PDF Service Manual Yanmar C12R Crawler Carrier - 1 MB
Keep your Yanmar C12R(EP) Crawler Carrier in excellent condition with this official service manual.
This guide is packed with detailed information for maintenance, troubleshooting, and repair.
It covers the engine, hydraulic system, undercarriage, and all other major components.
Professional technicians will find the schematics and step-by-step instructions invaluable for any service task.
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--- Page 3 ---
1. GENERAL CAUTIONS FOR
MAINTENANCE WORK
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.
1-1 4480306
--- Page 4 ---
1. GENERAL CAUTIONS FOR
MAINTENANCE WORK
1-10 Air Release Procedure for H.S.T. System
1. Air Release Procedure for H.S.T. System
When hydraulic oil is put into the H.S.T. after replacing or repairing the H.S.T., release air according to the following
procedure.
If any excessive wear is found in disassembly, be sure to replace the hydraulic oil and the return filter.
(1) Remove the return hose on the top of the H.S.T. to fill the inside of the H.S.T. with hydraulic oil.
• If there is no hydraulic oil in the H.S.T. pump, put 0.6 L of hydraulic oil into the pump.
(2) Install the return hose on the H.S.T.
(3) After starting the engine, idle it for about 5 minutes.
(4) Stop the engine, and check for oil leak and the oil level in the hydraulic oil tank.
(5) Restart the engine, and travel the vehicle forward and backward at medium speed 3 or 4 times.
(6) Stop the engine after running it at the rated speed for a while, and check the oil level in the hydraulic oil tank.
Return hose Hydraulic oil tank
H.S.T.
2. Air-Venting of Each Hydraulic Component
Operate engine at medium speed and activate the respective circuit for about 10 to 15 minutes.
3. Air-Venting of Hydraulic Cylinders
(1) Set the engine speed at low idling range.
(2) Extend and retract the cylinder up to 1.97 to 3.9 in. (50 to 100 mm) from each stroke end slowly 4 or 5 times.
1.97 to 3.9 in. 1.97 to 3.9 in.
(50 to 100 mm) (50 to 100 mm)
Retraction stroke end Retraction stroke end
Note :
The extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end for the blade cylinder.
(3) Then, fully extend and retract the cylinder 3 or 4 times.
1-11 4480306
--- Page 5 ---
2. TECHNICAL DATA
2-3 Hydraulic Circuit Schematic
Dump speed Up 3.9
(sec.) Down 2.8
Control valve 2233 to 2318 (15.4 to 16.0)
Relief pressure
HST (High) 3959 to 4002 (27.4 to 27.7)
(PSI (MPa))
HST (Low) 58 to 87 (0.4 to 6.0)
Dump cylinder
2.4 1.2 10.5
( 60 30 266.5)
A1 B1
T
Control valve
Line filter
10
35.6PSI
(0.25MPa)
P
Engine
2TNE68-EFW
7.7kW/2800rpm
(10.5PS/2800rpm)
B1 Pga B2 HST (18Z+GP
Gear pump
0.25cu.in./rev
(4.1cm3/rev) Motor
1.12cu.in./rev
(18.3cm3/rev)
Pump
0 to 1.12cu.in./rev
(0 to 18.3cm3/rev)
S Pgb T
Suction filter
150 mesh
2-3-1 4480306
--- Page 6 ---
3. SERVICING STANDARDS
Applicable model 2TNE68-EFW
Item Unit Standard Wear limit
Piston ring
0.1185 to 0.1191
Ring groove width −
(3.010 to 3.025)
0.1169 to 0.1177
Ring width (B) −
(2.970 to 2.990)
Oil ring in. (mm)
0.0008 to 0.0022
Clearance between groove and ring −
(0.020 to 0.055)
0.0059 to 0.0138
End gap 0.0591 (1.5)
(0.150 to 0.350)
Connecting rod
Ø1.5354 to 1.5361
Crank pin metal inside dia. −
(Ø39.000 to 39.016)
0.0585 to 0.0591
Crank pin metal thickness −
(1.487 to 1.500)
Crank pin side
Ø1.4161 to 1.4165
Crank pin outside dia. Ø1.4138 (Ø35.91)
(Ø35.970 to 35.980)
0.0013 to 0.0023
Oil clearance 0.0059 (0.15)
(0.033 to 0.059)
in. (mm)
Ø0.7884 to 0.7889
Bush hole inside dia. Ø0.7913 (Ø20.10)
(Ø20.025 to 20.038)
Ø0.7870 to 0.7874
Piston pin side Piston pin outside dia. Ø0.7835 (Ø19.90)
(Ø19.991 to 20.000)
0.0010 to 0.0019
Oil clearance 0.0079 (0.2)
(0.025 to 0.047)
0.0012 (0.03) or less
Distortion 0.0031 (0.08)
for 0.39370 (100)
Cam
Ø1.4150 to 1.4157
Cam shaft outside dia. Ø1.4114 (Ø35.85)
(Ø35.940 to 35.960)
Gear side
0.0016 to 0.0033
Oil clearance −
(0.040 to 0.085)
Ø1.4138 to 1.4148
Cam shaft outside dia. Ø1.4114 (Ø35.85)
(Ø35.910 to 35.935)
Intermediate
0.0026 to 0.0045
Oil clearance −
(0.065 to 0.115)
in. (mm) Ø1.4150 to 1.4157
Cam shaft outside dia. Ø1.4114 (Ø35.85)
(Ø35.940 to 35.960)
Flywheel side
0.0016 to 0.0049
Oil clearance −
(0.040 to 0.125)
Cam shaft bend 0.0008 (0.02) or less 0.0020 (0.05)
1.1799 to 1.1823
Intake 1.1723 (29.75)
(29.970 to 30.030)
Cam height
1.1799 to 1.1823
Exhaust 1.1723 (29.75)
(29.970 to 30.030)
3-2-3 4480306
--- Page 7 ---
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 ..................... 4-1-6
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed .................. 4-1-9
4-1-7 Checking the Cooling Water System and Radiator
for Water Leakage ..................................................................... 4-1-9
4-1-8 Checking the Sensors.............................................................. 4-1-10
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.................................................................... 4-4-1
4-4-3 Governor Mechanism................................................................. 4-4-2
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 ................................................................................... 4-5-2
4-5-3 Glow Plug................................................................................... 4-5-4
--- Page 8 ---
4. ENGINE
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed
(1) First warm up the engine. Then, gradually increase the Maximum idling speed adjusting bolt
engine speed up to the maximum idling speed. (Refer to Decrease Increase
Section "2-1 Specifications".)
(2) If the maximum idling speed differs from the specified one,
adjust the maximum idling speed using the maximum
idling speed adjusting bolt.
(3) Set the minimum idling speed to the specified value, Minimum idling speed
(Refer to Section "2-1 Specifications") by turning the mini- adjusting bolt
mum idling speed adjusting bolt.
Note : Increase
The illustration shows the partial perspective view of the gover- Regulator handle Decrease
nor for the direct injection system.
4-1-7 Checking the Cooling Water System and Radiator for Water Leakage
1) Checking the Cooling Water System for Water Leakage
Note :
The cooling water system can be checked effectively while the
engine is warm.
(1) Supply cooling water up to the normal water level in the
radiator. Attach the cap tester body to the radiator.
(2) Start operating the cooling water pump, and set the pres- Cap tester
sure of the tester to 13.05 to 15.95 PSI (0.09 to 0.11 MPa).
Checking the cooling water system
Any lower reading of the pressure gauge on the cap tester ( for water leakage )
indicates water leakage from the cooling water system.
Then, find out the portion of the cooling water system from
which cooling water leaks.
2) Checking the Radiator Cap
Attach the radiator cap to a cap tester. Set the pressure of the
tester to 13.05 to 15.95 PSI (0.09 to 0.11 MPa). Check if the
cap is opened at the set pressure. If not, replace the cap,
because it is defective.
Radiator cap
(Checking the radiator cap)
4-1-9 4480306
--- Page 9 ---
4. ENGINE
2) Checking the Push Rod Bend, Measuring the Tappet
Stem Outside Diameter and Checking the Tappet Con-
tact Surface
Put the push rod on the surface plate to check that there is no
clearance between the push rod and the surface plate. Mea-
sure the tappet stem outside diameter with a micrometer.
Standard Wear limit
Push rod bend
Thickness gauge
Stem outside
diameter
Guide hole Refer to Section "3-2 Engine"
Tappet
inside
diameter
Oil clearance (Measuring the push rod bend)
3) Other Inspections
(1) Valve rocker arm shaft spring
Check if the rocker arm shaft spring is free from corro-
sion and wear. If not, replace it with a new one.
(2) Wear of intake/exhaust valve rocker arm and valve cap
Check the intake / exhaust valve rocker arm for the con-
tact surface with the valve cap. If any of them is exces-
sively worn or partially flaked, replace it.
(3) Check the portion where the valve clearance adjust
screw is in contact with the push rod. If the portion is (Measuring the tappet stem outside diameter)
worn or flaked, replace the push rod or the adjust screw.
Adjust screw
Check of contact surface
Check of contact
surface of rocker arm
Push rod
Abnormal contact surface Normal contact surface
(Checking the tappet contact surface)
4-2-9 4480306
--- Page 10 ---
4. ENGINE
Standard Wear limit
Crank Crank pin
pin outside dia.
Outside
dia.
Refer to Section "3-2 Engine"
Crank Main metal
journal thickness
Oil
clearance
6) Precautions for Installation of the Metal Caps
(1) The lower half of the metal on the cap side has no oil groove.
(2) The upper half of the metal on the cylinder block side has an oil groove.
(3) Check the cylinder block alignment No.
(4) Place the embossed mark "FW" of the cap on the flywheel side.
(5) Place the main metal as a reference one on the flywheel side.
Main metal (reference)
Thrust metal (flywheel side)
Main metal
Metal cap (reference)
Metal cap
Metal cap
7) Undersized Main Metal by 0.0098 in. (0.25 mm) and Oversized Thrust Metal by 0.0098 in. (0.25 mm)
Main metal Thrust metal
Metal thickness Metal thickness
Part code No. in. (mm) Part code No. in. (mm)
Standard Standard
719260-02870 0.064 (1.625) 119260-02940 0.084 (2.125)
4-2-19 4480306
--- Page 11 ---
4. ENGINE
4) Adjusting the torque rise
For the injection pump provided with a torque rise spring
Rack indicator scale [in. (mm)]
as an injection quantity increasing mechanism, make the 12 Torque rise stroke L
following torque rise adjustment for increasing the fuel R5
injection quantity.
R7
(1) The torque rise spring is incorporated in the fuel
limit bolt (the full load stopper bolt).
Use a dummy nut for the adjustment, as shown in
the figure, with no torque rise stroke during the
adjustment.
Remove the dummy nut after the adjustment to shift
0 N5 N6 N1
the torque rise stroke. Adjust the torque rise spring Pump speed (rpm)
after adjusting the fuel limit bolt and the maximum
idling speed. Dummy nut in contact
with torque rise spring
[1] Set the governor control lever to the full load posi-
tion and lower the pump speed gradually from the
rated RPM to check that the control rack shifts the
torque rise stroke L smoothly.
[2] Keep the injection pump at the maximum RPM N5 to
check that the injection quantity is within the speci-
fied range.
L
Dummy nut Torque rise
stroke
Dummy nut
in. (mm)
0.59
(15) 0.67
(17)
(19.6)
0.77
0.12 (3)
0.47 (12)
Part code No. 158090-51520
4-4-4 4480306
--- Page 12 ---
5. STRUCTURE AND OPERATION
5-3 Power Transmission
5-3-1 Outline of H.S.T.
H.S.T. is an acronym of Hydro Static Transmission.
5-3-2 Features of H.S.T.
1) The H.S.T. provides smooth changes between forward travel, backward travel and neutral by using travel pedal
and F/R lever.
2) When the travel pedal and F/R lever are set in the neutral position, the braking function (dynamic brake) works,
so that the vehicle can be stopped without using the mechanical brake.
3) The H.S.T. has a high pressure relief valve which operates in an overload state to protect the H.S.T. itself from
damage.
4) The H.S.T. also has a valve for keeping the travel pedal in neutral, which provides a wide neutral position to
ensure that the vehicle is stopped.
No. Part
1 Center section
2 Housing
22 23 57
3 Gasket (for housing)
4 Input shaft
5 Output shaft
7 Plunger
8 Shoe
9 Plunger block
14 Retainer
15 Retainer holder
16 Valve plate (for pump)
17 Valve plate (for motor)
18 Movable swash plate
23 21 24 19 Fixed swash plate
57
1 20 Thrust plate
16 21 Trunnion cover (A)
3 7 14 8 211815
22 Trunnion cover (B)
2 23 Bushing (DD)
24 Oil seal 20 × 35 × 8
25 Seal cover
39 Oil seal 25 × 45 × 8
57 O-ring 1A G55
4 63 Parallel pin 6 × 12
39 64 Parallel pin 4 × 14
67 67 External snap ring C 25
67
5
64
25
24 17 9 20 19 63
5-3-1 4480306
--- Page 14 ---
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Outline ................................................................................................. 6-1-1
6-2 H.S.T.................................................................................................... 6-2-1
6-3 Control Valve ....................................................................................... 6-3-1
6-4 Pressure Measurement Procedure ...................................................... 6-4-1
6-4-1 H.S.T........................................................................................... 6-4-1
6-4-2 Control Valve .............................................................................. 6-4-2
--- Page 15 ---
6. HYDRAULIC EQUIPMENT
4. Disassembly and Reassembly
1) Exploded View and Parts
47
52 51 48 50 49 33
35
36 42 59 44 43 22 23 57 62
27
36
29 26 38
54
31
30
28
34
37
32
23 21 24
57
1 A
B 16
41 40 11 3 10 13 7 14 8 20 18 15
Section B-B 6
46 2
70
65
45
4
56 71
69 69
39
12 67
55 67
5
60
25
View A-A 68
24 6 17 9 20 19 63 58
B A
6-2-8 4480306
--- Page 16 ---
6. HYDRAULIC EQUIPMENT
3) Reassembly
Tightening torque :
7.3 to 8.9 ft.lbf Anaerobic extra-strength adhesive :
Tightening torque : (9.9 to 12.1 N.m) Apply Three Bond 1323N or its equivalent.
29.2 to 35.7 ft.lbf Tightening torque :
(39.6 to 48.4 N.m) 1.53 to 1.87 ft.lbf (2.07 to 2.53 N.m)
Tightening torque : Tightening torque :
19.6 to 23.8 ft.lbf 16.2 to 19.9 ft.lbf
(26.5 to 32.3 N.m) (22.0 to 27.0 N.m)