SEBM010911
Shop Manual
PC60-7 PC60-7B HYDRAULIC EXCAVATOR SERIAL NUMBERS
PC60-7 52374 and up PC60-7B 52374 and up PC60-7 55720 and up (For Norway)
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
Copyright 2004 Komatsu Printed in U.S.A. Komatsu America Corp. November 2004
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SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWORD
GENERAL
FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
k
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
5
Oil, water
Places where oil, water or fuel must be added, and the capacity.
6
Drain
Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained.
a
4
3 2
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
★ The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. ★ For coating materials not listed below, use the equivalent of products shown in this list. Category
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
• Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030
50 g
Polyethylene container
• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
• Used as heat-resisting sealant for repairing engine.
50 g
Polyethylene container
• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min. • Used mainly for adhesion of metals, rubbers, plastics and woods.
Adhesives
Three bond 1735
790-129-9140
• Used as adhesive or sealant for metal, glass and plastic.
Aron-alpha 201
790-129-9130
2g
Polyethylene container
• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.
LG-1
790-129-9010
200 g
Tube
• Used as adhesive or sealant for gaskets and packing of power train case, etc.
LG-5
790-129-9080
1 kg
Can
• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Tube
• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.
LG-6
790-129-9020
200 g
Gasket sealant LG-7
790-129-9070
1 kg
Tube
• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Three bond 1211
790-129-9090
100 g
Tube
• Used as heat-resisting sealant for repairing engine.
Tube
• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case
Three bond 1207B
00-10
• Used as sealant for machined holes.
419-15-18131
100 g
FOREWORD
Category
Molybdenum disulphide lubricant
Grease
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LM-G
09940-00051
60 g
Can
• Used as lubricant for sliding portion (to prevent from squeaking).
Tube
• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Molybdenum disulphide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
Hyper White Grease G2-T G0-T (*) *: For use in cold district
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
Biogrease G2B G2-BT (*) *: For high temperature and large load
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
200 g
• General purpose type Various
Various
Various
Various
400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can
400 g 16 kg
400 g 16 kg
• Used for normal temperature, light load bearing at places in contact with water or steam.
• Used for heavy load portion
• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has Bellows type less effects on microorganisms, Can animals, and plants.
SUNSTAR PAINT PRIMER 580 SUPER
20 ml
Glass container
SUNSTAR GLASS PRIMER 580 SUPER
20 ml
Glass container
• Used as primer for cab side (Using limit: 4 months)
Primer
Caulking material
SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
320 ml
Polyethylene container
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
Adhesive for cab glass
Adhesive
417-926-3910
• Used as primer for glass side (Using limit: 4 months) • "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190
1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5
16 18 20 22 24
24 27 30 32 36
235 – 285 320 – 400 455 – 565 610 – 765 785 – 980
23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100
27 30 33 36 39
41 46 50 55 60
1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630
118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Tightening torque
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12
Tightening torque
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
mm
mm
14 20 24 33 42
Varies depending on type of connector.
Tightening torque (Nm {kgm})
Norminal No.
02 03, 04 05, 06 10, 12 14
Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010
{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
mm
mm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
Tightening torque (Nm {kgm})
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5
{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}
Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12
10 0 2 24 0 4 43 0 6 77 0 12
1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12 14
802 10 0 2 12 0 2 24 0 4 36 0 5
0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
kgm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9
0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Thread size Nominal thread Root diameter size - Threads per (mm) (Reference) (mm) inch, Thread series
Range
Target
34 – 54 {3.5 – 5.5}
44 {4.5}
–
9 — – 18UN 16
14.3
34 – 63 {3.5 – 6.5}
44 {4.5}
14
–
–
22
54 – 93 {5.5 – 9.5}
74 {7.5}
–
11 — – 16UN 16
17.5
24
59 – 98 {6.0 – 10.0}
78 {8.0}
18
–
–
04
27
84 – 132 {8.5 – 13.5}
103 {10.5}
22
13 — – 16UN 16
20.6
05
32
128 – 186 {13.0 – 19.0}
157 {16.0}
24
1 – 14UNS
25.4
06
36
177 – 245 {18.0 – 25.0}
216 {22.0}
30
3 1 — – 12UN 16
30.2
(10)
41
177 – 245 {18.0 – 25.0}
216 {22.0}
33
–
–
(12)
46
197 – 294 {20.0 – 30.0}
245 {25.0}
36
–
–
(14)
55
246 – 343 {25.0 – 35.0}
294 {30.0}
42
–
–
02
03
00-14
19
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
2 Color White & Red
—
Code
—
WB
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
3
4
Auxiliary
Color White & Black
—
Code
—
WL
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
Color White & Blue
—
Code
—
—
Color White & Green
—
—
Code
—
—
—
Color
—
—
—
WG
RY
Black & Red Red & Yellow RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
5 Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
6 Red & Blue Yellow & White Green & Blue
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line from A. (2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 C 2.165 2.559 2.953 3.346 3.740
6
7
8
9
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {
}.
Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
10-04
01 GENERAL
Dimension ....................................................... 01-2 Specifications ................................................. 01-4 Weight Table ................................................... 01-6 Table of oil and coolant capacities ................ 01-8
PC60-7
01-1 (10)
DIMENSION
GENERAL
Whe
value3
marked%
are
for
btade
svecification SKP04180
only.
WORKING RANGE
XThe
value3
marked* are ooerat ions. SKP04181
01-2
GENERAL
SPECIFICATIONS
SPECIFICATIONS PC60-7 Machine model Standard specification Serial Number
52374 -
57999
0.25
0.25
kg
6,200
6,700
Max. digging depth
mm
4,100
4,100
Max. vertical wall depth
mm
3,505
3,505
Max. digging reach
mm
6,360
6,360
Max. reach at ground level
mm
6,220
6,200
Max. digging height
mm
7,150
7,150
Max. dumping height
mm
5,015
5,015
Max. lifting height of blade
mm
-
410
Max. lowering depth of blade
mm
-
270
kN {kg)
47 (4,800)
‘47 (4,800)
rpm
12
Operating weight
f
E tj
52374 -
m3
Bucket capacity
8 :
57999
Blade specification
‘t:
2
Max. digging force Swing speed
12
Swing max. slope angle
deg.
20
20
Travel speed
Km/h
Lo 2.8 Hi 4.5
Lo 2.8 Hi 4.5
Gradeability
deg.
35
35
kPa {kg/cm’}
29.42 (0.301
30.40 to.311
Overall length (for transport)
mm
6,080
6,080
Overall width
mm
2,225
2,280
Overall width of track
mm
2,150
2,150
Overall height (for transport)
mm
2,590
2,590
Overall height (to top of cab)
mm
2,590
2,590
Ground clearance, counterweight
mm
750
750
Ground pressure (standard shoe width: 450 mm)
-
z
._0
P
E .n
Min. ground clearance
mm
350
350
Tail swing radius
mm
1,750
1,750
Min. swing radius of work equipment
mm
1,750
1,750
Height of work equipment at min. swing radius
mm
5,460
5,460
Length of track on ground
mm
2,130
2,130
Track gauge
mm
1,700
1,700
Height of machine cab
mm
1,750
1,750
Blade width x height
mm
-
2,260x470
-
01-4 0
PC60-7
GENERAL
SPECIFICATIONS
PC60-7 Machine model
58001 and up
58001 and up
m3
0.25
0.25
Operating weight
kg
6,200
6,700
Max. digging depth
mm
4,100
4,100
Max. vertical wall depth
mm
3,505
3,505
Max. digging reach
mm
6,360
6,360
Max. reach at ground level
mm
6,220
6,200
Max. digging height
mm
7,150
7,150
Max. dumping height
mm
5,015
5,015
Max. lifting height of blade
mm
—
410
Max. lowering depth of blade
mm
—
270
kN {kg}
47 {4,800}
47 {4,800}
Swing speed
rpm
12
12
Swing max. slope angle
deg.
20
20
Travel speed
Km/h
Lo 2.8 Hi 4.5
Lo 2.8 Hi 4.5
Gradeability
deg.
35
35
kPa {kg/cm2}
29.42 {0.30}
30.40 {0.31}
Overall length (for transport)
mm
6,080
6,080
Overall width
mm
2,225
2,280
Overall width of track
mm
2,150
2,150
Overall height (for transport)
mm
2,590
2,590
Overall height (to top of cab)
mm
2,590
2,590
Ground clearance, counterweight
mm
750
750
Min. ground clearance
mm
350
350
Tail swing radius
mm
1,750
1,750
Min. swing radius of work equipment
mm
1,750
1,750
Height of work equipment at min. swing radius
mm
5,460
5,460
Length of track on ground
mm
2,130
2,130
Track gauge
mm
1,700
1,700
Height of machine cab
mm
1,750
1,750
Blade width x height
mm
—
2,260 × 470
Max. digging force
Ground pressure (standard shoe width: 450 mm)
Dimensions
Blade specification
Bucket capacity
Working ranges
Performance
Serial Number
Standard specification
01-5-1 (10)
PC60-7
GENERAL
WEIGHT TABLE
WEIGHT TABLE ¤
These weights are for reference when handling or transporting components. Unit: kg PC60-7 Machine model Standard specification
Blade specification
52374 and up
52374 and up
382
382
6
6
Serial No.: 52374 – 59774
31
31
Serial No.: 59775 and up
36
36
Revolving frame
638
638
Operator’s cab
260
260
Operator’s seat
20
20
Fuel tank (excl. fuel)
50
50
Hydraulic tank (excl. hydraulic oil)
58
58
Serial No.: 52374 – 58000
685
685
Serial No.: 58001 and up
715
715
Hydraulic pump assembly
57
57
7-spool control valve
43
—
8-spool control valve (with blade)
—
48
Swing circle assembly
99
99
Swing machinery assembly
43
43
Swing motor assembly
22
22
Center swivel joint
13
16
1,200
1,342
613
735
• Idler
54 × 2
54 × 2
• Idler cushion
40 × 2
40 × 2
• Carrier roller
3.4 × 2
3.4 × 2
• Track roller (Serial No.: 52374 – 60156)
13.3 × 10
13.3 × 10
(Serial No.: 60157 and up)
12.4 × 10
12.4 × 10
• Travel motor
90 × 2
90 × 2
• Sprocket
25 × 2
25 × 2
• Standard triple shoe (450 mm)
400 × 2
400 × 2
• Wide triple shoe (600 mm)
480 × 2
480 × 2
• Swamp shoe (700 mm)
590 × 2
590 × 2
• Rubber shoe (450 mm)
366 × 2
366 × 2
Serial Number Engine assembly (excl. water, oil) PTO (coupling) assembly Radiator, oil cooler assembly
Counterweight
Track frame assembly • Track frame
Track shoe assembly
01-6 (11)
PC60-7
GENERAL
WEIGHT TABLE
Unit: kg PC60-7 Machine model Standard specification
Blade specification
52374 and up
52374 and up
Boom assembly
410
410
Arm assembly
160
160
Link assembly
55
55
Bucket assembly
210
210
Blade assembly
—
360
Boom cylinder assembly
90
90
Arm cylinder assembly
72
72
Bucket cylinder assembly
51
51
Blade cylinder assembly
—
44
Serial Number
PC60-7
01-7
GENERAL
TABLE OF OIL AND COOLANT CAPACITIES
TABLE OF OIL AND COOLANT CAPACITIES RESERVOIR
KIND OF FLUID –30
SELECTION ACCORDING TO AMBIENT TEMPERATURE –20
–10
0
10
20
30
CAPACITY (¬)
40°C Specified
Refill
SAE 30CD SAE 10WCD
14.5 (11.0)
Engine oil pan SAE 10W-30CD
13 (10.5)
SAE 15W-40CD PTO case
0.5(0.35) 0.5(0.35)
Swing machinery case Final drive case (left and right, each)
1.5
1.5
1.7
1.7
0.06
—
90
57
130
—
GO 140
0.21 – 0.23 <0.16 – 0.18>
—
ALBANIA EP-2
0.047 – 0.052
—
Cartridge : 0.5 + Piping : 1.5
—
16 (10.3)
—
SAE 30CD Engine oil
Idler (left and right, each)
SAE 30CD
SAE 10WCD SAE 10W-30CD Hydraulic system
SAE 15W-40CD
Hydraulic oil
HO46-HM (Note 1)
ASTM D975 No. 2 Fuel tank
Diesel fuel ª1
Track roller (each)
Gear oil
Carrier roller (each) Cartridge for automatic greasing system (Note 2) Cooling system
Grease NLGI No. 2 NLGI No. 2 Coolant
Add Komatsu genuine Super Coolant (AF-ACL) ª1: ASTM D975 No. 1
01-8 (11)
NLGI No. 0 (Note 3)
( <
) : Serial Number 58001 and up > : Serial Number 60157 and up
PC60-7
GENERAL
TABLE OF OIL AND COOLANT CAPACITIES
A
FUEL, OIL l
f
Select the fuel and oil according to the ambias shown in the table. ent temperature The specified oil capacity indicates the total amount of oil including the oil in the piping the refill capacity indifor each component; cates the amount of oil added when the oil is changed for normal inspection and mainte-
nance. When starting the engine in ambient temperatures of below CI’C, even if the daytime temperature rises to lO”C, always use SAElOW or SAE 1OW-30. Note 1: For hydraulic oil H046-HM, use the oil recby Komatsu. ommended and Maintenance See the Operation Manual for details of the procedure for changing the oil. Note 2: There are two types of automatic greasing available: the standard type cartridges (NLGI No. 2) and the cold area type (NLGI No. 0). When changing the automatic greasing cartridge from the standard type to the cold area type, or from the cold area type to the standard type, please see the OpManual. eration and Maintenance Note 3: If the cold area type grease (NLGI No. 0) is used in warm areas, some grease will drip from the ends of the work equipment pins, but there is no problem in the lubricating performance. 1:
A
6 ‘0 2
-4
ANTI-FREEZE Super Coolant (AF-ACL) is Komatsu genuine added at a proportion of 30% to the cooling water, so there is no need to change the density for down to -10X. temperatures goes below -lO’C, adjust the If the temperature density according to the table below.
+
Use tap water for the coolant.
01-9
10
STRUCTURE AND FUNCTION
Radiator, oil cooler ..................................... PTO (coupling) ............................................ Engine control ............................................ Power train diagram .................................. Swing circle ................................................ Swing machinery ....................................... Track frame ................................................. Idler cushion ............................................... Hydraulic piping drawing .......................... Hydraulic circuit diagram .......................... Hydraulic tank.. ........................................... Hydraulic pump .......................................... Control valve.. ............................................. Self-pressure reducing valve.. ................... CLSS ............................................................ Swing motor.. ............................................. Center swivel joint.. .................................... Travel motor ............................................... Valve control ............................................... Work equipment, swing PPC valve ........... Travel PPC valve ......................................... Service PPC valve ....................................... Solenoid valve ............................................ Hydraulic cylinder ...................................... Work equipment.. ....................................... Work equipment pin automatic greasing system ....................................... Electrical allocation diagram (l/2). ............ Electrical allocation diagram (2/2). ............ Electrical circuit diagram ........................... Electric control system.. ............................. Machine monitor system ...........................
PC60-7
IO- 2 IO- 3 IO- 4 IO- 5 IO- 6 IO- 7 IO- 8 IO- 9 IO- 10 lo- 11 IO- 12 IO- 13 IO- 40 IO- 51 IO- 56 IO- 86 IO- 90 IO- 92 IO- 98 10-100 IO-104 IO-I 08 1O-l 12 IO-I 14 IO-I 16 IO-117 lo-130 IO-131 IO-132 IO-134 IO-142
10-l
STRUCTURE AND FUNCTION
PTO (COUPLING)
e
PTO (COUPLING)
B-B
h
A-A SKP03033
1. 2. 3. 4.
Drain plug Shaft Coupling Flywheel
5. 6. 7. 8.
Pump case Breather/oil Cage Level plug
filler plug
1o-3
STRUCTURE AND FUNCTION
ENGINE CONTROL
ENGINE CONTROL
SLPO3034
1. Fuel control dial 2. Starting switch 3. Starting motor 4. Stop lever 5. Battery 6. Fuel injection pump 7. Governor lever
1o-4
Outline . The engine can be stopped and started simply by using the starting switch. . The engine stop solenoid has a fail-safe mechanism which acts to drive the fuel injection pump stop lever to the RUN position when the starting switch is turned ON, so if there is any abnormality in the electrical system, the engine stops.
STRUCTUREAND FUNCTION
POWER TRAIN DIAGRAM
h
POWER TRAIN DIAGRAM
SKP03035
1. 2. 3. 4. 5. 6.
Idler Center swivel joint Control valve Swing brake solenoid valve Travel speed solenoid valve Travel motor
7. 8. 9. 10. 11.
Hydraulic pump Engine Swing motor Swing machinery Swing circle
1o-5
STRUCTURE AND FUNCTION
SWING CIRCLE
SWING CIRCLE
A-A
I
I
CII
2 3
SKP03036
I, 2. 3. 4. 5.
Swing circle outer race Ball Swing circle inner race Plug Grease nipple
S.
Inner race, outer race zone position
1 O-6
Specifications Reduction Amount
ratio- 76 =7 60 -10 . of grease: 5 e (G2-LI)
IDLER CUSHION
STRUCTURE AND FUNCTION
IDLER CUSHION
SKP03039
1. Yoke 2. Rod (piston) 3. Front support (cylinder) 4. Recoil spring 5. Wear ring 6. Packing 7. Rear support 8. Lubricator 9. Drain plug
Specifications Amount of grease:
120 cc
1o-9
STRUCTURE AND FUNCTION
HYDRAULIC Ir
PIPING DRAWING
For details of this page, see page 90-3.
HYDRAULIC PIPING DRAWING
STRUCTURE AND FUNCTION
HYDRAULIC *
For details
HYDRAULIC CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
of this page, see Daae 90-5.
4
10-l 1
STRUCTURE AND FUNCTION
HYDRAULIC
HYDRAULIC TANK
TANK
5
4 B-B
A-A
c-c
D-D
SKP03046
1. 2. 3. 4. 5. 6. 7. 8.
Return filter Safety valve Cap Vacuum valve Pressure valve Sight gauge Suction strainer Drain plug
10-12
Specifications Tank capacity: 71 e Amount of oil inside tank: 57 e Cracking pressure of pressure valve : 0.04 I 0.01 MPa IO.39 + 0.15 kg/cm? Cracking pressure of vacuum valve : 0 - 0.05 MPa (0 - 0.46 kg/cm? Actuating pressure of safety valve : 0.10 k 0.02 MPa il.05 f 0.2 kg/cm*)
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
HYDRAULIC PUMP PS
0
0
& 0
0
PX3
PDA
PDl
PA2
1
PLS
/
CZ
SXPO7085
PA PA2 PA3 PDl
: Pump discharge : LS pressure inlet port : Drain port : Pump drain
1.
Main pump
PC60-7
PDA: PLS : PM : PS :
Pump air bleed port LS pressure inlet port L mode selection pilot port Pump suction
JO-73 0
STRUCTURE AND FUNCTION
HYDFtAULlC PUMP
1. MAIN PUMP
PX3
PDA
PDI
PA2
PLS
A _c CZ
PA : PA2 : PA3 : PDA: PDI : PLS : PM : PS :
Pump discharge LS pressure inlet port Drain port Pump air bleed port Pump drain LS pressure inlet port L mode selection pilot port Pump suction
IO-14 0
*
The main pump consists of one unit formed by the pump, servo piston, PC valve, and LS valve. The explanation in STRUCTURE AND FUNCTION is divided into two parts: the pump and PC valve + LS valve.
PC60-7
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
A-A
SKP03049
1. Shaft 2. Cradle 3. Case 4. Rocker cam 5. Shoe
6. 7. 8. 9. IO.
Piston Cylinder block Valve plate Spring Servo piston
h
70-75
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
Function . The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. . It is possible to change the discharge amount by changing the swash plate angle.
a
Structure . Cylinder block (7) is supported to shaft (I) by spline a, and shaft (I) is supported by the front and rear bearings. The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. . Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. l
10-M
.
l
SKP03050
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
F
Operation 1) Operation of pump i) Cylinder block (7) rotates together with shaft (I), and shoe (5) slides on flat surface A. When this happens, rockercam (4) moves along cylindrical surface 6, so angle a between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. Angle a is called the swash plate angle. ii)
C
Center line X of rocker cam (4) maintains swash plate angle a in relation to the axial direction of cylinder block (71, and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volume E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F - E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. At the same time, the volume of chamber F becomes larger, and as the volume becomes larger, oil is sucked in. (The diagram shows chamber F at the end of the suction process and chamber E at the end of the discharge process.)
SKP0305
j
I
‘E SKP03052
iii) If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 01, the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.) iv) In other words, there is a proportional relationship between swash plate angle a and the pump discharge amount.
7
‘E SKP03053
JO-J7
STRUCTURE
2) .
.
.
.
Control
AND FUNCTION
of discharge
PUMP
amount
If swash plate angle a becomes larger, the difference in volumes E and f becomes larger and discharge amount Q increases. Swash plate angle a is changed by servo piston (IO). Servo piston (IO) moves in a reciprocal movement ( 1 1according to the command from the PC and LS valve. This straight line movement is transmitted to rocker cam (4), and rocker cam (41, which is supported by the cylindrical surface to cradle (2), moves in a rotating motion on the cylindrical surface in the ({ ) direction. With servo piston (701, the area receiving the pressure is different at the top and bottom, so main pump discharge pressure (self pressure) PP is always connected to the pressure chamber at the small diameter piston end (top). Output pressure Pen of the LS valve is brought to the pressure chamber at the large diameter piston end (bottom). The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter piston end, and the ratio between the pressure-receiving area at the small diameter piston end and the large diameter piston end controls the movement of servo piston (10).
lo-18
HYDRAULIC
SKP03054
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
2. PC VALVE, LS VALVE, SERVO PISTON
PP
1;
14
i3
i2
D-D SXPll7087
PA2: PA3: PLS: PM : PP :
LS pump pressure port Drain port Control valve LS pressure inlet port Mode selection solenoid pressure inlet port Main pump pressure port
Servo piston 1. Servo piston 2. Lever 3. Spring
1O-20 GO
PC valve 4. Piston 5. Spring 6. Seat 7. Spring 8. Piston
LS valve 12. Plug 13. Sleeve 14. Spring 15. Piston
9. Sleeve
10. Piston 11. Plug
PC60-7
STRUCTURE AND FUNCTION
LS valve Function . The LS valve controls
.
.
6 5 s
-
l
the pump discharge amount according to the amount of movement of the control lever, that is the oil flow demanded by the actuator. The LS valve detects the oil flow demanded by the actuator from the differential pressure APLS between input pressure Pa2 of the control valve (downstream pressure of self-pressure reducing valve) (Note 1) and control valve outlet pressure PLS, and controls main pump discharge amount 0. (Pa2 is called the LS pump pressure, PLS is called the LS pressure, and APLS is called the LS differential pressure.) In other words, the pressure loss (= LS differential pressure APLS) generated by the flow of oil from the pump passing through opening area of the control valve spool is detected. By controlling pump discharge amount 0 so that this pressure loss remains constant, a pump discharge amount is supplied in accordance with the demands of the control valve by controlling pump discharge amount Q. Main pump discharge pressure PP, LS pump pressure Pa2, and LS pressure PLS are brought to the LS valve. The relationship between pump discharge amount 0 and LS differential pressure APLS changes as shown in the diagram on the right.
HYDRAULIC PUMP
CP/m
i n)
0
.z? L
E 2
1 LS
differential
1. 96 (201 pressure
MPa 1 k o/cm’) APu
SKP04182
Note 1: Previously, the pump discharge pressure and control valve outlet port pressure were brought to both sides of the LS valve as the LS differential pressure /PLS. However, the LS differential pressure changes according to the differential pressure at the self pressure reducing valve, so it is necessary to bring the self pressure reducing valve downstream pressure = control valve inlet port pressure and control valve outlet port pressure to the LS valve.
A
1O-21
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
Operation 1.
When control valve is at HOLD position
To actuator
Control
Self-Pressure
(Small
X
(Laroe
valve
reducino
valve
diameter
end)
diameter
end)
,
,,,,
, I /
vg
.,I,I, SKP04183
1o-22
STRUCTURE
.
.
.
.
.
b 0
G z
l
AND FUNCTION
HYDRAULIC
PUMP
The LS pressure PLS is brought from the control valve outlet port to spring chamber a of the LS valve. LS pump pressure Pa2 at the control valve inlet port is brought to chamber b at the tip of the sleeve on the opposite side. by The position of piston (15) is determined the size of pump pressure Pa2 and the combined force of LS pressure PLS + force of spring (14). Before the engine is started, servo piston (I) is pushed down (direction of minimum swash plate angle) by spring (3). After the engine is started, if all the control valves are at the neutral position, no pressure oil flows to the control valve outlet port, so LS pressure PLS is 0 MPa IO kg/cm2). (Spring chamber a is connected to the drain circuit through the control valve spool.) At the same time, LS pump pressure Pa2 is held at the unload pressure of approx. 2.7 MPa (27 kg/cm2}. For this reason, piston (15) is pushed to the right (01, portc and portd are interconnected, and pump pressure PP is brought from port d to chamber X at the large diameter end of servo piston (1). Pump pressure PP is always supplied to chamber Y at the small diameter end of servo piston (I), but the force applied to the large diameter end of servo piston (1) is greater because of the difference in area at both ends of the piston, so servo piston (I) moves up in swash plate the direction of the minimum angle (fi 1.
7o-23
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
2.
When opening
area of control valve is maximum
(lever operated fully)
To actuator
Self-Pressure
reducing
valve
r-----------
/
/11111,1,,,,,,, 1,1,,,,,,,,,,,, <11111,11,,,,,,
\ x’
ILaroe
diameter
end)
SKP04184
1 O-24
STRUCTURE
.
.
.
.
.
AND FUNCTION
HYDRAULIC
PUMP
When the control lever is operated fully, that is, when the area of opening of the control valve becomes larger, the difference between LS pump pressure Pa2 and LS pressure PLS (LS differential pressure APLS) becomes smaller. LS pressure PLS brought to spring chamber a of the LS valve becomes close to LS pump pressure Pa2, and piston (15) is pushed to the left (c 1by the combined force of LS pressure PLS + force of spring (14). This closes port c and interconnects port d and port e. As a result, the pressurized oil acting on chamber X at the large diameter end of servo piston (I) flows from port d to port e and is connected to port f of the PC valve. At this point, port f of the PC valve is drained inside the pump case through the inside of the piston, so the pressure in chamber X at the large diameter end of servo piston (I) also becomes the drain pressure. Because of this, servo piston (1) is moved down in the direction of the maximum swash plate angle ( I ) by pump pressure PP acting on chamber Y at the small diameter end of the piston.
h
1o-25
STRUCTURE
3.
AND FUNCTION
When opening
HYDRAULIC
area of control
valve is small (small movement
PUMP
of lever)
To actuator
Control
Self-Pressure
valve
reducine
valve
diameter
end)
r-----------
l hall
I
,
l-
X
(Large
diameter
end)
SKP04185
1O-26
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
h
.
l
When the control lever is operated in small movements, or when it is operated to the HOLD position (in other words, when the area of opening of the control valve becomes smaller), the difference between LS pump pressure Pa2 and LS pressure PLS (in other words, LS pressure APLS) becomes larger. When this happens, the movement is the same as for [I. When control valve is at HOLD position]: LS pump pressure Pa2 pushes piston (14) to the right (L), so servo piston (I) is moved up in the direction of the minimum swash plate angle (t 1. In other words, the basic LS set differential pressure of the LS valve is taken as 1.96 MPa I20 kg/cm% In the range from the neutral position of the control valve to the small area of opening of the control valve (fine control), in the area where the LS differential pressure APLS is more than 1.96 MPa (20 kg/cm3, the pump swash plate angle moves in the minimum direction. If the area of opening of the control valve is further increased, and LS differential pressure APLS goes below 1.96 MPa {20 kg/cm?, the pump swash plate angle is moved in the maximum direction.
A
1 O-27
STRUCTURE AND FUNCTION
4.
HYDRAULIC PUMP
When pump flow is amount demanded by control valve
To actuator /‘J, %
I‘/
Control valve
Self-Pressure
reducine
-d
r------------
(Small
I
valve
diameter
end1
1
1;
E ‘I
:;
‘/
:;
‘, ‘, ,
H
‘/
i_ i
/ X
(Large
diameter
end)
SKP04186
1 O-28
STRUCTUREAND FUNCTION
.
l
-
l
l
l
.
.
HYDRAULICPUMP
Let us take the area receiving the pressure at the large diameter end of servo piston as Al, the area receiving the pressure at the small diameter end as A2, the pressure acting on the large piston diameter end as Pen, and the pressure acting on the small piston diameter end as PP. When the flow of oil from the pump reaches the flow demanded by the control valve, LS pump pressure Pa2 acting on port b of the LS valve and the combined force of LS pressure PLS + force of spring (14) acting on spring chamber a are balanced, so piston (15) stops at almost the central position. As a result, port c, port d, and port e open approximately the same amount, so the pump pressure flows from port c to port d. Part flows from port e to the tank case and is drained, so the pressure is reduced by approx. l/2 and flows to chamber X at the large diameter end of servo piston (1). At this point, the relationship between the area receiving the pressure at both ends of piston (1) is A2 : Al = 1 : 2, so the pressure applied to both ends of servo piston (1) becomes PP : Pen = 2 : 1. This makes the force acting on both ends of servo piston (I) I : 1, so servo piston (1) stops in that position and the pump discharge amount is balanced with the oil flow demanded by the control valve. The force of the spring is adjusted so that Pa2 - PLS = APLS i 1.96 MPa (20 kg/cm21 at the point where piston (15) is balanced. In other words, when the area of opening of control valve is l/2, the pump swash plate angle is also l/2, and when the area of opening of control valve is l/4, the pump swash plate angle is also l/4. LS differential pressure APLS is always held at 1.96 MPa I20 kg/ cm2), so the pump discharge amount is in accordance with the area of opening of the control valve. For example, after balancing at an area of opening l/4 of the control valve, if the system is operated to 314 of the area of opening of the control valve, LS differential pressure APLS will drop momentarily. As a result, the LS valve is actuated and the pump discharge amount is increased, but when the pump swash plate angle rises to 3/4, the LS differential pressure APLS rises to 1.96 MPa {20 kg/cm21,so it is balanced in this position.
PC60-7
1O-29
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
PC valve Function When discharge pressure PP becomes higher, the area of opening of the control valve becomes larger, and even if the LS valve tries to increase pump discharge amount Q, the PC valve carries out control to prevent any increase above fixed discharge amount Q to match discharge pressure PP. It carries out approximate horsepower control to prevent the hydraulic horsepower absorbed by the pump from exceeding the engine horsepower. . In other words, if the load during operations becomes larger and pump discharge pressure PP rises, pump discharge amount Q is reduced; and if pump discharge pressure PP goes down, pump discharge amount Q is increased. The relationship between pump discharge pressure PP and pump discharge amount 0 is as shown in the diagram on the right. Normally, it is set to the pump absorption torque for the standard mode, but if the mode selector solenoid valve signal is input, the pump absorption horsepower is reduced by approx. 20% as shown by the curve for the light load mode. l
Standard Lioht
mode load
mode
2 c: Pump
discharoe
preesure
PP
SKP04187
l
1O-30 0
PC60-7
STRUCTURE
AND FUNCTION
HYDRAULIC
Operation 1.
When
actuator
load is large (pump discharge
pressure
PP is high) To PPC valve 4%
Control
‘e reducin
r-----
I
-_--
--/
(Smal I diameter
(Large
diameter
end1
end) SKP04188
1 O-32
PUMP
STRUCTURE AND FUNCTION
.
.
.
. c--
.
.
. 4
HYDRAULIC PUMP
When the load on the actuator becomes high and pump discharge pressure PP rises, piston (8) is pushed to the left (-1 because of the relationship between the cross-sectional area of piston portions Sl and S2 (Sl > S2). As a result, port f and port g are interconnected, pump pressure PP flows from port g to port f, and at the same time, port f and the drain circuit are shut off. If the LS valve takes action to increase the pump discharge amount, spool (15) of the LS valve is moved to the left (-1 and port d and port e are interconnected. As a result, pump pressure PP from port f of the PC valve flows from port e of the LS valve to port d, enters chamber X at the large diameter end of servo piston (I), and stops the movement of servo piston (1). If pump discharge pressure PP rises further, piston (8) moves to the left (-1 and servo piston (I) moves up in the direction of the minimum swash plate angle ( 8 1 because of the pressure in chamber X at the large diameter end. When servo piston (I) moves up ( t 1, piston (4) is moved to the right (-1 through lever (2). As a result, springs (5) and (7) are moved in the direction of compression and piston (8) is pushed back to the right. When piston (8) is pushed back to the right and port f and port g are shut off, servo piston (1) stops moving up ( t ). The position where servo piston (I) stops is higher (closer to the minimum swash plate angle) than when the pump discharge pressure is low.
7o-33
STRUCTURE AND FUNCTION
2.
When actuator
HYDRAULIC PUMP
load becomes
smaller
(pump discharge
pressure
PP drops)
To PPC valve :, fi ; Mode selector solenoid valve
Control
valve
Self-Pressure reducing valve
knal
x
I diameter
(Large
diameter
end)
end) SKP04189
STRUCTURE
.
.
.
.
AND FUNCTION
HYDRAULIC
PUMP
When the load on the actuator becomes smaller and pump discharge pressure PP drops, piston (8) is pushed to the right (*) by the force of springs (5) and (7). As a result, port g and port f are shut off, and at the same time, port f is connected to the drain circuit. When this happens, if the LS valve is acting to increase the pump discharge pressure, the limit of the PC valve disappears, so the pressurized oil in chamber X at the large diameter end of servo piston (I) passes from port d of the LS valve to port e, and flows from port f of the PC valve to the drain circuit as explained in the section on the LS valve. For this reason, servo piston (1) is moved down in the direction of the maximum swash plate angle (1 ) by the pressure in chamber Y at the small diameter end.
1o-35
STRUCTURE
3.
When
AND FUNCTION
mode selector
HYDRAULIC
solenoid
valve signal pressure
is input
To F
valve ? Mode selector solenoid valve
Iw1
I PLS Control
Self-aressure
valve
reducing
valve d
r----
I
___-_
-c/
(Snal I diameter
(Larae
d isneter
end)
end) SKP04190
lo-36
PUMP
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
4
When mode selector solenoid valve signal pressure is input When the mode selector solenoid valve is turned ON and signal pressure PM is input to port PM, it acts on piston (10) and piston (IO) pushes piston (8) to the left (- 1. As a result, springs (5) and (7) are compressed and the spring load is increased, so the pump absorption torque is reduced by approx. 20%. l
l
_-
PC60-7
1o-37 0
HYDRAULIC PUMP
STRUCTURE AND FUNCTION
4.
Action of spring
To PPC valve
Mode selector solenoid valve
i
Emal I diameter
end)
(Laroe
end)
-
diameter
I SKPO4191
1 O-38
PC60-7
STRUCTURE AND FUNCTION
The spring load of springs (5) and (7) in the PC valve is changed by the swash plate angle. When servo piston (1) moves, lever (21 moves, and piston (5) moves to the right or left according to the direction of rotation of lever (2). If piston (4) moves to the right (-1, spring (5) and spring (7) are compressed. If it moves further to the right (-1, spring (5) contacts seat (61, so only spring (7) functions as a spring. In other words, the spring load is changed by piston (5) extending or contracting springs (5) and (7). The pump absorption torque curve, which shows the relationship between pump discharge pressure PP and discharge amount Q, is a bent curve as shown in the diagram on the right because springs (5) and (7) have different spring loads. In addition, if mode selection solenoid valve signal pressure PM is input, even if it changes, springs (5) and (7) are pushed from the right through piston (8), so the spring load changes. The position where spring (8) stops, in other words, the pump absorption torque, is determined by the position where the force of springs (5) and (7) is in balance with pump pressure PP + mode selection pressure PM acting on piston (8). In other words, if pump discharge pressure PP increases, pump discharge amount Q is reduced; and if pump discharge pressure PP goes down, pump discharge amount 0 is increased. The pump absorption torque, which shows the relationship between pump discharge pressure PP and pump discharge amount 0, moves in parallel from a to b as shown in the diagram on the right according to the increase in each signal pressure.
Rxo-7
HYDRAULIC PUMP
Pump discharge
Pump discharse
Pressure
pressure
PP
PP
SKPO4192
SKP04193
1o-39
CONTROL VALVE
STRUCTURE AND FUNCTION
CONTROL VALVE Outline The following five types of control valve are used. . 6-spool valve (standard 1 . 7-spool valve (standard + 1 service valve) . 8spool valve (standard + 2 service valve) 8-spool valve (blade specification + 1 service valve) . 9-spool valve (blade specification + 2 service valve) l
Ir
Each service valve is an add-on type where one valve each can be added, so it is possible to add valves or remove valves if necessary. An explanation is given of the external appearance for all types. Only an explanation of the 8-spool valve (blade specification + 1 service valve) is given for the cross section. * The cross-sectional structure of the service valve is the same as the structure for the standard bucket valve, so see the bucket valve for details. Names, name of ports (common for all external view diagrams) 1. No. 1 service valve 2. No. 2 service valve 3. No. 3 service valve P Al Bl A2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 87 A8 B8 A9 B9
TSW TC TB LS PP TS PA1 PBI PA2 PB2 PA3 PB3 PA4 PB4 PA5 PB5 PA6 PB6 PA7 PB7 PA8 PB8 PA9 PB9
: to swing motor : to oil cooler : to tank : to pump LS valve : from PPC shuttle valve : to tank : from left swing PPC valve : from right swing PPC valve : from L.H. travel FORWARD PPC valve : from L.H. travel REVERSE PPC valve : from R.H. travel FORWARD PPC valve : from R.H. travel REVERSE PPC valve : from boom RAISE PPC valve : from boom LOWER PPC valve : from arm OUT PPC valve : from arm IN PPC valve : from bucket DUMP PPC valve : from bucket CURL PPC valve : from blade RAISE PPC valve : from blade LOWER PPC valve : from service 1 PPC valve : from service 1 PPC valve : from service 2 PPC valve : from service 2 PPC valve
: from main pump : to swing motor MB : to swing motor MA : to L.H. travel motor A : to L.H. travel motor B : to R.H. travel motor B : to R.H. travel motor A : to boom cylinder bottom : to boom cylinder head : to arm cylinder head : to arm cylinder bottom : to bucket cyiinder head : to bucket cylinder bottom : to attachment 7 : to attachment 1 : to attachment 2 : to attachment 2 : to attachment 3 : to attachment 3
1O-40 0
Pc60-7
STRUCTURE AND FUNCTION
CONTROL VALVE
EXTERNAL VIEW 6-spool valve (standard)
LS A PA6
n
11
PA6
PB3
/ PA1
-
/D-cl
TC
/
/AtPI4
TSW
TS
TB
sxPo7oaa
PC60-7
1o-41 0
STRUCTURE AND FUNCTION
CONTROL VALVE
7-spool valve (standard + 1 service valve)
LS
PA7,
I
_pB7
PA1
P’
SXPO 7089
1 O-42 0
PC60-7
STRUCTURE AND FUNCTION
CONTROL VALVE
8-spool valve (standard + 2 service valve) 8-spool valve (blade specification + 1 service valve)
TSW
1 I
SJPO7090
Pc60-7
1O-42- 1 0
STRUCTURE AND FUNCTION
CONTROL VALVE
9-spool valve blade specification 2 service valve
SJPO7091
1 O-42-2 0
Pc60-7
STRUCTURE AND FUNCTION
CONTROL
VALVE
CROSS SECTION * The cross section shows the 8-spool
valve (brade specification + 1 service valve). structure of the 8-spool The cross-sectional valve service valve is the same as the structure of the bucket valve, so see it. 8
A-A
1. 2. 3. 4. 5. 6. 7. 8.
Suction valve (L.H. travel A) Suction valve (R-H. travel A) Suction valve (boom bottom) Suction valve (arm head) Suction valve (bucket head) Plug (blade head) Suction valve (service A) Safety valve
Pc60-7
SJPO7092
9. 10. 11. 12. 13. 14. 15. 16.
Suction Suction Suction Suction Suction Suction Suction Cooler
valve valve valve valve valve valve valve bypass
(service B) (blade bottom) (bucket bottom) (arm bottom) (boom head) (R.H. travel B) (L.H. travel B) valve
1o-43 0
STRUCTURE AND FUNCTION
CONTROL VALVE
B-B SJPO7093
1. Main relief valve 2. Spool (swing) 3. Spool (L.H. travel) 4. Spool (R-H. travel) 5. Spool (boom)
1o-44 0
6. 7. 8. 9.
Spool Spool Spool Spool
(arm) (bucket) (blade) (service)
PC60-7
STRUCTUREAND FUNCTION
CONTROL VALVE
I9
c-c SJPO7094
1.
2. 3. 4. 5. 6. 7.
Swing pump pressure circuit orifice Pressure compensation valve F (swing) Pressure compensation valve F (L.H. travel) Pressure compensation valve F (R.H. travel) Pressure compensation valve F (boom) Pressure compensation valve F (arm) Pressure compensation valve F (bucket)
F’C60-7
8. Pressure compensation valve F (blade) 9. Pressure compensation valve F (service) 10. Pump pressure detection plug 11. Pressure compensation valve (service) 72. Pressure compensation valve (blade) 13. Pressure compensation valve R (bucket) 14. Pressure compensation valve R (arm)
15. Pressure compensation valve R (boom) 16. Pressure compensation valve R (R.H. travel) 17. Pressure compensation valve R (L-H. travel) 18. Pressure compensation valve R (swing) 19. LS select valve * F: Flow control valve R: Reducing valve
7o-45 0
CONTROL VALVE
STRUCTURE AND FUNCTION
D-D
1. 2. 3. 4. 5.
Check Check Check Check Check
1 O-46 0
valve valve valve valve valve
SJPO7095
(service) (blade ,B side only) (bucket) (arm) (boom)
PC60-7
STRUCTURE AND FUNCTION
CONTROL VALVE
G-G \
5
4
H-H SKP03076
L.H., R.H. travel valve I. 2. 3. 4. 5.
Suction valve (A) Suction valve (B) Spool Pressure compensation Pressure compensation
PC&7
Boom valve 6. Suction valve (bottom)
valve R valve F
7. 8. 9. IO.
Suction valve (head) Spool Pressure compensation Pressure compensation
valve R valve F
1o-47
STRUChE
CONTROL VALVE
AND FUNCTION
E-E
SJPO7096
1. 2. 3.
Main relief valve Lift check valve LS select valve
1 O-48 0
Swing valve 4. Spool 5. Pressure compensation valve R 6. Pressure compensation valve F
PC60-7
STRUCTURE AND FUNCTION
CONTROL VALVE
J-J
6
K-K (BB-BB) SJPO7097
Arm valve 1. Suction valve (head) 2. Suction valve (bottom) 3. Spool 4. Pressure compensation valve R 5. Pressure compensation valve F
Pc60-7
Bucket valve (service valve) 6. Suction valve (head) 7. Suction valve (bottom) 8. Spool 9. Pressure compensation valve R IO. Pressure compensation valve F
1o-49 0
STRUCTURE AND FUNCTION
CONTROL VALVE
6
5
M-M
Ii
1. 2. 3. 4. 6. 6. 7.
Pump pressure detection plug Safety valve Pressure release plug LS bypass plug Swing pressure compensation valve F Swing pressure compensation valve R Unload valve
1O-50 0
AA-AA
‘IO
SJPO7098
BLADE VALVE 8. Suction valve (bottom) 9. Spool 10. Pressure compensation valve R 11. Pressure compensation valve F
PC60-7
STRUCTURE
AND FUNCTION
SELF-PRESSURE
REDUCING
VALVE
h
SELF-PRESSURE
REDUCING VALVE
!=!!=!
c\ -
d
a
SKP03079
a. b. c.
Port PI (from main pump) Port PC (to main pump) Port Pr
d.
(supplies oil to electromagnetic valve, EPC valve, etc.) Port T (to hydraulic tank)
valve,
PPC
1o-51
STRUCTURE
AND FUNCTION
SELF-PRESSURE
A-A
REDUCING
8
SKPOJOBO
1. 2. 3. 4. 5. 6.
Valve (reducing valve) Valve (sequence valve) Spring (sequence valve large) Spring (sequence valve small) Plate Screw
1o-52
7. 8. 9. 10. 11.
Poppet Spring (reducing valve pilot) Spring (reducing valve main) Spring (safety valve) Ball
VALVE
STRUCTURE
AND FUNCTION
Operation 1. Engine stopped . Poppet (7) is pushed against the seat by spring (8): Pr + T closed Valve (I) is pushed against the plug by spring (9): PI + Pr open Valve (2) is pushed by spring (3) and spring (4): PI + PZ closed l
SELF-PRESSURE
REDUCING
VALVE
Pl
l
T
1
Pr
9
7
Engine stoPPed SKP04194 P2
2. (I) At HOLD (2) When load (pressure
.
P2) is low (operations where work equipment moves under own weight, such as boom LOWER, arm IN) Note: When pressure P2 (load pressure) is lower than self-pressure reducing valve output pressure (pressure Pr) Valve (2) is subjected to force from spring (31, spring (4), and pressure Pr (0 kg/cm* when engine is stopped) in the direction to close the circuit between port PI + P2. However, if hydraulic oil flows in from port PI (pressure Pl), (force of spring (3) and spring (4) + area 0 d of valve (2) x pressure Pr) are balanced, and the opening between Pl and P2 is adjusted in order to maintain pressure Pl and pressure Pr at the above set value. If pressure Pr goes above the set pressure, poppet (7) opens and hydraulic oil flows from port Pr + spool (I) orifice -+ poppet (7) opening -+ tank circuit. As a result, a difference in pressure is generated on both sides of spool (I) orifice, so spool (1) moves in the direction to close the opening between PI + Pr, and pressure Pr is maintained at the certain pressure by which pressure PI is reduced (set pressure) by the amount of this opening.
PC60-7
\
T
I
Pr
9
7
At low loed (boor LOWEkmovino down under own neioht) SKP04195
1o-53 0
STRUCTURE AND FUNCTION
3.
When load pressure (pressure P2) is high When load pressure (pressure P2) is increased and pump discharge amount is increased by operation such as digging Pressure PI also increases (pressure Pl) > (spring (3) and area d of valve (2) x pressure Pr), and valve (21 moves to the end of its stroke. As a result, the amount of opening between PI + P2 increases, so the passage resistance becomes smaller and the horsepower loss of the engine is reduced.
.
4.
SELF-PRESSURE REDUCING VALVE
If pressure Pr goes above the set pressure, poppet (7) opens and hydraulic oil flows from port Pr + spool (1) orifice + poppet (7) opening + tank circuit. As a result, a difference in pressure is generated on both sides of spool (I 1orifice, so spool (1) moves in the direction to close the opening between PI + Pt. Pressure Pr is maintained at the certain pressure by which pressure Pl is reduced (set pressure) by the amount of this opening.
2
R
PI
1
Pr
At
hioh
load
pressure
7 SKP04196
When abnormally high pressure is generated If pressure Pr of the self-pressure reducing valve becomes abnormally high, ball (11) pushes against the force of spring (10) and separates from the seat. Hydraulic oil flows from output port Pr + T, and pressure Pr is lowered to protect the equipment (PPC valve, electromagnetic valve, and other equipment using the pressure oil from port Pr) from abnormal high pressure.
1o-54
Pcoo-7
CLSS
STRUCTURE AND FUNCTION
CLSS 1. OUTLINE OF CLSS Features CLSS stands for Closed center Load Sensing System, and has the following features. 1) Fine control not influenced by load 2) Control enabling digging even with fine control 3) Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations 4) Energy saving using variable pump control
PLS i___________________---_-
Structure The CLSS consists of a variable capacity single piston pump, control valve, and actuators. The pump body consists of the main pump, the PC valve and LS valve.
l
l
Control
valve
I I I I I I , I
+
Lb+ PP
Servo va I ve
1O-56 0
SDP02561
PC60-7
STRUCTURE AND FUNCTION
CLSS
2. BASIC PRINCIPLE 1) Control of pump swash plate angle . The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS ) (load pressure of actuator) is constant. (LS pressure APLS = Pump discharge pressure PP - LS pressure PLS 1
.
Ir
If LS differential pressure APLS becomes lower than the set pressure of the LS valve, the pump swash plate becomes larger; if it becomes higher than the set pressure of the LS valve, the pump swash plate becomes smaller. For details of the operation, see HYDRAULIC PUMP
0 I
71 Main
I
LS differential
9reasure
APLS SDP02563
B PP
Dump
k I
i a_________ I__________
Mi n.
/
Max.
Servo Piston
I
I
I
LS _. valve
I
i
___1I
_ ______J
. +q-@i Ditferential 9rcwre Iar1elfli9b)
kssaae
I I I I
Diftcrential saal I (Low)
9rc99vrc
II
SEP02562
PC60-7
1o-57 0
CLSS
STRUCTURE AND FUNCTION
2) Pressure compensation control . A pressure compensation valve is installed
downstream (outlet port) of the notch in the spool of each valve. In this way, the flow of oil from the pump is divided in proportion to the area of openings Sl and S2 of each valve.
to the inlet port side of the control valve spool to balance the load. When two actuators are operated together, this valve acts to make pressure difference AP between the upstream (inlet port) and
Load
Load
W w Actuator
AP
AP
LS valve
I O-58
SKPO4200
Pao-7
STRUCTURE
AND FUNCTION
CLSS
A
3. OPERATION FOR EACH FUNCTION AND VALUE Hydraulic circuit diagram and name of values
Bucket
Arm
1. Unload valve (LS pressure + 2.6 MPa (27 kg/cm2)) 2. Safety valve (27.5 MPa I280 kg/cm2}) 3. Pressure compensation valve 4. Suction valve 5. Main relief valve (24.5 MPa (250 kg/cm2}) 6. Lift check valve (cracking pressure: 0.13 MPa (1.3 kg/cm211 7. Cooler bypass valve (cracking pressure: 0.81 MPa (8.3 kg/cm211 8. LS select valve
Boom
Travel
Travel
Swine
I 270/c.’
TW I
6*
_________________--------4
TB TC
,‘.i
-.I
SKP04201
1o-59
STRUCTURE
CLSS
AND FUNCTION
1) Unload valve Function 1. When the control valve is at HOLD, pump discharge amount 0 discharged by the minimum swash plate angle is released to the tank circuit.
When this happens, pump discharge pressure PP is set at 2.6 MPa (27 kg/cm21 by spring (2) inside the valve. (LS pressure PLS: 0 MPa (0 kg/cm*))
SKP030SS
Operation When control valve is at HOLD . Pump discharge pressure PP is acting on the left end of spool (I) and LS pressure PLS is acting on the right end. When the control valve is at HOLD, LS pressure PLS is not generated, so only pump discharge pressure PP has any effect, and PP is set only by the load of spring (2). As pump discharge pressure PP rises and reaches the load of spring (2) (2.6 MPa I27 kg/ cm*}), spool (1) is moved to the right (0). The oil in pump circuit is then connected to tank circuit T through the drill hole in sleeve (2). l
l
1O-60
l
In this way, pump discharge set to 2.6 MPa (27 kg/cm*}.
pressure
PP is
STRUCTURE
2.
AND FUNCTION
CLSS
When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of spring (2) (2.6 MPa (27 kg/cm21), the unload valve opens, so LS differential pressure APLS becomes 2.6 MPa (27 kg/cm21.
During fine control of the control valve, when the demand flow for the actuator is within the amount discharged by the minimum swash plate angle of the pump, pump discharge pressure PP is set to LS pressure PLS + 2.6 MPa (27 kg/cm2}.
SKP03089
Operation During fine control of control valve When fine control is carried out on the control valve, LS pressure PLS is generated and acts on the right end of spool (1). When this happens, the area of the opening of the control valve spool is small, so there is a big difference between LS pressure PLS and pump discharge pressure PP. When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of spring (2) (2.6 MPa (27 kg/cm2)), spool (I) moves to the right O), and pump circuit PP and tank circuit T are connetted . l
l
In other words, pump discharge pressure PP is set to a pressure equal to the spring force (2.6 MPa {27 kg/cm2)) + LS pressure PLS, and LS differential pressure APLS becomes 2.6 MPa (27 kg/cm*).
l
-
70-61
STRUCTURE
3.
CLSS
AND FUNCTION
When the control the demand flow greater than the minimum swash
oil out to tank circuit T is cut off, and all of pump discharge amount Q flows to the actuator circuit.
valve is being operated and for the actuator becomes pump discharge from the plate angle, the flow of the
SKP03090
Operation Control valve operated l When the control valve is operated to a larger stroke, LS pressure PLS is generated and acts on the right end of spool (1). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure PLS and pump discharge pressure PP is small. . For this reason, the difference in pressure between pump discharge pressure PP and LS pressure PLS does not reach the load of spring (2) (2.6 MPa (27 kg/cm?), so spool (I) is pushed to the left (0) by spring (2).
1 O-62
l
As a result, pump circuit PP and tank circuit T are shut off, and all the pump discharge amount Q flows to the actuator circuit.
STRUCTURE
AND FUNCTION
of LS pressure 2) Introduction Function . The LS pressure is the actuator load pressure at the outlet port end of the control valve. With the control valve, it reduces pump pressure PP at reducing valve (3) of the pressure valve to the same pressure as compensation actuation pressure A, and sends it to the LS
CLSS
l
circuit PLS. In addition, orifice C is installed midway between pump circuit PP and reducing valve (3), and it acts as a damper. With the travel valve, actuator circuit pressure A is taken directly to the LS circuit PLS.
h
SKP03091
-
Operation 1. Main control valve (boom, arm, bucket, swing) When spool (I) is operated, pump pressure l PP flows from flow control valve (2) and notch a in the spool through bridge passage b to actuator circuit A. . At the same time, reducing valve (31 also moves to the right (-1, so pump pressure PP brought from orifice c has its pressure reduced by the pressure loss at notch d. It goes to LS circuit PLS, and then goes to spring chamber PLSl. . When this happens, LS circuit PLS is connected to tank circuit T from LS bypass plug (4) (see the section on the LS bypass plug).
.
.
The area at both ends of reducing valve (3) is the same (SA = SLS), and actuator circuit pressure PA (= A) acts on the SA end. The reduced pump pressure PP acts on SLS at the other end. As a result, reducing valve (3) is balanced at a position where actuator circuit pressure PA and the pressure of spring chamber PLSI are the same. Pump pressure PP reduced at notch d becomes actuator circuit pressure A and is taken to LS circuit PLS.
1O-63
CLSS
STRUCTURE AND FUNCTION
SKPO3199
2. .
.
.
*
Travel valve
When spool (I) is operated, pump pressure PP flows from flow control valve (2) and notch a in the spool through bridge passage b to actuator circuit A. At the same time, reducing valve (3) is moved to the right (0) by actuator circuit pressure PA, and notch c and notch d are interconnected respectively with travel junction circuit e and LS circuit PLS. As a result, actuator circuit pressure PA (= A) passes from notch c through notch d and goes to LS circuit PLS. The travel circuit is different from the work equipment circuit: actuator circuit pressure PA goes directly to LS circuit PLS.
1O-64
STRUCTURE
AND FUNCTION
CLSS
A
3) LS bypass plug Outline 1. This releases the residual pressure of LS pressure PLS. 2. This makes the speed of the rise in pressure of LS pressure PLS more gentle. In addition, with this discarded throttled flow,
it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effective LS differential pressure.
SKP03199
Operation . The pressurized oil for LS circuit PLS passes from clearance filter a (formed by the clearance between LS bypass plug (1) and thevalve body) through orifice b and flows to the tank circuit.
-
1O-65
STRUCTURE AND FUNCTION
CLSS
4) Pressure compensation valve Function . During compound operations,
if the load pressure becomes lower than the other actuator and the oil flow is about to increase, compensation is received.
(When this happens, the other actuator being used for compound operation (right side) is at a higher load than the actuator on this side (left side).)
SKI'04202
Operation . If the load pressure of the other actuator (right
.
.
.
side) becomes higher during compound operations, the oil flow in actuator circuit A on this side (left side) tries to increase. If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLSI, and reducing valve (I) and flow control valve (2) are pushed to the left (o ). Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA, and pressure loss is generated between PP and PPA. Flow control valve (2) and reducing valve (1)
1O-66
.
are balanced in position where the difference in pressure between PLS and PA acting on both ends of reducing valve (2) and the pressure loss between PP and PPA on both sides of flow control valve (2) are the same. In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of both spools used during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch a of each spool.
STRUCTURE
AND FUNCTION
CLSS
4
5) Area ratio of pressure compensation valve Function . The pressure compensation valve determines the compensation characteristics by carrying out fine adjustment of the area ratio (S2/Sl) between area S2 of reducing valve (I) and area Sl of flow compensation valve (2) to match the characteristics of each actuator.
r
Sl: Area of flow control valve (2) - area of piston (3) S2: Area of reducing valve (I 1 - area of piston (3) ,
\ PLS SKP03093
Area ratio (S2:Sl) and compensation characteristics When ratio is 1.00: [pump pressure PP - spool notch upstream pressure PPBI i ILS circuit pressure PLS - actuator circuit pressure PA (= A)] and oil flow is divided in proportion to area of opening of spool. When ratio is more than 1.00: PP - PPB > PLS - PA (= A) and oil flow is divided in a proportion less than area of opening of spool. When ratio is less than 1.00: PP - PPB c PLS -PA (= A) and oil flow is divided in a proportion more than area of opening of spool. l
l
Ratio of area
Valve
Ratio of area
Service
0.98
L.H. travel
1.00
Bucket
0.98
R.H. travel
1.oo
Arm
0.96
Swing
0.98
Boom
0.96
Blade
1.00
Valve
l
-
1O-67
STRUCTURE
CLSS
AND FUNCTION
6) L.H., R.H. travel junction circuit Function . To compensate for any difference in the oil flow in the left and right travel circuits when traveling in a straight line, the junction circuit opens when the left and right travel spools are operated. In this way, the flow of oil to the left and right travel motors is almost the same when trav-
l
eling in a straight line, so there is no travel deviation. When steering the machine, the difference in the load pressure returns the reducing valve of the travel valve on the inside of the turn, so the junction circuit is closed and the machine can be steered.
L. H. travel
R. H. travel 3
Left
A \
RinhtA \
E
1
b
Operation When traveling in a straight line . When left and right travel spools (I) are operated, the pump discharge flows from pump circuit PP and circuit PA to actuator circuit A. . When traveling in a straight line, to make actuator circuit PA equal, left and right reducing valves (2) are pushed to the right (0) by the same amount, and notch a and the travel junction circuit are opened. . In this way, the left and right travel actuator circuits are interconnected by the travel junction circuit, so if any difference occurs in the flow of oil to the left and right travel motors, the difference is compensated to prevent any deviation in travel.
1 O-68
C
SKP04203
STRUCTURE AND FUNCTION
CLSS
4
L. H. travel
R. H. travel
4
SKP04204
Steering when traveling . When traveling in a straight line, if left travel
.
-
spool (left 1) is returned to the neutral position and steering is operated, a difference (right A > left A) is generated in the load pressure of left and right travel actuator circuits PA, and LS pressure PLS becomes the same pressure as right A (the side with the high load pressure). As a result, flow control valve (3) on the left travel side is pushed to the left (0) by LS circuit PLS, that is, right travel load pressure right A, so the opening of the left notch a is closed, the left and right travel circuits are shut off, and it becomes possible to operate the steering when traveling.
l
Damper b is provided in the circuit to dampen any excessive characteristics in the opening or closing of the travel junction circuit if the spool is operated suddenly.
1 O-69
STRUCTURE
CLSS
AND FUNCTION
71 Travel LS bypass circuit Function . When the travel and another actuator are operated at the same time, the amount of oil discarded by the throttle in LS circuit PLS inprecreases and the pressure compensation cision of the travel circuit is relaxed to keep
.
the drop in the travel speed to the minimum. When the travel is operated independently or any other actuator is operated independently, the bypass circuit is closed.
SKP03094
Operation Normal operation When boom spool (I) is operated, LS circuit PLS becomes the same pressure as boom circuit pressure Al. . At the same time, LS circuit pressure PLS also goes to spring chamber PLSl of reducing valve (2) of the travel valve. The travel spool is not being operated, so travel actuator circuit PA is closed, and check valve (4) inside flow control valve (3) is also l
l
.
closed. As a result, when the boom is operated indethe travel LS bypass circuit is pendently, closed.
1O-70
STRUCTURE
CLSS
AND FUNCTION
SKP03095
Travel + other actuator operated LS circuit When boom spool (I) is operated, cirboom as pressure same the becomes PLS cuit pressure Al. With the actuator circuit pressure, the boom higher than the is normally RAISE pressure the pressure of so travel pressure (Al B A2), valve reducing inside PLSI spring chamber (2) of the travel valve is higher than travel cirl
l
.
l
For this (which is pressure duce the
LS circuit reason, the same pressure Al), flows to travel pressure.
PLS pressure as boom circuit circuit A2 to re-
cuit pressure PA. valve (2) moves to the As a result, reducing left, LS pressure of spring chamber PLSl goes a and pushes check valve (4) from orifice from passage b and pasflows oil so open, sage c to travel circuit PA.
10-71
STRUCTURE
AND FUNCTION
8) Boom regeneration circuit Function 1. When the boom is being lowered, if bottom pressure A of cylinder (I) is higher than head pressure B, and there is hydraulic drift, this
CLSS
sends the return oil flow at the bottom end to the head end to increase the cylinder speed by that amount.
PU
SKP03821
Operation . If there is hydraulic drift when lowering the boom, pressure A at the bottom end of boom cylinder (1) becomes higher than pressure B at the head end. . When this happens, part of the return oil at the bottom end passes through regeneration passage a of boom spool (I), pushes check valve (3) open, and flows to the head end. . As a result, the boom lowering speed is increased.
1 O-72
STRUCTURE AND FUNCTION
2.
When lowering the boom, if head pressure B of cylinder (I 1is greater than bottom pressure A, and the work equipment is in the digging
CLSS
process, check valve (3) closes and shuts off the circuit between the head and bottom ends.
SKP03822
Operation . When the boom is lowered, if the work equipment is in the digging process, pressure B at
.
the head end of cylinder (I) becomes higher than pressure A at the bottom end. When this happens, check valve (3) is closed by spring (4) and pressure B at the head end, so the circuit between the head circuit and bottom circuit is shut off.
A
7o-73
STRUCTURE
CLSS
AND FUNCTION
9)
LS select valve Function . When the swing + boom RAISE are operated together, this valve ensures the high pressure which is generated when driving the swing, and prevents swing LS pressure a from flow-
ing into LS circuit PLS. vents the boom RAISE ping.
In this way, it prespeed from drop-
PLS
SKP03823
Operation Normal operation . Normally, except when boom RAISE is operated, the pilot pressure does not act on pilot port BP. . In this condition, pump pressure PP pushes valve (1) open and goes to reducing valve (4) of the swing valve. When the swing is operated, LS pressure PLS is generated in accordance with the load pressure and flows to the pump LS valve.
1o-74
STRUCTURE AND FUNCTION
CLSS
SKP03824
Swing + boom RAISE at same time . When the swing + boom RAISE are operated at the same time, the signal pressure from the boom RAISE PPC circuit is sent to into pilot port BP. When this pilot pressure BP acts on piston (2) and becomes stronger than spring (3), piston (2) is pushed fully to the left (0 1. Valve (1) closes, and pump pressure PP stops flowing to reducing valve (4) of the swing valve.
l
l
PC60-7
l
As a result, swing LS pressure PLS is not generated, so only the boom RAISE LS pressure goes to the pump LS valve, and the pump discharge amount is controlled by the boom RAISE LS pressure. The size of pilot pressure BP is determined by the amount the control lever is operated.
1o-75
STRUCTURE
4. 1) .
.
.
Operation of system as a whole When all control valves are at HOLD
Pump discharge amount Q all flows from unload valve (6) to tank (1). None of the spools (each spool A) is being operated, so the LS pressure PLS is not generated. At the same time, the LS pressure PLS is connected to the tank circuit by LS bypass plug (6), so it is the tank pressure. In this condition, LS differential pressure APLS becomes the unload pressure-tank pressure, and becomes higher than the LS set pressure of LS valve (4), so main pump (2) is set to the minimum swash plate angle.
‘I. Hydraulic tank Hydraulic pump 2. Main pump
3. PC valve 4. LS valve 5. Servo piston Control valve 6. LS bypass plug
7. Pump pressure detection plug & LS damper 8. Bucket valve 8A. Spool 8B. Pressure compensation valve (flow control valve) 8C. Pressure compensation valve (reducing valve) 8D. Check valve 9. Arm valve 9A. Spool 9B. Pressure compensation valve (floLv control valve) 9C. Pressure compensation valve (reducing valve) 9D. Check valve 10. Boom valve IOA. Spool IOB. Pressure compensation valve (flow control valve) IOC. Pressure compensation valve (reducing valve) 10D. Check valve 11. R.H. travel valve IIA. Spool 11 B. Pressure compensation valve (flow control valve) 1IC. Pressure compensation valve (reducing valve)
1O-76 0
ciss
AND FUNCTION
12. L.H. travel valve 12A. Spool 12B. Pressure compensation (flow control valve) 12C. Pressure compensation (reducing valve) 13. Swing valve 13A. Spool 13B. Pressure compensation (flow control valve) 13C. Pressure compensation (reducing valve) 14. LS select valve 15. Unload valve 16. Main relief valve 17. Cooler bypass valve 18. Lift check valve 19. Swing pump pressure circuit 20. Central safety valve
valve valve
valve valve
orifice
Actuator 21. Bucket cylinder 22. Arm cylinder 23. Boom cylinder
24. L.H. travel motor 25. R.H. travel motor 26. Swing motor Self-pressure reducing 27. Sequence valve 28. Reducing valve
*
valve
The suction valve is not shown.
PC60-7
STRUCTURE AND FUNCTION
*
CLSS
For details of this page, see page 90-7.
9’
r
PC60-7
I i
I
7o-77
CLSS
STRUCTURE AND FUNCTION
When swing is operated individually When swing spool (13A) is operated, pump discharge amount 0 flows to swing motor (26). At the same time, LS pressure PLS is generated and unload valve (15) closes. LS pressure PLS becomes the load pressure of swing motor (26). In the swing circuit, the difference between pump discharge pressure PP and LS pressure PLS, in other words, LS differential pressure APLS, becomes the same as the LS set pressure of LS valve (4). As a result, the swash plate angle of main pump (2) is kept at a point midway between the minimum and maximum angles, and the main pump discharges the oil flow demanded by the swing circuit (approx. 50%). When the swing is operated independently, pump discharge amount Q does not become 100%. With swing pressure compensation valves (1381 and (130, the pump pressure PP passes from LS select valve (141, goes through orifice (191, and flows to the left end of flow control valve (13B). so it moves fully to the right.
1. Hydraulic tank Hydraulic pump 2. Main pump 3. PC valve 4. LS valve 5. Servo piston Control valve 6. LS bypass plug 7. Pump pressure detection plug & LS damper 8. Bucket valve 8A. Spool 8B. Pressure compensation valve (flow control valve) 8C. Pressure compensation valve (reducing valve) 8D. Check valve 9. Arm valve 9A. Spool 9B. Pressure compensation valve (flow control valve) 9C. Pressure compensation valve (reducing valve) 9D. Check valve 10. Boom valve IOA. Spool
1O-78
11.
12.
13.
14. 15. 16. 17. 18. 19. 20.
1OB. Pressure compensation (flow control valve) IOC. Pressure compensation (reducing valve) IOD. Check valve R.H. travel valve 11A. Spool IlB. Pressure compensation (flow control valve) IIC. Pressure compensation (reducing valve) L.H. travel valve 12A. Spool 128. Pressure compensation (flow control valve) 12c. Pressure compensation (reducing valve) Swing valve 13A. Spool 138. Pressure compensation (flow control valve) 13C. Pressure compensation (reducing valve) LS select valve Unload valve Main relief valve Cooler bypass valve Lift check valve Swing pump pressure circuit Central safety valve
valve valve
valve valve
valve valve
valve valve
orifice
Actuator 21. Bucket cylinder 22. Arm cylinder 23. Boom cylinder 24. L.H. travel motor 25. R.H. travel motor 26. Swing motor Self-pressure reducing valve 27. Sequence valve 28. Reducing valve Ir
The suction valve is not shown.
PCXO-7
STRUCTURE AND FUNCTION
CLSS
.
*
For details of this page, see page 90-9.
PC60-7
1o-79
CLSS
STRUCTURE AND FUNCTION
When left and right travel are operated at same time When left and right travel spools (IIA) and (12A) are operated, pump discharge amount Q flows to left and right travel motors (24) and (251, and at the same time, LS pressure PLS is generated and unload valve (15) closes. When this happens, reducing valves (IIC) and (12C) of the left and right travel valves move to the right, the travel junction circuit is interconnected, and this prevents any deviation in travel. When left and right travel spools (IlA) and (12A) are 100% open, if pump discharge amount Cl is almost lOO%, the pressure is set so that it becomes the same as the LS set differential pressure, and main pump (I) is kept at the maximum swash plate angle. If left and right travel spools (11A) and (12A) are less than 100% open, pump discharge amount 0 is controlled in accordance with the area of opening of the spool by LS differential pressure APLS.
1. Hydraulic tank Hydraulic pump 2. Main pump 3. PC valve 4. LS valve 5. Servo piston Control valve 6. LS bypass plug 7. Pump pressure detection plug & LS damper 8. Bucket valve 8A. Spool 88. Pressure compensation valve (flow control valve) 8C. Pressure compensation valve (reducing valve) 80. Check valve 9. Arm valve 9A. Spool 9B. Pressure compensation valve (flow control valve) 9C. Pressure compensation valve (reducing valve) 90. Check valve IO. Boom valve IOA. Spool IOB. Pressure compensation valve (flow control valve)
1 O-80 0
11.
12.
13.
14. 15. 16. 17. 18. 19. 20.
IOC. Pressure compensation (reducing valve) 100. Check valve R.H. travel valve IIA. Spool 11 B. Pressure compensation (flow control valve) 11 C. Pressure compensation (reducing valve) L.H. travel valve 12A. Spool 12B. Pressure compensation (flow control valve) 12C. Pressure compensation (reducing valve) Swing valve 13A. Spool 138. Pressure compensation (flow control valve) 13C. Pressure compensation (reducing valve) LS select valve Unload valve Main relief valve Cooler bypass valve Lift check valve Swing pump pressure circuit Central safety valve
valve
valve valve
valve valve
valve valve
orifice
Actuator 21. Bucket cylinder 22. Arm cylinder 23. Boom cylinder 24. L.H. travel motor 25. R.H. travel motor 26. Swing motor Self-pressure reducing valve 27. Sequence valve 28. Reducing valve Ir
The suction valve is not shown.
Pcoo-7
STRUCTUREAND FUNCTION
+
CLSS
For details of this page, see page 90-I 1.
PC60-7
1 O-81
CLSS
STRUCTURE AND FUNCTION
Boom + arm operated at same time If boom spool (IOA) is operated to RAISE and arm spool (9A) is operated at the same time to OUT, pump discharge amount 0 flows to each cylinder (23) and (22). When this happens, the load pressure of boom cylinder (23) is greater than the load pressure of arm cylinder (221, so the oil tries to flow to arm cylinder (22) where the load pressure is low. However, the pressure on the upstream side of arm spool (9A) is compensated by pressure compensation valves (9B) and (90, which receive the load pressure of the boom (= maximum LS pressure PLS). In this way, the pressure difference between the upstream pressure and downstream pressure of boom spool (lOA) and arm spool (9A) becomes equal, so the flow of oil from main pump (2) is divided in proportion to the area of opening of each spool. If the area of opening of boom spool (lOA) and arm spool (9A) is lOO%, even if pump discharge amount 0 becomes lOO%, LS differential pressure APLS is set so that it does not reach the LS valve set differential pressure, so main pump (I) is held at the maximum swash plate angle. If the area of opening of boom spool (10A) and arm spool (9A) is less than lOO%, pump discharge amount Q is controlled in accordance with the area of opening of the spools by LS differential pressure APLS.
Hydraulic tank Hydraulic pump 2. Main pump 3. PC valve 4. LS valve 5. Servo piston Control valve 6. LS bypass plug 7. Pump pressure detection plug & LS damper 8. Bucket valve 8A. Spool 88. Pressure compensation valve (flow control valve) 8C. Pressure compensation valve (reducing valve) 8D. Check valve 9. Arm valve 9A. Spool
1 O-82 0
9B.
Pressure compensation (flow control valve) 9C. Pressure compensation (reducing valve) 9D. Check valve 10. Boom valve IOA. Spool IOB. Pressure compensation (flow control valve) 1OC. Pressure compensation (reducing valve) IOD. Check valve 11. R.H. travel valve IIA. Spool 118. Pressure compensation (flow control valve) IIC. Pressure compensation (reducing valve) 12:L.H. travel valve 12A. Spool 12B. Pressure compensation (flow control valve) 12c. Pressure compensation (reducing valve) 13. Swing valve 13A. Spool 138. Pressure compensation (flow control valve) 13C. Pressure compensation (reducing valve) 14. LS select valve 15. Unload valve 16. Main relief valve 17. Cooler bypass valve 18. Lift check valve 19. Swing pump pressure circuit 20. Central safety valve
valve valve
valve valve
valve valve
valve valve
valve valve
orifice
Actuator 21. Bucket cylinder 22. Arm cylinder 23. Boom cylinder 24. L.H. travel motor 25. R.H. travel motor 26. Swing motor Self-pressure reducing valve 27. Sequence valve 28. Reducing valve *
The suction valve is not shown.
PC60-7
CLSS
STRUCTUREAND FUNCTION
*
For details of this page, see page 90-13.
L.-.-.-.-._~-~-_-.l.-_-.-.__---__-----_-.__-.-._.__-_-.-._
I
L
Ii.
PC60-7
1O-83
CLSS
STRUCTURE AND FUNCTION
5) l
l
.
.
.
Boom RAISE + swing used at same time When boom spool (IOA) is operated to RAISE and swing spool (13A) is operated at the same time, pump discharge amount 0 flows to boom cylinder (23) and swing motor (26). When this happens, LS select valve (14) is actuated, and pump circuit PP and swing reducing valve (13C) circuit are shut off, so the swing LS pressure is not generated and LS differential pressure APLS becomes the load pressure of boom cylinder (23). In addition, when swing pressure compensation valves (138) and (13C) move to a certain position, the pump pressure PP introduction passage is shut off. As a result, they cannot move to the end of their stroke, and they are held at the position where the passage between pump circuit PP and spool (13A) is throttled. In other words, swing pressure compensation valves (13B) and (130 do not operate to receive compensation when the swing motor load becomes small in normal swing operation; they are held at the position to receive compensation from the start of the swing. If the area of opening of boom spool (IOA) and swing spool (13A) is lOO%, even if pump discharge amount 0 becomes lOO%, LS differential pressure APLS is set so that it does not reach the LS valve set differential pressure, so main pump (1) is held at the maximum swash plate angle. If the area of opening of boom spool (lOA) and swing spool (13A) is less than lOO%, pump discharge amount 0 is controlled in accordance with the area of opening of the spools by LS differential pressure APLS.
1. Hydraulic tank Hydraulic pump 2. Main pump 3. PC valve 4. LS valve 5. Servo piston Control valve 6. LS bypass plug 7. Pump pressure detection plug & LS damper 8. Bucket valve 8A. Spool 8B. Pressure compensation valve (flow control valve)
1 O-84 0
8C.
9.
10.
11.
12.
13.
14. 15. 16. 17. 18. 19. 20.
Pressure compensation (reducing valve) 8D. Check valve Arm valve 9A. Spool 9B. Pressure compensation (flow control valve) 9C. Pressure compensation (reducing valve) 9D. Check valve Boom valve IOA. Spool IOB. Pressure compensation (flow control valve) IOC. Pressure compensation (reducing valve) IOD. Check valve R.H. travel valve IIA. Spool 1 IB. Pressure compensation (flow control valve) 1 IC. Pressure compensation (reducing valve) L.H. travel valve 12A. Spool 12B. Pressure compensation (flow control valve) 12C. Pressure compensation (reducing valve) Swing valve 13A. Spool 138. Pressure compensation (flow control valve) 13C. Pressure compensation (reducing valve) LS select valve Unload valve Main relief valve Cooler bypass valve Lift check valve Swing pump pressure circuit Central safety valve
valve
valve valve
valve valve
valve valve
valve valve
valve valve
orifice
Actuator 21. Bucket cylinder 22. Arm cylinder 23. Boonl cylinder 24. L.H. travel motor 25. R.H. travel motor 26. Swing motor Self-pressure reducing valve 27. Sequence valve 28. Reducing valve t
The suction valve is not shown. PC60-7
STRUCTURE AND FUNCTION
*
CLSS
For details of this page, see page 90-15.
!I I I
r-7
I I I f I
I I ! I i-
1O-85
STRUCTURE AND FUNCTION
SWING MOTOR
r
bzi
A-A
/
1 \
13 12
11
\
B-B
10
A
c-c
1. 2. 3. 4. 5. 6. 7.
Output shaft Case Thrust plate Shoe Piston Center spring Cylinder
SKP03102
8. 9. IO. 11. 12. 13. 14.
Valve plate End cover Brake spring Brake piston Disc Plate Suction-safety
valve
c4
1 O-87
STRUCTURE AND FUNCTION
SWING MOTOR
SUCTION-SAFETY VALVE Function When the swing is stopped, the outlet port circuit of the motor is closed by the control valve, but the motor continues to be turned by the inertia of the swing. As a result, the pressure at the outlet port of the motor becomes abnormally high and there is danger that the motor will be damaged. . The safety valve is installed to prevent this problem. It acts to release the abnormally high pressure oil from the outlet port of the motorto port S, and also functions as a swing brake. . The suction valve supplies an amount of oil equivalent to the amount of oil released by the safety valve. It sends this oil from port S to the inlet port of the motor to prevent any cavitation. l
Operation 1. When starting swing . If the swing control lever is operated to swing to the left, the pressurized oil from the pump passes through the control valve and is supplied to port MA. . When this happens, the pressure at port MA rises and the starting force is generated in the motor, so the motor starts to turn. The oil from the outlet port of the motor flows from port MB through the control valve and returns to the tank. 2. When stopping swing . When the swing control lever is returned to the neutral position, no more pressurized oil is supplied from the pump to port MA. At the same time, the oil from the outlet port of the motor returns from the control valve to the tank, and the circuit is closed. . The pressure at port MB rises, and rotating resistance to the motor is generated, so the brake starts to take effect. If the pressure at port MB rises to the set pressure of safety valve (I 1,safety valve (1) opens and releases the pressurized oil at port MB to port s. . No pressurized oil is supplied at port MA, but the swing continues, so negative force is generated. When this negative pressure drops to the set pressure of suction valve (2). suction valve (2) opens and oil is supplied from port S to prevent cavitation.
1O-88
Control
valve
STRUCTURE
SWING
SWING
AND FUNCTION
MOTOR
BRAKE Self-Pressure reducing valve
Operation 1. Swing brake solenoid valve de-energized . If the swing brake solenoid valve is de-energized, the flow of pressurized oil from the main pump is shut off, and port B is connected to the tank circuit. As a result, brake piston (11) is pushed down ( 1) by brake spring (IO), pushes disc (12) and plate (13) together, and the brake is applied.
l
SKP04212
2. l
.
l
l
Swing brake solenoid valve energized When the swing brake solenoid valve is energized, the valve is switched, and pressurized oil from the main pump enters port B and flows to brake chamber a of brake piston (11). The pressurized oil entering chamber a overcomes brake spring (IO) and pushes brake piston (11) up ( t 1. As a result, disc (12) and plate (13) are separated and the brake is released.
Self-pressure reducing valve
E
I
solenoid
valve
10 II
SWP0722
PC60-7
I
1O-89 0
STRUCTURE AND FUNCTION
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT Serial No. : 52374 - 57999
Tl
A4 Al 81
Dl
T2
J
A-A
G2
‘A2
82 SWPO7124
Al. A2. Bl. B2. Cl. C2.
From main control valve To L.H. travel motor port From main control valve To L.H. travel motor port From main control valve To R.H. travel motor port
1O-90 0
port A2 A port B2 B port B3 A
Dl. From main control valve port A3 D2. To R.H. travel motor port B Gl. From travel speed solenoid valve G2. To L.H. and R.H. travel motor port C Tl. To tank T2. To L.H. and R.H. travel motor port D
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
fuo-7
CENTER SWIVEL JOINT
STRUCTURE AND FUNCTION
Serial No.: 58001 and up
DRl
Al
Dl Gl
G2 02
A2 OR2 82
Al. AZ. Bl. B2. Cl. C2.
From main control valve To L.H. travel motor port From main control valve To L.H. travel motor port From main control valve To R.H. travel motor port
PC60-7
port A2 A port B2 B port B3 A
Dl. From main control valve port A3 D2. To R.H.‘travel motor port B Gl. From travel speed solenoid valve G2. To L.H. and R.H. travel motor port C DRl.To tank DR2. To L.H. and R.H. travel motor port D
SWPO7125
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
1o-90- 1 0
CENTER SWIVEL JOINT
STRUCTURE AND FUNCTION
BLADE SPECIFICATION MACHINE Serial No. : 52374 - 57999
11
Al
Dl
El Fl
/
A-A
T2
F2
G2
D2
A2
_
Al. A2. Bl. 82. Cl. C2. Dl. D2.
From main control valve port To L.H. travel motor port A From main control valve port To L.H. travel motor port B From main control valve port To R.H. travel motor port A From main control valve port To R.H. travel motor port B
1O-90-2 0
A2 B2 B3 A3
E2 SKP03106
El. From blade control valve port A E2. To blade cylinder bottom Fl. From blade control valve port B F2. To blade cylinder head Gl. From travel speed solenoid valve G2. To L.H. and R.H. travel motor portC Tl. To tank T2. To L.H. and R.H. travel motor port D
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
PC60-7
CENTER SWIVEL JOINT
STRUCTURE AND FUNCTION
Serial No. : 58001 and up
DRl
A-A
SFPO6676
Al. A2. Bl. 82. Cl. C2. Dl. D2.
From main control valve port To L.H. travel motor port A From main control valve port To L.H. travel motor port B From main control valve port To R.H. travel motor port A From main control valve port To R.H. travel motor port B
Pc60-7
A2 82 83 A3
El. From blade control valve port A E2. To blade cylinder bottom Fl. From blade control valve port B F2. To blade cylinder head Gl. From travel speed solenoid valve G2. To L.H. and R.H. travel motor port C DRl .To tank DR2.To L.H. and R.H. travel motor port D
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
10-91 0
STRUCTURE AND FUNCTION
TRAVEL MOTOR
TRAVEL MOTOR
SKP03107
a. Port b. Port c. Port d. Port e. Port
Cl A D B C2
(to tank) (from control valve) (from travel speed solenoid valve) (from control valve) (to tank)
Specifications Model : GMOSVL Hydraulic motor Motor capacity : Lo 39.8 cc/rev Hi 25.1 cc/rev Rated speed : Lo 1785 rpm Hi 2773 rpm Brake release pressure : 0.45 MPa (4.6 kg/cm2} Travel speed switching pressure : 1.96 - 6.86 MPa {20 - 70 kg/cm2} Final drive Reduction ratio : 62.4 Speed : Lo 28.6 rpm Hi 44.4 rpm
lo-92 0
PC60-7
STRUCTURE AND FUNCTION
TRAVEL MOTOR
SLPO3108
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Check valve Check valve spring Counterbalance valve Return spring End cap Spring Regulator valve Brake piston Plate Disc
PC60-7
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Swash plate Floating seal RV gear RV gear Crankshaft Driven gear Cover Drive gear Shaft Coupling
21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Drain plug Center shaft Regulator piston Case Spindle Piston Cylinder Brake spring Valve plate Check valve
7o-93
STRUCTURE AND FUNCTION
TRAVEL MOTOR
OPERATION OF MOTOR 1) At low speed (motor swash plate angle at maximum)
1 reducii;alvei
SUP07126
The travel speed solenoid valve is deenergized, so the pilot pressure oil from the self pressure reducing valve does not flow to port D. For this reason, regulator valve (6) is pushed fully to the left (-1 by spring (7). Because of this, it pushes check valve (321, and the main pressure oil from the control valve going to end cover (5) is shut off by regulator valve (6). At the same time, the pressurized oil at chamber a of regulator piston (23) passes through passage b in regulator valve (6) and is drained to the motor case.
1o-94 0
l
As a result, swash plate (11) is pushed in the maximum swash plate angle direction by the main pressure inside cylinder chamber P, the motor capacity becomes the maximum, and the system is set to low speed.
PC60-7
STRUCTURE AND FUNCTION
2.
TRAVEL MOTOR
At high speed (motor swash plate angle at minimum)
SWPO7127
l
l
l
When the travel speed solenoid valve is energized, the pilot pressure oil from the self pressure reducing valve flows to port D, and pushes regulator valve (6) to the right(m). Because of this, the main pressure oil from the control valve passes through passage b in regulator valve (61, enters regulator piston (23) at the bottom, and pushes regulator piston (23) to the left (-1. As a result, swash plate (11) is pushed in the minimum swash plate angle direction, the motor capacity becomes the minimum, and the system is set to high speed.
Pcoo-7
1o-95 0
STRUCTURE AND FUNCTION
TRAVEL MOTOR
OPERATION OF PARKING BRAKE 1. l
.
l
When starting to travel When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (31, opens the circuit to the parking brake, pushes open check valve (311, and flows into chamber a of brake piston (8). It overcomes the force of spring (281, and pushes piston (8) to the left (o 1. When this happens, the force pushing plate (26) and disc (27) together is lost, so plate (26) and disc (27) separate and the brake is released.
--
2. l
l
l
SLP04216
When stopping travel When the travel lever is placed in hold, counterbalance valve spool (3) returns to the hold position and the circuit to the parking brake is closed. The pressurized oil in chamber a of brake piston (8) is drained to the case from the orifice in the check valve, and brake piston (8) is pushed to the right (0) by spring (28). As a result, plate (26) and disc (27) are pushed together, and the brake is applied.
SLPO4217
1O-96
Pc60-7
STRUCTURE
AND FUNCTION
VALVE CONTROL
VALVE CONTROL
SKP03116
1. 2. 3. 4. 5. 6. 7.
Travel PPC valve L.H. travel control lever R.H. travel control lever R.H. work equipment PPC valve R.H. work equipment control lever Blade control lever PPC lock solenoid valve
1 O-98
8. Hydraulic pump 9. Control valve 10. L.H. work equipment control lever 11. L.H. work equipment PPC valve 12. Safety lock lever
A B C D E F G
: Boom LOWER : Boom RAISE : Bucket CURL : Bucket DUMP : Arm OUT : Arm IN : Swing left
H : Swing I : Blade J : Blade K : Travel L : Travel
right RAISE LOWER FORWARD REVERSE M: Safety lock ON N : Safety lock OFF
STRUCTURE AND FUNCTION
WORK EQUIPMENT,
5
SWING
PPC VALVE
7
4
8
D-D
B-B
E-E SSPW274
-
1. 2. 3. 4. 5. 6.
Spool Metering spring Centering spring Piston Disc Nut (for connecting
7. 8. 9. 10. 11.
Joint Plate Retainer Body Filter
lever)
10-101
STRUCTURE AND FUNCTION
WORK EQUIPMENT, SWJNG PPC VALVE
Operation 1) At hold Ports A and B of the control valve and ports Pl and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I). (Fig. I)
2) Fine control (hold + fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed. Spool (I) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure from port PPPC of the main valve is sent through fine control hole f and goes from port PI to port A. When the pressure at port PI rises, spool (1) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port PI escapes. As a result, spring (1) moves up and down until the force of metering spool (2) is balanced with the pressure of port PI. The relationship of the positions of spool (I 1 and body (IO) (fine control hole f is in the middle between drain chamber D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port PI also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port Pl) and the force of the return spring of the control valve spool are balanced. (Fig. 2)
-
u (Fig. 2)
10-102
SLP04221
(Fig. 1)
SLP04222
STRUCTURE
3)
AND FUNCTION
WORK EQUIPMENT,
SWING
PPC VALVE
Fine control (control lever returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port Pl. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port Pl is released. If the pressure at port Pl drops too much, spool (1) is pushed down by metering spring (2) so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port PI supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)
U
SLPO4223
u
SLP04224
(Fig. 3)
4)
At full stroke Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole f is shut off from drain chamber D and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from port PPPC of the main valve passes through fine control hole f and flows from port Pl to chamber A to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. (Fig. 4)
(Fig. 4)
PC60-7
10-103
STRUCTURE AND FUNCTION
TRAVEL PPC VALVE
A-A
B-B
D-D SAP01 506
1. 2. 3. 4.
Piston Plate Collar Body
PC60-7
5. 6. 7. 8.
Valve Metering spring Centering spring Bolt
10-105
STRUCTURE AND FUNCTION
TRAVEL PPC VALVE
Operation 1) At hold Ports A and B of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
2) Fine control (hold + fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed. Spool (I) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the self pressure reducing valve is sent through fine control hole f and goes from port Pl to port A. When the pressure at port PI rises, spool (I) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port Pl escapes. As a result, spool (I) moves up and down until the force of metering spring (2) is balanced with the pressure of port Pl. The relationship of the positions of spool (I) and body (IO) (fine control hole f is in the middle between drain chamber D and pump pressure chamber PP) does not change until retainer (91 contacts spool (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port Pl also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port Pl) and the force of the return spring of the control valve spool are balanced. (Fig. 2)
10-106 0
(Fir.
1) SLPO4225
(Fia. 21 SLPO4226
PC60-7
STRUCTURE
AND FUNCTION
TRAVEL PPC VALVE
.
3)
Fine control (control lever returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port PI. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port PI is released. If the pressure at port PI drops too much, spool (I 1 is pushed down by metering spring (21, so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port Pl supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)
(FI I. 3) SLPO4227
4)
At full stroke Disc (5) pushes down piston (41, and retainer (9) pushes down spool (1). Fine control hole f is shut off from drain chamber D and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole f and flows from port PI to chamber A to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. (Fig. 4)
IF i 9. 4) SLPO4228
Pc60-7
10-107 0
STRUCTURE AND FUNCTION
SERVICE PPC VALVE
SERVICE PPC VALVE
a
b
n B
SDP00027
a. b. c. d.
Port T (to tank) Port P (from self pressure reducing valve) Port Pl PortP2
10408 0
1. Spool
2. 3. 4. 5. 6. 7. 8.
Metering spring Centering spring Piston Lever Plate Retainer Body
Pc60-7
SERVICE PPC VALVE
STRUCTURE AND FUNCTION
Operation 1) At hold Ports A and 6 of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
2)
Fine control (hold + fine control) When piston (4) starts to be pushed by lever (51, retainer (7) is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the self pressure reducing valve is sent through fine control hole f and goes from port Pl to port A. When the pressure at port PI rises, spool (I) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port Pl escapes. As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure of port PI. The relationship of the positions of spool (1) and body (8) (fine control hole f is in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (7) contacts spool (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port PI also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port Pl) and the force of the return spring of the control valve spool are balanced. (Fig. 2)
(Fio.II
(Fia.2)
PC60-7
SKP04229
SKP04230
10-109 0
STRUCTURE AND FUNCTION
3)
SERVICE PPC VALVE
Fine control (control lever returned)
When lever (5) starts to be returned, spool (I) is pushed up by the force of centering spring (3) and the pressure at port PI. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port Pl is released. If the pressure at port PI drops too much, spool (I 1 is pushed down by metering spring (21, so fine control holef is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port PI supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3) (Fie.3)
4)
SKP04231
At full stroke
Lever (5) pushes down piston (41, and retainer (7) pushes down spool (I 1. Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole f and flows from port Pl to chamber A to push the control vaive spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. (Fig. 4)
iFio.4)
10-l10 0
SKP04232
PC60-7
STRUCTURE AND FUNCTION
SOLENOID
SOLENOID VALVE
VALVE
a
b
SKP03134
a. b. c. d. e. f. g. h.
PortT (to tank) Port P (from self pressure reducing valve) Port Tl (from PPC valve) Port T2 (from LS select valve) Port Al (to PPC valve) Port A2 (to swing motor) Port A3 (to L.H., R.H. travel motor) Port A4 (to pump PC valve)
10-l 12 0
1. 2. 3. 4. 5.
PPC safety lock solenoid valve Swing brake solenoid valve Travel speed solenoid valve Mode selection solenoid valve Block
PC60-7
STRUCTURE
SOLENOID
AND FUNCTION
8
1
1. 2. 3. 4. 5. 6. 7. 8.
VALVE
Nut Plunger Coil Connector Push pin Spring Spool Block
SLPO3135
6 5 L?
Operation When solenoid is deenergized l The signal current does not flow from the controller, so coil (3) is deenergized. . For this reason, spool (7) is pushed to the left (-1 by spring (6). . As a result, port A closes and the pressurized oil from the control pump does not flow to the actuator. At the same time, the oil from the actuator flows from port B to port C, and is then drained to the tank.
elf-pressure educing valve)
SLP04233
When solenoid is energized When the signal current flows to the solenoid valve, coil (3) is energized, and propulsion force is generated to move plunger (2) to the right (-1. l For this reason, spool (7) is pushed to the right (0) by push pin (5). l As a result, the pressurized oil from the control pump flows from port A to port B, and then flows to the actuator. At the same time, port C is closed, and this stops the oil from flowing to the tank.
l
Self-Pressure reducing valve)
SLPO4234
4
10-l 13
STRUCTURE AND FUNCTION
HYDRAULIC
HYDRAULIC CYLINDER
CYLINDER
BLADE CYLINDER
SKPO3138
1. 2. 3. 4. 5.
6. 7. 8. 9. 10.
Head bushing Piston rod Cylinder head Wear ring Rod packing
Cylinder Piston ring Wear ring Piston nut Bottom bushing
Specification
Inside
diameter
Unit: mm
of cylinder
Boom
Arm
115
100
Bucket 90
Blade 120
65
60
55
70
840
865
710
130
Max. stroke
2,150
2,193
1,765
679
Min. stroke
1,310
1,328
1,055
549
70
65
60
80
Outside
diameter
of piston rod
Stroke
Width
across flats of piston nut
10-114
STRUCTURE AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT
SLPO3139
1. 2. 3. 4. 5. 6. 7. 8.
Bucket Bucket cylinder Arm Arm cylinder Boom Boom cylinder Blade cylinder Blade
10416
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
STRUCTURE AND FUNCTlON
1. SYSTEM DIAGRAM
Electric
erease
DUMIP
Main
valve&If-Pressure
reducins
valve)
Starting relese
switch
valve
I a
Flow
divider
valve
Flow
divider
valve
I
Flow divider
Monitor
Panel
valve
SKP04235
lo-118
PC60-7
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
2. OPERATION OF SYSTEM The automatic greasing system adds the hours of operation of the equipment, and every time the total reaches 5 hours, it carries out greasing. The boom RAISE oil pressure switch signal is used to detect operation of the work equipment.
l
.
Unit
Specification value
Greasing interval
H
5
Min
15
~~~.________________---________--__
rr 2 0, z .2 ._ : ?! 0, Q, .E H
P ._ J b .o Ti; E
Calculation of areasin
z
0
I
4
W
.
5 3 0
ii
Suskmsion calculation
of
of SKP04236
Start of calculation
When input signal (boom RAISE) is turned ON during suspension of calculation
End of calculation
When starting switch is turned off and controller power source is turned off
Greasing timing
When total calculation for greasing interval (hatched area) reaches 5 hours
Max. pressure
kg/cm2
245
Discharge amount
cc/min
12
Tank capacity
-
Grease used
-
500 cc cartridge G2-LI (for standard specification, when machine is shipped), %GO-LI (for cold areas, available for supply) Greasing point
No.
z F B 5
--I
t
SusDension calculation
AZ tE
z
- -___ ______
__________________
ON ‘---
E 5 -0 0
z
% En aE OX 5cl
The amount of grease for each work equipment pin is set according to the load on the pin.
Item
Greasing time
& zL Yz 8
.
Amount of grease
cc each time
0
Arm, bucket connecting
0
Arm, link connecting
0
Bucket cylinder foot pin
@
Boom, arm connecting
0
Arm cylinder
@I
Arm cylinder foot pin
0
Boom cylinder
pin
pin
rod pin
Amount
of grease 0.80 0.65 0.25
pin
0.25 0.15 0.15
rod pin
0.15
@
Boom cylinder foot pin
0.35
@
Boom foot pin
0.35 x 2
10-719
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING
SYSTEM
3. COMPONENTS OF SYSTEM 1)
Controller
1. 2. 3.
Connector Controller Fuse
Input/output CN-P44
Name of signal
No. 1 Specification
Model: LC2MP
I
1
I
Power source +24V
1Input/output I
-
2
GND
-
3
-
-
4
Abnormality signal
output
Boom RAISE signal
Input
5 1 6
10-120
signals
1 Starting switch ON signal
I
Input
I
I
STRUCTURE AND FUNCTION
2)
WORK EQUIPMENT PIN AUTOMATIC
GREASING SYSTEM
Electric grease pump
SLP03827
1. 2. 3. 4. 5. 6.
Motor Grease cartridge Air bleed plug Pump Pressure switch Connector
Specification Model: LD05CP
10-121
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
Operation 1. Greasing, pressurizing . When motor (1) rotates in the normal
.
l
direction, eccentric shaft (2) rotates counterclockwise and pump piston (4) is operated in a reciprocal movement by link plate (3). During the return stroke (-1 of pump piston (41, the grease inside cartridge (5) is sucked in, and on the discharge stroke 01, check valve (6) is pushed open and the grease is pushed out to discharge port P. Pressure release spool (7) is moved to the right (~1 by pin (8) of eccentric shaft (2) and pressure release hook (9). This shuts off discharge port P and return passage T, so the pressurized condition is maintained.
6 \ P SKP03828
.
.
When the pressure inside the pump rises and goes above the set pressure, indicator (IO) is pushed to the left (-1, pressure switch (11) is switched ON, and motor (I) stops. When the pressure goes down again and pressure switch (1 I) is turned OFF, motor (1) starts again and the pressurized condition is maintained.
SKP03829
1o-1 22
STRUCTURE
AND FUNCTION
WORK EQUIPMENT
PIN AUTOMATIC
GREASING
SYSTEM
4
.
If abnormal pressure is generated in the circuit at discharge port P end, safety valve (12) opens and releases the pressure to return circuit T to protect the equipment from damage.
P SKP03830
2) .
.
.
l
.
Release of pressure, waiting for work When the greasing is completed, motor (1) rotates in reverse, and eccentric shaft (2) rotates clockwise. Pressure release spool (7) is moved to the left (0) by pin (8) of eccentric shaft (2) and pressure release hook (9). As a result, discharge port P and return circuit T are interconnected, and the pressure in the circuit is released to cartridge (5). When this happens, pump piston (4) moves in a reciprocal motion, but the discharged grease flows to return circuit T, so the pressure does not rise. When the pressure in the circuit drops, indicator (IO) is pushed back, and pressure switch (I I) is turned OFF, motor (1) stops. If pressure switch (II) is not turned off, the controller automatically rotates motor (I) in the opposite direction to release the pressure.
8 7
9
11
IO
P SKP03831
h
70-l 23
STRUCTURE
AND FUNCTION
3) Flow divider valve Type installed to revolving
WORK EQUIPMENT
PIN AUTOMATIC
GREASING
frame
b SBPO1460
a. b.
From electric grease pump To boom cylinder foot pin @I
10-124
SYSTEM
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC
GREASING SYSTEM
Type installed to boom
a
b
d
e SBP01461
a. b. c. d. e. f.
From electric grease pump To left boom foot pin @ To right boom foot pin @ To arm cylinder foot pin @I To boom cylinder rod end pin @ To arm flow divider valve
70-7 25
STRUCTURE AND FUNCTION
WORK EOUIPMENT
PIN AUTOMATIC GREASING SYSTEM
Type installed to arm
a
b
C
d
e
i SBPO1462
a. b. c. d. e. f.
From boom flow divider valve To bucket cylinder foot pin @ To arm, link connecting pin @ To arm, bucket connecting pin @ To boom, arm connecting pin @ To arm cylinder rod end pin @
10-126
STRUCTURE
AND FUNCTION
WORK EQUIPMENT
PIN AUTOMATIC
GREASING
SYSTEM
4
A. B. C. D. E. F.
Structure
Discharge port Discharge port Measurement chamber Piston chamber Oil passage Supply port
1. Measurement piston 2. Head 3. Body 4. Spring 5. Spring retainer 6. Pilot piston
I-. 0
s fi
-
SAP01469
Operation 1) Supply . When grease from the pump is supplied to supply port F, the pressure at supply port F rises and pilot piston (6) is pushed up. As a result, oil passage E opens and the grease enters piston chamber D of measurement piston (I) from oil passage E. l
u
SAP01463
C
lo-127
Measurement piston (I) is pushed down by the grease in piston chamber D, and the grease in measurement chamber C is discharged to the work equipment pins from discharge ports A and B. At the end of this stroke, pilot piston (6) is pushed back down by measurement piston (I), and supply port F and oil passage E are closed. In this way, the measurement and discharge process for one cycle is completed.
C
SAP0 1464
2)
.
l
Resetting When the pump enters the pressure release mode, measurement piston (I) is pushed back up by spring (4). When this happens, the grease in piston chamber D passes from oil passage E through the inside of pilot piston (61, and enters measurement chamber C to reset the system to the initial stage in preparation for the next time of actuation.
SAP0 I!465
lo-128
STRUCTURE AND FUNCTION
3)
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
Boom RAISE oil pressure switch
Structure
of
circuit SLP04237
1. Plug Switch 3. Connector
2.
Specifications Structure Actuation Resetting
: N-0. contact of contact (ON) pressure: 0.5 + 0.1 MPa (5.0 + 1.0 kg/cm*} (OFF) pressure: 0.3 ? 0.05 MPa (3.0 + 0.5 kg/cm*)
IO-129
ELECTRICAL ALLOCATION DIAGRAM
STRUCTURE AND FUNCTION
ELECTRICAL ALLOCATION
DIAGRAM
(l/Z)
INSIDE CAB
3
2’
‘IO
I13
1. 2. 3. 4. 5. 6.
Alarm buzzer brake Swing holding controller Horn switch Speaker Monitor panel Fuel control dial
10-130
7. 8. 9. IO. 11. 12.
Starting switch Fuse box Swing lock prolix switch Radio Wiper switch Swing lock switch
12 SLPO3142
13. Travel speed switch (standard specification machine) 14. PPC lock limit switch 15. Travel boost switch (blade specification machine) 16. Heater 17. One-touch slow-down switch 18. Glow resistance
ir
E20107
sensor
45. Horn
43. Air conditioner 44. Wiper motor
unit
38. Battery 39. Electric grease pump 40. Automatic greasing controller 41. Boom RAISE oil pressure switch 42. Swing oil pressure switch
35. Alternator 36. Battery relay 37. Fusible link
32. Window washer sensor 33. Coolant temperature 34. Air conditioner compressor (option)
30. Glow plug 31. Starting motor
29. Engine stop solenoid
26. Room lamp 27. Antenna 28. Engine oil pressure
21. Fuel level sensor 22. Mode selection solenoid valve 23. Travel speed solenoid valve 24. Swing brake solenoid valve 25. PPC lock solenoid valve
19. Front lamp lamp
20. Working
STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM *
For details of this page, see page 90-19.
ELECTRIC CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
AIR CONDITIONER ELECTRIC CIRCUIT DIAGRAM
ComPressor
SKP04238
IO-133
ELECTRONIC CONTROL SYSTEM
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM TOTAL SYSTEM DIAGRAM
Safety lock lever
Arm
II
Swina
/ Travel
motor:
Xe””
r L. H. travel
’ Tre valve
R. H. trave
dl-b tt tt
i-
3Decification
I
!_____________
Enoine
One-touch slow-down switch
Decelerate motor
I; Monitor
Battery
relay
7
To each
Panel
solenoid
valve SKP04239
STRUCTURE AND FUNCTION
1.
ELECTRONIC CONTROL SYSTEM
Pump control function
z Main
control
Self-Pressure reducins valve
h
valve
,----I
Mode selection solenoid valve
I
Ensine
Main
I
Fuel
injection
,.:
Pump
DUUID
+ Servo Piston
I
Limit snitch
Battery
wv
Fuse
box
121 1-1
J
” SKP04240
Function To reduce the drop in engine speed when the engine is running at low speed, this system controls the speed by automatically lowering the pump absorption torque when the engine is running at low speed.
l
PC60-7
1o-1 35
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
Operation Fuel dial
control set en-
gine speed
Mode
Actuation
Engine torque curve5 Serial No. : 52374 - 57999
Mode selector solenoid Below 1,400 rpm
Above 1,400 rpm
Light load
valve is turned ON and signal pressure is sent to TCC valve to reduce pump absorption torque by approx. 15% from normal in order to prevent any drop in engine speed.
Normal
Mode selection solenoid valve is turned OFF and signal pressure does not flow to TCC valve, so pump absorption torque is set to normal (100%).
Enpine
I
i
my
torque
sorption
14000rpm
torque
1950rpm
Ennine
speed
SKP04241
Serial No. : 58001 and up Ens ine
torpue
/
2. 250r
1.400rPm Ens ine
Pump absorption
speed
torque
pm SWPO712!3
Pump absorption torque curve
Standard Light
Pump dischsrne
lo-136 0
pressure
mode load
mode
SKP04242
PC60-7
STRUCTURE
2.
Swing
AND FUNCTION
lock, swing
ELECTRONIC
SYSTEM
holding brake function
Swine Left valve
CONTROL
I I
0
PPC
1
Solenoid
valve
Self-Pressure reducino valve
1
‘----?Srino
1
7
brake
=T
Swine witch
,_
lock
1
5 -+ _Swins
brake
holdine controller
_.,orolix
:‘Swins
lock
Monitor
Panel
::
SKP04243
Function . This machine is equipped with a swing and swing holding brake function.
lock
JO-137
STRUCTURE AND FUNCTION
Operation 1) Swing lock, swing holding brake function . The swing lock (manual) can be locked at any desired position, and the swing holding brake (automatic) is interconnected with the swing, so it prevents any hydraulic drift after the swing is stopped.
ELECTRONIC CONTROL SYSTEM
l
r
Swing lock switch and swing lock, swing holding brake Actuation
Swing 1OFF OFF holding brake
ON
2)
Swing lock prolix function . If any abnormality occurs in the control-
*
*
ler, and the swing holding brake is not actuated normally or the swing cannot be operated, the swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated. Even if the swing lock prolix switch is turned ON, if the swing lock switch is still ON, the swing lock is not canceled. When the swing lock is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift of the swing.
Swing brake is applied approx. 4 seconds after swing lever is returned to neutral. When swing lever is operated, brake is released and swing operations can be carried out freely. When swing lock is actuated, swing is fixed in position. Even if swing lever is operated, swing lock is not canceled and swing operations cannot be carried out.
ON
ON
Swing lock
OFF
prolix switch (when fhere is abnor- (when controller malrty in controller)
Swing lock switch
1 ON
actuated
1
OFF
released
normal)
1
ON
actuated
(
OFF
iz,JEted
SLP04244
10-138
is
1
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
3. Travel speed selection function
?yFL
Main
control
valve
I ,
Travel
8
1 Travel
!
solenoid
motor
speed valve
Travel speed switch (standard specification machine) I
Travel (blade I-
4 Battery
Engine
Battery relay
P
boost pedal specification
Main P”“P
Fuse box
SKP04245
Function This machine is equipped with a travel speed selection function. . The standard specification machine is equipped with a travel speed switch to switch between high and low speeds; the blade speci-
Operation
l
fication machine is equipped with a travel boost pedal (low speed when released, high
speed when depressed).
, LOW
HIGH
Released
OFF
Max.
Low speed
(2.8) I ,:_l_
IDepressed 1
ON
1 Min.
l gegtnd I
Travel speed se- Standard speci- Bladespecificalection method fication machine tion machine Panel switch Boost switch
PC60-7
1
0
X
X
0
10-139
STRUCTURE AND FUNCTION
4.
ELECTRONIC CONTROL SYSTEM
One-touch slow-down function
Engine
Governor I ever
Fuel
control
One-touch slow down sxi tch
dial
Battery
relay
Fuse
box
SKP04246
Function
When the machine is out of action for a short time, such as when waiting for work or waiting for a dump truck, if the One-touch slow-down switch at the top of the left lever is pressed, and the engine speed will drop immediately to the deceleration speed to reduce fuel consumption and noise. When starting work again, press the switch again to restore the engine speed immediately to the set speed.
Operation Enoine speed
(rwnl
-
Deceleration
,
Max.I
speed
-
I
Max.1
T imebec) Deceleration
ON
Deceleration
OFF SKP04247
10-140 0
PC60-7
STRUCTURE
5. 1)
AND FUNCTION
ELECTRONIC
CONTROL
SYSTEM
System components Swing holding brake controller
r-J-
1. 2.
Controller Connector
, Input/output
signals
CN-Cl
12 IGND
0
2)
Swing oil pressure switch * Same as boom RAISE oil pressure switch in “Work equipment pin automatic greasing system”.
3)
Mode selection solenoid valve Swing brake solenoid valve Travel speed solenoid valve * For details, see SOLENOID VALVE.
1 3 1Oil pressure switch1 Input 4
Solenoid
valve
output
10-141
1
STRUCTURE AND FUNCTION
MACHINE
MONITOR
MACHINE MONITOR SYSTEM
SYSTEM
Buzzer
m Buzzer
Switch
lamp. heater
signal
sional 0
Sensor
Workino
F
sional
SLPO4248
Function . The machine
.
.
monitor system is a system that uses sensors installed at various parts of the machine to observe the condition of the machine. It then processes this information and displays it on a panel to inform the operator of the condition of the machine. The panel display can be broadly divided into the following: 1. The monitor portion, which issues a warning when any abnormality is found in the machine. 2. The pilot portion, which displays the operation and the condition of the machine 3. The gauge portion, which always displays the condition of the machine Switches for electrical attachments are also installed inside the monitor panel.
lo-142
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
4
1. MONITOR PANEL
W-Pi
CN-KJ
Ct+P2
Ch-K3
W-P3
J Ct+K7
f+
-
Outline . The monitor panel has a monitor display function and switches for electrical components. . It has a built-in CPU (Central Processing Unit) which processes the data and outputs the display. . A liquid crystal display is used for the gauge display; lamps are used for the monitor dis-
SLPO3154
input/output signals (monitor Dane11
CN-Pl
10 Charge
Input
level
11 Automatic greasing
Input
12 Swing
Input
lock
Input
13 Preheating
I - I l@mJtl
play. 17
1Fuel
I but I
level
I - I
IslCN-P2
(light
switch)
1151 Buzzer 16 Night lighting
CN-P3
input
(heater switch)
1”2”1=
I 3
I Heater
14 IGND
Lo
I
-
10-143
I
STRUCTURE
MACHINE
AND FUNCTION
MONITOR
6 1. 2. 3. 4. 5. 6.
Service meter Coolant temperature gauge Fuel level gauge Light switch One-touch slow-down pilot lamp Fuel control dial
@ r2
Symbol
z
”
Display item Engine oil
0 ,*:,0
pressure
7. 8. 9. IO. 11. 12.
Display method When the starting switch is turned ON with the engine running, the display is as follows: Normal : OFF Abnormal:ON (buzzer sounds if abnormality occurs
Below 49kPaI0.5 kg/cm* 1 When there is defective charging
q
Automatic
SIP03158
greasing
When there is abnormality
SKP03155
Heater switch Preheating pilot lamp Automatic greasing caution lamp Swing lock pilot lamp Charge caution lamp Engine oil pressure caution lamp
Display range
Charge amount
SYSTEM
when
I
engine
is running)
Normal : OFF Abnormal: ON
el (left) lights up,
T
SAW0528
0w
Preheating
.
When preheating
SAP00526
5 E
I :7’: I
Swing
.%%., ““._.,“.
.z w
*
When
swing
locked
Heater switch
Lo-idlio
Lights up when swing lock switch is ON Liahts
m Light switch SKP031M
UD
when one-touch decel switch is ON
-
Lo : Heater fan Lo Hi : Heater fan Hi
-
1. Monitor panel lights up 2. Monitor panel, head light and work lamp light up
IPT
10-144
is
,
One-touch decel
lOI r
lock
When the starting switch is at HEAT, lamp is ON (30 set); and after this it flashes for 10 sec., then goes OFF to indicate completion of preheating
STRUCTURE
AND FUNCTION
2. SENSOR . The signals l
The contact
1)
from the sensors are input directly to the monitor panel. type sensors are always connected at one end to the chassis
Category of display
Type of sensor
Caution
Engine oil pressure
Gauges
MACHINE
Sensor method Contact
MONITOR
ground.
When normal
When abnormal
OFF (open)
ON (closed) -
Coolant temperature
Resistance
-
Fuel level
Resistance
-
Engine oil pressure sensor
1.
I
2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
1. 2. 3.
Connector Plug Thermistor
Qg @
6 8
w
T
SYSTEM
2)
Coolant temperature
Structure of circuit
SLPO4249
sensor
@==+a
Structure
of
circuit
SLPO4250
?O-145
STRUCTURE AND FUNCTION
3)
MACHINE MONITOR SYSTEM
Fuel level sensor
1. 2. 3. 4.
l/2
EMPTY
Structure
of
circuit
3
4 A-A
10-146
SLPO3836
Float Connector Cover Variable resistance
20
TESTING AND ADJUSTING
Standard value table for engine related parts.. ................................................ 20-2 Standard value table for chassis related parts.. ................................................ 20-3 Standard value table for electrical related parts ................................................ 20-12 Tools for testing, adjusting and troubleshooting ........................................ 20-101 Measuring engine speed ........................... 20-102 Measuring exhaust gas color.. .................. 20-104 Adjusting valve clearance.. ........................ 20-105 Measuring compression pressure ............ 20-107 Measuring blowby pressure.. .................... 20-109 Testing and adjusting fuel injection timing ..................................................... 20-109-2 Measuring engine oil pressure ............. .20-109-7 Testing and adjusting alternator belt tension ............................................ 20-109-9 Adjusting engine stop solenoid linkage ................................................................ 20-109-10 Adjusting fuel control linkage ............. .20-109-12 Testing and adjusting of hydraulic pressure in work equipment, swing and travel circuits .......................... 20-110
* 1.
2.
3. AI
A
A A
Adjusting PC valve ..................................... 20-I 11 Measuring LS differential pressure and adjusting LS valve.. .................................. 20-I 12 Testing hydraulic pressure in the control circuit.. ....................................................... 20-l 13 Testing outlet pressure of solenoid 20-I 14 valve .......................................................... Measuring PPC valve output pressure ..................................................................... 20-I 15 Adjusting work equipment and swing PPC valve .................................................. 20-I 15 Testing travel deviation.. ............................ 20-I 16 Measuring oil leakage.. .............................. 20-I 17 Releasing remaining pressure in hydraulic circuit.. ....................................................... 20-I 19 Checking of clearance of swing circle bearing ...................................................... 20-120 Checking and adjusting of track shoe 20-121 tension ...................................................... Testing wear of sproket.. ......................... 20-121-l Bleeding air.. ............................................... 20-122 Automatic greasing controller .................. 20-124 Troubleshooting ......................................... 20-20 1
Note the following when making judgments using the standard value tables for testing, adjusting, or troubleshooting. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. These standard values are not the standards used in dealing with claims. When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Machine model
PC60-7
Seriaol Number
52374-57999
Engine item
4D102E-1
Measurement conditions
Unit
High idling Engine speed
Low idling
[Ati[:iceleration
Permissible value
1,950 + 50 rpm
Rated speed
Exhaust gas color
Standard value
950 * 50 1,750
-
Max. 4.0
7.0
Max. 2.0
3.0
1 ~‘$~~
0.25 Valve clearance
Exhaust valve (normal temperature)
I
mm
Compression pressure
Oil temperature: 40-60°c (engine speed: 250 rpm) (SAE 15W-40 oil)
Blowby pressure (Orifice dia.: 5.813mm)
(Coolant temperature: operating range) Pa At rated output knrnl-$c (SAE 15W-40 oil)
MPa (kg/cm’
0.51
Min. 2.41 {Min. 24.6)
Min. 1.01 (Min. 10.3) (Differentiol pressure between cylinders)
Max. 803.6 (Max. 821 (Ref.)
3,400 (3471 (Ref.)
0.34 - 0.52 (3.5 - 5.31
(21)
Min. 0.1 (Min. 1.01
0.07 (0.7)
(Coolant temperature: operating range)
Oil pressure
At high idling (SAE 15W-40)
MPa (kg/cm;
At low idling (SAE15W-40)
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before top dead center (B.T.D.C.)
Belt tension (air compressor)
20-2 0
Deflection when pressed with finger force of approx. 58.8Ni6kgI.
“C
( o1
80-110
15*1
2.1
120
15*1
deg
mm
6-10
Pc60-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Machine model
PC60-7
Seriaol Number
58001 and up
Engine
4D95LE-2
Item
Measurement conditions
Unit
High idling Engine speed
Low idling
Standard value
Permissible value
2,250 ? 60
rpm
Rated speed
1,05o+;c 2,100
At sudden acceleration
Max. 5.0
Max. 7.0
At high idling
Max. 1.0
Max. 2.0
Exhaust gas color
Intake valve Valve clearance
Exhaust valve (normal temperature)
Compression pressure
Oil temperature: 40 - 60°C (engine speed: 320 - 360 rpm) (SAE 15W-40 oil)
Blowby pressure (Orifice dia.: 5.613mm)
(Coolant temperature: operating range) At rated output (SAE 15W-40 oil)
0.35 mm
-
0.50
Min. 2.94 {Min. 30)
Min. 2.06 {Min. 21}
Max. 490 {Max. 501 (Ref.)
Nax. 980 (Max. 100) (Ref.)
0.34 - 0.59 (3.5 - 6.0)
Min. 0.25 (Min. 2.5)
0.29 - 0.54 (3.0 - 5.5)
Min. 0.21 {Min. 2.11
At low idiing (SAE30)
Min. 0.1 {Min. I.01
Min. 0.08 {Min. 0.8)
At low idling (SAElOW)
Min. 0.08 {Min. 0.8)
Min. 0.07 {Min. 0.7}
80- 110
120
MPa kg/cm:
Pa -H2C
(Coolant temperature: operating range) At high idling (SAE30)
Oil pressure
At high idling (SAEIOW)
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before top dead center (B.T.D.C.)
Belt tension (air compressor)
Deflection when pressed with finger force of approx. 58.8N(6kgI.
f’C60-7
MPa kg/cm:
“C
(“1
dw
mm
12 f 0.75
6-10
20-2- 1 0
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTlNG
STANDARD
VALUE TABLE FOR CHASSIS RELATED PARTS Machine model
PC60-7
Item
Measurement conditions
I l
1 pump relief (LS relief)
l
l
Hydraulic oil temperature: 45 - 55 “C Coolant temperature: within operating range 1 pump relief: arm relief
Jni -
P= a
Boom control valve
I Arm control valve
b
b
a
e
n
1
1-4
Bucket control valve 1 nm
Blade control valve Boom control lever
I6ztO.l .5?0.1
BLPO1255
I
l
l
Arm control lever
jM.1 9.5fl.l 6.5W
l
l
Center of the lever knob Read the max. value to the end of stroke Engine stopped Excluding neutral play
Bucket control lever Swing control lever
100+10
Travel control lever
nm
115* 15
I I
loo*
10
115f15
Blade control lever Boom, bucket, arm swing, blade Play of control lever Travel lever
Max. 10
I
Boom control lever
l
l
l
Arm control lever l
Bucket control lever
Engine at full speed Hydraulic oil temperature: 45 - 55 “C Fit a push-pull scale to the center of the control lever knob to measure Read the max. value to the end of stroke N kg1
Max. 10
15.7 f 4.9 11.6 f 0.5)
15.7 * 4.9 (1.6 f: 0.5)
13.7 f 4.9 11.4 f 0.51
13.7 + 4.9 (1.4f 0.5)
13.7 f 4.9 11.4 f 0.51
13.7 f 4.9 Il.4 + 0.5)
15.7 * 4.9 (1.6 f 0.5)
15.7 * 4.9 Il.6 * 0.51
Blade control lever -
t 1: Serial No. 58001 and up PC@7
20-3 0
?
(D
v)
Swing
B9
Y
0-
W t
w
A
OP
I +
Y
v
0-
9
(3
o w
0 0 3
Y
000
9
cn
N
h
cn
og
OP h
P
N
3
?
Y
q9
Hydraulic pressure
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
Machine Cats gor -
T
model
Measurement Work
equipment
PC60-7
Jni
Standard value
Permissible value
;ec
2552
30
m-r
0
0
lmir
Max. 3.5
7.0
28.8 i 3
34
Hi
19.8 + 2
25
Lo
25.3 k 1.7
29
Hi
16.2 + 1
19
conditions
posture Max. reach
Time taken to swing TAP00950
l
l
l
Hydraulic swing
drift of
EAP03503
Enginezed Hydraulic oii temperature: 45 - 55°C Set machine on 15” slope, and set upper structure at 90” to the side. Make match marks on swing circle outer race and track frame. Measure distance that match marks move apart after 15 minutes. l
Leakage motor
Engine at high idling Hydraulic oil temperature: 45 - 55°C Swing one turn, and measure time taken to swing next 5 turns
from swing
l
l
l
Engine at high idling Hydraulic oil temperature: Swing lock switch ON Relieve swina circuit.
45 - 55°C
-
-
Lo
Travel
Travel
BAP03504
speed (1)
Engine at high idling Hydraulic oil temperature: 45 - 55°C Raise track on one side at a time, rotate one turn, then measure timr I taken for next 5 turns with no load
-
;ec
speed (2) l
l
l
Engine at high idling BApo3505 Hydraulic oil temperature: 45 - 55°C Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.
20-5 0
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
PC60-7
Machine model Measurement conditions
item
lnit
Standard value
Permissible value
nm
Max. 200
Max. 220
nm
0
0
irnil
2
5
BAP03605
rravel deviation
Engine at high idling Hydraulic oil temperature: 45 - 55°C Run up for at least 10 m, and measure deviation when traveling next 20 m on flat ground. Ir Use a hard horizontal surface.
BAP03506 f
Measure dimension e
Hydraulic drift of travel
BAP03507
1 Engine stopped 1 Hydraulic oil temperature: 45 - 55°C 1 Stop machine on 12” slope with sprocket facing straight up the slope. m Measure the distance the machine moves in 5 minutes.
Leakage of travel motor Lock
oin !AP00951
. Engine at high idling Hydraulic oil temperature: 45 - 55°C Lock shoes and relieve travel circuit.
l
l
20-6 0
-
TESTING
STANDARD
AND ADJUSTING
Machine Item
r
Total work squipment [hydraulic drift at tip of bucket teeth )
VALUE TABLE FOR CHASSIS
model
Measurement
r
U nit -
conditions
RELATED PARTS
PC60-7 Standard value
Permissible value
Max. 550
825
Max. 4
60
Max. 41
59
Max. 20
30
3.1 f 0.3
3.9
3.3 + 0.3
3.9
3.6 f 0.4
4.5
2.7 + 0.3
3.5
3.1 ?I 0.3
3.9
2.1 f 0.2
2.6
Posture for measurement
i Boom cylinder (amount of retraction of cylinder)
TAP00952
Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. Bucket: rated load Horizontal, flat ground Levers at neutral Engine stopped Hydraulic oil temperature: 45 - 55°C Start measuring immediately after setting. Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes.
Arm cylinder (amount of exten. sion of cylinder)
Bucket cylinder (amount of retraction of cylinder)
-
Boom Bucket teeth in contact with ground
I Cylinder fully extended
TAP00953 l
l
Engine at high idling Hydraulic oil temperature: 45 - 55°C
Arm Cylinder fully retracted
,ec.
I Fully extended
TAP00954 l
l
Engine at high idling Hydraulic oil temperature: 45 - 55°C
Bucket Cylinder fully retracted
I Fully extended
TAP00955 l
l
Engine at high idling Hydraulic oil temperature: 45 - 55°C
-
20-7 0
TESTING
STANDARD
AND ADJUSTING
Machine
r
model
Measurement
Item
VALUE TABLE FOR CHASSIS
Jnit
conditions
PC60-7 Standard value
Max. 2.9
Boom
RELATED PARTS
Permissible value
3.9
BAPO3513
Lower boom and measure time take from point where bucket contacts ground to point where chassis rises from ground Engine at low idling Hydraulic oil temperature: 45 - 55°C
sec. 1.0
Arm BAP03514 l
l l
Stop arm suddenly and measure time taken for arm to stop Engine at low idling . Hydraulic oil temperature: 45 - 55°C
BAP03515
Bucket l
l l
Stop bucket and measure time taker for bucket to stop at bottom and the start again Engine at low idling Hydraulic oil temperature: 45 - 55°C
10
Max. 2.3
Boom
Cylinders l
l
l
Center swivel joint
Hydraulic
oil temperature: 45 - 55°C Engine at high idling Relieve circuit to be measured
Arm
Max. 2.2
15
clmi’ Max. 2.0
Bucket
Max. 10
50
Max. 500
550
Engine at high idling Hydraulic oil temperature: 45 - 55°C *Use a hard horizontal surface.
l l
Lc
20m
-I
Travel deviation wher work equipment + travel are operated
mn
BAP03506
t Measure
dimension
e
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
r
Machine model Catf !m
item
Main piston pump
PC60-7
T
Measurement conditions
See next page
Unit
Wmin
PC60-7 value st~Z!ZrdPermissible
See next page
20-9 0
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
Catl PC60-7 Discharge Qor
amount of main piston pump Serial No. : 52374 - 57999
15(
lO(
50
0
71150) IS. 6UOOl 24. 5(250) 4.Ii501 !.t(lOO)II. PIMP
l
dirchrrr oressure Pl WPafb/cr’) BAPOOQ56
Pump speed: At 1,750 rpm
Check point
Test pump discharge pressure (MPa(kg/cmV
Average pressure (MPa(kg/cm*))
Standard value for discharge amount QfVmin)
Judgement standard lower limit QfUmin)
As desired
PI
Pl
See graph
See graph
* The error is large near the point where the graph curves, so avoid measuring at this point. Ir When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-10 0
K60-7
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
Cat1 PC60-7 Discharge amount of main piston pump gor Serial No. : 66001 and up
0
50
100 19. 8)
150
Pump d i scharse
Pressure
200 (19. 6)
250 (24. 51
300
Pl (HPa(ka/cm’)) TXP02153
l
Pump speed: At 2,100 rpm Check point
Test pump discharge pressure (MPafkg/cm*))
Average pressure fMPafk&mz))
Standard value for discharge amount Q(.f/min)
Judgement standard lower limit QUYmin)
As desired
Pl
Pl
See graph
See graph
* The error is large near the point where the graph curves, so avoid measuring at this point. t When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
pc60-7
20-I 1 0
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ELECTRICAL BELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS sy! ten
Component
Engine oil pressurt3 sensor
Alternator
Zonnector No.
Measurement conditions
Judgment table Normal conditions are as shown in the table below.
1) Starting switch OFF 2) Disconnect CNP13
While the engine running (l/2 throttle or above) + 27.5 - 29.5 V % With a degraded battery, or in cold district, voltage may not rise for some time after starting the engine.
1) Start the engine.
CN-Pl3
CN-M5
Normal conditions are as shown in the table below. Coolant temperature sensor
EN-P7
25°C
. Between (1) and (2)
105°C
Approx. 40 kQ Approx. 3.3 kR
Normal conditions are as shown in the table below. Fuel sensor
IN-P5 ZN-P6
1) Starting switch OFF 2) Disconnect CNP7
FULL stopper Between CN-
1) Starting switch OFF 2) Disconnect CNP5 and CN-P6
EMPTY
Normal conditions are as shown in the table below. Swing lock switch
CN-X5
I) Starting switch OFF 2) Disconnect CNx5
Normal conditions are as shown in the table below.
Light switch
CN-P2 I
I
Between(P), (3) and (4)
Switch 2
Continuity detected
Normal conditions are as shown in the table below.
Heater switch
1) Starting switch OFF 2) Disconnect CNP3
CN-P3
1
I
Switch Hi
20-12 0
11 Starting switch OFF 2) Disconnect CNP2
Between (2) and (4)
~~~~~~
Continuity detected
Pc60-7
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Inspection/adjustment item
Engine speed
siymbol
Remarks
Part Name
Part No.
1
799-203-8001
Multi-tachometer
2
795-790-2500
Adapter assembly
799-101-1502
Digital thermometer
Digital display L: 60 - 2,000 rpm H: 60 - 19,999 rpm
A
Coolant and oil temperatu re
B
-99.9 - 1,299 “C
1
799-101-5002 790-261-1203
Digital hydraulic tester
Pressure gau e : 2.5{25), 5.9f601, 39.2{400}, 58.!!(6001 MPaIkg/cmZI e: 68.6 Pressure MPa gau 1708 kg/cm*}
2
799-401-2320
Hydraulic gauge
0.98 MPa (10 kg/cm*)
Adapter
Both male and female 14 x 1.5 (female PT1/8) Both male and female 18 x 1.5 (female PT1/8) Both male and female 22 x 1.5 (female PT1/8)
Hydraulic tester
.790-261-1311 Hydraulic oil pressure
3
C
l
790-261-1321
l
790-261-1331
I 4 I 799-401-2701
/
1 Differential pressuregauge 1
5
1 Compression pressure
2 3
Blowby pressure
E
Valve clearance
F
Exhaust gas color
Adapter
Both male and female 14 x 1.5 (female PT1/8)
l
790-261-1370
Nut
For 14 x 1.5 blind
l
07003-31419
Gasket
For blind
795-502-l 590 I
D
I
I
.790-261-1360
Compression gauge I
790-553-l 110
l
Adaoter
0 - 6.9 MPa (0 - 70 kg/cm21 Kit No.: 795-502-1205
Blowby checker
0 - 4,900 Pa IO - 500mmHzOI
795-553-l 110
l
799-201-1504 Commercialy available
Feeler gauge
1
799-201-9000
Handy smoke checker
2
Commercialy available
Smoke r\^+-* IIIcil%zil
G
f.Xs~ll$ ‘anon .. 0 - - -19 Y0 ^’ sndard color samples) !Disc.olc%r n x l/10 Bosch 1index) 0-294N{O-30kgI
H
Operating force
I
Work equipment speed
J
Voltage and resistance value measurement
K
Air breeding from the auto lubricator piping
Valve clearance I Fuel injection timing Measurement of wear on sprocket tooth
PC60-7
Push-pull scale 0-490N(O-50kgI
Stroke, hydraulic drift
Sensor harness diagnosis
Is/ Commercialy available Commercialy available
Scale
79A-264-0211
Tester
1
799-601-2600
T-adapter box
2
799-601-7000
Adapter assembly
1
21T-3811390
Nipple
2
07020-00000
Fitting
1
795-799-l 130
Gear
2
795-102-2102
Spring pusher
3
Commercialy available
Dial guage
790-607-1031
Wear gauge
L
hll
Stop watch
I.,
0
P
1 Cranking tool
20-101 0
TESTING AND ADJUSTING
MEASURING ENGINE SPEED A When installing or removing a measuring equipment, be careful not to touch any high temperature parts. Ir
Measure the engine speed under the following conditions. . Coolant temperature : Within operating range . Hydraulic oil temperature : 45 - 55 “C
Serial No. : 52374 - 57999 1.
Remove the fan gurad (I).
2.
Remove the cap (2) for speed pick-up port.
3.
Install the adapter assembly (A21 to the revolution taking off port and install the sennsor @ for the tachometer. Then connect to the tachometer body (Al I.
4.
Start the engine, and measure the engine speed when it is set to the conditions for measurement.
A
When measuring the engine speed, be careful not to touch any rotating parts or high temperature parts.
1) Measurement
of the low-idling and highidling speed: Measure the engine speeds when the fuel lever is set to the low-idling and high-idling. 2) Measurement of the speed at the pump relief: Measure the engine speeds at it full capacity when each pump is relieved.
20-102 0
MEASURING ENGINE SPEED
TESTING
MEASURING
AND ADJUSTING
ENGINE
SPEED
Serial No. : 58001 and up 7.
Remove
2.
Install sensor I of tachometer Al to the tachometer.
3.
Start the engine, and measure when it is set to the conditions
a
the fan gurad
(I 1. Al,
then connect
the engine speed for measurement.
Stnce the fun guard is kept removed during measurement of the engine speed, never stand near the fan (rotary part). Take care not to catch the tachometer cable in the fan. 1)
2)
PC60-7
Measurement of the low-idling and highidling speed: Measure the engine speeds when the fuel tever is set to the low-idling and high-idling. Measurement of the speed at the pump relief: Measure the engine speeds at it full capacity when each pump is relieved.
20- 103 0
MEASURING EXHAUST GAS COLOR
TESTING AND ADJUSTING
MEASURING EXHAUST GAS COLOR l
f A
1.
When air or when 62. Raise range
the coolant temperature before measuring.
to the operating
When removing or installing the measuring equipment, be careful not to touch any high temperature part.
Measuring with handy SmOk8 checker Gl 1) Fit filter paper in tool Gl.
2)
3)
2.
measuring in the field when there is no power supply, use smoker checker Gl; recording official data, use smoke meter
Insert the exhaust gas intake port into the exhaust pipe, accelerate the engine suddenly, and at the same time operate the handle of tool Gl to catch the exhaust gas on the filter paper. Remove the filter paper and compare it with the scale provided to judge the condition.
Measurina with smoke meter 62 1) Insert-probe into the outlet port of exhaust
2)
3)
4)
5) 6)
7)
pipe, then tighten the clip to secure it to the exhaust pipe. Connect the probe hose, accelerator switch plug, and air hose to tool 62. t The pressure of the air supply should be less than 1.5 MPa 115 kg/cm% Connect the power cord to the AClOOV outlet. -k When connecting th8 port, check first that the power switch of tool 62 is OFF. Loosen the cap nut of the suction pump, then fit the filter paper. * Fit the filter paper securely so that the exhaust gas does not leak. Turn the power switch of tool G2 ON. Accelerate the engine suddenly, and at the same time, depress the accelerator pedal of tool G2 and catch the exhaust gas color on th8 filter paper. Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (10 sheets or more) inside the filter paper holder, and read the indicated value. BLPO21
20-104 0
PC60-7
ADJUSTING
VALVE CLEARANCE
ADJUSTING
AND ADJUSTING
TESTING
VALVE CLEARANCE
Serial No. : 52374 - 57999 1. Remove the cylinder head cover. 2.
Set cranking tool 0 to the flywheel.
3.
Rotate the crankshaft in the normal direction to a point where timing pin (1) enters the hole in the gear. Push pin (I) in lightly while cranking. * + The position where the pin enters the hole is the No. 1 top dead center.
4.
At this position, adjust the clearance of the valves chart. At the marked 0 in the valve arrangement same time, make match marks on the crankshaft pulley and timing gear case, then remove timing pin (1).
Valve
arreneement
Crl
5.
Next, rotate the crankshaft one turn (360”) in the normal direction, align the match marks made in Step 4 accurately, then adjust the valve clearance of the remaining valves marked 0. Ir To adjust the valve clearance, loosen locknut (41, then insert feeler gauge F between rocker arm (6) and valve stem (51, and turn adjustment screw (3) until the clearance is a sliding fit. Then tighten locknut (4) to hold the adjustment
screw in position.
m
Locknut: 24 f 4 Nm (2.45 rt 0.41 kgm} -4-
2
Ir
Firing order : 1 -3
*
valve clearance Intake side .. . .. . . . .. . . . . . . .. .. . .. 0.25 mm Exhaust side .. . .. . . .. . . . . . . . .. . . 0.51 mm
PC60-7
Exhaust
Intake
I
inder
I
NO.
0
valve
valve
l
0
1
3
0
0
0
I 0
0
TKP00642
ADJUSTING VALVE CLEARANCE
TESTING AND ADJUSTING
Serial No. : 58001 and up 1. Remove the cylinder head cover.
2.
Turn the crankshaft forward and match “1.4TOP” line (1) on the crank pulley to pointer (2).
3.
When cylinder No. 1 is at the compression top dead center, adjust the valves as indicated by 0 in the valve position table. Turn the crankshaft forward by 360 degrees, then adjust the valves as indicated by 0 in the valve position table.
Valve
arrangement
I 4.
TOP00308
Insert tool F between rocker lever (3) and valve stem (4). and turn adjustment screw (5) so that tool F will move lightly, then tighten locknut (6). w
Locknut : 44.1 f 4.9 Nm (4.5 rt 0.5 kgm}
*
The valve clearance may be adjusted according to the following procedure; Bring cylinder No. 1 to the compression top dead center and adjust the valve clearance of cylinder No. 1. Then, turn the crankshaft by 180 degrees and adjust the valve clearance of each cylinder according to the firing order. Firing order: 1 - 2 - 4 - 3 After tightening the locknut, check the valve clearance again.
/
F
’
BWPO4013
l
*
4
20-106 aI
3
5
6
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING
MEASURING PRESSURE
COMPRESSION
Serial No. : 52374 - 57999 a
While measuring the compression pressure, take care not to touch the exhaust manifold, etc. to get burnt and not to catch your clothes in the fan or fan belt. For details, see ADJUSTING VALVE CLEARANCE.
1. Adjust the valve clearance accurately.
2. Warm up the engine until the oil temperature 40 - 60°C. -_
is
BLP02908
3. Remove the nozzle holder assembly of the cylinder to be measured. For details, see REMOVAL OF NOZZLE ASSEMBLY. 4.
Install adapter D2 to the nozzle holder mounting part, then connect compression gauge Dl.
5. Install multi-tachometers Al and A2. Ir See MEASURING ENGINE SPEED. 6. Disconnect engine stop solenoid terminals (M3, M37). 7.
Rotate the engine with the starting motor and measure the compression pressure. pressure when the Read the compression pointer of the compression gauge stops. When measuring the compression pressure, measure the engine speed and check that it is in the range of the measuring condition. After measuring the compression pressure, install the nozzle holder assembly. For details, see INSTALLATION OF NOZZLE ASSEMBLY.
PC60-7
20-107 0
TESTING
AND ADJUSTING
MEASURING
COMPRESSION
PRESSURE
Serial No. : 58001 and up a
While measuring the compression pressure, take care not to touch the exhaust manifold, etc. to get burnt or catch your clothes in the fan or fan belt.
1. Adjust the valve clearance accurately. For details, see ADJUSTING VALVE CLEARANCE. 2.
3.
Warm up the engine 40 - 60-c. Remove nozzle holder der to be measured.
until
the oil temperature
is I
assembly
4.
Install adapter D3 to the nozzle part, then connect compression
5.
Install multi-tachometer Sr See MEASURING
Al. ENGINE
(1) of the cylin-
BwP04009
r
SPEED.
Disconnect engine stop solenoid terminals (M3, M37) (2) and fix the governor lever of the injection pump to the non-injection position, then rotate the engine with the starting motor and measure the compression pressure.
*
Read the compression pressurewhen the pointer of the compression gauge stops. After measuring the compression pressure, install the nozzle hoider assembly.
20- 108 0
II
holder mounting gauge Dl.
6.
*
I
PC60-7
TESTING AND ADJUSTING
MEASURING
BLOWBY PRESSURE
MEASURING BLOWBY PRESSURE Serial No. : 52374 - 57999 *
to the operating Raise the coolant temperature range before measuring the blowby pressure.
1.
Install the blowby breather hose (1).
2.
Run the engine at the rated output and measure the blow-by pressure.
checker
to the tip of engine
A
When measuring the blowby pressure, be careful not to touch any high temperature parts or rotating parts.
*
The blowby should be measured with the engine running at rated output. If it is inpossible to check at rated output, measure at high idling. In this case, the blowby value will be about 80% of the value at rated
l
*
FCbO-7
output. Blowby varies greatly according to the condition of the engine. Therefore, if the blowby value isconsidered abnormal, checkfor problems connected with defective blowby, such defective exas excessive oil consumption, dirty or deprematurely haust gas color, and teriorated oil.
20- 109 0
TESTING
Serial
MEASURING
AND ADJUSTING
No. : 58001
and up
1.
Remove
2.
Install
3.
install cylinder head cover (I!, then by checker E to the oil filler.
4.
Run the engine at the rated the blow-by pressure. A
cylinder
BLOWBY PRESSURE
head cover
plug E to breather
(1)
tube
(2)
output
Install
blow-
and measure
Do not touch a hot part or a rotary ing measurement.
part dur-
*
The regular blow-by pressure is measured while the engine is running at the rated output. An approximate value can be obtained in the field by performing relief operation. . If rated-output operation or relief operation cannot be performed, measure the blow-by pressure while the engine is running at high idling. In this case, the measure blow-by pressure is about 80% of that measured at the rated output. * The blow-by pressure may vary largely with the condition of the engine. If the measured blow-by pressure is judged abnormal, check for high oil consumption, bad exhaust gas color, deterioration or dirtiness of oiI, etc. which are related to improper blow-by pressure. After finishing measurement, remove plug E without fail. l
*
BWPO40 I I
20- 109- 1 0
PC60-7
TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING
.-
TESTING AND ADJUSTING FUEL INJECTION TIMING Serial No. : 52374 - 57999 1. Testing 1) Using cranking tool 0, rotate the crankshaft in the normal direction to a point where timing pin (1) enters the hole in the gear. 2) Remove plug (2), turn over timing pin (3), and check that timing pin (3) meshes with timing pin pointer (4) at the injection pump end.
2.
Adjusting . If timing pin does not mesh 1) Remove the injection pump. For details, see REMOVAL OF FUEL INJECTION PUMP 2) Rotate the camshaft of the injection pump to align timing pin (3) with timing pin pointer 3)
(4). Install the injection pump. For details, see INSTALLATION JECTION PUMP
OF FUEL INBLPOIO5I
PC60-7
2 BLPO1052
20- 109-2 0
TESTlNG AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION THING
Serial No. : 58001 and up
I
Adjustment by use of match marks Apply this method usually. (When installing the fuel injection pump to the original engine without repairing it, when checking only the injection timing, etc.) Bring cylinder No. 1 to the compression top dead center. 1) Turn the crankshaft forward and match “1.4TOP” line (1) on thecrank pulley to pointer (2). 2) Check that cylinder No. 1 is at the compression top dead center by the following method. If the following condition is not obtained, turn the crankshaft one more turn. * If the fuel injection pump is removed: Check that “C” is seen at the tooth tip of idler gear (3). * If the fuel injection pump is installed to the engine: Remove the head cover and check that both air intake valve and exhaust valve of cylinder No. 1 are closed (both air intake valve and exhaust valve of cylinder No. 1 have the valve clearance).
BWPO4015
Remove front cover (4) of the fuel injection pump. Install the fuel injection pump holder and drive gear as one unit to the engine. Insert the timing check pin 4.0 - 4.5 mm in diameter and 80 mm in length in hole “a” of the front gear cover and match it to the hole of the drive gear. + Check that the timing check pin enters straight and the hole of the fuel injection pump holder is aligned with the mounting hole of the front gear cover (in which the mounting bolt will be inserted). * If the holes are deviated from each other, remove the fuel injection pump and check its engagement with the drive gear.
4 a
‘1
BYPOIO I 6
Remove the timing check pin and tighten each bolt.
20-109-3 0
f’C60-7
TESTlNG AND ADJUSTlNG
TESTlNG AND ADJUSTING FUEL INJECTlON TIMING
Adjustment by use of match marks (When installing a repaired or replaced fuel injection pump, when checking after disassembling or replacing the gear train) the cylinder
head cover.
1.
Remove
2.
Bring cylinder No. 1 to the compression top dead center. 1) Turn the crankshaft forward and match injection timing line (1) on the crank pulley to pointer (2). 2) Check that both air intake valve and exhaust valve of cylinder No. 1 have the valve clear-
BWPO4012
ance. If either or both of the valves do not have + the valve clearance, turn the crankshaft one more turn.
3.
Remove snap ring (3) from the front end of the rocker shaft, then remove air intake rocker arm (4) of cylinder No. 1.
TXP02154
the valve
4.
Using spring pusher 02, compress spring and remove valve cotter (5).
5.
Loosen spring pusher 02 and remove spring seat (6) and valve spring (7).
BWPO402I6
6.
Turn the stem of air intake valve (8) with the fingers while it is in contact with the top of piston (9) to fit it securely.
.I ,9
BEPOl063
Pcoo-7
20- 109-4 0
TESTING AND ADJUSTING
TESTING AND ADJUSTING FUEL INJECTION TIMING
7. Apply dial gauge 03 to the valve stem end and turn the crankshaft forward. Set the dial gauge to 0 when its pointer starts turning in reverse. 8. Turn the crankshaft about 45” degrees in reverse from the compression top dead center of cylinder No. 1. 9. Turn the crankshaft forward so that the dial gauge indicates standard dimension “a”. This dimension is equivalent to BTDC 12 + 0.75”. Ir Standard dimension: 1.69 f 0.22 mm It Be sure to adjust the above dimension by turning the crankshaft forward.
4027
10. Disconnect fuel injection pipe (10) of cylinder No. 1. 11. Remove delivery valve holder (111, and remove delivery valve (12) and spring (13) from its inside. Then, install delivery valve holder (I 1) again. 12. Set the fuel injection lever to the FULL position. 13. Loosen the nut at the oblong hole of the injection pump mounting flange, then loosen the injection pump mounting bolts (14).
BEP01065
14. Turning the injection pump outward and operating the priming pump, move the injection pump toward the cylinder block little by little and stop when the fuel stops flowing out of the delivery valve holder. Ir If the injection pump is slanted out, the injection timing is delayed. If the former is slanted toward the cylinder block, the latter is advanced. 15. Tighten injection pump mounting bolts (14) alternately. 16. lighten the nut at the oblong hole of the injection pump mounting flange. 17. Turn the crankshaft forward and check that the dial gauge indicates 0 k 0.22 mm when cylinder No. 1 is at the top dead center (when the pointer of the dial gauge starts moving in reverse). If the pointer of the dial gauge is out of this range, repeat the above steps from 7.
20-109-5 0
PC&7
TESTING
AND ADJUSTING
TESTING
AND ADJUSTING
FUEL INJECTION
TIMING
18. Remove the delivery valve holder (I 1) and install delivery valve (12) and spring (13) to it, then install delivery valve holder (14) again. Replace the O-ring and copper gasket of the * delivery valve. Tighten the delivery valve 3 times to secure g it. (If it is not tightened sufficiently, the gasket may be broken.) Delivery valve holder : w 32.4 f 2.0 Nm (3.3 + 0.2 kgm} 19. Connect w
fuel injection pipe (3). Sleeve nut : 23.5 i 1.0 Nm 12.4 + 0.1 kgm)
20. Install valve spring (7) and valve seat (6). 21. Compress the valve spring with spring 02 and install valve cotter (5). 22. Install air intake rocker arm (4) of cylinder then install snap ring (3). Install the snap ring securely. * 23. Install the cylinder m
pusher
No. 1,
head cover.
Cylinder head cover mounting bolt : 8.8 * 1.0 Nm 40.9 f 0.1 kgml
-
PC607
20-109-6 0
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE t
Measure the engine oil pressure under the following conditions. Coolant temperature: Within operating range l
Serial No. : 52374 - 57999 Remove engine oil pressure sensor (11, then install the adapter of oil pressure gauge kit Cl and oil pressure gauge C2 (1.0 MPa {lo kg/ cm2)). Start the engine, and measure the oil pressure with the engine at low idling and high idling.
20- 109-7 0
Pc60-7
TESTING
PC60-7
AND ADJUSTING
MEASURING
ENGINE
OIL PRESSURE
20- 109-8 c3
TESTING AND ADJUSTING
TESTING AND ADJUSTING
ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION Serial No. : 58001 and up Testing Press the intermediate point of the belt between the alternator and fan pulley with force of about 58.8 N I6 kg}, and check that the belt is deflected by6-10mm. l
Adjusting 1. Remove the cover from the side of the alternator. 2.
Loosen belt tension adjustment bolt (I) and alternator mounting nut (2).
3.
Move alternator toward the front of the machine body with a bar, then tighten belt tension adjustment bolt (I).
4.
Tighten mounting nut (2).
20- 109-9 0
BWPO4022
Pcoo-7
TESTING AND ADJUSTING
ADJUSTING Seeial
No. : 52374
ADJUSTING ENGINE STOP SOLENOID LINKAGE
ENGINE STOP SOLENOID
LINKAGE
- 57999
Testing 1. Turn ON the starting switch and check that lever (5) can move toward rod (4) (it has some play) at this time. Since the clearance cannot be checked visu* ally, check it by feeling with the hand. (Reference) Clearance “a” between lever (5) and stopper (6): 1 - 2 mm If the above clearance is too large, the engine t output may not be heightened to the full level. If the former is eliminated, the solenoid may
FlKP02577
burn.
Adjusting 1. Loosen mounting bolt (7) of solenoid (I). 2. Move solenoid (I) in the direction of the arrow (A) to the end. The hole of bracket (8) is oblong. t 3. Turn ON the starting switch to operate solenoid 4.
5.
6. 7.
8.
(1). Move solenoid (1) in the direction of the arrow (B) by the hand until lever (5) comes in contact with stopper (6). Since clearance “a” cannot be checked visut ally, move the solenoid to check the clearance by feeling with the hand. If solenoid (1) is moved forcibly in the direc* tion of the arrow (B) after lever (5) comes in contact with stopper (61, the solenoid may
EKPO2691
burn. After lever (5) comes in contact with stopper (61, move solenoid (1) by 1 - 2 mm in the direction of the arrow (A). -k Since clearance “a” cannot be checked visually, check it by the moving distance of the solenoid. Tighten mounting bolt (7) of solenoid (1). Operate the solenoid several times and check that linkage (2) - (4) do not interfere with another part and the solenoid is not heated abnormally. If the parts between solenoid (1) and linkage (4) assemble them into a have been disassembled, in advance, then install the subsub-assembly assembly to the engine. adI) When installing the above sub-assembly, the of ends both just distance “a” between rod to the following value. + a:163mm Ir Screwing depth b on solenoid side : 15 mm Screwing depth c on lever side : 15 mm *
Pcoo-7
20-109-10 0
ADJUSTING ENGINE STOP SOLENOID LINKAGE
TESTING AND ADJUSTING
Serial No. : 58001 and up *
If the fuel injection pump or engine stop solenoid has been replaced, adjust the engine stop linkage according to the following procedure.
1.
If the engine stop solenoid has been replaced, install the used rod to the new solenoid. (Keep rod nuts (4) and (5) loosened.) w
Sr
Threads
of rod (all threaded part) : Liquid adhesive (LT-2)
Do not apply adhesive to the part of 5 mm from each end, however.
2.
Turn ON the starting switch to operate the solenoid without connecting the injection pump stop lever and rod.
3.
Push stop lever (1) toward connect rod (2).
4.
Adjust the length of rod (2) by turning it until stop lever (1) comes in contact with the internal stopper on the operation side.
the operation
1
r ~
BEPOO804
Rod
is
shortened
Rod
is
lenrthencd
side and
TXP02155
5.
Tighten
6.
Loosen the rod by l/2 - 1 turn to lengthen it (by 1 - 2 mm) to make play between stop lever (I) and stopper on the operation side.
7.
Tighten locknuts (4) and (5). * Tighten these nuts securely so that rod (2) will not turn.
8.
Check that the engine starts and stops normally and the solenoid is not heated abnormally.
nut (3) and install the cotter pin.
BEP00806
20-109-11 0
Pao-7
TESTlNG AND ADJUSTlNG
ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL LINKAGE t If the fuel injection pump, servo motor, and cable have been replaced, or if the engine speed is not the specified value, adjust as follows.
Serial No. : 52374 - 57999 1.
Adjusting control linkage I) If the parts have been replaced, connect the cable securely to the fuel injection pump governor lever. Connect to the bottom hole of the fuel in* jection pump governor lever. 2) Turn the starting switch to the ON position and the fuel control dial to the FULL position. 3) Put fuel injection pump governor lever (1) in contact with the FULL stopper. 4) In the above condition, pull cable (2) with a force of approx. 98 N {approx. 10 kg}, and temporarily tighten nuts (3) and (4). * lighten nuts with the cable pulled to remove any play. 5) Loosen nut (3) 2 turns and tighten nut (4) 2 turns, then tighten both nuts. 6) Start the engine and check that it is running at the specified speed.
2.
Adjusting engine stall prevention switch * This should be actuated when the speed goes below 1400 rpm. 1) Turn the starting switch to the ON position and the fuel control dial to LOW. 2) Adjust bracket (7) so that the clearance between the tip of limit switch (5) and plate (6) mm. is3-4 * The hole in bracket (7) is an oblong hole. 3) Check that limit switch (5) is not at the end of its stroke when the fuel control dial is turned to FULL.
PC60-7
20-109-12 0
TESTING
Serial 1.
AND
ADJUSTING
No.
: 58001
Adjusting
control
--_
ADJUSTING
FUEL
CONTROL
LINKAGE
and up linkage
Ii
If any part has been replaced, connect ttip cable to the injection pump governor l!:v,ir securely. * Connect the cable to the lowest hole of ttle injectron pump governor lever. 2; Turri ON ?he starting switch and set the fuel contra! dial to the FULL posItion 31 Brrrig injectron pump govfrnor lever !I, to stooper (21 on the FULL side. 4! Pulling cable 13) with force of about 98 N 110 kg.; uncj_‘f tho above conciitior1, rtghten i?cltS (4) and 15) temporarily. * Tighten the nLlts while pulling the cable to elimirrate play, 51 Return nut (4) by 2 turns and tighten nut (5) by 2 turns to retighten them. 6) Start the engine and check that it runs at the specified speed. 2.
Adjusting
* li 2)
31
engine
stall
preventing
switch
This swatch operates when the engine speed lowers below 1400 rpm. Turn ON the starting switch and set the fuel control dial to the LOW position. Adjust the clearance between the end of limit switch 161 and plate !7) to 3 - 4 mm by moving bracket (81. t The hole of bracket (8) is oblong. Set the fuel control dial to the FULL position, and check that limit switch (6) is not at the stroke end at this time.
20-109-13 0
PC60-7
TESTING
TESTING AND ADJUSTING OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS
AND ADJUSTING
TESTING AND ADJUSTING OF HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS 1.
Measuring * Hydraulic oil temperature
g
.
l
at measurement : 45 - 55 “C
Place the work equipment of the ground and stop the engine. Slowly loosen the oil filler cap on the hydraulic oil tank to release the pressure in the tank, and set the safety lock lever to the lock position. Remove the pressure detection plug (I) (lOmm, P=1.25) from the circuit to be measured, and connect the oil pressure gauge Cl (58.8 MPa (600kg/cm2)).
Measuring
of unload pressure
Measure the hydraulic oil pressure with the engine at the full speed and the control lever at NEUTRAL.
l
Measuring
of pump relief pressure
Measure the hydraulic oil pressure when each actuator is relieved with the engine at the full speed. * However, since the set pressure of the swing motor safety valve is lower than the main relief pressure, this measurement actually measure the relief pressure of the safety valve. Furthermore, the travel motor is not equipped with a safety valve.
20-110 a
Pc60-7
TESTING
AND ADJUSTING
ADJUSTING
PC VALVE
Adjusting main relief valve Loosen the lock nut (1) and turn the adjustment screw (2) to adjust. -k Turn the adjustment screw : . CLOCKWISE to increase the pressure; . COUNTERCLOCKWISE to decrease the pressure. t Adjusting amount for one turn of the adjustment screw : 12.5 MPa I128 kg/cm? N
Lock nut : 39.2 + 4.5 Nm 14.5 _+0.5 kgm} 966
BBPOl.944
ADJUSTING
PC VALVE
*
In case the engine speed lowers as a load becomes larger, or in case the work equipment speed is slow even though the engine speed, pump discharge pressure and LS differential pressure are normal, adjust the PC valve according to the following procedure.
1.
Loosen the lock nut (1). For the cases of slow speed, turn the sleeve (2) clockwise, and for the cases of lowering of engine speed, turn the sleeve counterclockwise. Ir Clockwise rotation of the sleeve “increases” the suction torque of the pump, and counterclockwise rotation “decreases” the suction torque. * Rotation range of the screw shall be within “180”. for both clockwise and counterclockwise”.
2.
After adjustment w
finished,
tighten
BBPOl.345
the lock nut.
Lock nut: 100.45 * 12.25 Nm (10.25 ? 1.25 kgmt
20-111 0
TESTING AND ADJUSTING
MEASURING LS DlFFERENTlALPRESSUREAND ADJUSTlNG LS VALVE
MEASURING LS DIFFERENTIAL AND ADJUSTING LS VALVE 1.
PRESSURE
Measuring LS differential pressure 1)
Measurement
using
a differential
pressure
gauge i) Remove the plug (1) and (2) (PT l/8), and install the oil pressure measurement plug Cl. Then connect to the defferential pressure gauge C4. *
ii)
Connection of differential pressure gauge: High pressure side: connect to plug (1) High pressure side: connect to plug (2)
Measure the LS differential cording to the conditions Table 1.
pressure shown
acin
Table 1 Work mode
Fuel lever
Operation
S
I Full ILever at NEUTRAL
S
I
Full
Vehicle speed : Hi Travel idling (lever full)
I
%
Travel idling at one side
2)
Measurement
using
Differential pressure MPa{kg/cm2) 2.5 - 3.9 (25 - 401
2.1 + 0.1
I 121.5 * 1)
a hydraulic
pressure
gauge * Use a same gauge. i) Remove the plug (1) and (2) (PT l/8), and install the oil pressure measurement plug. ii) Install the oil pressure gauge Cl (39.2 MPa {400 kg/cm?) to the pump discharge pressure measurement plug. Ir Reading of the gauge shall be 9.8 MPa {IO kg/cm*) step. (If a pressure gauge of 39.2 MPa I400 kg/cm2) is not available, one of 58.8 MPa (600 kg/cm7 may be used.) iii) Measure the pump discharge pressure according to the conditions shown in Table 1. * Read the indicator needle at a right angle to the scale accurately. iv) Remove the oil pressure gauge Cl and install it to the LS pressure measurement plug. v) Measure the LS pressure according to the conditions shown in Table 1. + Read the indicator needle at a right angle to the scale accurately. (Pump discharge pressure) - (LS pressure) = LS differential pressure
20-112 0
BaPo1814
TESTING AND ADJUSTING
2.
TESTING HYDRAULIC PRESSURE IN THE CONTROL CIRCUIT
Adjusting of the LS valve If the values obtained during the measurement of the differential pressure according to the foregoing conditions are not in the “standard value range”, adjust the LS valve according to the following procedure. 1) Loosen the lock nut (2) and turn the screw (3) to adjust. . Turn the screw : CLOCKWISE to increase the differential pressure; COUNTERCLOCKWISE to decrease the differential pressure. l Adjusting amount for one turn of the screw : 1.29 MPa (13.2 kg/cm3 2) After the adjustment finished, tighten the lock nut (2). w
(Caution)
Lock nut: 0.56 f 0.07 Nm (5.75 f 0.75 kgm} Make sure to adjust the LS valve with measuring the differential pressure.
TESTING HYDRAULIC PRESSURE IN THE CONTROL CIRCUIT 1.
88PO184
I
Measuring * Hydraulic
oil temperature at measurement: 45 - 55 “C 1) Remove the pressure detection plug (1) (PT l/8) and install the hydraulic pressure gauge Cl (5.9 MPa (60 kg/cm2)). 2) Start the engine and measure with the engine at the full speed.
RRP01815
g3 6
d
EBPOl816
TESTING
AND ADJUSTING
TESTING
OUTLET
PRESSURE
OF SOLENOID
VALVE
TESTING OUTLET PRESSURE OF SOLENOID VALVE Measuring Hydraulic *
oil temperature
: at measurement 45 - 55 “C
Disconnect the output hose (2) of the solenoid valve, and install the hydraulic pressure gauge Cl (5.9 MPa {SO kg/cm2)) with using the adapter C3 contained in the pressure gauge kit. of the solenoid the outlet pressure Measure in shown to the conditions valve according
1.
2.
Table 1.
Table 1 Solenoid name
1
Operation of solenoid
Oil pressure MPa{kg/cm2
Brake canceled
ON
2.9 f 0.5 (30 f 5)
All levers except travel at NEUTRAL (5 sec. after returning to NEUTRAL)
Brake actuated
OFF
f:,
Travel speed select at Hi Engine running Travel lever operated
Travel speed Hi
ON
2.9 f 0.5 130 f 5)
Motor swash plate angle at minimum
OFF
f:,
Motor swash plate angle at maximum
Measurement conditions
perating conditio
Swing or work equipment lever operated ;Gneg parking
l
2
Travel speed select
l
Travel speed select at Lo, or engine at full speed .%&+ty lock lever at RUN
3
4
%
Remarks
PPC oil pressure lock
Safety lock lever at LOCK side
Oil pressure applied on PPC valve circuit
ON
Oil pressure not applied on PPC valve circuit
OFF
G,
2.8 - 2.9 129 - 301
Fuel control
lever full
Oil pressure applied on mode select circuit
OFF
c:r
Fuel control
lever slow
Oil pressure not applied on mode select circuit
ON
2.9 f 0.5 I30 f 5)
Mode select
Operation of solenoid valve ON : Continuous (oil pressure generated) ioil press;re : 0) OFF : Not continuous
20-114 0
Travel speed Lo
6 & z
TESTING
ADJUSTING
AND ADJUSTING
MEASURING
MEASURING PPC VALVE OUTPUT OF WORK EQUIPMENT AND SWING
PRESSURE PPC VALVE
PPC VALVE OUTPUT
Ir
Hydraulic
1.
Measuring PPC valve output pressure 1) Disconnect the hose (I) of the circuit to be measured. Install adapter C3 between the hose and el2) bow. 3) Install oil pressure gauge Cl (5.9 MPa I60 kg/cm211 to adapter C3. 4) Run the engine at high idling, operate the control lever of the circuit to be measured, and measure the oil pressure.
oil temperature
when measuring: 45 - 55 “C
BBPOl820
ADJUSTING EQUIPMENT VALVE Ir -r g
1. 2. 3.
4. -
OF WORK AND SWING PPC
If there is excessive play in the work equipment or swing lever, adjust as follows. Place the work equipment on the ground and stop the engine. Slowly loosen the oil-filler cap of the hydraulic oil tank to release the pressure inside the tank. Remove the PPC valve. Remove the boot (1). Loosen the lock nut (2), and adjust the amount of play of the lever by adjusting the position of the disk (3). Ir Play of the lever : 0.5 - 3mm (at the point 200mm away from the rotation center of the lever) Ir When the lock nut (2) tightened, the amount of play of the lever will decrease. So, adjust considering the amount of decrease. Fix the disk (3) and tighten the lock nut (2) with a specified torque. Q$XI
Locknut: 112.7 + 14.7 Nm Ill.5
BBPO184.3
f 1.5 kgml
J
20-115 0
TESTING AND ADJUSTING
TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION 1.
Set the machine in the travel posture. Ir For the travel posture, extend the bucket and arm cylinder rods fully, and hold the boom angle at 45”.
2.
Travel for 10 m, then measure the deviation when traveling for the next 20 m. * Measure with the engine at high idling. t Install the hydraulic pressure gauge and measure the pump discharge pressure at the same time. I
at
the
IOm midoolnt
Make
EEPOle.49
a mark
Marl”ark this
deviation TLPOO732
20-116 0
TESTING
MEASURING
AND ADJUSTING
OIL LEAKAGE
w
MEASURING OIL LEAKAGE *
1.
Hydraulic
oil temperature
when measuring: 45 - 55 “C
Work equipment cylinder * If the hydraulic drift of the work equipment is outside the standard value, measure the leakage inside the cylinder as follows, and judge if the cause of the hydraulic drift is in the cylinder or in the control valve. If the leakage is within the standard value, the problem is in the control valve. If the leakage is greater than the standard value, the problem is in the cylinder. 1) Fully extend the rod of the cylinder to be measured, then stop the engine. 2) Disconnect piping (I) at the head end, then block the piping at the chassis end with a blind plug.
Posture boom
CYI
for measurino inder
l
l
A 3)
4)
Be careful not to disconnect at the bottom end.
I
-
Posture
for
meeeurino
TBP00958
(Irk
bucket
cylinder
the piping
Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine at high idling. Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.
TBP00959
Boom
cylinder
f-l 7 End
of
stroke
Disconnect
Hose f:
0 Hose 7
Rel iet Pressure
Ii
TEP00960
TLPOO963
Bucket
Arm
cylinder
TBP00962
cylinder
TBP00981
TESTING
AND ADJUSTING
2.
Swing motor 1) D&connect the drain hose (1) of the swing motor and the drain hose (2) of the swivel joint, and fit a blind cap at the hose end. 2) Attach a vinyl hose to the elbow side of the motor and receive leaking oil with a measuring cylinder. 3) Turn the swing lock switch ON. 4) Start the engine and operate the swing relief with the engine at high idling. 5) After keeping this condition for 30 seconds, measure the oil leakage for the next one minute. * After the first measurement, swing by 180” and repeat the measurement.
3.
Travel motor 1) Disconnect the drain hose (3) of the travel motor, and fit a blind cap on the hose end. 2) Attach a vinyl hose to the elbow side, and receive oil with a measuring cylinder. 3) Fit the block @ under the track shoe grouser. Or, fit the block @ between the sprocket and the frame to lock the track shoe. 4) Start the engine and operate the swing relief with the engine at high idling.
A 5)
*
MEASURING
OIL LEAKAGE
Incorrect lever operation possibly causes an accident, therefore, give and confirm signals properly. After keeping this condition for 30 seconds, measure the oil leakage for the next one minute. This measurement shall be repeated several times with running the motor slightly (change the relative positions between the valve plate and cylinder, and piston and cylinder.). BLPOO170
20-118 0
BLPOO171
TESTING AND ADJUSTING
RELEASING REMAINING IN HYDRAULIC CIRCUIT
RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT
PRESSURE
-k
No accumulator is installed, so the pressure remaining in the piping between the control valve and the hydraulic cylinder or swing motor cannot be released by operating the control levers. Therefore, when removing the above piping, be careful of the following points.
1.
Run the engine at low idling, operate the hydraulic cylinders so that they are not relieved at the end of the stroke, lower the work equipment to the ground, then stop the engine. * If the engine is stopped with the cylinder relieved at the end of the stroke, wait for 5 10 minutes before starting the operation.
2.
When removing the piping, gradually loosen the sleeve nut of the piping to slowly release the pressure remaining in the piping. Remove the piping when the oil stops spurting out.
20-l 19 0
CHECKING OF CLEARANCE OF SWING CIRCLE BEARING
TESTING AND ADJUSTING
CHECKING OF CLEARANCE OF SWING CIRCLE BEARING Procedure of checking clearance of swing circle bearing mounted on machine 1. Fix a magnet-type ner) circle of the probe to the end circle. Set the dial gauge
dial gauge to the outer (or inswing circle, and attach the surface of the inner (or outer) at the front or rear.
Or
frame
frame
TLPOO733
2.
to the maximum Extend the work equipment reach, and set the tip of the bucket to the same height as the bottom of the revolving frame. At this time, the front of the upper structure will tilt down and the rear will rise.
3.
Set the dial gauge to the zero point.
BAP0352!
4.
Set the arm more or less at right angle to the ground surface, and lower the boom until the front of the machine comes off the ground. At this time, the upper structure will tilt back, so the front will rise and the rear will go down.
5.
Read the value on the dial gauge at this point. The value is the clearance of the swing circle bearing.
A 6.
never put your While measuring, foot under the under-carriage.
hand or
Restore the condition in Step 2, and check that the dial gauge has returned to the zero point. If to the zero point, repeat it has not returned Steps 2 to 5.
20-120 0
BAP0352
TESTING WEAR OF SPROCKET
TESTING AND ADJUSTING
TESTING WEAR OF SPROCKET Wear
limit
line
TWP01404
1.
Remove the track shoe assembly. Ir See DISASSEMBLY AND ASSEMBLY, Removal of road liner (Rubber pad) assembly or Removal of steel shoe assembly.
2.
Align wear gauge P with the sprocket. * Align the datum line, the align the sprocket wave pattern and wear gauge wave pattern.
3.
Judge the wear of the sprocket. * If the sprocket wave pattern is above the wear limit line, it is possible to use the sprocket as it is. * If the sprocket wave pattern has reached the wear limit line, replace the sprocket with a new part.
20-121-l 0
Pc60-7
TESTING AND ADJUSTING
BLEEDING AIR
BLEEDING AIR Order for operations and procedure for bleeding air
l
Replace swing motor
l
Replace travel motor, swivel
Note 1: Bleed the air from drained. 1.
the travel
motors
only when
the oil inside
the motor
case
has been
Bleeding air from pump 1) Loosen air bleed plug (I) and air bleeder (2), and check that oil oozes out from the plug. 2) When oil oozes out, tighten plug(l) and air bleeder (2). w
*
2.
Plug: 17.64 + 1.96 Nm Il.8 & 0.2 kgm)
Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low idling for 10 minutes.
Bleeding air from hydraulic cylinders I) Start the engine and run at idling for approx. 5 minutes. 2) Run the engine at low idling, then raise and lower the boom 4 - 5 times in succession. * Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances.
20-122 0
PC60-7
BLEEDING AIR
TESTING AND ADJUSTING
3)
4) *
3.
Run the engine at high idling and repeat Step 2). After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. Repeat Steps 2) and 3) to bleed the air from the arm and bucket cylinders. When the cylinder has been replaced, bleed the air before connecting the piston rod. Be particularly careful not to operate the cylinder to the end of its stroke when the piston rod has been connected to the LOWER end of the boom cylinder.
Bleeding air from travel motor 1) Disconnect motor drain hose (3). 2) Run the engine at low idling and check that oil oozes out from the nipple. 3) If oil oozes out, connect hose (3).
-..
.-
__ _ __
4
ZO-123 0
TESTING
AUTOMATIC Display
AUTOMATIC
AND ADJUSTING
GREASING
GREASING
CONTROLLER
CONTROLLER
on the panel and special functions
DAIKIN
Blade type ,[TYPe:bCT-IO1
/Power
, 7-segment
Ress t IESC) (I* i t ch-
Grease
-SetI
. eelect
LED
LED
LED,
-Alarm
Level
fuse
LED
ino
LED
Start
(SET) swi tch
Item
selection(D)swi
(V)switch\
6 TAP00965
s G
1.
Display at starting switch ON
Display at auto-greasing operation
3.
When the auto-greasing interval set in the auto-greasing setting mode has elapsed, and when the “START” switch is pressed, display on the control panel will change as shown below.
Self diagnosis of the controller is carried out with all LEDs lighting up for a short time period and the lamp 0 at right bottom corner of the -/-segment LED flashing. After the selfanalysis, auto repressurization is carried out, and normal display will appear on the panel. 2.
Display at normal operation The power LED lights up, and the lamp III at the bottom right corner of the 7-segment LED flashes.
Pump operating
Pressure maintaining
Pump depressurizing
---m +J--\: In (+J \ ---m 0
7-segment LED
stop
.--------_____________________c-_l
indication
TAP00966
Power LED
ON
ON
ON
Greasing
ON
Flash (slow)
Flash (quick)
20-124 0
LED
TESTING
4.
AND ADJUSTING
AUTOMATIC
Error code indication When a trouble occurs, the alarm LED starts to blink, and the 7-segment LED automatically changes to display an error code to require remedy by an operator. 1) Actual display Ex.: Pump pressurization failure (required pressure not obtained within the greasing period) 2)
\\\I!//
GREASING
\\\I///
JgJgpJ ///I\\\
///I\\\
t
To erase the error code, and to resume the pump operation and timer-count of the greasing interval, perform the following procedure. i) When the 7-segment LED displays “abnormal pressure” indication: Press the [RESET/ESCI button once, and “small dot” will be displayed. ii)
When the 7-segment LED displays normal setting” indication:
“ab-
CONTROLLER
TAP00967
L \I,
Press and hold the IRESET/ESCI switch for more than 5 seconds and release the button. Display shows “0” for about 2 seconds, and the “small dotflashing” on the display. 5.
-/?:
Auto-greasing setting function In case the work equipment is used in a remarkable severe condition, or it is used for longer period in a construction site where grease flows out excessively, such as rivers and streams, if more frequent greasing than the original setting interval is required, change the setting values on the controller to shorten the greasing interval. Note 1) Make sure to explain users that shorter greasing interval will shorten the service life of the grease cartridge comparing with the standard of 500 hours because grease consumption per hour increases. Note 2) If there is no more necessity to shortening the greasing interval, restore the original setting values (a=6, b=6, c=O) on the controller.
ZO-125 0
TESTING
AND ADJUSTING
AUTOMATIC
GREASING
CONTROLLER
4
4)
To determine a setting item, push the q switch while the intended setting item is flashing. t When the q switch is pushed, the setting item and code No. flash alternately. * Figure displayed immediately after pressing the q switch is the presently stored code No.
GREASING When the
areasina
time
is
selected
loretsina
5)
To select a code No., press the lpi switch. . The code No. increases as the @ switch is pressed.
6)
To store the code No., press the [SET] switch while desired code No. is flashing. Ir By pressing the [SET] switch, the 7-segment LED returns to the status described in the section l), and setting of the next item is enabled. ’ Setting of code No. in item [al finished ’ --+ To item lb1 Setting of code No. in item [bl finished + To item [cl Setting of code No. in item [cl finished \ + To item [al
4
To continue the setting: Repeat the procedures from 2) to 6) in the same manner.
E!
:When
(3min) m
is
tine) TAP00969
selected
Push the switch
wz/l-iol p.x+-‘:ili:i~
,tem (orease
time)
p_
,tem
TAP00971
To terminate the auto-greasing setting mode: Press the IESCI switch. Ir f When the setting item (alphabet) only is flashing . .. . . . Press the IESCI switch once. When the setting item (alphabet) and code No. (number) are flashing alternately . . .. . . Press the [ESCI switch twice. Press and hold the IESCI switch for 5 seconds. Ir When the switch is released after held for 5 seconds, “0” will flash on the 7-segment LED to indicate the controller has been reset.
20-127 0
TESTING
AND ADJUSTING
List of auto-greasing
Note 1. 2. 3. 4.
20-128 0
setting
AUTOMATIC
GREASING
CONTROLLER
codes
Fields marked with a oblique line are not available. Code No. setting shall be done to each item. Original setting values of the auto-greasing controller at the time of shipping from the factory are a=6, b=6 and c=O. Item “c’ must be always set to “0”. If other value is set to this item, auto-greasing may not be carried out during operation. * If other value than “0” is mistakenly set in this item, reset the value.
TESTING
AUTOMATIC
AND ADJUSTING
GREASING
CONTROLLER
4
AIR BLEEDING FROM EACH COMPONENT OF AUTO-GREASING Work procedure
and bleeding
SYSTEM
procedure Air bleeding procedure
Air bleeding item 1 Initial grease filling into main greaser piping and distributor.
Work details
l
2
3
4
Air bleeding from auto_ greasing pump
Air bleeding from greasing lateral piping
Operation
Replacement, repair of auto-greasing pump Replacement of auto-greasing piping Replacement of auto-greasing distributor
l l
0
0
)
0
+
0
>
0
>
0
0
f
0
0
f
0
0
>
0
Removal of auto-greasing piping . Removal of auto-greasing distributor l
l
b 0
z z
l
In cold district, when grease is changed from G2-LI to GO-LI
0
Thermal contraction of grease due to change in temperature
1.
-i
0
*
Initial grease filling into main greaser piping and distributor. the hose (1) under the pump, 1) Disconnect and remove the boom cylinder bottom distributor plug (2) and the arm distributor plug (3).
EBP03534
2)
Fix the tools Ml and M2 to the tor plug section, fill the grease, that new grease comes out of under the pump and the boom tom distributor plug. * Discharge foreign matters air completely. a
arm distribuand confirm the hose end cylinder botand residual
Greasing piping : Grease (G2-LI) (standard type) : Grease (GO-L11 (cold area type) EEPO353!
20-l 29 0
TESTING AND ADJUSTING
3)
AUTOMATIC GREASING CONTROLLER
Connect the hose (1) under the pump, and fix the boom cylinder bottom distributor plug (2) and the arm distributor plug (3). m
Plug (21, (3) : 1.76 +_0.19 Nm jO.18 +_0.02 kgml
a
Plug (21, (3) : Liquid gasket (LG-5)
BflPO3537
2.
Air bleeding from auto-greasing pump I) Remove the air bleeding screw (1 1. (Allen key size : 5mm) 2)
3)
4)
Turn ON the starting switch and push the [START] switch to run the pump. * Discharge residual air in the pump together with grease. Ir Accumulated timer-count in the greasing interval timer is reset, and timer will start counting after greasing is completed. After confirming that only grease comes out of the air bleeding screw (I), turn OFF the starting switch to stop the pump. Tighten the air bleeding screw (I ). w
Air bleeding screw : 2.94 + 0.98 Nm to.3 k 0.1 kgm)
DAIRIW IWWRTRIEL LTO
r?l wD:LcRn
rn8
n Pnm
I
TAP00972
20-130 0
TESTING
3.
AND ADJUSTING
AUTOMATIC
GREASING
CONTROLLER
Air bleeding from greasing lateral piping 1) Push the [START] switch on the greasing controller to run the pump.
TAP00972
2)
Confirm that one series of greasing process (pressurization + pressure holding --3 depressurization) has been completed and the operation is in the wait mode (small dot flashing).
’ With the standard
setting of the setting item b on the controller (greasing time = 61, it will take about 15 minutes after I . pressing the [START] switch.
6 ‘0 z
3)
Fill the grease with a grease gun into the air bleeding plug of each distributor, and confirm that the grease comes out of the work equipment pins or clearance at the bearing sections.
TAP00973
4
20-131 0
AUTOMATIC GREASING CONTROLLER
TESTING AND ADJUSTING
Confirmation indicator 1.
method
of depressurizing
spool
The position of the depressurizing spool indicator (1) can be visually checked by removing the screw (3), cap (2) and rubber packing (4) at the side of the pump.
REP03541
TBP00974
2.
During depressurizing process and waiting process, the depressurizing spool indicator is coming out from the pump body by approx. 7.5mm.
3.
During the pressurizing process and pressure holding process, the depressurizing spool indicator is stored in the pump body without any protrusion.
PPIOX.
5rm
Depressurizins waitine Process
6
Preasurizine and pressure holding
erocess TBP00975
20-l 32 0
AUTOMATIC GREASING CONTROLLER
TESTING AND ADJUSTING
Replacement
of controller
fuse
.
Replacement of the controller fuse shall be carried out according to the following procedure.
1.
Remove the rubber or similar tool.
cap (I) with
a screwdriver
1 IMP03543
BEP03544
2.
Remove the fuse (2) with long-nose and replace with a new fuse. Ir Fuse : Blade type ATC-10
3.
Fix the rubber cap.
pliers, etc.,
BBP0354
20- 133 0
TESTING
Confirmation procedure from distributor 1.
2.
AUTOMATIC
AND ADJUSTING
for discharge
GREASING
CONTROLLER
amount
On the discharge amount adjusting caps on each distributor, figures are embossed which indicate the discharge amount. Correspondence of discharge amount and figures on the cap is as shown in the table below.
Figure embossed on thedischarge amount adjusting cap
I
2
3
4
5
6
TBP00976
Quintuple distributor for arm Adjusting cap
A
B
C
D
E
Embossed figure
1
4
6
2
1 A
Discharge amount (cc)
0.45
0.25
Greasing objective piston
Bucket cylinder foot
Arm/ link joint
0.65
0.25
0.15
Arm/ bucket joint
Arm/ boom joint
Arm cylinder rod end
B
C
D
E lino
TBPOO977
Cspool
distributor
for boom
I
F
G
H
I
si
Greasing objective piston
Boom foot
Boom foot
Arm cylinder root
Boom cylinder rod end
From oreasi
t
PUblIP -
the arm ributor
TBPOO978
Distributor
for boom cylinder foot
Adjusting cap
J
Embossed figure
1
Discharge amount (cc) Greasing objective piston
0.35 Boom cylinder bottom From the oreawn TBPO0979
20-134 0
TROUBLESHOOTING Points to remember when troubleshooting ..........................................................................................
20-202
Sequence of events in troubleshooting
20-203
................................................................................................
Points to remember when carrying out maintenance .........................................................................
20-204
Checks before troubleshooting ..............................................................................................................
20-212
Connector types and mounting locations .............................................................................................
20-213
Connection table for connector pin numbers .......................................................................................
20-217
Method of using judgement table .........................................................................................................
20-227
Method of using troubleshooting charts.. .............................................................................................
20-228
Failure modes and judgement table.. ....................................................................................................
20-230
Troubleshooting of electrical system (E mode) ....................................................................................
20-251
Troubleshooting of engine (S mode) .....................................................................................................
20-301
Troubleshooting of hydraulic and mechanical system (H mode) .......................................................
20-351
Troubleshooting of machine monitor system (M mode) .....................................................................
20-401
Troubleshooting of auto-greasing system (D mode) ...........................................................................
20-451
PGO-7
20-201 0
TROUBLESHOOTING
POINTS TO REMEMBER
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WHEN TROUBLESHOOTING
a
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
A
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.
A
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: . Parts that have no connection with the failure or other unnecessary parts will be disassembled. . It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out through prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occured apart from the problem that had been reported? 2) Was there anything strange about the machine before tha failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Were there abnormal symptoms about the machine?
20-202 0
2) 3) 4)
Check checking items before starting. Check other checking items. Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. * When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occureed. Then, remove the root cause.
PCXO-7
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TROUBLESHOOTING
SEQUENCE
OF EVENTS IN TROUBLESHOOTING
TEW00181
TEWOOlEO step
1 Examination. 1)
When
confirmation
a request
of symptoms
for repairs
IS received,
fwst
-----
ask the followmg pomts. . Name of customer
-
Type, serial number
.
Details
of jobslte,
Ask questIons
2)
2
-----
Ring I Ring 1
of machme
etc.
to gain an outlIne
of the prob-
lem. .
Condition
*
Work being carved
of failure out at the time of the
TEW00182
failure . .
Operating
environment
Past histov,
details of maintenance,
etc.
step 2 lDetermining
probable
locatlon
;
a
of cause]
. 1)
Look shop
at the troubleshooting section of the manual to find locations of possible
I’*“°Cu4~w 1.‘.1..1..1
f
causas.
TEWO0184
step
3 reparation 1)
of troubleshootmg
tools
Look at the table of troubleshooting the shop manual
and prepare
=tools in
TEWOO185
aa Gap
the necessary
* . 2)
I’
T-adapter Hydrauhc
pressure
gauge
kut. etc.
Look in the parts book and prepare essary
7 1.
tools.
replacement
the net-m
parts.
Pinpoint
.
Decide
1)
Before
21
locations
of failure
(carry
out
1
troubleshooting) action to take starting
repair
simple
troubleshooting,
*
Check before startmg
*
Other
that
and
items
check items
See the Troubleshooting manual,
IoCate
failures.
select
matches
Sectton
of the shop
a troubleshooting the symptoms,
flowchart
and
carry
out
troubleshooting. TEWOO187
/step 6 Re-enacting .
Dwe
failure
and operate
the condition
&
the machine
and ludge
is really
a
step 5 Ask operator
questions
to
confirm
details
of
fatlure. *
.
Was thaw
anythmg
strange
chme before the fallure * . TEWOO189
to confirm
If there
Did the failure
about
the
occur suddenly?
Had any repatrs been carried out before failure?
ma-
occurred? the TEW0019C
20-203 0
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TROUBLESHOOTING
POINTS TO REMEMBER
WHEN CARRYING
OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1.
POINTS TO REMEMBER ELECTRIC EQUIPMENT
WHEN
HANDLING
1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harness @ Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
I @
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
TEU00192
Imvro9er
con9ressin
TEW00193
20-204 0
TROUBLESHOOTING
POINTS
TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
\
I High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
0
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. * When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. Ir If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
TEW00194
\
$
1
TEW00196
20-205 0
TROUBLESHOOTING
2) Removing, wiring 0
installing, harnesses
POINTS
TO REMEMBER
and drying connectors
WHEN
CARRYING
OUT MAINTENANCE
and
Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Ir Never pull with one hand.
Loch
When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. Ir If the connector is twisted up and down or to the left or right, the housing may break.
I Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. Ir If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-206 0
TBWOO4B5
TROUBLESHOOTING
0
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors Check the connector visuallv. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. * If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. * If there is any damage or breakage, replace the connector.
0
TEW00199
Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. Ir If the connector cannot be corrected easily, remove the clamp and adjust the position.
0
If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
20-207 0
TROUBLESHOOTING
l
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. @ Disconnect the connector and wipe off the water with a dry cloth. * If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
TEW00196
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
j
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. * After completely drying the connector, blow it with contact restorer and reassem ble.
“‘:
’
TEWOOZOZ
T-adapter
TEW00203
20-208 0
TROUBLESHOOTING
3)
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Handling control box
0
0
The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.
TEWOO204
Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. Ir If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. * If there is any change, there is probably defective contact in that circuit.
20-209 0
TROUBLESHOOTING
3.
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
11 Be careful of the operating environment. Avoid adding hydraulic
oil, replacing filters, repairing the machine in rain or high winds, places where there is a lot of dust.
or or
2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3)
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
I Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
20-210 0
TEWOOZOB
TROUBLESHOOTING
5)
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Change hydraulic oil when the temperature high.
is
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6)
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
TEW00210
7)
Cleaning operations After repairing the hydraulic
equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3~) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
TEWOOZll
20-211 0
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING Judgement standard
Remedy
1. Check fuel level
-
Add fuel
2. Check for dirt or water in fuel
-
Clean, drain
3. Check hydraulic
oil level
-
Add oil
4. Check hydraulic
oil strainer
-
Clean, drain
Item
5. Check swing machinery
Add oil
oil level
6. Check engine oil level (level of oil in oil pan)
-
Add oil
7. Check cooling water level
7
Add water
8. Check condition
of dust indicator
-
Clean or replace
9. Check hydraulic
oil filter
Replace
1. Check for loose or corroded
battery terminals
2. Check for loose or corroded
alternator
Check for loose or corroded 3* terminals
starting
1. Check for abnormal
-
Tighten or replace Tighten or replace
terminal: motor
-
Tighten or replace
Repair
noise or smell
Repair
2. Check for oil leakage 3. Bleed air from system
1. Check battery voltage
(engine
stopped)
-
Bleed air
20-3QU
Replace Add or replace
2. Check level of battery electrolyte 3. Check for discolored,
-
burnt, or bare wiring
4. Check for missing wiring clamps,
hanging
Replace Repair
wire
Checks for getting wet onto wiring 5. (check carefully getting wet at connectors and terminals) 6. Check for broken or corroded
fuses
Check alternator voltage 7. (engine running at over half throttle) Noise when battery relay is operated 8. (switch starting switch from ON to OFF)
20-212 0
Disconnect connector and dry connection
After running for few min. 27.5 - 29.5 U
Replace Replace
I -
6 z L.z
CONNECTOR TYPES AND MOUNTING
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS Ir Address column in the table indicates the addresses in the connector location diagram
LOCATIONS
(3D drawing).
Serial No. : 52374 - 57999
Ml6
6
Wiper motor, intermediate
B-1
Ml8
M
3
Wiper switch
E-2
Ml9
M
2
Wiper switch
F-2
PA
9
Radio
E-l
1 1 1 Horn switch
) A-4
M21
DAM 1
l-
1M22 1
DA2
4
Diode (Solenoid)
-
El1
1
Heater relay in
P-9
El2 1
)
1 1 Heater relay coil
I-
El3 1
(
1 1 Heater relay out
I-
lM4
El4
1
Ribbon heater
-
F61
6
Fuse box
F-7
Hl
1 S
I 16 I Intermediate
1A-2
H2
p
1 2 TIntermediate
1A-2
H3
S
8
Intermediate
A-2
K5
X
4
Fuel control motor relay
A-4
K6
SWP
4
Fuel control motor relay
F-6
K7
SWP
4
Fuel control motor
F-7
K33 1
I
2 1 Deceleration indicator
I-
M
IM27)
I
1TC-terminal 1
M3 M4
S
Ml01
M
16
(
Ml1 1 L I
of starting motor
1 O-9
Engine stop solenoid
Q-9
Intermediate
B-2
1 I Working lamp, intermediate
I ~-7
2 I Fusible link
I R-8
6
I
1 I Roomlamp
~~ unit (option)
1 P-l
I L-7 Q-8
2
Window washer
M29
2
Speed selection switch (for STD) D-1
M
[ M301 M [
M35
x
-1:
2 I Optional power source
IM31 IKESOl 4
2
I Wiper
I L-5
motor
Air conditioner condenser (option)
_
1 1 I Engine stopsolenoid
M40
1
M41
1
I-
Travel boost pedal switch (for blade) Travel boost pedal switch (for blade)
C_l C_l
I
2 I Sefty relay (s, R-terminal)
I O-1
bl
I
l
I-
1~4
I M I
2 1 Buzzer
1A-3
If’5
I
1 I Fuel sensor
1 L-6
lM75)
X
I
P6 P7
Pcxo-7
I Air conditioner
I
M28 KESl
lM371
M2
-
M
I-
1 Diode (Solenoid)
Horn
Ml7
D11 1~~~11 2 1 Diode 1 4
1
x
I Sefty relay B-terminal
1
Fuel sensor
L-6
2
Water temperature sensor
P-9
20-2 13 0
CONNECTOR TYPES AND MOUNTING
TROUBLESHOOTING
‘13 ‘44
SWP
jlIx
Engine oil pressure switch
Q-8
6
Auto-greasing controller
R-3
2 I Swina oressure switch
I
S,4
1
M
I Q-2 I
2
PPC hydraulic lock switch, intermediate
F-2
315
1
Fuel lever limit switch
Q-9
518
1
Fuel lever limit switch
P-9
Tl
1
Battery relay, B-terminal
R-6
r2
1
Ground to revolving frame
S-5
T4
1
Alternator, B-terminal
Q-2
111 Starting switch (ACC)
I c-4
4
LOCATIONS
r9
rio T16 + 1 1 I Battery relay, M-terminal
T17T T18
1 Batterv relav. E-terminal
I R-t5 I I R-7 I
Vl
Ix
2
PPC hydraulic lock solenoid
N-9
v3
x
2
Mode selection solenoid
M-9
v4 +
x
2
Swing holding brake solenoid
N-9
v5
x
1
Swing lock prolix switch
F-6
4
Swing lock switch
E-l
y
x3 + x4 X5
M
BR
(1)
(Battery relay, M-terminal)
-
RB
(1)
(Battery relay, B-terminal)
-
20-214 0
PC60-7
CONNECTOR TYPES AND MOUNTING LOCATIONS
TROUBLESHOOTING
Serial No. : 52374 - 57999
I6 I
M24
//I M41
Pao-7
Ml0
I”29 M32
M33
20-215 @
TROUBLESHOOTING
Serial *
No. : 52374 - 57999
For details of this page, see page 90-201.
20-216 0
CONNECTOR TYPES AND MOUNTING
LOCATIONS
TESTING
*
CONNECTOR
AND ADJUSTING
Address column
in the table indicates the addresses
TYPES AND
in the connector
MOUNTING
LOCATIONS
location diagram
(3D drawing).
Serial No. : 58001 and up
Cl
M
4
Engine starting relay
Dl
KESl
2
Diode
D2
KESl
2
D5
KESl
2
D8
KESl
2
DA2 IKESl]
A-3
~M18
M
3
Wiper switch
E-2
-
Ml9
M
2
Wiper switch
F-2
Diode
-
IM2ll
Diode
-
IM22 I
1 1 1 Horn switch
1A-4
Diode
-
lM231
1 1 1 SDeaker
1A-5
2 1 Diode (Solenoid)
PA 1 9 1 Radio
IM28IKES11
2 I Windowwasher
1M29 1 M I
2 1 Soeed selection switch (for STD) 1 D-1
1 1 1 Glow plug
I o-9
FBl I
1 6 I Fuse box
1 F-7
M30
M
M31 KESl
;
X
4
SWP
6
K7
[SWPI
6 I Fuel control motor
1 2 I Deceleration indicator
K33]7
X
F-6
1 F-7
M37
Fuel control motor relay
-
Ml
1
B-terminal of starting motor
P-9
M2
1
C-terminal of starting motor
P-8
M
1
M3 M4
Engine stop solenoid I
1
S
16
N-9 I
Intermediate
B1 r-l::,
Wiper motor
I x
2
K35
4
1M331
M35
I-
Optional power source
1 11 Decceleration
1~341
Fuel control motor relay
2
p321 A-4
Fuel control motor relay
K6
E-l
I-
El2 1 X
K5
1
I
-1 D-l
1 I Decceleration switch
1D-l
1 I Air compressor (option)
I o-9
2
I
bl
I
’
_
Air conditioner condenser (option) L
1
M40
M-l switch
1 I
-
Engine stop solenoid Travel boost pedal switch (for blade)
C_l
I-
I Optional power source
IPI I~~~0401 16 I Monitor
N-9 8
oanel
I A-8
M5
1
R-terminal of alternator
Q-6
P2
KEST
4
Monitor panel
B-8
M8
1
Light
G-8
P3
KEST
4
Monitor panel
C-8
M
2
Buzzer
A-3
1
Fuel sensor
J-9
1 1 Fuel sensor
I K-9
M9
M
1
Working lamp
l-9
P4
Ml0
M
1
Working lamp, intermediate
l-9
P5
Mfl/LTYJFusible
linkk
Ml2 IKESI~ 3 I Car heater Ml41
L I
2 I Fusible link
1 P-8
(P67
1 F-5
IP7
1 Q-8
11:
I
I X I 2 I Water
temoerature sensor
P44 SWP
6
Auto-greasrng controller
s2
2
Swing pressure switch
x
I o-9
Cl-4
20-2 16- 1 0
CONNECTOR TYPES AND MOUNTING LOCATIONS
TESTING AND ADJUSTING
0 t;
2
3 .v) I . $=a,
z” sg
z”.z
$ tB oom RAISE nressure switch
12
S4
2
Mounting location
s12
1
PPC hydraulic lock switch
-
s13
1
-
2
PPC hydraulic lock switch PPC hydraulic lock switch, intermediate
s15
1
Fuel lever limit switch
P-B
s14 I
l
I Fuel lever limit switch
1 P-B
S14
M
F-2
Batterv relav. B-terminal
Ill
4
Starting switch (B)
Tll
1
Starting switch (R2)
D-8
ri7
1
Battery relay, M-terminal
Q-8
r18
1
Batterv relav, E-terminal
Q-7
Swing holding brake solenoid
M-9
Ki V5
1 X 1 2 1 Speed selection solenoid
Ill
x4
Swing lock prolix switch
M
mm
1
Swing lock prolix switch
F-5
4
Swing lock switch
E-l
x4 X5
IA
20-216-2 @
Pc60-7
CONNECTOR TYPES AND MOUNTING LOCATIONS
TESTING AND ADJUSTING
Serial No. : 58001 and up
P2
r\ \ \
\
S 14
tit9
Ml8
\ X6
Mil
9 do
f’C60-7
~12
M33
BWPO41I4
20-2 16-3 0
TESTING AND ADJUSTING
CONNECTOR TYPES AND MOUNTING
LOCATIONS
Serial No. : 58001 and up
20-216-4 0
fuo-7
CONNECTOR TYPES AND MOUNTING
TESTING AND ADJUSTING
LOCATIONS
T18
T16 Tl T17 Y6 T4 Pi3 M76 34 P44 ‘92 St -N76
\ Y77
\ \ \
/
I
T6 (tl3)
(Ml71
(Ii21 (Hl)
M31
Y27
+
Pc60-7
20-216-5 m
TROUBLESHOOTING
CONNECTION
CONNECTION *
TABLE FOR CONNECTOR
The terms male and female refer to the pins, while refer to the mating portion of the housing.
No. of pins
TABLE FOR CONNECTOR PIN NUMBERS
T
the terms
PIN NUMBERS male housing
and female
Female
housing)
housing
X type connector Male (female
housing)
(male
2
m
TEWCiXZl
TEwoo222
TEW00223
TEWO0224
2
4
TEW00226
20-217 0
TROUBLESHOOTING
No. of pins
CONNECTION
T
TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector Male (female housing)
Female (male housing)
6 6
3
TEWO0235
8
4
8
8
TEWoO237
m
i
12
4 TEW00238
1 1
4
5
8
9
12
__.__1-
5
0
0
9 BLwoO34
BLPOOO35
11
8
4
ld
i
1
14
3
i
io ‘14
14
TEWCKl240
1
4
5
16 9
BLpooO36
20-218 0
i6
BLFQw37
TROUBLESHOOTING
No. of pins
2
CONNECTION
T
TABLE FOR CONNECTOR
PIN NUMBERS
M type connector Male (female
Female
housing)
(male
housing)
E= i
BLFUCO3B
BLFucQ39
3
2
I, 3 Y 1’ IO
;5 i
1
3
2
4
@
TEW00243
TEWOOZM
TEww245
TEW00246
4 aI
1
4
4
1
6 @ j
‘6
6
3
TEWC0248
TEW00247
1
4
8
4
BLFWO41
20-219 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
S type connector Female (male housing)
Male (female housing)
8
4’
‘8
1
6
5
io
TEWO0249
10
12
20-220 0
II
TEW00251
Ii
‘5
EEL00114
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
S type connector Male (female
Female
housing)
(male
housing)
10
5
IO 1
IO
EEL00117
5
EEL00118
6
BLmO043
12
5
8
1
16
7
TEW00254
16
7
16BLFCOO44
TEW00256
20-221 0
TROUBLESHOOTING
No. of pins
CONNECTION
T
TABLE FOR CONNECTOR
PIN NUMBERS
MIC connector Male
(female
housing)
Female
(male housing)
5
9
BLpoow8
7
13
13
17
21
lYrTY/ TEWCfQ59
20-222 0
b 0 F
8
w
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T
AMP040 Male (female
type connector Female
housing) 4
8
6
12
(male
housing)
8
12
6
7
i
7
1'
ELKmO55
8
BLPOOO56
16
16
8
16
1
9
9
1
BLmOO57
10
TEW00232
20
20
10
20
IL
11
1 TEWOGW
20-223 0
CONNECTION
TROUBLESHOOTING
No. of pins
T
AMP070 Male (female
Female
(male 1
7
7
a8
4
6
BLPOOO59 1
12
20-224 0
9
PIN NUMBERS
type connector
housing) 1
TABLE FOR CONNECTOR
‘6 9
1
housing)
TROUBLESHOOTING
No. of pins
2
CONNECTION
T
TABLE FOR CONNECTOR PIN NUMBERS
L type connector Male (female
housing)
Female
(male
housing)
1
Etl q
m
2
TEW00257
E.33
TEWOO258
20-225 0
TROUBLESHOOTING
No. of pins
CONNECTION
T
Automobile Male (female
housing)
TABLE FOR CONNECTOR
PIN NUMBERS
connector Female
(male housing)
FB B 6
BLPoax5
b 1
2
2
ED 4' BLFwoE7
'3 BLPOOCM
BLPwo69
BLmco70
1
e
8
\
8
ELF’00072
20-226 0
TESTING AND ADJUSTING
METHOD OF USING JUDGEMENT
METHOD OF USING JUDGEMENT
TABLE
TABLE
This judgement table is a tool to determine if the problem with the machine is caused by an abnormaiity in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E-00, H-00) matches the symptoms. * The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of the monitor system (M-00). (See the contents for troubleshooting of the monitor system) Troubleshooting of travel, work equipment and swing device (PPC Hydraulic pressure lock, swing brake, power mode, travel speed) FAILURE MODES AND JUDGMENT TABLE
N
[Procedure 1 I Locate the failure mode. Ask the operator questions and try to re-enact the failure (check the failure symptoms on the actual machine). Use this information to locate the appropriate failure symptom from Failure Modes No. 1 No. 26 in the Judgement Table. [Procedure 21 Judge if the failure is in the electrical system, or in the hydraulic or mechanical system. 1) Connect a T-adapter or socket between the wiring harness and connector for solenoids marked with a 0 in the Judgement Table, then follow the troubleshooting procedures and measure the voltage for each to check if it is the normal voltage. 2) Is the voltage the same as in the table (when normal)? Voltage is same as in table (when normal) -_j go to appropriate troubleshooting (H-00) for hydraulic or mechanical system. If voltage is different from table (when normal) -+ go to appropriate troubleshooting (E-00) for electrical system. [Procedure 31 Carry out appropriate troubleshooting (YES/NO troubleshooting).
20-227 0
METHOD OF USING TROUBLESHOOTING
TESTING AND ADJUSTING
CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS 1.
Category of troubleshooting Troubleshooting
Component
Code No.
E-00 H-00
(
M-00 2.
code number
Troubleshooting
of electrical system
Troubleshooting
of hydraulic, mechanical system
Troubleshooting
of machine monitor system
Method of using troubleshooting table for each troubleshooting mode II Troubleshooting code number and problem The title of the troubleshooting chart gives the troubleshooting code, and failure mode (problem with the machine). (See Example (1))
2) Distinguishing conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, a)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. (See Example (2)) 3)
Method of following troubleshooting .
.
.
.
chart
Check or measure the item inside 1-r , and according to the answer follow either the YES line or the NO line to go to the nextNb . (Note: The number written at the top right corner of the 0 is an index number; it does not indicate the order to follow.) Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. (See Example (3)) Below the 0 there are the methods for inspection or measurement, and the judgement values. If the judgement values below the 0 are correct or the answer to the question inside the 0 is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. Below the 0 is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item 1).
4)
General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at the top of the page and marked with Ir. (See Example (4)) The precautions marked * are not given in the 0, but must always be followed when carrying out the check inside the I .
5)
Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6)
tools.
For de-
Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem).
20-228 0
“0 5 z
TESTING AND ADJUSTING
METHOD OF USING TROUBLESHOOTING
CHARTS
0 0
E-6 a)
Power mode cannot be changed
Work equipment speed is slow when engine speed is middle and higher
0
Remedy
Cause
2 YES YE
(male1 (1) and (2). and between (21 and the chassisnormal?
* 20 - 60R. * Between (2)chassis: 1MR or higher. - Starting switch OFF. Disconnect V3.
between V3 (2) and the chassis
Defective mode select solenoid
NO
5vs Is the resistance value between V3 (female) (1) and S15 normal?
YES
l
a Fuel lever full: 1V or lower. * Starting switch ON. * Fuel lever full. l
Is the resistance value between the limit switch terminals normat?
YE 3 between V3 (1) and the chassis
.20-30V * Starting switch ON.
YES 1 r
and the chassis
Fuel lever lowiding: 20 -30V. NO * Starting switch ON. Switch only. NO = Fuel lever * Full side: 1R or lower. lowiding. * Lowidling side: 1MR or higher. * Starting switch OFF. * Disconnect the switch terminals. l
1Q or lower. NO * Starting switch OFF. Disconnect V3.
l
3reaking wire or contact ‘ailure in the wire harness )etween limit switch terninal H2f2) - chassis tarth Breaking wire or contacl failure in the wire harness between V3 (female) (2) H3flj - S15
teplace
leplace the vire harness
ieplace the vire harness
l
Defective fuel limit switch
Breaking wire in the wire harness between fuse2 H3(4) - V3 (female) (1)
Short-sircuit to the ground in the wire harness bet. ween V3 (female) (2) H3fl) - S12 Defective switch
fuel lever
leplace the vire harness
-
Refer to the item H-l
2 YES Is the resrstance value between the limit switch terminals normal?
_
Switch only. * ON side: NO 1R or lower. * OFF side: 1 MD or higher. * Starting switch OFF. * Disconnect the switch terminal. l
-
Refer to the item H-l
Are the resistsnce vslues between V3
leplace the vire harness
limil
l
Ir * +
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. When the fuse 2 is not blown out.
20-229 0
FAILURE MODES AND JUDGMENT
TESTING AND ADJUSTING
FAILURE MODES AND JUDGMENT
r
TABLE Control valve
Pump
Parts causing failure
!i
72 z 2
s ii .-E Failure mode
s
-0
?! *L
rz Q z
iog i_; E p iz.2
: mo E ?
k ‘5 4 Y
;
Zt __ j .z
Fe jg >o
: T k z 2 i:
’
Speeds of all work equipments, travel and swing are slow or lack of power Remarkable drop in engine speed, or enqine stalls All work equipments, travel and swin(l do not work Abnormal sound (around the pump) Fine control not carried out properly Boom movement is slow, or no power Arm movement is slow, or no power Bucket movement is slow, or no power Boom does not move Arm does not move Bucket does not move Excessive hvdraulic drift Excessive time lag In compound operations, work equipments, movement of larger load side is slow In compound operations, swing and boom, boom UP movement is slow In compound operations, swing and travel, travel speed drop is too large In compound operations, travel and work equipment (boom UP), travel speed drop is too large In the same direction in both forward and backward Curving in travel In the different directions for forward and backward Curving is larger at start Travel speed is slow, or no power Steering operation is difficult Travel speed selection unavailable Travel does not work (onlv one side)
~~
.E
z $ _m m
Excessive shock when stopping - swing(One direction only) Excessive abnormal sound when stopping swing When brake is ON Excessive hydraulic drift of swing When brake is OFF Swing speed is faster than the specified speed Blade movement is slow, or no power Blade does not move Excessive hydraulic drift of blade Troubleshooting mode in the electric system
20-230 0
0 -
H -
-
TABLE
TESTING
AND ADJUSTING
FAILURE MODES
I
Solenoid Travel speed select solenoid
Swing brake solenoid
valve
TABLE
mob
PPC Hydraulic pressure lock solenoia
1) Connect a l-adapter 1) Connect a T-adapter to the swing brake to the travel speed solenoid V4. select solenoid V5. 2) Operate the swing 2) Operate the travel lock switch with the speed select switch starting switch ON. with the starting switch ON. 3) Is the voltage between (1) and 12) of 3) Is the voltage beV4 as shown between (1) and (2) of low? V5 as shown below)
1) Connect a T-adapter to the PPC hydraulic pressure lock solenoid Vl. 2) Operate the PPC hydraulic pressure lock lever with the starting switch ON. 3) Is the voltage between (1) and (2) of Vl as shown below?
(Normal)
(Normal;
(Normal)
AND JUDGMENT
node select solenoic
ll-
) Connect
a T-adapter to the mode select solenoid V3. 1Operate the fuel lever with the starting switch ON. ) Is the voltage between (1) and (2) of V3 as shown below?
(Normal
~~~~~
0
0
I
0
I
w
I
I
I E-3
E-4
I
I E-5
E-l
E-2
20-231 0
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) E-l
Work equipment
does not move even when the PPC hydraulic pressure lock lever is set to
the DRIVE side ..................................................................................................................................... E-2
Work equipment
20-252
does move even if the PPC hydraulic pressure lock lever is at the LOCK
position ................................................................................................................................................
20-253
E-3
Does not swing ....................................................................................................................................
20-254
E-4
Swing brake does not work ................................................................................................................
20-258
E-5
Travel speed cannot be switched ......................................................................................................
20-260
a)
Cannot be switched to Hi ............................................................................................................
20-260
b)
Cannot be switched to Lo ............................................................................................................
20-260
Power mode cannot be changed .......................................................................................................
20-261
a)
Work equipment
20-261
b)
Excessive engine speed drop at engine speed middle and lower ...........................................
E-6
E-7
speed is slow when engine speed is middle and higher.. ...........................
20-261
Engine does not start ..........................................................................................................................
20-262
a)
Starter does not work ...................................................................................................................
20-262
b)
Engine stop solenoid does not work ..........................................................................................
20-264
E-8
Engine does not stop ..........................................................................................................................
20-265
E-9
Wiper does not work ...........................................................................................................................
20-266
PC607
20-251 0
E-l
TROUBLESHOOTING
E-l t * *
Work equipment does not move even when the PPC hydraulic pressure lock lever is set to the DRIVE side Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to rest&removed connectors. When the fuse 2 is not blown out. Cause
Yl
2 YES Are the resistance values between Vl (male) (11 nad (2). and between (2) and chassisnormal?
l20-30R 1
value between
* Lock lever at DRIVE side: 1V or lower. * Starting switch ON. * Lock lever at DRIVE side. N
Defective PPC hydraulic pressure lock solenoid
* Between 12) and chassis: 1MR or higher. . Starting switch OFF. * Disconnect Vl.
YES
Breaking wire in the wire harness between lock switch terminal - S14 (2) - M4 (5) -chassis ground, or contact failure
I
Is the resistance value between
YEiS
~~
value between Vl (1) and chas-
-
Refer to the section H-3
NO
3
Remedy
I
NO hioher. Release side: 1MSl or lower. * Starting switch OFF. . Disconnect the switch terminals. NO
ieplace
Iepair or eplace
Breaking wire in the wire harness between Vl ffe. male) (2) - M4 (7) - S14 (1) - S12, or contact fail. ure
lepair or eplace
Defective PPC hydraulic pressure lock switch
qeplace
Breaking wire in fuse 2 H3 14) - Vl (female) t 1I, OI contact failure
lepair or eplace
”
l
*20-3W * Starting switch ON.
E-l
Related electric circuit diagram
PPC hvdrau I ic pressure snitch
ch-Dta
lock
PPC hvdrau ch-vl
(x2)
pressure solenoid
~Iic
I ock
TXPO2156
20-252 0
K60-7
E-2
TROUBLESHOOTING
E-2 Ir Ir
Work equipment does move even if the PPC hydraulic pressure lock lever IS at the LOCK position.
Before carrying out this troubleshooting, check for engagement failure at relating Before proceeding to the next step, make sure to restore removed connectors.
YES
i l
Short-circuit to the ground in the wire harness vetween Vl (female) (2) - M4 (7) - S14 (1) s12
2 YES A
Is the resistance value of the PPC hydraulic pressure lock switch normal?
Lock lever at
-
Refer to the section H-3
1 Is the voltage value between Vl (2) and the chassis normal?
connectors.
LOCK side: NO 20 - 3ov. * Starting switch No *Switch only. ON. Lock side: 1 MR or higher. * Lock lever at Release side: 1MR or lower. LOCK side. Starting switch OFF.
Defective PPC hydraulic pressure lock switch
Replace
l
l
l
E-2
Related electric circuit diagram
PPC hvdraul ic Pressure lock switch
Ct+Dt
ch-vl
8
(x2)
PPC hydraulic pressure lock solenoid
TXP02156
Pc60-7
20-253 0
E-3
TROUBLESHOOTING
E-3 Ir * * Ir
Does not swing
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. When the fuse 2 is not blown out. Carry out this troubleshooting with both swing lock switch and swing prolix switch being [OFF].
-
4 YES Are the resistance values between V4 (male) Ill-(2).and between (21and the chassis normal?
20 - 600. NO * Between (2) and body: 1MQ or higher. Starting switch OFF. YE Disconnect V4. * 5 l
Is the voltage between V4 (1) and the chassis normal?
YE
l
3(Conditions are the same as the item 2. 2 ES
6 YES
l
* 20 - 3ov. % Conditions are the same as the item 2.
lock switch termi-
h
chassis normal? * 20 - 3ov. % Conditions are the NO same as the item
L-t
1
Is the voltage C-l (4) and (2) normal?
* 20 - 3ov. Start the engine, and operate the swing lever. M Operate the lever in the manner that the machine does not swing. l
YES When a short x!Conditions are the same as the item 2.
1
Is the voltage between Sl (1) and the chassis normal?
N0
between C-l (1)
9 YES
~
k
* 20 - 3ov. * Starting switch ON.
the voltage iormal? s 1V or lower. NO % Conditions are the same as the item 2.
YES
l20-3ov. l
11
10
Starting switch ON.
Is the voltage between Cl (3) and (2) normal?
NO
* 20 - 3ov. Starting switch ON.
l
1sthe remstance
11 VES
1_
1 NO I 1MR or higher. * Starting switch OFF. * Disconnect Cl. l
NO
NO
20-254 al
PC60-7
E-3
TROUBLESHOOTING
I
.______I
Remedy
Cause
Refer to the section H-22
-
Defective swing brake solenoid
Repair or replace
Replace
Repair or replace
%
,~I
Defective timer
.~I
r;Fzp
swing pressure
I
Breaking wire or contact failure in the wire harness between Sl (female) (2) -chassis ground
Repair or replace
Breaking wire or shortcircuit to the ground in betthe wire harness ween Sl (female) (1) - H3 (2) -Cl (female) (3)
Repair or replace
I
Replace
Repair or replace
Breaking wire or contact failure in the wire harness between fuse2 - Cl (female) (1)
Repair or replace
20-255 0
TROUBLESHOOTING
E-3
Related
E-3
electric circuit diagram Swns
Swine
lock
switch
lock
GND Pow r source.24V Pow r source 24V Controller Ch-Cl
CN-SP
(X2)
CN-V4
(X2)
SWI~P Dressure
(M4)
Power source.24V
&
CND %;y;horessure
a--
SWIIIO brake solenoid Sw~no
Drolfx
swatch
cNMF
CN-x3
Fuse
2
1
L
7
I1
TAP0098
20-256 0
I
E-4
TROUBLESHOOTING
E-4 * *
Swing brake does not work connectors.
failure at relating check for engagement Before carrying out this troubleshooting, connectors. removed Before proceeding to the next step, make sure to restore
ES
YES
I YES
between V4 (1) and the chassis * Wheb lever at NEUTRAL: 1V or
.20 - 3ov. - starting switch
a Starting witch ON.
ON. mLever at NEUTRAL.
lower.
6 YES
disconnected, is
YES c %(Conditons are same as the item3.
N
switch normal? * Switch only. Switch OFF: 1Mn or higher. * Switch ON: ln or lower. Starting switch OFF. * Disconnect the switch terminal. l
l
20-258 0
41
and the chassis normal?
N
value between Cl (female) (3) and
* 20 - 60R. NO Between (2) -chassis: 1MR or higher. Starting switch OFF. - Disconnect V4. l
l
* 1MR or higher. * Starting switch OFF. * Disconnect Cl and Sl.
30
TROUBLESHOOTING
E-4
~IRefertotheitemH-27
-
Defective timer
Replace
I
>I
Defective timer
. Defective swing brake solenoid Short-circuit to the ground in the wire haness between Sl (female) (1) H3 (2) -Cl (female) (3)
)I
Defectwe prolix switch
1Replace
Repair or replace
Rep’ace
Replace
20-259 0
E-5
TROUBLESHOOTING
Travel speed cannot be switched
E-5
failure at relating connectors. check for engagement Before carrying out this troubleshooting, Before proceeding to the next step, make sure to restore removed connectors. When the fuse 2 is not blown out.
* * *
Cause
al
2 YES
Refer to the item H-20
Arethe resistance 1 1
Defective travel speed se sorenoid
the chassisnormal? -20-6oR. * Between (2) chassis: 1MR or higher. * Starting switch OFF. * Disconnect V5.
Ilect
NO
IBreaking wire or contac failure in the wire harness 5 YES ; 1 IDetween select switch ter 1Is the resistance 1 r Ininal (1) - M29(1) -M4(5 YES value between -chassis ground - V5 (female) (2) 4 Breaking wire or contac and the switch p failure in the wire harnesl terminal normal? Is the resistance between V5 (female) (2) * 1Q or lower. YES value at the travNC 1 M4(10) - M29(2) - selec Starting switch OFF. el speed select switch terminal * Disconnect V5 switch 3 switch normal? terminal. p Defective travel speed se * Switch only. Is the voltage Ilect switch NO . Hi side: 1R or between V5 (1) lower. and the chassis * Lo side: IMR or normal? I higher. 2 IBreaking wire in the win * 20 - 3ov Iharness between fuse2 * Starting switch IH3(4) - V5 (female) (1) NO ON.
1
Is the voltage between V5 (2) and the chassis normal? - Switch at Hi side: 1V or lower. * Starting switch ON. * Move the switch to Hi side.
Replace
Repair or ‘eplade
?epair or .eplade
l
N’
Replace
qepair or .eplade
Cannot be switched to Lo YES
Idefer to the item H-20
l-iiz&lII and the chassis normal?
* ~;~tc&&t
Lo side:
* Starting switch ON. - Move the switch to Lo side.
E-5
-
values between V5 h’nalel Ill and (2). and between (2) and
Yf
bl
Remedy
Cannot be switched to Hi
NO
Short-circuit to the grounc
2 YES
Is the resistance value at the travel speed select switch normal? * Switch onlv. - Lo side: 1G;ln or higher. * Hi side: 1R or lower. * Starting switch OFF.
NO
1 In the wire harnass bet \ween V5 (female) (2) IM4(10) - M29(2) - switch Iterminal (2)
3epair or eplade
IDefective travel speed se Ilect switch
teplace
Related electrical circuit diagram
CN-If3 (SB) Tra swi
speed select
TAP00982
20-260 0
TROUBLESHOOTING
E-6
E-6
Power mode cannot be changed
t * *
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. When the fuse 2 is not blown out.
a)
Work equipment speed is slow when engine speed is middle and higher
cause
2 YES Are the resistance values batwaan v3 Imale) (1) and (21. and between (2) and the chassisnormal7
YE
l20-60R.
Refer to the item H-l
Defective mode select solenoid
No
Between (2) chassis: 1MR or higher. * Sdl;?ing switch
-
teplace
l
1 Is the voltage between V3 (2) and the chassis normal?
l
5YEs
Disconnect V3.
YES 4 Is the resrstanca yEs value between _ the limit switch terminals nor3 ma17
Fuel lever full: 1V or lower. * Starting switch ON. Fuel lever full. l
l
Is the voltage between V3 (1) and the chassis normal? l20-30V Starting switch ON.
N
_
_
1R or lower. NO * Starting switch OFF. Disconnect V3. l
tepair or eplade
Breaking wire or contac failure in the wire harness between V3 (female) (2) H3(1) -s15
tepair or eplade
Defective fuel limit switch
Ieplace
Breaking wire in the wire harness between fuse2 H3(4) - V3 (female) (1)
lepair or eplade
l
* Switch only. . ON side: NO 1R or lower. * OFF side: 1MR or higher. Starting switch OFF. Disconnect the switch terminals.
l l
l
b)
lo the resistance value between V3 (female) (1) and S15 normal7
Breaking wire or contact failure in the wire harness between limit switch terminal -chassis ground
No
Excessive engine speed drop at engine speed middle and lower YES 1
between V3 (2) and the chassis . Fuel lever lowiding: 20 -30V. Starting switch ON. * Fuel lever lowiding. l
Refer to the item H-l
I I I 2 YES
Is the resrstance value between L the limit switch NO terminals normal?
-
Short-sircuit to the grounc in the wire harness between V3 (female) (2) s15
tepair or eplade
Defective switch
teplace
-
NO * Switch only. * Full side: 1R or lower. At low-idling side: 1MD or higher. . Starting switch OFF. Disconnect the switch terminal.
fuel lever limr
l
l
E-6
Related electrical circuit diagram Limit
switch Ch-v3
OFF ON cl+sl6
(X2)
Mode select solenoid
3
00-J
_t
OCh-H3
3
(98)
TXPO2167
Pc60-7
20-26 0
1
E-7
TROUBLESHOOTING
Engine does not start
E-7 * Ir
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. 4 YES
81 Starter does not work
Yf
.
Is the voltage between the terminal B of the starter and the chassis normal?
-
* Starting switch ON. . Approx. 24V.
NO
Is there sound of the starter pinion 6 YES Is there continuity YES between the ter- mmal C of the starting switch 5 and chassis? Is there continuity * Turn the starting between the terswitch to START. minals S and R of safty relay?
2
YE!
relay make a sound when the starting switch is turned OFF?
* Starting
switch ON+OFF.
Is the voltage and specific gravity of
24V or higher. * Specific gravity: 1.26 or more. l
NO
NO
10 YES r 1 IS there continuity . YES between tne cnas- sis ground and the _ terminal E of bat9 tery relay? Is the reslatancevar yes ue of the wire harNO - “ass between BR of _ the starting switch 8 and ER of tha batten, relavxzz!L * Between starting between the terYES NO switch BR - batm minal B and BR of 7 tery relay BR: lfl or lower. the starting * Between harness -chassis: 1Mn or lower. switch? Is the voltage at -* Turn ON the starting * Disconnect both starting switch and battery the terminal B of relay ends. switch. the starting switch * Remove the rermi- NO normal? NO nel B. . Connect 6) side of
NO
E-7
a)
Related
electrical
circuit diagram
ch-MI
6
(L2) F,._:“_
_:_L
Ch-Ott B I,
switch
IL‘ StartIns
II
n.,,.rr
TAPOO9e.4
20-262 0
PC60-7
E-7
TROUBLESHOOTING
Cause
Remedy
Defective starter
Reolace
Contact failure in the wire harness between (+) terminal of battery - B-terminal of battery relay - Mterminal of battery relay B-terminal of starter
Replace
Breaking wire or contact failure in the wire harness between C-terminal of staning switch - Hl (3) - M75 (1) safty relay M75 (2) - Dll battery relay Wt. and B-terminal of slaner - safty relay -C-terminal
teplace
qeplace
Defective safty relay
qeplace
Defective battery relay
qeplace
Contact failure in the wire harness between Eterminal of battery relay -ground terminal of revolving frame
3eplace
Breaking wire or contact failure in the wire harness between BR-termiswitch nal of startin BR-terminal o B battery relay Defective starting switch (between B - R)
Replace
Ft’p,“~~t~~~r’,,~~~~~~t~~~~ ween I+) terminal of batteq - B-terminal of battery relay - Ml5 (1) 12) - Hl (2) B-ter. minal of stamng switch (include fusible link) Lack of battery capacity
Replace
Charge or replace
20-263 0
TROUBLESHOOTING
b)
E-7
Engine stop solenoid
does not work
2 YES 1 Is the resistance II YES value between the - engine stop solenoid terminal and the 1 chassis normal? Is the voltage between the engine _ stop solenoid terminal and the chassis normal? *20-30V * Starting ON.
switch
la or lower. NO * Starting switch OFF. Disconnect the solenoid terminal. 3 YES Is the voltage between the - terminal ACC of the NO starting switch and the chassis normal7 l
l
*20-30V Starting ON. l
E-7
b)
Defective
Related
engine
NO
Breaking wire or contact failure in the wire harness between solenoid terminal -chassis
Repair or replace
Breaking wire or contact failure in the wire harness between ACC terminal of starting switch - Hl (4) solenoid terminal
Repair or replace
Defective (berween
Replace
starting switch B - ACC)
switch
electrical
Stsrtino
circuit diagram
switch
Ct+Hl
616) Engine
stop
77?
20-264 0
stop so-
I lenoid
solenoid
TAP00985
TROUBLESHOOTING
E-8
m
E-8 * Ir
Engine does not stop
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Cause
1
YES I
Is the voltage between the engine stop solenoid terminal and the chassis normal?
2 YES Is the voltage between the terminal ACC of the starting switch and the chassis normal?
i*
1V or lower. *When turning ~0 OFF the starting switch.
* 1V or lower. * Starting switch OFF. Disconnect the ACC terminal.
Remedy
Defective engine stop solenoid
Replace
24V line harness terminal switch -
Repair or replace
contacts the wire berween ACCof starting Hl (41 -solenoid
Defective starting switch (between B - ACC)
NO
Replace
l
6
is
E-8
Related
electrical
circuit diagram
s
StartIne @
snitch ‘Ty”’
Ensinf
solen;
TAP00985
20-265 0
TROUBLESHOOTING
E-9 * *
E-9
Wiper does not work
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Remedy
3 YES Is the resistance value between Ml8 (female) (2) and M31 (female) ft t normal?
y?,
YES -
1 Is the voltage between M31 (3) and (2) normal? * 20 - 3ov. * Starting switch ON.
‘Istheresistance value between the terminals 6 and L of the wiper switch normal?
-NO . Tn or lower. . Starting switch OFF. . Disconnect Ml6 and M31.
-
-
* Between B - L: switch ON: 1R or lower swith OFF: 1MR or higher.
_
.
NO
YES
4
* Nz
Does the buzzer sound normally?
-
.
Defective wiper motor
Replace
Breaking wire or contact failure in the wire harness between L terminal of wiper switch - Ml6 (2) M4 (15) - Ml7 (1) - M31 (female) (1)
Repair or replace
Defective wiper switch
Replace
Breaking wire or contact failure in the wire harness between fuse4 - Ii1 (8) M4 (female) (6)
Repair or replace
fuse4 is blown out
Replace
NO
E-9
Related electrical circuit diagram ctwoe
(KES)
Wssher
ir
TAP00986
20-266 0
TROUBLESHOOTING
Method
s-
s- 2
chart . . . . . .. . . . .. . . . . .. . .. .. . .. . . . .. . . . .. .. . . . .. . . .. . . .. .. . . . . . . .. . .. . . . . . .. . .. . . . . . . . . . . . . . . .. . .. . 20-302
of using troubleshooting
1 Starting
performance
is poor (Starting
20-306 20-308 20-308
Engine does not turn ......................................................................................................
(2) Engine turns no but exhaust smoke comes out (Fuel is not being injected).
........... ..20-30 9
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
......... ..20-310
s- 3
Engine does not pick up smoothly
s- 4
Engine stops during operations
s- 5
Engine does not rotate smoothly
S- 6
Engine
lacks output (or lacks power)
s- 7
Exhaust
smoke is black (Incomplete
S- 8
Oil consumption
6
s-
Oil becomes
z
s-10
Fuel consumption
s-11
Oil is in cooling water,
s-12
Oil pressure caution
s-13
Oil level rises (Water,
s-14
Water temperature
s-15
Abnormal
S-16
Vibration
9
always takes time). ...............................................
Engine does not start ............................................................................................................ (I)
z
OF ENGINE (S MODE)
(Follow-up
........................................................................................... (Hunting)
........................................................................
................................................................................... combustion).
is excessive (or exhaust
contaminated
is poor) ......................................................
.............................................................
gas is blue). ......................................................
quickly ......................................................................................
is excessive ............................................................................................. or water spurts back, or water
level goes down.. ........................
lamp lights up (Drop in oil pressure)
...............................................
fuel in oil) ..........................................................................................
becomes too high (Overheating).
........................................................
noise is made ....................................................................................................... is excessive..
..........................................................................................................
20-311 20-312 20-313 20-314 20-315 20-316 20-317 20-318 .20-319 .20-320 20-321 20-322 20-323 20-324
20-301 0
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING chart is divided into three This troubleshooting check items, and troublesections: questions, and check items are The questions shooting. used to pinpoint high probability causes that can or simple be located from the failure symptoms tools. inspection without using troubleshooting tools or direct inspection Next, troubleshooting are used to check the high probability causes to make final confirmation. [Questions] Sections @ + @I in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @I are items that can be obtained from the user, depending on the user’s level. [Check items1 carries out simple inspection The serviceman to narrow down the causes. The items under @ in the chart on the right correspond to this. down the causes narrows The serviceman @ that he has obtained from information from the user and the results of @ that he has obtained from his own inspection. [Troubleshooting] is carried out in the order of Troubleshooting starting with the causes that have probability, been marked as having the highest probability gained from IQuestions] and from information [Check items].
20-302 0
CHART
CHART
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
CHART
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with 0. Check each of the [Questions] and [Check items] in turn, and marked the 0 or 0 in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause.
‘%l.
%2.
For (Confirm recent repair history) in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. Use the A in the Cause column as reference for [Degree of use (Operated for long period)] in the (Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for
troubleshooting.
---I
*1
Confirm recent repair history.
r2
Degree of use
Operated
for long period
AAA
20-303 0
TROUBLESHOOTING
.
METHOD
OF USING TROUBLESHOOTING
CHART
Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
combustion) s-7 Exhaust gas is black (incomplete General causes why exhaust gas is black . Insufficient intake of air . Improper condition of fuel injection . Excessive injection of fuel
20-304 0
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
CHART
Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items1 section and the five Cause items in the vertical column.
Three symptoms
Add up the total of 0 and 0 marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: QOQ (2) Air leakage between turbocharger and head: 00 (3) Clogged, seized injection nozzle: 0 (4) Defective contact of valve, valve seat: 0 (5) Worn piston ring, cylinder: 0
The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the
20-305 0
TROUBLESHOOTING
S-l
Starting
S-l
performance
is poor (Starting
always takes time)
Possible causes of the engine not starting though exhaust gas being discharged. . Electrical system is defective. . Fuel supply is insufficient. . Air intake is insufficient. . Fuel selection is improper. (Under the ambient temperature of -10°C or lower, use ASTM 0975 No.1 t
Battery charging rate temper*t”re
20°C 0°C -10°C l
l
100%
90 %
60 %
75 %
70 %
1.28 1.29 1.30
1.26 1.27 1.26
1.24 1.25 1.26
1.23 1.24 1.25
1.22 1.23 1.24
A battery can be used if the specific gravity shows 70% or higher charging rate shown in the above table. In cold weather, 75% or higher charging rate is required.
Dust indicator lamp is ON. Battery charge lamp is ON. Starter motor runs slowlv.
0: Most probable caus A: Possible causes due to
20-306 0
dging from Questions and check items) th of use (used for a long period1
I
Causes
I
TROUBLESHOOTING
S-l
Causes
20-307 0
s-2
TROUBLESHOOTING
S-2 Engine does not start (1) Engine does not turn General .
. l
causes why engine does not turn
Internal *
I
parts of engine seized
If internal parts of the engine are seized, carry out troubleshooting for “Engine stops during operations”. Defective electrical system Failure in power train
Legend 0: Possible causes (judging from Cluastions and check items) 0: Most probable causes (judging from Questions and check items) A: Possible causes due to length of use (used for a long period) 0: Items to confirm the cause.
Condition of horn when starting switch is turned
Ahl
Horn does not sound
I
Horn volumr .- ‘ation is low
0
in nniaa
QQ
0 Makes rattling noise and does not turn When starting switch is turned to START, pinion does not move out
Q
I
When starting switch is turned to ON, there is no clicking sound Battery terminal is loose
.s
When starting switch is turned ON, linkage is not actuated
.g
When battery is checked, battery electrolyte is found to be low
.i
1 Soecific aravitv of electrolyte, voltaoe of batterv is low
I!
For the following conditions 1) - 5). turn the starting switch OFF, connect the cord, and carry out troubleshooting
3) When terminal B and terminal C of safety relay are
%
solenoid is disconnected
Remedy
20-308 0
-
Causes
I
TROUBLESHOOTING
(2)
s-2
Engine turns but no exhaust out (Fuel is not being injected)
smoke comes
General causes why engine turns but no exhaust comes out
. . .
Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly
t
Standards for use of fuel
smoke
in winter) /
AMBIENT KIND nC rL”lY CI I ,,I7
VT
I
-4 -20
14 -10
Causes
I
TEMPRATURE
32 b
50 io
68 20
86OF 30°C
)
Legend 0: Possible causes (judging from Questions and check items) 0: Most probable causes (judging from Questions and check items) A: Possible causes due to length of use fused for a long period) m Items to confirm the cause
I I Confirm
recent repair history
Dearee of use of machine
1 Operated
for long period
Exhaust smoke suddenly stops coming out (when starting again Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be emptv There is leakaae from fuel oioina Mud is stuck to fuel tank cap
/
When startina switch is turned ON, linkaae is not actuated When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) lniection oumo couolina does no rotate. 2) No fuel comes out even when fuel filter air bleed plug is loosened 3) No fuel spurts out even when injection pump sleeve nut is loosened Rust and water are found when fuel tank is drained Inspect injection pump directly
Inspect feed pump directly When fuel filter, strainer are inspected directly, they are found to be cloaaed When feed pump strainer is inspected directly, it IS found to be clogged When fuel cao is lnsoected directlv. it is found to be cloaaed Even though the linkage of the fuel cut solenoid is disconnected, it doesnot work Even though the linkage of the engine stop motor is disconnected, it does not work
20- 309 0
TROUBLESHOOTING
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine not start . . . .
Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil
Legend 0: Possible causes (judging from Questions and check items) 0: Most probable causes (judging from Questions and check items) A: e to length of use (used for a long period)
20-310 0
s-2
TROUBLESHOOTING
s-3
S-3 Engine does not pick (Follow-up
is podr)
General causes why engine
. . .
.
up
smoothly
-
Causes
does not pick up smoothly
Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injction Improper fuel used
:gend : Possible ceases (judging from Cluestions end check items) : Mostprobable causes (judging from Questions and check items)
.
20-311 0
S-4
TROUBLESHOOTING
S-4 Engine stops during operations General causes why engine stops during operations . Seized parts inside engine . Insufficient supply of fuel . Overheating * .
If there is overheating and the engine stops, carry out troubleshooting for overheating.
Failure in power train *
If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.
Legend 0: Possible ceuses (judging from Ouestions and check items) 0: Most probable causes (judging from Questions and check items) e to length of use (used for a long period)
Condition when engine stopped
Fuel tank is found to be empty Replacement tn Clnraratinn
of filters has not been carried out according
Non-specified
fuel is being used
When feed nump is operated, operation is too light or too heavy
When control rack is pushed, it is found to be heavy, or does not return
20-312 0
Causes
s-5
TROUBLESHOOTING
S-5 Engine does not rotate smoothly (Hunting) General causes why engine . . .
does not rotate smoothly
Air in fuel system Defective governor mechanism Defective electric governor mechanism (engine with electric governor) Ir
If hunting stops when electric governor rod is disconnected, carry out troubleshooting for the chassis.
Leoend --a-
0: 0: A: 0~
Possible causes (judging from Questions and check items) Most probable causes (judging from Questions end check items.1 Possible causes due to length of usa (used for a long period) Items to confirm the cause. Confirm recent repair history
1I z
Condition of hunting
to Ooeration Manual Rust, water are found when fuel tank is drained Leakage from fuel piping When feed pump is operated, 1) No resoonse. liaht. return is auick 2) No response, liaht. return is normal Engine speed sometimes
rises too far
Enaine is sometimes difficult to stoo
I
I
I
lolo lol
Seal on iniection pump has come off
.
20-3 13 0
TROUBLESHOOTING
S-6
S-6 Engine lacks output (or lacks power) General
. . .
causes why engine
lacks output
Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used (if non-specified fuel is used, output drops) Lack of output due to overtaking
. .
*
If there is overheating and lack of output, carry out troubleshooting for overheating.
Legend 0: Possible ceuses (judging from Duestions and check items) 0: Most probable causes (judging from Questions and check items) A: Possible causes due to length of use fused for a long period) 0: Items to confirm the cause.
to Operation Non-specified
Manual fuel is being used
QQ00
Dust indicator lamp is red PI^^l, O’acn ?, lnzarl Blue under ligl.. .._..
/’ Color of exhaust gas Noise of interference
Q
is heard from around turbocharger
08
I
I
I lal
Blow-by gas is excessive Engine pickup is poor and combustion
6 1-1
I
1 I
1 I
I
I
I 0
8
is irregular
When exhaust manifold is touched immediately engine, temperature of some cylinders is low
0
00
@@
0
after starting
There is hunting from engine (rotation is irregular) Clanging sound is heard from around cylinder head High idling speed of engine is low
I
Leakage from fuel piping When air cleaner element is inspected directly, it is found to be clogged When turbocharger is rotated by hand, it is found to be heavy
20-314 0
I
0
High idling speed under no load is normal, but speed suddenly drops when load is applied
When compression
I
I I I I I I I I I
pressure is measured,
it is found to be low
. 0 0
0
TROUBLESHOOTING
s-7
S-7 Exhaust smoke is black (Incomplete combustion) General . . .
causes why exhaust
smoke is black
Causes
Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel
Legend 0: Possible causes (judging from Questions and check items) 0: Most probable causes (judging from Questions and check items) A: Possible causes due to length of use (used for a long period) 0: Items to confirm the cause. 1 Confirm recent repair historv
I
I I I I I I I I
I II
Color of exhaust gas
I I Power was lost /
Noise of interference
is heard from around turbocharger
@I
Dust indicator lamp is red
lel
Blow-bv gas is excessive
I
Engine pickup is poor and combustion is irregular
Ir I
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
I I 5
I
01
1 1 1 I I Isl II I-I 1 181 I
I
I
1 I II I I
1 1 I I II II lololol I I
I
1 I I I II II I
I
I
1-n
0
I
Clanging sound is heard from around cylinder head
When turbocharaer
is rotated bv hand, it is found to be heaw
When control rack is pushed, it is found to be heavy, or does not return
IlI
I
I
I
I
I
I
I
8
20-315 0
s-a
TROUBLESHOOTING
S-8 Oil consumption is excessive (or exhaust smoke is blue) Ir
Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)
Causes
General causes why oil consumption is excessive Abnormal combustion of oil External leakage of oil Wear of lubrication system
l
. l
Legend 0: Possible causes (judging from Questions and check items) nd check items)
Amount of blow-by gas
1 When compression
pressure is measured,
it is found to be low
10 10 l
When breather element is inspected, it is found to be clogged with dirty oil
l
Iii I 2
0.0.
G
shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with oil
20-316 0
0
test of oil cooler shows there is leakage
Excessive play of turbocharger
I
0
There is external leakage of oil from engine Pressure-tightness
l
I
I
I
I
I
I I I 144 1 IO l 0
s-9
TROUBLESHOOTING
S-9 Oil becomes contaminated General causes why oil becomes
.
quickly
contaminated
quickly
Entry of exhaust gas due to internal wear Clogging of lubrication passage Improper fuel Improper oil used Operation under excessive load
. . . l
Legend uestions and check items) rom Questions and check items) use fused for a long period) Confirm recent repair history E
Degree of use of machine
Operated for long period
.G_ $ Engine oil must be added more frequently 3
Non-specified
A
A 0
oil is being used
Color of exhaust gas
Blue under light load
A
Q
63
Black Excessive Amount of blow-by gas E
z
C
2 6
None
When 011filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Engine 011temperature
0
rises quickly
0
Q
0
0
0
0 I
QO
i’ %
0
.4 0 ‘: E
Q Q
5
.
20-3 17 0
TROUBLESHOOTING
S-IO
S-10 Fuel consumption General
. . .
is excessive
causes why fuel consumption
Leakage of fuel Improper condition Excessive injection
is excessive
Causes
I
of fuel injection of fuel
Legend Cl: Most probable causes (judging from Questions and A: Possible causes due to length of use (used for s Ion
Exhaust smoke color
temperature of some cylinders is low
.$
Match mark on injection pump is misaligned
6
There is external leakage of fuel from engine
0 0
Engine oil level uses and smells of diesel fuel
0
Engine low idling and high idling speeds are high
0
20-318 0
QQ 0
I
S-l 1
TROUBLESHOOTING
S-II
Oil is in cooling water, or water spurts back, or water level goes down
General
. .
/
Causes
/
causes why oil is in cooling water
Internal Internal
leakage in lubrication system leakage in cooling system
Legend 0: Possible causes (judging from Questions and check items) 0: Most probable causes (judging from Questions and check items) A: Possible causes due to length of use (used for a long period) 0: Items to confirm the cause.
Pressure-tightnesstest of oil cooler shows there is leakage Pressure-tightnesstest of cylinder head shows there is leakage Remove oil pan and inspect directly
20-3 0
19
s-12
TROUBLESHOOTING
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) General
. .
causes why oil pressure lamp lights up
. .
Leakage, clogging, wear of lubricating system Defective oil pressure control Improper oil used (improper viscosity) Deterioration of oil due to overheating
*
Standards
for engine Selection
oil selection
of SAE No. according
Legend 0: Possible causes (judging from Cluestions and check items)
Condition when oil pressure lamp lights up
20-320 0
to
Causes
TROUBLESHOOTING
s-13
S-13 Oil level rises (Water, fuel in oil) *
If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
.
Water in oil (milky white) Fuel in oil (diluted, and smells of diesel fuel) Entry of oil from other component
.
.
Legend 0: Possible causes (judging from Cluestions and check items) 0: Most probable causes (judging from Ouestions and check items) A: Possible causes due to length of use U.ed for a long period)
Lz
‘G
x f 1
Lx
z
I-
Remove injection pump and inspect directly Defective contact with thermostat
0
seal valve
0
Remove oil pan and check directly
00
Remedy
8 $ ; % 5PB=OtnLPB
8 2
t; 8 U,m
z p: 2-m
8 IO
dPdSPSL?SBd
20-321 0
TROUBLESHOOTING
S-14 Water temperature high (Overheating)
s-14
becomes too
General causes why water temperature high
. . . .
Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature in power train *
20-322 0
becomes too
Carry out troubleshooting
for chassis.
Causes
s-15
TROUBLESHOOTING
noise is made
S-15 Abnormal
Judge if the noise is an internal noise.
*
General causes why abnormal
. . .
noise or an external
noise is made
due to defective parts Abnormality Abnormal combustion Air sucked in from intake system
Degree of use of machine
Operated for long period
A
z .g b:
Condition of abnormal noise
Gradually occurred
0
d
Non-specified
/
P,,rlfirnl” -----...,
0 A ”
AA vv
nrr,,rr&-4 “__“..“_
00
fuel is being used
Engine oil must be added more frequently n, _ I -‘--“-\t rrgr load owe unoer Color of exhaust gas Black Metal particles are found in oil filter Blow-by gas is excessive Noise of interference is heard from around turbocharger Engine pickup is poor and combustion
is abnormal
Clanging sound is heard from around cylinder head Leakage of air between turbocharger
and head, loose clamo
@ 0 fi 1-1
I 1 ]@I I@] I 1 I I@/ I 1 1 lo] I I I 101 I
I
I I ) / I
I 1 1 I I
A
I”1 1 I 1 I I I
I I
A
I”1 1 I
I I I I 1 1 I
1
Vibrating noise is heard from around muffler
Ic I
I
I
I
I
1-1
I
I
I
I
I I I I I I I.1 I I I I I
r
Fan is deformed, belt is loose When valve clearance is checked. it IS found to be outside Remove cylrnder head cover and inspect directly
II
When muffler is removed, abnormal
I I I I I I / ’ ’
noise disappears
20-323 0
S-16
TROUBLESHOOTING
S-16 Vibration *
If there is abnormal noise together with the vibration, carry out troubleshooting also for “Abnormal noise is made”.
General
. . .
is excessive
causes why vibration
Defective parts (abnormal Improper alignment Abnormal combustion
is excessive wear, breakage)
Legend 0: Possible causes (judging from Questions and check items) 0: Most probable csuses (judging from Questions and check items) A: Possible causes due to length of use (used for a long period)
20-324 0
/
Causes
I
4
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) Troubleshooting
flow charts for each failure mode
All work equipments,
travel, swing
H-l
Speeds of all work equipments,
swing and travel are slow or lack of power
H-2
Excessive
H-3
All work equipments,
H-4
Abnormal
H-5
Fine control ability is poor, or response
drop in engine speed, or engine
............ ..20-35 2
stalls ...........................................................
travel and swing do not move.. ...................................................
sound is generated
(around
20-354 20-355
the pump) .........................................................
20-355
is poor .............................................................
20-356
Work equipment H-6
Boom movement
H-7
Arm movement
H-8
Bucket movement
H-9
Work equipment
..................................................................
20-356
is slow or lacks of power.. .....................................................................
20-358
is slow or lacks of power..
is slow or lacks of power..
.................................................................
(but travel and swing are normal). ................................................................................... H-10 H-l 1
Excessive Excessive
Compound 6 E; w”
H-12
20-360
(boom, arm, bucket) does not move
hydraulic
drift (boom,
arm, bucket) ................................................................
time lag (engine at low speed)
.......................................................................
20-361 20-361 20-362
operations
In compound
operations,
work equipments,
movement
of one with
larger load is slow ............................................................................................................. H-13
In swing + boom RAISE operation,
H-14
In travel + swing operation,
H-15
In travel + work equipment
boom RAISE movement
20-362 .20-363
..........................................
20-363
travel speed drop is excessive
... 20-363
travel speed drop is excessive (boom RAISE) operation,
is slow ..........................
Travel system
.
during travel
H-16
Vehicle curves unintentionally
H-17
Travel deviation
H-18
Travel speed is low, or lacks of power
..................................................................
20-364
is larger at starting ................................................................................
20-364
............................................................................
20-364
operation
is difficult.. .........................................................................................
H-19
Steering
H-20
Travel speed cannot be switched..
H-21
Travel does not work (one side only) ..............................................................................
...................................................................................
20-367 20-368 20-368
Swing system
.
H-22
Does not swing (both sides, one side only) ....................................................................
H-23
Swing
H-24
Excessive
overrun when stopping
H-25
Excessive
shock when stopping
H-26
Excessive
abnormal
H-27
Excessive
hydraulic drift of swing (when the swing brake is released
H-28
Swing
H-29
Blade speed is slow, or lack of power
H-30
Blade does not move ........................................................................................................
H-31
acceleration
is poor ............................................................................................... swing (both sides, one side only) ..........................
swing (one direction
noise when stopping
speed is faster than the specified
Excessive
only) .........................................
swjng (one direction
only). ....................... or activated).
speed.. ............................................................
.............................................................................
hydraulic drift of the blade ..............................................................................
20-369 20-370 20-372 20-373 .20-373 . 20-374 20-375 20-375 20-376 20-376
20-351 0
H-l
TROUBLESHOOTING
H-l
Ir
Speeds of all work equipments, of power.
swing and travel are slow or lack
Before starting this troubleshooting, make sure that the main pump does not make any abnormal sound. (If abnormal sound is made, carry out troubleshooting described in H-4.)
YES
41
n
oes t e pressure become normal when the PC valve is adiusted?
I- Refer
to the section of TESTING AND ADJUSTING.
YE
YE
1 ~Is the PPC setting pressure norma17 I
sure of the main
24.545” MPa (2502’ kg/cm?. - Engine at high idling. Arm relief.
l
l
I
I
f Referring to the section of TESTING AND ADJSTING, check 1 and measure the NO oil pressure in the circuit.
20-352 0
mode select solenoid normal? c * 0.2 * 0.2MPa 12 * 2kg/cm3 * Engine at high idling . * Arm relief.
N
I
6 YES Does the pressure become normal when the unload valve is replaced?
NO
5
YES
1 ZZ$&jHNO NO
H-l
TROUBLESHOOTING
Adjustment PC valve
Defective
failure of the
PC valve
Repair or replace
Defective piston pump
Repair or replace
Malfunction of the mode select solenoid valve
Rep,ace
_ Malfunction of the unload valve
Malfunction relief valve
of the main
Defective the oil pressure devices in the PPC setting pressure circuit (Refer to INSPECTION AND ADJUSTMENT)
K60-7
Adjust
Repair or replace
Replace
Repair or replace
20-353 0
H-2
TROUBLESHOOTING
H-2 *
Excessive drop in engine speed, or engine stalls
Confirm that the main relief pressure is normal. Remedy
YES
Clogging in the throttle ir the servo
1 Is there any clogging in the throt-
3 YES
-
NO
Is the engine spaed at arm relief normal? 9 See the table below.
%
Table
Does the condiYES don become normal when the PC 2 valve is replaced)
NO
Defective PC valve, or adjustment failure of the PC valve
idjust, or .eplace the PC lalve
Defective servo piston
qeplace Piston pump sssemblv)
Refer to the troubleshootof the engine fSI
-
1 ing
NO
If the engine speed is still lower than the speed shown in Table 1 even after the PC valve is replaced with a new one, carry out the troubleshooting in the section 6). If the engine speed is higher than that value, it can be judged that the PC valve is defective (replace).
1 Serial No.
Model
Engine speed at arm relief
Condition
l
52374-57999 PC66
Min. 1,650 rpm l
-
56001 and up
20-354 0
Min. 2,000 rpm
Engine at high idling Swing lock switch ON With the arm dump at the stroke end, shift the lever
to the full side gradually,
and
read
the
value where the engine spead drop is largest.
Fc60-7
H-3, H-4
TROUBLESHOOTING
H-3
All work equipments,
travel and swing do not move
Cause
YES
Remove
Is the PPC setting pressure normal?
NO
the
f+Jw,“---’ check v comes out 01
YES
-Crank thee with the starter motor.
Is the PTO spline
I
1
NO
Remedy
Defective PPC oil pressure lock solenoid valve
Replace
Defective self-reducing pressure valve, or defective control circuit
Replace
Defective main piston pump
Repair or replace
Defective PTO spline
Repair or replace
6
z
z
H-4
Abnormal
(around the pump)
sound is generated
Cause
F= YES
3 When the engine YES_ is stopped once, do the bubbles disappear? 2
YE
To the section 4
_ Defective hydraulic oil NO
Are there bubbles inside the hydraulic oil tank’
T
Remedy
I
Iqeplace lydraulic oil
YI
strainer clogged 1 Is the oil level in the hydraulic tank normal?
+ZForeign matter: Cloth, etc.
NO
n
Is the suction strainer clogged with metallic fereign matters’ Or, are metal chrps sticking to the drain plug?
Defect inside the pump
Repair or replace
Operate for a short time and observe for any change in conditions
Recheck (depending of the change in conditions)
Lack of hydraulic oil
Refill the hydraulic oil
.
20-355 0
H-5, H-6
TROUBLESHOOTING
H-5
Fine control ability is poor, or response is poor
I 1
YES
Clogging in the LS circuit throttle
Is the throttle in the LS circuit clogged?
Defective LS valve, or defective servo piston
NO
H-6 Ir
Remedy
Cause
Boom movement
Clean
Replace
6 2 Lu
is slow or lacks of power
When the travel and swing speeds are normal.
Is the leak amount from the hydraulic cylinder normal?
YES
5YES
-
l
Does the spool
YES_ of the control
lief, is the pump relief pressure is
1250$ kg/cm? * Engine at high idling.
20-356 0
* 2.9 + 0.5MPa (30 + 5 kg/cm? . Engine at high idling.
ND
_ -
valve move smoothly?
2 Is the output YES pressure of the PPC valve normal? 1
-
‘I
-
With the boom UP relief, is the _ *Max. 15cc/min. NO 4 pump relief presEngine at high idling. Is the pressure sure normal? * Make it relief at the compensation stroke end. YES valve normal? * l.OMPa (lOkg/cm*) - Does the pressure - . Engineat high NO compensation idling. 3 valve move . 24.5 ‘i”MPa smoothly?
‘250 $” kg’cm2) NO
NO
TROUBLESHOOTING
H-6
Remedy
Cause
IMalfunction of the regen,aration valve
3eplace
IDefective hydraulic ,der gasket
Zorrect or eplace
IMalfunction
cylin-
of the suctior
valve
Defective pressure corn. pensation valve, or mat function of the pressure comprensation valve
Malfunction of the contro valve spool
IDefective PPC valve
Iblalfunction of the safety - ! /abe and the suctiom I falve
3eplace
Zorrect or ,eplace
Corrector replace
leplace
teplace
20-357 0
H-7
TROUBLESHOOTING
H-7 *
Arm movement
is slow or lacks of power
When the travel and swing speeds are normal.
5 YES
Is relief pressure XES
~66 -
~66
2 YES 1_
pump relief pressure is normal? * 24.5’b;cMPa I250 so kg/cm’) * Engine at high idling.
_
Is the output pressure of the PPC valve normal?
Does the spoof r of the control valve move smoothly?
* 2.9 + 0.5MPa (30 + 5 kg/cm’) * Engine et high idling.
NO
NO
Is leakage from arm cylinder nor- _ mal?
of pump normal when arm circuit is relieved? NO
-
NO
NO
- Max. 15cclmin NO * Engine at high idling * Make it relief at the stroke end
20-358 0
_
-
6 YES A
3
Is the pressure compensation V&e nOrmal? Does the pressure compensation valve move snoothly?
TROUBLESHOOTING
H-7
Cause
To ‘A
Malfunction valve
=I
of the suction
Defective pressure corn pensation ;alve. or mal function of the pressure comprensation valve
Repair or replace
Malfunction of the contra valve spool
Repair or replace
Defective PPC valve
I
Replace
Malfunction of the safeb and suction valve
Replace
Malfunction of the regen eration valve
Repair or replace
Defective arm cylinder piston gasket
Repair or
1replace
20-359 0
TROUBLESHOOTING
H-8 *
H-8
Bucket movement
is slow or lacks of power
When the travel and swing speeds are normal.
3 YES YES 2 YES
-
1 With the arm relief, is the pump relief pressure is normal?
* 24.5 *i’MPa 1250 2 kg/cm’) Engine at high idling.
-
Does spool of the control valve nove smoothly?
-
IS the OUtpUt pressure of thePPC valve normal?
* 2.9 * 0.5MPa 00 f 5 kg/cm’} . Engine at high idling.
To ‘A
F--t=
NO
x NO
ND
Malfunction of the control valve spool
Repair or replace
Defective PPC valve
Replace
Defective the safety valve and the suction valve
Replace
Malfunction of the suction valve
Replace
Defective
Repair or
l
5 YES YES
Prom .A. -m[-i
Is the leak
!$r!~~~L~~
stroke end. NO
20-360 0
bucket cylinder
yis;;;t;k;;ess.,.
com_ replace
pensation valve, or matfunction of the pressure compensation valve
Repair or replace
TROUBLESHOOTING
H-S
*
H-9, H-10
Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)
When the boom, arm or bucket is operated
independently.
Remedy
Cause
YES
1
Is the output pressure of the PPC valve norma17
L_
NO
* 2.9 + 0.5MPa (30 * 5 kg/cm’) * Engine at high idling.
Defective control valve spool
Repair or replace
Defective PPC valve
Replace
H-10 Excessive hydraulic drift (boom, arm, bucket) b
0 5
z
.X
Because the safety valve and the suction valve commonly serve for the boom, arm and bucket, if excessive hydraulic drift occurs equally for boom, arm and bucket, it can be judged that the cause is defective safety valve or suction valve.
Remedy
Cause
2 YES Does the condition become normal when the suction valve is replaced?
YES 1 -
from the hydraulit cylinder nor-
-
* Refer to the section of . TESTING AND ADJUSTING. * Max. 15cc/mtn. * Engine at high idling. * Make it relief at the stroke end.
-NO
Malfunction of the suction valve
Defective oil tightness the control valve spool
Replace
of
Defective hydraulic cylinder piston gasket
Replace
Replace
20-36 0
1
H-11, H-12
TROUBLESHOOTING
H-l 1 Excessive time lag (engine at low speed) *
When the speeds of the work equipments
are normal.
Cause
Defective suction valve
Engine at low idling Time
) 1
Boom
I
Arm
Remedy
Clean or replace
tsec) lag
Max. 3.9 Max. 1.0
1
Max. 1.0
Bucket
H-12 In compound operations, larger load is slow
work equipments,
movement
of one with IO s
Engine at full speed
Ir
Table
z
1 Remedy
Cause Malfunction of the pressure compensation valve
Replace (Replace the pressure compensation valve of the smaller load side) Weplace
Combination
of compound
as the valve stack assembly.)
operations
Larger load side
1
Boom raise + Arm in
Boom raise
2
Boom raise + Arm out
Arm out
3
Boom raise + Bucket curl
Boom raise
4
Arm out + Bucket curl
Arm out
5
Boom lower + Arm out
Arm out
20-362 0
H-13, H-14, H-15
TROUBLESHOOTING
H-13 In swing + boom RAISE operation, Ir
When the machine
works normally
in independent
boom RAISE movement operations
of swing and boom UP.
Malfunction
H-14 In travel + swing operation, When the machine
of the LS se-
works normally
travel speed drop is excessive
in independent
operations
of swing and travel. Cause
H-15 In travel + work equipment drop is excessive *
When the machine and travel.
Repair or replace
lect va’ve
/
Ir
is slow
works normally
(boom RAISE) operation,
in independent
operations
Remedy
travel speed
of the work equipment
Cause
Malfunction
(boom
UP)
Remedy
of the pres-
~$t~~~~~~~~~a,$ve (Pressure compensation valve for travel)
Repair or replace
20-363 0
H-16
TROUBLESHOOTING
H-16 Vehicle curves unintentionally
during travel
*
When the speeds of the work equipment
and swing are normal
a)
Curves to the same side in both forward
and backward
travel Cause
3 YES
YE
Defective final drive
F3epair or r eolace
t
boes the pressure compensation valve of the curving side move smoothlv?
berween output presswes of the left and right travel PPC
I3efective pressure corn. sensation valve, or mal. -I iunction of the pressure (:ompensation valve
F7epair or r eplace
-[
I3eplace
valves normal?
* Output pressure difference for totWard and backward travel: 0.2MPa (2kg/cm2jN or lower. * Enaine at hiah idlhg. Travel relief.
Iefective travel PPC valve
Is the lever of the
-t
NO
I4djustment
failure of the ! I4djust ravel lever linkage damp :r
l
From “A” -
5 YES When the left and right hoses between the control valve and the swivel are interchanged.does 6 YES the vehicle curves to the opposite diIs the drain rection? amount of the NO travel motor nor- mal? * Max. 5Umin. * Engine at high idling. . Travel relief.
20-364 0
NO
Iefective control valve ;pool
FIepair or r eolace
FReplace the swivel joint gar ,- ,yasket, or replace the assembly Defective travel motor internal leakage, brake, Repair or counterbalance valve, replace I or check valve 3efective ket
TROUBLESHOOTING
b1 Curving
H-16
side is different
for forward
and reverse travel
YES Does the contorol valve spool at the slower side move smoothly? NO
Fig. 1 Location
of defective
swivel joint packings
and direction
Defective swivel joint gasket
Repair or replace
Malfunction of the control valve spool
Repair or replace
of travel deviation
Forward Rioht
forward
onlr
I Reverse Riaht
\
reverse
left Reverse
forward
and
forward
Forward Left
reverse
only
TI
(Drain)
Al
(Rioht forward)
B,
(Rioht reverse)
C,
(Left forward)
D,
(Laft reverse)
El
I Reverse
Forratd _ Rioht
forward
right
reverse
Left
forward
left
reverse
(Travel seeed)
and
f
Forward
Reverse
and / Reverse
Bottom Direction in forward
of deviation and reverse
is
defferent
Direction in forward
of deviation and reverse
is
same
TDP00987
20-365 0
H-17, H-18
TROUBLESHOOTING
H-17 Travel deviation *
is larger at starting
When the travel speed is normal (However, in case the travel deviation occurs also in normal travel, carry out the troubleshooting the section H-16 “Vehicle curves unintentionally during travel” first.)
F= Cause
2 YES IS the phenomenon ys Is the phenomenon interchangedwhen the left and right has- _ es between the swivel joint and rhe nomr ars interchanged? f Refer to the section of TESTING AND ADJUSTING.
interchayed whenthe left and r~ ht hoses _ between(1 e comrol valveandthe swivel joint are interchanged? NO
LO
in
Remedy
Malfunction of the control valve spool
Replace the control valve assembly
Defective swivel joint gasket
Replace the gasket, or assembly
Defective travel motor (Malfunction of the travel countervalance valve)
Replace the motor assembly
H-18 Travel speed is low, or lacks of power Ir *
When travel deviation does not occur. (In case the travel deviation occurs also, carry out the troubleshooting in the section H-16 “Vehicle curves unintentionally during travel” first.) When the work equipment speed is normal.
Remedy
Cause
2
~~
I
- 24.5*i.r’MPa (250 ::‘kg/cm’). - Engine at high idling.
20-366 0
I
YES
Defective PC valve
Replace
Refer to the troubleshooting for the engine (S)
-
Defective main relief valve, or adjustment failure of the main relief valve
Adjust or
H-19
TROUBLESHOOTING
H-19 Steering operation
is difficult
Cause
2 YES
Both sides
L
NO
YES RI
One side only
Defective travel motor servo piston or center swivel joint
Repair or replace
Malfunction of the travel speed select solenoid valve
Repair or replace
Defective pressure compensation valve or malfunction of the pressure compensation valve
Repair or replace
Malfunctron of the suction velve of the control valve
Repair or replace
defective check valve of the travel motor
Replace
j=H-
- 2.9 z 0.5MPa (30 f 5 kg/cm’) * Engine at high idling.
for both left and
Remedy
become normal when the left and right pressure compe”SatlO” valves
4YES when the sucdon valves of the control valve are inter(Low, High )
.
.
20-367 0
TROUBLESHOOTING
H-20
H-20, H-21
Travel speed cannot be switched
I YES
1
Is the output pressure of the travel speed select solenoid valve normal7
Cause
Remedy
Malfunction of the travel speed select servo piston of the travel motor
Replace
Malfunction of the travel speed select solenoid valve
Repair or replace
-
NO - 2.9 + 0.5 MPa (30 + 5 kg/cm’) *Travel speed select switch at Hi. *Travel switch ON. - Engine at high idling.
H-21 Travel does not work (one side only) Remedy
YES
r
3 YES
ters come out of the fimal drive
Defective final drive
iepair or eplace
Malfunction of the suction valve of the control valve
leplace
Malfunction of the counterbalance valve
leplace
NO - Max. 5 e /min. . Engine at high idling. - At travel relief.
20-368 0
‘so.LL_
travel motor
teplace
H-22
TROUBLESHOOTING
H-22 Does not swing (both sides, one side only) a)
Does not swing to either left or right Remedy
Cause
3 YES
Defective ery
swing
machin-
Repair or replace
Defective swing holding brake or swing motor
Repair or replace
Defective operation of swing brake solenoid valve
Repair or replace
Defective swing sure switch
Replace
YES eH-2 Is output pressure of swing - brake solenoid 1 valve normal?
L
YES ,_ Are two of swing oil pressure switchs normal7
-
-
* 2.9 + O.SMPa (30 f 5 kg/cm? NO + Operate swing lever. * Turn swina lock switch ON flock). Engine at high idling. l
NO
b)
oil pres
Does not swing in one direction
Cause
1 YES Is swing oil pressure switch normat?
Remedy
To ‘A’
Defective swing 5ure switch
3 -II
YES
oil pres-
leplace
Defective swing motor safety valve
leplace
Defective operation of control valve spool
lepair or eplace
Defective PPC valve
Ieplace
YE 2
From ‘A‘
put pressure no-
0.5 MPa * Operate Swing lever. . Turn swing lock switch ON flock). * Engine at high idling.
20-369 0
H-23
TROUBLESHOOTING
H-23 Swing acceleration
is poor
2 YES 7
Both sides {Ftl
NO
6 YES 1Does the condition 1 r
YES
I;ri$ioroneside
41
. Engine at high idling.
YES -
-
One side only -
Is the output pressure of the PPC valve normal? . 2.9 * 0.5MPa (30 + 5 kg/cm? * Enaine at full speed. . Swing lock switch ON (LOCK).
%
When there is not an adapter to block the circuit. Hose of the PPC valve exchange hose of swing for hose of arm (in and out) or boom (raise), and then operate reverse.
20-370 0
-
Is the output ressure of the FPC valve tat shuttle block
I
* Conditions are same as the item5. % Remove the inlet NO hose of the PPC shuttle block, fit an adapter and block the tip. NO
H-23
TROUBLESHOOTING
Remedy
Repair or replace
Defective pressure pensation valve
com-
Defective swing motor safety valve
Replace
Replace
Defective swing motor suction valve
.~I
zam;;o,;
of the control
Repair or replace
of the PPC Connect or Malfunction replace shuttle valve (for swing)
Defective PPC valve
20-371 0
TROUBLESHOOTING
H-24
H-24 Excessive overrun when stopping swing (both sides, one side only) a)
One direction
only
Cause
2 YES t Is woblem
b)
re-
Both directions
I
Cause Defective
20-372 0
swina
motor
I 1
Remedy
Defective PPC valve
Replace
Defective swing motor safety valve
Replace
Defective operation of control valve spool
Correct or replace
I I
Table 1
1
I
Remedv ReDair or replace
I
H-25, H-26
TROUBLESHOOTING
H-25 Excessive shock when stopping swing (one direction only)
I
I
Cause
I YES
1
Rem-b
I
Defecttve PPC valve
Replace
Defective operation of control valve spool
Correct or replace
Does contorol valve spool move smoothly’ NO
6 z
z
H-26 Excessive abnormal
noise when stopping swing (one direction
only)
I YES
Remedy
Cause
Defective swing motor safety valve
Replace
Defective swing motor suction valve
Replace
Defective en/
swing
machin
Repair or replace
Defective
back
pressure
1
YES 2 oes condition ecome normal rhen suction
_
A NO
3 YES Is dirt found in swing machincry?
-
7
:
Repair or
va’ve
.
20-373 0
I
H-27
TROUBLESHOOTING
H-27 Excessive hydraulic drift of swing (when the swing brake is relased or activated) a)
When
the swing
brake is released
I 2 YES
One side only -
Is the phenomenon reversed when left and right safety valves are interchanged? NO
3 YES Is the drain Both sides
-
Of the motor normal?
atTIOUt’It
* 7 e /min. * Engine at high idling. * At swing relief.
b)
When the swing
1
Cause
Defective swing motor safety valve
Replace
Defective swing motor suction valve
Repair or replace
Defective oil tightness of the control valve spool
Replace
Defective swing motor
Repair or replace
-
NO
brake is activated Cause
1 YES Is the output pressure of the swing brake sole- noid valve normal?
NO * 0.2 + 0.2 MPa (2 t 2 kg/cm? Swing lock switch ON (LOCK). * Engine at high idling. l
20-374 0
Remedy
~rdfmtiOn
of the
Remedy
SWhg
Repair
or
replace
Malfunction
of the swing
_ brake solenoid valve
Repair or replace
1
H-28, H-29
TROUBLESHOOTING
H-28 Swing speed is faster than the specified speed
Cause
Malfunction valve
of the LS
Remedy
3place
H-29 Blade speed is slow, or lack of power h
+
When the work equipment,
travel and swing speeds are normal.
Remedy
F== 1
YES
Is the leak amount of the blade cylinder normal? NO - Max. 15cc/min. * Engine at high idling. - Release it at the stroke end.
Defective blade valve (relief valve, safety valve)
Adjust or replace
Defective blade cylinder piston gasket
Replace
20-375 0
H-30, H-31
TROUBLESHOOTING
H-30 Blade does not move *
When the blade is operated
independently
Cause
Remedy
Defective PPC valve
Defective control valve
Malfunction of control valve spool
Replace
Replace
Correct or replace
H-31 Excessive hydraulic drift of the blade Cause
1
YES
Is the leak amount of the blade cylinder normal? - Max. 15cc/min. NO - Engine at high idling. - Release it at the stroke end.
20-376 0
Defective oil tightness of _ the blade valve spool
Defective blade piston gasket
cylinder
Replace
Replace
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) Electric circuit diagram of the machine monitor systme . ... ............... ..... ............. .......... .. ... .... ... ........ 20-402 M-l No indicator lamp lights up when the starting switch is turned ON 20-403 (Bsecond self-check is not carried out either) ..................................................................... M-2 All the lamps remain lighting-up after 3-second self-check completed after the starting switch turned ON .............................................................................................. .20-403 Some lamps do not light up during self-check (all lamps lights up for 3 seconds) M-3 20-404 upon starting switch ON ........................................................................................................ a) All gauge lamps do not light up (caution lamp does light up) ................................... .20-404 b) Swing lock, auto-greasing failure or preheat does not light up (all gauge lamps light up) .............................................................................................. .20-404 c) Charge caution lamp does not light up ........................................................................ .20-404 d) Engine oil pressure caution lamp does not light up.. .................................................. .20-404 M-4 When turning ON the power (before engine starting), charge caution lamp 20-405 does not light up .................................................................................................................... M-5 When turning ON the power (before engine starting), engine oil pressure 20-405 caution lamp does not light up. ............................................................................................ M-6 At preheating, preheating indicator does not light up.. ..................................................... .20-406 M-7 Though the switch is operated, swing lock does not light up ............................................ 20-406 M-8 While engine running, engine oil pressure caution lamp lights up 20-407 (engine oil pressure is normal) ............................................................................................. Charge caution lamp lights up while engine running.. ...................................................... -20-407 M-9 .20-408 M-10 Abnormality in engine water temperature gauge .............................................................. a) Indicator remains in the lowest level (white range) and does not rise 20-408 after engine started. ........................................................................................................ b) Level rises immediately after starting the engine. Indicator goes in the red range though overheat does not occur. ............................. .20-408 c) Engine water temperature gauge lamp goes off ......................................................... .20-408 20-409 M-11 Abnormality in fuel gauge ..................................................................................................... a) All segments of the fuel gauge go off.. ......................................................................... .20-409 b) Fuel gauge indicates FULL though the level is low ..................................................... .20409 c) Fuel gauge does not indicate FULL though the tank is full ......................................... .20-409 20-411 M-12 Malfunction of the buzzer ...................................................................................................... 20-411 a) Buzzer does not sound .................................................................................................... b) Buzzer does not stop sounding ..................................................................................... .20-411 M-13 Service meter does not work while the engine is running ................................................ .20-412 a) When the charge caution lamp does not light up.. ...................................................... .20-412 b) When the charge caution lamp lights up, refer to the item M-9. ................................ .20-412 M-14 Auto-greasing abnormality alarm lights up (Auto-greasing controller is normal). ......... .20-412 20-413 M-15 Illumination does not light up ............................................................................................... a) Illumination at gauge section does not light up. ......................................................... .20-413 b) Illumination at the service meter section does not light up 20-413 (Service meter itself do work normally) ........................................................................ 20-414 M-16 Heater does not work ............................................................................................................. 20-414 a) Both Hi and Lo do not work ............................................................................................ 20-414 b) Lo only does not work ..................................................................................................... 20-414 c) Hi only does not work .....................................................................................................
Pc60-7
20-401 0
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM Serial No. : 52374 - 57999 CN-P44
(SWPB) Windor rasher Eoom(u~)slonrl switch Strrtine
sitnr
..
h
)
CN-BR ,Tl
6
Horn
TAP009aa
20-402 0
FC60-7
TESTING AND ADJUSTlNG
ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM
Serial No. : 58001 and up
Boo swi Window rasher
Diode
Wiper
switch
-I
Room
I IlD
A.yX
p7 Coolant sensor
I
Start
Glow
temp.
in0
mot
simal
DI
I
TXPOZI
20-4020
68
1
M-l,
TROUBLESHOOTING
M-2
L.
M-l
* Ir
No indicator lamp lights up when the starting switch is turned ON (3-second self-check is not carried out either) Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
F
Cause
YES 1 Is the voltage between Pl tfemale) (1) (2) and (3) (4) normal? * Starting switch ON. * 20 - 3ov.
2 YES
j Is the fuse2 nor,_ mal (not blown NO off)? 6
-
Remedy
Defective monitor panel
Replace
Breaking wire or connection failure in the wire harness between Pl (1) (2) - fusel, or between Pl (3) (4) - H2 (2) chassis ground
Repair or replace
Blown-off fuse
Check for cause or fuse blown off, and replace the fuse
NO
M-l
Related electrical
circuit
CN-nl I CN-Pl c To the
Monitor
battery
relay
Panel
TAP00989
M-2 * * *
All the lamps remain lighting-up after 3-second self-check completed after the starting switch turned ON
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Check the fuse before this troubleshooting.
Cause
-
Defective monitor panel
Remedy
Replace
20-403 0
M-3
TROUBLESHOOTING
M-3
Some lamps do not light up during self-check (all lamps lights up for 3 seconds) upon starting switch ON
* * *
Before carrying out this troubleshooting, check for engagement failure at relating Before proceeding to the next step, make sure to restore removed connectors. Check the fuse before this troubleshooting.
a)
All gauge lamps do not light up (caution lamp does light up)
connectors.
Cause
Remedy
Iefective monitor panel
teplace
Defective light bulb
leplace
Iefective monitor panel
leplace
breaking wire in the :harge caution bulb
leplace
breaking wire in the !nglne oil pressure :aution bulb
Ieplace
failure or preheat does not b1 Swing lock, auto-greasing light up (all gauge lamps light up) 1 YES Is there breaking wire in the bulb of the item that ;o;s not light P *Visual check for breaking wire in bulbs.
c)
-
NO
Charge caution
lamp does not light up
1 YES
- Visual check for breaking wire in the bulb.
d)
Engine oil pressure 1
caution
lamp does not light up
YES
Is there breaking wire in the bulb 7 To the item M-5 - Visual check for breaking wire in the bulb.
20-404 0
NO
M-4, M-5
TROUBLESHOOTING
M-4
*
When turning ON the power (before engine starting), charge caution lamp does not light up
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Check for the breaking wire in the bulb (lamp) before this troubleshooting.
* t
YES 1 Is the voltage between Pl (10) and Pl (3) normal? * Starting switch ON. - o-5v.
2 YES Is the voltage between R-terminal M5 of the afterna- tor and the chassis ground normal?
NO
Starting switch ON. lo-5v.
Remedy
Defective monitor panel
Replace
Breaking wire or contact failure in the wire harness between Pl (10) - Hl (7). M5 (alternator R-terminal)
Repair or replace
Defective alternator
Replace
NO
l
Related electrical circuit
M-4
I
Cause
CN-P -
I
CN-Hl I\
terfiinal CN-M5
I
TAP00990
M-5
When turning ON the power (before engine starting), engine oil pressure caution lamp does not light up.
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Check for the breaking wire in the bulb (lamp) before this troubleshooting. 2
-
Is the continuity YES between Pl ffe1 - male) (91 and Pl gay7aleale, (3) norIs the continuity between the terminal pl3 and the _ chassis ground normal?
* Starting switch ON. * 0 - 5R or lower.
M-5
* Disconnect Pl. * Starting switch ON. 0 - 5R or lower.
YES
Defective monitor panel
Breaking wire in the wire harness between Pl (9) Hl (10) -terminal P13
NO
l
Defective engine sor
No
Related electrical circuit diagram Monitor
Repair or replace
oil sen-
I
panel
Terminal
CN-P13
Hl (S16) @
Engine oil Pressure sensor
TXPO2159
PCoo-7
20-405 0
M-6, M-7
TROUBLESHOOTING
At preheating,
M-6 * + *
preheating
indicator does not light up
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. If the lamp does not light up also during the self-check upon power ON, refer to M-2. 1
YES
Defective monitor panel
Replace
Breaking wire or contact failure in the wire harness between Pl (female) (13) -TlO Matting switch Rl) or defective starting switch
Repair or replace
Is the voltage between Pl (13) and 13) normal?
. Set
the starting switch to the HEAT psition. -20 - 3ov.
M-6
Related electrical circuit diagram CN-Pl -
tCh-TIO @
Stkrtino
switch
RI
TAP00992
M-7
Though the switch is operated,
swing lock does not light up
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
1 * I
2 YES
Defective monitor panel
Replace
I Breaking wire or contact failure m the wire herness between Pl (female) (12) - Hl (9) - M4f3) - X5 (female) (1). or between X5 Warnale (2) - M4 15) chassis ground Defective switch
* ursconnect X3. Swing lock switch ON. l
M-7
electrical circuit diagram
swing
lock
Repair or
Rep,ace
Swine lock ssitch Ch-Hl
CM-X6 Monitor
oansl 5 ”
)W” CL-Y9 -., .._
III 0
nl/
I%I TAP00993
20-406 0
Pctm-7
M-8. M-9
TROUBLESHOOTING
.
While engine running, engine oil pressure caution lamp lights up (engine oil pressure is normal)
M-8 *
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
*
Remedy
Defective engine sure sensor
YES 1 Does the engine oil pressure cau- _ tion lamp go off7 * Remove the ter-
Are Pl Ifemale) (9) and the chas-
. ;t~;:~~~ngine,~o
;;ey70und
2 YES 4
insu-
NO . Continuity check between Pl (female) (9) and chassis ground. *lMR-mR.
oil pres-
Replace
Defective monitor panel
Replace
Wire harness between ter. minal P13 - Hl (10) - Pl (female) (9) touches the chassis ground
Repair or replace
Related electrical circuit diagram
M-8
Monitor
Panel
Terminal
I
I
CN-Pls 3
Hl (S16)
Pl (04Oi6)
1
Eneine Pressure sensor
a=
oil
TXPO2169
M-9 *
Charge caution lamp lights up while engine running
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
*
Cause
2 YES Is the voltage batwean Pl (female) (10) and (3) norma17
YES 1Is the voltage betwaan MI hnale) (1) (alternator R-terminail and the chassis
_ -
Engine l20-3ov. l
stmt.
No
Remedy
Defective monitor panel
Replace
Wire harnass between Pl (10) - Hl (7). M5 (alternator R-termmal) touches the chassis ground
Repair or replace
~~$f$$
Replace
ground normal? . Disconnect M5. Engine start. 20 - 3ov. l
* NO
,9”,“t~:ner~
l
M-9
Related electrical circuit diagram CN-Pl
CN-H
I
terminal CN-ML Q
Monttor
panel
Al ternatar R-terminal
. TAP00990
Pc60-7
20-407 0
M-10
TROUBLESHOOTING
M-10 * t
a)
Abnormality
in engine water temperature
gauge
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
Indicator remains in the lowest level (white range) and does not rise after engine started. Defective engine temperature sensor
YES 1) Level rises by one step, and finally all seg2 YES ments go off. p * Starting switch one step, and fiON. :t a short NO nallv all segConm ments go off. crrcun connector to P7 (female). * Starting switch ON. NO Make a shortcircuit between Pl (6) and (3).
water
Replace
Breaking wire or contac failure in the wire harnesr between Pl (female) (6) Ii1 (5) - P7 ffamale) (1) or batwaan Pl (female) (2) chassis ground
Repair or replace
Defective monitor panel
Replace
l
l
b)
Level rises immediately after starting the engine. Indicator goes in the red range though overheat does not occur. 2 YES
Defective monitor panel
Is the resistance YES value between P7 1 - (male) (1) and (21 normal? _
*Disconnect P7. * Engine start. * Resistance: 4kR or higher.
1earth normai? * Engine start. * O.lV or lower.
cl
_
NO
NO
Engine water temperature
* Starting switch -_. UN.
l
Disconnect P7
2 YES
* Disconnect Pl. Resistance: 1kR or higher.
Check and repair
Iefective engine :emparature sensor
Beplace
water
monitor panel
Nire harness between Pl female) (6) - Hl (5) - PI female) (1) touches the :hassis ground, or teaks
NO
l
M-10
eontact failure between Pl Ifemale) (3) - H2 (2) - chassis ground
hfactive
Is the resistance value between Pl (female) (6) and (3) normal?
1 NO
Replace
gauge lamp goes off
YES Does the lowest level lamp light up?
Defective engine water temperature sensor
Beplace
qepair or ,eplace
Related electrical circuit diagram CN-Ii1 W-P7
M-l Monitor
-
Coolrnt tenverrture
seneor
1
Mncl W-q
K
CN-HP rfr TAP00994
20-408 0
PC60-7
M-11
TROUBLESHOOTING
M-11 Ir Ir
Abnormality
in fuel gauge
Before carrying out this troubleshooting, check for engagement failure at relating Before proceeding to the next step, make sure to restore removed connectors.
connectors.
Cause
a)
All segments
of the fuel gauge go off. Ilefective fuel sensor Mode of braking wire )ut of order)
YES 1; Does the fuel gauge indicates FULL fall segments llight up)?
2 YES
-
* Starting switch ON. * Connect P5 ffemale1 and P6 h-nale). -Wait for about 1 minute.
Remedy
Does the fuel _ gauge indicates NO FULL fall segments llight up)?
_
is
qeplace
3reaking wire or contact ‘ailure in the wire harness aetween Pl (female) (7) -13 (6) - P5 (female), or betNeen P6 (male) -chassis around
3epair or .eplace
Defective monitor panel
Seolace
Defective monitor panel
Replace
&%e harness between Pl [female) (7) - H3 (6) - P5 [female) (1) touches the chassis ground
Repair or replace
Defective fuel sensor
Replace
Contact failure in Pl ffemale) (3) - HZ (2) -chassis ground
Check and repair
Defective monitor panel
Replace
Contact failure between Pl (female) (3) - H2 (2) chassis ground
Check and repair
Defective fuel sensor
Replace
*Starting switch ON. NO * Make a short-circuit between Pl (7) and (3). Wait for about 1 minute.
l
b)
Fuel gauge indicates
FULL though
the level is low 3 YES
between P{(3) and the chassis ground normal?
-
* Engrne start. * O.lV or lower.
* Remove the sensor. * Moving the float by NO hand, measure the resistance between P5 (male) and P6 (female). *At position F: 1OQ or higher. . At position E: 85R or higher. NO
c)
Fuel gauge does not indicate
FULL though
YES 1 TIs the resistance value of the sensor normal?
_ 2 YES
-
Is the voltage
* Measure the reg$farkfeFc$s;rsNO
between Pl (3) and the chassis ground normal?
(female). . At postion F: 10R or lower.
= Engine start. * O.lV or lower.
the tank is full
NO
20-409 CD
M-11
TROUBLESHOOTING
M-l 1
Related
electrical
circuit diagram
Ck-Pl Monitor
ch-HJ
CN-P6
Dane1
TAP00995
20-410 0
TROUBLESHOOTING
M-12
M-12
Malfunction
of the buzzer
t Ir
Before carrying out this troubleshooting, check for engagement failure at relating Before proceeding to the next step, make sure to restore removed connectors.
a)
Buzzer does not sound
connectors.
Cause
YES
Defective monitor panel
1 When Pl (female) (15) and (3) are connected. does the buzzer sound?
* Connect Pl (fe;;fe’ (15) and * Start ing switch ON.
b)
Breaking wire or contact failure in the wire harness between P4 (female) (1) Pl (female) (151, or defective buzzer
-
2 YES :
Is the voltage between P4 (2) N~-J and chassis ground normal? * Start ing switch ON. * 20 - 3ov.
_
Breaking wire or contact failure in the wire harness between fuse2 - P4 (female) (21
NO
Remedy
Replace
Pepair or replace
PePair or raPface
Buzzer does not stop sounding Cause
YES
Defective monitor panel
Remedy
Replace
Does the buzzer when Pl IS dis-
, - Disconnect
Pl. * Starting switch ON.
Ml2
NO
Related electrical
Wire harness between P4 (female) (lb- Pl (female) (15) touches the chassis ground
circuit diagram CN-P4 Monitor
Buzzer
Panel
To the
battery
relay
TAP00996
20-411 0
1
TROUBLESHOOTING
M-13 +
M-13, M-14
Service meter does not work while the engine is running
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
*
When the charge caution
al
1
Remedy
Cause
lamp does not light up
YES Defective monitor panel
Replace
Breaking wire or contact failure in the wire harness between Pl (10) - H7 M5 (alternator R-terminal)
Repair or replace
Is the voltage between Pl (female) (10) and (3) mormal? NO
* Engine start. * 20 - 3ov.
b)
When the charge caution
M-13
Related
electrical
lamp lights up, refer to the item M-9.
circuit diagram CN-PI
CN-Hl
terminal CN-M6
TAP00990
M-14
* *
Auto-greasing ler is normal)
abnormality
alarm lights up (Auto-greasing
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. ,
Is the voltage between Pl (11) and Pl (3) normal? * Start ing switch ON. * 18 - 30V.
YES
2 YES Is the voltage between P44 (4) NO and the chassis ground normal? * Start ing switch ON. * 18 - 30V.
M-14
Related
Cause
electrical
NO
Remedy
Defective monitor panel
Replace
Breaking wire or contact failure in the wire harness between Pl (11) - Hl (13) P44 (female) (41
Repair or replace
Refer to the troubleshooting of the auto-greasing controller
Replace
circuit diagram CN-Pl
CN-Hl
ch-P44 Auto-ereasino
controller
TAP00997
20-412 0
control-
M-15
TROUBLESHOOTING
M-15
Illumination
does not light up
* *
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
a)
Illumination
at gauge section does not light up.
Breaking wire in the illumination lamp (inside the monitor panel)
YE 1 Is the voltage between Pl Hemale) (16) and (3) normal?
L_
Starting switch i ON. Light switch ON. * 20 - 3ov.
l
l
z w
b)
Illumination
Breaking wire or contact failure in the wire harness between Pl (female) (16) - P2 (female) (3)
2
1Is the voltage . between P?(3) / and the chassis ground normal?
11
Repair
or
replace
_ 3 YES
Is the voltage * Starting switch _ between P2 (4) NO and the chassis ON. * Light switch ON. ground normal? .20 - 3ov. * Startina switch ON. * 20 - 3ov.
Defective light switch
Breaking wire in the wire harness between P2 (female) (4) - fuse4, or blown-off fuse
NO
I
Replace
Repair or replace
at the service meter section does not light up (Service meter itself do work normally)
Cause
-
M-15
Replace
Defective monitor panel
Remedy
Replace
Related electrical circuit diagram To the work
Monitor
Iieht
Dsnsl a>J
Lioht
To the battery
srltch
relay TAP00998
20-413 0
TROUBLESHOOTING
M-16 *
M-16
Heater does not work
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
t
a)
Both Hi and Lo do not work 2 YES Is the continuity between P3 (4) and the body earth?
:ES Are continuities of the heater switch (between male _ terminals of P3) as shown in Table 17 * Starting switch ON. * Disconnect P3. Table
_
* Starting switch OFF.
NO
Defective heater switch
NO
Terminals of continuity
position
1 1
Lo Hi
Between
(3) - (4)
Between
12) - (4)
Remedy
Cause
Lo only does not work 2
Is there continuity between P3 (male) (3) and (4)7
_
. Disconnect P3. * Starting switch OFF. - Heater switch Lo.
YES
Is the continuity between Ml2 (fe- _ male) (2) and the body earth?
:E”
c)
Breaking wire or contact failure in the wire harness between P3 (female) (4) - body earth
1
Switch
b)
Refer to the troubleshooting of the heater
Disconnect M12. * Starting switch OFF. * Heater switch Lo.
l
NO
NO
Refer to the troubleshooting of the heater
-
Breaking wire or contact failure in the wire harness between P3 (female) 13) - Ml2 (female) (2)
Repair or replace
Defective heater switch
Replace
Refer to the troubleshooting of the heater
-
Hi only does not work 2 :E”
, Is there continuity between P3 (male) (2) and (4)? * Disconnect P3. - Starting switch OFF. Heater switch Hi.
_
YES
Is the continuity between Ml2 (fe- _ male) (3) and the body earth? * Disconnect M12. * Starting switch OFF. * Heater switch Hi.
NO
NO
Breaking wire or contact failure in the wire harness between P3 (female) (2) - Ml2 (female) (3)
Repair or replace
Defective heater switch
Replace
l
M-16
Related electric circuit diagram CN-p3
cN-~12
CN-ti2 TAP00999
20-414 0
TROUBLESHOOTING OF AUTO-GREASING SYSTEM (D MODE)
D-l
[Alternate
blinking of [El and [a]] Abnormality
in pump pressurization
D-2
[Alternate
blinking of [El and [bll Abnormality
in depressurization
[Alternate
blinking of [El and [cl] Abnormality
in pressure
D-3
[Alternate
blinking of [El and IO]] Abnormality
in controller
D-4
Abnormal
sound is generated
is displayed
on the monitor
from the work equipment
panel and greasing
controller
....... ..20-45 2
is displayed.
detection
is displayed.
........... ..20-45 4
setting is displayed.................20-45
pin, though
controller..
is displayed..
no abnormality
..................................................
goes off ...........................................................................
D-5
All LEDs on the greasing
D-6
Pump does not run even though the start-up
4
switch is pressed.. .........................................
20-456 20-458 .20-458
20-451 0
TROUBLESHOOTING
D-l
D-l
[Alternate blinking of [El and [all Abnormality tion is displayed
in pump pressuriza-
When disconnecting the connector for troubleshooting during this abnormality is occurring, if [El and [a] do not blink alternately any more when the start-up switch is turned ON after reconnecting the connector, the problem has been corrected. In case the starting switch is turned OFF once after the trouble occurred, turn ON the starting switch and the start-up switch, and confirm that [El and [al blink alternately (if not, the trouble has been corrected). Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. YES
leakage from the main piping or cnnections?
‘ES
4-l 3
NO
Is there grease leakage from the mating face of the distributor valve?
4
I Is ttte greasecar- 1
1
Is there grease remaining in the grease cartridge?
NO
tridge loosening due to insufficient tightening? I
YES
r
After
N
i
~~~~N~~~~ PONENT OF AUTOGREASING SYSTEM” in the “TESTING AN0 ADJUSTING’.
20-452 0
D-l
TROUBLESHOOTING
Remedy
Cause
-I
I.oosening in joints, ‘ective main piping
or de or nip
7ghten the Dints, or replace
I3le
IDefective
distributing
valve
I nsufficient tightening 01 t he rease cartridge ‘Re Ber to the section of. ‘AIR BLEEDING FROM EACH COMPONENT OF AUTO-GREASING SYSTEM’ in the ‘TESTING AND ADJUSTING’
9 YES Is the voltage
yES
8
-
ween
YES _
7
-
Is the reistance value between (1) and (2) of the pressure detecting switch normal?
Is there
continuity
between
(2) and
l
-
(3) of the motor? -
-Startingswitch
. Max. 1R. * Turn OFF the starting switch once NO and turn it ON again, then turn ON the starvup switch. . Disconnect the connector for the pressure detecting switch.
OFF.
and
pump leakage)
-
normal?
NO * 20 - 3Ov. * Turn ON the starting switch, and then turn ON the start-up switch. NO
Tightening Bir bleeding
bet-
(21 and (3) of
the motor
i I3efective tinternal
seplace
- IIefective
qeplace
controller
IDefective
pump Breaking wire or contact failure in the motor or
I the wire
Defective pump Breaking wire or contact failure in the pressure detecting switch or the wire harness
deration
in the main
Aeration
in the pump
IEmpty
Replace
harness
grease
pipng
cartridge
qeplace
-
-
Replace
20-453 0
D-2, D-3
TROUBLESHOOTING
[Alternate blinking of [El and [bll Abnormality IS displa ed. [Alterna Ye blinking of [El and [cl] Abnormality IS displayed.
D-2
Ir Ir
* Ir
in depressurization in pressure detection
When disconnecting the connector for troubleshooting during this abnormality is occurring, if this error code is not displayed when the connector is reconnected, the problem has been corrected. In case the starting switch is turned OFF once after the trouble occurred, turn ON the starting switch and confirm the error code (if the error code is not displayed, the trouble has been corrected). Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Cause
2 YES
Defective controller
Remedy
Replace
YES !s the depressuriz, - mg spool indicator mormal? Is the resistance value between (1) _ . Refer to the section NO and (2) of the of ‘CONFIRMATION METHOD pressure detecting OF THE DEPRESSURIZING switch normal? SPOOL INDICATOR’ in the ‘TESTING AND ADJUSTING’ * Max. 1MQ. : ~~;/~;~;t;
,o,Nn:NO
Defective pump lD&,;tive depressurizing
Replace
Defective pump pot;tive depressurizing
Replace
nectar for the pressure detecting switch.
D-3 *
* Ir
[Alternate blinking of [El and [O]] Abnormality IS displayed
in controller
setting
In case the starting switch is turned OFF once after the trouble occurred, turn ON the starting switch and confirm that alternate blinking of [Eland [Ol is displayed (if not displayed, the trouble has been corrected). Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
1 YES
I
Replace
Reset
20-454 0
TROUBLESHOOTING
in, Abnormal sound is enerated from the work equipment though no abnorma 9ity is displayed on the monitor pane Pand greasing controller.
D-4
* *
D-4
Before carrying out this troubleshooting, check for engagement failure at relating Before proceeding to the next step, make sure to restore removed connectors.
connectors.
YEiS
I
YES 6
2
1Is there YE S
grease leakage from the piping
J
there any crush in
1
the greasing troller
con-
correct?
Does
YES
Does grease
YES
the lateral
YE
grease port?
hose under
20-456 al
-
side of
-20 - 3ov. * Boom RAISE
-
relief.
NO
piping?
I. - Supply grease by a grease gun to the fitting of the distributing valve.
I
NO
come
* Start-up switch ON. * Disconnect the pump.
out of the delivery port of the distributing valve, or is the delivery amount of the distribting valve
bet-
P44 (5) and
come
out of the end of the bearing
ween
(2) normal?
5
out of the pump delivery
Is the voltage -
the
* Start-up
ON.
switch
NO
8 w
D-4
TROUBLESHOOTING
4
Remedy
Cause
I
7 YES
Incorrect setting
Is there clogging -
in the grease
hole
-
of the bushing?
NO
,I
Refer to the section of ‘CHANGING PROCEDURE OF SETrING VALUES OF THE GREASING CONTROLLER’ in the ‘TESTING AND ADJUSTING’ Defective breaking
(female)
~1~~
Aeration
1 Defective
Modification I
Pressure switch, or wirs or contact fai-
. $~“~$e,f~$,~~$~
6
Replace
Defective bushing
p&
Replace
(5) in the lst?ral Piping
jBleeding 1Replace
distributing
Replace
Incorrect setting Refer to the section of ‘CHANGING PROCEDURE OF SElNNG VALUES OF THE GREASING CONTROLLER’ in the ‘TESTI ING AND ADJUSTING’
Reset
I
20-457 0
D-5, D-6
TROUBLESHOOTING
D-5
All LEDs on the greasing controller goes off
When a T-adapter is inserted after disconnecting a connector, or when the connector is replaced after disconnecting the T-adapter for troubleshooting during the trouble is occurring, if all LEDs light up for a short period and the lamp m at the bottom right of the 7-segment LED blinks, the trouble has been corrected. In case the starting switch is turned OFF once after the trouble occurred, turn ON the starting switch and confirm that all LEDs and the lamp at bottom right of the 7-segment LED go off. (if all LEDs light up for a short period and the lamp mat the bottom right of the 7-segment LED blinks, the trouble has been corrected.) Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Cause
2
.
NO
Max.10.
* Disconnect P44 and Hl.
D-6
YES
Defective controller
Remedy
Replace
Defective controller fuse
Replace
Breaking wire or contact failure in the wire harness between P44 (female) (1) - Hl (female) (14). or P44 (female) (6) - Ii1 (female) (41
Replace
Pump does not run even though the start-up switch is pressed.
When a connector is replaced after disconnecting it for the troubleshooting during the trouble is occurring, if the pump starts to work when the start-up switch is pressed, the trouble has been corrected. In case the starting switch is turned OFF once after the trouble occurred, turn ON the starting switch and confirm that the pump does not work. (if the pump does work, the trouble has been corrected.) Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
Cause
1
YES
Are the voltagesbetween 12)and (3) of the mot&. and bet- _ w*en (1) and I21of the pressuredetecting switchnormal? * 20 - 3ov. *Start-up switch ON.
20-458 0
Defective pump
Defective controller NO
Remedy
Replace
D-l, 2,3,4,
TROUBLESHOOTING
D-l, 2,3,4,
5, 6 Related electrical
5,6
~reas~no
ch-i’44
CIRCUIT
DIAGRAM
circuit diagram ch-s4
Auto
RELATED ELECTRICAL
controller
(xi?)
Boom RAISE
~ressurc
switch
Chassis around
(swP6)
Monitor
_-f-Y
Black
Panel
..v L
TAP01000
20-459 0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................30-3 PRECAUTIONS WHENCARRYING OUT OPERATION ...................................... 30-4 SPECIAL TOOLLIST ................................. 30-6 SKETCHESOFSPECIAL TOOLS ..............30- 9 *STARTING MOTOR Removal and Installation ....................... 30- 12 *ALTERNATOR 30- 13 Removal and Installation ....................... * FUEL INJECTION PUMP Removal .................................................. 30- 14 Installation .............................................. 30-16 *WATER PUMP Removal and Installation ....................... 30- 18 * NOZZLE HOLDER 30- 19 Removal and Installation ....................... *THERMOSTAT Removal and Installation ....................... 30- 20 *ENGINE OIL COOLER CORE 30- 21 Removal .................................................. Installation .............................................. 30- 22 CYLINDER HEAD Removal .................................................. 30- 23 Installation .............................................. 30- 28 ENGINE. MAIN PUMP Removal .................................................. 30- 31 Installation .............................................. 30- 37 RADIATOR. HYDRAULIC COOLER Removal .................................................. 30- 38 30-40 Installation .............................................. FUEL TANK Removal and Installation ....................... 30- 41 CENTER SWIVEL JOINT Removal .................................................. 30- 42 30- 43 Installation .............................................. Disassembly and assembly ...................30- 44 SPROCKET Removal and Installation ....................... 30- 45 TRAVEL MOTOR Removal and Installation ....................... 30- 46 Disassembly and assembly..................30-46-2
SWING MOTOR. SWING MACHINERY Removal and Installation ....................... SWING MOTOR Disassembly ........................................... Assembly ............................................... SWING MACHINERY Disassembly ............................................ Assembly ................................................ REVOLVING FRAME Removal .................................................. Installation .............................................. SWING CIRCLE Removal and Installation ....................... IDLER. RECOIL SPRING Removal and Installation ....................... RECOIL SPRING Disassembly ............................................ Assembly ................................................ IDLER Disassembly ............................................ Assembly ................................................ 61 TRACK ROLLER Removal and Installation ....................... Disassembly ............................................ Assembly ................................................ 66 CARRIER ROLLER Removal and Installation ....................... TRACK SHOE Removal and Installation ....................... HYDRAULIC TANK Removal .................................................. Installation .............................................. MAIN PUMP Removal .................................................. Installation .............................................. 73 MAIN PUMP INPUT SHAFTOIL SEAL Removal and Installation .......................
30- 47 30-47-1 30-47-5 30- 48 30- 51 30- 54 30- 55 30- 56 30- 57 30- 58 30- 59 30- 60 3030- 63 30- 64 3030- 68 30- 69 30- 70 30-71 30- 72 3030- 74
The items marked with* shall be applied to only machines. serial Nos . 52374 - 57999 (with 4D102E-1 engines).
PC60-7
30- I
8
CONTROL VALVE Removal .................................................. 30- 75 Installation .............................................. 30-76 Disassembly ............................................ 30- 78 Assembly ................................................ 30- 82 MA1N RELIEF VALVE Disassembly and assembly ...................30- 86 SOLENOID VALVE Removal and Installation ....................... 30- 87 WORK EQUIPMENT LEFT SIDE PPC VALVE (FOR ARM. SWING CONTROL) Removal and Installation ....................... 30- 88 WORK EQUIPMENT RIGHT SIDE PPC VALVE (FOR BOOM. BUCKET CONTROL) Removal and Installation ....................... 30- 89 WORK EQUIPMENT PPC VALVE (FOR BOOM. ARM. BUCKET. SWING CONTROL PPC VALVE) Disassembly ............................................ 30- 90 Assembly ................................................ 30- 91 TRAVEL PPC VALVE Removal and Installation ....................... 30- 92 Disassembly and assembly ...................30- 94 BOOM CYLINDER Removal .................................................. 30- 96 Installation .............................................. 30- 97 ARM CYLINDER Removal .................................................. 30- 98 30- 99 Installation .............................................. BUCKET CYLINDER Removal .................................................. 30-100 Installation .............................................. 30-101 BLADE CYLINDER Removal .................................................. 30-102 Installation .............................................. 103 30HYDRAULIC CYLINDER Disassembly ............................................ 30- 104 Assembly ................................................ 30-107 WORK EQUIPMENT Removal .................................................. 30-110 Installation 1 .............................................. 11 30BUCKET Removal .................................................. 30- 11 2 30- 113 Installation .............................................. ARM Removal .................................................. 30- 114 Installation .............................................. 11 30- 5 BUCKET ARM Removal .................................................. 30- 11 6 Installation .............................................. 30- 117 BOOM Removal .................................................. 30-118 Installation .............................................. 119 30BLADE Removal and Installation ....................... 30-120 OPERATOR'S CAB Removal and Installation ....................... 30-121
30-2
8
COUNTERWEIGHT Removal and Installation....................... MONITOR Removal and Installation....................... SWING CONTROLLER Removal and Installation....................... AUTO-GREASING CONTROLLER Removal and Installation....................... AUTO-GREASING PUMP Removal and Installation.......................
30- 122 30- 123 30- 123 30- 124 30- 124
PC60-7
DISASSEMBLY
METHOD
AND ASSEMBLY
OF USING
MANUAL
METHOD OF USING MANUAL 1.
When removing or installing unit assemblies (1) When removing or installing a unit assembly, the order of work and techniques used are given operation is not given. for the removal operation; the order of work for the installation and the procedure are marked a, 12) Any special techniques applying only to the installation same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF 0 0 0 0 ASSEMBLY . . .. .. . .. . . . Trtle of operation . .. . . . .. .. . . .. . . . . .. .. . . .. .. . .. .. . . .. . . . . .. . . . . . . .. . . . . . .. . .. .. . . Precautions related to safety when carrying out the a operation (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operation XxXx 1. when * .. . . . .. .. . . .. .. . . . . .. . .. . . . . . . . . . . . . . . . . . . . .. . .. . . . . . .. . . . . . . . Technique or important point to remember removing XXXX (1). is listed for use durIndicates that a technique (2) . .. . .. . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. .. . . . . .. . a 2. AAAA 3.
ing installation J U U U assembly (3) b . .. . . . .. . . . .. . .. .. . . . . . . ... . . . . . . . . .. . . . .. . . .. . .. . .. . . . See Lubricant and Coolant .(.
Table
OF 0 0 0 0 ASSEMBLY.... Title of operation INSTALLATION . Carry out installation in the reverse order to removal. .... .... ........ ............. ..... ......... ... .... Technique used during installation p . . . .. ... . . . .. ... . .. .. . .. .. . . . .. . . . . . .. . . . . . .. . . . . . . . . . . Technique or important point to remember installing AAAA (2). . Adding water, oil . . . . .. .. . . . .. . .. .. .. . . . . . . .. . . Step in operation * . . . . .. . .. . .. .. .. . .. . . . .. . . . . .. . . .. .. . . .. . . .. . . .. . .. . . . . Point to remember when adding water or oil Q
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity
when
when filling with oil and water of or assembly) so be sure to fol-
2.
(disassembly or removal precautions when carrying out installation General WHEN CARRYING OUT OPERATION, units are given together as PRECAUTIONS low these precautions when carrying out the operation.
3.
Listing of special tools (1) For details of the description, part number, and quantity of any tools (Al, etc.) that appear in the procedure, see the SPECIAL TOOLS LIST given in this manual. operation (2) The tools marked b in the SPECIAL TOOLS LIST are not available as an assembly. (31 Items listed as 79OT- 0000
- 0000
in the SPECIAL TOOL LIST are tools prohibited
for supply.
(4) The items marked in the Sketch Column of the SPECIAL TOOL LIST are special tools with sketches introduced in this Shop Manual, but Komatsu cannot accept any responsibility for special tools according to the sketch. manufactured
30-3 0
PRECAUTIONS WHEN CARRYING OUT OPERATION
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS
WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) general precautions given below when carrying out the operation.]
1. . . . . . . . . . .
*
of units, be sure to follow
the
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting 1) Hoses and tubes using sleeve nuts
it during disassembly
operations. 6
2)
Nommal number
Plug (nut end)
02
07376-50210
07221-202lO(Nut),07222-00210
03
07376-50315
07221-20315 (Nut),07222-00312
04
07376-50422
07221-20422 (Nut),07222-00414(Plug)
05
07376-50522
07221-20522(Nut),07222-00515(Plug)
06
07376-50628
07221-20628(Nut),07222-00616(Plug)
10
07376-51034
07221-21034(Nut),07222-01018
(Plug)
12
07376-51234
07221-21234(Nut),07222-01219
(Plug)
30-4 0
Usethetwo
Items belowasa
(Plug) (Plug)
Split flange type hoses and tubes Nommalnumber
3)
Sleeve nut(elbowend):
Sleeve headitubeend)
Hange(hoseend)
Split flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
If the part
is not under
hydraulic
pressure,
the following
corks can be used.
set
z
G
DISASSEMBLY
2.
-s.
PRECAUTIONS
WHEN
CARRYING
OUT OPERATION
Precautions when carrying out installation work lighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. . When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-PI. After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. . When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. . When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
*
3.
AND ASSEMBLY
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times in succession, stopping 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. * When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run Then check the water level again. the engine to circulate the water through the system. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment has been removed for repair, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. l
l
.
l
l
30-5 0
SPECIAL TOOL LIST
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST Tools with part number 79OT-000-0000 cannot be supplied (they are items to be locally manufactured). n .. . . . .. . . Cannot be substituted, should always be installed (used) Necessity: available 0 .. . . . .. . . Extremely useful if available, can be substituted with commercially part N .. . .. .. .. Tools with new part numbers, newly developed for this model New/remodel: R .. . . .. .. . . Tools with upgraded part numbers, remodeled from items already available for other models Blank . . . Tools already available for other models, used without any modification Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
Nature of work, remarks
Component Disassembly, assembly of swin machinery assemb 9 y
Disassembly, assembly of recoil sprrng assembly
Removal, hydraulic bly
IW lo
Compressor B
141
I
I
& installer IW 1 1 1
1
installation
of
B 790-101-1600
1791-616-1030 Removal, installation track shoe assembly
Removal, collar
Push tool
Remover
of
installation of pump assem-
01 2 11 ( 796T-297-1110
Push tool
Ml
lo Replacement
of oil seal for pump shaft
Multi-wrench
Wrench assembly Disassembly, assembly of hydraulic cylinder assembly
E
Socket across Socket across Socket across Socket across
(width flats: 80) (width flats: 70) (wrdth flats: 60) (width flats: 65)
Expander
30-6 0
n
I
1 III
n
’
n
l
n n 1.1
installation
1 1
11
/
of
DISASSEMBLY AND ASSEMBLY
Nature of work
SPECIAL TOOL LIST
T
Symbol
Part No.
t 5
Part Name
!;
New ske
Uv A
796-720-l 670
Ring
0
1
07281-01279
Clamp
0
1
796-720-1660
Ring
0
1
07281-01159
Clamp
0
1
796-720-l 650
Ring
0
1
07281-01029
Clamp
l
I
790-201-1702
Push tool KIT
n
1
790-201-1811
l
Push tool
1
790-101-5021
l
Grip
1
01010-50816
- Bolt
1
790-201-1702
Push tool KIT
790-201-1781
l
Push tool
1
790-101-5021
l
Grip
1
01010-50816
l
Bolt
1
790-201-1702
Push tool KIT
790-201-1771
l
Push tool
1
790-101-5021
l
Grip
1
01010-50816
l
Bolt
1
790-201-1702
Push tool KIT
790-201-1791
l
Push tool
1
790-101-5021
l
Grip
1
01010-50816
l
Bolt
1
790-201-1500
Push tool KIT
790-201-1620
l
Plate
1
790-101-5021
l
Grip
1
01010-50816
l
Bolt
1
790-201-1500
Push tool KIT
790-201-1610
l
Plate
1
790-101-5021
l
Grip
1
1 Bolt
I Ill
Nature of work, remarks
tch
Blade
_ Boom, arm
Installation of piston ring
Bucket
Blade
6
r0
;;
sf
Disassembly, assembly of hydraulic cylinder assembly
E
)
Imi1)
,B
Arm
Press fitting of coiled bushing
1 Bucket
11 Boom
.
I
n
1
,
Blade
1
7
Boom 1 01010-50816
pi
l
Insertion of dust seal
I I Bucket
.
30-7 0
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
Nature of work, remarks
Nature of work
Disassembly, assembly of hydraulic cylinder assembly
I
I
790-201-1500
I Push tool KIT
Insertion of
E
I I
Removal, installation of work equipment assembly
I 790-441-1810 I *Sleeve 1-2 I 792-900-1530 I Screw 1-1
1-3
1
Washer
1
240 Adapter
1
1-4 01643-33080 Removal, installation of boom assembly
Removal, installation of fuel injection pump assembly Removal, installation of nozzle holder assembly
1-5
I I c u
796-900-1
I I l l lo I Ill I
Nut
01803-13034
F
Removal, installation of engine cylinder head assembly
I I
11.1
Pulling out of boom foot pin
I 790-101-4000 I Puller (50ton long) I I 1 I I I 790-101-1102 I Pump I Ill I
2
3
Wrench (angle 110tightening wrench)
Tightening of cylinder head bolt
1
790-331-1
2
795-799-1130
Gear
.I
Barring
1
795-799-1390
Puller
I.
Removal of drive gear
2
795-799-1130
Gear
.I
Barring Pulling out of nozzle holder
H
795-799-1
170Puller
I.
1
790-501-5200
Unit repair stand
1
2
790-901-2110
Bracket
1
Plate
1 1
3790-901-1371 790-901-1 390
4
2
1
Plate
I 799-301-1600 I Oil leaktester KIT I I 1 I I
Disassembly, assembly of swing motor
0 0
Disassembly, assembly of motor
t
Pulling out brake piston
Removal, installation of cylinder block spring
Press fitting of oilseal Press fitting of main bearing outer race I
6
30-8
8
I
796-126-1 140
Push tOOI
1
Push tool kit No. 790-1 - 01 5001
I
Press fitting of main
0 bearing inner race
PC60-7
DISASSEMBLY SPECIAL AND ASSEMBLY
Nature of work
Symbol
PC60-7
I
P 8
Part No. 796-126-1
7 Disassembly, assembly of swing motor
TOOL LIST
Part Name 130Push tool
01435-00816
Bolt
Commercially available
Torque wrench
Nece-
ssiv
New’Ske Nature of work, tch remarks Press fitting of sub bearing inner race Measurement of 1 turning torque of drive shaft 1
Q’V
mriel
30-8-1
8
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note:
A.
Komatsu cannot accept any responsibility sketches.
for
special tools
manufactured
according
to these
Push tool
/ fU’
___________-
3
1 ! v)
a;
JO
CAP03570
l-J-d B2.
MATERIAL
HEAT TREATMENT
STKM13A
Spacer
4
0. 5
_ L
200
co.5
-I CAP03571 MATERIAL
HEAT TREATMENT I
STKM13A
4
30-9 0
DISASSEMBLY AND ASSEMBLY
D2-1.
SKETCHES OF SPECIAL TOOLS
Push tool
E
e
---
CI
c2
1 I cy d .7-Z
_-
=:
Cl
s
=
I L
Cl
CAP03572
D2-2.
Spacer
I -_. eo. co. CAP03573 HEAT TREATMENT
MATERIAL s43c
I
PART NAME SPACER
Q’TY I
790-201-2730 A
30-10 0
1
DISASSEMBLYAND ASSEMBLY
Fl-1.
SKETCHES OF SPECIAL TOOLS
Sleeve
z CAP03574
03
PLATE
SS41P
1
02
HANGER
SS41B
1
01
PIPE
STKM13A
SYM.1 PART NAME
i MATERliL
HEAT TREATMENT
MATERIAL I
K60-7
1 1 (IWISET
SEE DWG
30-l 1 0
@
2
I
2 2
?
W
269
r
lr
w
L 1 185
190 130
285
I
-I
544
1
W
0
P
75. 25-75. 75 -
b
88.9-89. ' 7 2 2. 5 - 7 2 7. 5
3
:1 r
-
W
0
..
OF SPECIAL TOOLS
DISASSEMBLY ANDSKETCHES ASSEMBLY
P3-3. Washer a
-P
rr
DWPOl633 TREATMENT HEAT MATER
I AL SS400B
796T-266-1120 P4-1.Push
A
tool
0 Lo
8
-
l
b
v 30-11-3
8
DWPO I634
I
TREATMENT HEAT
I
796T-266-1110
MATERIAL SS400B
A PC60-7
OF SPECIAL TOOLS
DISASSEMBLY AND SKETCHES ASSEMBLY
P4-2. Spacer
A I
B
W
N . w .
3
w -
0
I
__
I
coco
.
.
LDLD
co.
5
co.
5
i
co. 5
i 1
i
I
100
co. 5
DWPOl636 1225001400
7 9 0 - 2 10 - 2 7 2 0 P6.Push
a
tool
LD
I
/
/I
1 LD
cu
W 0
e - 0 I O 0 %
a
LD
D i
N
-a
\
1
a 1
c1. 5-
5
I
100
I
DWPO1636 HEAT TREATMENT 1124001900
MATER I AL
STKMl7A
PARTNAME
I PC60-7
PUSH TOOL
796-126-1140
A 30-11-4 @
>
->
i
4.
-1421.
3-421. 7
DISASSEMBLY AND ASSEMBLY
STARTING MOTOR
REMOVAL OF STARTING MOTOR ASSEMBLY Serial No. : 52374 - 57999 Disconnect the cable from the negative(-) terminal of the battery.
1. Open engine hood.
2. Remove stating motor side cover(1). 3. Disconnect 4 wirings (2) . 4.
Remove 2 mounting bolts (3).
5.
Remove starting motor assembly(4).
INSTALLATION OF STARTING MOTOR ASSEMBLY Serial No. : 52374 - 57999 Carry out installation in the reverse order to moval.
re-
Starting motor assembly mounting bolt: 43 f 6 Nm (4.38 f 0.61 kgm)
30-12 @
PC60-7
ALTERNATOR
DISASSEMBLV AND ASSEMBLY
REMOVAL OF ALTERNATOR ASSEMBLY Serial No. : 52374 - 57999 A
Disconnect the cable from the negative H terminal of the battery.
1.
Open engine hood.
2.
Remove fan guard (11, then remove fan (2) and move towards radiator.
3.
Disconnect 2 wires (3). Ir Before disconnecting the wiring, fit tags to distinguish the mounting position.
4.
Remove clamp (4) of heater hose.
5.
Using wrench 0, raise tensioner (5) and remove fan belt (6). A
6.
I
Be extremely careful not to get your fingers caught when removing the belt.
Remove alternator mounting bolt (7) and spacer m (8).
7. Remove mounting bolt (9) of alternator mounting plate, then remove alternator assembly (IO). m
CBP02805
INSTALLATION OF ALTERNATOR ASSEMBLY Serial No. : 52374 - 57999 l
Carry out installation in the reverse order to removal.
w
Alternator assembly mounting bolt (71, (9) : 43 f 8 Nm t4.38 4 0.61 kgm}
I
K60-7
”
.
CBP02807
FUEL INJECTION PUMP
DISASSEMBLY AND ASSEMBLY
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY Serial No. : 52374 - 57999 g
Disconnect the cable from the negative (-1 terminal of the battery. 1. Open engine hood.
2. Remove washer tank (I) together with bracket, and move towards main pump. 3. Remove oil filter assembly (2) together with If bracket, then move towards main pump. 4. Remove intake hose cover (31, then remove intake hose (4). 5. Remove fan guard (5). * Clamp (6) of the fuel control cable is also tightened with one of the fan guard mounting bolts.
6. Disconnect fuel control cable (71, then remove together with bracket (81, and move towards radiator. * When disconnecting, check the position of the lever mount hole. 7. Disconnect 2 wires (IO) of engine stop solenoid assembly (91, and remove together with bracket (II). * The (+) and (-1 terminals of the 3 solenoid terminals are used. Spacers (12) are used on two of the bracket * a mounting bolts. 8. Disconnect fuel inlet hose (13) and return hose (14). Fuel will flow out when the hoses are discont nected, so insert wooden plugs in the hoses to prevent the fuel from leaking. 9. Remove lubrication tube (15). 10. Disconnect spill hose (161, then disconnect 2 tubes (17) between fuel injection pump and fuel filter 11 block. II.
Disconnect delivery tube (18).
30-14 0
m
I
Ii
7
CBPO2810
DISASSEMBLY AND ASSEMBLV
FUEL INJECTION PUMP
12. Using tool H2, rotate engine in normal direction, and push No. 1 cylinder compression top dead center positioning pin (19) into gear. + Push the pin lightly against the gear and rotate the engine slowly. + After determining the TDC position, check if the meshing of the timing pin has come out.
13. Remove bracket (20) at bottom of injection pump and bracket (21) at governor end.
14. Rotate cap (22) and remove, then remove washer (23) and nut (24). + Be extremely careful not to drop the nut and washer inside the case when removing.
22
15. Using tool Hl, pull drive gear of fuel injection pump, and loosen from shaft.
Pcoo-7
. CBPO2814
CBPO2815
DISASSEMBLYAND ASSEMBLY
FUEL INJECTIONPUMP
16. Remove 4 nuts (251, then remove fuel injection pump assembly
(26).
115)
NSTALLATION OF FUEL INJECTION PUMP ASSEMBLY Serial No. : 52374 - 57999 l
Carry out installation in the reverse order to removal.
a Ir
6
Coat one of the 3 mounting bolts (marked z in the diagram on the right) of the oil filter assembly bracket with gasket sealant. Oil filter assembly bracket mounting bolt : Gasket sealant (LG-7)
\
CRPO')AlA
a .
Length of mounting spacer (12) : Ll = 12.0 mm, L2 = 44.5 mm
m
‘pzJ
m
Tube eye joint (17) : 29.4 + 4.9 Nm (3.0 + 0.5 kgm)
m
Delivery tube sleeve nut (18) : 43 + 6 Nm (4.38 + 0.61 kgm)
.
Install the fuel injection pump assembly as follows. 1) Check that the No. 1 cylinder is at compression top dead center. Ir For details, see Removal Step 12. 2) Remove plug (271, then remove timing pin (28). 3) Reverse the position of timing pin (28), align the groove of the timing pin with pointer (29) inside the pump, then temporarily tighten plug (271. * If the tooth of pointer (29) cannot be aligned with the timing pin hole, rotate the shaft of the fuel injection pump to align the pointer tooth.
30-16 0
CBPO2620
CBPO282 1
Pc60-7
DISASSEMBLY AND ASSEMBLY
4)
Align pump camshaft with pump drive gear and install fuel injection pump assembly (26). then tighten nut (25). w Nut (25) : 43 + 6 Nm 44.38 + 0.61 kgm1
5)
Assemble washer (241, and tighten nut (23) temporarily. * Be extremely careful not to drop the nut and washer inside the case when installing. m Ir *
Temporary tightening of nut (23) : 12.5 + 2.5 Nm Il.27 + 0.25 kgm}
This is not the final torque value. To prevent damage to the timing pin, be careful not to tighten the nut to more than the above tightening torque.
6)
Remove meshing of engine timing pin (19).
7)
Remove plug (271, reverse position of timing pin (281, then assemble and install plug to fuel injection pump. QS
8)
Plug (27) : 14.7 Nm U.5 kgm1
Tighten drive nut (23) of fuel injection pump fully. w
9)
FUEL INJECTION PUMP
Nut (23) : 95 f 10 Nm (9.7 + 1.02 kgm1
For remaining installation, carry out in reverse order to removal. CBPO2825
Pcoo-7
30-17 0
WATER PUMP
DISASSEMBLY AND ASSEMBLY
REMOVAL OF WATER PUMP ASSEMBLY Serial No. : 52374 - 57999 1. Drain coolant.
2.
Open engine hood.
3.
Remove fan guard (I), then remove fan (2), and move towards radiator.
4.
Using wrench 0, raise tensioner (31, then remove fan belt (4).
Beextremely careful not to get your fingers caught when removing the belt.
A 5.
Remove tensioner (3).
a
6.
Remove water pump assembly (5).
a
INSTALLATION OF WATER PUMP ASSEMBLY Serial .
No. : 52374 - 57999
Carry out installation in the reverse order to removal.
w
Tensioner mounting bolt : 43 + 6 Nm 14.38 k 0.61 kgm)
QEI
Water pump assembly mounting bolt : 24 + 4 Nm t2.45 f 0.41 kgm)
If
l
Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
30-18 0
NOZZLE HOLDER
DISASSEMBLY AND ASSEMBLY
REMOVAL OF NOZZLE HOLDER
ASSEMBLY Serial No. : 52374 - 57999 Open engine hood. Disconnect delivery tube (1) at nozzle holder asa sembly end. m
Remove spill tube (2).
m Remove nozzle holder assembly (3). + If it is difficult to remove the nozzle holder assembly, use tool J to remove it. * Be careful not to let dirt or dust get into the nozzle holder assembly mount.
INSTALLATION
OF NOZZLE
HOLDER ASSEMBLY Serial No. : 52374 - 57999 l
CBP02831
Carry out installation in the reverse order to removal.
Delivery tube sleeve nut : 30 f 5 Nm (3.06 + 0.51 kgml
Joint bolt : 8 f 2 Nm IO.81 f 0.20 kgm}
Nozzle holder assembly : 60 + 9 Nm (6.12 + 0.92 kgm}
*
PC&7
Nozzle holder assembly thread portion : Seizure prevention compound (Molycoat 1000) When assembling the nozzle holder, clean the nozzle holder mount, and check that there is no dirt or dust inside the sleeve before assembling. Tighten the mounting bolts gradually in turn and be careful not to tighten unevenly.
I
30-19 0
DISASSEMBLY AND ASSEMBLY
REMOVAL Serial
OF THERMOSTAT
THERMOSTAT
ASSEMBLY
No. : 52374 - 57999
1. Drain coolant.
2.
Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR ASSEMBLY.
3.
Disconnect radiator inlet hose (1).
4.
Disconnect bypass hose (2).
5.
Remove alternator bracket (3).
6.
Remove thermostat housing (4).
7.
Remove thermostat (5).
CBP02832
INSTALLATION OF THERMOSTAT ASSEMBLY Serial .
.
No. : 52374 - 57999
Carry out installation in the reverse order to removal.
m
Alternator bracket mounting bolt: 24 * 4 Nm I2.45 ?I 0.41 kgm)
w
Thermostat housing mounting bolt : 24 + 4 Nm i2.45 + 0.41 kgm}
Refilling with water Add water through water filler to the specified level. * Run the engine to circulate the water through the system. Then check the water level again.
30-20 0
K60-7
ENGINE OIL COOLER CORE
DISASSEMBLY AND ASSEMBLY
REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY Serial No. : 52374 - 57999 1. Drain coolant. 2. Remove engine hood assembly. 3. Remove alternator assembly. For details, see REMOVAL OF ALTERNATOR SEMBLY. 4. Remove
muffler
drain pipe (I).
5. Remove fire prevention
cover (2).
6. Remove 4 nuts (4) of exhaust 7. Remove muffler fold pipe (3).
8. Remove
(5) together
intermediate
9. Remove exhaust
AS-
manifold
pipe (3).
with exhaust
mani-
clamp (6) of heater hose.
manifold
(7).
10. Disconnect 2 oil filter hoses (8) and remove hose clamps (3 places). Ir Remove the clamps at 3 places: 1 on the left side of the engine and 2 under the engine.
Pcoo-7
30-21 0
DISASSEMBLY AND ASSEMBLY
ENGINE OIL COOLER CORE
11. Remove engine oil cooler assembly (9) together with oil filter hose (8). a
12. Remove cooler core (10) from engine oil cooler assembly (9).
CBP02839
INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY Serial No. : 52374 - 57999 l
Carry out installation in the reverse order to removal.
m
30-22 0
Oil cooler assembly mounting bolt : 24 + 4 Nm (2.45 + 0.41 kgm)
FcbO-7
DISASSEMBLY
AND ASSEMBLY
CYLINDER
HEAD
REMOVAL OF CYLINDER HEAD ASSEMBLY a
Disconnect the cable from the negative minal of the battery.
1.
Drain coolant.
2.
Open engine
hood
assembly
(-)
ter-
(1).
I
I -
3.
Remove
muffler
4.
Remove fire prevention
5.
Remove 4 nuts (5) of exhaust manifold pipe (41, then remove muffler (6) together with exhaust manifold pipe. a
6.
Remove
7.
Remove water temperature sensor connector from oil filter assembly bracket (81, then remove oil filter assembly (8) together with bracket, and move towards counterweight. a
CBPO2840
drain pipe (2). cover (3).
7. =
5.- -
B-
intake hose (7).
I
30-23 0
DISASSEMBLY
CYLINDER
AND ASSEMBLY
8. Remove
fan guard (10).
9. Remove
fan (1 I) and move towards
10. Using wrench 0, raise tensioner fan belt (13). A
radiator.
(12), then remove
Re extremely careful not to get your fingers caught when removing the belt.
I
11. Remove
radiator
inlet hose (14).
12. Remove intermediate clamp, heater hose (15) and electrical wiring (16).
30-24 0
and disconnect intake air heater
HEAD
DISASSEMBLY
AND ASSEMBLY
13. Remove tensioner
CYLINDER
HEAD
(17) together with bracket (18). a
bolts of alternator holder 14. Remove 3 mounting bracket (19), then move alternator assembly towards partition plate.
15. Remove
exhaust
manifold
(20).
a
6 z I?
CBPO2849
16. Disconnect (21).
water temperature
sensor connector
17. Remove clamps (22) and (23) (2 places), then rem move delivery tube (24).
stop engine 18. Disconnect bracket (25) from head.
solenoid
mounting
19. Remove spill hose (26) and tube (27) between inm jection pump and fuel filter block. clamp (28), then remove 20. Remove intermediate tube (29) between fuel supply pump and fuel film ter block.
30-z 0
DISASSEMBLY
21. Remove
CYLINDER
AND ASSEMBLY
intake commector
22. Remove fuel filter assembly 23. Remove intermediate
(30).
(31).
clamp (33), (34) for spill tube
(32).
24. Remove
spill tube (35).
25. Remove nozzle holder assembly 26. Remove
head cover (37).
27. Remove rocker arm assembly *
(36).
m (38). Loosen the locknut and turn the adjustment screw back 2 - 3 turns.
30-26 0
HEAD
DISASSEMBLY
28. Remove
AND ASSEMBLY
CYLINDER
HEAD
push rod (39).
CBPO2856
bolts in order
29. Remove cylinder head mounting shown in diagram on right.
Intake
side
m
Q-Q-8
Exhaust
30. Lift off cylinder I+ kP
Cylinder
31. Remove cylinder
head assembly head assembly
side
DBP00511
(40).
: 36 kg
head gasket (41).
.
CBPO2858
30-27 0
DISASSEMBLY
AND ASSEMBLY
CYLINDER
HEAD
INSTALLATION OF CYLINDER HEAD ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
Exhaust manifold
w a +
pipe mounting nut (5) : 37 - 49 Nm (3.8 - 5 kgm)
Coat one of the 3 mounting bolts (marked % in the diagram on the right) of the oil filter assembly bracket with gasket sealant.
&
Oil filter assembly
m
Tensioner
w
CflPO281Fi
bracket mounting bolt: Gasket sealant (LG-71
bracket (18) mounting bolt: 24 _+4 Nm (2.45 _+0.41 kgm)
m *
Tighten the mounting bolts in the order (1) (8) shown in the diagram on the right. (20) mounting bolt : 43 f 6 Nm (4.38 + 0.61 kgm}
Exhaust manifold
Delivery tube (24) sleeve nut Fuel injection pump end : 43 f 6 Nm 14.38f 0.61 kgm} Nozzle holder end : 30 + 5 Nm (3.06 f 0.51 kgm} Joint bolt for tube (27) : 29.4 + 4.9 Nm (4.38 + 0.61 kgm}
Joint bolt for tube (29) : 29.4 _+4.9 Nm (4.38 _+0.61 kgm} Intake connector (30) mounting bolt: 24 + 4 Nm (2.45 + 0.41 kgm}
Lock nut for nozzle holder assembly (36) : 60 + 9 Nm I6.12 f 0.92 kgm) Nozzle holder assembly thread portion : Seizure prevention compound (Molycoat 10001
30-28 0
I
CEPO2922
DISASSEMBLY
m
CYLINDER
AND ASSEMBLY
HEAD
Head cover (37) mounting bolt : 24 f 4 Nm f2.45 f 0.41 kgml
pY-j1-z-iq p-iJ . Install the rocker arm assembly Ir
and cylinder head assembly as follows. Check that there is no dirt or dust on the cylinder mount surface or inside the cylinder.
Set cylinder head gasket (41) to cylinder block. t Check that the gasket is aligned with the holes in the block. Raise cylinder head assembly (40) and set to cylinder block.
1
1
Assemble push rod (39). 6 Add engine oil to the push rod socket portion.
-_. 4.
Fit rocker arm assembly (381, and tighten mounting bolts by hand. * Check that the ball portion of the adjustment screw is fitted securely in the socket portion of the push rod. & Put engine oil on the seat surface and thread of the 8 mm and 12 mm diameter mounting bolts.
I
.
30-29 0
DISASSEMBLY
AND ASSEMBLY
CYLINDER
Tighten cylinder head mounting bolts in order shown in diagram. & Put engine oil (SAE15W-40) on the seat surface and thread of the mounting bolts. m
Intake
Cylinder head mounting bolt : 1st step: Tighten all bolts in order @ - @ to 90 f 5 Nm (9.18 + 0.51 kgm). * Check in the same order that all the bolts are tightened to 90 * 5 Nm i9.18 + 0.51 kgm}. 2) 2nd step: For the long bolts (@I,@, 0, @), tighten further in order @ - @ to 120 + 5 Nm (12.24 & 0.51
HEAD
side
1)
Exhaust
kgm}. Check that the long bolts in Step (2) are tightened to 120 + 5 Nm I12.24 + 0.51 kgm1. 3rd step: i) When using tool G-l l Using angle tightening wrench (tool G-l), tighten bolts a further 90” in order @ -@. ii) When not using tool G-l l Make match marks with a felt pen on bolt head, then tighten bolt a further 90”.
side
nRPn”ri
*
3)
Tighten rocker arm assembly ameter: 8 mm). w
mounting
Cl POl6?0
bolts (di-
Rocker arm mounting bolt (diameter: mm) : 24 k 3 Nm I2.45 + 0.31 kgm)
Adjust valve clearance. For details, see TESTING justing valve clearance.
G-1
AND ADJUSTING,
marks
under
8
Ad-
Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.
and
head
bal
4 DKP00451
CLPOl522
30-30 0
II
ENGINE, MAIN PUMP
DISASSEMBLY AND ASSEMBLY
REMOVAL OF ENGINE, MAIN PUMP
ASSEMBLY Serial No. : 52374 - 57999
A A
1.
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (-1 terminal of the battery. Remove hydraulic tank strainer, then use tool Dl to stop oil. Ir When not using tool Dl, remove the drain plug, and drain the oil from the hydraulic tank and piping. -
t
Hydraulic
2.
Drain coolant.
3.
Remove
tank : Approx. 68 f?
engine hood (I).
CBPO2840
4.
Disconnect
hose (2) from reservoir tank.
2-
5.
Disconnect hose (3) of window wiring 14).
washer
tank and
sf’C60-7
CEPO2861
CBPO2882
30-3 1 0
DISASSEMBLY
AND ASSEMBLY
ENGINE,
6.
Remove counteweight assembly (5). For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY.
7.
Remove undercover cover under pump.
8.
Remove
9.
Remove starting
muffler
under
engine
MAIN PUMP
and under-
cover (6) and partition
plate (7).
motor side cover.
10. Remove cover (8) at intake hose portion, then remove intake hose (9) and intermediate clamp (10).
11. Disconnect
ground connection
( 11) from pump.
CBPO266f
30-32 0
PC60-7
DISASSEMBLY
AND ASSEMBLY
ENGINE,
12. Disconnect suction tube (12). LS pressure inlet hose (13), and LS pump pressure inlet hose (14).
main pump outlet hose (15), drain 13. Disconnect hose (16), mode selector pilot pressure hose (171, and blade sensing pilot pressure hose (18).
6 z z 14. Disconnect fuel control bracket (20).
cable (19) together
with
15. Disconnect 2 stop solenoid wires (211, water temperature sensor connector (22), and engine oil pressure sensor wiring (231, then remove intermediate clamps (24) (2 places).
16. Disconnect fuel supply hose (251, fuel return hose (261, and spill hose (27).
MAIN
PUMP
DISASSEMBLY
ENGINE,
AND ASSEMBLY
17. Remove fan guard (28).
18. Remove fan (29). and move towards
19. Using wrench 0, fan belt (31). (g
raise tensioner
radiator.
(30) and remove
Be extremely careful not to get your fingers caught when removing the belt.
20. Disconnect electrical intake air heater wiring (32) and heater hose (33), then remove intermediate clamp (1 place). 21. Remove
30-34 0
radiator
inlet hose (34).
MAIN PUMP
DISASSEMBLY AND ASSEMBLY
22. Remove ternator
ENGINE, MAIN PUMP
2 alternator wires (351, then remove assembly (36).
23. Remove
alternator
24. Remove
radiator
mounting
al-
bracket (37).
outlet hose (38).
25. Disconnect heater hose (39), then remove hose mounting elbow (40).
heater
39
26. Disconnect
30
CBPO2876
3 starting motor terminal C wiring (41). a
.
CBPO287
27. Disconnect and wiring
.
starting motor terminal connector (43).
B wiring (42) a
DISASSEMBLY
ENGINE,
AND ASSEMBLY
28. Sling engine and main pump assembly, loosen engine mount bolts (44).
and
29. Remove mount bolts, then raise engine and main pump assembly (45) slowly, and lift off. m Ir When removing the engine and main pump assembly, check that all the wiring and piping has been disconnected, and be careful not to hit any other parts when lifting off. I+ kg
30-36 0
Engine, main pump assembly
: 465 kg
MAIN PUMP
ENGINE, MAIN PUMP
DISASSEMBLY AND ASSEMBLY
INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY Serial No. : 52374 - 57999 l
Carry out installation in the reverse order to removal.
m
Starting motor assembly, terminal C mounting nut (dia.: 5mm): 2.5 - 3.0 Nm IO.25 - 0.31 kgml
w
B Starting motor assembly, terminal mounting nut (dia.: IOmm): 15.7 - lg.6 Nm (1.6 - 2.0 kgm)
*
Set the engine mount rubber as shown in the diagram on the right, then install the engine and main pump assembly.
@j
w
l
l
Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
Front
of
chassis
Rear
of
chassis DBP00512
Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Q
l
Engine mount mounting bolt: 277 +-31.9 Nm (28.25 +_3.25 kgml
Hydraulic tank : 68 k?(SAElOW-CD)
Bleeding air. Bleed the air from the fuel system. For details, see TESTING AND ADJUSTING, Bleeding air.
K60-7
30-37 0
DISASSEMBLY
ENGINE,
AND ASSEMBLY
MAIN PUMP
REMOVAL OF ENGINE, MAIN PUMP ASSEMBLY Serial No. : 58001 and up
a
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
a 1.
Disconnect the cable from the negative minal of the battery.
(-) ter-
Remove hydraulic tank strainer, then use tool Dl to stop oil. + When not using tool 01, remove the drain plug, and drain the oil from the hydraulic tank and piping. &
Hydraulic
tank : Approx.
68 i?
2.
Drain coolant.
3.
Remove
4.
Remove two heat insulation move muffler (2).
5.
Disconnect
6.
Disconnect following hoses from main pump. 0 Drain hoses (4) and (5) Mode selector solenoid pressure input hose (6) 0 Main pump discharge hose (7) LS pump pressure input hose (8) + LS pressure input hose (9) 0 Suction tube (I 0)
engine side cover. panels (I), then re-
air intake hose (3).
l
l
a
If oil is stopped with tool Dl and drain hoses (4) and (5) are disconnected, oil flows out. Accordingly, prepare plugs (07376-50628) in advance.
30-37- 1 0
PC60-7
DISASSEMBLY
AND ASSEMBLY
7. Disconnect
ground
8. Disconnect
two wires
PC60-7
wire
ENGINE,
(11) from
(12) from
main
MAIN
PUMP
pump.
alternator.
30-37-Z 0
DISASSEMBLY
AND ASSEMBLY
14. Disconnect
two engine
15. Remove fuel control bracket as one unit. 16. Disconnect
ENGINE,
stop solenoid lever
two starting
limit
motor
wires
switch
wires
17. Disconnect fuel control cable (22). + Before disconnecting this cable, ting dimension.
MAIN
PUMP
(19).
(20) and
(21). EG check its fit-
fuel feed hose (231, fuel return hose 18. Disconnect n (24), and spill hose (25). * If the fuel feed hose is disconnected, fuel flows out. Accordingly, prepare a wooden plug, etc. in advance. 19. Disconnect
two heater
20. Disconnect
radiator
hoses (26).
inlet hose (27) and outlet
hose
(28). 21. Remove
fan guard
(29).
air conditioner compressor assembly 22. Remove (OP) from engine assembly according to following procedure. * When removing compressor assembly after releasing refrigerant (R134a): I) Using tool X, release all refrigerant (R134a). 2) Disconnect two air conditioner pipes (37) from air conditioner compressor assembly (30). * When removing compressor assembly without releasing refrigerant (R134a): 1) Loosen two lock bolts (32) and one mounting bolt (33) of the air conditioner compressor to remove air conditioner compressor belt (34). 2) Remove air conditioner compressor assembly (30) and air conditioner piping together, then secure them out of engine with ropes, etc.
30-37-3 0
PC60-7
DISASSEMBLY
ENGINE,
AND ASSEMBLY
MAIN PUMP
tempo23. Sling engine and main pump assembly rarily and remove four engine mounting bolts 135). (36). 24. Lift off engine and main pump assembly * Check that the all wiring and piping have been disconnected and the assembly WIII not interfezwith the machine body and radiator. [kg/
Engine
and main
pump
assembly: 370 kg
INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY Serial No. : 58001 and up l
Carry out installation moval.
in the reverse
order
to re-
/ *
N
l
l
Adjust the fuel control cable. TESTING AND ADJUSTING, control cable.
l
see fuel
Fuel hose joint bolt : 29.4 t+ 4.9 Nm {3.0 i 0.5 kgml
Refilling with water Add water through water filler to the specified level. Run the engine to circulate thewater through the system. Then check the water level again. Refilling with oil (hydraulic tank) Add oil through oil filler to the specified Run the engine to circulate the oil through tem. Then check the oil level again. Hydraulic
l
For details, Adjusting
tank : 68 e (SAElOW-CD)
Bleeding air. Bleed the air from the fuel system. For details, see TESTING AND Bleeding air.
ADJUSTING,
Charging air conditioner with gas Using tool X, charge the air conditioner refrigerant (R134a).
PC60-7
level. the sys-
circuit with
30-37-4 0
DISASSEMBLY AND ASSEMBLY
RADIATOR, HYDRAULIC COOLER
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY Serial No. : 52374 - 57999
A
a
Lower ground oil filler side the
the work equipment completely to the and stop the engine. Then loosen the cap slowly to release the pressure inhydraulic tank.
Disconnect the cable from the negative minal of the battery.
(-1 ter-
1. Remove hydraulic tank strainer, then use tool Dl to stop oil. * When not using tool Dl, remove the drain plug, and drain the oil from the hydraulic tank and piping. -
:
Hydraulic
CBPO2833
tank : Approx. 68 t
2. Drain coolant. 3. Remove
engine hood.
4. Remove counterweight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY. 5. Remove cover (1) at intake hose portion. then remove intake hose (2) and intermediate clamp (31. 6. Remove 3 fuse connectors (4) from air cleaner bracket, then remove battery relay assembly (5).
7. Remove
air cleaner bracket (6).
PCBPO
12883
30-38 0
DISASSEMBLY
8. Remove
RADIATOR,
AND ASSEMBLY
frame
COOLER
(7).
\
hydraulic 9. Disconnect outlet hose (9).
cooler
inlet hose (8) and
10. Remove fan guard (IO). Clamp (11) of the fuel control cable is also * tightened with one of the fan guard mounting bolts.
11. Remove fan (121, then move it towards
PC60-7
HYDRAULIC
radiater.
,
I
CEPO2884
DISASSEMBLY AND ASSEMBLY
12. Disconnect radiator inlet hose (13)and outlet hose (14).
13. Sling radiator and hydrauliccooler assembly (151, then remove mounting bolts, and lift off radiator and hydraulic cooler assembly (15). + When raising the radiator and hydrauliccooler assembly, be extremely careful not to damage the core, and stop to remove the fan during the removal operation.
RADIATOR, HYDRAULIC COOLER
1 I II
I--
-
CBPO28
INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY Serial No. : 52374 - 57999 .
Carry out installation in the reverse order to removal.
.
Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
.
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. @
30-40 0
Hydraulic tank : 68 t (SAElOW-CD)
Pcoo-7
RADIATOR, HYDRAULIC COOLER
DISASSEMBLY AND ASSEMBLY
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY Serial No. : 58001 and up g
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
A
Disconnect the cable from the negative (-) terminal of the battery. 1. Remove hydraulic tank strainer, then use tool Dl to stop oil. Ir When not using tool Dl, remove the drain plug, and drain the oil from the hydraulic tank and piping. - :
li!L CBPO2833
L
I
Hydraulic tank : Approx. 68 t
2. Drain coolant. Remove engine hood. Remove CounterJveight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY.
CBPO2882
Remove 3 fuse connectors (4) from air cleaner bracket, then remove battery relay assembly (5). 6. Remove air cleaner bracket (6).
I-------b
I
CBPO2883
7. Remove frame (7).
' ' ' CBPO28184
Pc60-7
DISASSEMBLY
RADIATOR,
AND ASSEMBLY
8. Disconnect hydraulic outlet hose (9).
cooler
HYDRAULIC
COOLER
inlet hose (8) and
9. Remove fan guard (10). +r Clamp of the fuel control cable is also tightened with one of the fan guard mounting bolts. IO. Remove
fan (12), then move it towards
11. Disconnect
radiater.
radiator inlet hose and outlet hose .
12. Sling radiator and hydraulic cooler assembly (151, then remove mounting bolts, and lift off radiator and hydraulic cooler assembly (15). When raising the radiator and hydraulic cooler * assembly, be extremely careful not to damage the core, and stop to remove the fan during the removal operation.
INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY Serial No. : 58001 and up Carry out installation moval.
in the reverse
order to re-
Refilling with water Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Hydraulic
30-40-2 0
tank : 68 e (SAElOW-CD)
PC60-7
DISASSEMBLY
AND ASSEMBLY
FUEL TANK
c
REMOVAL OF FUEL TANK ASSEMBLY a
Disconnect the cable from the negative minal of the battery.
(-) ter-
+
Turn the chassis 45” to the right and lower work equipment completely to the ground.
1.
Drain fuel. -
:
Fuel tank : Approx.
130 !Z(when full)
2
2.
Open engine hood.
3.
Remove
handrail
4.
Remove
right side cover (2).
5.
Disconnect
the
I
(1).
2 fuel level sensor wiring connectors
(3).
f; ;3 z
6.
Disconnect
fuel return hoses (4).
7.
Disconnect
fuel return hose (5) at fuel tank end.
8.
Disconnect
fuel supply hose (6).
9.
Remove mounting sembly (7). LO rz?l
bolts, and lift off fuel tank asa
Fuel tank assembly
INSTALLATION ASSEMBLY l
Carry out installation moval.
CEPO289 I
: 55 kg
OF FUEL TANK in the reverse
order to re-
CBP02893
l
Thread
w
Fuel tank mounting bolt : 176.5 f 19.6 Nm (18 + 2 kgm}
Refilling
Ia .
of fuel tank mounting bolt : Thread tightener ILT- 2)
&
with oil (fuel tank) Fuel tank : Approx.
130 e (when full)
I
//
CBP02894
CENTER SWIVEL JOINT
DISASSEMBLY AND ASSEMBLY
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY a
*
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap of the hydraulic tank slowly to release the pressure inside the hydraulic tank.
3
Mark all the piping with tags to prevent mistakes in the mounting position when installing. 1. Disconnect
2 travel moter drain hoses (I 1.
2. Remove elbow (2). 3. Disconnect
4 right and left travel motor inlet and outlet hoses (3).
4. Disconnect
2 blade hoses (4).
5. Disconnect
2 travel motor speed
selector
hoses
(5).
6. Disconnect
upper side drain
hose (6) of swivel
joint.
7. Disconnect
hoses (7) between
control
valve and
swivel joint.
8. Remove swivel joint stopper bracket (8). 9. Remove
swivel joint mounting bolts (bottom), then raise center swivel joint assembly, and lift (m off center swivel joint assembly (9).
f CBPO2897
30-42 0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY . Carry out installation in the reverse order
CENTER
SWIVEL
JOINT
to re-
moval.
.
l
of swivel joint mounting bolt : Thread tightener (LT-2)
&
Thread
m
Swivel joint mounting bolt : 110.25 + 12.26 Nm (11.25 f 1.25 kgm)
Refilling with oil (hydraulic tank) t Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air + Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air.
.
30-43 0
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY ASSEMBLY
CENTER SWIVEL JOINT
OF CENTER SWIVEL JOINT
1.
Remove
cover (1).
2.
Remove
snap ring (2).
3.
Using tool 0, pull out swivel rotor (4) and ring (3) from swivel shaft (5).
4.
Remove snap ring (61, then remove and slipper seal (8).
oil seal (7)
CBP0357E
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1.
Assemble
2.
Using push tool 0, press fit oil seal (7) to swivel rotor (41, then install snap ring (6). &
3.
slipper seal (8) to swivel shaft (5).
Lip of oil seal : Grease (G2-LI)
Set swivel shaft (5) to block, and using push tool, tap swivel rotor (4) with a plastic hammer to install. * Be extremely careful not to damage the lip of the oil seal and slipper seal when installing the rotor.
COP03576
Yi!3f I
4.
Install ring (3) and secure with snap ring (2).
5.
Fit O-ring and install cover (1).
I
CLIP03577
30-44 0
DISASSEMBLY AND ASSEMBLY
SPROCKET
-
REMOVAL OF SPROCKET 1.
Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Swing work equipment 90” and jack up machine with work equipment, then set block 0 between track frame and track shoe.
3.
Remove mounting slightly.
4.
Set eyebolt and nut to mounting lift off sprocket (I 1. &I km
Sprocket
bolts, and pull out sprocket (1) a bolt hole, and
CBPO3578
: 25 kg
INSTALLATION
OF SPROCKET
ij
z
l
2
Carry out installation moval.
in the reverse
order to re-
m bolt : Thread tightener (LT-2)
&
Thread of sprocket mounting
w
Sprocket
mounting bolt : 205.8 + 19.6 Nm (21 k 2 kgm)
.
30-45 0
DISASSEMBLY
AND ASSEMBLY
TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR ASSEMBLY 1.
Remove sprocket. For details, see REMOVAL
a
OF SPROCKET.
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
2.
Remove
3.
Disconnect 4 travel motor hoses (2), then remove 4 nipples, and lift off travel motor assembly (3). a Ir Install blinds plug in the disconnected hoses. Ir Be extremely careful not to damage the nipple seal surface of the hose mount. &
kg
m
cover (I 1.
Travel motor assembly
: 95 kg
INSTALLATION OF TRAVEL MOTOR ASSEMBLY .
Carry out installation moval.
&
order to re-
Thread of cover mounting bolt : Thread tightener
(LT-2)
m
Cover mounting bolt : 65.7 + 6.9 Nm I6.7 + 0.7 kgml
6
Thread of travel motor mounting bolt : Thread tightener (LT-2)
m
Travel motor mounting bolt : 276.85 + 31.85 Nm (8.25 + 3.25 kgm}
Ir
.
in the reverse
Bleed the air from the travel motor (hydraulic tank). For details, see TESTING AND ADJUSTING, Bleeding air from travel motor.
Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-46 0
I
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
DISASSEMBLY. ASSEMBLY OF TRAVEL MOTOR GM09VL2
CONTENTS Safety
.................................................................................................................................................
30-46-3
Sectional drawing. single view drawing. and parts list Sectional drawing of assembly ....................................................................................................
30-46-4
Single view disassembly drawing of reduction gear assembly ................................................
30-46-6
.............................................. Single view disassembly drawing of hydraulic motor assembly
30-46-7
Parts list .........................................................................................................................................
30-46-8
TOOIS .................................................................................................................................................
30-46-9
Tightening torque ..............................................................................................................................
30-46-15
Weight table .......................................................................................................................................
30-46-15
Disassembly .......................................................................................................................................
30-46-16
Maintenance standard table.............................................................................................................
30-46-36
Assembly
...........................................................................................................................................
30-46-38
............................................................................ Dimensions table of clearance adjustment parts
30-46-60
Performance confirmation test.........................................................................................................
30-46-61
30-46-2
8
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
SAFETY TYPES AND MEANING OF WARNING TERMS The four warning terms shown in the following table are used in the maintenance manual according of expected accident). to the degreeof expected danger (or the scale an Understand the meaning of these warning terms and observe the instructions given together with these terms.
WARNING TERM
1 1
WARNING
I I
1
CAUTION
I
DANGER
MEANING This term means that there is an imminent danger and is used when neglecting the given procedure or instructioncan cause death or serious injury.
This term means that there is a latent danger and is used when neglecting the given procedure or instruction can cause death or serious injury.
This term means that there is a latent danger and is used when neglecting the given procedure or instruction can cause injury of medium or light degree or damage of equipment or devices.
This symbol is used to draw the reader’s attention or emphasize some information.
The terms of Danger and Warning do not appear in this maintenance manual, however.
PC60-7
30-46-3
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
SECTIONAL DRAWING, SINGLE VIEW DRAWING, AND PARTS LIST SECTIONAL DRAWING OF ASSEMBLY
127
130
123 126
173 137
121
A-A
I68 I52 I74 I44 I78 0-0 DWP02120
30-46-4
8
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
SINGLE VIEW DISASSEMBLY DRAWING OF REDUCTION GEAR ASSEMBLY 21
I
28
21 5
30
1
DWPOZ 122
30-46-6
8
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
SINGLE VIEW DISASSEMBLY DRAWING OF HYDRAULIC MOTOR ASSEMBLY
DWPOP I23
PC60-7
30-46-7 @
MOTOR
BLY AND ASSEMBLY TRAVEL DISASSEM
PARTS LIST Sym bc
Qtj
-
REDUCTION GEAR ASSEMBLY
1
Hub
1
2 3 19 37
Spindle kit Spindle assembly * * Spindle * * Hold flange Reamer bolt Expander
1 1 1 1 3 1
4 5 9 12 22 23
RV gear assembly RV gear kit * * RV gear A * * RV gear B Crankshaft Spacer Tapered roller bearing Needle roller bearing
1 1 1 1 3 6 6 6
6
Input gear
1
7
Spur gearkit Spur gear
1 3
8
Cover
1
10 31
F seal kit Distance piece Floating seal
1 1 1
11 14 15 16 17 18
Collar Distance piece Coupling Shaft Pin Ring
20
Snap ring t: Above 1.90 up to 1.95 k A t interval of 0.05> t: Above 2.45 up to 2.50
1
I
21 24 25 26 27 28 29 30 33
1 3 1 1 24 1
I
Ball bearing C-type snapfor shaft C-type snapfor shaft Steel ball O-ring O-ring O-ring O-ring Hexagon socket head plug
30-46-8 @
-
Part named
3
2 1 3 1 2 1 1 1 3
Sym bc
101 123 144 152 154 174 178 179 199
Part named
-
37)
HYDRAULIC MOTOR
1
Rear flange kit Rear flange Spool Hexagon socket headplug Plug Hexagon socket headplug O-ring Orifice Filter Nameplate
1 1 1 3
2 6
2 1 1 1
Shaft Swash plate Cylinder block
1
103 104
105 106
Piston kit Piston assembly Piston Shoe
1 9 1 1
107 108 109 110 112 113 114 115 116 121 124 125 126 127 128 130 132 135 136 137 139 141 142 143 145 149 150 151 153
Retainer plate Thrust ball Timing plate Washer Piston Spring Spring Friction plate Mating plate Plug Plug Spring retainer Plug Va Ive Spring Spring Oil seal O-ring O-ring O-ring O-ring Parallel pin Parallel pin Hexagon socket headbolt THS snap ring Deep groove ball bearing Deep groove ball bearing Roller Thrust plate
1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 1 1 2 2 1 2 2
161 162
Piston assembly b Piston b Shoe
1 1 1
102
1 1
8
8
1 1 1 3
1
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
TOOLS 1. Standard tools
Applicable parts (Index No.in structural/ disassembly drawing)
Name
TypeIStandard
Q'ty
126,143,121,152,33
Torque wrench
Nominal size: 1800, dial type
1
19,124,160
Torque wrench
Nominal size: 5600, dial type
1
33
Hexagon wrench
Nominal size: 8
1
126
Hexagon wrench
Nominal size: 10
1
152
Hexagon wrench
Nominal size: 6
126
Hexagon socket
Nominal size: IO, insertion angle: 12.7
143
Hexagon socket
Nominal size: 8, insertion angle: 12.7
1
124,160
Socket
Nominal size: 36, insertion angle: 12.7
1
19
Socket
Nominal size: 27, insertion angle: 12.7
1
124,160
Adapter
Insertion angle: 12.7 x 19.05
124,160
Spanner
Round strong spanner 36
1,165,21,11,132
Hammer
Nominal size: 12
8, IO, 102, 112
Plastic hammer
L = Approx. 300
1
24,25
Snap ring pliers
For shaft
1
20,145
Snap ring pliers
For hole
1
Center punch
$9.5 x 100
21
Pin punch
$ 4 150 ~
1, 2 for slinging products
Sling
Hook, wire rope
Cleaning of products and parts
Washing brush
1
Cleaning of products and parts
Wire brush
1
Draining of lubricating oil and hydraulic oil
Container
3
W450 x D300 x H I 20
Steel ball receiver For match marks
Paint marker
17
Wire netting basket
11
Rubber mat
149
Leather gloves
Supply of oil
Jug
33
Sealing tape
PC60-7
Vat for general use
1 set
White oil paint
1 2 pcs. 1 1 pair
For hydraulic oil and lubricating oil
2 1
30-46-9 @
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
2. Devices Applicable parts (Index No. in structural/ disassembly drawing)
Name
Type/Standard
Qty
of products
Work tablefor general use
Cleaning of products and parts
Cleaning tank
For rough cleaning and finish cleaning
1 set
104, 149
Press work table
Capacity of press: Min. 1.96 kN (200 kg}
1 set
149
Heating tank
Heating ability: Min. 100°C
1 set
Disassembly, assembly
1 set
Capacity: 500 x 500 x 500 1
Electric drill
Portable electric drill
1
(Max. drill diameter: $10) 1
Drill
1
161, 162, 163 for drying cleaned
Compressed air
Pressure: 294 - 490 kPa (3 - 5 kg/cm2}
products and parts Lathe
3
1 set
3. Measuring tools Applicable parts (Index No. in structural/ disassembly drawing) For adjustment of thickness
Name
TypeEtandard
Qty
Thickness gauge
Measurement range: 0.04- 0.3 mm
2
Outside micrometer
Measurement range: 0 - 25 mm Min. division: 0.01
1 1
of snap ring (20)
For adjustment of thickness of snap ring (20) For adjustment of preload on
Unit-type depth
Measurement range: 0 - 25 mm
ball bearincl (21)
micrometer
Min. division: 0.01
30-46-10 @
PC60-7
P
I
cn)
*I
I
P P
0
0
-
N
r
0
0
w
N 0 0
CTI 0
-
N 0 0
r
D
ID
P
N 0 0
r
0
m
P
0
-
N 0
r
0
P
ln
-
N 0 0
r
0
* r 0
0
2
-
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
TIGHTENING TORQUE
BoWNut to be used
Applicable part (Structural drawing)
I
19 33 124
I I I
126 143 144 121
I
Name
I
Reamer bolt
M20 P2.5 PT3/8
Plug
M30 PI.5
Hexagon socket head
bolt
Hexagon head socket
plug
I I I
M24 P1.5 M I 0 P1.5 PT1/8
27
I I I
M20
Plug
152
Plug
154
Hexagon socket headplug
Tightening torque (Nm (kgml)
flats(mm)
Nominal size
Hexagon socket headplug
Plug
Width across
I
41.16{4.2)
8
3.92 (0.4)
36
35.28 (3.6)
10 8
5
I I I
12.74(1.3) (0.59) 5.78 1.23(0.125)
26
GDL-1/16-S
5.88 (0.6)
6 PF1/4
2.94 (0.3)
4
0.98 (0.1)
WEIGHT TABLE Applicable part (Structural drawing)
Name
I 1 2 101 11.85 Rear
PC60-7
I
Travel motor assembly
Weight (kg)
I
Approx. 90 21.75
Spindle Hub
26.65
flange assembly
30-46-15
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
DISASSEMBLY 1. Preparation Beforedisassemblingthetravelmotor,prepare the following items. 1) Preparation of work table Preparea worktablefordisassembling the travel motor. The work table must beso strong that the internal parts of the travel motor can be disassembled and assembledon it and its top must beso wide that those parts can be arranged on it and will not move or fall during the work. Spread a rubber or vinyl sheet over the work table. 2) Preparation of tools and materials Prepare the tools and materials shown in the tool section.
2. General precautions for work Since the disassembled internal parts are coated with hydraulic oil, the are slippery. Take care not to let them slip down to hurt you or themselves. Combustible liquid suchas kerosene is used t o clean the parts. Handle it very carefully since it can cause a fire and a burn on you. Before disassembling the travel motor, consider the inspection items, characteristics of the detected trouble, etc. and then work according to the given disassembly procedure. Since the parts are made very precisely, handle them carefully. Take care not to hit them against each other or drop them. If a firmly fitted partis removed by hitting or prying it, it may have burrs or may be broken. As a result, it cannot be installed any more and the performance may be lowered by it. Work on such a part patiently. If the travel motor is left disassembled partly or perfectly, its parts may be rusted by moisture and dust. Accordingly, if it is obliged to interrupt the work, take rust-preventive measures and protect the parts from dust. When disassembling, make match marks on the matingfaces of the parts. Arrange the removed parts wellso that they will not be damaged orlost. Replace each seal once the travel motor is disassembled, as a rule. Accordingly, prepare the all replacement seals before disassembling.
30-46-16 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
3. Cleaning of travel motor 1) Tighten eyebolts into the mounting screw holes of spindle(2).
a
Install the2 eyebolts symmetrically into the mounting screw holes of the spindle.
2
2) Install wires to the eyebolts and sling the travel motor and carry into the cleaning tank. 3) Cleaneach part of the travel motor with a washing brush.
a
Since the space between hub (1) and spindle (2) (in which the floatingseal is installed) is filled with soil and sand, clean it very carefully.
CLZOO11i7
158
4.
Installation of travel motor 1) Install the travel motor to the worktable.
a
Matching the screw holes of hub (1) t o those of the worktable, insert the travel motor in the mounting hole of the worktable carefully.
1 CLZOO159
2)
Fix the travel motor to the worktable with two hexagon socket head bolts.
/
CLZOO160
PC60-7
30-46-17
8
TRAVEL MOTOR
DISASSEMBLY AND ASSEMBLY
5.
Draining lubricating oil 1) Turn over the travel motor. 2) Loosenhexagonsocketheadplugs(33)(3 pieces).
a
(33) are If the hexagon socket head plugs removed, oil flows out when the travel motoristurnedover.Accordingly , loosen them to the degree that they can be loosened with the fingers.
3) Turn over the travel motor. 4) Removehexagonsocketheadplugs(33)(3 pieces) from cover (8) and drain the lubricating oil.
a
When draining the lubricating oil, place a container under the worktable.
\
\
CLZOOf 6 2
6. Removal of cover 1) Turn over the travel motor. faces of hub 2) Make match marks on the mating marker. paint oil (1) and cover (8) withan
3)
Find out the closed gap of ring (18) and make at a point on outside a punch hole for drilling of the hub about20 m m inside from the end of ring (18).
30-46-18 G9
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
I
Closed.
gap
Cover
Ring
Hub
DWPO21 I 1
4) Make a hole 2 m m i n diameter with an electric drill from outside of hub (1) toward ring
z'
Apply the drill to the punch hole and make the hole straight until the ring is pushed by the ring and raised from the cover. Wipe off the metal chips made by drilling so that they will not stick to the parts to be disassembled.
5) Insert the steelbar in the hole to push out ring
X'
At this time, the tip of ring (18) is pushed out above cover(8).
0167
6) Hold the tip of ring (18) pushed up above cover (8) with the hands and remove ring (18) from (1). the ring groove of hub
PC60-7
30-46-19
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
7) Tighten the eyebolts for PT into the screw holes for hexagon socket head plugs (33) of cover (8). (2 places) 8) Install hooks and wires to the eyebolts for PT and lift off cover(8) with a crane.
a
If cover(8) cannot be removed easily because of theresistance of O-ring(29), hit its rim lightly with a plastic hammer when lifting it up.
9) Remove O-ring (29) from cover
a
(8).
Do not reuse removed O-ring (29).
7. Removal of input gear 1)RemoveC-typeshaftsnaprings shaft (1 6).
(24) f r o m
2) Remove input gear (6) from shaft (16).
3) Remove shaft (16) from coupling (15). 4) Remove steel ball (26) from shaft (16). 5) Remove coupling (15) from shaft (102).
30-46-20 @
PC60-7
MOTOR
DISASSEMBLY TRAVEL AND ASSEMBLY
8. Removal of rear flange 1) Turn over the travel motor.
a
The following work is executed to remove the plugs easily when the inside of the rear flange needs to be disassembled. At this time, loosen the plugs to the degree that they can be removed with the fingers. If the inside of the rear flange does not need to be disassembled, do not loosen the plugs. 2) Loosen plugs (124) (2 pieces). 3) Loosen plugs (126) (2 pieces).
a
I73 I
This work is executed to remove the plugs easily when the inside of the rear flange needs to be disassembled. If the inside of the rear flange does not need to be disassembled, do not loosen the plugs.
I174 I
4) Remove hexagon socket head bolts (143) pieces).
(8
00175
5) Remove rear flange (101) from spindle (2).
a
Hold therear flange with both hands and lift up straight carefully to remove. If it is pried forcibly or hitremove, to timing plate (109) may fall and may be broken.
6) Remove springs (113) (8 pieces).
176
PC60-7
30-46-21
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
7) Remove parallel pin (142) from spindle (2).
CLZOO I 7 7
8 ) Remove O-ring (30) from spindle (2).
a
9.
Do not reuse removed O-ring (30).
Disassembly of rear flange 1) Place rear flange (101) with the mating face for spindle(2) up. 2) Remove timing plate (109) from rear flange (101).
a
The timing plate may be fitted to the mating face of the rear flange because of oil and may not be removed easily. In this case, insert a spatula in the cast groove on the mating face of the rear flange and raise off the timing plate lightly. If a sharp tool such as a screwdriver is inserted between the mating faces, the matingfaces will be damaged and oilwill leak. Accordingly, do notuse such a sharp tool.
/
CLZOO179
\
/
3) Removeparallelpin(141)fromrearflange (101).
30-46-22 @
PC60-7
\
0
w
V
V
0
cn
)
0
0
-
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
2) Lift up rear flange (101) with the hole of the removed ring down, and stopper (164), spring (166), and valve (163) can be removed from the rear flange.
a
Remove ring (165) only when the pilot valve needs to be replaced. If ring (165) is removed, the hole is scratched. Accordingly, repair the hole carefully after removing the ring. Do not reuse the removed ring (165). If the above parts cannot be removed by lifting the rear flange with the hole down, apply compressed air gradually to the 2nd-speed selector port. If the compressed air is applied suddenly, the parts may jump out and may hurt you. Apply it gradually and carefully.
*
12. Removal of plug 1) Remove plug (152) onlywhen it is required to do so. If malfunction is caused b y dirt, etc., remove this plug and clean the oil port thoroughly. At this time, take care not to let steel ball (168) fall. 2) Remove O-ring (174) from plug (152).
A D O not reuse removed O-ring (174).
*
13. Disassembly of parking brake unit If compressed air is applied suddenly, piston (112) may jump out of spindle (2) and may hurtyou.Accordingly,place a protective cover, etc. over piston (1 12). 1) Apply compressed air to the tube hole for the parking brake on spindle (2) to take piston (1 12) out of spindle (2). 2) Take O-rings(135)and(139)outofpiston (112).
a
PC60-7
Do not reuse removed O-rings (135) and (1 39).
30-46-25
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
14. Disassembly of hydraulic motor
a
If the travel motor is laid on itsside, the oil a container flowsout.Accordingly,place under the travel motor.
Turn the travel motor by90 degrees. Drain the oil from the travel motor. Hold cylinder block(104)with the hands and turn it to both directions2 -by 3 turns toseparate shoe (106)from thrust plate(153). If cylinder block (104)is pulled out without performing the above action, shoe (106)is left on swash plate (103)and the parts sticking to cylinder block (104)(piston, shoe, etc.) come off cylinder block (104)and fall in spindle(2). Pull cylinder block (104)out of shaft (102).
*
a
At this time, friction plate (1 15)and mating plate(1 16)are removed togetherwith cylinder block(104). Remove friction plate(1 15)and mating plate (1 16)from removed cylinder block(104). Removethe piston assembly [piston (105)and shoe (106)land retainer plate (107)from cylinder block (104).
a
At this time, hold retainer plate (107)with both hands and remove it together with the above parts. Piston (105)and shoe (106)are made in one unity by drawing them at the spherical part of the piston. It is impossiblet o separate piston (105)and shoe (106) from each other without damaging shoe (106).If either or both of them need to be replaced, replacethem as a set (hereinafter, referred toas the piston assembly) and replace the 9 sets (hereinafter, referred toas the piston kit). Pull piston assemblies (105)and (106)(9 assemblies) out of retainer plate(107).
CLZOO194
CLZOOl96
30-46-26 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
8) Take thrustball (104).
MOTOR
(108) out of cylinder block
108
I
IO4
CLZOO196
9) Take rollers(151) (3 pieces) out of cylinder block (104).
I04
I
CLZOO197
15. Removal of springs in cylinder block Place cylinder block (104) on the press work table.
a
When removing the springs align holder (I) with the washer to prevent damage of the cylinder block caused by contact. Cover the cylinder block with a vinyl sheet for protection. Remove the springs only when they need t o be replaced. Place holder (I) onwasher(110).Securing holder (I) with thepress, remove roundR-type snap ring (145) from the snap ring groove of cylinder block (104)with snap ring pliers. Release the press gradually until the spring force is lost. If the press is released suddenly, the spring may jump out to hurt you. Accordingly, release the press slowly.
101 98
H o l d e r 11)
*
i n l
DWP02 1 12
PC60-7
30-46-27
8
0
w w
Y
N
0
0 N
0
N
0
-
N
\
0
-
N
0 0
N
0
-
0 W
-
N
r
0
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
4) Take 2 pivots (176) and 2 parallel pins (177) out of spindle (2). At the following step, the 2nd-speed selector piston assembly may jump out and hurt you because of compressed air. Accordingly, put a protective cover over the 2nd-speed selector pistonassembly. 5) Supply compressed air to the passage of spindle (2) to take the 2nd-speed selector piston assembly (piston and shoe) and spring (185) out of spindle (2).
*
Piston assembly
a
L
Piston (161) Shoe (162)
Compressed air: 0.29 - 0.49 MPa (3 - 5 kg/cmz) Piston (161) and shoe (162) are madein one unity by drawing them at the spherical part of the piston.It is impossible to separate piston (161) and shoe (162) from each other without damagingpiston (161). If either or both of them need to be replaced, replace them as a set (hereinafter, referred toas the pistonassembly).
17. Removal of deep groove ball bearing
a
Remove the deep groove ball bearing only when it needs to be removed. 1) Place holder (11) on the press work stand and put shaft (102) i n it. 2) Push the shaft end with the press to remove deepgroove ball bearing (149)from theshaft.
a
102 aD
Do not reuse the deep groove ball bearing. DWP021 I 3
18. Removal of spur gears 1) Turn over the travel motor. When the snap ring is removed, it may Take come off the pliers nose and fly out. care. 2) Remove C-type shaft snaprings (25) (3 pieces) from crankshafts (9).
PC60-7
30-46-29
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
3) Remove spur gears (7) (3 pieces) from crankshafts (9).
00206
4) Remove distance pieces (14) (3 pieces) from crankshafts (9).
19. Removal of hold flange 1) Turn over the travel motor. 2) Set clamps (2 pieces) to hub (1) and spindle (2) to secure them. At thistime, setthe clamps symmetrically.
a
If hold flange(3) is removed without setting the clamps, hub (1) and spindle (2) will separate from each other and spindle (2) will fall from the work table.Be sure t o use the clamps. 3) Turn over the travel motor.
1 08
4) Remove snap rings (20) (3 pieces) from hold flange (3).
2
30-46-30 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
5) Make match marks on snap ring (20) and hold flange (3) with an oil paint marker.
a
Make these marks so that the snap ring and hold flange will be installed to the original positions.
6) Loosen reamer bolts (19) (3 pieces).
a
The threaded parts of the reamer bolts (19) are coated with adhesive. When the reamer bolts are loosened, if the adhesive sticks to their reaming parts, they maybe seizedand may not be removed easily. Accordingly, loosen the reamer boltsas slowly as possible. If they become heavy, do not loosen them forcibly but tighten them again, then loosen slowly. The tightening torque of these reamer bolts is 411.6 f 63.7 N m (42 k 6.5 kgm}. Since the threaded parts are coated with adhesive, larger torque than 411.6 k 63.7 N m (42 f 6.5 kgm} is required to loosen them, however. 7) Remove hold flange (3) from spindle (2). 8) Make match marks on hold flange (3)and spindle (2) with an oil paint marker.
a
PC60-7
Make these marksso that hold flange (3) will be installed to the position of spindle (2) before disassembly. The 3 holes on spindle(2) for installing reamer bolts (19) have been made simultaneously. When spindle (2) or hold flange (3) needs to be replaced, replace both of them as an assembly. (Hereinafter, this assemble will be referred to as the spindle assembly.)
30-46-31
8
0
w P
v
0
Y
Iu
Y
w
P
N
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
22. Removal of ball bearing, RV gear assembly, and pin 1) Hit the end of pin (17)with pin punch @and hammer @ t o remove ball bearing(21)from hub (1). At this time,RV gear assembly[RV gear A(4), RV gear B (5),crankshaft (9), tapered roller bearing (22),needle roller bearing (23),and spacer (12)]and pin (17)are removed, too.
a
Y
17
21
When removing ball bearing (21),hit 3 4 points on the periphery of the pin end lightly so that the bearing will not be slanted.
u
DWPOZ I 14
If the outer race of ball bearing (21)is removed from hub(I), ball bearing (211, RV gear assembly and pin(17)fall from hub (1). Accordingly, place a container and a rubber mat on it under the work table to protect the falling parts.
2) Remove ball bearing (211,RV gear assembly, and pin (17)which fell from thehub. RVgear A (4) and RV gear B (5) of theRV gear assembly can be separated from crankshaft (9).
a
Remove tapered roller bearing (22), needle roller bearing (23),and spacer (12) from crankshaft (9) onlywhen they need to be replaced.
23. Removal of ball bearing and collar 1) Turn over the travel motor. 2) Hit the end of collar (11) with pin punch @ and hammer @from the cover (8) side of hub (1) to remove ball bearing(21)and collar (11) from hub (1).
a
If ball bearing (21)and collar ( 1 1 ) are removed, they fall from hub (1). Accordingly, placea rubber mat under the work table to protect those parts.
II 21
I PC60-7
DWPOZI 16
30-46-33
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
24. Removal of spindle parts 1) Remove oil seal (132) from spindle (2).
a
Never reuse removed oil seal (132).
I
DWPO.21 I6
2) Take floating seal (31) out of spindle (2).
I I
I
‘
” C L Z O10220
3) Take outer races (3 pieces) of tapered roller bearings (22).
a
The outerraces of tapered roller bearings (22) may stickto the spindle and may not be taken out easily because of the lubricating oil films. In thiscase, hit thecenter of the mounting hole of the spindle (2) lightlywith an aluminumbar, and the oil films are broken and the outerraces can be takenout easily.
.I .20022 I
25. Disassembly of hold flange parts 1) Take the outer races of tapered roller bearings (22) out of hold flange (3).
30-46-34 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
26. Rough cleaning of parts 1) Classify the parts into hub (l),spindle(2), hold flange (3), rear flange (IOI) and , the other parts (hereinafter, referred to as the internal parts). 2) Put the hub, spindle, cover, and rear flange in the cleaning tank and clean them.
a
Clean these parts and remove soil and sand from them carefully. j , Kerosene is combustible. Take care of fire extremely. 3) Puttheinternalpartsandkeroseneinthe rough cleaning container and clean them.
a
If dirty parts are washed in water soon after they are put kerosene, in they may be scratched. Accordingly, leave them i n kerosene until the dirt and grease become loose and float.
27. Finish cleaning 1) Put the parts and kerosenein the finishcleaning container and clean them carefullyto their inside, turning them slowly. 2) Wipe kerosene off the parts withclean cloths.
a
PC60-7
Drythe inside of hub ( I ) , spindle (2), and hold flange(3) by blowing compressed air againstthem in a clean and place. dry After dryingthem, apply hydraulic oil to them. Dry the inside of rear flange (IOI), hydraulic motorparts, and RV gear assembly naturally in a clean and dry place. After dryingthem, apply hydraulic oil to them. If pins (17) (24 pieces) are handled roughly, they may scratch each other and may be lost. Accordingly, handle them very carefully.
30-46-35
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
MAINTENANCE STANDARD TABLE Disassemble and inspect the GM motor according to the following standard. Handle its parts carefully. In particular, take care not to damage the moving parts and sliding parts. 1) Seals Replace the all seals (O-rings, oil seals, and floating seals) once they are removed, evenif they are free from damage. 2) Maintenance standard for worn parts i) Replace all the parts which have visible extremedamages. ii) Replace the parts which have the following trouble (phenomenon).
Part No.
Part name
Trouble
Standard value Standard dimension)
Allowable value (Criterion)
Clearance 12-18~
Clearance 23 c1
Spindle kit Spindle Hold flange Reamer bolt
Part surface hasvisible serious damage. Part surfaceis scuffed or worn easily.
RV gear assembly RV gear (A) RV gear (B) Crankshaft Tapered roller bearing Needle roller bearing
RV gear tooth surface is worn unevenly. When crankshaft (9) is revolved, each part does not move smoothly.
10
Distance piece
Sliding surface has flaw. Sliding surface is worn abnormally.
20
Snap ring
Periphery or end faces are worn abnormally.
21
Ball bearing
There is bruise. Sutface is flaked. Sutface is worn unevenly.
Rear flange kit Rear flange
Spool
30-46-36 @
Moving part against spool (123) has flaw. Clearance between rear flange and spool is large. Contact face againstvalve (127) has flaw. Depth to contact face against valve (127) is large. Outside sutface has flaw. Outside sutface is worn unevenly.
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
Part No.
Part name
MOTOR
Trouble
102
Shaft
Contact face against oil seal (132) is worn. Spline is worn.
153
Thrust plate
Thrust plate is seized.
Cylinder block
Spline is worn. Inside of bore is worn remarkably. Sliding surface against timing plate (109)is scratched and worn unevenly.
Standard value Allowable value Standard dimension) (Criterion)
Piston assembly
Piston Shoe
There is axial clearance between piston (105) and shoe (106). Shoe isworn abnormally. Shoe isworn unevenly.
Retainer plate
Periphery and end faces are worn unevenly.
Thrust ball
Spherical sliding parts against retainer plate (107)is worn unevenly.
Timing plate
Sliding surface is seized and worn unevenly.
115
Friction plate
116
Mating plate
Both end faces are worn unevenly. Specified torque is not produced. Plate is seized.
127
Valve
Seat surface has flaw.
149
Deep groove ball bearing
There is bruise.
150
Deep groove ball bearing
Surface is worn unevenly.
163
Valve
Outside surface has flaw.
PC60-7
Clearance: 0.05 mm
3raking torque: 82.38Nm{8.4kgm}
Clearance: 0.15 mm
3raking torque: 82.38Nm{8.4kgm}
Surface is flaked.
30-46-37
8
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
ASSEMBLY Carry out assembly in the reverse order to disassembly, as a rule.
3. Assembly procedure
1. Preparation Prepare a worktable, tools, and materials for disassembling, similarly to preparation for disassemb Iy. 2. General precautions for work 1) Observe the same general precautions with disassembly. 2) Removeallmetalchipsandforeignmatter from theall parts andcheck that any part does not have a burr, bruise, etc. before assembling. If thereis any burr or bruise, remove it with an oilstone. 3) Replace the O-rings, oilseals, and floatingseal with new ones. 4) Replace the reamer bolts with new ones, as a rule. If it is obliged to reuse one, remove all a brush. If boltseat has adhesive from it with any flaw, removeit with an oilstone and then degrease the reamer bolt. 5) Since the reamer bolt holes of spindle (2) and threaded parts of reamer bolts (19) are to be coated with adhesive when they are assembled, degrease them. 6 ) When fitting the O-rings, oil seals, and floating seals, take care not to damage them. (Apply a little amount of grease to their surface so that they will fit smoothly.) 7) When installing the hydraulic motor parts and moving or sliding parts of the valves, be sure to apply clean hydraulic oil (NAS Standard Grade 9 or higher) to them. 8 ) When assembling, do not put on cloth gloves. (If they are used, a fiber can cause malfunction.) 9) Tighten each bolt or plug to the torque shown in the torque table. I O ) After finishing the assembly work, plug the all ports to prevent dirt from entering them.
30-46-38 @
a
If any part is replaced before assembling, the preload on the ball bearing and thickness of the snap ring may need to be adjusted. Accordingly,see if any of the following part has been replaced before assembling. 1)Replacementpartswhichrequireadjustment of preload on ball bearing Hub (I), spindle (2), collar (II), hold flange (3),ball bearing (21) 2) Replacementpartswhichrequireadjustment of thickness of snap ring
a
Spindle (21, hold flange(3),crankshaft (9),spacer (12), tapered roller bearing (22), snap ring (20) If any of the above part is replaced before assembling, be sure to use only the adjusted parts. If a part which has not been adjusted is used, the travel motor will malfunction and cause breakage soon. Accordingly, observe this precaution.
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
4.
MOTOR
Reassembly of hub assembly 1 ) Check that any of hub (I),spindle (21, hold flange (31, collar (111, and ball bearings (21) (2 pieces) has not been replaced with new one.
a
If any of the above parts has not been replaced, go to the next step. If any of the above parts has been replaced, adjust the preload on the ball bearing before going to the next step. 2) Tighten 2 eyebolts symmetrically into the screw holes of hub (1). 3) Install hooks and wires to the eyebolts and sling and install hub(1) to the worktable with a crane.
a
Matching the screw holes of hub (1) to those of the worktable, insert the hub in the mounting hole of the worktable carefully. 4) Fix hub (1) to the worktable with hexagon socket head bolts.
5) Install collar (11)to hub (1).
6) Insert ball bearing (21)in hub (1).
a
Applya pin punch to the rim of ball bearing (21) and hit it lightly witha hammer all round to fit the bearing little by little.
00229
PC60-7
30-46-39
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
7) Apply grease to O-ring(28) and fit O-ring(28) to the O-ring groove of hub (1).
I
II I
I
\
CLZOO2 I6
8) Install distance piece (IO)to hub (1).
a
If distance piece(IO)is difficult to insert, hit it lightlywitha plastic hammer. I f t h e distance piece is inserted suddenly, 0ring (28) may be broken cause to oil leakage. Take care.
CLZOO231
5. Reassembly of spindle assembly 1 ) Apply grease to the O-ring of floating seal (31) and then fit floating seal (31)to the floating seal groove of spindle(2).
a
Remove the O-ring from the floating seal and apply grease thinly all round 0the ring. Fit the O-ring to the groove of the spindle correctlyand set the floatingseal so that it will be parallel with the groove face of the spindle. 2) Install 2 eyebolts symmetrically to spindle(2). 3) Install hooks and wires to the eyebolts and sling spindle(2) with the crane and insert it in hub (1) slowly.
17"
30-46-40 @
\
'
CLZOO214
PC60-7
2
<
0
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
iii) Insert RV gear B (5) in hub (1).
a
Since the phases of RV gear A (4) and RV gear B (5) are matched, set the punch holes on the ends of those gears at the same position.
8 ) Insertpins(17) (24 pieces)between the pin spaces of hub(1) andtooth spaces of thegear.
a
Apply lubricating oil to pins (17) before inserting them.
I
9) Insert ball bearing (21) in hub (1).
a
Apply pin punch @ to the rim of ball bearing (21) and hit it lightly with hammer @ all round to fit the bearing little by little.
OWP02 1 17
6. Installation of hold flange 1) Fit hold flange(3)to the inner race of ball bearing (21) in hub (1).
a
When fitting hold flange(3) to ball bearing (21), set the match marks on spindle (2) and crankshaft(9) to the positions before disassembly. If hold flange (3) does not enter the inner race of ball bearing (21) smoothly, hit it evenly and lightly with a plastic hammer.
30-46-42 @
t \
I
CLZOO241
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
7. Tightening of reamer bolts 1) Apply anti-seizure lubricating oil to the reaming parts of reamer bolts (19) and apply adhesive to the threaded parts of the reamer bolts. 2) Tighten reamer bolts (19) (3 pieces) until hold flange (3) is press fitted to ball bearing (21) perfectly.
a
If reamer bolts (19) are stained with oil or grease, degrease, clean, and dry in air for 10 minutes and then apply adhesive to their threaded parts. 3) Tightenreamerbolts(19) (3 pieces) to the specified torque.
a
/
Reamer bolts (19): 41 1.6 f 63.7 Nm (42 f 6.5 kgm} Tighten 3 reamer bolts (19) evenly little by little. If only 1 or2 of them are tightened first, hold flange (3) will slant and ball bearing (21) will not be fitted accurately in hold flange (3) and can cause seizure of reamer bolts (19). If theseats of 3 reamer bolts (19) are not fitted accuratelyto the surface of the hold flange, inspect and remove thecause.
1 CLZOO242
\
4) Turn over the travel motor.
-
I
3
CLZOO243
5) Remove the clamps (2 pieces).
6) Turn over the travel motor.
3
7) Fit the outer race of tapered roller bearing(22) to hold flange(3).
I
j2
/
CLZOO244
8. Fitting of snaprings 1) Check that any of spindle (2), hold flange (3), crankshaft (9),tapered roller bearing (22), spacer (12), and snap rings (20)has not been replaced with new one.
a
PC60-7
If any of the above parts has not been replaced, go to the next step. If any of the above parts has been replaced, adjust the axial clearance of tapered roller bearing (22) before going to the next step.
20
30-46-43
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
a
When replacing only snap rings (20), select the same ones as the used ones or similar ones from12 types. 2) Fit snap rings (20) to the snap ring holes in hold flange(3).
a
Fit 3 snap rings (20) to the positionsbefore disassembly, matching them to the match marks on hold flange (3). When using new snap rings (20), select ones having the thickness selected in theprevious process. 3) Install distance pieces(14) (3 pieces) to crankshaft (9).
9. Installation of spur gears 1) Install spur gears (7) (3 pieces) to crankshaft
(9).
00206
a
Install spur gears (7) (3 pieces) t o crankshaft (9), matching their match marks (punch holes) as shown in the figure below.
S e tm a t c hm a r k s bunch oles) of s p u rg e a r s to t h e s ep o s i t i o n s .
Hold flanae
I
DWP01916
2) Install C-type shaft snap rings (25) (3 pieces) to thesnap ring grooves of crankshaft(9).
30-46-44 G9
PC60-7
MOTOR
DISASSEMBLY TRAVEL AND ASSEMBLY
IO. Press fitting of oil seal 1) Turn over the travel motor.
2) Apply lithium grease to the lip of the oil seal and press fit oil seal (132) to the oilseal hole of spindle (2) with holder(Ill) and a hammer.
Spindle
Oil s e a l
DWPOL 1 10
~
11. Installation of shaft 1) Put deep groove ball bearing (149) in a heating tank andheat it at 100 & 10°C for 10 minutes and then insertit in shaft(102).
a
Put on leather gloves to insert the bearing and take care not to get burnt. Insert deep groove ball bearing (149) shaft until it is fitted to the flange of(102).
CLZOO251
Fit parallelpins(177)(2pieces9tothepin holes of spindle(2). 3) Apply lithium grease as paste to pivots (176) (2 pieces) and fit them to parallel pins (177) of spindle (2). 4) Install piston assembly [piston(161) and shoe (16211 to spindle (2). 5) Turn the travel motor by 90 degrees. 2)
6) Fit shaft (102) to spindle (2).
a
PC60-7
Fit shaft (102) to spindle (2) slowly, taking care that it will not damage the lip of oil seal (132) fitted in spindle (2). If the lip is damaged,oil will leak and the travel motor will be broken soon.
102
30-46-45
8
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
7) Apply molybdenum disulfide grease to thrust plate (153)and install it to swash plate (103).
53
8) Install swash plate (103)to spindle (2).
a
Apply grease to mating faces of swash plate (103)and spindle (2). When installing swash plate (103)t o spindle (21, match its steel ball holes t o steel balls (167)(2 pieces) fitted to spindle (2).
2
CLZOO254
12. Reassembly of cylinder block 1 ) Insert washer(1 IO), spring (1 141,washer (1 IO), and round R-type snap ring (145)in cylinder block (104)in order. 2) Place cylinder block (104)on the press work table.
I
cLz00200
3) Place holder (I) on washer (1 IO). Securing it with the press, install round R-type snap ring (145)to thesnap ring groove of cylinder block (104)with snap ring pliers.
a
Cover cylinder block (104)with a vinyl sheet to protect its contact face against timing plate (109).
CLZOOI 98
30-46-46 @
PC60-7
n
P
I
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
2)FitO-rings(135)and(139)totheO-ring grooves of piston (112). At this time, apply grease thinly to O-rings (135) and (139). 3) Turn the travel motor by 90 degrees.
4) Install piston (112) in spindle (2).
a
If piston (112) does not enter spindle (2) smoothly because of theresistance of 0rings (135) and (139), hit its end lightly w i t h a plastic hammer. When installing piston (112), take care not to damage the O-rings.
15. Reassembly of brake valve partsin rear flange 1) Install O-rings (137) (2 pieces) to plugs (126) (2 pieces).
a
Apply grease to O-rings (137).
137
12'
CLZOO263
2) Installvalve(127)andspring(130)to each plug (126). At this time, apply grease to the spring to lower the spring force and connect the valve, spring, and plug by utilizing the adhesion of thegrease. 3) Insert each plug (1261, to which valve (127) and spring (130) are installed, i n rear flange (101).
CLZOO264
30-46-48 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
a
MOTOR
When inserting each plug (126), place rear flange (101) on the work table with the plug mounting screw hole up and align the plug with the screw hole. Protect the O-ring and prevent removal of spring (130) from valve (127) caused b y contact of the inside wall of the rear flange and valve. If spring (130) comes off valve (127), the valve will not fit to the seat of rear flange (101) and oilleak.
4) After inserting plugs (126) (2 pieces), tighten them into rear flange (101) temporarily with a hexagon wrench.
I
CLZOO 184
5) Insert spool (123) i n rear flange (101).
a * *
When inserting the spool, apply hydraulic oil toit. When installing the spool, align it with the hole of therear flangeso that its outside surface and the inside surface of the rear flange will not be damaged. If the hole of the rear flange and outside surface of the spool are damaged bycontact, internal leakage will occur after assembly and the performance of the travel motor will lower.
CLZOO266
6) Fit O-rings (136) to plugs (124).
a
PC60-7
Apply grease to O-rings (136).
30-46-49
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
7) Install spring retainers(125) and springs (128) to plugs (124). 8)Installplugs(124)(2pieces)torearflange (101).
a
When installing each plug to the rear flange, take care not to deform the spring.
I
128
CLZOO268
9) Tighten plugs (124) (2 pieces) into rear flange (101) temporarily with aspanner.
CLZOO182
16. Reassembly of rear flange parts 1) Installation of pilot valve in rear flange i) Place the rear flange with the mating face against spindle (2) up.
ii) Insert valve (163) i n rear flange (101).
CLZOO270
iii) Fit spring (166) to valve (163) and place stopper (164) over them.
c L2100271
30-46-50 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
iv) Bend new ring (165)a little and put it in rearflange(lOl)fromabovestopper(164) and insert it in the ring groove.
a
Be sure to fit ring (165)to the ring groove of rear flange (101). If ring (165)is not fitted to the ring groove, valve (163)does not operated stably and high speed and low speed cannot be selected normally. Be sure to use new ring(165). 2) Apply hydraulic oil to deep groove ball bearrear flange(101). ing (1 50)and fit it to
164
CLZOO272
6'0
"OJ CLZOO273
3) Fit parallel pins (141)(2 pieces) to the pinholes of rear flange(101).
I
CLZOO274
4) Apply grease to the mating face of timing plate (109)against rear flange(101). 5) Install timing plate (109)t o rear flange (IOI), using parallel pins (141)as guides.
a
PC60-7
Install timing plate (109) until it fits torear flange (101). The timing plate must be fitted so that it will not fall from the rear flange when it is installed to spindle (2).
30-46-51
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
17. Connection of rear flange andspindle 1) Fit O-rings (30)and (27) to the O-ring grooves of spindle(2).
a
When fitting O-ring (30), do not apply grease t o it. If grease is applied at this time, it may ooze out through the joint of therear flange and spindle while travel motor is operating. Since the grease oozing out can be mistaken for oil leakage, do not applygrease to O-ring (30).
2) Fit parallel pins (142) (2 pieces) to spindle (2). 3) Supply hydraulic oil of 0.55 liters into spindle (2).
4) Install rear flange (101) to spindle (2), matching its pin holesto parallel pins (142) (2 pieces) fitted to spindle(2).
a
r
When installing rear flange (101) to spindle (2), install springs(113) (8 pieces) to the rear flange. At this time, apply grease to springs (1 13) to prevent them from coming off the rear flange.
.ZOO278
5) Tightenhexagonsocketheadbolts(143) (8 pieces) into spindle (2) to the specified torque. Hexagon socket head bolts (143): 57.82 k 9.8 Nm (5.9 k 1.0 kgm}
30-46-52 @
PC60-7
m
3 v
(L1
It
?
S
:
rc
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
19. Reassembly of cover 1) Supply lubricating oilof 1.7 liters into hub(1). 2) Fit O-ring (29) to the O-ring groove of cover Apply grease to O-ring (29).
3) Install cover (8) to hub (1).
a
Match them match marks of cover (8) and hub (1) to install them to the positions before disassembly. Install cover (8) by hitting its periphery lightly with a plastic hammer. If it is installed suddenly by hitting it strongly, the O-ring will be broken and lubricating oil will leak.
4) Fit ring (18) to the ring grooveof hub (1).
5) Wind sealing tape onto hexagon socket head plugs (33) (2 pieces) and tighten them into cover (8) to specified torque.
a
Hexagon socket head plugs (33): 39.2 f 14.7 Nm (4 f 1.5 kgm) Wind the sealing tape onto each hexagon socket headplug (33)at least2 turns. Tighten each hexagon socket head plug (33) until the number of threads projected from the end of cover (8) becomes
*I.
30-46-54 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
20. Removal of travel motor 1) Turn over travel motor.
2) Remove the travel motor mounting boltsfrom the worktable.
3) Tighteneyebolts (2 pieces) into the screw holes of spindle(2).
a
Install 2 eyebolts symmetrically to the screw holes of spindle (2). 4) Install hooks and wires to the eyebolts and remove the travel motor from the work table with thecrane.
0289
PC60-7
30-46-55
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
21. Adjustment of preload on ball bearing
a
A proper preload must be applied to ball bearing (21) to secure a proper life span. If any part which affects the preload is replaced, assemble the parts temporarily and check the preload according to the following procedure. If the GM motor is assembled without checking the preload, it will malfunction and will be broken soon. Parts which affect preload on ball bearing Hub ( I ) , spindle (2), hold flange (31, ball bearing (21), collar (1 1) If any of the above parts is not replaced, skip this process and goto 6.1. The following are the procedures for checking and adjust the preload.
1
CLZOO290
Adjustment procedurefor preload on ball bearing 1) Install the main bearing preload adjustment j i g @ t ospindle (2) and tighten the special nut @ t o press fit ball bearing (21) to hub (1). Special nut @: 39.2 Nm (4 kgm} 2) Measuredepth "A" with depth micrometer a t h r o u g h the measurement hole of the main bearing preload adjustment jig. 3) Since dimension "B" of main bearing preload adjustment jig@ is known, obtain clearance "C" by the following formula. Measured value
"C" = "A" - "B"
B: Dimension of jig C: Standard dimension
/\-'
j
'
CLZOO291
a
DWPO2 1 1 9
30-46-56 @
PC60-7
DISASSEMBLY TRAVEL AND ASSEMBLY
4) Obtain dimension "D" of hold flange (3). 5) Adjust hold flange(3) by the following methods, depending on the measurement in 2) 4) above. Dimension "C" is the standard dimension of the hold flange. i) Whenthemeasureddimensionofhold flange (3) is smaller than the standard dimension Cut face E of hold flange(3) with a lathe, etc. to the standard dimension. ii)Whenthemeasureddimensionofhold flange is within the tolerance of the standard dimension Use the hold flangeas it is. iii) When measured dimension D of hold flange (3) is larger than the standard dimension Replace the spindle assembly with new one. New hold flange (3) has an adjustment allowance.
MOTOR
tVFace E
I
a
Since the hold flange and spindle are used together, they are made in an assembly. Accordingly, it is impossible to replace only the hold flange.Replace bothholdflange and spindle together. The assembly of the hold flange and spindle is called the spindle assembly. When replacing the spindle assembly, execute the disassembly and assembly procedures again.
6) Remove the main bearing preload adjustment jig @from spindle(2).
7) After adjusting the hold flange according to above steps i), ii), and iii), go to6.1.
PC60-7
30-46-57
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
22. Adjustment of axial clearance of tapered roller bearing
a
If any of the following parts is replaced, the axial clearanceof tapered roller bearing (22) must be adjusted to a proper level by adjusting the thickness of snap ring (20). If the GM motor is assembled without adjusting the axialclearance of the tapered roller bearing, it will malfunction and will be broken soon. Spindle (21, hold flange (31,crankshaft (9), spacer (12), snap ring PO), tapered roller bearing (22) If any of the above parts is not replaced, go to 8 without adjusting the snap ring thickness. The following is the method of adjusting axial clearance of the tapered roller bearing. 1) Lightly hit the outer race of tapered roller bearing (22) installed tocrankshaft (9) with a hammer and holder(IV).
I
I
CLZOO296
I
CLZOO295
20
a
This action is required to insert the RV gear assembly in spindle(2) securely. 2) Fit thinnest snap ring (20) to the snap ring groove in hold flange(3). (20) with 3) Lightly hit the peripheryof snap ring the hammer and holder (IV).
a
Check that the RV gear assembly is inserted securely in spindle(2).
I
30-46-58 @
I
PC60-7
DISASSEM TRAVEL BLY AND ASSEMBLY
MOTOR
4) Insert a thickness gauge between snap ring (20) and tapered roller bearing (22) to measure the clearance. 5) Measurem ent of snap ring thickness Set thickness of snap ring (Max.) Max. = (Thickness of thickness gauge) + (Thickness of snap ring fitted at present) Set thickness of snap ring (Min.) Min. = (Thickness of thickness gauge) + (Thickness of snap ring fitted at present) (0.05 mm)
20
22
/J CLZ0029t
6) After the snap ring thickness is decided, select one from the 12 types and install it to the hold flange. (See 23. Dimensions table of clearance adjustment parts.) 7) After installing the snap ring having the decided thickness, go to8.2.
00299
PC60-7
30-46-5 9
8
DISASSEMBLY TRAVEL AND ASSEMBLY
MOTOR
DIMENSIONS TABLE OF CLEARANCE ADJUSTMENT PARTS No.
1
GM Model
GM09VL2
Part name
Snap ring (20) Type symbo1
Dimension t
A
Above 1.90 up to 1.95
B
Above 1.95 up to 2.00
C
Above 2.00 up to 2.05 Above 2.05 up to 2.10 D
E
Above 2.10 up to 2.15
F
Above 2.15 up to 2.20
G
Above 2.20 up to 2.25
H
Above 2.25 up to 2.30
I
Above 2.30 up to 2.35
J
Above 2.35 up to 2.40
K
Above 2.40 up to 2.45 Above 2.45 up to 2.50 L
DWP01915
30-46-60 @
PC60-7
MOTOR
DISASSEMBLY TRAVEL AND ASSEMBLY
PERFORMANCE CONFIRMATION TEST After maintaining theG M motor, test its performance according to the following procedure.
1. Necessarymeasuringinstruments
I 1 I Pressuregauge(For3.43MPa(35kg/cm2}) I 2 I Measuring cylinder (For 5 liters) 3
2.
I I
2 pcs.
1 PC.
Stopwatch
1 PC.
Test procedure
and
.....................
piping of GM motor
Install the GM motor to the machine body (sprocket) and pipe it. Do not install the track, however [sincethe performance test of the GM motor (no-load operation) is executed]. Notes)
Running-in of
Pipe the GM motor so that a pressure gauge (main circuit) can be installed andthe draining rate of the hydraulic motor can be measured. 2. Do not install the GM motor by hitting it with a hammer, etc. but install it carefully by utilizing the bolt holes. 1.
I Operating time I
..................... Right/Left
3
1 minute or more foreach
Performance confirmation test on GM motor
I1I
Preparatory operation beforetestn.Operate ..........
2 Confirmation test
I I
........................................
Criteria
until temperaturerises to thefollowing points. Hydraulic oil temperature: 45 - 55°C Outside temperatureof hubof reduction gear assembly: 40 - 80°C Measure the following items to check the performance. Drive pressure of GM motor Max. 1.57 MPa (16 kg/cm2}at 10 rpm Draining rate of hydraulic motor Max. 0.5 Iiterdmin. at 10 rpm
J. Acceptable J( Install track.
PC60-7
4 Rejected
JI Disassemble and adjust again.
30-46-61
8
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY
REMOVAL OF SWING MOTOR, SWING MACHINERY ASSEMBLY
a a
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulictank. An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing.
1.
Disconnect swing motor suctionhoses (1).
2.
Disconnect 2 swing motor main porthoses (2).
3. Disconnect swing motor brake pressure release hose (3).
4.
Disconnect 2 swing motor drainhoses (4).
5. Disconnect 3 hoses (5) between control valve and swivel joint.
6. Remove mounting bolts,then sling swing machinery and swing motor assembly ( 6 ) ,and use forcing screwCiJ t o remove. When removing the swing machinery and swing motor assembly, lift off slowly and be careful not to damage the wiring or piping.
*
00
& Swing machinery and swing motorassembly : 70 kg
INSTALLATION OF SWING MOTOR, SWING MACHINERY ASSEMBLY Carry out installation in the reverse order to removal.
Swing machinery case mating surface : Gasket sealant (LG-4) Swing machinery and swing motor assembly mounting bolt: 276.85 f 31.85 Nm (28.25 f 3.25 kgm}
Refilling with oil (hydraulictank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
*
Bleeding air Bleed the air from the swing motor. For details, see TESTING AND ADJUSTING, Bleeding air.
PC60-7
30-47
0
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
DISASSEMBLY OF SWING MOTOR ASSEMBLY LMF40AB-2 WITH BRAKE 1. Swingmotor assembly Set swing motor assembly(1) to tool P I .
2.
Endcover 1) Loosenplug (2). 2) Remove end cover (3). The valve platemay be sticking to the end cover. Take care not to drop the valve plate. 3) Remove outer race (4) and spacer (5). 4) Remove plug (21, spring (6),and relief valve (7).
7
5
\
*
/J
\
I
DWP01641
3. Brakespring Remove brake spring(8). 4. Valve plate Remove valve plate(9). When reusing the valve plate, keep it, taking care not to damage its contact surface against the cylinderblock.
*
DWPOI642
5.
Brake piston Supply compressed air with tool P2 to remove brake piston (IO). Air pressure: 0.39 MPa (4 kg/cm2}
P2
*
a
If the air pressure is too high, the brake piston jumps out. Take care.
I 30-47-1
8
IO
DWPOI 643
PC60-7
0
v)
n
3 Q
W
2
-m
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
2) Disassembly of cylinder block and piston assembly Pull piston assembly(19) out of cylinder block (18) and remove retainer guide (20) and preload pins (21). When the cylinder block and piston assembly is removed from the shaft assembly or when the piston assembly is pulled out of the cylinder block, the preload pins may come off and fall. Take care not to 18’ miss the preload pins.
*
I
DWPOl648
3) Disassembly of piston assembly Pull piston (23) out of retainer shoe (22).
4) Disassembly of cylinder block i) Set tool P3 to cylinder block (18). ii) Fix the bolt of tool P3 with a wrench, etc. and tighten the nut to compress the spring and remove snap ring (24). iii) Loosen then nut of tool P3 gradually to release spring (25) and then remove tool P3. iv) Remove spacer (26), spring (251, and spacer (26) from cylinder block (18).
I DWPOl660
IO. Shaft assembly 1) Remove thrust plate (27) and spacer (28)from shaft assembly (17).
17 DWPO1661
30-47-3
8
PC60-7
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
2) Remove bearing (30)from shaft (29)with push tool (2).
30
DWPO 1 6 5 2
11. Plate Remove plate (13) from motor case (12). When the shaft and cylinder block assembly are removed from the motor case, the plate can be removed.
,I2
*
12. Oil seal and outer race 1) Remove snap ring (31) from motor and then remove oilseal (32). 2) Remove outer race (33).
case 12
Y
DWPO1664
13. When theabove disassembly work is not necessary and only the oil seal needs to be replaced, replace the oil seal according to the following procedure. 1) Remove snap ring (31). 2) Push out oil seal (32) with bar @ (the end of which may be hit with a hammer) to the core and then pry out the seal. oil Hit the central part between outside and inside of the oil seal and pry out2 places opposite toeach other such as A and B in the figureat right. Take care not to damage the shaftcase.
* *
PC60-7
30-47-4
8
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
ASSEMBLY OF SWING MOTOR ASSEMBLY LMF40AB-2 WITH BRAKE Clean the all parts and remove burrs, etc. from them. Coat their slidingsurfaces with engine oil(E010-CD) before installing. Be sure tocheck the following parts before installing. i) Contact of the cylinder block and valve plate (See the section of contactcheck procedure.) ii) Contact of the valve plate and end cover (See the section of contactcheck procedure.)
1. Motor case 1) Press fit outer race (33)with tool P5. 2) Set tool P I to motor case (12).
33
I
!2
PI
I 2.Shaftassembly 1) Press fit bearing (30)to shaft (29) with toolP6 to form them into shaft assembly (17). Press the end of the bearing inner race with tool P6 until the bearing fits to the shaft end. Press fitting load: 1,834 - 7,119 N (187 - 726 kg}
* *
Press fitting surface of bearing: Lubricating oil (EOIO-CD)
DWPOl657
P6
I7 30 29
hi
OWPOI658
2) Install shaft assembly (17) to motorcase (12). 3) Install thrust plate (27) and spacer(28). After installing thrust plate (27) to the motor case, turn it to the right and left to check that it is installed accurately.
*
17
30-47-5
8
PC60-7
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
3. Cylinder block and piston assembly 1) Assembly of cylinder block i) Install spacer (26), spring (25), and spacer (26) to cylinder block (18). ii) Set tool P3 to cylinder block (18). iii) Fix the bolt of toolP3 with a wrench, etc. and install the nut to compress spring (25) and install snap ring (24). Checkthat the snap ring is fixed to the groove securely. iv) Remove tool P3.
*
DWPO1650
2) Assembly of piston assembly (22). Install piston (23) to retainer shoe
23
I
22'
DWPOl649
3) Assembly of cylinder block and piston assembly i) Install 3 preload pins (21) to cylinder block (18). Apply grease (G2-LI) to the preload pins to prevent them from coming out. ii) Install retainer guide (20) to cylinder block (18) and then install piston assembly (19) to form them into cylinder block and piston assembly (16). Match the splines of the cylinder block and retainer guide toeach other. I
*
4) Install cylinder blockand piston assembly (16) to motor case (12). Take care sufficiently that the preload pins will not fall.
*
DWPO1648
I
I'
PC60-7
1
DWPO1660
30-47-6 @
DISASSEMBLY AND ASSEMBLY
4.
SWING MOTOR
Plate, disc, and piston 1 ) Install plate (13)and disc (14)in order. Do not clean the disc with trichloroethylene or denatured alcohol or blow air strongly against it.
*
Disc surface: Lubricating oil (E010-CD)
2) Fit the O-ring and install brake piston (IO).
5. Adjustment of shaft end play 1 ) Set hydraulic jack@ under the bottom end of the shaft and press fit sub-bearing (15)with tool P7 and puller 0. Press the end of the sub bearing inner race with tool P7 until the bearing fits to the shaft end. Press fitting load: 1,412 - 5,237 N {I 44 - 534 kg} (May be increased to9.8 kN {1,000 kg).)
* *
Press fitting surface of bearing: Lubricating oil (E010-CD)
2) Installspacer (5) and outer race (4)to end cover (3). Installthespacerwhichhasbeenremoved. 3) Install valve plate (9) to end cover (31,matching it to the dowel pin. Check that the valve plate does not interfere with the bearing and pin. When installing the valve plate, do not give an impact to it. (If an impact is given, the slidingsurface may be damaged and distorted.)
P7
. .
.
DWPOl663
* * *
30-47-7 @
DWPOl664
PC60-7
DISASSEMBLY AND ASSEMBLY
SWING MOTOR
4) Install end cover(3) horizontally to motorcase (12). Take care sufficiently that the valve plate will not fall. Do not install the spring and O-ring of the parking brake.
* *
Mounting bolt: 110.3 f 12.3 Nm (11.25 f 1.25 kgm}
I
12
DWPO1665
0
5) Push the shaft end with puller to shift the shaft toward the end cover. Pushing out load: 981 - 1,079 N (100 - 110 kg) 6) Install an eyebolt to the shaft end and pull up the shaft and measure the end play with dial gauge End play: 0.05 - 0.25 m m
* *
8.
I 7) If the end play is out of the standard range, adjust it according to the following procedure. i) Remove the end cover. ii) Remove the valve plate and outerrace. iii) Select a proper spacer from the following table. Spacer tobe used Thickness (mm) 1.6 70s-7T-12260 1.7 70s-7T-12270 70s-7T-12360 1.8 70s-7T-12370 1.9 70s-7T-12380 2.0 70s-7T-12390 2.1 70s-7T-12460 2.2 iv) Install the selected spacer and assemble I the parts again according to steps 5-2) 5-6) and measure the end play. v) After adjusting the end play, remove the end cover. 6.
Endcover assembly 1) Install relief valve (7)and spring (6) in order and then fit the O-ring and tighten plug (2) temporarily.
I PC60-7
DWPO1666
n DWPO1667
-7
I
I-\
v
v
I DWPOI 6 6 8
30-47-8
8
DISASSEMBLY AND ASSEMBLY
2) Install brake spring
SWING MOTOR
(8).
3) Fit the O-ring to the motor case and install end cover (3) horizontally, matching it to the dowel pin. Take care sufficiently that the brake spring and valve platewill not fall. Check that end cover does not interfere with the pin. Take care sufficiently that the O-ring is not caught in the motorcase and end cover.
* * *
I
DWPO1669
Mating face of motor case: Gasket sealant [LG-7 or LG-5 (LOCTITE 572/575)]
m Mounting bolt: 110.3 f 12.3 Nm {11.25 f 1.25 kgm} 4) Tightenplug (2).
I
I DWPO1670
m Plug (2): 166.7 f 19.6 Nm (17 f 2 kgm} 7. Measurement of turning torque of swing motor assembly Set tool P8 to the motor shaft and release the brake and then revolve the shaft at the speed of 3 - 5 sechurn and measure its turning torque. The turning torque must not fluctuate while the shaft is revolved. Fluctuation of turning torque:0 - 1.96 N m (0 - 0.2 kgm) Turning torque: 10.8 - 16.7 N m (1.1 - 1.7 kg m> Brake releasing pressure: 2.94 & 0.29 MPa (30 3 kg/cm2}
*
*
DWPO1671
31
8. Oil seal 1) Checkthat thereare not burrs and sharpedges at the corners of the shaft. 2) Press fit oil seal (32) with tool P4. Clean the oil seal lip.
*
& Oil seal lip end (all round): Grease (G2-LIS) 3) Install snap ring (31).
30-47-9
8
DWPO1672
PC60-7
DISASSEMBLYAND ASSEMBLY
SWING MOTOR
CONTACT CHECK OF CYLINDER BLOCK, VALVE PLATE, AND END COVER 1. Contact check of cylinder block and valve plate This check is not necessary when both of the cylinder block and valve plate are spares (new). Perform this check when either of the cylinder block or valve plate is a spare or is repaired. If the contact is improper, correct it by lapping the parts on a surface plate. Make a centering tool for the cylinder block and valve plate. This tool may be made of a soft material such as plastic, Bakelite, etc. Degrease the parts to be checked. Do not wipe the parts with a cloth. Set the tool and apply check paint to the cylinder block. Apply the paint thinly. Press the valve plate with force 39.2 of - 49.0 N (4 - 5 kg} against the cylinder block and turn it by 90 degrees and then return it to its original position. Repeat this motion 2- 3 times. Remove the valve plate and transfer the contact surface onto a tape and check it. The standard contact area is as follows.
* * *
*
CY I i n d r!r b l o c k
C e n t e Vtr oianol gvl e
plate
DWPO I 6 7 3
I
I
a seal
V aCl vyel i np dl ae tr e
block DWPO I 6 7 4
Sealing part a Min. 80%
Valve platec.
I
*
Cylinder blocke.
I
Min. 80%
I
For the details of the work procedure, see the guide to parts judgment.
2. Valve plate and end cap 1) Remove all oil and grease from the parts to be checked. Do not wipe with a cloth. 2) Paint the end cap with inspection paint, then put the valve plate on top. Coat thinly with paint. 3) Push the valve plate with a force39.2 of -49.0 N (4-5 kg} against the endcap, turn the valve plate go", then turn itback to the original position. Repeat this process 2 or3 times. 4) Remove the valve plate, transfer the contact surface to a tape, and check the contact surface. The contact of the mating surface of the valve plate and end cap must cover at least 80% without any variation. If the contact is defective, use a surface plate and correct by lapping.
* *
Valve
P
there and more
I
DKP00664
* *
PC60-7
30-47-10 @
DISASSEMBLY
DISASSEMBLY ASSEMBLY 1.
MACHINERY
OF SWING MACHINERY I
Draining oil Loosen drain plug and drain oil from swing machinery. -
2.
SWING
AND ASSEMBLY
:
Swing machinery
case : Approx.
Swing motor assembly Remove swing motor assembly
1.5 e
(1).
CBPD3582
3.
No. 1 sun gear, No. 1 carrier assembly 1) Remove No. 1 sun gear (2). 2) Remove No. 1 carrier (3).
CBPO3583
3)
Disassemble No. 1 carrier assembly as follows. i) Remove snap ring (4), then remove thrust washer (5), gear (6). bearing (7), and thrust washer (8).
CBPO3584
ii)
Knock in pin (9) and knock out shaft (10). * After removing the shaft, remove pin
(9). iii) Remove
thrust washer
(11) from carrier
(12).
CBPO3585
30-48 0
DISASSEMBLY
4.
AND ASSEMBLY
SWING
No.2 sun gear Remove No.2 sun gear (13).
15
5.
Ring gear Remove ring gear (14).
6.
No. 2 carrier assembly I) Remove No. 2 carrier assembly
(15).
CBPO3587
CBPO3586
2) Disassemble
No. 2 carrier
assembly
as fol-
lows. i) Remove snap ring (161, then remove thrust washer (17). gear (18). bearing (19). and thrust washer (20). ii) Knock in pin (21). and knock out shaft (22). Ir After removing the shaft, remove pin (21). iii) Remove thrust washer (24).
7.
MACHINERY
I11
17
I6 I9
20
(23) from carrier 21
Collar I) Set shaft and case assembly to press, push bearing (25) with push tool A. Operate the press gradually and press fit * the bearing to a point where the split collar can be removed. 2) Remove split collar (26).
CBPO3589
8.
.
Shaft assembly I) Set block @ to shaft and case assembly (271, then using push tool @I, remove shaftassembly (28) with press. 2) Remove bearing (25).
CBPO3591
30-49 0
DISASSEMBLY
3)
AND ASSEMBLY
SWING
Set shaft assembly to press, then using push tool 0, remove bearing (29) and collar (30) from shaft (31 I.
MACHINERY
0,
31 CBPO3592
9.
Dust seal, oil seal, bearing outer race I) Remove dust seal (32) and oil seal (33) from case (34).
CBP03593
2)
Using puller 0, remove bearing (35) and (36) from case (34).
outer races
CBP03594
30-50 0
DISASSEMBLY
AND ASSEMBLY
SWING
MACHINERY
rc4
ASSEMBLY
OF SWING
MACHINERY
Ir
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Oil seal Using push tool 0,
press fit oil seal (33) to case
(34). It Replace the oil seal with a new part. 6 Lip oil seal: Grease (G2-LI)
35
2.
Bearing outer races Using push tool, press fit outer races (35) and (36) to case (34).
3.
Shaft assembly 1) Install collar (30) to shaft (31).
CBPO3595
CEPO3596
2) Using push tool 8, press fit bearing (29) with press.
s
CBPO3597
Lu
3)
Set case assembly
4)
Using push tool 0, press fit bearing (25) with a press to a point where split collar enters. Ir Press-fitting force : Max. 11.76 kN {1200
-
Ir
(37) to shaft assembly
(28).
kg} Press fit the bearing slowly while rotating the case.
5)
Install split collars (26).
6)
Using push tool 8, press fit shaft (31) with press until split collar (26) is fixed in position.
7)
Screw bolt (IOmm, P=1.5mm) into case, then using push- pull scale @, measure tangential force in direction of rotation. Ir Tangential force : Max. 147 N {15 kg) The tangential force is the maximum force * at the start of rotation.
CBPO3696 1 1
CBP03599
CBP03600
CBPO3601
DISASSEMBLY
AND ASSEMBLY
SWING
4.
Dust seal Using push tool @, press fit dust seal (32). * Replace the dust seal with a new part.
5.
No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. i) Install thrust washer (23) to carrier (24). ii) Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (22). iii) Insert pin (21). or After inserting the pin, caulk the pin portion of the carrier. * Check that the stepped difference between the shaft and carrier is less than 0.2 mm. iv) Assemble thrust washer (20), bearing (19). gear (18), and thrust washer (17), then install snap ring (16). 2)
6.
CBPO3568
(15) to shaft and
Ring gear Install ring gear (14). 6
7.
Install No. 2 carrier assembly case assembly.
MACHINERY
Ring gear mating surface : Gasket sealant (LG-4 or LG-6)
No. 2 sun gear Install No. 2 sun gear (15).
30-52 0
CBP03566
CBPO3567
DISASSEMBLY AND ASSEMBLY
8. No. 1 carrier assembly 1) Assemble No. 1 carrier assemblv as follows. i) install thrust washer (11) to carrier (12). ii) Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (10). iii) Insert pin (9). + After inserting the pin, caulk the pin portion of the carrier. * Check that the stepped difference between the shaft and carrier is less than 0.2 mm.
SWING MACHINERY
CBPO35B5
iv) Assemble thrust washer (8), bearing (7), gear (6), and thrust washer (5), then install snap ring (4).
CEPO3584
2) 3)
Install No. 1 carrier assembly (3). Install No. 1 sun gear (2).
9. Swing motor assembly Install swing motor assembly (1). w
Mounting bolt : 66.15 f 7.35 Nm (6.75 + 0.75 kgm)
&
Motor mating surface : Gasket sealant (LG-4 or LG-6)
CBPO3583
10. Refilling with oil, adding grease Tighten drain plug and add engine oil through oil filler. I& &
PC60-7
Swing machinery case : Approx. 1.5 fi Swing machinery case : Grease fG2-LB Approx. 110 cc
CEPO3582
30-53 0
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME
REMOVAL OF REVOLVING ASSEMBLY
FRAME
Serial No. : 52374 - 57999 a
Disconnect the cable from the negative . minal of the battery.
(-) ter-
1. Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. 2.
Remove counterweight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY.
3.
Disconnect
grease tube (1).
4.
Disconnect
boom cylinder hose (2).
5.
Sling boom cylinder assembly (31, then remove lock plate (41, and remove pin (5).
6.
Remove r&lLO
boom cylinder assembly Boom cylinder
assembly
(3).
: 105 kg
7.
Remove cover (6) at intake hose end, then remove intake hose (7) and clamp (8).
8.
Remove oil filter assembly (9) together with bracket, and move to a point where there is no interference with lifting tool.
9.
Disconnect all hoses (IO) between control valve and swivel joint, and drain hose (1 I).
10. Remove
11
swivel joint stopper bracket (12).
CEPO2003
30-54 0
CBPO2904
Pc60-7
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME
11. Raise block 0, set between wire and frame, then sling, taking care that wire does not contact engine.
12. Remove
mounting bolts, then lift off revolving (x frame assembly (14). * Leave 2 mounting bolts each at the front and rear, use a lever block to adjust the balance of the revolving frame assembly to the front and rear, and left and right, then remove the remaining bolts, and lift off. A
When removing the revolving frame assembly, be careful not to hit the center swivel joint assembly.
ccl ka
Revolving
frame assembly
: 2300 kg
INSTALLATION OF REVOLVING FRAME ASSEMBLY Serial No. : 52374 l
- 57999
Carry out installation moval.
&
Mating
in the reverse order to re-
surface of swing circle :
Gasket sealant (LG-7) &
Thread
of revolving
frame mounting
bolt
: Thread tightener (LT-2) w
.
Revolving
frame mounting bolt : 277.5 + 32.4 Nm (28.3 f 3.3 kgm)
Refilling with oil (hydraulic tank) t Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
l
Bleeding air Ir Bleed the air from the swing motor. For details, see TESTING AND ADJUSTING, Bleeding air.
Fc60-7
30-55 0
REVOLVING FRAME
DISASSEMBLY AND ASSEMBLY
REMOVAL OF REVOLVING FRAME ASSEMBLY Serial No. : 58001 and up
A
Disconnect the cable from the negative (-1 terminal of the battery.
1. Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. 2. Remove counterweight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY.
1
CBP03220
3. Disconnect grease tube (I 1. 4. Disconnect boom cylinder hose (2). 5. Sling boom cylinder assembly (31, then remove lock plate (41, and remove pin (5). 6. Remove boom cylinder assembly (3). 6 LII
Boom cylinder assembly : 105 kg CEPO322 I
7. Disconnect all hoses (IO) between control valve and swivel joint and drain hose (11). 8. Remove swivel joint stopper bracket (12).
CfJPO2904
CrlPO2903 L
9. Raise block 0, set between wire and frame, then sling, taking care that wire does not contact engine.
,.-
30-55-l 0
-
CBPO2905
PCbO-7
DISASSEMBLY
REVOLVING
AND ASSEMBLY
FRAME
10. Remove mounting bolts, then lift off revolving (f frame assembly (14). Leave 2 mounting bolts each at the front and * rear, use a lever block to adjust the balance of the revolving frame assembly to the front and rear, and left and right, then remove the remaining bolts, and lift off. When removing the revolving frame assembly, be careful not to hit the center swivel joint assembly.
A
6 La
Revolving
frame assembly
: 2300 kg
INSTALLATION OF REVOLVING FRAME ASSEMBLY Serial l
No. : 58001
and up
Carry out installation moval.
6
&
Mating
in the reverse order to re-
surface of swing circle : Gasket sealant
Thread of revolving
frame mounting
: Thread tightener m
Revolving
(LG-1) bolt (LT-2)
frame mounting bolt : 277.5 + 32.4 Nm (28.3 f 3.3 kgm)
.
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified * Run the engine to circulate the oil level. through the system. Then check the oil level again.
.
Bleeding air Ir Bleed the air from the swing motor. For details, see TESTING AND ADJUSTING, Bleeding air.
Pcbo-7
’
30-55-2 0
SWING CIRCLE
DISASSEMBLY AND ASSEMBLY
REMOVAL 1.
2.
OF SWING CIRCLE ASSEMBLY
Remove revolving frame assembly. For details, see REMOVAL OF REVdLVlNG ASSEMBLY. Lift off swing circle assembly
(1).
rel
: 110 kg
kg
Swing circle assembly
FRAME
m
INSTALLATION OF SWING CIRCLE ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
race zone Outer
race
soft
zone
DBP00513
m Ir
Set the soft zone S mark on the inside ring of the inner race on the left side of the chassis as shown in the diagram, then install to the track frame.
&
Surface of circle teeth : Grease (G2-LII
6
Mounting
m
Mounting bolt : 276.85 f 31.85 Nm (28.25 f 3.25 kgm)
30-56 0
bolt : Thread tightener (LT-2)
PC60-7
IDLER, RECOIL SPRING
DISASSEMBLY AND ASSEMBLY
I
REMOVAL OF IDLER. RECOIL SPRING ASSEMBLY 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Sling idler and recoil spring assembly out to the front to remove. I+ kP
3.
-
Idler, recoil spring assembly
Disconnect recoil spring assembly assembly (2).
(11, and pull
: 95 kg (3) from idler a
CEiPO3606
: 60 kg
&I kg
Idler assembly
&I kg
Recoil spring assembly
: 35 kg
INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY . 6 z z
Carry out installation moval.
in the reverse order to re-
I
m 6
CBPO3606
Thread of recoil spring assembly mounting bolt : Thread tightener (LT-2)
30-57 0
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
RECOIL SPRING
OF RECOIL SPRING ASSEMBLY
CBPO3607
1. Remove lock plate (11, then remove lubricator (3).
2.
3.
Remove yoke piston spring assembly (4).
assembly
seat (2) and
(5) from
I
recoil
I
Disassembly of recoil spring assembly 1) Set recoil spring assembly (4) to tool B.
A
2)
4.
The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous.. Ir Installed load of spring : 42.63 kN (4,350 kg} Apply hydraulic pressure slowly to compress spring, then remove nut (6). Ir Compress the spring to a point where the nut becomes loose. t Release the hydraulic pressure slowly to remove the spring tension. * Remove pilot (8) and cylinder (9) from spring (7). + Remove O-ring (10) from cylinder.
Disassembly of yoke piston assembly I) Remove wear ring (12) from yoke piston (11). 2) Remove snap ring (13), then remove U-packing (14).
30-58 0
I I
-
CBPO3606
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
C
ASSEMBLY OF RECOIL SPRING ASSEMBLY 1.
2.
Assembly of yoke piston assembly 1) Assemble U-packing (14) to yoke piston (ll), and secure with snap ring (13). 2) Assemble wear ring (12). Assembly of recoil spring assembly 1) Install O-ring (IO) to cylinder (9). 2) Assemble cylinder (9) and pilot (8) to spring (7), and set to tool B. 3) Apply hydraulic pressure slowly to compress spring, and tighten nut (6) so that installed length of spring is dimension “a”. Installed length “a” of spring : 322 mm * 6
4)
Remove B.
Thread of nut : compound Anti-friction recoil spring assembly
(4) from tool
Fill inside of cylinder with a minimum of 120 cc of grease. Inside cylinder : Grease (G2-LI) &
4.
(5) to recoil yoke piston assembly Assemble spring assembly (4). Voke piston sliding portion wear ring : a Grease (G2-LI)
5.
,Y
CBPO3609
(LM-P)
3.
6 ;; z
IO
with Fill OreaSe
OLPOO453
Fit lubricator (3) and seat (2), and secure with lock plate (1). Install the valve so that the direction of the * fitting is to the outside.
.
30-59 0
DISASSEMBLY
DISASSEMBLY 1. Remove 2.
IDLER
AND ASSEMBLY
dowel
OF IDLER ASSEMBLY
pin (I 1, then remove
support (2).
Remove floating seal (3) from support (2) and idler (4).
3.
Pull out idler (4) from shaft (5) and support assembly (5). Ir It is filled with approx. 90 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.
4.
Remove floating seal (6) (on opposite side) from idler (4) and shaft (5) and support assembly (7).
5.
Remove dowel from shaft (5).
6.
Remove
pin (8). then remove
bushings
support
(7)
(9) and (IO) from idler (4).
CBPO36 12
CBPO3611
30-60 0
DBPOO236
IDLER
DISASSEMBLY AND ASSEMBLY -
ASSEMBLY OF IDLER ASSEMBLY 1.
Press fit bushings
(9) and (10) to idler (4).
DBP00238
2.
Fit O-ring and install support (7) to shaft (5) with dowel pin (8).
3.
Install floating seal (6) to idler (4) and shaft (5) and support assembly (7). Coat the sliding surface of the floating seal * with oil, and be careful not to let any dirt or dust get stuck to it. Remove all grease and oil from the contact + surface of the O-ring and the floating seal.
-
6 G z
I
CBPO3617
4.
Assemble idler (4).
shaft (5) and support
assembly
(7) to
CtlPO3618
5.
Add oil between Q
shaft 15) and idler (4).
Oil : 60 cc (SAE3OCD)
DBPOO241
30-61 0
IDLER
DISASSEMBLY AND ASSEMBLY
6.
Install floating seal (3) to idler (4) and support (2). Ir Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. Ir Remove all grease and oil from the contact surface of the O-ring and the floating seal.
4
3
3
CBPO3620
7.
Install O-ring, then install support (2) with dowel pin (1).
CBPO3621
30-62 0
DISASSEMBLY
REMOVAL 1.
TRACK ROLLER
OF TRACK ROLLER ASSEMBLY
Lower work equipment to ground, then loosen a lubricator (11, and relieve track tension. g
2.
AND ASSEMBLY
The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out easily, move the machine backwards and forwards.
bolts of track roller, then mounting Remove 90”, jack up machine with equipment swing work work equipment, and remove track roller assema bly (2) towards outside of machine.
CBP03622
DBP00245
INSTALLATION OF TRACK ROLLER ASSEMBLY l
-
Carry out installation moval.
in the reverse order to re-
a Ir
Adjust the track shoe tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
&
Thread of track roller assembly mounting bolt : Thread tightener (LT-2) Position the plug on the outside of the chassis, then set the track roller assembly to the mounting position. Operate the work equipment control levers to lower the machine gradually, and tighten the mounting bolts partially. Operate the work equipment control levers to lower the machine completely to the ground, then tighten the mounting bolts fully.
30-63 0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY ASSEMBLY 1.
Remove
2.
Remove floating
TRACK ROLLER
OF TRACK ROLLER I
pin (I 1, then remove collar (2).
I
2
seal (3) from collar (2) and roller
(4).
DBP0024
3.
Pull out roller Ir It is filled oil at this area from
(4) from shaft (5). with 75 - 85 cc. of oil, so drain the point or lay a cloth to prevent the becoming dirty.
DBP00247
DBP00249 I
30-64 0
I
DBP00248
DBP00250
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
4.
Remove floating seal (6) (on opposite roller (4) and shaft (5).
5.
Remove
bushings
side) from
(7) and (8) from roller (4). 5
CBPO3629
CBPO3630
30-65 0
TRACK ROLLER
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF TRACK ROLLER ASSEMBLY 1. Using push tool 0, to roller (4).
press fit bushings
(9) and (IO)
2.
Assemble
3.
Install floating seal (6) to shaft (5). * When assembling the floating seal, clean the contact surface of O-ring (6~) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal.
coliar (8) to shaft (51, and install pin (7).
4.
Install floating seals (6) and (3) to roller (4). * For details of the precautions when installing floating seals (6b) and (6d). and (3b) and (3dL see the precautions marked * for Step 3.
5.
Assemble
DBPD0252
CEPD363?
CBPO3634
CBPO3635
shaft (5) to roller (4).
6.
Turn over roller (4) and shaft (5) assembly.
7.
Add oil between
shaft (5) and idler (4).
Oil: 75 - 8%~ (SAEBOCD)
CBP03636
8.
Install floating seal (3) to collar (2). * For details of the precautions when installing floating seals (3a) and (3c), see the precautions marked + for Step 3.
CBP036
30-66 0
CEPO3638
DISASSEMBLY AND ASSEMBLY
9. Assemble
TRACK ROLLER
collar (2) to shaft (5), and install pin (1).
CBPO3639
30-67 0
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
REMOVAL OF CARRIER ROLLER ASSEMBLY 1.
Lower work equipment, then loosen lubricator (l), m and relieve track tension.
A
The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.
2.
Using hydraulic jack 0, push up track to a position where carrier roller assembly can be removed, then remove carrier roller assembly (2). m
CBPO3622
INSTALLATION OF CARRIER ROLLER ASSEMBLY l
Carry out installation moval.
@?4
a
30-68 0
in the reverse
order to re-
Adjust the track tension For details, see TESTING AND ADJUSTING, Testing and adjusting track tension.
Thread of carrier roller assembly ing bolt : Thread tightener (LT-2)
mount-
CBPO3640
DISASSEMBLY
TRACK SHOE
AND ASSEMBLY
-
REMOVAL OF TRACK SHOE ASSEMBLY 1.
Lower work equipment, then loosen lubricator (I), I” and relieve track tension. &
2.
The adjustment high pressure. more than one come out, move forwards.
cylinder is under extremely Never loosen the lubricator turn. If the grease does not the machine backwards and
Move machine forward so that position of master pin is at front of idler, and set block @ in position. pin.
CBPO3622
a
3.
Using tool C, pull out master
4.
Remove tool C, and pull out temporary pin, and remove dust seal, then drive machine in reverse a to lay out track (2).
CEPO3641
INSTALLATION OF TRACK SHOE ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
u It
Adjust the track tension. For details, see TESTING AND ADJUSTING, ing and adjusting track tension.
a Test-
m *
DBP00260
Use tool C and press fit the master pin so that the protrusion dimension “a” from the master pin is the same at both ends of master pin.
/x3& *
When assembling the dust seal, coat the bushing contact surface with grease (G2-LI).
30-69 0
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY
TANK
REMOVAL OF HYDRAULIC TANK ASSEMBLY A
Lower the work equipment completely to the around and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Drain oil from hydraulic tank. -
:
Hydraulic
tank : Approx.
68 fl
2.
Open engine hood.
3.
Remove
handrail
4.
Remove
right side cover (2).
5.
Remove
rubber hose clamp (3).
6.
Remove hose clamp (4). then disconnect
7.
Disconnect hoses (61, (71, (81, and (9). Ir Make match marks before disconnecting.
(1).
hose (5).
CRPO2906
8.
Lift off hydraulic
tank assembly
(10).
Hydraulic
tank assembly
: 70 kg
r+ kn
CBPO2907
a
CBPO3223
30-70 0
HYDRAULIC TANK
DISASSEMBLY AND ASSEMBLV
INSTALLATION OF HYDRAULIC TANK ASSEMBLY .
l
Carry out installation moval.
in the reverse order to re-
&
Thread of hydraulic
w
Hydraulic
tank mounting bolt : Thread tightener (LT-2)
tank mounting bolt : 176.5 + 19.6 Nm I18 f 2 kgml
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through system. Then check the oil level again.
Ia .
Hydraulic
the
tank : 68 b?(SAEIOWCD)
Bleeding air Bleeding air from hydraulic tank. For details, see TESTING AND ADJUSTING, the air.
Pc60-7
Bleed
30-71 0
MAIN PUMP
DISASSEMBLY AND ASSEMBLY
REMOVAL OF MAIN PUMP
ASSEMBLY Serial No. : 52374 - 57999 A
Lower the work equipment completely to the around and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove the hydraulic tank strainer, and using tool Dl, stop the oil. + When not using tool Dl, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. - :
cePo2833
Hydraulic tank : Approx. 65 E
Remove engine hood, then remove undercover under pump. Remove engine safty lever bracket (1). Remove muffler drain pipe (2). Remove muffler cover (3) and muffler assembly (4) togather with exhaust manifold cnnector (5) .
6. Disconnect main pump suction tube (6).
\
7. Disconnect main pump outlet hose (7). 8. Disconnect main pump drain hose (8). 9. Disconnect hose (9).
power mode select pilot pressure
10. Disconnect LS pressure input hose (IO). 11. Disconnect LS pump pressure input hose (1 I). 12. Disconnect blade sennsing pilot pressure hose (12).
30-72 0
1 ‘6cspo*910
DISASSEMBLY AND ASSEMBLY
MAIN PUMP
13. Disconnect ground cable (13).
14. Sling main pump assembly (141, and using forcing screws @ to remove main pump assembly. a &I km
Main pump assembly : 56 kg
INSTALLATION ASSEMBLY
OF MAIN PUMP
UJ
CBPO29l3 I
Serial No. : 52374 - 57996 l
Carry out installation in the reverse order to removal.
6
l
Refilling with oil (PTO gear case) Add engine oil through the oil filler to the specified level. Q
9
PTO gear case : 0.35 e (SAESOCDI
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Q
l
Mating surface of pump case : Gasket sealant (LG-6)
Hydraulic tank : 68 l (SAElOWCD)
Bleeding air Bleed the air from main pump. For details, see TESTING AND ADJUSTING, Bleeding air.
Pc60-7
30-73 0
DISASSEMBLY
MAIN PUMP
AND ASSEMBLY
REMOVAL OF MAIN PUMP ASSEMBLY Serial
a I.
No. : 58001
and up
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove the hydraulic tank strainer, and using tool Dl, stop the oil. * When not using tool Dl, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. :
-
Hydraulic
tank : Approx.
68 t
2.
Drain cooling water.
3.
Remove engine side cover.
4.
Remove two heat insulation move muffler (2).
5.
Disconnect
6.
Disconnect following hoses from main pump. * Drain hoses (4) and (5) Mode selector solenoid pressure input hose
panels (I), then re-
air intake hose (3).
l
l
l
g
f6t Main pump discharge hose (71 LS pump pressure input hose (8) LS pressure input hose (9) Suction tube (IO) If oil is stopped with tool Dl and drain hoses (4) and (5) are disconnected, oil flows out. Accordingly, prepare plugs (07376-50628) inadvance.
7590
30-73- 1 @
PC60-7
DISASSEMBLY
MAIN
AND ASSEMBLY
wire
(11) from
main
PUMP
pump
7.
Disconnect
ground
8.
Sling main ing screws
(141, and using forcpump assembly I to remove main pump assembly.
!” Main
pump
assembly
INSTALLATION ASSEMBLY Serial
.
No. : 58001
Matrng
OF MAIN PUMP
and up
Carry out installation moval.
&I,
: 60 kg
surface
order
to re-
of pump case : Gasket sealant
(LG-6)
in the reverse
Refilling with oil (PTO gear case) Add engine oil through the oil filler to the fied level. I&
speci-
PTO gear case : 0.35 e (SAEBOCD)
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. the the oil through Run the engine to circulate again. level oil the check Then system. %
Hydraulic
tank : 68 !Z(SAEIOWCD)
Bleeding air Bleed the air from main pump. AND see TESTING For details, Bleeding air.
PC60-7
ADJUSTING,
30-73-2 0
DISASSEMBLY AND ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP INPUT SHAFl= OIL SEAL 1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP ASSEMBLY 2.
Remove PTO assembly (1).
3.
Remove snap ring (21, then remove spacer (3).
4.
Lever up oil seal (4) with a screwdriver to remove. a It When removing the oil seal, be extremely careful not to damage the shaft.
INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL l
Carry out installation in the reverse order to removal.
a
Mounting bolt : Thread tightener (LT-2)
w
PTO bearing cage mounting bolt : 55.15 f 7.35 Nm I6.75 + 0.75 kgm)
&
Lip of oil seal : Grease (G2-LI)
&&
Coat the outside circumference of the oil seal thinly with grease (G2-LB, then press fit.
*
30-74 0
Use tool D2 to press fit oil seal (4).
PC60-7
DISASSEMBLY
AND ASSEMBLY
CONTROL
VALVE
REMOVAL OF CONTROL VALVE ASSEMBLY a
g
h
to the completely Lower the work equipment Then loosen the ground and stop the engine. oil filler cap slowly to release the pressure inside the hydraulic tank. is not installed, so loosen the An accumulator sleeve nut of the hose slowly and check that no oil spurts out before removing. the + Make match marks before removing hoses.
1.
Disconnect hoses (I 1, (2) and (3). Sr Disconnect 8 hoses (2) and (3).
2.
Disconnect hoses (4) and (5) between valve and each actuator in order from top. + The order of the hoses from the top is as follows: blade, bucket, arm, boom, R.H. travel, L.H. travel, swing.
3.
Disconnect
4.
Remove
5.
Disconnect
6.
Remove U-bolt mounting ing oil cooler inlet hose.
hoses (6), (71, and (8).
clamp (9).
hoses (IO), (11). (12) and (13). bracket (14) for secur-
CBPO2917
DISASSEMBLY AND ASSEMBLY
7.
Sling control valve assembly (151, then remove 4 mounting bolts of control valve mounting bracket, and lift off control valve assembly together with bracket. &I kg
Control valve assembly : 60 kg
INSTALLATION OF CONTROL VALVE ASSEMBLY l
l
l
Carry out installation in the reverse order to removal. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air t Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see TESTING AND ADJUSTING, Bleeding air.
30-76 0
CONTROL VALVE
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY +
*
Ir
CONTROL
OF CONTROL VALVE ASSEMBLY
The set pressure of the safety valve cannot be adjusted when it is installed on the machine, so do not disassemble. Except for the R.H. and L.H. travel, the spools and pressure compensation valves are not interchangeable, so always mark them before removing them. Loosen the plug with the spool still assembled in the valve body.
1.
Remove main relief valve assembly (I), safety valve assembly (21, LS select valve assembly (3). and unload valve assembly (4).
2.
Swing control valve 1) Remove case (5), then remove spring (6) and retainer (7). 2) Remove plug (8) from spool (121, then remove spring (9) and valve (10).
1)
2)
4.
Travel control valve I) Remove case (51, then remove and retainer (7). 2) Remove spool (13).
spring (6)
Remove case (5). then remove spring (6) and retainer (7). Remove plugs (8) and (11) from spool (141, then remove spring (9) and valve (IO). t Plug (8) is for the RAISE valve plug (11) is for the LOWER valve.
and
5.
Arm control valve 1) Remove case (5), then remove spring (6) and retainer (7). 2) Remove plug (8) from spool (151, then remove spring (9) and valve (IO).
6.
Bucket control valve 1) Remove case (51, then remove spring and retainer (7). 2) Remove plug (8) from spool (16).
7. 3.
VALVE
(6)
Blade control valve I) Remove case (51, then remove spring (6) and retainer (7). 2) Remove plug (8) from spool (17), then remove spring (9) and valve (IO).
Boom control valve
Blade Bucket
LOVER TILT
Arm Boom R. Ii. travel L.It. travel
LOWER REVERSE
REVERSE
DAPDD514
30-78 0
6 E w”
DISASSEMBLY
8.
AND ASSEMBLY
Pressure compensation valve 1) For swing i) Remove plug (18). then remove valve (19). spring (20). and valve (21). ii) Remove piston (22) from valve (21). 2) For travel i) Remove plug (18), then remove valve (23), spring (20), and valve (24). ii) Remove orifice (25) from valve (23). 3) For boom i) Remove plug (18), then remove valve (26), spring (20), and valve (27). ii) Remove piston (28) from valve (27). 4) For arm i) Remove plug (18), then remove valve (29), spring (201, and valve (30). ii) Remove piston (31) from valve (30).
CONTROL
5)
6)
VALVE
For bucket i) Remove plug (18), then remove valve (32), spring (20), and valve (33). ii) Remove piston (34) from valve (33). For blade i) Remove plug (18), then remove valve (35), spring (20), and valve (36). ii) Remove piston (37) from valve (36).
9. Remove
suction valve (38).
10. Remove plug (39), then and check valve (41).
remove
spring
(40)
11. Remove plug (43) from body (42), then remove springs (44) and (45) and poppet (46). + ’ The springs are different so be careful to distinguish them. 12. Remove plugs (47) and (48).
CAP0371 9
30-79 0
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
CAP03720
30-80 0
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
I
6
5 CAP03721
30-8 7 0
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
CONTROL
OF CONTROL VALVE ASSEMBLY
*
Except for the R.H. and L.H. travel, the spools and pressure compensation valves are not interchangeable, so always mark them before disassembling them.
5)
.
Before assembling with engine oil.
6)
1.
2.
coat the sliding
Fit O-ring and backup (47) and (48). m
VALVE
surface
ring and install plugs
For travel i) Assemble orifice (25) in valve (23). ii) Assemble valve (23) spring (20), and valve (24) in body, then fit O-ring and install plug (18). For swing i) Assemble piston (22) in valve (21). ii) Assemble valve (21), spring (20). and valve (19) in body, then fit O-ring and install plug (18).
Plug : 39.2 + 4.9 Nm I4 + 0.5 kgm)
Assemble poppet (46) and springs (45) and (44) to body (42), then fit O-ring and install plug (43). m
3.
Assemble check valve (41) and spring (40) to body, then fit O-ring and install plug (35). m
4.
Plug : 29.4 + 4.9 Nm i3 + 0.5 kgm}
Fit O-ring and install suction valve (38). m
5.
Plug : 127.4 & 19.6 Nm I13 + 2 kgm}
Plug : 44.1 + 4.9 Nm I4.5 + 0.5 kgm}
Pressure compensation valve 1) For blade i) Assemble piston (37) in valve (36). ii) Assemble valve (36), spring (20), and valve (35) in body, then fit O-ring and install plug (18). m
Plug: 139.65 * 22.05 Nm (14.25 f 2.25 kgm)
2)
For bucket i) Assemble piston (34) in valve (33). ii) Assemble valve (33), spring (20), and valve (32) in body, then fit O-ring and install plug (18). For arm i) Assemble piston (31) in valve (30). ii) Assemble valve (30), spring (20), and valve (29) in body, then fit O-ring and install plug (18). For boom i) Assemble piston (28) in valve (27). ii) Assemble valve (27). spring (20), and valve (26) in body, then fit O-ring and install plug (18).
3)
4)
CAP03722
30-82
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
CAP03721
30-83
DISASSEMBLY
6.
AND ASSEMBLY
CONTROL
Blade control valve 1) Assemble spool (17) in body. 2) Assemble valve (10) and spring (9), then fit O-ring and install plug (8). Plug : 17.15 + 2.45 Nm il.75
w
3)
* 0.25 kgm)
Assemble retainer (7) and spring (6), then fit O-ring and install case (5). w
Case mounting bolt : 11.27 f 1.47 Nm il.15 + 0.15 kgm}
*
The tightening torques are the same for all the valves, so refer to the tightening torque for the blade valve when tightening the other valves.
3)
Assemble retainer (7) and spring then fit O-ring and install case (5). 10. Travel control valve I) Assemble spool (13) in body. 2) Assemble retainer (7) and spring then fit O-ring and install case (5).
8.
9.
Bucket control valve 1) Assemble spool (16) in body, then fit Oring and install plug (8). 2) Assemble retainer (7) and spring (6), then fit O-ring and install case (5). Arm control valve 1) Assemble spool (15) in body. 2) Assemble valve (10) and spring (9), then fit O-ring and install plug (8). 3) Assemble retainer (7) and spring (6), then fit O-ring and install case (5). Boom control valve 1) Assemble spool (14) in body. 2) Assemble valve (10) and spring (9), then fit O-ring and install plugs (11) and (8). Sr Plug (8) is for the RAISE valve and plug (11) is for the LOWER valve.
2
Blade
(6),
(6),
11. Swing control valve 1) Assemble spool (12) in body. 2) Assemble valve (IO) and spring (9), then fit O-ring and install plug (8). 3) Assemble retainer (7) and spring (6). then fit O-ring and install case (5). 12. Fit O-ring
and install unload
valve assembly
(4). w
7.
VALVE
Unload
13. Fit O-ring
valve : 166.6 f 19.6 Nm (17 + 2 kgm}
and install
LS select valve assem-
bly (3). w
LS select valve : 127.4 f 19.6 Nm {I3 k 2 kgm}
14. Fit O-ring
and install
safety valve
assembly
(2). w
Safety and suction valve : 98 * 9.8 Nm {IO f 1 kgm)
15. Fit O-ring and install sembly (1).
w
main
relief
valve
as-
Main relief valve : 53.9 f 4.9 Nm 15.5 + 0.5 kgm)
LOWER TILT
OunP IN
t
8
OUT
R. Ii. travel L.H. travel Swine
I 30-84
w
2
c
CY
RAISE FORWARD
FORWARD RIGHT
DAP00511
6 6 z
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
0
A--
46
Y
16
16
CAP03720
30-85
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
MAIN RELIEF VALVE
OF MAIN RELIEF VALVE ASSEMBLY
1.
Loosen nut (1). and pull out adjustment screw (21, then remove spring (3) and poppet (4). Ir Before loosening nut (I), measure the protrusion dimension of adjustment screw (2) from the end face of the nut.
2.
Remove snap ring (6) from sleeve move valve (7) and spring (8).
3.
Remove
(5), then
re-
backup ring (9) from sleeve (5).
ASSEMBLY Assemble (5).
OF MAIN RELIEF
backup
ring (9) and O-ring
to sleeve
Assemble spring (8) to valve (71, and assemble in sleeve (51, then install snap ring (6). Assemble (5).
poppet
(4) and spring
(3) in sleeve
Screw adjustment screw (2) into sleeve (51, adjust so that protrusion dimension from end face of locknut (I) is the same as when it was disassembled, then secure with locknut (1). w
+
30-86 0
Locknut : 88.6 + 9.8 Nm I7 + 1 kgm} Check and adjust the relief pressure. For details, see TESTING AND ADJUSTING, Testing and adjusting pressure in work equipment, travel, swing circuits.
CAP03723
DISASSEMBLY
SOLENOID
AND ASSEMBLY
VALVE
4
REMOVAL OF SOLENOID VALVE ASSEMBLY A
Disconnect the cable from the negative minal of the battery.
H
ter-
1. Open engine hood. 2.
Remove 4 solenoid wiring connectors clip, then disconnect. t Record the connection number connectiong position of the wiring.
3.
Disconnect 9 hoses (2). * Mark the connecting position with tags before disconnecting.
4.
(I) from m and the
of the hoses
Remove mounting bolts (31, then remove noid valve assembly (4).
sole-
When removing solenoid valve as individual part Remove nut (51, then remove solenoid valve (6). a
INSTALLATION OF SOLENOID VALVE ASSEMBLY l
Carry out installation moval.
Check the connector
in the reverse order to re-
number,
then connect.
Mounting
nut (5) : 4.9 + 0.1 Nm (0.5 f 0.1 kgm)
Solenoid
valve as individual part (6) : 39.2 f 9.8 Nm {4 + 1 kgml
30-87 0
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT LEFT SIDE PPC VALVE
REMOVAL OF WORK EQUIPMENT LEFT SIDE PPC VALVE ASSEMBLY (FOR ARM, SWING CONTROL)
A 1.
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove boot (2) from cover (11, raise to top, then remove lever (3). * Check the direction of the lever.
2.
Disconnect
clamp (4).
3.
Remove cover (1). * Remove the mounting wards rear.
bolts and move
to-
4.
Remove mounting bolts of PPC valve assembly (5). then raise PPC valve assembly, and disconm nect 6 hoses (6).
5.
Remove
PPC valve assembly
(5).
m
INSTALLATION OF WORK EQUIPMENT LEFT SIDE PPC VALVE ASSEMBLY (FOR ARM, SWING CONTROL) l
Carry out installation moval.
m
in the reverse order to re-
Hose joint bolt :
39.2 f 4.9 Nm I4.0 f 0.5 kgm)
t
30-88 0
If there is excessive play in the control levers, adjust the PPC valve. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.
CEPO3646
WORK EQUIPMENT RIGHT SIDE PPC VALVE
DISASSEMBLY AND ASSEMBLY
REMOVAL OF WORK EQUIPMENT RIGHT SIDE PPC VALVE ASSEMBLY (FOR BOOM, BUCKET CONTROL) g
to the completely Lower the work equipment Then loosen the ground and stop the engine. oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Remove boot (2) from cover (11, raise to top, then disconnect wiring of horn, and remove lever (3). Ir Check the direction of the lever. It Move cover (1) up.
2.
Disconnect
3.
Remove mounting bolts of PPC valve assembly (5), then raise PPC valve assembly, and disconm nect 6 hoses (4).
4.
Remove
wiring clamp.
PPC valve assembly
(5).
a
6 E 2
w
CBPO3649
CEPO3650
INSTALLATION OF WORK EQUIPMENT RIGHT SIDE PPC VALVE ASSEMBLY (FOR BOOM, BUCKET CONTROL) l
Carry out installation moval.
m
in the reverse
order to re-
Hose joint bolt :
39.2 * 4.9 Nm t4.0 * 0.5 kgm)
Ir
If there is excessive play in the control leFor details, see vers, adjust the PPC valve. Adjusting PPC TESTING AND ADJUSTING, valve.
30-89 0
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT PPC VALVE
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY (FOR BOOM, ARM, BUCKET, SWING CONTROL PPC VALVE) 1.
Remove
nut (l), then remove
disc (2) and boot
(3). 2.
Remove bolts, then remove plate (5). Ir Do not remove joint (4) unless it is to be replaced.
3.
Remove
4.
Pull out piston (81, and remove retainer (91, springs (10) and (11). and shim (12). * Spring (10) consists of a set of two types of springs with different installed loads, so check the mounting position (oil port) and mark with tags to prevent mistakes when installing.
5.
Pull out valve (13) from body (14).
30-90 0
seal (6) and collar (7).
DISASSEMBLY
AND ASSEMBLY
WORK EQUIPMENT
PPC VALVE
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY (FOR BOOM, ARM, BUCKET, SWING CONTROL PPC VALVE) 1.
Assembly
2.
Assemble
7.
valve (13) to body (14). shim
(12) and spring
(11) to valve
(13). * When assembling spring (111, set the end with the small coil diameter (inside diameter) at shim (12) end. 3.
Assemble
spring
(101, retainer
Assemble boot (3) and disc (2), and tighten with nut (1). m *
Nut:
112.7 i 14.7 Nm Ill.5
+ 1.5 kgm}
After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.
(91, and piston
(8). Ir The number of loops in the coil for spring (10) is different for each of the hydraulic ports below, so be careful when installing. )I
+
& *
The position of each port is marked bottom of the valve body.
on the
Piston : Grease (GZ-LII When assembling piston (8). coat the outside of the piston and the inside of the hole in the body with grease. -
4.
Fit O-ring to collar (7) and assemble (141, then install seal (6).
5.
Install plate (5). w
6.
Mounting bolt : 13.23 f 1.47 Nm II.35
5-7.1
in body
2 0.15 kgm)
Install joint (4) w
Sliding portion of joint : Grease
QZI
Female thread of body : Thread tightener
Ir
w *
(G2-LI)
CLIP03652
(LT-2)
Coat two places on the female thread with one drop each of Loctite as shown in the diagram. Joint : 44.1 + 4.9 Nm (4.5 + 0.5 kgmi Keep strictly to the joint tightening
torque.
30-91 0
DISASSEMBLY AND ASSEMBLY
TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC VALVE ASSEMBLY 4h
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Remove
floor mat.
2.
Remove
bottom cover.
3.
Remove
levers (1).
a
4.
Remove
cover (2).
a
5.
Remove
covers (3), then remove
6.
Disconnect 6 PPC hoses (51, and remove PPC valve assembly (6).
springs (4). travel a
INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY l
Carry out installation moval.
+
in the reverse
Adjust the travel lever. For details, see TESTING Adjusting travel lever.
order to re-
AND ADJUSTING,
bolt : 19.6 f 1.96 Nm I2.0 * 0.2 kgm)
m
Cover mounting
w
Hose mounting fiats: 30mm) :
joint
bolt (width
across
39.2 ? 4.9 Nm I4.0 + 0.5 kgm} w
Hose mounting flats: 22mm) :
joint
bolt (width
across
29.4 rt:4.9 Nm I3.0 + 0.5 kgm}
30-92 0
CBPO3654
DISASSEMBLY
TRAVEL PPC VALVE
AND ASSEMBLY
DISASSEMBLY
OF TRAVEL PPC
1.
Remove cover and cam assembly (I), then remove shims (2). Check the number and thickness of shims t (2) for each mounting position, and keep in a safe place.
2.
Remove
plate (3).
3.
Remove
seal (4) and collar (5).
4.
(7), Pull out piston (6). and remove retainer springs (8) and (91, and shims (10). Check the number and thickness of shims * (IO) for each mounting position, and keep in a safe place.
5.
Pull out valve (11) from body (12).
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Assemble
valve (I I) in body (12).
2.
shims (10) and spring (9) to valve Assemble (II). Ir Assemble the same number and thickness of shims (IO) as was removed during disassembly. Standard shim thickness : 0.3 mm at the top and Spring (9) is not symmetrical * bottom, so assemble with the small coil diameter (inside diameter) at the shim end.
3.
Assemble &&
spring (8), retainer
Outside circumference
(7). and piston (6). of piston, body hole : Grease fG2-LI)
4.
Fit O-ring to collar (5) and assemble (II), then install seal (4).
5.
Assemble
6.
Fit cover and cam assembly (I) shims (21, then tighten with bolt. xII1,
30-94 0
in body
plate (3) and assemble
Sliding portion of shaft, connecting portion of lever and piston : Grease (G2-LI)
L
CBPO3656
DISASSEMBLY
*
TRAVEL PPC VALVE
AND ASSEMBLY
the same number and thickness of Assemble shims (2) as was removed during disassembly. Standard shim thickness : 1.6 mm m
Mounting bolt (a) : 27.93 ? 3.43 Nm (2.85 * 0.35 kgm}
m
Mounting bolt (b) : 30.87 f 3.43 Nm (3.15 + 0.35 kgm)
b
CLIP03657
30-95 0
DISASSEMBLY AND ASSEMBLY
BOOM CYLINDER
REMOVAL OF BOOM CYLINDER ASSEMBLY
A
Extend the arm and bucket fully, lower the work equip ment completely to the ground, and put the safety lock lever in the LOCK position.
1.
Disconnect
2.
Sling boom cylinder assembly (21, and remove lock plate, then remove head pin (3). m Sr There are shims installed, so check the number and thickness, and keep in a safe place.
3.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. t Set stand under the cylinder assembly, and adjust the position for slinging the cylinder assembly.
A
grease tube (1).
An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing.
4.
Disconnect
left and right hoses (5).
5.
Disconnect
grease tube (4).
6.
Remove plate, and remove bottom pin (61, then remove boom cylinder assembly (2). 1121 t There are shims installed, so check the number and thickness, and keep in a safe place.
CBPO3659
& kg
30-96 0
Boom cylinder
assembly
: 105 kg
DISASSEMBLY
BOOM
AND ASSEMBLY
CYLINDER
4
INSTALLATION OF BOOM CYLINDER ASSEMBLY Carry out installation moval.
l
&
Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI
&
Greasing
A Ir
l
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder rod (7) and plate (8) is below 1 mm. Ir Standard shim thickness : 1.0 mm
Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI
&
Greasing
Ir
l
after assembling
&
A
6 E z
in the reverse order to re-
after assembling
DBPOOE.15
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder bottom (9) and bracket (10) is below 1 mm. Ir Standard shim thickness : 1 .O mm, 2.0 mm
Bleeding air Ir Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-97 0
DISASSEMBLY AND ASSEMBLY
ARM CYLINDER
REMOVAL OF ARM CYLINDER ASSEMBLY Curl the bucket and arm in, lower them onto a block, then set the safety lock to the LOCK position.
a
1.
Sling arm cylinder
2.
Disconnect
3.
Remove Ir
4.
A
assembly.
grease tube (I).
head pin (2). m so check the There are shims installed, number and thickness, and keep in a safe place. lock plate, then remove
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. is not installed, so loosen the An accumulator sleeve nut of the hose slowlv and check that no oil spurts out before removing.
5.
Disconnect
left and right hoses (3).
6.
Disconnect
grease tube (4).
7.
Raise arm cylinder assembly, remove plate, then remove bottom pin (51, and remove arm cylinder /EJ assembly (6). so check the There are shims installed, * number and thickness, and keep in a safe place. c+ kll
30-98 0
Arm cylinder
assembly
: 80 kg
DISASSEMBLY
AND ASSEMBLY
ARM CYLINDER
INSTALLATION OF ARM CYLINDER ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
&
Inside surface of bushing when bling pin : Anti-friction compound
&
Greasing
A Ir
after assembling
assem(LM-PI
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder rod (7) and bracket (8) is below 1 mm. Standard shim thickness : 1 .O mm
DBP00517
Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Greasing
6
A
5 2
*
l
w l
after assembling
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder bottom (10) and bracket (9) is below 1 mm. * Standard shim thickness : 1 .O mm
DBP00518
Bleeding air Ir Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-99 0
DISASSEMBLY AND ASSEMBLY
BUCKET CYLINDER
REMOVAL OF BUCKET CYLINDER ASSEMBLY
A
Extend the bucket cylinder piston rod approx. 20 mm, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.
1.
Set block 0
under arm top.
2.
Set blocks @ and @ between
3.
Sling bucket cylinder
4.
Remove
5.
Remove lock plate, then remove head pin (21, and tie piston rod with wire to prevent it from coming a out.
link and arm.
assembly. CBPO3667
A
6.
A
a
lock bolt (1).
If pin (2) comes out, link (7) will fall, so be careful that block @ does not come out. * There are shims installed, so check the number and thickness, and keep in a safe place. Disconnect
left and right hoses (3).
UJ
CBPO3666
An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing.
7.
Disconnect
8.
Raise bucket cylinder assembly, remove plate, then remove bottom pin (51, and remove bucket a cylinder assembly (6). * There are shims installed, so check the number and thickness, and keep in a safe place. IL”Ikm
30-l 00 0
grease tube (4).
Bucket cylinder
assembly
: 60 kg
A
‘3
CBP03669
DISASSEMBLY
INSTALLATION l
BUCKET CYLINDER
AND ASSEMBLY
Carry out installation moval.
OF BUCKET in the reverse
o .@j=
order to re-
m
--
Ir
When tightening the locknut, tighten so that the clearance between the plate and nut is 0.5 - 1.5 mm.
6
Inside surface of bushing when bling pin : Anti-friction compound
xTI1,
Grease after assembling
A *
pin: Grease
Grease after assembling
Ir
l
l
--
_-
0. 5-l. 5un
CEP00059
assem(LM-P)
(LM-G)
I
Max
Inn
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between link (8) and link (7) is below 1 mm. Standard shim thickness : 1.0 mm, 2.0 mm
Inside surface of bushing when bling pin : Anti-friction compound
A
--------.----
D0P00519
assem(LM-PI
pin: Grease (LM-G)
I
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder bottom (10) and bracket (9) is below 1 mm. Ir Standard shim thickness : 1 .O mm
Bleeding air Ir Bleed the air from the cylinder. For details, see TESTING ADN ADJUSTING, Bleeding air from hydraulic cylinder.
DBP00520
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30- 101 0
DISASSEMBLY AND ASSEMBLY
BLADE CYLINDER
REMOVAL OF BLADE CYLINDER ASSEMBLY a
Swing the work equipment 45”. lower the work equipment to the ground, then lower the blade to the ground, and stop the engine. Operate the blade control lever 2 - 3 times to release the remaining pressure in the hydraulic piping.
g
Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank, then set the safety lock lever to the LOCK position.
1.
Remove
blade cylinder
protection
cover.
2.
Sling blade cylinder assembly (I), and remove m head mounting pin (2). Ir There are shims installed, so check the number and thickness, and keep in a safe place.
3.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out.
Q,
An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing.
4.
Disconnect
5.
Remove bottom pin (41, and lift off blade cylinder m assembly (1). * There are shims installed, so check the number and thickness, and keep in a safe place. r9 LP
30-102 0
hoses (3).
Blade cylinder
assembly
: 50 kg
DISASSEMBLY
AND ASSEMBLY
BLADE CYLINDER
INSTALLATION OF BLADE CYLINDER ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
(XI A
l
l
When aligning the position of the pin hole, never insert your fingers in the pin hole. Assemble the shims securely to their origi* nal position. Bleeding air Bleed the air from the cylinder. + For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
4
30-l 03 0
HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1.
Cylinder assembly I) Set cylinder assembly (I) in tool El. 2) Using hydraulic pump or power wrench, loosen head assembly (2) with tool E2. 3) Pull out piston rod assembly (3). * Place a container under the cylinder to catch the oil.
CBP03674
2.
Piston rod assembly 1) Set piston rod assembly (3) in tool El. 2) Using hydraulic pump or power wrench, loosen nut (4) with tool E3. * Width across flats of nut: Unit: mm Cylinder
Boom
Arm
Bucket
Blade
Width across flats of nut
70
65
60
80 CRP03675
3)
4) 5)
Remove piston assembly (5) and retainer (6). l Retainer (6) is used for the boom and arm cylinders only. Remove plunger (7). l Boom and arm cylinder only Remove collar (8) and head assembly (9).
I
30-104 0
CBP03677
DISASSEMBLY
6)
AND ASSEMBLY
HYDRAULIC
CYLINDER
Remove cap (12), pull out 9 balls (101, then remove plunger (11). Arm cylinder only l
I
CBPO3678
Boom, arm, bucket cylinder 3.
Disassembly I) Remove 2) Remove
of piston assembly wear ring (13). piston ring (14).
“fl:
6
s w
CBPO3679
Blade cylinder
ti’:
CtlPO3680
30-105 0
HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY
Boom, arm, bucket cylinder 4.
Disassembly 1) Remove 2) Remove 3) Remove seal (19). 4) Remove 5) Remove 6) Remove
of cylinder head assembly O-ring and backup ring (15). O-ring (17). snap ring (18). then remove
22 I5 dust 21
rod packing (20). buffer ring (21). bushing (22).
20
17
I CBP03661
I
,Blade cylinder
I
,
20
22
19
I
30-l 06 0
111 CBPO3662 1
DISASSEMBLV
AND ASSEMBLY
HYDRAULIC
CYLINDER
w
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY Ir Ir
Be careful not to damage the packings, dust seals, and O-rings. Do not try to force the backup ring into position. Warm it in warm water (50 - 60°C) before fitting it.
I,
Assembly
of cylinder head assembly
I) Using tool E6, press fit bushing (22).
2) Assemble
CAP03683
buffer ring (21).
3)
Assemble
47
Using tool E7, install dust seal (197, and secure with snap ring (18).
22
57
Install backup ring (15) and O-ring.
21
6)
Install O-ring (17).
20
'
CAP03684
rod packing (20).
I5
I7
I9 Ia
2.
CBPO3681
Assembly of piston assembly 1)
Using tool E4, expand piston ring (14). + Set the piston ring on the tool E4, and turn the handle 8 - 10 times to expand the ring.
2)
Set tool E5 in position, ring (14).
and compress
piston
CAP03688
3)
6
CAP03687
Assemble wear ring (13). Ir Be careful not to open the end gap of the ring too wide. Ring groove : Grease (G2-LII
CBPO3879
30-l 07 0
DISASSEMBLY
3.
AND ASSEMBLY
HYDRAULIC
CYLINDER
Piston rod assembly 1) Set plunger (1:) to piston rod, assemble 9 balls (IO), then secure with cap (12). * Check that there is a slight play at the tip of the plunger. l Arm cylinder only
2) Assemble 3)
4)
5)
head assembly
(9).
Fit O-ring and backup ring, and assemble collar (8). l Boom and arm cylinder only Assemble plunger (71. l Boom and arm cylinder
only
Assemble retainer (61. l Boom and arm cylinders piston assembly
only
6)
Assemble
7)
Set piston rod assembly
8)
Using tool E3, tighten nut (4).
A
Nut : Thread tightener
m
Nut:
21
CBPO3678
(5).
(2) to tool El.
(LT-2)
I
CBPO3677
2597 f 259.7 Nm (265 * 26.5 kgm)
Bucket
2156 f 215.6 Nm 1220 f 22 kgm}
Blade
3969 f 399.9 Nm (405 f 40.5 kgm)
I
CBPO3676
4.
Cylinder assembly 1) Set cylinder to tool El. 2) Install piston rod assembly (3). * Push the piston rod in fully.
CBPO3675
30-108 0
DISASSEMBLY AND ASSEMBLY
3)
HYDRAULIC CYLINDER
Using hydraulic pump or power wrench, tighten head assembly (2) with tool E2.
w
Head assembly Cylinder
: Tightening
torque
Boom
960.4 f 96.04 Nm (98 f 9.8 kgm)
Arm
784 + 78.4 Nm I80 f 8 kgm) 1st step: Tighten to 1176 - 1372 Nm (120 - 140 kgm). CBPO3674
2nd step: Loosen to 0 Nm (0 kgm). Bucket 3rd step:lighten
to 392 Nm (40 kgm).
4th step: Angle tightening (distance of turning 3.5 - 4.5 mm) Blade
980.0 f 98.0 Nm (100 f 10 kgm)
30-l 09 0
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
REMOVAL OF WORK EQUIPMENT ASSEMBLY g
Extend the arm and bucket fully, lower the work equipment completely to the ground, and set the safety lock lever to the LOCK position.
1. Disconnect
grease tube (I 1.
2.
Sling boom cylinder assembly (2). remove lock plate, then remove head pin (3). m Ir There are shims installed, so check the number and thickness, and keep in a safe place.
3.
Lower boom cylinder
A
assembly
onto stand.
An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing.
4.
Disconnect hoses (4) and (51, and secure to valve with rope. * Install blind plugs at the male end and in the disconnected hoses.
5.
Disconnect lamp.
6.
Disconnect
7.
Raise work equipment assembly, remove plate, then remove foot pin (8) using tool F, and remove B work equipment assembly (9). + There are shims installed, so check the number and thickness, and keep in a safe place. r%ke
wiring
connector
(6) for working
I
5
I CEPO3666
grease hose (7).
Work equipment
assembly
: 1000 kg
CBPO36.99
CBPO3690
30-110 0
DISASSEMBLY
AND ASSEMBLY
WORK EQUIPMENT
INSTALLATION OF WORK EQUIPMENT ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
&
Inside surface of bushing when assembling pin : Anti-friction compound (LM-P)
&
Grease after assembling
A *
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder rod (IO) and bracket (11) is below 1 mm. Standard shim thickness : 1.0 mm
DBP00521
Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling
A t
l
l
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between boom (12) and bracket (13) is below 1 mm. * Standard shim thickness : 0.5 mm, 1.0 mm
0BP00522
Bleeding air Bleed the air from the cylinder. * For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-111 0
DISASSEMBLY AND ASSEMBLY
REMOVAL BLY a
BUCKET
OF BUCKET ASSEM-
Set the back of the bucket facing down, lower the work equipment completely to the ground, and set the safety lock lever to the LOCK position. rings (1 I and (2).
1.
Remove
2.
Pull out pin (31, and remove connecting pin (4) a between link and bucket. Sr There are shims installed, so check the number and thickness, and keep in a safe place.
3.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out.
4.
Pull out pin (51, and remove plate (6), then remove connecting pin (7) between arm and bucket. a + There are shims installed, so check the number and thickness, and keep in a safe place.
5.
After raising work equipment, nect bucket assembly (8). &I kg
Bucket assembly
CBPO3691
swing to discon-
3694
: 215 kg
COP03695
30-112 0
DISASSEMBLY
BUCKET
AND ASSEMBLY
4
INSTALLATION SEMBLY l
Carry out installation moval.
OF BUCKET ASin the reverse order to re-
Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling
A *
pin : Grease (LM-Gl
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between bucket boss (9) and link (IO) is below 1 mm. Standard shim thickness : 1.0, 1.6, 3.2 mm
I
*
DBP00523
anti-friction
Inside surface of bushing when assembling pin, inside surface, end face of spacer (12) : Anti-friction compound (LM-P) Grease after assembling
A Ir *
pin : Grease (LM-G)
/
-11
DBPOO524
When aligning the position of the pin hole, never insert your fingers in the pin hole. Insert the O-ring at the end face of the bucket boss securely. Adjust the shim thickness so that the clearance between arm top (11) and spacer (12) is below 0.5 mm. Ir Standard shim thickness : 0.5 mm
30-l 13 0
ARM
DISASSEMBLY AND ASSEMBLY
REMOVAL
OF ARM ASSEMBLY
1. Remove bucket assembly. For details, see REMOVAL BLY.
OF BUCKET ASSEM-
2. Secure front link to arm with wire. 3. Pull in arm so that it is easy to remove
pin at arm cylinder head, then lower arm and bucket cylinder assembly (1) on to block (iJ.
A
Set the safety lock lever to the LOCK position.
4. Set block @ between 5. Disconnect
arm cylinder
CBPO3696
and boom.
grease tube (2).
6. Remove
lock plate, then remove arm cylinder m head pin (3). * There are shims installed, so check the number and thickness, and keep in a safe place.
7. Start engine,
and retract piston rod, then tie piston rod with wire to prevent it from coming out.
A
An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing.
8. Disconnect left and right hoses (4). Install blind plugs at the male end and in the * disconnected hoses. 9. Disconnect
grease hose (5).
10. Remove elate, then remove connecting _.pin (6) bem tween arm and boom. * There are shims installed, so check the number and thickness, and keep in a safe place. ll
After raising boom, swing to remove bucket cylinder assembly (I). & ks
30-l 14 0
Arm, bucket cylinder assembly link) : 240 kg
arm and
(including
CBPO3699
DISASSEMBLY
INSTALLATION l
ARM
AND ASSEMBLY
Carry out installation moval.
OF ARM ASSEMBLY in the reverse order to re-
&
Inside surface of bushing when compound bling pin : Anti-friction
&
Grease after assembling
pin : Grease
A *
l
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder rod (7) and bracket (8) is below 1 mm. Standard shim thickness : 1.0 mm *
Inside surface of bushing when compound bling pin : Anti-friction
assem(LM-P)
&
Grease after assembling
pin : Grease
(LM-G)
+
4
(LM-G)
a
A
l
assem(LM-P)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between boom top (9) and arm bottom (10) is below 0.5 mm. Ir Standard shim thickness : 0.5 mm, 1.0 mm
DBP00517
Max.
0. 5hm DBP00525
Bleeding air Bleed the air from the cylinder. * For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) + Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-l 15 0
DISASSEMBLY
BUCKET
AND ASSEMBLY
REMOVAL OF BUCKET ASSEMBLY
a
l
l
ARM
ARM
Curl the bucket and arm in, lower them onto a block, then set the safety lock to the LOCK position.
A
Loosen the oil filler cap slowly to release pressure inside the hydraulic tank.
1. Set block @ between
the
arm cylinder and boom.
2.
Disconnect
3.
Remove lock plate, then remove arm cylinder m head pin (2). * There are shims installed, so check the number and thickness, and keep in a safe place.
4.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. g
grease tube (I).
An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing. CBPO3704
5.
Disconnect left and right hoses (3). * Install blind plugs at the male end and in the disconnected hoses.
6.
Disconnect
7.
Remove lock plate, then remove connecting pin a (5) between arm and boom.
8.
After raising boom, swing to remove bucket and arm assembly (6). * There are shims installed, so check the number and thickness, and keep in a safe place. & LP
30-116 0
grease
hose (4).
Bucket, arm assembly
: 450 kg
DISASSEMBLY
AND ASSEMBLY
BUCKET.
INSTALLATION OF BUCKET ARM ASSEMBLY l
Carry out installation moval.
l
in the reverse order to re-
6
Inside surface of bushing when assembling pin : Anti-friction compound (LM-P)
&
Grease after assembling
a Ir
ARM
pin : Grease (LM-GI
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder rod (7) and bracket (8) is below 1 mm. * Standard shim thickness: 1.0 mm
DEP00517
Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI Grease after assembling
A Ir
l
l
pin : Grease WI-GI
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between boom (9) and arm bottom (IO) is below 0.5 mm. * Standard shim thickness : 0.5 mm, 1.0 mm
DBP00525
Bleeding air * Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to curculate the oil through the system. Then check the oil level again.
30-l 17 0
DISASSEMBLY AND ASSEMBLY
BOOM
1. Remove bucket and arm assembly. For details, see REMOVAL OF BUCKET, ASSEMBLY.
ARM
2. Lower
boom assembly completely to ground, and set safety lock lever to LOCK position.
3. Disconnect
grease tube (I).
4. Sling boom cylinder
assembly (27, and remove lock plate then remove head pin (3). m * There are shims installed, so check the number and thickness, and keep in a safe place.
5. Lower boom cylinder assembly
A
onto stand.
An accumulator is not installed, so loosen the sleeve nut of the hose slowly and check that no oil spurts out before removing.
6. Disconnect
hoses (4) and (5). and secure to valve with rope. It Install blind plugs at the male end and in the disconnected hoses.
7. Disconnect
wiring
connector
5
CBPO3688
(6) for working
lamp.
8. Disconnect
grease hose (7).
9. Raise boom assembly remove
and remove foot pin (8) using tool F.
plate,
then
a 10. Lift off boom assembly (9). * There are shims installed, so check the number and thickness, and keep in a safe place. & km
Boom assembly
(with arm cylinder)
:
CBPO3689
445 kg
CBPO3706
30-118 0
DISASSEMBLY
INSTALLATION SEMBLY l
BOOM
AND ASSEMBLY
Carry out installation moval.
OF BOOM ASin the reverse order to re-
&
Inside surface of bushing when bling pin : Anti-friction compound
&
Grease after assembling
A *
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between cylinder rod (10) and bracket (11) is below 1 mm. Standard shim thickness : 1.0 mm
Inside surface of bushing when bling pin : Anti-friction compound Grease after assembling
A *
l
l
assem(LM-P)
DBPDO521
assem(LM-P)
pin : Grease (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between boom (12) and bracket (13) is below 1 mm. * Standard shim thickness : 0.5 mm, 1.0 mm
DBPD0522
Bleeding air Bleed the air from the cylinder. * For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) + Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-119 0
BLADE
DISASSEMBLY AND ASSEMBLY
REMOVAL
A
OF BLADE ASSEMBLY
Swing the work equipment equipment to the ground, to the ground, and stop the blade control lever 2 the remaining pressure in
45”. lower the work then lower the blade the engine. Operate - 3 times to release the hydraulic piping.
Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank, then set the safety lock lever to the LOCK position.
A
1.
Remove
2.
Sling blade cylinder assembly (lb, and remove m bottom pin (2). * Start the engine, retract the blade cylinder rod, then lower it onto a block. * There are shims installed, so check the number and thickness, and keep in a safe place.
3.
Sling blade assembly, and remove left and right m pins (3). * There are shims installed, so check the number and thickness, and keep in a safe place.
4.
Remove &I kg
blade cylinder
blade assembly Blade assembly
INSTALLATION SEMBLY l
Carry out installation moval.
A Ir
A t
protection
cover.
: 350 kg
OF BLADE ASorder to re-
When aligning the position of the pin hole, never insert your fingers in the pin hole. Insert the shims securely.
When aligning the position of the pin hole, never insert your fingers in the pin hole. Assemble the shims securely to their original position.
30- 120 0
6 5 CEPO3708
(4).
in the reverse
CBPO3707
z
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
w
REMOVAL OF OPERATOR’S CAB ASSEMBLY
A
Disconnect the cable from the negative (-1 terminal of the battery.
1. Remove floor mat.
2.
Disconnect speaker wiring (I), room lamp wiring (21, antenna wiring (3), and washer hose (4). * Fit tags to mark the male and female ends of the connectors to prevent mistakes when connecting.
3.
Disconnect wiper motor wiring connector (5).
4.
Remove 9 cab mounting bolts. t Check the position of the chassis ground connection.
5.
Lift off operator’s cab assembly (6).
CBPO3709
& ha
Operator’s cab assembly : 250 kg
INSTALLATION OF OPERATOR’S CAB ASSEMBLY l
CBPO3710
Carry out installation in the reverse order to removal.
CBPO3
CBPO3712
PC60-7
30-121 0
DISASSEMBLY
AND ASSEMBLY
COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT ASSEMBLY Serial No. : 52374 1. Open engine
- 57999
hood.
cover (I) at intake hose side.
2.
Remove
3.
Disconnect
reservoir tank hose (2).
24.
window Disconnect connector (4).
5.
Set eyebolts and sling.
washer
tank hose (3) and
@ to counterweight
assembly
(51,
3-
6.
CBPO2920
CBPO292 1
Remove 4 mounting bolts (4), then lift off coun(“. terweight assembly (5). r+ kg
Counterweight
assembly
: 650 kg
INSTALLATION OF COUNTERWEIGHT ASSEMBLY Serial No. : 52374 - 57999 l
Carry out installation moval.
in the reverse order to re-
If bolt : (LT-2) tightener Thread
of counterweight
mounting
&
Thread
m
mounting bolt : Counterweight 549.2 + 58.8 Nm I56 & 6 kgm)
*
adjust When installing the counterweight, so that the clearance and stepped difference is uniform on the left and right.
30-122 0
FCbO-7
DISASSEMBLY
COUNTERWEIGHT
AND ASSEMBLY
REMOVAL OF COUNTERWEIGHT ASSEMBLY Serial No. : 58001
and up
1.
Remove engine hood.
2.
Disconnect
3.
Remove air intake hose (2). Ir Disconnect clamp (3).
4.
Remove cover (4).
5.
Remove window
6.
Set eyebolts and sling.
7.
Remove mounting bolts, weight assembly (6). &I kg
reservoir tank hose (I 1.
washer
rank (5) from bracket.
@ to counterweight
Counterweight
then
assembly
assembly
(6),
lift off counter1111
: 715 kg
INSTALLATION OF COUNTERWEIGHT ASSEMBLY Serial No. : 58001 and up *
Carry out installation moval.
in the reverse order to re-
bolt : (LT-2)
6
Thread of counterweight mounting Thread tightener
w
Counterweight mounting bolt : 549.2 k 58.8 Nm I56 + 6 kgml
Ir
When installing the counterweight, adjust so that the clearance and stepped difference is uniform on the left and right.
PC60-7
30- 122- 1 0
DISASSEMBLY
SWING
AND ASSEMBLY
MONITOR CONTROLLER
.
REMOVAL OF MONITOR SEMBLY
AS-
A.
Drsconnect the cable from the negative minal of the battery.
(-) ter-
1.
Remove boot (2) from cover (1). raise to top, then remove lever (3). * Check the direction of the lever.
2.
Disconnect
3.
Remove
horn wiring.
.
cover (lb, and disconnect
3 connectors
(4). 4.
Remove
monitor
assembly
INSTALLATION ASSEMBLY l
6 ;5 r
e
CBPO3713
(5) from cover (I 1. m
OF MONITOR
Carry out installation movaf.
in the reverse
order to re-
m w
Mounting
nut of monitor assembly : 8.33 + 0.49 Nm (0.85 _+0.05 kgmf
1
TROLLER ASSEMBLY
A
Disconnect the cable from the negative minal of the battery.
t-j ter-
1.
Tip operator’s seat over to front, then disconnect wiring connector (I 1 under operator’s seat.
2.
Remove mounting assembly (2).
bolts, then remove
-
CBPO3715
controller
INSTALLATION OF SWING CONTROLLER ASSEMBLY l
W
Carry out installation moval.
in the reverse
order to re-
30-123 0
DISASSEMBLY
CONTROLLER AUTO-GREASING PUMP AUTO-GREASING
AND ASSEMBLY
REMOVAL OF AUTO-GREASING CONTROLLER ASSEMBLY a
Disconnect the cable from the negative minal of the battery.
(-) ter-
hood.
1.
Open engine
2.
Disconnect 3 wiring connectors (1). Fit tags to mark the male and female ends * of the connectors to prevent mistakes when connecting.
3.
Remove 2 mounting ler assembly (2).
bolts, then remove control-
INSTALLATION OF AUTOGREASING CONTROLLER ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
REMOVAL OF AUTO-GREASING PUMP ASSEMBLY A
Disconnect the cable from the negative minal of the battery.
(-) ter-
hood.
1.
Open engine
2.
Remove 2 wiring connectors hose (2).
3.
Remove 2 mounting assembly (3).
(1). and disconnect m
bolts, then remove
pump
INSTALLATION OF AUTOGREASING PUMP ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
a +
Bleeding air inside circuit see Bleeding For details, greasing device.
30-124 0
air from
auto-
CBP03716
40
MAINTENANCE
STANDARD
Swing machinery ......................................... 40- 2 Swing circle .................................................. 40- 3 Track frame ................................................... 40- 4 Idler ............................................................... 40- 5 Track roller .................................................... 40- 6 Carrier roller.. ................................................ 40- 7 Track shoe ..................................................... 40- 8 Hydraulic pump ............................................ 40-l 1 Control valve.. ............................................... 40-I 2 Self-pressure reducing valve.. .................... .40-24 Swing motor ................................................. 40-26 Center swivel joint.. ...................................... 40-27 Work equipment, swing PPC valve ............ .40-29 Travel PPC valve ........................................... 40-30 Service PPC valve ......................................... 40-31 Work equipment ........................................... 40-32 Hydraulic cylinder ........................................ 40-36
do- 1
MAINTENANCE STANDARD
SWING CIRCLE
SWING CIRCLE
Unit: mm
No.
1
Check item
Clearance between bearing and circle
PC60-7
Criteria
Remedy
Standard clearance
Clearance limit
0.3 – 1.2
2.0
Replace
40-3 (10)
MAINTENANCE
STANDARD
TRACK FRAME
TRACK FRAME
1*32Nm .25*3.25knml
SKP03170
Unit: mm
No
Check item
1
Vertical width of idler guide
2
Horizontal width of idler guide
3
40-4
MAINTENANCE
IDLER
STANDARD
IDLER
Unit: mm
No.
Standard size
Repair limit
460
452
415
407
Outside diameter of protrusion of idler
’ 2
Remedy
Criteria
Check item
Outside diameter of tread
I of idler 3
Width of protrusion of idler
43
37
4
Overall width of idler
100
92
5
Width of tread of idler
28.5
32
6
Standard size
Clearance between shaft and bushmg
44 7
8
PC&7
Play of idler in axial direction
Thickness of idler tread (thickness at tread surface)
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
-0.250 -0.290
+0.062 0
0250 0.352
1.5
Replace bushing
Repair limit :1.5
I Standard size
Repair limit
12
8
Rebuild or replace
40-5
MAINTENANCE STANDARD
TRACK ROLLER
TRACK ROLLER Serial No.: 52374 – 60156
Unit: mm
No.
Item
Criteria
Remedy
Basic dimension
Allowable limit
1
Outside diameter of projected part
ø 149
—
2
Outside diameter of tread
ø 120
ø113
3
Width of flange
43
36.6
4
Overall width
129
—
5
Width of tread
43
47.3
6
7
8
9
Clearance between shaft and bushing
Interference between roller and bushing
Side clearance of track roller (Each side)
Thickness of tread (at center of width of tread)
40-6 (11)
Allowance
Overlay or replace
— Overlay or replace
Basic dimension
Shaft
Hole
Standard clearance
Allowable clearance
ø 38
–0.250 –0.270
+0.075 – 0.025
0.225 – 0.345
1.5
Allowance
Basic dimension
Shaft
Hole
ø48
+0.117 +0.087
+0.030 0
Standard Allowable interference interference Replace 0.057 – 0.117
—
Standard clearance
Allowable clearance
0.38 – 0.73
1.5
Basic dimension
Allowable limit
36
32.5
Overlay or replace
PC60-7
TRACK ROLLER
MAINTENANCE STANDARD
Serial No.: 60157and up
Unit: mm
No.
Item
Criteria
Remedy
Basic dimension
Allowable limit
1
Outside diameter of projected part
ø 139
—
2
Outside diameter of tread
ø 110
ø103
3
Width of flange
43
36.6
4
Overall width
136.6
—
5
Width of tread
46.8
51.1
6
7
Clearance between shaft and bushing
Interference between roller and bushing
8
Side clearance of track roller (Each side)
9
Thickness of tread (at center of width of tread)
PC60-7
Allowance
Overlay or replace
— Overlay or replace
Basic dimension
Shaft
Hole
Standard clearance
Allowable clearance
ø 40
–0.250 –0.270
+0.165 – 0.020
0.230 – 0.435
1.5
Allowance
Basic dimension
Shaft
Hole
ø44
+0.150 +0.100
+0.025 – 0.020
Standard Allowable interference interference Replace 0.075 – 0.170
—
Standard clearance
Allowable clearance
0.53 – 1.06
1.5
Basic dimension
Allowable limit
33
29.5
Overlay or replace
40-6-1 (11)
MAINTENANCE
STANDARD
CARRIER ROLLER
CARRIER ROLLER
_’
-..--_I
~,.________.
/,5 ;/ I
_------------
1
,*’
..-._-__-
_-----------.
/;,-*
/
‘/
_________\-‘:
7___.___~____________-.I__._.._..--~\
“<_J
I\ SKP03173
Unit: mm
No.
Criteria
Check item Standard
1
Outside diameter
2
Width of tread
3
:,he-k$ness of carrier roller
PC40-7
of tread
size
Remedy Repair limit
82
78
Rebuild or replace
100
-
Replace
Standard size
Repair limit
10
8
Rebuild or replace
40-7 0
MAINTENANCE
STANDARD
TRACK SHOE
TRACK SHOE TRIPLE SHOE, SWAMP SHOE
I
\
9 Swamp shoe
SLPO3174
40-8
Pc60-7
MAINTENANCE
TRACK SHOE
STANDARD
.
Unit: mm
Criteria
Check item Standard 1
Link pitch
2
Outside diameter bushing
3
Height of grouser
I
size
Remedy
154.25
157.25
41.2
37.2
20
12
of
Triple
I
Reoair limit
Turn or replace
It is possible to carry out lug welding or rebuilding until repair limit has been reached.
Swamp
4
5
6
Height of link
interference between bushing and link
70
74
Standard size
Tolerance Shaft
1
Hole
Standard interference If it exceeds interference limit, replace
Interference between regular pin and link
7
Interference between master pin and link
8
Protrusion
of bushing
Tightening bolt
torque of shoe
g
-
Adjust
Default
: 118 * 20 Nm
Tighten
(12 f 2 kgm, additional Standard
clearance
I
tightening
: 90 f 103
Clearance
26
18
14
4
20
16
limit
. 12
Thickness
PC60-7
of bushing
If it is less than interference limit, replacewith oversize
8.4
4.4 (Heavy)
Weld lug or rebuild
Rebuild replace
or
Turn or replace
40-9 0
MAINTENANCE
STANDARD
RUBBER SHOE
RUBBER SHOE
fi_------__+_j
\
f
\\ j___il
A
i .j, j
A-A
SKPO3175
Unit: mm No.
Criteria
Check item
1
Wear of lug height
2
Wear of roller guard
3
Wear of meshing of sprocket
4
Wear of roller tread height
40-10
portion
Remedy
Standard size
Repair limit
30
5
101
81
3
-2
28.5
23.5
Replace
MAINTENANCE
STANDARD
HYDRAULIC
HYDRAULIC PUMP
PUMP
0
0
0
0
CJ El Y
m
12.3*7.4Nm \(1.25~0.751uml
z /
m
\
1 10.5 f 12.5Nm
I1 1.25* 1.25ks.d
SXPO7103
PCbO-7
40-11 0
MAINTENANCE
STANDARD
CONTROL VALVE
CONTROL VALVE 6-SPOOL OIL PRESSURE ASSIST TYPE (STANDARD SPECIFICATION)
E D
---I
E
SKP03177
40-l 2
PC60-7
MAINTENANCE
7-SPOOL
STANDARD
HYDRAULIC PUMP
OIL PRESSURE ASSIST TYPE (STANDARD + 1 SERVICE VALVE)
I
-c
l-l-GA
D---l
I
c
SKP03178
MAINTENANCE
CONTROL VALVE
STANDARD
(STANDARD SPECIFICATION)
A-A SKP03179
Unit: mm Criteria
Check item
No.
Remedy Repair limit
Standard size Freelengthx OD Installedlength Installed load 1
Free length
Installed load
Cooler bypass valve spring 50.2 x 21.6
40-14 0
33
231.4 N 123.6 kg}
-
185.3 N 118.9 kg}
Re@acf!
sprmg if damaged deformed
or
MAINTENANCE
HYDRAULIC PUMP
STANDARD
4
(STANDARD + 1 SERVICE VALVE)
A-A SKP03180
Unit: mm
No.
Criteria
Check item
Remedy Repair limit
Standard size Freelengthx OD Installedlength Installed load
.
1
Free length
Installed load
Cooler bypass valve spring I 50.2 x 21.6
33
231.4 N (23.6 kg1
-
185.3 N (18.9 kg)
Replace
. spring if damaged or deformed
40-15'
MAINTENANCE
CONTROL VALVE
STANDARD
(STANDARD SPECIFICATION)
I
I
I
3
I
3
I
I
I
I
2
SKP03181
No.
Remedy
Criteria
Check item
Repair limit
Standard size ,
Spool return spring (work equipment, travel)
x OD InstalledlengthInstalledload Freelength
Free length
Installed load
41.1 x 19.3
40.5
34.3 N (3.5 kg)
-
27.4 N 12.6 kg1
2
Spool return spring
(swing)
42.3 x 19.2
40.5
61.7 N 16.3 kg)
-
49 N (5 kg}
3
Spool return spring (boom, arm)
42.3~ 19.2
40.5
54.9 N (5.6 kg)
-
44 N 14.5 kg1
40-16
Replace spring if damaged or deformed
MAINTENANCE
STANDARD
HYDRAULIC PUMP
t
(STANDARD + 1 SERVICE VALVE)
I
I
I
3
1
3
I
I
I
I
2
2
.
B-0
SKP03182
Unit: mm
Spool return spring (work equipment,
travel)
MAINTENANCE
CONTROL VALVE
STANDARD
(STANDARD SPECIFICATION)
139.7*22.1Nm (14.25*2.25krml
140:22Nm f14.25*2.251oml
SKP03183
Unit: mm
No
Check
Standard 1
Pressure compensation valve spring
Remedy
Criteria
item
Repair limit
size
Freelengthx OD Installedlength Installed load 28 x 14.4
14.5
13.7 N Il.4 kg)
Free length
Installedload
-
11 N Il.12 kg)
2
Pressure compensation valve spring
33.4 x 14.4
21.5
56 N 15.7 kg}
-
44.7 N 14.56 kg)
3
Pressure compensation valve spring
30.85 x 5.2
20
27.7 N (2.82 kg}
-
22.2 N 12.26 kg)
-
-
40-18
Replace spring if damaged deformed
or
MAINTENANCE
STANDARD
HYDRAULIC PUMP
.
(STANDARD + 1 SERVICE VALVE)
139.7*22.lNm (14.25*2.25bd
402 22Nm 4.25*2.25ksml
c-c SKP03184
Unit: mm Check item
No.
Criteria
Remedy
Standard size 1
Pressure compensation valve
Repair limit
Free length x 00 Installed length Installed load
spring
Free length
Installed load
28 x 14.4
14.5
13.7 N {1.4 kg)
-
11 N il.12 kg)
2
valve Pressure spring compensation
33.4 x 14.4
21.5
56 N 15.7 kg)
-
44.7 N (4.56 kg)
3
Pressure compensation valve spring
30.85 x 5.2
20
27.7 N i2.82 kg)
-
22.2 N (2.26 kg}
Replace spring if damaged or deformed
4
40-l 9
MAINTENANCE
STANDARD
CONTROL
VALVE
(STANDARD SPECIFICATION)
D-D
SKP03185
Unit: mm
Criteria
Check item
Remedy I Reoair r--- limit -~ -
Standard size Freelengthx CID Installedlength Installed load
Free length
Installed load
Check valve spring 27.2 x 6.9
40-20
22
3.9 N (0.4 kg}
-
3.14 N (0.32 kg)
Replace spring if damaged deformed
or
MAINTENANCE
HYDRAULIC PUMP
STANDARD
(STANDARD + 1 SERVICE VALVE)
r D-D
No.
SKPO3186
Remedy
Criteria
Check item
Repair limit
Standard size x OD installedlength Installed load Freelength 1
Free length
Installed load
Check valve spring 27.2 x 6.9
PC60-7
22
3.9 N (0.4 kg)
-
3.14 N IO.32 kg}
Re@ac?
sprmg If damaged or deformed
40-21
MAINTENANCE
CONTROL VALVE
STANDARD
SXPO7104
No.
Check item
I
Criteria
I Standard size
Lift check valve spring
1
40-22 0
Repair limit
lengthInstalledload FraelangthxOD Installed 55.7 x 22.3
44.9
Remedy
36.3 N 13.7 kg)
Free length
-
Installed load
Re@acf!
_ spring If
29 N 12.96 kg)
damaged or deformed
Pc60-7
MAINTENANCE
HYDRAULIC PUMP
STANDARD
M-M SXPO7105
PC60-7
40-23 0
MAINTENANCE
STANDARD
SELF-PRESSURE REDUCING VALVE
SELF-PRESSURE REDUCING VALVE
/
SXPO7106
40-24 0
Pc60-7
MAINTENANCE
STANDARD
SELF-PRESSURE REDUCING VALVE
.
66. I 6. 75* 0. 75 lo.1
22. 05* 2.45Nm 2. 25* 0. 25 km1
9.8*2Nm l*O. 2 km)
B-B
5
SXPO7107
I No.
Check
item
I
I Criteria
I
2
Spring (reducing
size
Repair limit
Free length x OD Installedlength installed load valve main)
ZLZing
19.2 x 7.2
16.1
16.5 x 7.2
12.7
valve pilot) 3
Remedy I
Standard ,
Unit: mm
Spring (sequence
valve large)
4
Spring (sequence
valve small)
5
Spring
71 x 18
63x
10
52
I
54
Free length
19.6 N G’ kg)
-
17.7 N il.8 kg}
20.6 N {2.1 kg}
-
18.6 N il.9 kg}
-
294.4 N t30 kg)
-
I (13.6 kg)
316.5 N (32.3 kg} 149.9 N i15.3 kg)
I
Installed load
Replace spring if damaged deformed
or
133.3 N
I
.
PC60-7
(safety valve)
40-25 0
MAINTENANCE
STANDARD
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT Serial No. : 52374 - 57999
-2 -
.L
\ -
66. 6* 19. 6Nm (7~2b/cn*l
-
SKP03192
Unit: mm Check item
,
Clearance between rotor and shaft
PC60-7
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
60
0.056 - 0.105
0.111
Replace
40-27 0
MAINTENANCE
STANDARD
CENTER SWIVEL JOINT
Serial No. : 58001 and up
31.4*2.9Nm ~3.2~0.3knl
SFPO6909
Unit: mm No.
Clearance between rotor and shaft
1
40-28 0
Criteria
Check item
Remedy
Standard size
Standard clearance
Clearance limit
60
0.056 - 0.105
0.111
Replace
PC60-7
STRUCTURE AND FUNCTION
CENTER SWIVEL JOINT
BLADE SPECIFICATION MACHINE Serial No. : 52374 - 57999
= = -
I
I . -
D T
SKP03193
Unit: mm
,
Criteria
Check item
No.
t$cyhnc;
pC60-7
Remedy
Standard size
Standard clearance
Clearance limit
70
0.056 - 0.105
0.111
between rotor
Replace
40-28-l 0
STRUCTURE AND FUNCTION
CENTER SWIVEL JOINT
Serial No. : 58001 and up
31.4*2.9Nm (3.2*0.3koml
2 -
66.6* 19.6Nm 'i7* &ml
\ -
>
> -Y
16.7*2.9Nm (1.7*0.3kml
SFPO6910
Unit: mm
Check item
No.
Clearance between rotor and shaft
,
40-28-2 0
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
70
0.056 - 0.105
0.111
Replace
PC&7 0
MAINTENANCE
TRAVEL PPC VALVE
STANDARD
TRAVEL PPC VALVE
C-C
D-O
SXPO7109
Unit: mm
No.
Remedy
Criteria
Check item
Repair limit
Standard size Centering spring
1
Metering spring
2
40-30 0
x OD InstalledlengthInstalledload Freelength 48.1 x 15.5
32.5
108N 111 kg1
26.5 x 8.15
24.7
17 N {1.7kg}
Free length
Installed load
-
86 N 18.8 kg}
-
14N t1.4 kg)
Replace spring if damaged or deformed
PC60-7
MAINTENANCE
STANDARD
SERVICE PPC VALVE
SERVICE PPC VALVE
Check item
NO.
Criteria Standard
size
Repair limit
Free length x OD Installedlength Installed load 1
2
Centering
Metering
spring
spring
Remedy
Free length
Installed load
33.6 x 15.3
28.4
124.5 N {12.7 kg)
-
100.0 N (10.2 kg1
22.7 X 6.1
22.0
16.7 N Il.7 kg}
-
13.7 N Il.4 kg}
Replace spring if damaged deformed
or
40-3 1
MAINTENANCE
STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
A-A
E-E
J-J
N-N
F-F
K-K
SLPO3837
40-32
MAINTENANCE
\
r
STANDARD
WORK EQUIPMENT
1
No.
Check item
1
Clearance between bushing and mounting pin of revolving frame and boom
Criteria
Clearance between bushing and mounting pin of boom and arm
3
Clearance between bushing and mounting pin of boom and arm
4
Clearance between bushing and mounting pin of boom and arm
T
Shaft
Hole
Standard clearance
Clearance limit
65
- 0.030 -0.100
+0.174 +O.lOO
0.130 0.274
1.0
+0.174 +O.lOO
0.130 0.274
1.0
1.0
60
1 :;:f;;
50
- 0.225 - 0.285
- 0.062 -0.120
0.105 0.223
50
-0.225 - 0.285
- 0.062 .-0.120
0.105 0.223
1.0
5
+0.149 +O.lOO
0.325 0.434
1.0
6
+0.173 +O.lOO
0.130 0.273
1.0
+0.142 +0.080
0.105 0.229
1.0
-
.
1
Remedy
Standard size
* 2
Tolerance
Replace
7
Clearance between bushing and mounting in of track frame and bla Be (blade specification machine)
Unit: mm
50
-0.225 -0.287
1
40-33
MAINTENANCE STANDARD
WORK EQUIPMENT
DIMENSIONS OF WORK EQUIPMENT 1. Arm
40-34 (11)
PC60-7
MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm PC60-7
No.
Measuring point
Basic dimension
—
ø 60
1 Arm side
Allowance Shaft
Hole
– 0.030 – 0.100
+ 0.100 0
71.5
+ 1.0 0
70
± 1.2
2 Cylinder head side 3
—
ø 60
Boom side
220
Arm side
220
– 0.030 – 0.100
+ 0.100 0 + 0.5 0 – 0.5 – 1.0
4
5
—
142.4
± 2.0
6
—
218.8
± 1.0
7
—
458.6
± 1.0
8
—
1,650
—
9
—
2,093.9
± 3.0
10
—
1,661.2
± 1.3
11
—
258.7
± 0.3
12
—
15.1
± 1.0
13
—
395.1
± 0.1
14
—
342
± 0.1
15
—
312.2
—
16
—
1,066.9
—
17
—
ø 50
Link side
200
Bucket side
200
– 0.225 – 0.285 – 1.0 – 2.0 + 2.0 0
18
19
—
ø 50
20
Arm as individual part
188
21
When pressfitting bushing
200
0 – 0.150
– 0.225 – 0.285
0 – 0.150 – – – –
0.5 1.0 0.5 1.4
Min.
1,055
± 1.5
Max.
1,765
—
22
PC60-7
40-34-1 (11)
MAINTENANCE
STANDARD
WORK EQUIPMENT
.
2.
Bucket
i A-A
SKP03838
.
Unit: mm
NO. 1 2
[
PC60-7
NO.
PC60-7
309.8
12
71
38.6
13
296
3
I
97.1
I
14
I
0 18
4
I
312.2
I
15
I
0 100
5
1
1,057.2
6
1
143.7
I
17
I
18
1
71
-
16
1
0115 95 75
8
60'
19
9
050
20
60
10
200
21
211
40
1 22
11
I
60
]
24
40-35
MAINTENANCE
STANDARD
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER l
:961i96. lNm(98*9. :785*76.5Nm(ao*a. Bucket:See below :981*9a. ONm(lOO* Blade
m
aknl Okml
y;
~2. 6OiO. :2. 65iO. Bucket:2. 16*0.
The diagram shows the boom cylinder.
26Nm(265*26. 26Nm(270*27kPnl 22Nm(220*22krmt
10. Okml
5kPml
(Width (Width (Width
across across across
f lats:70mml flals:65mm) flats:60mm)
SKP04262
Bucket cylinder Order for tightening head 1) Tighten to a tightening torque of 1270 * 98.10 Nm (130 + 10 kgm}. 2) Loosen to a tightening torque of 0.00 Nm IO kgm). 3) Tighten to a tightening torque of 392.0 Nm 140 kgm1. 4) Tighten cylinder head by additional angle. (Tighten 3.5 - 4.5 mm)
No -
Check item Name of cylinder
Clearance between piston rod and bushing
Shaft
Hole
Standard clearance
65
0.030 - 0.070
+0.250 +0.055
0.085 0.326
0.426
60
-0.030 -0.076
+0.151 +0.006
0.024 0.227
0.327
Bucket
55
0.030 - 0.076
+0.151 + 0.006
0.024 0.227
0.327
Blade
50
0.030 -0.104
+0.271 +0.075
0.105 0.375
0.675
Arm
60
- 0.030 -0.100
+0.174 +O.lOO
0.130 0.274
1.0
Bucket
50
- 0.030 -0.100
+0.174 +O.lOO
0.130 0.274
1.0
Blade
70
0.030 -0.104
+0.174 +O.lOO
0.130 0.278
1.0
1.0
Arm
-
2
Clearance between piston rod support shaft and bushing
-
Clearancecylinder between 3
bottom support shaft and bushing
-
40-36
Tolerance
I
Standard size
Boom
1
Criteria
I
Remedy
Clf?yr$ce
Replace bushing
Replace pin and bushing
Boom
65
-0.030 -0.100
+0.174 , +O.lOO
0.130 0.274
Arm
55
0.030 -0.100
+0.174 +O.lOO
0.130 0.274
1.0
Bucket
50
-0.030 -0.100
+0.142 + 0.080
0.130 0.274
1.0
Blade
70
0.030 -0.104
+0.174 +O.lOO
0.130 0.278
1.0
50
OTHER SPECIFICATION
PC60-7
PCbO-7
(For Norway)
. .. . . . . .. .. . . . .. . .. . .. .. . .. . .. . .. . . 50- 3
50- 1 0
PC60-7 (For Norway)
MACHINE MODEL
SERIAL NUMBER
PC60-7
55720 and up (For Norway)
.
PC60-7
This section contains only information related to the Norway For other information, see the PC60-7 Shop Manual.
specification.
CONTENTS GENERAL Dimension .............................................................................................................................................. Specifications ......................................................................................................................................... Weight table ........................................................................................................................................... Table of oil and coolant capacity .........................................................................................................
50505050-l
STRUCTURE AND FUNCTION Work equipment pin automatic grasing system (OPT) ..................................................................... Electrical allocation diagram ............................................................................................................... Electric circuit diagram ........................................................................................................................ Machine monitor system .....................................................................................................................
50-13 50-26 50-30 50-32
TESTING AND ADJUSTING Connector types and mounting TROUBLESHOOTING Troubleshooting
of machine
locations
monitor
..._........__.............................’
5 7 9 1
.... ....... ... .... ....... ............. ......... 50-35
system . . .. . .. .. . . . .. . . . . . . . . . . . . . . . . .. . . . .. . . . . .. .. .. . ... . .. . . .. . .. . . . .. ... ... . .. . .. . . .. . . 50-41
DISASSEMBLY AND ASSEMBLY Auto-greasing controller (OPT) .. . . . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . .. . . . . . . .. . . . . . . . ... . . . .. . . . .. .. . . .. . . . . .. . . .. . .. . . . .. .. .. .. .. . .. .. . . . .. 50-54 Auto-Greasing pump (OPT) .. . . .. .. . . . .. . . . .. . .. . . .. . . . .. . .. . .. . . .. . .. . . . . . . .. .. . . . . . ... . . . .. . . .. . . .. . .. . . . . .. . . .. . .. . . . .. ... . .. ... .. . .. . . .. 50-54
50-4 0
Pc60-7
GENERAL
GENERAL .
GENERAL DIMENSION
. *
The vallues maked C%are for blade specification
Pao-7
only.
50-5 0
GENERAL
GENERAL
WORKING RANGE
Ir
The vallues maked % are for shovel operations. SVPO6836
50-6 0
PC60-7
SPECIFICATIONS
GENERAL
SPECIFICATIONS PC60-7 Machine
model Blade specification
Serial Number
55720 and up
Bucket capacity
m3
0.25
weight
kg
6,700
depth
mm
4,100
Max. vertical wall depth
mm
3,505
Max. digging
Operating
Max. digging
mm
6,360
Max. reach at ground level
reach
mm
6,200
Max. digging
mm
7,150
mm
5,015
Max. lifting height of blade
mm
410
Max. lowering
mm
270
kN {kg)
47 (4,800)
height
Max. dumping
Max. digging
height
depth of blade
force
Swing
speed
rpm
12
Swing
max. slope angle
deg.
20
Travel speed
Km/h
Lo 2.8 Hi 4.5
Gradeability
deg.
35
kPa fkglcm?
30.40 iO.31)
Ground pressure (standard shoe width: 450 mm)
Overall
length (for transport)
mm
6,080
Overall
width
mm
2,280
Overall
width of track
mm
2,150
Overall
height (for transport)
mm
2,765
Overall
height (to top of cab)
mm
2,765
Ground
clearance,
mm
750
counterweight
mm
350
mm
1,750
mm
1,750
mm
5,460
Length of track on ground
mm
2,130
Track gauge
mm
1,700
Height of machine
mm
1,750
mm
2,260 x 470
Min. ground Tail swing
clearance
radius
Min. swing
radius of work equipment
Height of work equipment swing radius
cab
Blade width x height
Pao-7
at min.
50-7 0
GENERAL
SPECIFICATIONS
I
Machine model
Serial Number Model
mm
4- 102 x 120
e (cd
3.92 (3.9201
Flywheel horsepower
W/rpm (HP/mm
44X5/1,750 {54.2/l ,750)
Max. torque
lljrpm (kgm/rpm
Piston displacement
246/l ,200 c75/1,200}
Max. speed at no load
rpm
1,950
Min. speed at no load
rpm
950
Min. fuel consumption
g/kWh fg/HPhI
230 (1721
24V. 4.5kW
Starting motor Alternator
24V. 35A 12V. 70Ah x 2
Battery Radiator core type
CWXQ
Carrier roller (each side)
1
Track roller
5
(each side)
Track shoe
Assembly-type triple grouser, 39 (each side)
Type x No. Discharge amount Set pressure Type x no. Control method
Variable displacement piston type x 1 Umin
155
MPa (kg/cm?
24.5 (250? 6-spool type x 1 Hydraulic assist type
Travel motor
Fixed capacity piston type (with brake valve, parking brake) x 2
Swing motor
Fixed capacity piston type (with brake valve, parking brake) x 1
Hydraulic cylinder
Double-acting piston
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic cooler
50-8 0
55720 and up 40102
Type
[ ‘t t
Blade specification
4-cycle. water-cooled, in-line, vertical, direct injection
No. of cylinders-bore x stroke
0 c”
PC60-7
Air cooled (CFT-1)
KtW-7
GENERAL
WEIGHT TABLE
WEIGHT TABLE ¤
These weights are for reference when handling or transporting components. Unit: kg PC60-7 Machine model Blade specification Serial Number
Engine assembly (excl. water, oil)
382
PTO (coupling) assembly Radiator, oil cooler assembly
55720 and up
6 Serial No.: 55720 – 59774
31
Serial No.: 59775 and up
36
Revolving frame
638
Operator’s cab
260
Operator’s seat
20
Fuel tank (excl. fuel)
50
Hydraulic tank (excl. hydraulic oil)
58
Counterweight
Serial No.: 55720 – 58000
685
Serial No.: 58001 and up
715
Hydraulic pump assembly
57
7-spool control valve
—
8-spool control valve (with blade)
48
Swing circle assembly
99
Swing machinery assembly
43
Swing motor assembly
22
Center swivel joint
16
Track frame assembly • Track frame
1,342 735
• Idler
54 × 2
• Idler cushion
40 × 2
• Carrier roller
3.4 × 2
• Track roller (Serial No.: 55720 – 60156)
13.3 × 10
(Serial No.: 60157 and up)
12.4 × 10
• Travel motor
90 × 2
• Sprocket
25 × 2
Track shoe assembly • Standard triple shoe (450 mm)
400 × 2
• Wide triple shoe (600 mm)
480 × 2
• Swamp shoe (700 mm)
590 × 2
• Rubber shoe (450 mm)
366 × 2
PC60-7
50-9 (11)
GENERAL
WEIGHT TABLE
Unit: kg PC60-7 Machine model Blade specification Serial Number
55720 and up
Boom assembly
410
Arm assembly
160
Link assembly
55
Bucket assembly
210
Blade assembly
360
Boom cylinder assembly
90
Arm cylinder assembly
72
Bucket cylinder assembly
51
Blade cylinder assembly
44
50-10 3
PC60-7
GENERAL
TABLE OF OIL AND COOLANT CAPACITIES
TABLE OF OIL AND COOLANT CAPACITIES RESERVOIR
KIND OF FLUID –30
SELECTION ACCORDING TO AMBIENT TEMPERATURE –20
–10
0
10
20
30
CAPACITY (¬)
40°C Specified
Refill
SAE 30CD SAE 10WCD
14.5 (11.0)
Engine oil pan SAE 10W-30CD
13 (10.5)
SAE 15W-40CD PTO case
0.5(0.35) 0.5(0.35)
Swing machinery case Final drive case (left and right, each)
1.5
1.5
1.7
1.7
0.06
—
90
57
130
—
GO 140
0.21 – 0.23 <0.16 – 0.18>
—
ALBANIA EP-2
0.047 – 0.052
—
Cartridge : 0.5 + Piping : 1.5
—
16(10.3)
—
SAE 30CD Engine oil
Idler (left and right, each)
SAE 30CD
SAE 10WCD SAE 10W-30CD Hydraulic system
SAE 15W-40CD
Hydraulic oil
HO46-HM (Note 1)
ASTM D975 No. 2 Fuel tank
Diesel fuel ª1
Track roller (each)
Gear oil
Carrier roller (each) Cartridge for automatic greasing system (Note 2)
Grease
Cooling system
Coolant
NLGI No. 2 NLGI No. 2
Add Komatsu genuine Super Coolant (AF-ACL) ª1: ASTM D975 No. 1
PC60-7
NLGI No. 0 (Note 3)
( ) : Serial Number 58001 and up < > : Serial Number 60157 and up
50-11 (11)
GENERAL
TABLE OF OIL AND COOLANT CAPACITIES
FUEL, OIL Select the fuel and oil according to the ambient temperature as shown in the table. The specified oil capacity indicates the total amount of oil including the oil in the piping for each component; the refill capacity indicates the amount of oil added when the oil is changed for normal inspection and maintenance. When starting the engine in ambient temperatures of below 0°C. even if the daytime temperature rises to IOC, always use SAElOW or SAElOW-30. Note 1: For hydraulic oil H046-HM, use the oil recommended by Komatsu. See the Operation and Maintenance Manual for details of the procedure for changing the oil. Note 2: There are two types of automatic greasing cartridges available: the standard type (NLGI No. 2) and the cold area type (NLGI No. 0). When changing the automatic greasing cartridge from the standard type to the cold area type, or from the cold area type to the standard type, please see the Operation and Maintenance Manual. Note 3: If the cold area type grease (NLGI No. 0) is used in warm areas, some grease will drip from the ends of the work equipment pins, but there is no problem in the lubricating performance.
ANTI-FREEZE Komatsu genuine Super Coolant (AF-ACL) is added at a proportion of 30% to the cooling water, so there is no need to change the density for temperatures down to -1 O’C. If the temperature goes below -lO’C, adjust the density according to the table below.
*
Use tap water for the coolant.
5042 0
PCoo-7
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC
GREASING SYSTEM
.
STRUCTURE AND FUNCTION WORK EQUIPMENT (OPT)
PIN AUTOMATIC
GREASING
SYSTEM
SLPO3625
1. Flow divider valve (0, @I, @I,@, 0) 2. R.H. work equipment control lever
(boom RAISE) Flow divider valve (@J,0, @I>, Monitor panel Hydraulic pump Grease cartridge Controller Electric grease pump
3. 4. 5. 6. 7. 8. 9. Boom
RAISE oil pressure 10. Flow divider valve (@I>,
PC60-7
switch
Automatic greasing points
l
No. 1
Greasing point
1 @ 1 Arm, bucket connecting pin
pin
1
I
1@ I
Arm, link connecting
1 -6.J 1
Arm cylinder foot pin
10
I
Boom cylinder
rod pin
I
1@ I
Boom cylinder
foot pin
I
@
Boom foot pin
-7
I
50-13 0
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
1. SYSTEM DIAGRAM
Ilresse
Electric
-,-
&?““I
“““,I
DURD -
;z”’ Main
valvckelf-Pressure
I
’I
I
reducino
valve)
SIartina RAISE oil Pressure switch
1
m
switch
Automatic oreasine controller I
Betters THLT#-&
_-t m a
Monitor
Panel
/
Flow
divider
valve
Flow
divider
low
divider
valve
SKP04235
50-14 Co
f’C60-7
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
STRUCTURE AND FUNCTION
2. OPERATION OF SYSTEM . The automatic greasing system
.
adds the hours of operation of the equipment, and every time the total reaches 5 hours, it carries out greasing. The boom RAISE oil pressure switch signal is used to detect operation of the work equipment.
Calculation
The amount of grease for each work equipment pin is set according to the load on the pin.
-_-_-_-______-__-_
ON ---
Susmnsion calculation
.
of
calculation
oom, arm connecting pin
PC60-7
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
3. COMPONENTS OF SYSTEM 1) Controller
SLPO3826
1. 2. 3.
Connector Controller Fuse
Input/output
signals
CN-P44
Specification Model:
LC2MP
4
1 Abnormality signal
I
output
1 5
1 Boom RAISE sianal
I
lnout
6
50-M 0
Starting switch ON signal
Input
PCbO-7
I
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
.
2)
Electric grease pump
SLPO3827
1. Motor 2. Grease cartridge 3. Air bleed plug 4. Pump 5. Pressure switch 6. Connector
Pao-7
Specification Model: LD05CP
50-17 0
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
Operation 1. Greasing, pressurizing l
.
.
When motor (I) rotates in the normal direction, eccentric shaft (2) rotates counterclockwise and pump piston (4) is operated in a reciprocal movement by link plate (3). During the return stroke (+) of pump piston (41, the grease inside cartridge (5) is sucked in, and on the discharge stroke 01, check valve (6) is pushed open and the grease is pushed out to discharge port P. Pressure release spool (7) is moved to the right (0) by pin (8) of eccentric shaft (2) and pressure release hook (9). This shuts off discharge port P and return passage T, so the pressurized condition is maintained.
‘P SKP03828
.
.
When the pressure inside the pump rises and goes above the set pressure, indicator (IO) is pushed to the left (+I, pressure switch (11) is switched ON, and motor (1) stops. When the pressure goes down again and pressure switch (11) is turned OFF, motor (I) starts again and the pressurized condition is maintained.
SKP03829
50-18 0
PC60-7
STRUCTURE AND FUNCTION
.
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
If abnormal pressure is generated in the circuit at discharge port P end, safety valve (12) opens and releases the pressure to return circuit T to protect the equipment from damage.
9 \ P SKP03830
2) Release of pressure, waiting for work . When the greasing is completed, motor (1) .
.
.
.
rotates in reverse, and eccentric shaft (2) rotates clockwise. Pressure release spool (7) is moved to the left ( ) by pin (8) of eccentric shaft (2) and pressure release hook (9). As a result, discharge port P and return circuit T are interconnected, and the pressure in the circuit is released to cartridge (5). When this happens, pump piston (4) moves in a reciprocal motion, but the discharged grease flows to return circuit T, so the pressure does not rise. When the pressure in the circuit drops, indicator (IO) is pushed back, and pressure switch (11) is turned OFF, motor (I) stops. If pressure switch (11) is not turned off, the controller automatically rotates motor (1) in the opposite direction to release the pressure.
f’C60-7
1111,/1,,,,,,, lZl~~~1,,,,,,, 11111/1,,,/,,,
T
1
0 7
50-19 0
STRUCTURE AND FUNCTION
3)
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
Flow divider valve
Type installed
to revolving
frame
b SBPOI480
a. From electric grease pump b. To boom cylinder foot pin @I
50-20 @j
PC60-7
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
Type installed to boom
b
C
d
f SBPO1461
a. b. c. d. e. f.
From electric grease pump To left boom foot pin @ To right boom foot pin @ To arm cylinder foot pin @J To boom cylinder rod end pin @ To arm flow divider valve
.
P&50-7
50-2 1 CD
STRUCTURE AND FUNCTION
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
Type installed to arm
b
C
d
e
f SBPOl462
a. b. c. d. e. f.
From boom flow divider valve To bucket cylinder foot pin @ To arm, link connecting pin @ To arm, bucket connecting pin @) To boom, arm connecting pin @ To arm cylinder rod end pin @
50-22 0
PC&7
STRUCTURE AND FUNCTION
WORK EQUIPMENT
Structure
PIN AUTOMATIC GREASING SYSTEM
A. B. C. D. E. F.
Discharge port Discharge port Measurement chamber Piston chamber Oil passage Supply port
1. Measurement piston 2. Head 3. Body 4. Spring 5. Spring retainer 6. Pilot piston
A
SAP01469
Operation 11 Supply .
.
When grease from the pump is supplied to supply port F, the pressure at supply port F rises and pilot piston (6) is pushed up. As a result, oil passage E opens and the grease enters piston chamber D of measurement piston (1) from oil passage E.
I
6
SAP01463
Pc60-7
50-23 0
STRUCTURE
.
.
.
AND FUNCTION
WORK EQUIPMENT
PIN AUTOMATIC
GREASING
SYSTEM
Measurement piston (I) is pushed down by the grease in piston chamber D, and the grease in measurement chamber C is discharged to the work equipment pins from discharge ports A and B. At the end of this stroke, pilot piston (6) is pushed back down by measurement piston (11, and supply port F and oil passage E are closed. In this way, the measurement and discharge process for one cycle is completed.
SAP01464
2)
.
l
Resetting When the pump enters the pressure release mode, measurement piston (I) is pushed back up by spring (4). When this happens, the grease in piston chamber D passes from oil passage E through the inside of pilot piston (61, and enters measurement chamber C to reset the system to the initial stage in preparation for the next time of actuation.
u 50-24 0
SAP01465
Pc60-7
STFWCTURE
3)
AND FUNCTION
Boom RAISE oil pressure
a -----
1. Plug 2. Switch 3. Connector
F3c60-7
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
switch
I
_
I
I I
1
I
Structure
of
circuit SLPO4237
Specifications Structure of contact : N.O. contact Actuation (ON) pressure: 0.5 f 0.1 MPa {5.0 + 1 .O kg/cm2} Resetting (OFF) pressure: 0.3 + 0.05 MPa (3.0 + 0.5 kg/cm2}
50-25 0
ELECTRICAL ALLOCATION DIAGRAM
STRUCTURE AND FUNCTION
ELECTRICAL ALLOCATION
DIAGRAM
(l/2)
+ SVPO6837
50-26 0
PC60-7
STRUCTURE AND FUNCTION
ELECTRICAL ALLOCATION DIAGRAM
\ 21 \ 25
27
I
/
28
29 + SVPO6838
PC60-7
50-27 0
ELECTRICAL ALLOCATION DIAGRAM
STRUCTURE AND FUNCTION
(l/2) INSIDE CAB
34 33 \
.36
37
SVPO5B39
50-28 0
PCbO-7
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.
ELECTRICAL ALLOCATION DIAGRAM
Front lamp Working lamp Fuel level sensor Mode selection solenoid valve Travel speed solenoid valve Swing brake solenoid valve PPC lock solenoid valve Additional light (Front) Room lamp Additional light (Rear) Starting motor Antenna Glow plug Coolant temperature sensor Engine stop solenoid Window washer Engine oil pressure sensor Alternator Fusible link Battery relay Battery Electric grease pump (OPT) Automatic greasing controller (OPT) Boom RAISE oil pressure switch Swing oil pressure switch Heater unit Additional light relay Wiper motor Horn Horn switch Speaker Monitor panel Fuel control dial Starting switch Fuse box Swing lock prolix switch Additional light switch Radio Wiper switch Swing lock switch PPC lock limit switc Travel boost switch (blade specification machine) One-touch slow-down switch Glow resistance Alarm buzzer Swing holding brake controller
50-29 Co
STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM PC60-7 Serial No. 55720 and up for Norway. t
For details of this page, see page W-23.
:I’ 2::
,
:I _:
ELECTRIC CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
HEATER ER ELECTRIC CIRCUIT DIAGRAM
@
CONTOROL
SWITCH
@I F/C
ACT
SVPO5841
PC60-7
50-31 0
STRUCTURE AND FUNCTION
MACHINE
MONITOR
MACHINE MONITOR SYSTEM
SYSTEM
SLPO4248
Function . The machine monitor system is a system that uses sensors installed at various parts of the machine to observe the condition of the machine. It then processes this information and displays it on a panel to inform the operator of the condition of the machine. . The panel display can be broadly divided into the following: I_ The monitor portion, which issues a warning when any abnormality is found in the machine. 2. The pilot portion, which displays the operation and the condition of the machine 3. The gauge portion, which always displays the condition of the machine Switches for electrical attachments are also installed inside the monitor panel.
l
50-32 0
PCbO-7
STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM
1. MONITOR PANEL
CN-PI
CN-P2
W-P3
/
Iit-
Ch-K7
Outline l
.
l
SLPO3154
Input/output
signals
CN-Pl (monitor Dane11
The monitor panel has a monitor display function and switches for electrical components. It has a built-in CPU (Central Processing Unit) which processes the data and outputs the display. A liquid crystal display is used for the gauge display; lamps are used for the monitor dis-
15 I Starting
play.
1 6 1Coolant tempersture
No Name of signal
signal
CN-P2 (light switch)
PC60-7
No
Name
of signal
$ut,tt
IInput I I Input )
CN-P3 (heater switch)
50-33 0
MACHINE MONITOR SYSTEM
STRUCTUREAND FUNCTION
12
II
IO
9
8. 9. 10. 11. 12.
Coolant temperature gauge Fuel level gauge Light switch One-touch slow-down pilot lamp Fuel control dial
Symbol
Display item
7
6
SKP03155
7. Heater switch (al)
1. Service meter 2. 3. 4. 5. 6.
6
Preheating pilot lamp Automatic greasing caution lamp (~2) Swing lock pilot lamp Charge caution lamp Engine oil pressure caution lamp
Display method
Display range
Engine oil 0 b pressure Sp1po0520
Below 49kPaI0.5 kg/cm’ 1
-+ f3 C.-=.+
Charge amount
When there is defective charging
When the starting switch is turned ON with the engine running, the display is as follows: Normal : OFF Abnormal: ON (buzzer sounds if abnormality occurs when engine is running)
a
Automatic
SKPO3168
greasing
When there is abnormality
Normal : OFF Abnormal: ON
*2
el (left) lights up,
One-touch decel Heater switch
-
Lo : Heater fan Lo Hi : Heater fan Hi
%l
1. Monitor panel lights up Light switch Z3 2. Monitor panel, head light and work lamp light up sllm31u ~1: The switch is installed, but it cannot be used. ~2: Works only on machines equipped with the automatic greasing system (Option). t’C60-7 50-34 0
TESTING AND ADJUSTING
STRUCTURE AND FUNCTION
TESTING AND ADJUSTING CONNECTOR TYPES AND MOUNTING LOCATIONS * Address column in the table indicates the addresses in the connector location diagram
2 I Diode
D8
IKESII
DII
1~~~11 2 I Diode
DA1 I
1 4 I Diode (Solenoid) 4
Diode (Solenoid)
-
El1
1
Heater relay in
P-8
I
I I Heater relay coil
I-
El3
1
Heater relay out
-
El4
1
Ribbon heater
-
FB1 Hl
I
3
-
Ml4
L
2
MJ
L 1 2 1 Fusible link
Fusible link
Ml61
1
M22 1
1 1 I Horn switch
I Q-5 I
1 1 Horn
II-
DA2
El2 I
Ml2 KESl
(3D drawing).
I A-4 I
1 F-7
6 I Fuse box
( S 1 16 I Intermediate
) N-l
H2
L
2
Intermediate
N-l
H3
S
8
Intermediate
N-2
K5
X
4
Fuel control motor relay
A-4
M29 I M 1 2 1 Speed selection switch (for STD) 1 D-l 1
K6
SWP
4
Fuel control motor relay
F-6
M30
K7
SWP
4
Fuel control motor
F-7
M31 KESO
Deceleration indicator
-
M32/ l-~i-1 Decceleration ~~
2
Deceleration indicator
-
M331
-
2
K33 K34 K35
M
2
Fuel control motor relay
KlOl
-
1
Additional light (Right front)
M-9
K102 -
1
Additional light (Left front)
N-9
K$=I-_T-T-l-Addrtrnoal Ml
(
(
M2 1
1 N-9
2
Optional power source
4
Wiper motor
111
1
M40
M-l
switch
Decceleration switch
;rr;;l
-
boost pedal switch (for
;~zJ~I boost pedal switch (for
I D-1 I t D-l t
c-1
1 ( B-terminal of starting motor
( P-2
M41
1 1 ( C-terminal of starting motor
I P-3
M66
-
6
Wiper motor intermediate
Q-2
Engine stop solenoid
Q-8
M67
-
2
Additional light switch
F-4
Intermediate
N-2
M68
-
6
Additional light relay
P-3
1
M3 M4
light (Rear)
M
S
16
1
1
C-l
I Q-3 I I p-2 I
M5
1
R, E-terminal of alternator
a-7
iiGl --T--i]
M8
1
Light
M-l
M751
1 K-9
M76
1
Sefty relay B-terminal
-
MC-M
I
I
I Working lamp
x
I
Additional light intermediate
2 I Sefty relay (s, R-terminal)
Ml0
M
1
Working lamp, intermediate
M-9
M78
1
Optional power source
-
Ml1
L
2
Fusible link
Q-5
M79
1
Optional power source
-
L
Pc60-7
50-35 0
STRUCTURE
AND FUNCTION
f,
!jgi$.d
Pl
IAMd
16 1 Monitor
panel
P2
lKESl/
4 1 Monitor
panel
~3
IKESI~
4 I Monitor
panel
P4
M
Mounting
TESTING
11
location
1 A-81
Buzzer
K-4
P5
1
Fuel sensor
M-9
P6
1
Fuel sensor
M-9
2
Water temperature
sensor
P-8
P13
1
Engine oil pressure switch
Q-8
P44 SWP
6
Auto-greasing
Sl
x
2
Swing pressure switch
Q-3
s2
x
2
Swing pressure switch
Q-4
x
x3
I B-8I x4 I C-81x5
2
P7
controller
AND ADJUSTING
I -
Swing lock prolix switch
F-6
1 1 Swing lock prolix switch
I F-6
4 I Swing lockswitch
) E-l
1 I
I M I
(OPT) B-3
Boom RAISE pressure switch
I
Sl4
T2
M
1
2
I
PPC hydrauirc lock swrtcn, intermediate
1 IG round to revolving
I-1
frame
B-terminal
F-2
I Q-6 I
T4
-
1
Alternator,
T5
-
1
Ground to cab
P-9
T6
-
1
Starting switch (B)
C-8
T7
-
1
Starting switch (BR)
C-8
T8
-
1
Starting switch (ACC)
C-8
T9
-
1
Starting switch (C)
C-8
Q-8
T’8 I
I
1 I Battery relay, E-terminal
I Q-7 I
VI
I x
I
2 1 PPC hydraulic
1Q-91
v3
x
2
Mode selection solenoid
o-9
v4
x
2
Swing holding
O-9
2
Speed selection solenoid
v5
ix
50-36 0
lock solenoid
brake solenoid
o-9
PC60
STRUCTUREAND FUNCTION
Pc60-7
TESTING AND ADJUSTING
50-37 0
STRUCTUREAND FUNCTION
TESTINGAND ADJUSTING
SVPO5843
50-38 0
-t
Pao-7
TESTING AND ADJUSTING
STRUCTURE AND FUNCTION
(Y4)
MB
PC60-7
TROUBLESHOOTING TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) Electric circuit diagram M-l
No indicator (3-second
M-2
of the machine
monitor
systme.. ...................................................................
self-check
is not carried out either) .......................................................................
All the lamps remain
lighting-up
after 3-second
self-check
completed
Some lamps do not light up during self-check
upon starting switch ON.. ........................................................................................................
20-42
a)
All gauge lamps do not light up (caution
20-42
b)
Swing lock, auto-greasing
(all gauge lamps light up) .................................................................................................
20-42
c)
Charge caution
20-42
d)
Engine oil pressure caution lamp does not light up.. .....................................................
lamp does light up) ......................................
failure or preheat
does not light up
lamp does not light up ...........................................................................
When turning ON the power (before engine starting), charge caution lamp does not light up ......................................................................................................................
M-5
When turning ON the power (before engine starting),
M-6
At preheating,
M-7
Though the switch is operated,
M-8
While engine running,
swing lock does not light up ..............................................
20-44
engine oil pressure caution
Indicator
remains
Level rises immediately
20-46
Indicator goes in the red range though overheat does not occur. ............................... Engine water temperature gauge lamp goes off ............................................................ M-l 1 Abnormality in fuel gauge ....................................................................................................... a) All segments of the fuel gauge go off .............................................................................. Fuel gauge indicates
20-46
after starting the engine.
c)
FULL though
the level is low ........................................................
c)
Fuel gauge does not indicate FULL though the tank is full.. ......................................... Malfunction of the buzzer ........................................................................................................ a) Buzzer does not sound ...................................................................................................... b)
20-45 .20-45
in the lowest level (white range) and does not rise
after engine started ...........................................................................................................
b)
20-44
lamp lights up
...............................................................................................
Charge caution lamp lights up while engine running.. ........................................................ Abnormality in engine water temperature gauge .................................................................
b)
M-13
20-43
engine oil pressure 20-43
a)
M-12
20-42
caution lamp does not light up ............................................................................................... preheating indicator does not light up.. ........................................................
(engine oil pressure is normal) M-10
20-41
(all lamps lights up for 3 seconds)
M-4
M-9
20-41
after
the starting switch turned ON ................................................................................................. M-3
20-40
lamp lights up when the starting switch is turned ON
Buzzer does not stop sounding
........................................................................................
Service meter does not work while the engine is running ................................................... a) When the charge caution lamp does not light up ...........................................................
.20-46 20-46 20-47 20-47 20-47 .20-47 20-49 20-49 20-49 20-50 20-50
b)
M-14
When the charge caution lamp lights up, refer to the item M-9.. ................................. .20-50 Auto-greasing abnormality alarm lights up (Auto-greasing controller is normal). ........... .20-50
M-15
Illumination
PC60-7
does not light up.. .............................................................................................. at gauge section does not light up. ............................................................
a)
Illumination
b)
Illumination
at the service meter section does not light up (Service meter itself do work normally) .........................................................................
.20-51 20-51 .20-51
50-41 0
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM
ELECTRIC CIRCUIT DIAGRAM SYSTEM CN-P44 Boon
I
UP switch
fi
OF THE MACHINE
(SWP6) Power
MONITOR
1
aource:24V
--I slensl
Wiper
switch
iii
I I
Noni tar
Dene
Power rourre’24V Pore1 rourcr.24v GND GND Start aisnal Ctolull InI. ,1”,01 Fuel level aeeser
Alarm
buzzer
Illunination
(KESI) Lloht PIMI illumination Power source .24v IKESU_ Heater Hi Heater Lo Heater GND
I
1”
,
-
u
CN-HZ
(L2)
( ( 1
.
N76
Horn
snitch Horn
SVPO5845
50-42 0
PC60-7
TROUBLESHOOTING
M-2
No indicator lamp lights up when the starting switch is turned ON (3-second self-check is not carried out either)
M-l
Ir Ir
M-l,
Before carrying out this troubleshooting, check for engagement failure at relating Before proceeding to the next step, make sure to restore removed connectors.
connectors.
Cause
YES 1* Is the voltage between Pl (female) (1) (2) and 13) (41 normal?
2 YES
Is the fuse2 nor,_ ma, ,not b,own _ * Starting switch ON. NO off)? * 20 - 3ov.
Defective monitor panel
Replace
Breaking wire or connection failure in the wire harness between Pl (1) (2) - fuse2, or between Pl (3) (4) - H2 (2) chassis ground
Repair or replace
Blown-off fuse
Check for cause or fuse blownoff, and replace the fuse
NO
M-l
Related
electrical
Remedy
circuit
CN-Ml I CN-P
I
I * To the
Monitor
battery
relay
Panel
‘APO0989
M-2
+ t Ir
All the lamps remain lighting-up after S-second self-check completed after the starting switch turned ON
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Check the fuse before this troubleshooting.
Cause
Defective monitor panel
PC60-7
Remedy
Replace
50-43 0
M-3
TROUBLESHOOTING
M-3
*
Some lamps do not light up during self-check (all lamps lights up for 3 seconds) upon starting switch ON
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Check the fuse before this troubleshooting.
Ir *
al All gauge lamps do not light up (caution
lamp does light up) Cause
bl Swing lock, auto-greasing light up (all gauge 1 Is there breaking wire in the bulb of the item that zo;s not light P -Visual check for breaking wire in bulbs.
c)
failure or preheat lamps light up)
Remedy
befective monitor panel
teplace
defective light bulb
3eplace
lefective monitor panel
7eplace
Ireaking wire in the harge caution bulb
7eplace
breaking wire in the engine oil pressure :aution bulb
3eplace
does not
YES
-
NO
Charge caution 1
lamp does not light up
YES
Is there breaking wire in the bulb ? To the item M-4 l
Visual check for breaking wire in the bulb.
d)
NO
Engine oil pressure 1
caution
lamp does not light up
YES
Is there breaking wire in the bulb 7 To the item M-5 * Visual check for breaking wire in the bulb.
50-44 0
NO
fJc60-7
TROUBLESHOOTING
M-4
Ir * Ir
M-4, M-5
When turning ON the power (before engine starting), charge caution lamp does not light up
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Check for the breaking wire in the bulb (lamp) before this troubleshooting. YES 1 ,
2 YES Is the voltage between R-terminal M5 of the alterna- for and the chaws ground normal’
N6
_.^ NW
* Startmg switch ON. * 0 - 5v.
M-4
Related
electrical
Remedy
Defective monitor panel
between Pl (101
* Starting switch ON. .o-5v.
Cause
Breaking wire or contac failure in the wire harnes between Pl (10) - Hl (7: 2115(alternator R-terminal
Repair or replace
Defective alternator
Replace
circuit terminal
CN-Pl
CN-Ii
1
CN-M5
TAP00990
M-5
* + *
When turning ON the power (before engine starting), engine oil pressure caution lamp does not light up.
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Check for the breaking wire in the bulb (lamp) before this troubleshooting.
-2 YES .-_
Is the continuity YE iS between Pl (female) (9) and Pl 1 FaT?ale) (3) norbetween the terminal P13 and the
* Starting switch ON. -0 - 5R or lower
M-5
Related
I
* Disconnect Pl. * Starting switch ON. 0 - 5R or lower.
NO
l
circuit diagram CN-P Monttar
.
Remedy
Defective monitor panel
Replace
Breaking wire in the wire harness between Pl (91 ii1 (101 -terminal P13
Repair or replace
Defective engine sor
Replace
-
N0
electrical
Cause
panel
oil sen.
lerninrl
1
CN-H
1
CN-Pl3 QEnoine oil Pressure sensor
TAP0099
PC60-7
I
50-45 0
M-6, M-7
TROUBLESHOOTING
M-6 Ir + *
At preheating,
preheating
indicator does not light up
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. If the lamp does not light up also during the self-check upon power ON, refer to M-2.
YES
1
Is the voltage between Pl (13) and (3) normal? Set the starting switch to the HEAT psition. * 20 - 3ov.
-
NO
Defective monitor panel
Replace
Breaking wire or contact failure in the wire harness between Pl (female) (13) -TlD (starting switch RI) ct;tcsctive starting
Repair or replace
I
Related electrical
M-6
Remedy
circuit diagram W-P1 C&T1 0 @ Startins
switch RI TAP00992
M-7 * *
Though the switch is operated, swing lock does not light up
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. 2 YES
Is the continuity YES between Pl (fe, c male) (12) and the chassis ground? Is the continuity between X5 _ *Disconnect Pl. *Swing lock (male) (1) and switch ON. * Disconnect X5. * Swing lock switch ON.
M-7
-
NO
NO
Related electrical
circuit diagram
Remedy
Cause
Defective monitor panel
Replace
Breaking wire or contact failure in the wire bar. ness between Pl (female1 112) - Hl (9) - M4t3) - X5 [female) (1). or between X5 (female (2) - M4 (5) chassis ground
Repair or replace
Defective switch
Replace
swing
lock
Swine loch switch
Won itor
TAP90993
50-46 0
PC60-7
M-8, M-9
TROUBLESHOOTING
M-8
*
While engine running, engine oil pressure caution lamp lights up (engine oil pressure is normal)
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
*
YES 1 Does the engine oil pressure cau- _ tion lamp go off? p * Remove the terminal P13. NO * Start the engine.
Are Pl (female) (9) and the chassis ground insulated?
2 YES 1
- Continuity
check NO between Pl (female) (9) and chassis ground. - lMR-~4.
M-8
Related electrical
Cause
Remedy
Defective engine oil pressure sensor
Replace
Defective monitor panel
Replace
Wire harness between terminal P13 - Hl (101 - Pl (female) (91 touches the chassis ground
Repair or replace
circuit diagram Terminal Ch-H
ch-Pl Monitor
ch-PI3
1
@Enoine oil oressure Sensor
Panel
TAP00991
M-9 Ir Ir
Charge caution lamp lights up while engine running
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. 2
YES
Is the voltage betYES ween Pl (female) 1110) and (3) norIs the voltage bbtmal? Ween M5 (ma,e) ,,)
,
(alternator R-termi-
NO
nalt and the chassis ground normal? * Disconnect M5. * Engine start. * 20 - 3ov.
M-9
-
* Engine start. * 20 - 3ov.
Defective monitor panel
Wire harnass between Pl (10) - H1 (7), M5 (alterna. qepair or tor R-terminal) touches ,eplace the chassis ground
Insufficient power gener ation of the alternator
NO
Related electrical
circuit diagram CN-P
Xeplace
terminal
I
CN-H
I
CN-MB @
Monitor
qeplace
Panel
A’ ternator R- termanal
1 TAP00990
PC60-7
50-47 0
M-10
TROUBLESHOOTING
M-10 *
Abnormality
in engine water temperature
gauge
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
*
Remedy
Cause a)
Indicator remains in the lowest level (white does not rise after engine started.
range) and
VES
Defective engine temperature sensor
1 Level rises by one step, and finally all seg-
2 YES
* Starting switch one step, and fiON. NO nally all seg* Connect a shortments go off. circuit connector * Starting switch ON. NO to P7 (female). . Make a-shortcircuit between Pl (6) and (3).
b)
Level rises immediately after starting the engine. Indicator goes in the red range though overheat does not occur. 2 YES
Is the voltage between Pl (3) and the body earth normal? *Engine start. * O.lV or lower.
cl
. II ts tne resrstance YES value between P7 1 (male) (1) and (2) H normal? II NO _ Disconnect P7. * Engine start. * Resistance: 4kR or higher. l
NO
lA Does the lowest level lamp light up?
temperature
Breaking wire or contac failure in the wire harness between Pl (female) 16) Hl (5) - P7 (female) (1) or between Pl (female) (2) chassis ground
Repair or replace
Defective monitor panel
Replace
Defective monitor panel
Replace
Defective engine water temperature sensor
Replace
Contact failure between Pl (female) (3) - H2 12) - chassis ground
Check and repair
Defective engine temperature sensor
Replace
gauge lamp goes off
VES
water
2 YES
Is the resistance
-
L value between Pl NO (female) (6) and (3) normal? * Disconnect Pl. Resistance: 1kR or higher.
NO
l
M-10
Replace
rl
Engine water
* Starting switch ON. . Disconnect P7
water
Related
electrical
Defective monitor panel
?eplace
Wire harness between Pl (female) (6) - Hl (5) - P7 (female) (1) touches the chassis ground, or leaks
qepair or ,eplace
circuit diagram C&H
Manlitor
1
Coolant
Panel
Ct+HP rh TAP00994
50-48 0
Pc60-7
TROUBLESHOOTING
M-11 + Ir
M-11
Abnormality
in fuel gauge
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. Cause
a)
All segments
of the fuel gauge go off. Defective fuel sensor (Mode of braking wire i! out of order)
YES 11 Does the fuel gauge indicates FULL (all segments llight up)?
-
2 YES
.
-
Does the fuel _ gauge indicates
* Starting switch ON. . Connect P5 (fe_ NO FuLL ca’.’segments llrght up)? male) and P6 (male). * Starting switch ON.NO *Wait for about 1 . Make a short-circuit betminute. ween Pl (7) and (3). *Wait for about 1 minute.
b)
Fuel gauge indicates
FULL though
YES 2 YES Is the resistance ,- value of the sen1 sor normal?
I
-
-I
Do all segments of the fuel gauge go off7
* Engine start. * O.lV or lower.
NO Disconnect P5. * Starting switch ON. *Wait for about 1 minute. l
h
Fuel gauge does not indicate
,
LrzzA)& . Measure the re$~tfa~~ap;rars~~NO
(female). * At postion F: 1OQ or lower.
PC60-7
FULL though
YES ,
YES
and the chassis 1 ground normal?
. Engine start. . O.lV or lower.
NO
qepair or ,eplace
Defective monitor panel
qeplace
Defective monitor panel
qeplace
Wire harness between Pl female) (71 - H3 (6) - PE female) (1) touches the :hassis ground
qepair or eplace
Defective fuel sensor
qeplace
Zontact failure in Pl ffenale) (3) - HZ (2) -chassis yound
:heck and epair
Iefective monitor panel
leplace
-
* Remove the sensor. * Moving the float by NO hand, measure the resistance between P5 (male) and P6 (female). - At position F: 10R or higher. - At position E: 85fJ or higher.
between Pl (3) and the chassis
Breaking wrre or contact failure in the wire harness between Pl (female) (7) H3 (6) - P5 (female), or between P6 (male) -chassis ground
the level is low 3 YES
cl
Remedy
the tank is full
I
(Iontact failure between I‘1 (female) (3) - H2 (2) c:hassis ground
:heck and epair
1Iefective fuel sensor
leplace
50-49 0
M-l 1
TROUBLESHOOTING
M-l 1
Related
electrical
circuit diagram
ch-PI Monitor
Ch-HI
ch-P6
bane
TAP00995
50-50 0
PC60-7
TROUBLESHOOTING
M-12 *
M-12
Malfunction
of the buzzer
*
Before Before
carrying out this troubleshooting, check for engagement failure at relating proceeding to the next step, make sure to restore removed connectors.
a)
Buzzer does not sound
connectors.
Remedy
YES
Defective monitor panel
11 When Pl (female) (15) and (3) are connected, does the buzzer sound?
-
2 YES -
Is the voltage between P4 (2) NO and chassis ground normal?
* Connect Pl (fe;;;fef (15) and * Start ing switch ON.
* Start ing switch ON. * 20 - 3ov.
NO
Replace
Breaking wire or contact failure in the wire harness between P4 (female) (1) Pl (female) (15). or defective buzzer
Repair or replace
Breaking wire or contact failure in the wire harness between fuse2 - P4 (female) (2)
Repair or replace
I
b)
Buzzer does not stop sounding Cause
1
YES
Does the buzzer stop sounding when Pl is disconnected? Disconnect Pl. - Starting switch ON. l
Ml2
PC60-7
Related
NO
electrical
Remedy
Defective monitor panel
Replace
Wire harness between P4 (female) (1) - Pl (female) (151 touches the chassis ground
Repair or replace
circuit diagram
50-51 0
M-13, M-14
TROUBLESHOOTING
M-13
Service meter does not work while the engine is running
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. When the charge caution 1
Remedy
lamp does not light up
YES
Defective
Is the voltage between Pl (female) (101 and (31 mormal?
b)
When the charge caution
M-13
panel
Breaking wire or contact failure in the wire harness between Pl (10) - Ii7 M5 (alternator R-terminal)
NO
* Engine start. * 20- 3ov.
monitor
Related electrical
Replace
Repair or replace
lamp lights up, refer to the item M-9.
circuit diagram terminal
CN-Pl
Cly-M6
CN-H 1
o Monitor
0
Dane1
Al
ternatnr R-terminal
TAP00990
M-14
* Ir
Auto-greasing ler is normal)
abnormality
alarm lights up (Auto-greasing
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors. YES
Is the voltage between Pl (1 lb and Pl (3) normal?
* Starting switch ON. 18 - 30V. l
2 YES Is the voltage _ between P44 (4) NO and the chassis ground normal? * Start ing switch C-IN
-. .
NO
Related electrical
Panel
Replace
Breaking wire or contact failure in the wire harness between Pl (ll)-Hl (13)P44 (female) (4)
Repair or reolace
Refer to the troubleshooting of the auto-greasing controller
Replace
circuit diagram
ch-PI Monitor
panel
I
*18-3ov.
M-14
Remedy
Defective monitor
1*
control-
CN-H
1
ch-P44 Auto-oressin
controller
TAP00997
50-52 0
Pc60-7
TROUBLESHOOTING
M-15 *
Illumination
M-15
does not light up
*
Before carrying out this troubleshooting, check for engagement failure at relating connectors. Before proceeding to the next step, make sure to restore removed connectors.
a)
Illumination
Cause
at gauge section does not light up.
YES 1 Is the voltage between Pl (female) (16) and (3) normal? * Starting switch
_
YES 2
Is the voltage _ between P2 (3) , eii, swirch ON NO and the chassis ground normal? * 20 - 3ov.
Illumination
leplace
Breaking wire or contacl failure in the wire harness between Pl (female) (161 - P2 (female) (3)
:epair or eplace
_ 3
Is the voltage * Starting switch _ between P2 (4) NO and the chassis ON. * Light switch ON. ground normal? * 20 - 3ov. * Starting switch ON. * 20 - 3ov.
b)
Breaking wire in the illumination lamp (inside the monitor panel)
at the service meter section
YES
teplace
_ Breaking wire in the wire harness between P2 ffemale) (4) - fuse4, or blown-off fuse
NO
does not light up (Service meter itself do work normally)
Cause
Defective monitor panel
M-15
Related electrical
lepair or eplace
Remedy
leplace
circuit diagram To the work Iisht
Lioht
To the battery
switch
relsr TAP00998
PC60-7
Xl-53 0
AUTO-GREASING CONTROLLER AUTO-GREASING PUMP
TROUBLESHOOTING
DISASSEMBLY AND ASSEMBLY REMOVAL OF AUTO-GREASING CONTROLLER ASSEMBLY (OPT) Disconnect the cable from the negative minal of the battery.
dh
f-1 ter-
1.
Open engine hood.
2.
Disconnect 3 wiring connectors (I 1. * Fit tags to mark the male and female ends of the connectors to prevent mistakes when connecting.
3.
Remove 2 mounting ler assembly (2).
bolts, then remove
control-
INSTALLATION OF AUTOGREASING CONTROLLER ASSEMBLY (OPT) l
Carry out installation moval.
in the reverse order to re-
REMOVAL OF AUTO-GREASING PUMP ASSEMBLY (OPT)
A
Disconnect the cable from the negative minal of the battery.
(4 ter-
Open engine hood. Remove 2 wiring hose (2).
connectors
Remove 2 mounting assembly (3).
(I 1, and disconnect m
bolts, then remove
pump
INSTALLATION OF AUTO~o;;~SING PUMP ASSEMBLY l
Carry out installation moval.
@?r
Bleeding air inside circuit For details, see greasing device.
50-54 0
in the reverse order to re-
Bleeding
air from
auto-
PC60-7
90
OTHERS
Hydraulic piping drawing ............................ 90- 3 Hydraulic circuit diagram ............................ 90- 5 Overall system diagram (l/5) ...................... 90- 7 Overall system diagram (2/5) ...................... 90- 9 Overall system diagram (3/5) ...................... 90-I 1 Overall system diagram (4/5) ...................... 90-13 Overall system diagram (5/5) ...................... 90-l 5 Electrical allocation diagram ....................... 90-17 Electric circuit diagram Serial No. : 52374 - 57999 ...................... .90-19 Serial No. : 58001 and up ........................ 90-21 Electric circuit diagram (PC60-7 Serial No. 55720 and up for Norway). .............................................. 90-23 Connector types and mounting locations . .90-201
PC60-7
90-l 0
OTHERS
HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING +
The sketch shows the blade specification machine. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Bucket cylinder Arm cylinder Boom cylinder Swing motor Hydraulic tank R.H. travel motor Hydraulic pump Control valve Oil cooler L.H. travel motor L.H. work equipment PPC valve R.H. work equipment PPC valve Center swivel joint Travel PPC valve Blade cylinder (blade specification machine) PPC lock solenoid valve Swing lock solenoid valve Travel speed solenoid valve Mode selection solenoid valve
SLPO3044
90-3
HYDRAULIC Serial
No.
: 52374
CIRCUIT DIAGRAM - 57999
I
I
A-
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Hydraulic tank Hydraulic filter Strainer Breather Hydraulic pump Control valve 6A. Safety valve 68. Main relief valve 6C. Unload valve 6D. LS select valve 6E. Pressure compensation valve 6F. Swing spool 6G. Pressure compensation valve 6H. L.H. travel spool 61. R.H. travel spool 6J. Pressure compensation valve 6K. Boom spool 6L. Arm spool 6M. Bucket spool 6N. Blade spool Self-pressure reducing valve Boom cylinder Arm cylinder Bucket cylinder Blade cylinder Center swivel ioint Travel motor (i.H.) Travel motor (R.H.) Swing motor R.H. PPC valve L.H. PPC valve Travel PPC valve PPC shuttle valve Solenoid valve Oil cooler
90-5 $.
HYDRAULIC
CIRCUIT DIAGRAM
STANDARD SPECIFICATION Serial
No.
: 58001
SOLENOID ----
and
up
V4LVE
PUMP PRESSURE DETECTION PORT 0
[
‘/-SPOOL r-----
CONTROL
VALVE
w-1
1
}
’
j
BUCKET
CYLINDER
?’r LS
I@----+
L
, ._----__________ RIGHT
’
1
,Nl
ARM
-BOOM
CYLINDER
CYLINDER
PPC VAtYE,:
~~--~._.___._..______________________-_-_____ PI1
IBUCKET
DUMPI PA6
(BUCKfi
CURL) PBS
(REVERSE) PI.7 _----._______________________________________ _---..______, P7 .___TL__~_________----______________
I!!
4----._________.
(BOOM
TRAVEL
HOTOR
LOWER) PB4
(ARM
I Nl PB5
(ARM
OUT)
PAS
PA4
I
------!
,[+&
FORIAROI
_pR________________.___._____~,_____~ :
LEFT
7
, :
PA2
(REVERSE)
‘:LE :TR
LS
SELECT
VALVE SETTING PRESSURE:
SELF-PRESSURE REDUCING VALVE
BRAKE RELEASE PRESSURE:
p__ HYORAUL LS PRESSURE DETECTION
CAP SAFETY SETTING 0 03ato. IO. 39to.
IC
PUMP:
I-
;________________________________________..._.___________________~
’
p=-y VALVE PRESSURE OIsYPa lske/cdI
:
CHECK VALVE CRACKING PRESSURt O-O. 004SYQa IO-O. 046to/cm’I
2. 9WPM I30ko/cm’I
4.9WPI iSOk@/Cdl (FOR PEAK
CUII
BACK PRESSURE VALVE CRACKING PRESSURE: 0 13YPI I I. 3k#/C.‘l
’
BYPASS CRACKING 0 91YPI Id. 3kdCl’l
ISUING
TO LEFT1
CHECK VALVE PRESSURE:
)__
I__
SUCTION STRAINER
PC&l-7
LPV90
1
BYPASS STRAINER
RETURN
L_________________________________________
FILTER
90-5-2
HYDRAULIC
CIRCUIT DIAGRAM
BLADE SPECIFICATION
:
Serial No. 58001 S”LENO ------1
I D
and
PUMP PRESSURE IJETECTlOh PC;RT
up
YAL%;E
.____-__________-____________----------_-.__-.__.--_..__--.---.__.___.__
B-SPOgL
CONlR9t
VALVE
\
i LS )I( -1
/
@
j ARM
CYLINDER
PA ___ BLADE
PPC
VALVE
RAlSE LOWER
BUCKET
1
,
._--*..__________ RIGHJ PPC VALVE,:
(REVERSE1 WJCKET
; i :
III
I
,___.._________._____L~~_~.
; l_P3k_..______________
(ARM
’ P3B 1--.------
TRAVEL
MOTOR
CURL1 PBI
0”T)
PAS
I
BOOM
it-t-h
I A4
;_
c)
[I [r
mDnmLswA4
RIGHT)
PA1
___,---.,_46._._.______________________ (R(G9J JIAYEL
---._P_L___..___________________. (R,GIJ
-_"______._________________-.
:LE ;TR
JgAyEL
FOR1ARO~PA3 JLfF, ,RAYEL
(REVERSE)
REVERSE1 P82
LS
SELECT
SETTING PRESSURE: 19. IYPl l195kS/C~‘I
ELF-PRESSURE EDUCING VALVE
LS PRESSURE/ DETECTION
CAP SAFETY VALVE SETTING PRESSURE03.9fO.015YP8 io.39*0. !Skl/C.'l
2.9WPS l30tD/CD'l
0
,.QYPl 15Otr/cm'J IFOR PEAK CUT1
VALVE
BACK PRESSUR; VALVE ;,R,XpKJNC PRESSURE: (1. 3kdCdl
8YPA;S CHECK VALVE CRACKING PRESSURE: 0.81YPa (8. 3k0/CdI
BRAKE RELEASE
_^___ __
---[SUING TO LEFT1 :I ;:0 i__________..___....________~~____________________~_~ : ;--_‘_‘_“____‘-‘____________________---_______-________________, ; : : ’
CHECK VALVE CRACKING PRESSURi o-0.0045MPa l0-0.046kO/Cn'I SUClloN STRAINER
0YPAjS STRAINER
RET.URN
~.._____---------_._____________________~
FILTER
K60-7
90-5-4
OVERALL
OTHERS
SYSTEM
DIAGRAM
b
OVERALL SYSTEM DIAGRAM
(l/5)
WHEN ALL CONTROL VALVES ARE AT HOLD
SKP04205
90-7
OTHERS
OVERALL
OVERALL SYSTEM DIAGRAM
SYSTEM
DIAGRAM
(2/5)
WHEN SWING IS OPERATED INDEPENDENTLY
’I
SKP04206
90-9
OTHERS
OVERALL
OVERALL SYSTEM DIAGRAM
SYSTEM
DIAGRAM
(3/5)
WHEN LEFT AND RIGHT TRAVEL ARE OPERATED AT SAME TIME
r----
___-_-_ _-_---_-.-___ 1 t
1
I
I
I
J t
IB
iT= I
I
,
/I
L________.________
I
L
___-__ ----k-------SKP04207
90-11
OVERALL
OTHERS
SYSTEM
DIAGRAM
OVERALL SYSTEM DIAGRAM (4/5) WHEN BOOM + ARM ARE OPERATED AT SAME TIME
r
r-
-_-_---_-_-_
-t
-_.___----_-_
1
,b ,.
1
I
r-
SKP04208
90-13
OVERALL
OTHERS
SYSTEM
DIAGRAM
OVERALL SYSTEM DIAGRAM (5/5) WHEN BOOM RAISE + SWING ARE OPERATED AT SAME TIME
r-
-Pr I
SKP04209
90-M
ELECTRICAL
OTHERS
ALLOCATION
DIAGRAM
J ELECTRICAL ALLOCATION DIAGRAM
19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.
Front lamp Working lamp Fuel level sensor Mode selection solenoid valve Travel speed solenoid valve Swing brake solenoid valve PPC lock solenoid valve Room lamp Antenna Engine oil pressure sensor Engine stop solenoid Glow plug Starting motor Window washer Coolant temperature sensor Air conditioner compressor (option) Alternator Battery relay Fusible link Battery Electric grease pump Automatic greasing controller Boom RAISE oil pressure switch Swing oil pressure switch Air conditioner unit Wiper motor Horn
SLPO3143
90-l 7
ELECTLIC CIRCUIT DIAGRAM Serial
No.
: 52374
- 57999 SWING
PRESSURf
SWING CO
II I
PRESSURE
ANTENNA
RADIQ
LOCK LE
SWITCH
IH LA
SPEAKER
INDICATOR TRAVEL
ALARM
ATER r---------,
HORN
BATTERY RELAY
CND
1
SWITCH
II
SWING
RELEASE
STARTING SWITCH
I
I____--__-_-_
TRAVEL
ALARM
;
-I
cw-P. 1
MOTOR
ALARM BUZZER (BOdB) (A)
RELLAY
CONTROLLER
pC60-7
90-19 3:
ELECTLIC CIRCUIT DIAGRAM Serial
No.
: 58001
and up CAD!0
CONNECTjii
CONNECIIQN
TABLE
:RhYEL PEDAL IFOR
SiLEClOR SiYJTCH ASS'Y BLADE1
1
i------
I
EL
I-__ 1
SPEED
WIPER
INDICATOR TRAVEL ALARM r---------7
I 2:'
:::J
FUSE
BATTERY RELAY
I
GND
RING
SWITCH
1172
STARTING SWITCH
i
PC&7
TRAVEFALARM
/
90-21
ELECTRIC CIRCUIT DIAGRAM PC60-7 Serial No. 55720 and up for Norway.
PC60-7
90-23
CONNECTOR
OTHERS
CONNECTOR TYPES AND MOUNTING
TYPES AND MOUNTING
LOCATIONS
LOCATIONS
Serial No. : 52374 - 57999
I’
\
T4
M6
Y26
Y76
PC60-7
90-201 A
DataKom Publishing Corporation 440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186
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