Yanmar ViO12-2A User manual

SERVICE MANUAL
EXCAVATOR
ViO12-2A

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
2-3 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
3-4 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.................................................................................................................................................. 3-6-2
3-6-3 Bucket Teeth.............................................................................................................................................................. 3-6-2
3-7 List of Tightening Torque .................................................................................................................................................... 3-7-1
3-7-1 Machine...................................................................................................................................................................... 3-7-1
3-7-2 Engine........................................................................................................................................................................ 3-7-3
3-7-3 Tightening Torque for General Bolts and Nuts........................................................................................................... 3-7-3
CHAPTER 4
ENGINE
4-1 Exploded View (General layouts of major engine components).......................................................................................... 4-1-1
4-2 Measurement, Inspection and Adjustment.......................................................................................................................... 4-2-1
4-2-1 Measuring the Compression Pressure....................................................................................................................... 4-2-1
4-2-2 Adjusting the Valve Clearance................................................................................................................................... 4-2-2
4-2-3 Checking the V-belt Tension...................................................................................................................................... 4-2-3
4-2-4 Checking the Fuel Injection Valve.............................................................................................................................. 4-2-3
4-2-5 Checking and Adjusting Fuel Injection Timing ........................................................................................................... 4-2-5

4-2-6 Adjusting the Maximum (or Minimum) Idling Speed................................................................................................. 4-2-10
4-2-7 Checking the Cooling Water System and Radiator for Water Leakage ................................................................... 4-2-10
4-2-8 Checking the Sensors.............................................................................................................................................. 4-2-11
4-3 Measurement Procedure, Service Data and Corrective Action........................................................................................... 4-3-1
4-3-1 Cylinder Head............................................................................................................................................................. 4-3-1
4-3-2 Cylinder Block ............................................................................................................................................................ 4-3-6
4-3-3 Valve Rocker Arm ...................................................................................................................................................... 4-3-8
4-3-4 Piston and Piston Rings........................................................................................................................................... 4-3-10
4-3-5 Connecting Rod........................................................................................................................................................ 4-3-13
4-3-6 Cam shaft................................................................................................................................................................. 4-3-16
4-3-7 Crank shaft............................................................................................................................................................... 4-3-17
4-3-8 Gears........................................................................................................................................................................ 4-3-20
4-3-9 Trochoid Pump......................................................................................................................................................... 4-3-21
4-4 Precautions for Reassembly ............................................................................................................................................... 4-4-1
4-5 Electrical Equipment ........................................................................................................................................................... 4-5-1
4-5-1 Starter Motor .............................................................................................................................................................. 4-5-1
4-5-2 Alternator.................................................................................................................................................................... 4-5-2
CHAPTER 5
ELECTRIC SYSTEM
5-1 Parts Layout of Electrical Equipment ................................................................................................................................. 5-1-1
5-1-1 Electrical Equipment and Electric Wiring ................................................................................................................... 5-1-1
5-2 Monitor and Alarm Systems .............................................................................................................................................. 5-2-1
5-2-1 Part Name ................................................................................................................................................................ 5-2-1
5-3 Wiring diagram ................................................................................................................................................................. 5-3-1
5-2-2 Performances of Alarm Sensors .............................................................................................................................. 5-2-1
5-2-3 Operation of Alarm Sensors..................................................................................................................................... 5-2-2
5-2-4 Inspection of Electrical Equipment .......................................................................................................................... 5-2-3
5-4 Circuit Description of Engine Start and Stop ...................................................................................................................... 5-4-1
5-4-1 Start Engine ............................................................................................................................................................ 5-4-1
5-4-2 Engine Stop ............................................................................................................................................................. 5-4-2
5-4-3 Battery charge ........................................................................................................................................................ 5-4-3
5-4-3 Failure in Battery Charge ......................................................................................................................................... 5-4-3
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Outline................................................................................................................................................................................ 6-1-1
6-1-1 Control Valve Operation ............................................................................................................................................ 6-1-6
6-2 Hydraulic Circuit Schematic ............................................................................................................................................... 6-2-1
6-3 Circuit Operation ................................................................................................................................................................ 6-3-1
6-3-1 Boom ......................................................................................................................................................................... 6-3-1
6-3-2 Arm............................................................................................................................................................................ 6-3-5
6-3-3 Bucket ....................................................................................................................................................................... 6-3-9
6-3-4 Swing....................................................................................................................................................................... 6-3-13
6-3-5 Boom Swing ............................................................................................................................................................ 6-3-17

6-3-8 Track Gauge Change ............................................................................................................................................... 6-3-29
6-3-9 Simultaneous Operation of Travel and Blade........................................................................................................... 6-3-33
6-3-10 Simultaneous Operation of Boom Up and Bucket.................................................................................................. 6-3-37
6-3-11 Hydraulic P.T.O. .................................................................................................................................................... 6-3-41
6-4 Pressure Adjustment........................................................................................................................................................... 6-4-1
6-4-1 System Relief Valves ................................................................................................................................................. 6-4-1
6-4-2 Circuit Relief Valves ................................................................................................................................................... 6-4-2
6-4-3 Swing Brake Valve ..................................................................................................................................................... 6-4-3
6-4-4 Cut-Off Valve.............................................................................................................................................................. 6-4-4
6-5Hydraulic Pump ................................................................................................................................................................... 6-5-1
6-6 Control Valve ....................................................................................................................................................................... 6-6-1
6-7 Pilot Valve ........................................................................................................................................................................... 6-7-1
6-8 Cut-off Valve ....................................................................................................................................................................... 6-8-1
6-9 Swing Motor ........................................................................................................................................................................ 6-9-1
6-10 Travel Motor .................................................................................................................................................................... 6-10-1
6-3-6 Blade ....................................................................................................................................................................... 6-3-21
6-3-7 Travel ...................................................................................................................................................................... 6-3-25
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Engine of Machine ................................................................................................................................................................ 7-1-1
7-1-1Removal and Reinstallation of Engine ......................................................................................................................... 7-1-1
7-1-2Removal and Reinstallation of Starter Motor ............................................................................................................... 7-1-8
7-1-3Removal and Reinstallation of Fuel Injection Pump .................................................................................................. 7-1-11
7-1-4Removal and Reinstallation of Fuel Tank .................................................................................................................. 7-1-13
7-1-5Removal and Reinstallation ofRadiator ..................................................................................................................... 7-1-15
7-2 Undercarriage ..................................................................................................................................................................... 7-2-1
7-2-1 Outline ........................................................................................................................................................................ 7-2-1
7-2-2 Points of Reassembly ................................................................................................................................................ 7-2-2
7-2-3 Removal and Reinstallation ofCrawler ........................................................................................................................ 7-2-4
7-2-4 Disassembly and Reassembly ofIdler ........................................................................................................................ 7-2-5
7-2-5 Disassembly and Reassembly of Track Roller ............................................................................................................ 7-2-8
7-2-6 Removal and Reinstallation of Track Gauge Change Cylinder ................................................................................ 7-2-11
7-3 Controls ............................................................................................................................................................................... 7-3-1
7-3-1 Control Train .............................................................................................................................................................. 7-3-1
7-3-2 Mechanical Control Linkage ....................................................................................................................................... 7-3-2
7-3-3Adjustment of Travel and Blade Levers ...................................................................................................................... 7-3-4
7-3-4Adjustment of Boom Swing and P.T.O. Pedals and P.T.O. Pedal Lock ..................................................................... 7-3-5
7-3-5Adjustment of Lock Lever Switch ............................................................................................................................... 7-3-6
7-3-6Adjustment of Accelerator Lever ................................................................................................................................ 7-3-8
7-4 Swing Bearing ..................................................................................................................................................................... 7-4-1
7-4-1 Removal and Reinstallation of Swing Bearing ............................................................................................................. 7-4-1
7-5 Hydraulic Equipment ........................................................................................................................................................... 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Oil Tank ....................................................................................................... 7-5-1

7-5-2 Removal and Reinstallation of Control Valve ............................................................................................................. 7-5-6
7-5-3 Removal and Reinstallation of Swing Motor .............................................................................................................. 7-5-9
7-5-4 Removal and Reinstallation of Swivel Joint .............................................................................................................. 7-5-11
7-5-5 Disassembly and Reassembly of Swivel Joint ......................................................................................................... 7-5-15
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders ............................................................................................ 7-5-18
7-5-7 Removal and Reinstallation of Boom Swing Cylinder............................................................................................... 7-5-22
7-5-8Piping Layout .......................................................................................................................................................... 7-5-26
7-6 Implement .......................................................................................................................................................................... 7-6-1
7-6-1 Removal and Reinstallation of Implement .................................................................................................................. 7-6-1
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 Change of Blade Speed in Loaded Condition........................................................................................................ 10-1-4
10-1-6 Time Lag on Travel Speed Switching..................................................................................................................... 10-1-5
10-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change.......................................................... 10-1-6
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

1. GENERAL CAUTIONS FOR
MAINTENANCE WORK
1-1
1. General Cautions for Maintenance Work
1-1 Correct Work
Correct work means the quickest possible completion of according to the correct procedures and the specified stan-
dards.
It is important when conducting certain operations always to bear in mind the equipment, tools, gauges, materials, oil
and grease, etc. that you must have ready, as well as items to be checked, adjusted, or disassembled, and cautions
to watch out for.
1-2 Safety Precautions
(1) Never attempt servicing while engine is running or immediately after stopping operation.
(2) Wear work cloths, safety shoes and helmet.
(3) Check the equipment and tools before use. Especially, be sure to check the crane, lifting equipment and tools.
(4) When working together with other persons, allocate everyone's share of job, arrange the signals and act in con-
cert with the other persons.
(5) The operation of the crane and slinging work must be performed by qualified persons.
(6) Do not enter or pass under the raised load.
(7) Lift and support the massive parts by crane before removing the installation bolts.
(8) Disconnect cables from battery before repairing the electric system.
(9) Remove the battery when welding the machine.
1-3 Preparations
(1) Check the service record of the machine. (That is, check how many months or hours the machine has been
used since the preceding overhaul, what was the trouble then and what parts were replaced.)
(2) Have all servicing tools ready, i.e., tools, measuring devices (which have received periodic maintenance), con-
tainers, oil & grease, etc.
(3) Have the service literature (operation manual, parts catalog, etc.) ready.
1-4 Cautions for Disassembly and Reassembly
(1) Clean the machine before disassembly.
(2) Check and record the condition of the machine before disassembly :
• Model, machine number, operation hours
• Reasons for repair, history of repair
• Contamination of filters
• Fuel and oil condition
• Damage to parts, etc.
(3) Place alignment marks on the necessary parts to facilitate reassembly.
(4) Clean all the removed parts and new replacement parts and put them in order.
(5) Use new seals, split pins, etc. for reassembly.