-4 Controls ............................................................................................................................................................................... 3-4-1
3-5 Hydraulic Equipment ........................................................................................................................................................... 3-5-1
3-5-1 Hydraulic Cylinders .................................................................................................................................................... 3-5-1
3-6 Implement ........................................................................................................................................................................... 3-6-1
3-6-1 Front Attachments ...................................................................................................................................................... 3-6-1
3-6-2 Blade Moving Device.................................................................................................................................................. 3-6-3
3-6-3 Bucket Teeth .............................................................................................................................................................. 3-6-3
3-7 List of Tightening Torque .................................................................................................................................................... 3-7-1
3-7-1 Machine ...................................................................................................................................................................... 3-7-1
3-7-2 Engine ........................................................................................................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts ........................................................................................................... 3-7-4
CHAPTER 4
ENGINE
4-1 Measurement, Inspection and Adjustment .......................................................................................................................... 4-1-1
4-1-1 Measuring the Compression Pressure ....................................................................................................................... 4-1-1
4-1-2 Adjusting the Valve Clearance ................................................................................................................................... 4-1-2
4-1-3 Checking the V-belt Tension ...................................................................................................................................... 4-1-3
4-1-4 Checking the Fuel Injection Valve .............................................................................................................................. 4-1-3
4-1-5 Checking and adjusting the Fuel Injection Timing ...................................................................................................... 4-1-5
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed ................................................................................................... 4-1-7
4-1-7 Checking the Cooling Water System and Radiator for Water Leakage ..................................................................... 4-1-7
4-1-8 Checking the Sensors ................................................................................................................................................ 4-1-8
4-2 Measurement Procedure, Service Data and Corrective Action ........................................................................................... 4-2-1
4-2-1 Cylinder Head............................................................................................................................................................. 4-2-1
4-2-2 Cylinder Block ............................................................................................................................................................ 4-2-6
4-2-3 Valve Rocker Arm ...................................................................................................................................................... 4-2-8
4-2-4 Piston and Piston Rings ........................................................................................................................................... 4-2-10
4-2-5 Connecting Rod........................................................................................................................................................ 4-2-13
4-2-6 Cam shaft ................................................................................................................................................................. 4-2-16
4-2-7 Crank shaft ............................................................................................................................................................... 4-2-17
4-2-8 Gears........................................................................................................................................................................ 4-2-20
4-2-9 Trochoid Pump ......................................................................................................................................................... 4-2-21
4-3 Precautions for Reassembly ............................................................................................................................................... 4-3-1
4-4 Fuel Injection System .......................................................................................................................................................... 4-4-1
4-4-1 Fuel Injection Pump.................................................................................................................................................... 4-4-1
4-4-2 Fuel Injection Valve .................................................................................................................................................... 4-4-2
4-4-3 Governor Mechanism ................................................................................................................................................. 4-4-3
4-4-4 Specifications of Fuel Injection Pump ........................................................................................................................ 4-4-5
4-5 Electrical Equipment ........................................................................................................................................................... 4-5-1
4-5-1 Starter Motor .............................................................................................................................................................. 4-5-1
4-5-2 Alternator .................................................................................................................................................................... 4-5-3
4-5-3 Air Heater ................................................................................................................................................................... 4-5-4
CHAPTER 5
HYDRAULIC SYSTEM
5-1 Outline ................................................................................................................................................................................. 5-1-1
5-1-1 Control Valve Operation ............................................................................................................................................. 5-1-4
5-1-2 Additional Operation of Control Valve ........................................................................................................................ 5-1-6
5-2 Hydraulic Circuit Schematic ................................................................................................................................................ 5-2-1
5-3 Circuit Operation ................................................................................................................................................................. 5-3-1
5-3-1 Boom .......................................................................................................................................................................... 5-3-1
5-3-2 Arm............................................................................................................................................................................. 5-3-3
5-3-3 Bucket ........................................................................................................................................................................ 5-3-5
5-3-4 Swing.......................................................................................................................................................................... 5-3-7
5-3-5 Boom Swing ............................................................................................................................................................... 5-3-9
5-3-6 Blade ........................................................................................................................................................................ 5-3-11
5-3-7 Travel ....................................................................................................................................................................... 5-3-13
5-3-8 Non-Deviation Travel (with Boom, Arm, Bucket or Boom Swing Operation) ............................................................ 5-3-15
5-3-9 Simultaneous Operation of Boom Up and Arm Retract ............................................................................................ 5-3-17
5-3-10 Simultaneous Operation of Boom Up and Bucket .................................................................................................. 5-3-19
5-3-11 Simultaneous Operation of Arm and Bucket .......................................................................................................... 5-3-21
5-3-12 Simultaneous Operation of Boom Up and Swing ................................................................................................... 5-3-23
5-3-13 Hydraulic P.T.O...................................................................................................................................................... 5-3-25
5-4 Pressure Adjustment ........................................................................................................................................................... 5-4-1
5-4-1 Relief Valves .............................................................................................................................................................. 5-4-1
5-4-2 Swing Brake Valve ..................................................................................................................................................... 5-4-3
5-4-3 Cut-Off Valve .............................................................................................................................................................. 5-4-4
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump ................................................................................................................................................................... 6-1-1
6-2 Control Valve ....................................................................................................................................................................... 6-2-1
6-3 Pilot Valve ........................................................................................................................................................................... 6-3-1
6-4 Swing Motor ........................................................................................................................................................................ 6-4-1
6-5 Travel Motor ....................................................................................................................................................................... 6-5-1
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electrical Equipment of Machine and Engine ...................................................................................................................... 7-1-1
7-1-1 Parts Layout of Electrical Equipment ......................................................................................................................... 7-1-1
7-1-2 Monitor and Alarm Systems ....................................................................................................................................... 7-1-3
7-1-3 Wiring Diagram........................................................................................................................................................... 7-1-6
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging .......................................................................... 7-1-7
7-1-5 Removal and Reinstallation of Engine ....................................................................................................................... 7-1-9
7-1-6 Removal and Reassembly of Starter Motor ............................................................................................................. 7-1-16
7-1-7 Removal and Reinstallation of Fuel Injection Pump ................................................................................................. 7-1-17
7-2 Undercarriage ..................................................................................................................................................................... 7-2-1
7-2-1 Outline ........................................................................................................................................................................ 7-2-1
7-2-2 Major Parts ................................................................................................................................................................. 7-2-1
7-2-3 Points of Reassembly (Rubber Crawler Models) ....................................................................................................... 7-2-2
7-2-4 Points of Reassembly (Steel Crawler Models) ........................................................................................................... 7-2-3
7-2-5 Removal and Reinstallation of Crawler ...................................................................................................................... 7-2-5
7-2-6 Removal and Reinstallation of Travel Motor .............................................................................................................. 7-2-7
7-2-7 Disassembly and Reassembly of Idler ....................................................................................................................... 7-2-9
7-2-8 Disassembly and Reassembly of Track Roller ......................................................................................................... 7-2-12
7-2-9 Disassembly and Reassembly of Carrier Roller ....................................................................................................... 7-2-15
7-2-10 Installation of Floating Seal .................................................................................................................................... 7-2-17
7-2-11 Drawings of Jigs ..................................................................................................................................................... 7-2-18
7-3 Controls ............................................................................................................................................................................... 7-3-1
7-3-1 Control Train............................................................................................................................................................... 7-3-1
7-3-2 Mechanical Control Linkage ....................................................................................................................................... 7-3-2
7-3-3 Adjustment of Travel Levers....................................................................................................................................... 7-3-4
7-3-4 Adjustment of Boom Swing Pedal .............................................................................................................................. 7-3-5
7-3-5 Adjustment of Blade Control Lever ............................................................................................................................. 7-3-5
7-3-6 Adjustment of Lock Lever ........................................................................................................................................... 7-3-6
7-3-7 Adjustment Procedure of Travel Alarm Switch ........................................................................................................... 7-3-7
7-3-8 Adjustment Procedure of P.T.O. Pedal ...................................................................................................................... 7-3-8
7-3-9 Adjustment Procedure of P.T.O. Pedal Lock.............................................................................................................. 7-3-8
7-3-10 Adjustment of Accelerator Lever .............................................................................................................................. 7-3-9
7-4 Swing Bearing ..................................................................................................................................................................... 7-4-1
7-5 Hydraulic Equipment ........................................................................................................................................................... 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump ......................................................................................................... 7-5-1
7-5-2 Removal and Reinstallation of Control Valve ............................................................................................................. 7-5-3
7-5-3 Removal and Reinstallation of Swing Motor ............................................................................................................... 7-5-6
7-5-4 Removal and Reinstallation of Swivel Joint ................................................................................................................ 7-5-8
7-5-5 Disassembly and Reassembly of Swivel Joint ......................................................................................................... 7-5-11
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders ............................................................................................. 7-5-14
7-5-7 Hydraulic Oil Tank .................................................................................................................................................... 7-5-18
7-5-8 Piping Layout............................................................................................................................................................ 7-5-25
7-6 Work Implements ................................................................................................................................................................ 7-6-1
7-6-1 Removal and Reinstallation of Work Implements....................................................................................................... 7-6-1
7-7 New Cabin........................................................................................................................................................................... 7-7-1
7-7-1 Cabin .......................................................................................................................................................................... 7-7-1
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing.................................................................................................................................8-1
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended ...............................................................................................................................9-1
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns............................................................................................................................................................. 10-1-1
10-1-1 Natural Release of Bucket ...................................................................................................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................................................................................................... 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation ............................................................................................ 10-1-2
10-1-4 Thermal Shock of Travel Motor .............................................................................................................................. 10-1-3
10-1-5 Elongation of Boom Swing Cylinder on 75 degrees Swing .................................................................................... 10-1-4
10-1-6 Telescopic Motion of Boom Swing Cylinder with Lock Lever Set to Lock Position ................................................ 10-1-5
10-1-7 Time Lag on Travel Speed Switching..................................................................................................................... 10-1-6
10-1-8 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change .......................................................... 10-1-7
10-2 Troubleshooting .............................................................................................................................................................. 10-2-1
10-2-1 Machine and Engine............................................................................................................................................... 10-2-1
10-2-2 Electrical Equipment on Panel ............................................................................................................................. 10-2-22
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment ..............................................................................................................................................11-1
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work............................................................................................1-1
1-2 Safety Precautions...................................................................................1-1
1-3 Preparations ............................................................................................1-1
1-4 Cautions for Disassembly and Reassembly ............................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ...............1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping ......................1-2
1-7 Cautions for Handling Seals ....................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................1-3
1-9 Specifications of Hydraulic Hose .............................................................1-6
1-10 Air Release of Hydraulic Equipment ...................................................1-11
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Yanmar VIO30-2 Crawler-backhoe Parts Catalogue
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Description
This parts catalog contains detailed information about the parts of the Yanmar VIO30-2 crawler-backhoe model.
It covers the following:
- Vehicle: VIO30-2 C, VIO30-2 P, 20501 - 22139
- Engine: 3TNE82A-EBVB, 56889 - 78463; 3TNE82A-EBVC, 64110 -
This manual is of high quality, and all pages are printable. It is available in English language and is compatible with all versions of Windows and Mac. Adobe Reader is required to access the file.
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