Yanmar C30R-3 Crawler Carrier Service Manual

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Yanmar C30R 3 Crawler Carrier Service Manual – PDF DOWNLOAD

YANMAR C30R-3 CRAWLER CARRIER SERVICE MANUAL:

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DESCRIPTION:

Yanmar C30R 3 Crawler Carrier Service Manual – PDF DOWNLOAD

• Correct work means the quickest possible completion of according to the correct procedures and the specified standards.
• 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 concert 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. (10) Use explosion-proof lighting equipment when inspecting fuel, oil, cooling water and battery electrolyte. (11) Always relieve the internal pressure in the implement hydraulic circuit before carrying out inspection or maintenance work. 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), containers, 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.

TABLE OF CONTENTS:

Yanmar C30R 3 Crawler Carrier Service Manual – PDF DOWNLOAD

Cover............................................................................  1
Spine............................................................................  2
FOREWORD.........................................................................  3
CONTENTS.........................................................................  5
1. General Cautions for Maintenance Work......................................... 13
	1-1 Correct Work............................................................. 13
	1-2 Safety Precautions....................................................... 13
	1-3 Preparations............................................................. 13
	1-4 Cautions for Disassembly and Reassembly.................................. 13
	1-5 Cautions for Removal and Installation of Hydraulic Equipment............. 14
	1-6 Cautions for Removal and Installation of Hydraulic Piping................ 14
	1-7 Cautions for Handling Seals.............................................. 15
	1-8 Correct Installation of Hydraulic Hose................................... 15
	1-9 Specifications of Hydraulic Hose......................................... 18
	1-10 Air Release of Hydraulic Equipment...................................... 20
2. Technical Data................................................................ 27
	2-1 Specifications........................................................... 27
	2-2 Outline Drawing and Working Area......................................... 32
	2-3 Weight List of Main Parts................................................ 34
	2-4 Power Transmission....................................................... 36
	2-5 List of periodic inspection and servicing................................ 37
	2-6 Fuel, Lube Oil and Grease Recommended.................................... 39
	2-7 Hydraulic Circuit Schematic.............................................. 41
	2-8 Wiring Diagram........................................................... 43
3. Service Standards............................................................. 55
	3-1 Machine Performance...................................................... 55
		3-1-1 Three-side flaps wagon type........................................ 55
		3-1-2 Swing wagon type................................................... 58
	3-2 Engine................................................................... 62
		3-2-1 Nominal and Allowable Values....................................... 62
	3-3 Undercarriage............................................................ 66
	3-4 Controls................................................................. 68
	3-5 Hydraulic Cylinder....................................................... 70
	3-6 Work Implement........................................................... 71
	3-7 List of Tightening Torque................................................ 72
		3-7-1 Machine............................................................ 72
		3-7-2 Engine............................................................. 75
		3-7-3 Tightening Torque for General Bolts and Nuts....................... 77
		3-7-4 Hydraulic Fitting.................................................. 78
	3-8 Pressure Adjustment...................................................... 79
		3-8-1 Measuring the pressure............................................. 79
		3-8-2 Measuring the main pressure (effective differential pressure)...... 79
		3-8-3 Charge pressure measurement........................................ 80
		3-8-4 Dump pressure measurement.......................................... 81
		3-8-5 Pilot pressure measurement......................................... 81
		3-8-6 Wagon swing pressure measurement................................... 82
4. Engine........................................................................ 85
	4-1 Safety................................................................... 85
		4-1-1 Safety Statements.................................................. 85
		4-1-2 Safety Precautions................................................. 86
	4-2 Engine................................................................... 98
		4-2-1 Before You Begin Servicing......................................... 98
		4-2-2 Introduction....................................................... 99
		4-2-3 Special Service Tools..............................................100
		4-2-4 Measuring Instruments..............................................103
		4-2-5 Cylinder Head......................................................105
		4-2-6 Measuring and Adjusting Valve Clearance............................121
		4-2-7 Crankshaft and Camshaft Components.................................123
		4-2-8 EGR System.........................................................149
	4-3 Fuel System..............................................................158
		4-3-1 Before You Begin Servicing.........................................158
		4-3-2 System Structure...................................................159
		4-3-3 Fuel System Diagram................................................161
		4-3-4 Fuel System Components.............................................162
	4-4 Cooling System...........................................................170
		4-4-1 Before You Begin Servicing.........................................170
		4-4-2 Introduction.......................................................171
		4-4-3 Cooling System Diagram.............................................171
		4-4-4 Engine Coolant Pump Components.....................................172
		4-4-5 Engine Coolant System Check........................................173
		4-4-6 Engine Coolant Pump................................................173
	4-5 Lubrication System.......................................................179
		4-5-1 Before You Begin Servicing.........................................179
		4-5-2 Introduction.......................................................180
		4-5-3 Lubrication System Diagram.........................................180
		4-5-4 Checking Engine Oil Pressure.......................................181
		4-5-5 Oil Pump Components................................................181
	4-6 Starter Motor............................................................185
		4-6-1 Before You Begin Servicing.........................................185
		4-6-2 Introduction.......................................................185
		4-6-3 Starter Motor Specifications.......................................186
		4-6-4 Starter Motor Troubleshooting......................................187
		4-6-5 Starter Motor Components...........................................188
		4-6-6 Starter Motor......................................................189
	4-7 Alternator...............................................................200
		4-7-1 Before You Begin Servicing.........................................200
		4-7-2 Introduction.......................................................201
		4-7-3 Alternator Specifications..........................................201
		4-7-4 Alternator Troubleshooting.........................................202
		4-7-5 Alternator Components..............................................203
		4-7-6 Alternator Wiring Diagram..........................................204
		4-7-7 Alternator Standard Output.........................................205
		4-7-8 Alternator.........................................................206
	4-8 Electronic Control System................................................212
		4-8-1 Before You Begin Servicing.........................................212
		4-8-2 System Structure...................................................213
		4-8-3 Electronic Engine Speed Control....................................214
		4-8-4 Diesel Particulate Filter (DPF)....................................216
		4-8-5 How to Remove and Reattach the Diesel Particulate Filter (DPF).....221
		4-8-6 SF and DPF Maintenance Kit.........................................231
		4-8-7 Troubleshooting of Electronic Control System.......................232
		4-8-8 Replacement of Components..........................................236
		4-8-9 Installation Position of Sensors...................................240
	4-9 Electric Wiring..........................................................249
		4-9-1 Electric Wiring Precautions........................................249
	4-10 Failure Diagnosis.......................................................250
		4-10-1 Special Service Tools.............................................250
		4-10-2 Troubleshooting by Measuring Compression Pressure.................251
		4-10-3 Measured Value and Troubleshooting................................253
		4-10-4 Quick Reference Table for Troubleshooting.........................253
5. Electric System...............................................................260
	5-1 Electric Equipment of Machine............................................260
		5-1-1 Parts Layout of Electrical Equipment...............................260
		5-1-2 LCD Monitor and Alarm Systems......................................269
	5-2 Circuit Description of Engine Start and Stop.............................276
	5-3 vCircuit Description of Engine Start and Stop............................278
	5-4 Engine ECU (engine controller)...........................................280
		5-4-1 Engine ECU.........................................................280
		5-4-2 Circuit Description of Auto Deceleration Mode......................282
		5-4-3 Circuit Description of Eco Mode....................................283
		5-4-4 Control Functions..................................................284
	5-5 Error Code...............................................................298
6. Hydraulic System..............................................................316
	6-1 Outline..................................................................316
	6-2 Component Parts..........................................................317
		6-2-1 Arrangement of the main hydraulic equipment........................317
		6-2-2 Oil Flow...........................................................319
		6-2-3 Description of hydraulic main circuit..............................321
	6-3 Circuit Operation........................................................324
		6-3-1 Traveling and controlling direction................................324
		6-3-2 Wagon control......................................................329
	6-4 Hydraulic Pump (HST).....................................................333
		6-4-1 Main specifications................................................333
		6-4-2 Operation theory...................................................333
		6-4-3 Exploded view and Parts comprised..................................339
		6-4-4 Disassembly and Reassembly.........................................344
	6-5 Travel motor.............................................................378
	6-6 Swing Motor..............................................................423
	6-7 Control Valve............................................................452
	6-8 Pilot Valve..............................................................465
		6-8-1 Wagon control lever (pilot valve R)................................465
		6-8-2 Travel lever (pilot valve L).......................................495
	6-9 Proportional solenoid valve..............................................515
		6-9-1 Single solenoid valve..............................................515
		6-9-2 Triple solenoid valve..............................................516
	6-10 Triple solenoid valve...................................................517
	6-11 Hydraulic cylinder......................................................518
		6-11-1 Sectional View and Parts (Three-side flaps wagon type)............518
		6-11-2 Sectional View and Parts (Swing wagon type).......................519
		6-11-3 Disassembling and assembling......................................520
7. Adjustment and Repair.........................................................523
	7-1 Engine and Electric Equipment............................................523
		7-1-1 Removal and Reinstallation of Engine...............................523
		7-1-2 Removal and Reinstallation of Diesel Particulate Filter (DPF)......534
		7-1-3 Removal and Reinstallation of Starter Motor........................540
		7-1-4 Removing and reinstalling the fan belt.............................542
		7-1-5 Removal and Reinstallation of Radiator and Hydraulic Oil Cooler....544
		7-1-6 Removing and installing the fuel cooler............................549
		7-1-7 Removing and installing the fuel tank..............................551
		7-1-8 Removing and installing the LCD monitor............................555
		7-1-9 Removal and Reinstallation of Engine ECU...........................556
	7-2 Undercarriage............................................................558
		7-2-1 Removal and Reinstallation of Crawler..............................558
		7-2-2 Removal and Reinstallation of Travel Motor.........................565
		7-2-3 Disassembly and Reassembly of Idler and Grease Adjuster............568
		7-2-4 Disassembly and Reassembly of Carrier Roller.......................575
		7-2-5 Disassembly and Reassembly of Track Roller.........................579
		7-2-6 Installation of Floating Seal......................................588
	7-3 Controls.................................................................590
		7-3-1 Travel lever, wagon control lever, and lock lever components.......590
		7-3-2 Accelerator pedal components.......................................594
		7-3-3 Adjustment of Boom Swing Pedal.....................................595
	7-4 Hydraulic equipment......................................................597
		7-4-1 Removing and Reinstalling the hydraulic pump.......................597
	7-5 Wagon....................................................................661
		7-5-1 Wagon components (Three-side flaps wagon type).....................661
		7-5-2 Wagon components (Swing wagon type)................................666
		7-5-3 Removing and installing the canopy.................................668
8. Troubleshooting...............................................................673
	8-1 Troubleshooting..........................................................673
		8-1-1 Machine and Engine.................................................673
		8-1-2 HST relationship...................................................680
		8-1-3 Electrical Equipment...............................................688
APPENDIX.........................................................................  0
	C30R-3 Wiring Diagram........................................................  0

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