SM PC60-7 Sebd010911

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 (11)
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the c Page to be newly added Add
table below.
Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
00-1 (11) 10-3 10-43 (3) 10-85 10-119

00-2 (3) 10-4 10-44 (3) 10-86 (8) 10-120
00-2-1 (11) 10-5 10-45 (3) 10-87 10-121
00-2-2 (11) 10-6 10-46 (3) 10-88 10-122
00-2-3 (11) 10-7 (8) 10-47 10-89 (3) 10-123
00-3 10-7-1 (8) 10-48 (3) 10-89-1 (8) 10-124
00-4 10-8 10-49 (3) 10-89-2 (8) 10-125
00-5 10-9 10-50 (3) 10-89-3 (8) 10-126
00-6 10-10 10-51 10-89-4 (8) 10-127
00-7 10-11 10-52 10-89-5 (8) 10-128
00-8 10-12 10-53 (3) 10-89-6 (8) 10-129
00-9 10-13 (3) 10-54 10-89-7 (8) 10-130
00-10 10-14 (3) 10-56 (3) 10-89-8 (8) 10-131
00-11 10-15 10-57 (3) 10-90 (3) 10-132
00-12 10-16 10-58 10-90-1 (3) 10-133
00-13 10-17 10-59 10-90-2 (3) 10-134
00-14 10-18 10-60 10-91 (3) 10-135
00-15 10-20 (3) 10-61 10-92 (3) 10-136 (3)
00-16 10-21 10-62 10-93 10-137
00-17 10-22 10-63 10-94 (3) 10-138
00-18 10-23 10-64 10-95 (3) 10-139
00-19 10-24 10-65 10-96 10-140 (3)
00-20 10-25 10-66 10-97 (9) 10-141
00-21 10-26 10-67 10-98 10-142
00-22 10-27 10-68 10-100 (9) 10-143
10-28 10-69 10-101 10-144
01-1 (10) 10-29 10-70 10-102 10-145
01-2 10-30 (3) 10-71 10-103 10-146
01-4 (3) 10-32 10-72 10-104 (3)
01-5 (9) 10-33 10-73 10-105 20-1 (5)
01-5-1 (10) 10-34 10-74 10-106 (3) 20-2 (5)
01-5-2 (9) 10-35 10-75 10-107 (3) 20-2-1 (5)
01-6 (11) 10-36 10-76 (3) 10-108 (3) 20-3 (5)
01-7 10-37 (3) 10-77 10-109 (3) 20-4 (6)
01-8 (11) 10-38 10-78 (3) 10-110 (3) 20-5 (1)
01-9 10-39 10-79 10-112 (3) 20-6 (1)
10-40 (3) 10-80 (3) 10-113 20-7 (1)
10-1 10-41 (3) 10-81 10-114 20-8 (1)
10-2 (9) 10-42 (3) 10-82 (3) 10-116 20-9 (1)
10-2-1 (9) 10-42-1 (3) 10-83 10-117 (9) 20-10 (5)
10-2-2 (9) 10-42-2 (3) 10-84 (3) 10-118 20-11 (5)
PC60-7 00-2-1
(11)
20-12 (5) 20-206 (1) 20-309 (1) 20-412 (1) 30-37 (4)
20-101 (5) 20-207 (1) 20-310 (1) 20-413 (1) 30-37-1 (4)
20-102 (5) 20-208 (1) 20-311 (1) 20-414 (1) 30-37-2 (4)
20-103 (5) 20-209 (1) 20-312 (1) 20-451 (1) 30-37-3 (4)
20-104 (5) 20-210 (1) 20-313 (1) 20-452 (1) 30-37-4 (4)
20-105 (5) 20-211 (1) 20-314 (1) 20-453 (1) 30-38 (4)
20-106 (5) 20-212 (1) 20-315 (1) 20-454 (1) 30-39 (2)
20-107 (5) 20-213 (5) 20-316 (1) 20-456 (1) 30-40 (4)
20-108 (5) 20-214 (1) 20-317 (1) 20-457 (1) 30-40-1 (4)
20-109 (5) 20-215 (5) 20-318 (1) 20-458 (1) 30-40-2 (4)
20-109-1 (5) 20-216 (5) 20-319 (1) 20-459 (1) 30-41 (2)
20-109-2 (5) 20-216-1 (5) 20-320 (1) 30-42 (2)
20-109-3 (5) 20-216-2 (5) 20-321 (1) 30-1 (6) 30-43 (2)
20-109-4 (5) 20-216-3 (5) 20-322 (1) 30-2 (6) 30-44 (2)
20-109-5 (5) 20-216-4 (5) 20-323 (1) 30-3 (2) 30-45 (2)
20-109-6 (5) 20-216-5 (5) 20-324 (1) 30-4 (2) 30-46 (2)
20-109-7 (5) 20-217 (1) 20-351 (1) 30-5 (2) 30-46-2 (6)
20-109-8 (5) 20-218 (1) 20-352 (1) 30-6 (2) 30-46-3 (6)
20-109-9 (5) 20-219 (1) 20-353 (1) 30-7 (2) 30-46-4 (6)
20-109-10 (5) 20-220 (1) 20-354 (5) 30-8 (6) 30-46-5 (6)
20-109-11 (5) 20-221 (1) 20-355 (1) 30-8-1 (6) 30-46-6 (6)
20-109-12 (5) 20-222 (1) 20-356 (1) 30-9 (2) 30-46-7 (6)
20-109-13 (5) 20-223 (1) 20-357 (1) 30-10 (2) 30-46-8 (6)
20-110 (1) 20-224 (1) 20-358 (1) 30-11 (2) 30-46-9 (6)
20-111 (1) 20-225 (1) 20-359 (1) 30-11-1 (6) 30-46-10 (6)
20-112 (1) 20-226 (1) 20-360 (1) 30-11-2 (6) 30-46-11 (6)
20-113 (1) 20-227 (1) 20-361 (1) 30-11-3 (6) 30-46-12 (6)
20-114 (1) 20-228 (1) 20-362 (1) 30-11-4 (6) 30-46-13 (6)
20-115 (1) 20-229 (1) 20-363 (1) 30-11-5 (6) 30-46-14 (6)
20-116 (1) 20-230 (1) 20-364 (1) 30-12 (4) 30-46-15 (6)
20-117 (1) 20-231 (1) 20-365 (1) 30-13 (4) 30-46-16 (6)
20-118 (1) 20-251 (5) 20-366 (1) 30-14 (4) 30-46-17 (6)
20-119 (1) 20-252 (5) 20-367 (1) 30-15 (2) 30-46-18 (6)
20-120 (1) 20-253 (5) 20-368 (1) 30-16 (4) 30-46-19 (6)
20-121 (7) 20-254 (1) 20-369 (1) 30-17 (2) 30-46-20 (6)
20-121-1 (1) 20-255 (1) 20-370 (1) 30-18 (4) 30-46-21 (6)
20-122 (1) 20-256 (1) 20-371 (1) 30-19 (4) 30-46-22 (6)
20-123 (1) 20-258 (1) 20-372 (1) 30-20 (4) 30-46-23 (6)
20-124 (1) 20-259 (1) 20-373 (1) 30-21 (4) 30-46-24 (6)
20-125 (1) 20-260 (1) 20-374 (1) 30-22 (4) 30-46-25 (6)
20-126 (1) 20-261 (5) 20-375 (1) 30-23 (2) 30-46-26 (6)
20-127 (1) 20-262 (1) 20-376 (1) 30-24 (2) 30-46-27 (6)
20-128 (1) 20-263 (1) 20-401 (1) 30-25 (2) 30-46-28 (6)
20-129 (1) 20-264 (1) 20-402 (5) 30-26 (2) 30-46-29 (6)
20-130 (1) 20-265 (1) 20-402-1 (5) 30-27 (2) 30-46-30 (6)
20-131 (1) 20-266 (1) 20-403 (1) 30-28 (2) 30-46-31 (6)
20-132 (1) 20-301 (1) 20-404 (1) 30-29 (2) 30-46-32 (6)
20-133 (1) 20-302 (1) 20-405 (5) 30-30 (2) 30-46-33 (6)
20-134 (1) 20-303 (1) 20-406 (1) 30-31 (4) 30-46-34 (6)
20-201 (5) 20-304 (1) 20-407 (5) 30-32 (2) 30-46-35 (6)
20-202 (1) 20-305 (1) 20-408 (1) 30-33 (2) 30-46-36 (6)
20-203 (1) 20-306 (1) 20-409 (1) 30-34 (2) 30-46-37 (6)
20-204 (1) 20-307 (1) 20-410 (1) 30-35 (2) 30-46-38 (6)
20-205 (1) 20-308 (1) 20-411 (1) 30-36 (2) 30-46-39 (6)
00-2-2 PC60-7
(11)
30-46-40 (6) 30-67 (2) 30-121 (2) 50-7 (3) 90-9

30-46-41 (6) 30-68 (2) 30-122 (4) 50-8 (3) 90-11
30-46-42 (6) 30-69 (2) 30-122-1 (4) 50-9 (11) 90-13
30-46-43 (6) 30-70 (2) 30-123 (2) 50-10 (3) 90-15
30-46-44 (6) 30-71 (2) 30-124 (2) 50-11 (11) 90-17
30-46-45 (6) 30-72 (4) 50-12 (3) 90-19 (3)
30-46-46 (6) 30-73 (4) 40-1 50-13 (3) 90-21 (3)
30-46-47 (6) 30-73-1 (4) 40-2 (8) 50-14 (3) 90-23 (3)
30-46-48 (6) 30-73-2 (4) 40-2-1 (8) 50-15 (3) 90-201 (5)
30-46-49 (6) 30-74 (2) 40-3 (10) 50-16 (3)
30-46-50 (6) 30-75 (2) 40-4 50-17 (3)
30-46-51 (6) 30-76 (2) 40-5 50-18 (3)
30-46-52 (6) 30-78 (2) 40-6 (11) 50-19 (3)
30-46-53 (6) 30-79 (2) c 40-6-1 (11) 50-20 (3)
30-46-54 (6) 30-80 (2) 40-7 (3) 50-21 (3)
30-46-55 (6) 30-81 (2) 40-8 50-22 (3)
30-46-56 (6) 30-82 (2) 40-9 (3) 50-23 (3)
30-46-57 (6) 30-83 (2) 40-10 50-24 (3)
30-46-58 (6) 30-84 (2) 40-11 (3) 50-25 (3)
30-46-59 (6) 30-85 (2) 40-12 50-26 (3)
30-46-60 (6) 30-86 (2) 40-13 50-27 (3)
30-46-61 (6) 30-87 (2) 40-14 50-28 (3)
30-47 (2) 30-88 (2) 40-15 50-29 (3)
30-47-1 (6) 30-89 (2) 40-16 50-30 (3)
30-47-2 (6) 30-90 (2) 40-17 50-31 (3)
30-47-3 (6) 30-91 (2) 40-18 50-32 (3)
30-47-4 (6) 30-92 (2) 40-19 50-33 (3)
30-47-5 (6) 30-94 (2) 40-20 50-34 (3)
30-47-6 (6) 30-95 (2) 40-21 50-35 (3)
30-47-7 (6) 30-96 (2) 40-22 (3) 50-36 (3)
30-47-8 (6) 30-97 (2) 40-23 (3) 50-37 (3)
30-47-9 (6) 30-98 (2) 40-24 (3) 50-38 (3)
30-47-10 (6) 30-99 (2) 40-25 (3) 50-39 (3)
30-48 (2) 30-100 (2) 40-26 (8) 50-41 (3)
30-49 (2) 30-101 (2) 40-26-1 (8) 50-42 (3)
30-50 (2) 30-102 (2) 40-27 (3) 50-43 (3)
30-51 (2) 30-103 (2) 40-28 (3) 50-44 (3)
30-52 (2) 30-104 (2) 40-28-1 (3) 50-45 (3)
30-53 (2) 30-105 (2) 40-28-2 (3) 50-46 (3)
30-54 (4) 30-106 (2) 40-29 (9) 50-47 (3)
30-55 (4) 30-107 (2) 40-30 (3) 50-48 (3)
30-55-1 (4) 30-108 (2) 40-31 50-49 (3)
30-55-2 (4) 30-109 (2) 40-32 50-50 (3)
30-56 (2) 30-110 (2) 40-33 50-51 (3)
30-57 (2) 30-111 (2) 40-34 (11) 50-52 (3)
30-58 (2) 30-112 (2) c 40-34-1 (11) 50-53 (3)
30-59 (2) 30-113 (2) 40-35 50-54 (3)
30-60 (2) 30-114 (2) 40-36
30-61 (2) 30-115 (2) 90-1 (3)
30-62 (2) 30-116 (2) 50-1 (3) 90-3
30-63 (2) 30-117 (2) 50-3 (3) 90-5 (3)
30-64 (2) 30-118 (2) 50-4 (3) 90-5-2 (3)
30-65 (2) 30-119 (2) 50-5 (3) 90-5-4 (3)
30-66 (2) 30-120 (2) 50-6 (3) 90-7
PC60-7 00-2-3
(11)
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 danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive () terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
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
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 judge-
ments. 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 fur-
ther 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 under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance 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 com-
ponent, 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 When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
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 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
k Slinging with one rope may cause turning

wound onto the load.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
The allowable load value is estimated to be one-

sixth 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 Type 1

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 hydrau-
lic 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
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
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
Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
(Set of adhesive 1 kg
LT-3 and hardening Hardening Can
agent) agent:
Adhesives 500 g
Polyethylene Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
Quick hardening type adhesive
Three bond 790-129-9140 50 g Polyethylene Cure time: within 5 sec. to 3 min.
1735 container Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive
Aron-alpha Polyethylene Quick cure type (max. strength after
201 790-129-9130 2g container 30 minutes)
Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene Used at joint portions subject to high
648-50 container temperatures.
Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
Used as sealant for various threads,
LG-5 790-129-9080 1 kg Can pipe joints, flanges.
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Features: Silicon based, resistance
to heat, cold
Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond Used as heat-resisting sealant for re-
1211 790-129-9090 100 g Tube pairing engine.
Features: Silicone type, heat resist-

Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category 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).
Molybdenum Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum Used for heavy load portion

SYG2-400M 400 g 10 Bellows type
disulphide SYG2-400M-A 400 g 20 Bellows type
Grease grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
Seizure resistance and heat resist-
Hyper White SYG2-400T-A ance higher than molybdenum di-
Grease G2-T SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type
*: For high less effects on microorganisms,
SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
SUNSTAR "S" is used for high-tempera-

PENGUINE ture season (April - October)
SEAL 580 320 ml Polyethylene and "W" for low-temperature
SUPER "S" or container season (November - April) as
Adhesive "W" adhesive for glass.
(Using limit: 4 months)
Sika Japan, Polyethylene Used as adhesive for glass.
Sikaflex 256HV 20Y-54-39850 310 ml container (Using limit: 6 months)
SUNSTAR Used to seal joints of glass

PENGUINE 417-926-3920 320 ml Polyethylene parts.
SEAL No. 2505 container (Using limit: 4 months)
Caulking
material SEKISUI Used to seal front window.
SILICONE 20Y-54-55130 333 ml Polyethylene (Using limit: 6 months)
SEALANT container
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 Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5

8 13 27 34 2.8 3.5
10 17 59 74 6 7.5
12 19 98 123 10 12.5
14 22 153 190 15.5 19.5
16 24 235 285 23.5 29.5

18 27 320 400 33 41
20 30 455 565 46.5 58
22 32 610 765 62.5 78
24 36 785 980 80 100
27 41 1150 1440 118 147

30 46 1520 1910 155 195
33 50 1960 2450 200 250
36 55 2450 3040 250 310
39 60 2890 3630 295 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0

8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
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 Tightening torque
mm mm Nm kgm
14 19 24.5 4.9 2.5 0.5

18 24 49 19.6 52
22 27 78.5 19.6 82
24 32 137.3 29.4 14 3
30 36 176.5 29.4 18 3
33 41 196.1 49 20 5
36 46 245.2 49 25 5
42 55 294.2 49 30 5
00-12
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 14 59 74 6 7.5
12 17 98 123 10 12.5
16 22 235 285 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 Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 63 {3.5 6.5} 44 {4.5}

03, 04 20 Varies depending 84 132 {8.5 13.5} 103 {10.5}
05, 06 24 on type of 128 186 {13.0 19.0} 157 {16.0}
10, 12 33 connector. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1010 {76.0 103} 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 Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}

10 10 17 9.8 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 {9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 124.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
00-13
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 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 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.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 54 {3.5 5.5} 44 {4.5} 18UN 14.3
02 19 16
34 63 {3.5 6.5} 44 {4.5} 14
11
22 54 93 {5.5 9.5} 74 {7.5} 16UN 17.5
03 16
24 59 98 {6.0 10.0} 78 {8.0} 18
13
04 27 84 132 {8.5 13.5} 103 {10.5} 22 16UN 20.6
16
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4
3
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 12UN 30.2
16
(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
00-14
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
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 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
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2
Color White & Red White & Black Red & White Rellow & Red Green & White Blue & White
Code WB BY RB YB GR LR
3
Color White & Black Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG RG YL GB LB
5
Color White & Green Red & Green Yellow & Blue Green & Black Blue & Black
Code RL YW GL
6
Color 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 mil-
limeters 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.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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
C
A 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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 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
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 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
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 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
00-18
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
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
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
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)
GENERAL DIMENSION
Whe value3 marked% are for btade svecification only.

SKP04180
WORKING RANGE
XThe value3 marked* are

ooerat ions.
SKP04181
01-2
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC60-7
Machine model
Standard specification Blade specification
Serial Number 52374 - 57999 52374 - 57999
Bucket capacity m3 0.25 0.25
Operating weight kg 6,200 6,700

f
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
8 Max. lifting height of blade mm - 410
:
E Max. lowering depth of blade mm - 270
tj
t:
2
Max. digging force 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
Ground pressure
kPa {kg/cm} 29.42 (0.301 30.40 to.311
(standard shoe width: 450 mm)
-
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

z
._0 Min. ground clearance mm 350 350
P
Tail swing radius mm 1,750 1,750
E
.-
n 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 PC60-7
0
PC60-7
Machine model
Serial Number 58001 and up 58001 and up
Bucket capacity 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
Working ranges
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
Performance
Max. lifting height of blade mm 410

Max. lowering depth of blade mm 270
Max. digging force 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
Ground pressure
(standard shoe width: 450 mm) 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
Dimensions
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
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
01-5-1 PC60-7
(10)
GENERAL WEIGHT TABLE
WEIGHT TABLE
These weights are for reference when handling or transporting components.
Unit: kg
PC60-7
Machine model
Engine assembly (excl. water, oil) 382 382

PTO (coupling) assembly 6 6
Serial No.: 52374 59774 31 31
Radiator, oil cooler assembly
Serial No.: 59775 and up 36 36
Revolving frame 638 638
Operators cab 260 260
Operators seat 20 20
Fuel tank (excl. fuel) 50 50
Hydraulic tank (excl. hydraulic oil) 58 58
Serial No.: 52374 58000 685 685
Counterweight
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
Track frame assembly 1,200 1,342

Track frame 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
Track shoe assembly

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
01-6 PC60-7
(11)
Unit: kg
PC60-7
Machine model
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
PC60-7 01-7
GENERAL TABLE OF OIL AND COOLANT CAPACITIES
TABLE OF OIL AND COOLANT CAPACITIES

SELECTION ACCORDING TO AMBIENT TEMPERATURE CAPACITY ()
RESERVOIR KIND OF
FLUID 30 20 10 0 10 20 30 40C Specified Refill
SAE 30CD
SAE 10WCD
Engine oil pan 14.5 13
SAE 10W-30CD (11.0) (10.5)
SAE 15W-40CD
PTO case 0.5(0.35) 0.5(0.35)

Swing machinery
case SAE 30CD 1.5 1.5
Final drive case Engine oil
(left and right, 1.7 1.7
each)
Idler (left and SAE 30CD

right, each) 0.06
SAE 10WCD
SAE 10W-30CD 90 57
Hydraulic system SAE 15W-40CD
Hydraulic HO46-HM (Note 1)

oil
ASTM D975 No. 2 130

Fuel tank Diesel
fuel
1
0.21
Track roller 0.23
Gear oil GO 140 <0.16
(each)
0.18>
Carrier roller 0.047

(each) ALBANIA EP-2
0.052
Grease Cartridge
Cartridge for
automatic NLGI No. 2 : 0.5
greasing system +
(Note 2) NLGI No. 2 NLGI No. 0 (Note 3) Piping
: 1.5
Cooling system Coolant Add Komatsu genuine Super Coolant (AF-ACL) 16 (10.3)
1: ASTM D975 No. 1 ( ) : Serial Number 58001 and up
< > : Serial Number 60157 and up
01-8 PC60-7
(11)
FUEL, OIL
l Select the fuel and oil according to the ambi-
ent temperature as shown in the table.
f The specified oil capacity indicates the total
amount of oil including the oil in the piping
for each component; the refill capacity indi-
cates the amount of oil added when the oil is
changed for normal inspection and mainte-
nance.
1: When starting the engine in ambient tempera-
tures of below CIC, even if the daytime tem-
perature rises to lOC, always use SAElOW
or SAE 1OW-30.
Note 1: For hydraulic oil H046-HM, use the oil rec-
ommended by Komatsu.
A
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
6 cold area type, or from the cold area type
0 to the standard type, please see the Op-
2 eration 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 lubri-
cating performance.
ANTI-FREEZE
-4 Komatsu genuine Super Coolant (AF-ACL) is
added at a proportion of 30% to the cooling wa-
ter, so there is no need to change the density for
temperatures down to -10X.
If the temperature goes below -lOC, adjust the
density according to the table below.
+ Use tap water for the coolant.
01-9
10 STRUCTURE AND FUNCTION
Radiator, oil cooler ..................................... IO- 2

PTO (coupling) ............................................ IO- 3
Engine control ............................................ IO- 4
Power train diagram .................................. IO- 5
Swing circle ................................................ IO- 6
Swing machinery ....................................... IO- 7
Track frame ................................................. IO- 8
Idler cushion ............................................... IO- 9
Hydraulic piping drawing .......................... IO- 10
Hydraulic circuit diagram .......................... lo- 11
Hydraulic tank.. ........................................... IO- 12
Hydraulic pump .......................................... IO- 13
Control valve.. ............................................. IO- 40
Self-pressure reducing valve.. ................... IO- 51
CLSS ............................................................ IO- 56
Swing motor.. ............................................. IO- 86
Center swivel joint.. .................................... IO- 90
Travel motor ............................................... IO- 92
Valve control ............................................... IO- 98
Work equipment, swing PPC valve ........... 10-100
Travel PPC valve ......................................... IO-104
Service PPC valve ....................................... IO-I 08
Solenoid valve ............................................ 1O-l 12
Hydraulic cylinder ...................................... IO-I 14
Work equipment.. ....................................... IO-I 16
Work equipment pin automatic
greasing system ....................................... IO-117
Electrical allocation diagram (l/2). ............ lo-130
Electrical allocation diagram (2/2). ............ IO-131
Electrical circuit diagram ........................... IO-132
Electric control system.. ............................. IO-134
Machine monitor system ........................... IO-142
PC60-7 10-l
STRUCTURE AND FUNCTION PTO (COUPLING)
PTO (COUPLING)
B-B
A-A
SKP03033
1. Drain plug 5. Pump case

2. Shaft 6. Breather/oil filler plug
3. Coupling 7. Cage
4. Flywheel 8. Level plug
1o-3
ENGINE CONTROL
ENGINE CONTROL
SLPO3034
1. Fuel control dial

Outline
2. Starting switch . The engine can be stopped and started sim-
3. Starting motor ply by using the starting switch.
4. Stop lever . The engine stop solenoid has a fail-safe
5. Battery mechanism which acts to drive the fuel injec-
6. Fuel injection pump tion pump stop lever to the RUN position
7. Governor lever when the starting switch is turned ON, so if
there is any abnormality in the electrical sys-
tem, the engine stops.
1o-4
STRUCTUREAND FUNCTION POWER TRAIN DIAGRAM
POWER TRAIN DIAGRAM
SKP03035
1. Idler 7. Hydraulic pump

2. Center swivel joint 8. Engine
3. Control valve 9. Swing motor
4. Swing brake solenoid valve 10. Swing machinery
5. Travel speed solenoid valve 11. Swing circle
6. Travel motor
1o-5
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
A-A
I
I
CII
SKP03036
I, Swing circle outer race Specifications

2. Ball
Reduction ratio- 76 =7 60
3. Swing circle inner race -10 .
4. Plug Amount of grease: 5 e (G2-LI)
5. Grease nipple
S. Inner race, outer race zone position
1 O-6
STRUCTURE AND FUNCTION IDLER CUSHION
IDLER CUSHION
SKP03039
1. Yoke Specifications
2. Rod (piston) Amount of grease: 120 cc
3. Front support (cylinder)
4. Recoil spring
5. Wear ring
6. Packing
7. Rear support
8. Lubricator
9. Drain plug
1o-9
STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING

Ir For details of this page, see page 90-3.
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

* For details of this page, see Daae 90-5.
10-l 1
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
5 4
B-B
A-A
c-c D-D
SKP03046
1. Return filter Specifications

2. Safety valve Tank capacity: 71 e
3. Cap Amount of oil inside tank: 57 e
4. Vacuum valve Cracking pressure of pressure valve :
5. Pressure valve 0.04 I 0.01 MPa IO.39 + 0.15 kg/cm?
6. Sight gauge Cracking pressure of vacuum valve :
7. Suction strainer 0 - 0.05 MPa (0 - 0.46 kg/cm?
8. Drain plug Actuating pressure of safety valve :
0.10 k 0.02 MPa il.05 f 0.2 kg/cm*)
10-12
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
PS
0 0
& 0 0
PX3
PDA PDl 1
PA2 PLS
/
CZ
SXPO7085
PA : Pump discharge PDA: Pump air bleed port

PA2 : LS pressure inlet port PLS : LS pressure inlet port
PA3 : Drain port PM : L mode selection pilot port
PDl : Pump drain PS : Pump suction
1. Main pump
PC60-7 JO-73 -
0
STRUCTURE AND FUNCTION HYDFtAULlC PUMP
1. MAIN PUMP
PX3
PDA PDI
PA2 PLS
_c
CZ
PA : Pump discharge * The main pump consists of one unit formed

PA2 : LS pressure inlet port by the pump, servo piston, PC valve, and LS
PA3 : Drain port valve.
PDA: Pump air bleed port The explanation in STRUCTURE AND FUNC-
PDI : Pump drain TION is divided into two parts: the pump and
PLS : LS pressure inlet port PC valve + LS valve.
PM : L mode selection pilot port
PS : Pump suction
IO-14 PC60-7
0
A-A
SKP03049
1. Shaft 6. Piston
2. Cradle 7. Cylinder block
3. Case 8. Valve plate
4. Rocker cam 9. Spring
5. Shoe IO. Servo piston
70-75
Function
. The engine rotation and torque transmitted
to the pump shaft is converted into hydraulic
energy, and pressurized oil is discharged ac-
cording to the load.
. It is possible to change the discharge amount
by changing the swash plate angle.
a
SKP03050
Structure
. Cylinder block (7) is supported to shaft (I) . Piston (6) carries out relative movement in the
by spline a, and shaft (I) is supported by axial direction inside each cylinder chamber
the front and rear bearings. of cylinder block (7).
l The tip of piston (6) is a concave ball, and l Cylinder block (7) seals the pressure oil to
shoe (5) is caulked to it to form one unit. valve plate (8) and carries out relative rota-
Piston (6) and shoe (5) form a spherical bear- tion. This surface is designed so that the oil
ing. pressure balance is maintained at a suitable
. Rocker cam (4) has flat surface A, and shoe level.
(5) is always pressed against this surface The oil inside each cylinder chamber of cylin-
while sliding in a circular movement. der block (7) is sucked in and discharged
Rocker cam (4) brings high pressure oil at through valve plate (8).
cylindrical surface B with cradle (2), which
is secured to the case, and forms a static
pressure bearing when it slides.
10-M
Operation
1) Operation of pump
i) Cylinder block (7) rotates together with
shaft (I), and shoe (5) slides on flat sur-
face 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.
SKP0305 I
ii) Center line X of rocker cam (4) maintains
swash plate angle a in relation to the axial
direction of cylinder block (71, and flat
C
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 be-
tween volume E and F is created inside
cylinder block (7). The suction and dis-
charge is carried out by this difference F
- E.
In other words, when cylinder block (7)
rotates and the volume of chamber E be-
comes smaller, the oil is discharged dur-
ing that stroke.
At the same time, the volume of cham-
ber F becomes larger, and as the volume j E
SKP03052
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.)
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 cylin-
der block (7) becomes 0, so the pump
does not carry out any suction or dis-
charge of oil. (In actual fact, the swash
plate angle never becomes 0.)
iv) In other words, there is a proportional re-

7 E
lationship between swash plate angle a
SKP03053
and the pump discharge amount.
JO-J7
2) Control of discharge amount

. If swash plate angle a becomes larger, the dif-
ference in volumes E and f becomes larger
and discharge amount Q increases.
Swash plate angle a is changed by servo pis-
ton (IO).
. Servo piston (IO) moves in a reciprocal move-
ment ( 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 cylin-
drical 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 pres-
SKP03054
sure) 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 diam-
eter 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
2. PC VALVE, LS VALVE, SERVO PISTON
PP
1; 14 i3 i2
D-D
SXPll7087
PA2: LS pump pressure port PC valve LS valve

PA3: Drain port 4. Piston 12. Plug
PLS: Control valve LS pressure inlet port 5. Spring 13. Sleeve
PM : Mode selection solenoid pressure inlet port 6. Seat 14. Spring
PP : Main pump pressure port 7. Spring 15. Piston
8. Piston
Servo piston 9. Sleeve
1. Servo piston 10. Piston
2. Lever 11. Plug
3. Spring
1O-20 PC60-7
GO
LS valve
Function
. The LS valve controls the pump discharge CP/m i n)
0
amount according to the amount of move-
ment of the control lever, that is the oil flow
demanded by the actuator.
. The LS valve detects the oil flow demanded .z?
L
by the actuator from the differential pressure
APLS between input pressure Pa2 of the con-
trol valve (downstream pressure of self-pres- E
sure reducing valve) (Note 1) and control 2 1
1. 96 MPa
valve outlet pressure PLS, and controls main (201 1 k o/cm)
pump discharge amount 0. LS differential pressure APu
SKP04182
(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 dif-
ferential pressure APLS) generated by the
flow of oil from the pump passing through
opening area of the control valve spool is de-
tected. By controlling pump discharge
amount 0 so that this pressure loss remains
constant, a pump discharge amount is sup-
plied in accordance with the demands of the
6 control valve by controlling pump discharge
5 amount Q.
s l
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.
- Note 1: Previously, the pump discharge pres-

sure 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 reduc-
ing 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.
1O-21
Operation
1. When control valve is at HOLD position
To actuator
Control valve
Self-Pressure reducino valve
(Small diameter end) ,
X (Laroe diameter end) ,,,, , I / vg .,I,I,
SKP04183
1o-22
. The LS pressure PLS is brought from the con-

trol 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.
. The position of piston (15) is determined by
the size of pump pressure Pa2 and the com-
bined 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
b to chamber X at the large diameter end of
0
G servo piston (1).

z l Pump pressure PP is always supplied to cham-
ber Y at the small diameter end of servo pis-
ton (I), but the force applied to the large di-
ameter end of servo piston (1) is greater be-
cause of the difference in area at both ends of
the piston, so servo piston (I) moves up in
the direction of the minimum swash plate
angle (fi 1.
7o-23
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
. 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 cham-
ber X at the large diameter end of servo pis-
ton (I) flows from port d to port e and is con-
- nected 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.
1o-25
3. When opening area of control valve is small (small movement of lever)
To actuator
Control valve
Self-Pressure reducine valve
r-----------
l
I hall diameter end) ,
l-
X (Large diameter end)
SKP04185
1O-26
. 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.
l When this happens, the movement is the
same as for [I. When control valve is at HOLD
position]: LS pump pressure Pa2 pushes pis-
ton (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 po-
sition 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 mini-
mum 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 maxi-
mum direction.
1 O-27
4. When pump flow is amount demanded by control valve
To actuator
/J,
% I/
Control valve
Self-Pressure reducine valve
r------------ -d
I (Small diameter end1 1
1;
E
I
:;
/
:;
,
,
H
,
/
i_
/
(Large diameter end)
X
SKP04186
1 O-28
STRUCTUREAND FUNCTION 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.
l 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.
l 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 diam-
eter end of servo piston (1).
l 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) be-
comes 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.
l 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 open-
ing of control valve is l/4, the pump swash
plate angle is also l/4. LS differential pres-
sure APLS is always held at 1.96 MPa I20 kg/
cm2), so the pump discharge amount is in ac-
cordance with the area of opening of the con-
trol 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 posi-
tion.
PC60-7 1O-29
PC valve
Function
l When discharge pressure PP becomes higher,
Standard mode
the area of opening of the control valve be-
comes larger, and even if the LS valve tries to
Lioht load mode
increase pump discharge amount Q, the PC
valve carries out control to prevent any in-
crease above fixed discharge amount Q to
match discharge pressure PP. It carries out
approximate horsepower control to prevent 2
the hydraulic horsepower absorbed by the c:
pump from exceeding the engine horsepower. Pump discharoe preesure PP
. In other words, if the load during operations SKP04187
becomes larger and pump discharge pressure

PP rises, pump discharge amount Q is re-
duced; and if pump discharge pressure PP
goes down, pump discharge amount Q is in-
creased.
l 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.
1O-30 PC60-7
0
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 end1
(Large diameter end)

SKP04188
1 O-32
. When the load on the actuator becomes high

and pump discharge pressure PP rises, pis-
ton (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 intercon-
nected, 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
c--
to port d, enters chamber X at the large diam-
eter 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 pis-
ton (I) moves up in the direction of the mini-
mum 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 pis-
ton (1) stops moving up ( t ).
. The position where servo piston (I) stops is
higher (closer to the minimum swash plate
4
angle) than when the pump discharge pres-
sure is low.
7o-33
2. When actuator load becomes smaller (pump discharge pressure PP drops)
To PPC valve
:,
fi ;
Mode selector
solenoid valve
Control valve
Self-Pressure
reducing valve
knal I diameter end)
x (Large diameter end)
SKP04189
. 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 pres-
surized 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
3. When mode selector solenoid valve signal pressure is input
To F valve
Mode selector
solenoid valve
Iw1
I PLS
Control valve
Self-aressure reducing valve
r----
___-_ -c/
(Snal I diameter end)
I
(Larae d isneter end)
SKP04190
lo-36
When mode selector solenoid valve signal

pressure is input
l 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.
l As a result, springs (5) and (7) are com-
pressed and the spring load is increased, so
the pump absorption torque is reduced by
approx. 20%.
_-
PC60-7 1o-37
0
4. Action of spring
To PPC valve
Mode selector
solenoid valve
Emal I diameter end)

i -
(Laroe diameter end) I

SKPO4191
1 O-38 PC60-7
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 dis-
charge pressure PP and discharge amount Q,
is a bent curve as shown in the diagram on
the right because springs (5) and (7) have dif-
ferent 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
Pump discharge Pressure PP
changes. SKPO4192
The position where spring (8) stops, in other
words, the pump absorption torque, is de-
termined 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 in-
creased.
The pump absorption torque, which shows Pump discharse pressure PP
SKP04193
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 in-
crease in each signal pressure.
Rxo-7 1o-39
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
Outline
The following five types of control valve are used. TSW : to swing motor
. 6-spool valve (standard 1 TC : to oil cooler
. 7-spool valve (standard + 1 service valve) TB : to tank
. 8spool valve (standard + 2 service valve) LS : to pump LS valve
l 8-spool valve PP : from PPC shuttle valve
(blade specification + 1 service valve) TS : to tank
. 9-spool valve PA1 : from left swing PPC valve
(blade specification + 2 service valve) PBI : from right swing PPC valve
PA2 : from L.H. travel FORWARD PPC valve
Ir Each service valve is an add-on type where PB2 : from L.H. travel REVERSE PPC valve
one valve each can be added, so it is possible PA3 : from R.H. travel FORWARD PPC valve
to add valves or remove valves if necessary. PB3 : from R.H. travel REVERSE PPC valve
An explanation is given of the external appear- PA4 : from boom RAISE PPC valve
ance for all types. PB4 : from boom LOWER PPC valve
Only an explanation of the 8-spool valve (blade PA5 : from arm OUT PPC valve
specification + 1 service valve) is given for the PB5 : from arm IN PPC valve
cross section. PA6 : from bucket DUMP PPC valve
* The cross-sectional structure of the service PB6 : from bucket CURL PPC valve
valve is the same as the structure for the stan- PA7 : from blade RAISE PPC valve
dard bucket valve, so see the bucket valve for PB7 : from blade LOWER PPC valve
details. PA8 : from service 1 PPC valve
PB8 : from service 1 PPC valve
Names, name of ports PA9 : from service 2 PPC valve
(common for all external view diagrams) PB9 : from service 2 PPC valve
1. No. 1 service valve
P : from main pump

Al : to swing motor MB
Bl : to swing motor MA
A2 : to L.H. travel motor A
B2 : to L.H. travel motor B
A3 : to R.H. travel motor B
B3 : to R.H. travel motor A
A4 : to boom cylinder bottom
B4 : to boom cylinder head
A5 : to arm cylinder head
B5 : to arm cylinder bottom
A6 : to bucket cyiinder head
B6 : to bucket cylinder bottom
A7 : to attachment 7
87 : to attachment 1
B8 : to attachment 2
B9 : to attachment 3
1O-40 Pc60-7
0
EXTERNAL VIEW
6-spool valve (standard)
LS
A
PA6 11 n
PA6
PB3
/ /AtPI4
PA1
/
- /D-cl TC TSW TS
TB
sxPo7oaa
PC60-7 1o-41
0
7-spool valve (standard + 1 service valve)
LS
PA7,
I _pB7
PA1
P
SXPO
7089
1 O-42 PC60-7
0
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
9-spool valve blade specification 2 service valve
SJPO7091
1 O-42-2 Pc60-7
0
CROSS SECTION
* The cross section shows the 8-spool valve
(brade specification + 1 service valve).
The cross-sectional structure of the 8-spool
valve service valve is the same as the struc-
ture of the bucket valve, so see it.
A-A
SJPO7092
1. Suction valve (L.H. travel A) 9. Suction valve (service B)

2. Suction valve (R-H. travel A) 10. Suction valve (blade bottom)
3. Suction valve (boom bottom) 11. Suction valve (bucket bottom)
4. Suction valve (arm head) 12. Suction valve (arm bottom)
5. Suction valve (bucket head) 13. Suction valve (boom head)
6. Plug (blade head) 14. Suction valve (R.H. travel B)
7. Suction valve (service A) 15. Suction valve (L.H. travel B)
8. Safety valve 16. Cooler bypass valve
Pc60-7 1o-43
0
B-B
SJPO7093
1. Main relief valve 6. Spool (arm)

2. Spool (swing) 7. Spool (bucket)
3. Spool (L.H. travel) 8. Spool (blade)
4. Spool (R-H. travel) 9. Spool (service)
5. Spool (boom)
1o-44 PC60-7
0
STRUCTUREAND FUNCTION CONTROL VALVE
I9
c-c
SJPO7094
1. Swing pump pressure 8. Pressure compensation 15. Pressure compensation

circuit orifice valve F (blade) valve R (boom)
2. Pressure compensation 9. Pressure compensation 16. Pressure compensation
valve F (swing) valve F (service) valve R (R.H. travel)
3. Pressure compensation 10. Pump pressure detection 17. Pressure compensation
valve F (L.H. travel) plug valve R (L-H. travel)
4. Pressure compensation 11. Pressure compensation 18. Pressure compensation
valve F (R.H. travel) valve (service) valve R (swing)
5. Pressure compensation 72. Pressure compensation 19. LS select valve
valve F (boom) valve (blade) * F: Flow control valve
6. Pressure compensation 13. Pressure compensation R: Reducing valve
valve F (arm) valve R (bucket)
7. Pressure compensation 14. Pressure compensation
valve F (bucket) valve R (arm)
FC60-7 7o-45
0
D-D
SJPO7095
1. Check valve (service)

2. Check valve (blade ,B side only)
3. Check valve (bucket)
4. Check valve (arm)
5. Check valve (boom)
1 O-46 PC60-7
0
G-G
\
5 4
H-H
SKP03076
L.H., R.H. travel valve Boom valve

I. Suction valve (A) 6. Suction valve (bottom)
2. Suction valve (B) 7. Suction valve (head)
3. Spool 8. Spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F IO. Pressure compensation valve F
PC&7 1o-47
STRUChE AND FUNCTION CONTROL VALVE
E-E
SJPO7096
1. Main relief valve Swing valve

2. Lift check valve 4. Spool
3. LS select valve 5. Pressure compensation valve R
6. Pressure compensation valve F
1 O-48 PC60-7
0
J-J
K-K
(BB-BB)
SJPO7097
Arm valve Bucket valve (service valve)

1. Suction valve (head) 6. Suction valve (head)
2. Suction valve (bottom) 7. Suction valve (bottom)
3. Spool 8. Spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F IO. Pressure compensation valve F
Pc60-7 1o-49
0
5 6
M-M
Ii AA-AA IO
SJPO7098
1. Pump pressure detection plug BLADE VALVE

2. Safety valve 8. Suction valve (bottom)
3. Pressure release plug 9. Spool
4. LS bypass plug 10. Pressure compensation valve R
6. Swing pressure compensation valve F 11. Pressure compensation valve F
6. Swing pressure compensation valve R
7. Unload valve
1O-50 PC60-7
0
STRUCTURE AND FUNCTION SELF-PRESSURE REDUCING VALVE
SELF-PRESSURE REDUCING VALVE
!=!!=!
c\ d
- a
SKP03079
a. Port PI (from main pump)

b. Port PC (to main pump)
c. Port Pr
(supplies oil to electromagnetic valve, PPC
valve, EPC valve, etc.)
d. Port T (to hydraulic tank)
1o-51
A-A 8
SKPOJOBO
1. Valve (reducing valve) 7. Poppet

2. Valve (sequence valve) 8. Spring (reducing valve pilot)
3. Spring (sequence valve large) 9. Spring (reducing valve main)
4. Spring (sequence valve small) 10. Spring (safety valve)
5. Plate 11. Ball
6. Screw
1o-52
Operation
1. Engine stopped
. Poppet (7) is pushed against the seat by spring
(8): Pr + T closed
l Valve (I) is pushed against the plug by spring Pl
(9): PI + Pr open
l Valve (2) is pushed by spring (3) and spring
(4): PI + PZ closed
1 Pr 9 7
Engine stoPPed
SKP04194
2. (I) At HOLD P2
(2) When load (pressure P2) is low (opera- \
tions where work equipment moves un-
der 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 T
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 ad-
justed in order to maintain pressure Pl and Pr
I 9 7
pressure Pr at the above set value. At low loed
. (boor LOWEkmovino down under own neioht)
If pressure Pr goes above the set pressure, SKP04195
poppet (7) opens and hydraulic oil flows from
port Pr + spool (I) orifice -+ poppet (7) open-
ing -+ tank circuit.
As a result, a difference in pressure is gener-
ated on both sides of spool (I) orifice, so spool
(1) moves in the direction to close the open-
ing between PI + Pr, and pressure Pr is main-
tained at the certain pressure by which pres-
sure PI is reduced
(set pressure) by the amount of this opening.
PC60-7 1o-53
0
3. When load pressure (pressure P2) is high R 2

When load pressure (pressure P2) is increased
and pump discharge amount is increased by
operation such as digging
Pressure PI also increases (pressure Pl) > PI
(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.
. If pressure Pr goes above the set pressure,

poppet (7) opens and hydraulic oil flows from
port Pr + spool (1) orifice + poppet (7) open-
ing + tank circuit.
1 Pr 7
As a result, a difference in pressure is gener- At hioh load pressure
ated on both sides of spool (I 1orifice, so spool SKP04196
(1) moves in the direction to close the open-
ing between PI + Pt. Pressure Pr is main-
tained at the certain pressure by which pres-
sure Pl is reduced (set pressure) by the
amount of this opening.
4. 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 ab-
normal high pressure.
1o-54 Pcoo-7
STRUCTURE AND FUNCTION CLSS
CLSS
1. OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing l The CLSS consists of a variable capacity single
System, and has the following features. piston pump, control valve, and actuators.
1) Fine control not influenced by load l The pump body consists of the main pump,
2) Control enabling digging even with fine the PC valve and LS valve.
control
3) Ease of compound operation ensured by
flow divider function using area of open-
ing of spool during compound operations
4) Energy saving using variable pump con-
trol
PLS
i___________________---_- Control valve
I
I
I
I
I
I
,
I
+
Lb+
PP
Servo
va I ve SDP02561
1O-56 PC60-7
0
2. BASIC PRINCIPLE
1) Control of pump swash plate angle . If LS differential pressure APLS becomes
. The pump swash plate angle (pump discharge lower than the set pressure of the LS valve,
amount) is controlled so that LS differential the pump swash plate becomes larger; if it
pressure APLS (the difference between pump becomes higher than the set pressure of the
pressure PP and control valve outlet port LS LS valve, the pump swash plate becomes
pressure PLS ) (load pressure of actuator) is smaller.
constant. Ir For details of the operation, see HYDRAULIC
(LS pressure APLS = Pump discharge pres- PUMP
sure PP - LS pressure PLS 1
0 LS differential 9reasure APLS
I i a_________
SDP02563
71 I__________
B
PP
/ kssaae
Main Dump
Mi n. Max.
k
I I
. +q-@i
LS
_. valve
Servo
Piston
_ ___1I
______J
I
I
I
I
Ditferential I I Diftcrential 9rc99vrc

9rcwre Iar1elfli9b) saal I (Low)
I I
II
SEP02562
PC60-7 1o-57
0
2) Pressure compensation control

. A pressure compensation valve is installed downstream (outlet port) of the notch in the
to the inlet port side of the control valve spool spool of each valve.
to balance the load. In this way, the flow of oil from the pump is
When two actuators are operated together, divided in proportion to the area of openings
this valve acts to make pressure difference Sl and S2 of each valve.
AP between the upstream (inlet port) and
Load Load
w
Actuator
AP AP
LS valve SKPO4200
I O-58 Pao-7
3. OPERATION FOR EACH FUNCTION

AND VALUE 1. Unload valve
Hydraulic circuit diagram and name of values (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
Bucket (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:
Arm
0.81 MPa (8.3 kg/cm211
8. LS select valve
Boom
Travel
Travel
Swine
I
270/c.
TW
6* ,.i TB
TC
_________________--------- -.I
4
SKP04201
1o-59
1) Unload valve
Function
1. When the control valve is at HOLD, pump dis- When this happens, pump discharge pressure
charge amount 0 discharged by the mini- PP is set at 2.6 MPa (27 kg/cm21 by spring (2)
mum swash plate angle is released to the inside the valve. (LS pressure PLS: 0 MPa (0
tank circuit. kg/cm*))
SKP030SS
Operation
When control valve is at HOLD
. Pump discharge pressure PP is acting on the l In this way, pump discharge pressure PP is
left end of spool (I) and LS pressure PLS is set to 2.6 MPa (27 kg/cm*}.
acting on the right end.
l When the control valve is at HOLD, LS pres-
sure PLS is not generated, so only pump dis-
charge pressure PP has any effect, and PP is
set only by the load of spring (2).
l 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).
1O-60
2. During fine control of the control valve, when When the difference in pressure between
the demand flow for the actuator is within the pump discharge pressure PP and LS pressure
amount discharged by the minimum swash PLS reaches the load of spring (2) (2.6 MPa
plate angle of the pump, pump discharge (27 kg/cm21), the unload valve opens, so LS
pressure PP is set to LS pressure PLS + 2.6 differential pressure APLS becomes 2.6 MPa
MPa (27 kg/cm2}. (27 kg/cm21.
SKP03089
Operation
During fine control of control valve
l When fine control is carried out on the con- l In other words, pump discharge pressure PP
trol valve, LS pressure PLS is generated and is set to a pressure equal to the spring force
acts on the right end of spool (1). (2.6 MPa {27 kg/cm2)) + LS pressure PLS, and
When this happens, the area of the opening LS differential pressure APLS becomes 2.6
of the control valve spool is small, so there is MPa (27 kg/cm*).
a big difference between LS pressure PLS and
pump discharge pressure PP.
l 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 con-
-
netted .
70-61
3. When the control valve is being operated and oil out to tank circuit T is cut off, and all of
the demand flow for the actuator becomes pump discharge amount Q flows to the ac-
greater than the pump discharge from the tuator circuit.
minimum swash plate angle, the flow of the
SKP03090
Operation
Control valve operated
l When the control valve is operated to a larger l As a result, pump circuit PP and tank circuit T
stroke, LS pressure PLS is generated and acts are shut off, and all the pump discharge
on the right end of spool (1). amount Q flows to the actuator circuit.
When this happens, the area of the opening
of the control valve spool is large, so the dif-
ference between LS pressure PLS and pump
discharge pressure PP is small.
. For this reason, the difference in pressure be-
tween 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
2) Introduction of LS pressure
Function
. The LS pressure is the actuator load pressure circuit PLS.
at the outlet port end of the control valve. In addition, orifice C is installed midway be-
- With the control valve, it reduces pump pres- tween pump circuit PP and reducing valve
sure PP at reducing valve (3) of the pressure (3), and it acts as a damper.
compensation valve to the same pressure as l With the travel valve, actuator circuit pres-
actuation pressure A, and sends it to the LS sure A is taken directly to the LS circuit PLS.
SKP03091
Operation
1. Main control valve (boom, arm, bucket, swing)
l When spool (I) is operated, pump pressure . The area at both ends of reducing valve (3) is
PP flows from flow control valve (2) and notch the same (SA = SLS), and actuator circuit pres-
a in the spool through bridge passage b to sure PA (= A) acts on the SA end. The reduced
actuator circuit A. pump pressure PP acts on SLS at the other
. At the same time, reducing valve (31 also end.
moves to the right (-1, so pump pressure PP . As a result, reducing valve (3) is balanced at a
brought from orifice c has its pressure re- position where actuator circuit pressure PA
duced by the pressure loss at notch d. It goes and the pressure of spring chamber PLSI are
to LS circuit PLS, and then goes to spring the same. Pump pressure PP reduced at notch
chamber PLSl. d becomes actuator circuit pressure A and is
. When this happens, LS circuit PLS is con- taken to LS circuit PLS.
nected to tank circuit T from LS bypass plug
- (4) (see the section on the LS bypass plug).
1O-63
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 intercon-
nected 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
3) LS bypass plug
Outline
1. This releases the residual pressure of LS pres- it creates a pressure loss in the throttled flow
sure PLS. of the spool or shuttle valve, and increases
2. This makes the speed of the rise in pressure the stability by lowering the effective LS dif-
of LS pressure PLS more gentle. ferential pressure.
In addition, with this discarded throttled flow,
SKP03199
Operation
. The pressurized oil for LS circuit PLS passes
from clearance filter a (formed by the clear-
ance between LS bypass plug (1) and thevalve
body) through orifice b and flows to the tank
circuit.
1O-65
4) Pressure compensation valve

Function
. During compound operations, if the load (When this happens, the other actuator be-
pressure becomes lower than the other ac- ing used for compound operation (right side)
tuator and the oil flow is about to increase, is at a higher load than the actuator on this
compensation is received. side (left side).)
SKI'04202
Operation
. If the load pressure of the other actuator (right are balanced in position where the difference
side) becomes higher during compound op- in pressure between PLS and PA acting on
erations, the oil flow in actuator circuit A on both ends of reducing valve (2) and the pres-
this side (left side) tries to increase. sure loss between PP and PPA on both sides
. If this happens, the LS pressure PLS of the of flow control valve (2) are the same.
other actuator acts on spring chamber PLSI, . In this way, the pressure difference between
and reducing valve (I) and flow control valve upstream pressure PPA and downstream
(2) are pushed to the left (o ). pressure PA of both spools used during com-
. Flow control valve (2) throttles the area of pound operations is the same, so the pump
opening between pump circuit PP and spool flow is divided in proportion to the area of
upstream PPA, and pressure loss is generated opening of notch a of each spool.
between PP and PPA.
. Flow control valve (2) and reducing valve (1)
1O-66
5) Area ratio of pressure compensation valve

Function r
. The pressure compensation valve determines Sl: Area of flow control valve (2)
the compensation characteristics by carrying - area of piston (3)
out fine adjustment of the area ratio (S2/Sl) S2: Area of reducing valve (I 1
between area S2 of reducing valve (I) and , - area of piston (3)
area Sl of flow compensation valve (2) to
match the characteristics of each actuator.
\
PLS
SKP03093
Area ratio (S2:Sl) and compensation

characteristics
l When ratio is 1.00:
[pump pressure PP - spool notch upstream Ratio of Ratio of
Valve area Valve area
pressure PPBI i ILS circuit pressure PLS - ac-
tuator circuit pressure PA (= A)] and oil flow Service 0.98 L.H. travel 1.00
is divided in proportion to area of opening of
Bucket 0.98 R.H. travel 1.oo
spool.
l When ratio is more than 1.00: Arm 0.96 Swing 0.98
PP - PPB > PLS - PA (= A) and oil flow is di-
Boom 0.96 Blade 1.00
vided in a proportion less than area of open-
ing of spool.
l When ratio is less than 1.00:
PP - PPB c PLS -PA (= A) and oil flow is di-
-
vided in a proportion more than area of open-
ing of spool.
1O-67
6) L.H., R.H. travel junction circuit

Function
. To compensate for any difference in the oil eling in a straight line, so there is no travel
flow in the left and right travel circuits when deviation.
traveling in a straight line, the junction cir- l When steering the machine, the difference
cuit opens when the left and right travel in the load pressure returns the reducing
spools are operated. valve of the travel valve on the inside of the
In this way, the flow of oil to the left and right turn, so the junction circuit is closed and the
travel motors is almost the same when trav- machine can be steered.
L. H. travel R. H. travel
Left A RinhtA
\
\
b C SKP04203
Operation
When traveling in a straight line
. When left and right travel spools (I) are oper-
ated, the pump discharge flows from pump
circuit PP and circuit PA to actuator circuit A.
. When traveling in a straight line, to make ac-
tuator 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 junc-
tion circuit are opened.
. In this way, the left and right travel actuator
circuits are interconnected by the travel junc-
tion 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
L. H. travel R. H. travel
SKP04204
Steering when traveling

. When traveling in a straight line, if left travel l Damper b is provided in the circuit to dampen
spool (left 1) is returned to the neutral posi- any excessive characteristics in the opening
tion and steering is operated, a difference or closing of the travel junction circuit if the
(right A > left A) is generated in the load pres- spool is operated suddenly.
sure 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 cir-
cuit 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 steer-
ing when traveling.
1 O-69
71 Travel LS bypass circuit

Function
. When the travel and another actuator are op- the drop in the travel speed to the minimum.
erated at the same time, the amount of oil . When the travel is operated independently
discarded by the throttle in LS circuit PLS in- or any other actuator is operated indepen-
creases and the pressure compensation pre- dently, the bypass circuit is closed.
cision of the travel circuit is relaxed to keep
SKP03094
Operation
Normal operation
l When boom spool (I) is operated, LS circuit
PLS becomes the same pressure as boom cir-
cuit pressure Al.
. At the same time, LS circuit pressure PLS also
goes to spring chamber PLSl of reducing
valve (2) of the travel valve.
l 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
closed.
. As a result, when the boom is operated inde-
pendently, the travel LS bypass circuit is
closed.
1O-70
SKP03095
Travel + other actuator operated

LS circuit For this reason, LS circuit pressure PLS
l When boom spool (I) is operated, l
PLS becomes the same pressure as boom cir- (which is the same pressure as boom circuit
cuit pressure Al. pressure Al), flows to travel circuit A2 to re-
l With the actuator circuit pressure, the boom duce the pressure.
RAISE pressure is normally higher than the
travel pressure (Al B A2), so the pressure of
spring chamber PLSI inside reducing valve
(2) of the travel valve is higher than travel cir-
cuit pressure PA.
. As a result, reducing valve (2) moves to the
left, LS pressure of spring chamber PLSl goes
from orifice a and pushes check valve (4)
open, so oil flows from passage b and pas-
sage c to travel circuit PA.
10-71
8) Boom regeneration circuit

Function
1. When the boom is being lowered, if bottom sends the return oil flow at the bottom end
pressure A of cylinder (I) is higher than head to the head end to increase the cylinder speed
pressure B, and there is hydraulic drift, this 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 in-
creased.
1 O-72
2. When lowering the boom, if head pressure B process, check valve (3) closes and shuts off
of cylinder (I 1is greater than bottom pressure the circuit between the head and bottom
A, and the work equipment is in the digging ends.
SKP03822
Operation
. When the boom is lowered, if the work equip-
ment 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 bot-
tom circuit is shut off.
7o-73
9) LS select valve
Function
. When the swing + boom RAISE are operated ing into LS circuit PLS. In this way, it pre-
together, this valve ensures the high pressure vents the boom RAISE speed from drop-
which is generated when driving the swing, ping.
and prevents swing LS pressure a from flow-
PLS
SKP03823
Operation
Normal operation
. Normally, except when boom RAISE is oper-
ated, 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 oper-
ated, LS pressure PLS is generated in accor-
dance with the load pressure and flows to the
pump LS valve.
1o-74
SKP03824
Swing + boom RAISE at same time

. When the swing + boom RAISE are operated l As a result, swing LS pressure PLS is not gen-
at the same time, the signal pressure from the erated, so only the boom RAISE LS pressure
boom RAISE PPC circuit is sent to into pilot goes to the pump LS valve, and the pump
port BP. discharge amount is controlled by the boom
l When this pilot pressure BP acts on piston (2) RAISE LS pressure.
and becomes stronger than spring (3), piston l The size of pilot pressure BP is determined
(2) is pushed fully to the left (0 1. Valve (1) by the amount the control lever is operated.
closes, and pump pressure PP stops flowing
to reducing valve (4) of the swing valve.
PC60-7 1o-75
STRUCTURE AND FUNCTION ciss
4. Operation of system as a whole

1) When all control valves are at HOLD 12. L.H. travel valve
. Pump discharge amount Q all flows from un- 12A. Spool
load valve (6) to tank (1). 12B. Pressure compensation valve
. None of the spools (each spool A) is being (flow control valve)
operated, so the LS pressure PLS is not gen- 12C. Pressure compensation valve
erated. (reducing valve)
At the same time, the LS pressure PLS is con- 13. Swing valve
nected to the tank circuit by LS bypass plug 13A. Spool
(6), so it is the tank pressure. 13B. Pressure compensation valve
. In this condition, LS differential pressure APLS (flow control valve)
becomes the unload pressure-tank pressure, 13C. Pressure compensation valve
and becomes higher than the LS set pressure (reducing valve)
of LS valve (4), so main pump (2) is set to the 14. LS select valve
minimum swash plate angle. 15. Unload valve
I. Hydraulic tank 18. Lift check valve
19. Swing pump pressure circuit orifice
Hydraulic pump 20. Central safety valve
2. Main pump
3. PC valve Actuator
4. LS valve 21. Bucket cylinder
5. Servo piston 22. Arm cylinder
23. Boom cylinder
Control valve 24. L.H. travel motor
6. LS bypass plug 25. R.H. travel motor
7. Pump pressure detection plug & LS damper 26. Swing motor
8. Bucket valve
8A. Spool Self-pressure reducing valve
8B. Pressure compensation valve 27. Sequence valve
(flow control valve) 28. Reducing valve
8C. Pressure compensation valve
(reducing valve) * The suction valve is not shown.
8D. Check valve
9. Arm valve
9A. Spool
9B. Pressure compensation valve
(floLv control 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
1IC. Pressure compensation valve
(reducing valve)
1O-76 PC60-7
0
* For details of this page, see page 90-7.
r
I i I
PC60-7 7o-77
When swing is operated individually

When swing spool (13A) is operated, pump 1OB. Pressure compensation valve
discharge amount 0 flows to swing motor (flow control valve)
(26). At the same time, LS pressure PLS is IOC. Pressure compensation valve
generated and unload valve (15) closes. (reducing valve)
LS pressure PLS becomes the load pressure IOD. Check valve
of swing motor (26). 11. R.H. travel valve
In the swing circuit, the difference between 11A. Spool
pump discharge pressure PP and LS pressure IlB. Pressure compensation valve
PLS, in other words, LS differential pressure (flow control valve)
APLS, becomes the same as the LS set pres- IIC. Pressure compensation valve
sure of LS valve (4). (reducing valve)
As a result, the swash plate angle of main 12. L.H. travel valve
pump (2) is kept at a point midway between 12A. Spool
the minimum and maximum angles, and the 128. Pressure compensation valve
main pump discharges the oil flow demanded (flow control valve)
by the swing circuit (approx. 50%). 12c. Pressure compensation valve
When the swing is operated independently, (reducing valve)
pump discharge amount Q does not become 13. Swing valve
100%. 13A. Spool
With swing pressure compensation valves 138. Pressure compensation valve
(1381 and (130, the pump pressure PP passes (flow control valve)
from LS select valve (141, goes through ori- 13C. Pressure compensation valve
fice (191, and flows to the left end of flow con- (reducing valve)
trol valve (13B). so it moves fully to the right. 14. LS select valve
15. Unload valve
1. Hydraulic tank 17. Cooler bypass valve
18. Lift check valve
Hydraulic pump 19. Swing pump pressure circuit orifice
2. Main pump 20. Central safety valve
3. PC valve
4. LS valve Actuator
5. Servo piston 21. Bucket cylinder
22. Arm cylinder
Control valve 23. Boom cylinder
6. LS bypass plug 24. L.H. travel motor
7. Pump pressure detection plug & LS damper 25. R.H. travel motor
8. Bucket valve 26. Swing motor
8A. Spool
8B. Pressure compensation valve Self-pressure reducing valve
(flow control valve) 27. Sequence valve
8C. Pressure compensation valve 28. Reducing valve
(reducing valve)
8D. Check valve Ir The suction valve is not shown.
9. Arm valve
9A. Spool
(reducing valve)
9D. Check valve
10. Boom valve
IOA. Spool
1O-78 PCXO-7
PC60-7 1o-79
When left and right travel are operated at

same time
When left and right travel spools (IIA) and IOC. Pressure compensation valve
(12A) are operated, pump discharge amount (reducing valve)
Q flows to left and right travel motors (24) and 100. Check valve
(251, and at the same time, LS pressure PLS is 11. R.H. travel valve
generated and unload valve (15) closes. IIA. Spool
When this happens, reducing valves (IIC) and 11 B. Pressure compensation valve
(12C) of the left and right travel valves move (flow control valve)
to the right, the travel junction circuit is inter- 11 C. Pressure compensation valve
connected, and this prevents any deviation in (reducing valve)
travel. 12. L.H. travel valve
When left and right travel spools (IlA) and 12A. Spool
(12A) are 100% open, if pump discharge 12B. Pressure compensation valve
amount Cl is almost lOO%, the pressure is set (flow control valve)
so that it becomes the same as the LS set dif- 12C. Pressure compensation valve
ferential pressure, and main pump (I) is kept (reducing valve)
at the maximum swash plate angle. 13. Swing valve
If left and right travel spools (11A) and (12A) 13A. Spool
are less than 100% open, pump discharge 138. Pressure compensation valve
amount 0 is controlled in accordance with the (flow control valve)
area of opening of the spool by LS differen- 13C. Pressure compensation valve
tial pressure APLS. (reducing valve)
14. LS select valve
15. Unload valve
1. Hydraulic tank 16. Main relief valve
Hydraulic pump 18. Lift check valve
2. Main pump 19. Swing pump pressure circuit orifice
3. PC valve 20. Central safety valve
4. LS valve
5. Servo piston Actuator
21. Bucket cylinder
Control valve 22. Arm cylinder
6. LS bypass plug 23. Boom cylinder
7. Pump pressure detection plug & LS damper 24. L.H. travel motor
8. Bucket valve 25. R.H. travel motor
8A. Spool 26. Swing motor
(flow control valve) Self-pressure reducing valve
8C. Pressure compensation valve 27. Sequence valve
(reducing valve) 28. Reducing valve
80. Check valve
9. Arm valve Ir The suction valve is not shown.
9A. Spool
(reducing valve)
90. Check valve
IO. Boom valve
IOA. Spool
IOB. Pressure compensation valve
1 O-80 Pcoo-7
0
STRUCTUREAND FUNCTION CLSS
+ For details of this page, see page 90-I 1.
PC60-7 1 O-81
Boom + arm operated at same time

If boom spool (IOA) is operated to RAISE and 9B. Pressure compensation valve
arm spool (9A) is operated at the same time (flow control valve)
to OUT, pump discharge amount 0 flows to 9C. Pressure compensation valve
each cylinder (23) and (22). (reducing valve)
When this happens, the load pressure of 9D. Check valve
boom cylinder (23) is greater than the load 10. Boom valve
pressure of arm cylinder (221, so the oil tries IOA. Spool
to flow to arm cylinder (22) where the load IOB. Pressure compensation valve
pressure is low. However, the pressure on (flow control valve)
the upstream side of arm spool (9A) is com- 1OC. Pressure compensation valve
pensated by pressure compensation valves (reducing valve)
(9B) and (90, which receive the load pressure IOD. Check valve
of the boom (= maximum LS pressure PLS). 11. R.H. travel valve
In this way, the pressure difference between IIA. Spool
the upstream pressure and downstream pres- 118. Pressure compensation valve
sure of boom spool (lOA) and arm spool (9A) (flow control valve)
becomes equal, so the flow of oil from main IIC. Pressure compensation valve
pump (2) is divided in proportion to the area (reducing valve)
of opening of each spool. 12:L.H. travel valve
If the area of opening of boom spool (lOA) 12A. Spool
and arm spool (9A) is lOO%, even if pump dis- 12B. Pressure compensation valve
charge amount 0 becomes lOO%, LS differ- (flow control valve)
ential pressure APLS is set so that it does not 12c. Pressure compensation valve
reach the LS valve set differential pressure, (reducing valve)
so main pump (I) is held at the maximum 13. Swing valve
swash plate angle. 13A. Spool
If the area of opening of boom spool (10A) 138. Pressure compensation valve
and arm spool (9A) is less than lOO%, pump (flow control valve)
discharge amount Q is controlled in accor- 13C. Pressure compensation valve
dance with the area of opening of the spools (reducing valve)
by LS differential pressure APLS. 14. LS select valve
15. Unload valve
Hydraulic tank 17. Cooler bypass valve
3. PC valve
22. Arm cylinder
Control valve 23. Boom cylinder
8A. Spool
88. Pressure compensation valve Self-pressure reducing valve
8C. Pressure compensation valve 28. Reducing valve
(reducing valve)
8D. Check valve * The suction valve is not shown.
9. Arm valve
9A. Spool
1 O-82 PC60-7
0
STRUCTUREAND FUNCTION CLSS
L.-.-.-.-._~-~-_-.l.-_-.-.__---__-----_-.__-.-._.__-_-.-._
I
L
I-
i.
PC60-7 1O-83
5) Boom RAISE + swing used at same time

l When boom spool (IOA) is operated to RAISE 8C. Pressure compensation valve
and swing spool (13A) is operated at the same (reducing valve)
time, pump discharge amount 0 flows to 8D. Check valve
boom cylinder (23) and swing motor (26). 9. Arm valve
l When this happens, LS select valve (14) is ac- 9A. Spool
tuated, and pump circuit PP and swing reduc- 9B. Pressure compensation valve
ing valve (13C) circuit are shut off, so the (flow control valve)
swing LS pressure is not generated and LS 9C. Pressure compensation valve
differential pressure APLS becomes the load (reducing valve)
pressure of boom cylinder (23). 9D. Check valve
. In addition, when swing pressure compensa- 10. Boom valve
tion valves (138) and (13C) move to a certain IOA. Spool
position, the pump pressure PP introduction IOB. Pressure compensation valve
passage is shut off. As a result, they cannot (flow control valve)
move to the end of their stroke, and they are IOC. Pressure compensation valve
held at the position where the passage be- (reducing valve)
tween pump circuit PP and spool (13A) is IOD. Check valve
throttled. 11. R.H. travel valve
In other words, swing pressure compensation IIA. Spool
valves (13B) and (130 do not operate to re- 1 IB. Pressure compensation valve
ceive compensation when the swing motor (flow control valve)
load becomes small in normal swing opera- 1 IC. Pressure compensation valve
tion; they are held at the position to receive (reducing valve)
compensation from the start of the swing. 12. L.H. travel valve
. If the area of opening of boom spool (IOA) 12A. Spool
and swing spool (13A) is lOO%, even if pump 12B. Pressure compensation valve
discharge amount 0 becomes lOO%, LS dif- (flow control valve)
ferential pressure APLS is set so that it does 12C. Pressure compensation valve
not reach the LS valve set differential pres- (reducing valve)
sure, so main pump (1) is held at the maxi- 13. Swing valve
mum swash plate angle. 13A. Spool
. If the area of opening of boom spool (lOA) 138. Pressure compensation valve
and swing spool (13A) is less than lOO%, (flow control valve)
pump discharge amount 0 is controlled in ac- 13C. Pressure compensation valve
cordance with the area of opening of the (reducing valve)
spools by LS differential pressure APLS. 14. LS select valve
15. Unload valve
1. Hydraulic tank 17. Cooler bypass valve
3. PC valve
22. Arm cylinder
Control valve 23. Boonl cylinder
8A. Spool
8B. Pressure compensation valve Self-pressure reducing valve
28. Reducing valve
t The suction valve is not shown.

1 O-84 PC60-7
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1O-85
STRUCTURE AND FUNCTION SWING MOTOR
bzi A-A / 1 \ \ B-B
13 12 11 10
c-c SKP03102
1. Output shaft 8. Valve plate

2. Case 9. End cover
3. Thrust plate IO. Brake spring
4. Shoe 11. Brake piston
5. Piston 12. Disc
6. Center spring 13. Plate
7. Cylinder 14. Suction-safety valve
c4
1 O-87
SUCTION-SAFETY VALVE
Function
l 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 be-
comes 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.
Operation
1. When starting swing
. If the swing control lever is operated to swing Control valve
to the left, the pressurized oil from the pump
passes through the control valve and is sup-
plied 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 pres-
sure 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 gen-
erated.
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 pre-
vent cavitation.
1O-88
SWING BRAKE
Operation Self-Pressure
reducing valve
1. Swing brake solenoid valve de-energized
. If the swing brake solenoid valve is de-ener-
gized, the flow of pressurized oil from the
main pump is shut off, and port B is connected
to the tank circuit.
l 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.
SKP04212
Self-pressure
2. Swing brake solenoid valve energized reducing valve
l When the swing brake solenoid valve is ener-
gized, the valve is switched, and pressurized
oil from the main pump enters port B and
E
flows to brake chamber a of brake piston (11). I
. l The pressurized oil entering chamber a over-
comes brake spring (IO) and pushes brake
piston (11) up ( t 1. solenoid valve
l As a result, disc (12) and plate (13) are sepa-
rated and the brake is released. 10
II
SWP0722 I
PC60-7 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. From main control valve port A2 Dl. From main control valve port A3 1. Cover
A2. To L.H. travel motor port A D2. To R.H. travel motor port B 2. Body
Bl. From main control valve port B2 Gl. From travel speed solenoid valve 3. Slipper seal
B2. To L.H. travel motor port B G2. To L.H. and R.H. travel motor port C 4. O-ring
Cl. From main control valve port B3 Tl. To tank 5. Shaft
C2. To R.H. travel motor port A T2. To L.H. and R.H. travel motor port D
1O-90 fuo-7
0
Serial No.: 58001 and up
DRl
Al
Dl
Gl
G2
02
A2
OR2
82
SWPO7125
Al. From main control valve port A2 Dl. From main control valve port A3 1. Cover
AZ. To L.H. travel motor port A D2. To R.H.travel motor port B 2. Body
Bl. From main control valve port B2 Gl. From travel speed solenoid valve 3. Slipper seal
B2. To L.H. travel motor port B G2. To L.H. and R.H. travel motor port C 4. O-ring
Cl. From main control valve port B3 DRl.To tank 5. Shaft
C2. To R.H. travel motor port A DR2. To L.H. and R.H. travel motor port D
PC60-7 1o-90- 1
0
BLADE SPECIFICATION MACHINE

Serial No. : 52374 - 57999
11
Al
Dl
El
Fl
A-A
/
T2 F2
G2
D2
A2
_ E2
SKP03106
Al. From main control valve port A2 El. From blade control valve port A 1. Cover
A2. To L.H. travel motor port A E2. To blade cylinder bottom 2. Body
Bl. From main control valve port B2 Fl. From blade control valve port B 3. Slipper seal
82. To L.H. travel motor port B F2. To blade cylinder head 4. O-ring
Cl. From main control valve port B3 Gl. From travel speed solenoid valve 5. Shaft
C2. To R.H. travel motor port A G2. To L.H. and R.H. travel motor portC
Dl. From main control valve port A3 Tl. To tank
D2. To R.H. travel motor port B T2. To L.H. and R.H. travel motor port D
1O-90-2 PC60-7
0
Serial No. : 58001 and up
DRl
A-A
SFPO6676
Al. From main control valve port A2 El. From blade control valve port A 1. Cover
A2. To L.H. travel motor port A E2. To blade cylinder bottom 2. Body
Bl. From main control valve port 82 Fl. From blade control valve port B 3. Slipper seal
82. To L.H. travel motor port B F2. To blade cylinder head 4. O-ring
Cl. From main control valve port 83 Gl. From travel speed solenoid valve 5. Shaft
C2. To R.H. travel motor port A G2. To L.H. and R.H. travel motor port C
Dl. From main control valve port A3 DRl .To tank
D2. To R.H. travel motor port B DR2.To L.H. and R.H. travel motor port D
Pc60-7 10-91
0
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
SKP03107
a. Port Cl (to tank) Specifications

b. Port A (from control valve) Model : GMOSVL
c. Port D (from travel speed solenoid valve)
d. Port B (from control valve) Hydraulic motor
e. Port C2 (to tank) 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 PC60-7
0
SLPO3108
1. Check valve 11. Swash plate 21. Drain plug

2. Check valve spring 12. Floating seal 22. Center shaft
3. Counterbalance valve 13. RV gear 23. Regulator piston
4. Return spring 14. RV gear 24. Case
5. End cap 15. Crankshaft 25. Spindle
6. Spring 16. Driven gear 26. Piston
7. Regulator valve 17. Cover 27. Cylinder
8. Brake piston 18. Drive gear 28. Brake spring
9. Plate 19. Shaft 29. Valve plate
10. Disc 20. Coupling 30. Check valve
PC60-7 7o-93
OPERATION OF MOTOR
1) At low speed (motor swash plate angle at maximum)
1 reducii;alvei
SUP07126
The travel speed solenoid valve is deener- l As a result, swash plate (11) is pushed in the
gized, so the pilot pressure oil from the self maximum swash plate angle direction by the
pressure reducing valve does not flow to port main pressure inside cylinder chamber P, the
D. motor capacity becomes the maximum, and
For this reason, regulator valve (6) is pushed the system is set to low speed.
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 cham-
ber a of regulator piston (23) passes through
passage b in regulator valve (6) and is
drained to the motor case.
1o-94 PC60-7
0
2. At high speed (motor swash plate angle at minimum)
SWPO7127
l When the travel speed solenoid valve is ener-

gized, the pilot pressure oil from the self pres-
sure reducing valve flows to port D, and
pushes regulator valve (6) to the right(m).
l 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 pis-
ton (23) to the left (-1.
l 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
OPERATION OF PARKING BRAKE

1. When starting to travel
l When the travel lever is operated, the pres-
surized oil from the pump actuates counter-
balance valve spool (31, opens the circuit to
the parking brake, pushes open check valve
(311, and flows into chamber a of brake pis-
ton (8).
. It overcomes the force of spring (281, and
pushes piston (8) to the left (o 1.
l 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 re-
leased.
-- SLP04216
2. When stopping travel

l When the travel lever is placed in hold, coun-
terbalance valve spool (3) returns to the hold
position and the circuit to the parking brake
is closed.
l The pressurized oil in chamber a of brake pis-
ton (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).
l 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. Travel PPC valve 8. Hydraulic pump A : Boom LOWER H : Swing right

2. L.H. travel control lever 9. Control valve B : Boom RAISE I : Blade RAISE
3. R.H. travel control lever 10. L.H. work equipment C : Bucket CURL J : Blade LOWER
4. R.H. work equipment control lever D : Bucket DUMP K : Travel FORWARD
PPC valve 11. L.H. work equipment E : Arm OUT L : Travel REVERSE
5. R.H. work equipment PPC valve F : Arm IN M: Safety lock ON
control lever 12. Safety lock lever G : Swing left N : Safety lock OFF
6. Blade control lever
7. PPC lock solenoid valve
1 O-98
STRUCTURE AND FUNCTION WORK EQUIPMENT, SWING PPC VALVE
5 7
4
8
D-D
B-B
E-E
SSPW274
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
-
6. Nut (for connecting 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 - SLP04221
down. (Fig. 1)
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 cham-
ber 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 cham-
ber 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 bal-
anced 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 le-
ver, 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 SLP04222
(Fig. 2)
10-102
STRUCTURE AND FUNCTION WORK EQUIPMENT, SWING 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 Pl.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressur-
ized 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 pres-
sure 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 cham-
ber B to charge the oil. (Fig. 3)
U SLPO4223
(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 con-
nected to pump pressure chamber PP. There-
fore, 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)
u SLP04224
(Fig. 4)
PC60-7 10-103
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
A-A B-B
D-D
SAP01 506
1. Piston 5. Valve
2. Plate 6. Metering spring
3. Collar 7. Centering spring
4. Body 8. Bolt
PC60-7 10-105
Operation
1) At hold
Ports A and B of the control valve and ports
PI and P2 of the PPC valve are connected to
in spool (1). (Fig. 1)

When piston (4) starts to be pushed by disc
(51, retainer (9) is pushed. Spool (I) is also (Fir. 1)
pushed by metering spring (2) and moves SLPO4225
down.
ber PP, and the pilot pressure of the self pres-
sure reducing valve is sent through fine con-
trol hole f and goes from port Pl to port A.
When the pressure at port PI rises, spool (I)
ber 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).
ver, so the pressure at port Pl also rises in
(Fia. 21
valve spool are balanced. (Fig. 2) SLPO4226
10-106 PC60-7
0

When disc (5) starts to be returned, spool (1)
(3) and the pressure at port PI.
ized 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
the pressure at port Pl supplies the pump
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 con-
fore, the pilot pressure oil from the self pres-
sure reducing valve passes through fine con-
trol hole f and flows from port PI to chamber
A to push the control valve spool.
IF i 9. 4)
SLPO4228
Pc60-7 10-107
0
STRUCTURE AND FUNCTION SERVICE PPC VALVE
SERVICE PPC VALVE
n
B
SDP00027
a. Port T (to tank) 1. Spool

b. Port P (from self pressure reducing valve) 2. Metering spring
c. Port Pl 3. Centering spring
d. PortP2 4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
10408 Pc60-7
0
Operation
1) At hold
Ports A and 6 of the control valve and ports
PI and P2 of the PPC valve are connected to
in spool (1). (Fig. 1)

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.
ber PP, and the pilot pressure of the self pres- (Fio.II
SKP04229
sure reducing valve is sent through fine con-
trol hole f and goes from port Pl to port A.
When the pressure at port PI rises, spool (I)
ber 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 pres-
sure chamber PP) does not change until re-
tainer (7) contacts spool (1).
ver, so the pressure at port PI also rises in
valve spool are balanced. (Fig. 2)
(Fia.2)
SKP04230
PC60-7 10-109
0

When lever (5) starts to be returned, spool (I)
(3) and the pressure at port PI.
ized 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
the pressure at port PI supplies the pump
passes through port P2 and goes to chamber
B to charge the oil. (Fig. 3)
(Fie.3)
SKP04231
4) 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 con-
fore, the pilot pressure oil from the self pres-
sure reducing valve passes through fine con-
trol hole f and flows from port Pl to chamber
A to push the control vaive spool.
iFio.4)
SKP04232
10-l10 PC60-7
0
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE
a b
SKP03134
a. PortT (to tank) 1. PPC safety lock solenoid valve

b. Port P (from self pressure reducing valve) 2. Swing brake solenoid valve
c. Port Tl (from PPC valve) 3. Travel speed solenoid valve
d. Port T2 (from LS select valve) 4. Mode selection solenoid valve
e. Port Al (to PPC valve) 5. Block
f. Port A2 (to swing motor)
g. Port A3 (to L.H., R.H. travel motor)
h. Port A4 (to pump PC valve)
10-l 12 PC60-7
0
STRUCTURE AND FUNCTION SOLENOID VALVE
1. Nut
2. Plunger
3. Coil
4. Connector
5. Push pin
1 8 6. Spring
7. Spool
8. Block
SLPO3135
Operation
When solenoid is deenergized
l The signal current does not flow from the con-
troller, so coil (3) is deenergized.
. For this reason, spool (7) is pushed to the left
6 (-1 by spring (6).
5 . As a result, port A closes and the pressurized
L?
oil from the control pump does not flow to
the actuator.
At the same time, the oil from the actuator
elf-pressure
flows from port B to port C, and is then drained educing valve)
to the tank.
SLP04233
When solenoid is energized

l 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 con-
trol pump flows from port A to port B, and
then flows to the actuator.
Self-Pressure
At the same time, port C is closed, and this
reducing valve)
stops the oil from flowing to the tank.
SLPO4234
10-l 13
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BLADE CYLINDER
SKPO3138
1. Head bushing 6. Cylinder

2. Piston rod 7. Piston ring
3. Cylinder head 8. Wear ring
4. Wear ring 9. Piston nut
5. Rod packing 10. Bottom bushing
Specification Unit: mm
Boom Arm Bucket Blade
Inside diameter of cylinder 115 100 90 120
Outside diameter of piston rod 65 60 55 70
Stroke 840 865 710 130
Max. stroke 2,150 2,193 1,765 679
Min. stroke 1,310 1,328 1,055 549
Width across flats of piston nut 70 65 60 80
10-114
WORK EQUIPMENT
WORK EQUIPMENT
SLPO3139
1. Bucket
2. Bucket cylinder
3. Arm
4. Arm cylinder
5. Boom
6. Boom cylinder
7. Blade cylinder
8. Blade
10416
STRUCTURE AND FUNCTlON WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
1. SYSTEM DIAGRAM
Electric erease DUMIP
Main valve&If-Pressure reducins valve)
Starting switch
relese valve
I a Monitor Panel
Flow divider valve Flow divider valve I Flow divider valve
SKP04235
lo-118 PC60-7
STRUCTURE AND FUNCTION WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
2. OPERATION OF SYSTEM
l The automatic greasing system adds the . The amount of grease for each work equip-
hours of operation of the equipment, and ment pin is set according to the load on the
every time the total reaches 5 hours, it car- pin.
ries out greasing.
. The boom RAISE oil pressure switch signal
is used to detect operation of the work equip-
ment.
Item Unit Specification value

Greasing interval H 5
Greasing time Min 15
~~~.________________---________--__ - -___ ______

rr
& 2
zL 0,
z
.-
Yz
8 2
._
P
._ :
?!
0,
J Q,
b .E __________________
.o H Calculation ON ---
Ti; of areasin
E z
0
E I
z 5 t --I
-0 SusDension of Suskmsion of
0
AZ calculation calculation SKP04236
tE
z 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

%
En Discharge amount cc/min 12
aE
OX Tank capacity - 500 cc cartridge
5cl .
4 G2-LI (for standard specification, when machine is shipped),
W
Grease used -
%GO-LI (for cold areas, available for supply)
No. Greasing point Amount of grease
0 Arm, bucket connecting pin 0.80
0 Arm, link connecting pin 0.65

z
0 Bucket cylinder foot pin 0.25
F
B Amount of cc each @ Boom, arm connecting pin 0.25
5 grease time
0 Arm cylinder rod pin 0.15
5
3 @I Arm cylinder foot pin 0.15
0
ii Boom cylinder rod pin 0.15
0
@ Boom cylinder foot pin 0.35
@ Boom foot pin 0.35 x 2
10-719
3. COMPONENTS OF SYSTEM
1) Controller
1. Connector Input/output signals

2. Controller
CN-P44
3. Fuse
No. 1 Name of signal 1Input/output
Specification
Model: LC2MP
I 1 I Power source +24V I - I
2 GND -
3 - -
4 Abnormality signal output

5 Boom RAISE signal Input
1 6 1 Starting switch ON signal I Input I
10-120
2) Electric grease pump
SLP03827
1. Motor Specification
2. Grease cartridge Model: LD05CP
3. Air bleed plug
4. Pump
5. Pressure switch
6. Connector
10-121
Operation
1. Greasing, pressurizing
. When motor (1) rotates in the normal direc-
tion, eccentric shaft (2) rotates counterclock-
wise and pump piston (4) is operated in a re-
ciprocal 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.
l 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 dis-
charge 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 pres-
sure switch (1 I) is turned OFF, motor (1) starts
again and the pressurized condition is main-
tained.
SKP03829
1o-1 22
. If abnormal pressure is generated in the cir-

cuit at discharge port P end, safety valve (12)
opens and releases the pressure to return cir-
cuit T to protect the equipment from damage.
P
SKP03830
2) Release of pressure, waiting for work

. When the greasing is completed, motor (1)
rotates in reverse, and eccentric shaft (2) ro-
tates clockwise.
. Pressure release spool (7) is moved to the left
(0) by pin (8) of eccentric shaft (2) and pres-
sure release hook (9).
. As a result, discharge port P and return cir-
cuit T are interconnected, and the pressure in
the circuit is released to cartridge (5).
l When this happens, pump piston (4) moves
in a reciprocal motion, but the discharged
grease flows to return circuit T, so the pres- 8
sure does not rise. 7
. When the pressure in the circuit drops, indi-
cator (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. 9 11 IO P
SKP03831
70-l 23
3) Flow divider valve

Type installed to revolving frame
b
SBPO1460
a. From electric grease pump

b. To boom cylinder foot pin @I
10-124
Type installed to boom
a b d e
SBP01461

b. To left boom foot pin @
c. To right boom foot pin @
d. To arm cylinder foot pin @I
e. To boom cylinder rod end pin @
f. 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. From boom flow divider valve

b. To bucket cylinder foot pin @
c. To arm, link connecting pin @
d. To arm, bucket connecting pin @
e. To boom, arm connecting pin @
f. To arm cylinder rod end pin @
10-126
Structure A. Discharge port

B. Discharge port
C. Measurement chamber
D. Piston chamber
E. Oil passage
F. Supply port
1. Measurement piston
2. Head
3. Body
4. Spring
5. Spring retainer
6. Pilot piston
I-.
0
s SAP01469
fi
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.
- l As a result, oil passage E opens and the
grease enters piston chamber D of measure-
ment piston (I) from oil passage E.
u SAP01463
lo-127
Measurement piston (I) is pushed down by
the grease in piston chamber D, and the
grease in measurement chamber C is dis-
charged 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 C
(I), and supply port F and oil passage E are

closed.
In this way, the measurement and discharge
process for one cycle is completed.
SAP0 1464
2) Resetting
. When the pump enters the pressure release
mode, measurement piston (I) is pushed back
up by spring (4).
l When this happens, the grease in piston
chamber D passes from oil passage E through
the inside of pilot piston (61, and enters mea-
surement chamber C to reset the system to
the initial stage in preparation for the next
time of actuation.
SAP0 I!465
lo-128
3) Boom RAISE oil pressure switch
Structure of circuit
SLP04237
1. Plug Specifications
2. Switch Structure of contact : N-0. contact
3. Connector Actuation (ON) pressure:
0.5 + 0.1 MPa (5.0 + 1.0 kg/cm*}
Resetting (OFF) pressure:
0.3 ? 0.05 MPa (3.0 + 0.5 kg/cm*)
IO-129
STRUCTURE AND FUNCTION ELECTRICAL ALLOCATION DIAGRAM
ELECTRICAL ALLOCATION DIAGRAM (l/Z)

INSIDE CAB
IO
I13 12
SLPO3142
1. Alarm buzzer 7. Starting switch 13. Travel speed switch

2. Swing holding brake 8. Fuse box (standard specification machine)
controller 9. Swing lock prolix switch 14. PPC lock limit switch
3. Horn switch IO. Radio 15. Travel boost switch
4. Speaker 11. Wiper switch (blade specification machine)
5. Monitor panel 12. Swing lock switch 16. Heater
6. Fuel control dial 17. One-touch slow-down switch
18. Glow resistance
10-130
E20107
19. Front lamp

20. Working lamp
21. Fuel level sensor
22. Mode selection solenoid valve
23. Travel speed solenoid valve
24. Swing brake solenoid valve
26. Room lamp
27. Antenna
28. Engine oil pressure sensor
29. Engine stop solenoid
30. Glow plug
31. Starting motor
32. Window washer
33. Coolant temperature sensor
34. Air conditioner compressor (option)
35. Alternator
36. Battery relay
37. Fusible link
38. Battery
39. Electric grease pump
40. Automatic greasing controller
41. Boom RAISE oil pressure switch
42. Swing oil pressure switch
43. Air conditioner unit
44. Wiper motor
45. Horn
ir
STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM

AIR CONDITIONER ELECTRIC CIRCUIT DIAGRAM
ComPressor
SKP04238
IO-133
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM

TOTAL SYSTEM DIAGRAM
Safety
lock lever
II
Arm Swina
/ Travel motor:
Xe
r
L. H. travel R. H. trave
Tre
valve
dl-b
tt tt i-
I
3Decification
!_____________
Enoine
One-touch
Decelerate slow-down
I;
motor switch
Monitor Panel
7 To each solenoid valve

Battery relay SKP04239
1. Pump control function
z
Self-Pressure
h
reducins
valve
Mode selection
solenoid valve
,----I I
Main control valve
Ensine
,.:
Main Pump
I Fuel injection DUUID
Servo
Piston
I
Limit
snitch
Battery Fuse box

wv
121 J
1-1
SKP04240
Function
l 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.
PC60-7 1o-1 35
Operation
Fuel control Engine torque curve5
dial set en- Mode Actuation
gine speed Serial No. : 52374 - 57999
Mode selector solenoid
valve is turned ON and I Enpine torque
Below
Light load
signal pressure is sent to
TCC valve to reduce pump
i my sorption torque
1,400 rpm absorption torque by

approx. 15% from normal
in order to prevent any
drop in engine speed.
Mode selection solenoid

valve is turned OFF and
Above signal pressure does not
Normal 14000rpm 1950rpm
1,400 rpm flow to TCC valve, so
pump absorption torque Ennine speed
is set to normal (100%). SKP04241
Ens ine torpue

/
Pump absorption torque
1.400rPm 2. 250r pm
Ens ine speed
SWPO712!3
Pump absorption torque curve
Standard mode
Light load mode
Pump dischsrne pressure

SKP04242
lo-136 PC60-7
0
2. Swing lock, swing holding brake function
Swine I
I
0 1 Solenoid valve
Left PPC
valve
Self-Pressure
reducino valve
1 ----?Srino brake
1 =T
Swine lock
witch
,_
1
5
Monitor Panel
:Swins lock
-+ _Swins holdine _.,orolix ::
brake controller
SKP04243
Function
. This machine is equipped with a swing lock
and swing holding brake function.
JO-137
Operation
1) Swing lock, swing holding brake function
. The swing lock (manual) can be locked l Swing lock switch and swing lock, swing holding brake
r
at any desired position, and the swing
Actuation
holding brake (automatic) is intercon-
nected with the swing, so it prevents any Swing brake is applied approx.
hydraulic drift after the swing is stopped. Swing 4 seconds after swing lever is
1OFF OFF holding returned to neutral. When
brake swing lever is operated, brake
is released and swing opera-
tions can be carried out freely.
When swing lock is actuated,

swing is fixed in position. Even
ON ON if swing lever is operated,
swing lock is not canceled and
swing operations cannot be
carried out.
2) Swing lock prolix function

. If any abnormality occurs in the control- ON
Swing lock OFF
ler, and the swing holding brake is not ac- prolix switch (when fhere is abnor- (when controller is
malrty in controller) normal)
tuated normally or the swing cannot be
operated, the swing lock prolix switch can Swing lock
switch 1 ON 1 OFF 1 ON ( OFF 1
be operated to cancel the swing lock and
allow the swing to be operated.
* Even if the swing lock prolix switch is
actuated released actuated iz,JEted
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 hydrau-
lic drift of the swing.
SLP04244
10-138
3. Travel speed selection function
?yF- Main control valve

L
I
,
Travel motor
Travel speed switch
(standard specification
machine)
8 I
1 Travel speed
! solenoid valve
Travel boost pedal

(blade specification
I- Main
PP
4 Battery
Engine
Battery
relay
P Fuse
box
SKP04245
Function Operation
l 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- Low
, LOW Released OFF Max. speed
fication machine is equipped with a travel (2.8)
boost pedal (low speed when released, high I ,:_l_
speed when depressed). HIGH IDepressed 1 ON 1 Min. l gegtnd
I
Travel speed se- Standard speci- Bladespecifica-
lection method fication machine tion machine
Panel switch 0 X
Boost switch 1 X 0
PC60-7 10-139
4. One-touch slow-down function
Engine
Governor
I ever
One-touch
slow down
sxi tch
Fuel control dial
Fuse box
Battery relay
SKP04246
Function Operation
When the machine is out of action for a
short time, such as when waiting for work Enoine
speed (rwnl
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 Deceleration speed
reduce fuel consumption and noise. ,
When starting work again, press the switch Max.I I - Max.1
again to restore the engine speed immedi-
ately to the set speed.
T imebec)
Deceleration ON Deceleration OFF
SKP04247
10-140 PC60-7
0
5. System components
1) Swing holding brake controller
1. Controller
r-J-
2. Connector
,
Input/output signals
CN-Cl
12 IGND
1 3 1Oil pressure switch1 Input 1

0 4 Solenoid valve output
2) Swing oil pressure switch

* Same as boom RAISE oil pressure switch
in Work equipment pin automatic greas-
ing system.
3) Mode selection solenoid valve

Swing brake solenoid valve
Travel speed solenoid valve
* For details, see SOLENOID VALVE.
10-141
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Buzzer
m Switch signal
Workino lamp. heater
Buzzer sional
0
F
Sensor 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 ma-
chine. 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 warn-
ing when any abnormality is found in the
machine.
2. The pilot portion, which displays the op-
eration 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
1. MONITOR PANEL
W-Pi
CN-KJ
Ct+P2
Ch-K3
W-P3
Ct+K7
f+ SLPO3154
Outline input/output signals

. The monitor panel has a monitor display CN-Pl (monitor Dane11
-
function and switches for electrical compo-
nents.
. It has a built-in CPU (Central Processing Unit) 10 Charge level Input
which processes the data and outputs the
11 Automatic greasing Input
display.
. 12 Swing lock Input
A liquid crystal display is used for the gauge
display; lamps are used for the monitor dis- 13 Preheating Input
play. I - I
17 1Fuel level I but I 1151 Buzzer l@mJtl
Isl- I - I 16 Night lighting input
CN-P2 (light switch) CN-P3 (heater switch)

121=
I 3 I Heater Lo
14 IGND I - I
10-143
6 SKP03155
1. Service meter 7. Heater switch

2. Coolant temperature gauge 8. Preheating pilot lamp
3. Fuel level gauge 9. Automatic greasing caution lamp
4. Light switch IO. Swing lock pilot lamp
5. One-touch slow-down pilot lamp 11. Charge caution lamp
6. Fuel control dial 12. Engine oil pressure caution lamp
@ Symbol Display item Display range Display method

r2
Engine oil Below When the starting switch is turned ON with the engine
0 49kPaI0.5 kg/cm* 1 running, the display is as follows:
z ,*:,0 pressure Normal : OFF
When there is Abnormal:ON (buzzer sounds if abnormality occurs
Charge amount
defective charging I when engine is running)
q Automatic When there is Normal : OFF

SIP03158 greasing
abnormality Abnormal: ON
el (left) lights up,

SAW0528 T .
When the starting switch is at HEAT, lamp is ON (30 set); and
SAP00526
0w Preheating When preheating after this it flashes for 10 sec., then goes OFF to indicate
completion of preheating
5
E I :7: I
.%%.,
._.,. ,
Swing lock
When
locked
swing is
Lights up when swing lock switch is ON
lOI One-touch decel Lo-idlio Liahts UD when one-touch decel switch is ON
- Lo : Heater fan Lo
r Heater switch
* Hi : Heater fan Hi
.z IPT
w - 1. Monitor panel lights up
m Light switch
SKP031M 2. Monitor panel, head light and work lamp light up
10-144
2. SENSOR
. The signals from the sensors are input directly to the monitor panel.
l The contact type sensors are always connected at one end to the chassis ground.
Category of display Type of sensor Sensor method When normal When abnormal
Caution Engine oil pressure Contact OFF (open) ON (closed)

Coolant temperature Resistance - -
Gauges
Fuel level Resistance - -
1) Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
6
8
w
I Qg @ Structure
of circuit
SLPO4249
T 2) Coolant temperature sensor
1. Connector
2. Plug
3. Thermistor
@==+a
SLPO4250
?O-145
3) Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistance
l/2
EMPTY
3 4
A-A
SLPO3836
10-146
20 TESTING AND ADJUSTING
Standard value table for engine Adjusting PC valve ..................................... 20-I 11

related parts.. ................................................ 20-2 Measuring LS differential pressure and
Standard value table for chassis adjusting LS valve.. .................................. 20-I 12
related parts.. ................................................ 20-3 Testing hydraulic pressure in the control
Standard value table for electrical circuit.. ....................................................... 20-l 13
related parts ................................................ 20-12 Testing outlet pressure of solenoid
Tools for testing, adjusting and valve .......................................................... 20-I 14
troubleshooting ........................................ 20-101 Measuring PPC valve output pressure
Measuring engine speed ........................... 20-102 ..................................................................... 20-I 15
Measuring exhaust gas color.. .................. 20-104 Adjusting work equipment and swing
Adjusting valve clearance.. ........................ 20-105 PPC valve .................................................. 20-I 15
Measuring compression pressure ............ 20-107 Testing travel deviation.. ............................ 20-I 16
Measuring blowby pressure.. .................... 20-109 Measuring oil leakage.. .............................. 20-I 17
Testing and adjusting fuel injection Releasing remaining pressure in hydraulic
timing ..................................................... 20-109-2 circuit.. ....................................................... 20-I 19
Measuring engine oil pressure ............. .20-109-7 Checking of clearance of swing circle
Testing and adjusting alternator bearing ...................................................... 20-120
belt tension ............................................ 20-109-9 Checking and adjusting of track shoe
Adjusting engine stop solenoid linkage tension ...................................................... 20-121
................................................................ 20-109-10 Testing wear of sproket.. ......................... 20-121-l
Adjusting fuel control linkage ............. .20-109-12 Bleeding air.. ............................................... 20-122
Testing and adjusting of hydraulic Automatic greasing controller .................. 20-124
pressure in work equipment, Troubleshooting ......................................... 20-20 1
swing and travel circuits .......................... 20-110
* Note the following when making judgments using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine 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.
2. 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.
3. These standard values are not the standards used in dealing with claims.
AI 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.
A When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
A When checking the water level, always wait for the water to cool down. If the radiator cap is re-
moved when the water is still hot, the water will spurt out and cause burns.
A 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 4D102E-1
item Measurement conditions Unit Standard value Permissible value
High idling 1,950 + 50
Engine speed Low idling rpm 950 * 50
Rated speed 1,750 -
Max. 4.0 7.0

Exhaust gas color [Ati[:iceleration 1 ~$~~
Max. 2.0 3.0
0.25
Valve clearance mm
Exhaust valve I 0.51
(normal temperature)
Oil temperature: Min. 2.41 Min. 1.01

40-60c MPa {Min. 24.6) (Min. 10.3)
Compression pressure
(engine speed: 250 rpm) (kg/cm (Differentiol pressure
(SAE 15W-40 oil) between cylinders)
(Coolant temperature:
Max. 803.6 3,400
Blowby pressure operating range) Pa
(Max. 821 (3471
(Orifice dia.: 5.813mm) At rated output knrnl-$c
(Ref.) (Ref.)
(SAE 15W-40 oil)
operating range)
At high idling MPa 0.34 - 0.52 2.1

Oil pressure
(SAE 15W-40) (kg/cm; (3.5 - 5.31 (21)
At low idling Min. 0.1 0.07

(SAE15W-40) (Min. 1.01 (0.7)
Whole speed range

Oil temperature C 80-110 120
(inside oil pan)
Before top dead center ( o1

Fuel injection timing 15*1 15*1
(B.T.D.C.) deg
Deflection when pressed

Belt tension
with finger force of mm 6-10
(air compressor)
approx. 58.8Ni6kgI.
20-2 Pc60-7
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Seriaol Number 58001 and up
Engine 4D95LE-2
Item Measurement conditions Unit Standard value Permissible value
High idling 2,250 ? 60
Engine speed Low idling rpm 1,05o+;c
Rated speed 2,100
At sudden acceleration Max. 5.0 Max. 7.0

Exhaust gas color
At high idling Max. 1.0 Max. 2.0
Intake valve 0.35 -
Valve clearance mm
Exhaust valve 0.50
(normal temperature)
Oil temperature:
40 - 60C
(engine speed: MPa Min. 2.94 Min. 2.06
Compression pressure
320 - 360 rpm) kg/cm: {Min. 30) {Min. 21}
(SAE 15W-40 oil)
Max. 490 Nax. 980
Blowby pressure operating range) Pa
{Max. 501 (Max. 100)
(Orifice dia.: 5.613mm) At rated output -H2C (Ref.) (Ref.)
(SAE 15W-40 oil)
operating range)
At high idling 0.34 - 0.59 Min. 0.25

(SAE30) (3.5 - 6.0) (Min. 2.5)
At high idling 0.29 - 0.54 Min. 0.21

Oil pressure (SAEIOW) MPa (3.0 - 5.5) {Min. 2.11
kg/cm:
At low idiing Min. 0.1 Min. 0.08
(SAE30) {Min. I.01 {Min. 0.8)
At low idling Min. 0.08 Min. 0.07

(SAElOW) {Min. 0.8) {Min. 0.7}
Whole speed range

Oil temperature C 80- 110 120
(inside oil pan)
Before top dead center (1

Fuel injection timing 12 f 0.75
(B.T.D.C.) dw
Deflection when pressed

Belt tension
with finger force of mm 6-10
(air compressor)
approx. 58.8N(6kgI.
fC60-7 20-2- 1
0
TESTING AND ADJUSTlNG STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

-
Item Measurement conditions Jni
I
-
l Hydraulic oil temperature: 45 - 55 C
1 pump relief l Coolant temperature:
(LS relief) within operating range P=
l 1 pump relief: arm relief
-
a b e a b
Boom control valve
I n
Arm control valve 1 1-4
Bucket control valve 1

nm jM.1 9.5fl.l 6.5W I6ztO.l .5?0.1
BLPO1255
Blade control valve
I
-
Boom control lever l Center of the lever knob

l Read the max. value to the end of
stroke
Arm control lever l Engine stopped
l Excluding neutral play
Bucket control lever
Swing control lever 100+10 loo* 10

I
Travel control lever nm 115* 15 115f15

I
Blade control lever
Boom, bucket, arm

swing, blade
Play of control lever
Travel lever Max. 10 Max. 10
- I
15.7 f 4.9 15.7 * 4.9
Boom control lever l Engine at full speed
11.6 f 0.5) (1.6 f: 0.5)
l Hydraulic oil temperature: 45 - 55 C
l Fit a push-pull scale to the center of 13.7 f 4.9 13.7 + 4.9
Arm control lever the control lever knob to measure 11.4 f 0.51 (1.4f 0.5)
l Read the max. value to the end of
stroke 13.7 f 4.9 13.7 f 4.9
Bucket control lever
N 11.4 f 0.51 Il.4 + 0.5)
kg1 15.7 * 4.9 15.7 * 4.9
(1.6 f 0.5) Il.6 * 0.51
Blade control lever

-
t 1: Serial No. 58001 and up
PC@7 20-3
0
Swing Hydraulic pressure
?
3
v)
(D
?
N
P
Y cn
OP og
h h
(3 N
q9 B9 cn
9
0- 9
v o w 003 000
Y
Y
I +
OP
A
w
W
t
0-
Y
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Machine model
T PC60-7
Cats Measurement conditions Jni Standard Permissible

gor value value
-
Work equipment posture
Max. reach
Time taken to swing ;ec 2552 30

TAP00950
l Engine at high idling
l Hydraulic oil temperature: 45 - 55C
l Swing one turn, and measure time
taken to swing next 5 turns
Hydraulic drift of EAP03503

swing Enginezed m-r 0 0
Hydraulic oii temperature: 45 - 55C
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.
Leakage from swing l Hydraulic oil temperature: 45 - 55C
lmir Max. 3.5 7.0
motor l Swing lock switch ON
l Relieve swina circuit.
- -
Lo 28.8 i 3 34
Travel speed (1) BAP03504 - ;ec

Engine at high idling
Hydraulic oil temperature:
45 - 55C
Raise track on one side at a time, Hi 19.8 + 2 25
rotate one turn, then measure timr I
taken for next 5 turns with no load
Lo 25.3 k 1.7 29
Travel speed (2)

l Engine at high idling BApo3505
l Hydraulic oil temperature:
45 - 55C
Hi 16.2 + 1 19
l Run up for at least 10 m, and
measure time taken to travel
next 20 m on flat ground.
20-5
0
lnit Standard Permissible

item Measurement conditions value value
BAP03605
Engine at high idling
Hydraulic oil temperature: 45 - 55C
Run up for at least 10 m, and mea-
rravel deviation nm Max. 200 Max. 220
sure deviation when traveling next
20 m on flat ground.
Ir Use a hard horizontal surface.
BAP03506
f Measure dimension e
Hydraulic drift of
travel nm 0 0
BAP03507
1 Engine stopped
1 Hydraulic oil temperature: 45 - 55C
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 irnil 2 5

motor
Lock oin
!AP00951
. Engine at high idling

l Lock shoes and relieve travel circuit.
-
20-6
0
Machine model
-
r PC60-7
Item
r Measurement conditions U nit
-
Standard
value
Permissible
value
Total work
squipment Posture for measurement
[hydraulic drift at Max. 550 825
tip of bucket
teeth )
i
Boom cylinder
(amount of
retraction of Max. 4 60
cylinder) TAP00952
Place in above posture and measure

extension or retraction of
Arm cylinder each cylinder and downward move-
ment at tip of bucket teeth.
Max. 41 59
(amount of exten. Bucket: rated load
sion of cylinder) Horizontal, flat ground
Levers at neutral
Engine stopped
Bucket cylinder Start measuring immediately after
setting. Max. 20 30
(amount of
retraction of Measure hydraulic drift every 5
cylinder) minutes, and judge from results
for 15 minutes.
-
Boom
3.1 f 0.3 3.9
Bucket teeth in
contact with
ground
I l Engine at high idling

TAP00953
3.3 + 0.3 3.9
Cylinder fully l Hydraulic oil temperature:
extended 45 - 55C
Arm 3.6 f 0.4 4.5
Cylinder fully
retracted ,ec.
I TAP00954
2.7 + 0.3 3.5
Fully extended
45 - 55C
Bucket 3.1 ?I 0.3 3.9
Cylinder fully
retracted
I TAP00955 2.1 f 0.2 2.6

Fully extended l Engine at high idling
45 - 55C
-
20-7
0
Item
Machine model
Measurement conditions Jnit

r Standard
PC60-7
Permissible
value value
Boom Max. 2.9 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
sec.
Arm 1.0
BAP03514
l Stop arm suddenly and measure

time taken for arm to stop
l Engine at low idling .
BAP03515 10
Bucket
l Stop bucket and measure time taker
for bucket to stop at bottom and the
start again
l Engine at low idling
l
-
Cylinders Boom Max. 2.3
l Hydraulic oil temperature: Arm Max. 2.2 15

45 - 55C clmi
l Engine at high idling Bucket Max. 2.0
l Relieve circuit to be
Center swivel
measured Max. 10 50
joint

*Use a hard horizontal surface.
20m
Lc -I
Travel deviation wher

work equipment + mn Max. 500 550
travel are operated
BAP03506
t Measure dimension e
Machine model
r PC60-7
Catf
!m
item
T Measurement conditions Unit
st~Z!ZrdPermissible
value
Main piston
pump
See next page Wmin See next page
PC60-7 20-9
0
Catl PC60-7 Discharge amount of main piston pump

Qor
Serial No. : 52374 - 57999
15(
lO(
50
0
4.Ii501 !.t(lOO)II.
71150) IS.
6UOOl 24.
5(250)
PIMP dirchrrr oressure Pl WPafb/cr)
BAPOOQ56
l Pump speed: At 1,750 rpm
Test pump dis- Average Standard value for Judgement standard

Check point charge pressure pressure discharge amount lower limit
(MPa(kg/cmV (MPa(kg/cm*)) QfVmin) 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 K60-7
0
Cat1
PC60-7 Discharge amount of main piston pump
gor
0 50 100 150 200 250 300

19. 8) (19. 6) (24. 51
Pump d i scharse Pressure Pl (HPa(ka/cm))

TXP02153
l Pump speed: At 2,100 rpm
Test pump dis- Average Standard value for Judgement standard

Check point charge pressure pressure discharge amount lower limit
(MPafkg/cm*)) fMPafk&mz)) Q(.f/min) 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! Zonnector Measurement
Component Judgment table
ten No. conditions
Normal conditions are as shown in the table 1) Starting switch

below. OFF
2) Disconnect CN-
Engine oil pressurt3
CN-Pl3 P13
sensor
While the engine running 1) Start the engine.

(l/2 throttle or above) + 27.5 - 29.5 V
Alternator CN-M5 % With a degraded battery, or in cold
district, voltage may not rise for some
time after starting the engine.
-
below. OFF
Coolant tempera- EN-P7 2) Disconnect CN-
ture sensor 25C Approx. 40 kQ P7
. Between (1)
105C and (2) Approx. 3.3 kR

below. OFF
IN-P5 2) Disconnect CN-
Fuel sensor P5 and CN-P6
ZN-P6 FULL stopper Between CN-
EMPTY
Normal conditions are as shown in the table I) Starting switch

below. OFF
2) Disconnect CN-
Swing lock switch CN-X5 x5
-
Normal conditions are as shown in the table 11 Starting switch
below. OFF
2) Disconnect CN-
P2
Light switch CN-P2
I I
Between(P), (3) Continuity

Switch 2
and (4) detected

below. OFF
2) Disconnect CN-
P3
Heater switch CN-P3
I 1 ~~~~~~
Between (2) Continuity

Switch Hi
and (4) detected
20-12 Pc60-7
0
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Inspection/adjustment item siymbol Part No. Part Name Remarks
1 799-203-8001 Multi-tachometer Digital display

Engine speed A L: 60 - 2,000 rpm
2 795-790-2500 Adapter assembly H: 60 - 19,999 rpm
Coolant and oil tempera- B 799-101-1502 Digital thermometer -99.9 - 1,299 C
tu re
Pressure gau e : 2.5{25), 5.9f601,
1 799-101-5002 Hydraulic tester 39.2{400}, 58.!!(6001 MPaIkg/cmZI
e:
790-261-1203 Digital hydraulic tester 68.6
Pressure
MPa gau
1708 kg/cm*}
2 799-401-2320 Hydraulic gauge 0.98 MPa (10 kg/cm*)
Both male and female
.790-261-1311 14 x 1.5 (female PT1/8)
C 3 l 790-261-1321 Adapter 18 x 1.5 (female PT1/8)
Hydraulic oil pressure Both male and female
l 790-261-1331 22 x 1.5 (female PT1/8)
I 4 I 799-401-2701 1 Differential pressuregauge 1
/ I I

.790-261-1360 Adapter 14 x 1.5 (female PT1/8)
5 l 790-261-1370 Nut For 14 x 1.5 blind
l 07003-31419 Gasket For blind
1 795-502-l 590 Compression gauge

I I
D 2 l 790-553-l 110 0 - 6.9 MPa (0 - 70 kg/cm21

Compression pressure Kit No.: 795-502-1205
Adaoter
3 l 795-553-l 110
Blowby pressure E 799-201-1504 Blowby checker 0 - 4,900 Pa IO - 500mmHzOI

Commercialy
Valve clearance F available Feeler gauge
f.Xs~ll$ anon
.. 0
- - --
19 Y0
^
1 799-201-9000 Handy smoke checker sndard color samples)
Exhaust gas color G !Disc.olc%r n x l/10 Bosch
Commercialy Smoke r\^+-*
IIIcil%zil
2 available 1index)
0-294N{O-30kgI
Operating force H Is/ Push-pull scale
0-490N(O-50kgI
I Commercialy Scale
Stroke, hydraulic drift available
J Commercialy Stop watch
Work equipment speed available
Voltage and resistance K 79A-264-0211 Tester
value measurement
1 799-601-2600 T-adapter box
Sensor harness diagnosis L
2 799-601-7000 Adapter assembly
1 21T-3811390 Nipple
Air breeding from the auto hll
I.,
lubricator piping 2 07020-00000 Fitting
1
1 795-799-l 130 Gear Cranking tool
Valve clearance I 0 2 795-102-2102 Spring pusher

Fuel injection timing
3 Commercialy Dial guage
available
Measurement of wear on P 790-607-1031 Wear gauge
sprocket tooth
PC60-7 20-101
0
TESTING AND ADJUSTING MEASURING ENGINE SPEED
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 revolu-

tion 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 measure-
ment.
A When measuring the engine speed, be careful
not to touch any rotating parts or high tem-
perature parts.
1) Measurement of the low-idling and high-
idling 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 re-
lief:
Measure the engine speeds at it full capacity
when each pump is relieved.
20-102
0
TESTING AND ADJUSTING MEASURING ENGINE SPEED
7. Remove the fan gurad (I 1.
2. Install sensor I of tachometer Al, then connect

Al to the tachometer.
3. Start the engine, and measure the engine speed

when it is set to the conditions for measurement.
a 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) Measurement of the low-idling and high-

idling speed:
Measure the engine speeds when the fuel
tever is set to the low-idling and high-idling.
2) Measurement of the speed at the pump re-
lief:
Measure the engine speeds at it full capacity
when each pump is relieved.
PC60-7 20- 103

0
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

l When measuring in the field when there is no
air or power supply, use smoker checker Gl;
when recording official data, use smoke meter
62.
f Raise the coolant temperature to the operating
range before measuring.
A When removing or installing the measuring
equipment, be careful not to touch any high
temperature part.
1. Measuring with handy SmOk8 checker Gl

1) Fit filter paper in tool Gl.
2) Insert the exhaust gas intake port into the
exhaust pipe, accelerate the engine sud-
denly, and at the same time operate the
handle of tool Gl to catch the exhaust gas
on the filter paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measurina with smoke meter 62

1) Insert-probe into the outlet port of exhaust
pipe, then tighten the clip to secure it to the
exhaust pipe.
2) 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%
3) Connect the power cord to the AClOOV out-
let.
-k When connecting th8 port, check first
that the power switch of tool 62 is OFF.
4) 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.
5) Turn the power switch of tool G2 ON.
6) 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.
7) Lay the filter paper used to catch the ex-
haust gas color on top of unused filter pa-
pers (10 sheets or more) inside the filter pa-
per holder, and read the indicated value.
BLPO21
20-104 PC60-7
0
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING 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

marked 0 in the valve arrangement chart. At the Valve arreneement
same time, make match marks on the crankshaft
pulley and timing gear case, then remove timing
pin (1).
Crl inder NO. I 1 3 I
5. Next, rotate the crankshaft one turn (360) in the
Exhaust valve 0 0 0 0
normal direction, align the match marks made in
Step 4 accurately, then adjust the valve clearance Intake valve l 0 0 0
of the remaining valves marked 0.
Ir To adjust the valve clearance, loosen locknut
(41, then insert feeler gauge F between rocker I TKP00642
arm (6) and valve stem (51, and turn adjust-

ment screw (3) until the clearance is a sliding
fit. Then tighten locknut (4) to hold the ad-
justment screw in position.
m Locknut:
24 f 4 Nm (2.45 rt 0.41 kgm}
Ir Firing order : 1 -3 -4- 2
* valve clearance
Intake side .. . .. . . . .. . . . . . . .. .. . .. 0.25 mm
Exhaust side .. . .. . . .. . . . . . . . .. . . 0.51 mm
PC60-7
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
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

Valve arrangement
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.
I TOP00308
4. 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 accord-
ing to the following procedure; Bring cylin-
der 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 cylin-
/
der according to the firing order. F BWPO4013
l Firing order: 1 - 2 - 4 - 3
* After tightening the locknut, check the valve
clearance again.
4 3 5 6
20-106
aI
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
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 de-
1. Adjust the valve clearance accurately.
tails, see ADJUSTING VALVE CLEARANCE.
BLP02908
2. Warm up the engine until the oil temperature is
40 - 60C.
-_ 3. Remove the nozzle holder assembly of the cylin-

der 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.
Read the compression pressure when the
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 de-
tails, see INSTALLATION OF NOZZLE ASSEM-
BLY.
PC60-7 20-107
0
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
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 de-

tails, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine until the oil temperature is

40 - 60-c. I I II BwP04009
3. Remove nozzle holder assembly (1) of the cylin-

der to be measured. r
4. Install adapter D3 to the nozzle holder mounting

part, then connect compression gauge Dl.
5. Install multi-tachometer Al.

Sr See MEASURING ENGINE SPEED.
6. Disconnect engine stop solenoid terminals (M3,

M37) (2) and fix the governor lever of the injec-
tion pump to the non-injection position, then ro-
tate the engine with the starting motor and mea-
sure 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 PC60-7

0
TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
MEASURING BLOWBY PRESSURE

Serial No. : 52374 - 57999
* Raise the coolant temperature to the operating

range before measuring the blowby pressure.
1. Install the blowby checker to the tip of engine

breather hose (1).
2. Run the engine at the rated output and measure

the blow-by pressure.
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 en-

gine running at rated output.
l If it is inpossible to check at rated output, mea-
sure at high idling. In this case, the blowby
value will be about 80% of the value at rated
output.
* Blowby varies greatly according to the condi-
tion of the engine. Therefore, if the blowby
value isconsidered abnormal, checkfor prob-
lems connected with defective blowby, such
as excessive oil consumption, defective ex-
haust gas color, and prematurely dirty or de-
teriorated oil.
FCbO-7 20- 109

0
TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
1. Remove cylinder head cover (1)
2. Install plug E to breather tube (2)
3. install cylinder head cover (I!, then Install blow-

by checker E to the oil filler.
4. Run the engine at the rated output and measure

the blow-by pressure.
A Do not touch a hot part or a rotary part dur-

ing measurement.
* The regular blow-by pressure is measured

while the engine is running at the rated out-
put.
l 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 pres-
sure 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 pres-
sure.
* After finishing measurement, remove plug E
without fail.
BWPO40 I I
20- 109- 1 PC60-7

0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
.-

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 tim-
ing 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 INJEC-
TION PUMP
2) Rotate the camshaft of the injection pump to
align timing pin (3) with timing pin pointer
(4).
3) Install the injection pump.
For details, see INSTALLATION OF FUEL IN-
JECTION PUMP 2
BLPOIO5I BLPO1052
PC60-7 20- 109-2

0
TESTlNG AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION THING
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 check-
ing 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 compres-
sion 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 ex-
haust 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 diam-

eter 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 4
and the hole of the fuel injection pump holder
is aligned with the mounting hole of the front
a 1
gear cover (in which the mounting bolt will BYPOIO I 6
be inserted).
* If the holes are deviated from each other, re-
move the fuel injection pump and check its
engagement with the drive gear.
Remove the timing check pin and tighten each

bolt.
20-109-3 fC60-7
0
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 replac-
ing the gear train)
2. Bring cylinder No. 1 to the compression top dead

center.
1) Turn the crankshaft forward and match injec-
tion timing line (1) on the crank pulley to
pointer (2). BWPO4012
2) Check that both air intake valve and exhaust
valve of cylinder No. 1 have the valve clear-
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
4. Using spring pusher 02, compress the valve

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 fin-
gers while it is in contact with the top of piston
(9) to fit it securely.
.I
,9
BEPOl063
Pcoo-7 20- 109-4

0
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 cylin-
der No. 1.
9. Turn the crankshaft forward so that the dial gauge

indicates standard dimension a. This dimen-
sion is equivalent to BTDC 12 + 0.75.
Ir Standard dimension: 1.69 f 0.22 mm 4027
It Be sure to adjust the above dimension by turn-
ing the crankshaft forward.
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 injec-

tion pump mounting flange, then loosen the in- BEP01065
jection pump mounting bolts (14).
14. Turning the injection pump outward and operat-

ing 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 injec-
tion timing is delayed. If the former is slanted
toward the cylinder block, the latter is ad-
vanced.
15. Tighten injection pump mounting bolts (14) al-

ternately.
16. lighten the nut at the oblong hole of the injec-

tion 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, re-
peat the above steps from 7.
20-109-5 PC&7
0
18. Remove the delivery valve holder (I 1) and install

delivery valve (12) and spring (13) to it, then in-
stall delivery valve holder (14) again.
* Replace the O-ring and copper gasket of the
delivery valve.
g Tighten the delivery valve 3 times to secure
it. (If it is not tightened sufficiently, the gas-
ket may be broken.)
w Delivery valve holder :
32.4 f 2.0 Nm (3.3 + 0.2 kgm}
19. Connect fuel injection pipe (3).

w 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 pusher

02 and install valve cotter (5).
22. Install air intake rocker arm (4) of cylinder No. 1,

then install snap ring (3).
* Install the snap ring securely.
23. Install the cylinder head cover.
m 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 fol-
lowing conditions.
l Coolant temperature: Within operating
range
Serial No. : 52374 - 57999
Remove engine oil pressure sensor (11, then in-

stall 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 Pc60-7

0
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
PC60-7 20- 109-8

c3
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

ALTERNATOR BELT TENSION
Testing
l 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.
Adjusting
1. Remove the cover from the side of the alterna-
tor. BWPO4022
2. Loosen belt tension adjustment bolt (I) and al-

ternator mounting nut (2).
3. Move alternator toward the front of the machine

body with a bar, then tighten belt tension adjust-
ment bolt (I).
4. Tighten mounting nut (2).
20- 109-9 Pcoo-7

0
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID LINKAGE
ADJUSTING ENGINE STOP SOLENOID LINKAGE

Seeial No. : 52374 - 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
t If the above clearance is too large, the engine
output may not be heightened to the full level. FlKP02577
If the former is eliminated, the solenoid may

burn.
Adjusting
1. Loosen mounting bolt (7) of solenoid (I).
2. Move solenoid (I) in the direction of the arrow
(A) to the end.
t The hole of bracket (8) is oblong.
3. Turn ON the starting switch to operate solenoid
(1).
4. Move solenoid (1) in the direction of the arrow
(B) by the hand until lever (5) comes in contact
with stopper (6).
t Since clearance a cannot be checked visu- EKPO2691
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
burn.
5. 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 visu-
ally, check it by the moving distance of the
solenoid.
6. Tighten mounting bolt (7) of solenoid (1).
7. Operate the solenoid several times and check that
linkage (2) - (4) do not interfere with another part
and the solenoid is not heated abnormally.
8. If the parts between solenoid (1) and linkage (4)
have been disassembled, assemble them into a
sub-assembly in advance, then install the sub-
assembly to the engine.
I) When installing the above sub-assembly, ad-
just distance a between both ends of the
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
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID LINKAGE
* If the fuel injection pump or engine stop sole-

noid 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 Threads of rod (all threaded part) :

Liquid adhesive (LT-2) 1
BEPOO804
Sr Do not apply adhesive to the part of 5 mm
from each end, however.
2. Turn ON the starting switch to operate the sole-

r ~ Rod is shortened
noid without connecting the injection pump stop

lever and rod.
3. Push stop lever (1) toward the operation side and

connect rod (2).
4. Adjust the length of rod (2) by turning it until stop

lever (1) comes in contact with the internal stop-
per on the operation side.
Rod is lenrthencd
TXP02155
5. Tighten nut (3) and install the cotter pin.
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.
BEP00806
20-109-11 Pao-7
0
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 gov-
ernor 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 tem-
porarily tighten nuts (3) and (4).
* lighten nuts with the cable pulled to re-
move 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 be-
tween the tip of limit switch (5) and plate (6)
is3-4 mm.
* 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 AND ADJUSTING --_ ADJUSTING FUEL CONTROL LINKAGE
1. Adjusting control 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 engine stall preventing switch

* This swatch operates when the engine speed
lowers below 1400 rpm.
li Turn ON the starting switch and set the fuel
control dial to the LOW position.
2) 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.
31 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 PC60-7
0
TESTING AND ADJUSTING OF HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS
TESTING AND ADJUSTING OF

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING
AND TRAVEL CIRCUITS
1. Measuring
* Hydraulic oil temperature at measurement :
45 - 55 C
g 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 mea-
sured, and connect the oil pressure gauge
Cl (58.8 MPa (600kg/cm2)).
l Measuring of unload pressure

Measure the hydraulic oil pressure with the en-
gine 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 ac-
tually measure the relief pressure of the
safety valve.
Furthermore, the travel motor is not
equipped with a safety valve.
20-110 Pc60-7
a
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 adjust-
ment 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 be-
comes 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 ac-
cording 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
BBPOl.345
sleeve counterclockwise.
Ir Clockwise rotation of the sleeve increases
the suction torque of the pump, and coun-
terclockwise rotation decreases the suc-
tion torque.
* Rotation range of the screw shall be within
180. for both clockwise and counterclock-
wise.
2. After adjustment finished, tighten the lock nut.
w 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 PRESSURE

AND ADJUSTING LS VALVE
1. 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 measure-
ment plug Cl.
Then connect to the defferential pres-
sure gauge C4.
* Connection of differential pressure

gauge:
High pressure side: connect to plug (1)
High pressure side: connect to plug (2)
ii) Measure the LS differential pressure ac-

cording to the conditions shown in
Table 1.
Table 1
Differential
Work Fuel
Operation pressure
mode lever MPa{kg/cm2)
S I Full ILever at NEUTRAL 2.5 - 3.9

(25 - 401
Vehicle speed : Hi
S I Full ITravel idling (lever full)
2.1 + 0.1
I 121.5 * 1)
% Travel idling at one side
2) Measurement using 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 dis-
charge 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
BaPo1814
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 measure-
ment 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 pres-
sure) = LS differential pressure
20-112
0
TESTING AND ADJUSTING TESTING HYDRAULIC PRESSURE IN THE CONTROL CIRCUIT
2. 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 88PO184
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 Lock nut:
0.56 f 0.07 Nm (5.75 f 0.75 kgm}
(Caution) Make sure to adjust the LS valve with

measuring the differential pressure.
I
TESTING HYDRAULIC
PRESSURE IN THE CONTROL
CIRCUIT
1. 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 en- RRP01815
gine at the full speed.
g3
d
6
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
1. 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.
2. Measure the outlet pressure of the solenoid
valve according to the conditions shown in
Table 1.
Table 1
Operation Oil pressure

Solenoid name Measurement conditions perating conditio of solenoid MPa{kg/cm2 Remarks
Swing or work equipment 2.9 f 0.5

lever operated Brake canceled ON (30 f 5)
;Gneg parking
1
All levers except travel at
NEUTRAL (5 sec. after Brake actuated OFF f:,
returning to NEUTRAL)
Travel speed select at Hi Motor swash
2.9 f 0.5
l Engine running Travel speed Hi ON plate angle at
130 f 5) minimum 6
Travel speed l Travel lever operated
2 select &
Motor swash
Travel speed select at Lo, Travel speed Lo plate angle at z
OFF f:,
or engine at full speed maximum
Oil pressure 2.8 - 2.9
.%&+ty lock lever at RUN applied on PPC ON
valve circuit 129 - 301
PPC oil pressure
3 lock Oil pressure not
Safety lock lever at LOCK applied on PPC OFF G,
side valve circuit
Oil pressure
Fuel control lever full applied on mode OFF c:r
select circuit
4 Mode select
Oil pressure not 2.9 f 0.5
Fuel control lever slow applied on mode ON I30 f 5)
select circuit
% Operation of solenoid valve

ON : Continuous (oil pressure generated)
OFF : Not continuous ioil press;re : 0)
20-114
0
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING ADJUSTING OF WORK EQUIPMENT AND SWING PPC VALVE
MEASURING PPC VALVE OUTPUT
Ir Hydraulic oil temperature when measuring:

45 - 55 C
1. Measuring PPC valve output pressure

1) Disconnect the hose (I) of the circuit to be
measured.
2) Install adapter C3 between the hose and el-
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.
BBPOl820
ADJUSTING OF WORK
EQUIPMENT AND SWING PPC
VALVE
Ir If there is excessive play in the work equipment
-r or swing lever, adjust as follows.
g 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.
1. Remove the PPC valve.

2. Remove the boot (1).
3. 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.
4. Fix the disk (3) and tighten the lock nut (2) with
a specified torque.
- BBPO184.3
Q$XI Locknut:
J
112.7 + 14.7 Nm Ill.5 f 1.5 kgml
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
EEPOle.49
Make a mark
at the IOm midoolnt
Marlark this deviation
TLPOO732
20-116
0
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

* Hydraulic oil temperature when measuring:
Posture for measurino
45 - 55 C boom CYI inder
1. 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.
l If the leakage is within the standard
value, the problem is in the control valve.
l If the leakage is greater than the standard I - TBP00958
value, the problem is in the cylinder.
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
Posture for meeeurino (Irk bucket cylinder
2) Disconnect piping (I) at the head end, then
block the piping at the chassis end with a
blind plug.
A Be careful not to disconnect

at the bottom end.
the piping
3) Start the engine and apply the relief pres-

sure to the bottom end of the cylinder with
the engine at high idling.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one TBP00959
minute.
Boom cylinder
f-l
7 Disconnect Hose
End of stroke f:
0
Hose
Rel iet
7 Pressure
TLPOO963
Ii TEP00960
Bucket cylinder Arm cylinder
TBP00962 TBP00981
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
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 mea-
suring cylinder.
3) Turn the swing lock switch ON.
4) Start the engine and operate the swing re-
lief 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 re-
lief with the engine at high idling.
A Incorrect lever operation possibly causes an

accident, therefore, give and confirm signals
properly.
5) 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 cyl-
inder.).
BLPOO170 BLPOO171
20-118
0
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE

IN HYDRAULIC CIRCUIT
-k No accumulator is installed, so the pressure re-
maining in the piping between the control valve
and the hydraulic cylinder or swing motor can-
not 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 hy-

draulic 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 re-
lieved 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
TESTING AND ADJUSTING CHECKING OF CLEARANCE OF SWING CIRCLE BEARING
CHECKING OF CLEARANCE OF
SWING CIRCLE BEARING
Procedure of checking clearance of swing
circle bearing mounted on machine
1. Fix a magnet-type dial gauge to the outer (or in-
ner) circle of the swing circle, and attach the
Or
probe to the end surface of the inner (or outer)
circle.
Set the dial gauge at the front or rear. frame frame
TLPOO733
2. Extend the work equipment to the maximum

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 While measuring, never put your

foot under the under-carriage.
hand or
BAP0352
6. Restore the condition in Step 2, and check that

the dial gauge has returned to the zero point. If
it has not returned to the zero point, repeat
Steps 2 to 5.
20-120
0
TESTING AND ADJUSTING TESTING WEAR OF SPROCKET
TESTING WEAR OF SPROCKET
Wear limit line
TWP01404
1. Remove the track shoe assembly.

Ir See DISASSEMBLY AND ASSEMBLY, Re-
moval 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 Pc60-7
0
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 the travel motors only when the oil inside the motor case has been
drained.
1. 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 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.
2. 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 circum-
stances.
20-122 PC60-7
0
TESTING AND ADJUSTING BLEEDING AIR
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.
4) 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 cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cylinder.
3. 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).
-.. .- __ _ __
ZO-123
0
TESTING AND ADJUSTING AUTOMATIC GREASING CONTROLLER
AUTOMATIC GREASING CONTROLLER

Display on the panel and special functions
DAIKIN Blade type fuse

,[TYPe:bCT-IO1
/Power LED
, Grease LED
7-segment LED,
-Alarm LED
Ress t IESC) (I* i t ch-

-SetI ino LED
.
Start (SET) swi tch
Level eelect (V)switch-
\
Item selection(D)swi 6
TAP00965 s
G
1. Display at starting switch ON 3. Display at auto-greasing operation

Self diagnosis of the controller is carried out When the auto-greasing interval set in the
with all LEDs lighting up for a short time pe- auto-greasing setting mode has elapsed, and
riod and the lamp 0 at right bottom corner of when the START switch is pressed, display
the -/-segment LED flashing. After the self- on the control panel will change as shown be-
analysis, auto repressurization is carried out, low.
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.
Pressure
Pump operating Pump depressurizing
maintaining
7-segment
LED stop
In (+J
0 ---m
\ ---m +J--\:
.--------_____________________c-_l
indication
TAP00966
Power LED ON ON ON
Greasing LED ON Flash (slow) Flash (quick)
20-124
0
4. Error code indication

When a trouble occurs, the alarm LED starts to
\\\I!// \\\I///
blink, and the 7-segment LED automatically
changes to display an error code to require JgJgpJ
remedy by an operator. ///I\\\ ///I\\\
1) Actual display
t
Ex.: Pump pressurization failure (required
pressure not obtained within the
greasing period)
2) To erase the error code, and to resume the

pump operation and timer-count of the TAP00967
greasing interval, perform the following
procedure.
i) When the 7-segment LED displays ab-
normal pressure indication:
Press the [RESET/ESCI button
L
once, and small dot will be dis-
played.
ii) When the 7-segment LED displays ab-

normal setting indication:
\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 remark-
able 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 inter-
val.
Note 1) Make sure to explain users that shorter
greasing interval will shorten the ser-
vice life of the grease cartridge compar-
ing with the standard of 500 hours be-
cause grease consumption per hour in-
creases.
Note 2) If there is no more necessity to shorten-
ing the greasing interval, restore the
original setting values (a=6, b=6, c=O)
on the controller.
ZO-125
0
4) To determine a setting item, push the q

GREASING
switch while the intended setting item is
When the areasina time is selected
flashing.
t When the q switch is pushed, the set-
ting item and code No. flash alternately.
* Figure displayed immediately after
pressing the q switch is the presently
stored code No.
loretsina tine)
TAP00969
5) To select a code No., press the lpi switch.

4
. 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-seg-
ment LED returns to the status de-
scribed in the section l), and setting of
the next item is enabled.
Setting of code No. in item [al finished
--+ To item lb1
E! :When (3min) is selected
m Push the
Setting of code No. in item [bl finished switch
+ To item [cl
wz/l-iol
Setting of code No. in item [cl finished
\ + To item [al
p.x+-:ili:i~ ,tem p_ ,tem
To continue the setting:

(orease time)
Repeat the procedures from 2) to 6) in the same TAP00971
manner.
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 re-
set.
20-127
0
List of auto-greasing setting codes
Note 1. Fields marked with a oblique line are not available.

2. Code No. setting shall be done to each item.
3. Original setting values of the auto-greasing controller at the time of shipping from the
factory are a=6, b=6 and c=O.
4. 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.
20-128
0
AIR BLEEDING FROM EACH COMPONENT OF AUTO-GREASING SYSTEM
Work procedure and bleeding procedure
Air bleeding procedure

Air bleeding item
1 2 3 4
Initial grease Air bleeding Air bleeding

filling into main from auto_ from greasing Operation
Work details greaser piping greasing pump lateral piping
and distributor.
l Replacement, repair of auto-greasing

pump 0 ) 0 + 0
l Replacement of auto-greasing piping

l Replacement of auto-greasing distributor 0 > 0 > 0
l Removal of auto-greasing piping

. Removal of auto-greasing distributor 0 f 0
l In cold district, when grease is changed

from G2-LI to GO-LI 0 -i 0 * 0 f 0
b l Thermal contraction of grease due to

0
change in temperature 0 > 0
z
z
1. Initial grease filling into main greaser piping

and distributor.
1) Disconnect the hose (1) under the pump,
and remove the boom cylinder bottom dis-
tributor plug (2) and the arm distributor
plug (3).
EBP03534
2) Fix the tools Ml and M2 to the arm distribu-

tor plug section, fill the grease, and confirm
that new grease comes out of the hose end
under the pump and the boom cylinder bot-
tom distributor plug.
* Discharge foreign matters and residual
air completely.
a Greasing piping
: Grease (G2-LI) (standard type)
: Grease (GO-L11 (cold area type)
EEPO353!
20-l 29
0
3) 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) Turn ON the starting switch and push the
[START] switch to run the pump.
* Discharge residual air in the pump to-
gether with grease.
Ir Accumulated timer-count in the greas-
ing interval timer is reset, and timer will
start counting after greasing is com-
pleted.
3) After confirming that only grease comes out
of the air bleeding screw (I), turn OFF the
starting switch to stop the pump.
4) Tighten the air bleeding screw (I ). -
w Air bleeding screw : DAIRIW IWWRTRIEL LTO
r?l
I
wD:LcRn
2.94 + 0.98 Nm to.3 k 0.1 kgm) rn8
n Pnm
<start
TAP00972
20-130
0
3. 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 de-
pressurization) 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
. pressing the [START] switch. I
6 3) Fill the grease with a grease gun into the air

0 TAP00973
bleeding plug of each distributor, and con-
z
firm that the grease comes out of the work
equipment pins or clearance at the bearing
sections.
20-131
0
Confirmation method of depressurizing spool

indicator
1. The position of the depressurizing spool indica-

tor (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 pro-

cess, the depressurizing spool indicator is com-
ing out from the pump body by approx. 7.5mm.
3. During the pressurizing process and pressure

holding process, the depressurizing spool indi-
cator is stored in the pump body without any PPIOX.
5rm
protrusion.
Depressurizins 6 Preasurizine and

waitine Process pressure holding erocess
TBP00975
20-l 32
0
Replacement of controller fuse
1
. Replacement of the controller fuse shall be car-
ried out according to the following procedure.
1. Remove the rubber cap (I) with a screwdriver

or similar tool.
IMP03543
BEP03544
2. Remove the fuse (2) with long-nose pliers, etc.,

and replace with a new fuse.
Ir Fuse : Blade type ATC-10
3. Fix the rubber cap.
BBP0354
20- 133
0
Confirmation procedure for discharge amount

from distributor
1. On the discharge amount adjusting caps on
each distributor, figures are embossed which
indicate the discharge amount.
2. Correspondence of discharge amount and fig-
ures on the cap is as shown in the table below.
Figure embossed on
thedischarge amount I 2 3 4 5 6
adjusting cap
TBP00976
Quintuple distributor for arm
Adjusting
A B C D E
cap
Embossed
1 4 6 2 1
figure
A B C D E
Discharge
0.25 0.45 0.65 0.25 0.15
amount (cc) lino
Greasing Bucket Arm/ Arm/ Arm/ Arm

objective cylinder link bucket boom cylinder
piston foot joint joint joint rod end
TBPOO977
Cspool distributor for boom
I F G H I
si
Boom From t the arm

Greasing Boom Boom Arm oreasi ributor
cylinder cylinder
objective piston foot foot PUblIP
root rod end
-
TBPOO978
Distributor for boom cylinder foot
Adjusting cap J
Embossed figure 1
Discharge amount (cc) 0.35
Greasing objective piston 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 WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
a Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely 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 ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 2) Check checking items before starting.
hurry to disassemble the components. 3) Check other checking items.
If components are disassembled immediately 4) Other maintenance items can be checked
any failure occurs: externally, so check any item that is con-
. Parts that have no connection with the fail- sidered to be necessary.
ure or other unnecessary parts will be dis- 4. Confirming failure
assembled. Confirm the extent of the failure yourself,
. It will become impossible to find the cause and judge whether to handle it as a real fail-
of the failure. ure or as a problem with the method of op-
It will also cause a waste of manhours, parts, eration, etc.
or oil or grease, and at the same time, will also * When operating the machine to reenact
lose the confidence of the user or operator. the troubleshooting symptoms, do not
For this reason, when carrying out trouble- carry out any investigation or measure-
shooting, it is necessary to carry out through ment that may make the problem worse.
prior investigation and to carry out trouble- 5. Troubleshooting
shooting in accordance with the fixed proce- Use the results of the investigation and in-
dure. spection in Items 2 - 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occured apart ing flowchart to locate the position of the
from the problem that had been reported? failure exactly.
2) Was there anything strange about the ma- * The basic procedure for troubleshooting
chine before tha failure occurred? is as follows.
3) Did the failure occur suddenly, or were 1) Start from the simple points.
there problems with the machine condition 2) Start from the most likely points.
before this? 3) Investigate other related parts or in-
4) Under what conditions did the failure oc- formation.
cur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before the Even if the failure is repaired, if the root cause
failure? of the failure is not repaired, the same fail-
When were these repairs carried out? ure will occur again.
6) Has the same kind of failure occurred be- To prevent this, always investigate why the
fore? problem occureed. Then, remove the root
3. Check before troubleshooting cause.
1) Were there abnormal symptoms about the
machine?
20-202 PCXO-7
0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEWOOlEO TEW00181
step 1
Examination. confirmation of symptoms
1) When a request for repairs IS received, fwst

-----
ask the followmg
.
-
pomts.
Name of customer
Type, serial number of machme
-----
2 Ring I Ring 1
. Details of jobslte, etc.

2) Ask questIons to gain an outlIne of the prob-
lem.
. Condition of failure
* Work being carved out at the time of the TEW00182
failure
. Operating environment
. Past histov, details of maintenance, etc.
step 2
lDetermining probable locatlon of cause] a ;
.
1) Look at the troubleshooting section of the
shop manual to find locations of possible I*Cu4~w
1..1..1..1 f
causas.
TEWO0184
step 3
reparation of troubleshootmg tools =-
TEWOO185
1) Look at the table of troubleshooting tools in aa
the shop manual and prepare the necessary Gap 7
tools. 1. Pinpoint locations of failure (carry out 1
I
* T-adapter troubleshooting)
. Hydrauhc pressure gauge kut. etc. . Decide action to take
2) Look in the parts book and prepare the net-m
essary replacement parts. 1) Before starting troubleshooting, IoCate and
repair simple failures.
* Check before startmg items
* Other check items
21 See the Troubleshooting Sectton of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEWOO187
/step 6
Re-enacting failure
. Dwe and operate the machine to confirm

the condition and ludge If there is really a
& step 5
* .
Ask operator
fatlure.
Was thaw
questions
anythmg
to
strange
confirm
about
details
the ma-
of
chme before the fallure occurred?

* Did the failure occur suddenly?
. Had any repatrs been carried out before the
TEWOO189 failure?
TEW0019C
20-203
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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 re-
pairs 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 WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted 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 fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful 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 TEU00192
@ Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
Imvro9er con9ressin
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
TEW00193
20-204
0
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 solder-
ing may be damaged, or the wiring may be
broken.
\
I TEW00194
High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, 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 short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity 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 sur-
face 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
1 TEW00196
* When wiping the mating portion of the

connector, be careful not to use exces-
sive 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 clean-
ing with compressed air.
20-205
0
2) Removing, installing, and drying connectors and

wiring harnesses
0 Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully, Loch
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 con-
nectors apart.
Ir Never pull with one hand.
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 TBWOO4B5
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 im-
proper contact to occur, so always cover
the connector.
20-206
0
0 Connecting connectors
Check the connector visuallv.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age 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. TEW00199
If any water has got inside the connec-
tor, 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, re-
place the connector.
0 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 po-
sition.
Ir If the connector cannot be corrected eas-
ily, 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
l 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 wa-
ter 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 com-
TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
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 connec-
tor.
j : TEWOOZOZ
Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected 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 reas-
sem ble. T-adapter
TEW00203
20-208
0
3) Handling control box

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.
0 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 con-
trol 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 con-
nected 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
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure 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, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
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. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared 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 en-
tering. 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 leak-
ing 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 TEWOOZOB
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 clean-
ing 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
5) Change hydraulic oil when the temperature is

high.
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 pos-
sible 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 equip-
ment, 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 sec-
ondary 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 ma-
chine, 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 re-
move, so it is an extremely effective device.
TEWOOZll
20-211
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Remedy
standard
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
5. Check swing machinery oil level Add oil
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 - Tighten or replace
6
2. Check for loose or corroded alternator terminal: Tighten or replace
z
L.z
Check for loose or corroded starting motor -
3* terminals Tighten or replace
1. Check for abnormal noise or smell Repair
2. Check for oil leakage Repair
3. Bleed air from system - Bleed air
1. Check battery voltage (engine stopped) 20-3QU Replace
2. Check level of battery electrolyte Add or replace
3. Check for discolored, burnt, or bare wiring - Replace
4. Check for missing wiring clamps, hanging wire Repair
Checks for getting wet onto wiring Disconnect

5. (check carefully getting wet at connectors connector and
and terminals) dry connection
6. Check for broken or corroded fuses - Replace
Check alternator voltage After running

7. (engine running at over half throttle) for few min. Replace
27.5 - 29.5 U I
Noise when battery relay is operated
8. (switch starting switch from ON to OFF) -
20-212
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

Ir Address column in the table indicates the addresses in the connector location diagram (3D drawing).
Serial No. : 52374 - 57999
Ml6 1 Horn -
Ml7 M 6 Wiper motor, intermediate B-1
Ml8 M 3 Wiper switch E-2
Ml9 M 2 Wiper switch F-2
D11 1~~~11 2 1 Diode I- M21 PA 9 Radio E-l
DAM 1 1 4 1 Diode (Solenoid) l- 1M22 1 1 1 1 Horn switch ) A-4

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 M I 6 I Air conditioner ~~
unit (option) 1 P-l
El4 1 Ribbon heater - IM27) I 1 I Roomlamp I L-7

F61 6 Fuse box F-7 M28 KESl 2 Window washer Q-8
Hl 1 S I 16 I Intermediate 1A-2 M29 M 2 Speed selection switch (for STD) D-1
H2 p 1 2 TIntermediate 1A-2 [ M301 M [ 2 I Optional power source -1:

H3 S 8 Intermediate A-2 IM31 IKESOl 4 I Wiper motor I L-5
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- M35 x 2 Air conditioner condenser

(option)
_
lM371 1 1 I Engine stopsolenoid I-

M40 1 Travel boost pedal switch (for C_l
blade)
M41 1 Travel boost pedal switch (for C_l
blade)
M2 I 1TC-terminal of starting motor 1 O-9 lM75) X I 2 I Sefty relay (s, R-terminal) I O-1
M3 1 Engine stop solenoid Q-9 bl I l I Sefty relay B-terminal I-
M4 S 16 Intermediate B-2
Ml01 M ( 1 I Working lamp, intermediate I ~-7

Ml1 1 L I 2 I Fusible link I R-8 1~4 I M I 2 1 Buzzer 1A-3
If5 I I 1 I Fuel sensor 1 L-6

P6 1 Fuel sensor L-6
P7 x 2 Water temperature sensor P-9
Pcxo-7 20-2 13
0
13 1 Engine oil pressure switch Q-8
44 SWP 6 Auto-greasing controller R-3
jlIx I 2 I Swina oressure switch I Q-2 I
S,4 M 2 PPC hydraulic lock switch, F-2

intermediate
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
4 111 Starting switch (ACC) I c-4

r9
rio
T16
+
T17T 1 1 I Battery relay, M-terminal I R-t5
I
T18 1 Batterv relav. E-terminal 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
y
x3
+
x4 1 Swing lock prolix switch F-6
X5 M 4 Swing lock switch E-l
BR (1) (Battery relay, M-terminal) -
RB (1) (Battery relay, B-terminal) -
20-214 PC60-7
0
Serial No. : 52374 - 57999
I6 I M24
//I I29
M41 Ml0 M32 M33
Pao-7 20-215
@
Serial No. : 52374 - 57999
20-216
0
TESTING AND ADJUSTING CONNECTOR TYPES AND MOUNTING LOCATIONS
* Address column in the table indicates the addresses in the connector location diagram (3D drawing).
Cl M 4 Engine starting relay A-3 ~M18 M 3 Wiper switch E-2
Dl KESl 2 Diode - Ml9 M 2 Wiper switch F-2
D2 KESl 2 Diode - IM2ll PA 1 9 1 Radio 1 E-l
D5 KESl 2 Diode - IM22 I 1 1 1 Horn switch 1A-4
D8 KESl 2 Diode - lM231 1 1 1 SDeaker 1A-5
DA2 IKESl] 2 1 Diode (Solenoid) I- IM28IKES11 2 I Windowwasher
El2 1 X 1 1 1 Glow plug I o-9 1M29 1 M I 2 1 Soeed selection switch (for STD) 1 D-1
FBl I 1 6 I Fuse box 1 F-7 M30 M 2 Optional power source -
M31 KESl 4 Wiper motor M-l
; p321 1 11 Decceleration switch -1 D-l
1M331 I 1 I Decceleration switch 1D-l

K5 X 4 Fuel control motor relay A-4 1~341 X I 1 I Air compressor (option) I o-9
F-6 M35 x 2 Air conditioner condenser _

K6 SWP 6 Fuel control motor relay (option)
K7 [SWPI 6 I Fuel control motor 1 F-7 M37 1 Engine stop solenoid N-9
I I L 8
K33]7 1 2 I Deceleration indicator I- M40

1 Travel boost pedal switch (for
blade)
C_l
K35 M 2 Fuel control motor relay -
Ml 1 B-terminal of starting motor P-9
M2 1 C-terminal of starting motor P-8
M3
1
1
I
Engine stop solenoid
I
N-9 bl I I Optional power source I-
M4 S 16 Intermediate B1
r-l::, IPI I~~~0401
16 I Monitor 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
M9 M 1 Working lamp l-9 P4 M 2 Buzzer A-3
Ml0 M 1 Working lamp, intermediate l-9 P5 1 Fuel sensor J-9
Mfl/LTYJFusible linkk 1 P-8 (P67 I 1 1 Fuel sensor I K-9

Ml2 IKESI~ 3 I Car heater 1 F-5 IP7 I X I 2 I Water temoerature sensor I o-9
Ml41 L I 2 I Fusible link 1 Q-8

11:
P44 SWP 6 Auto-greasrng controller
s2 x 2 Swing pressure switch Cl-4
20-2 16- 1
0
0
t; 2
I 3 .v) Mounting location 2
. $=a,
z sg z.z
$
S4 12 tB oom RAISE nressure switch
s12 1 PPC hydraulic lock switch -
s13 1 PPC hydraulic lock switch -

PPC hydraulic lock switch, F-2
S14 M 2 intermediate
s15 1 Fuel lever limit switch P-B
s14 I l I Fuel lever limit switch 1 P-B
Batterv relav. B-terminal
4 Ill 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
Ki
Swing holding brake solenoid M-9
V5 1 X 1 2 1 Speed selection solenoid IA
x4 Ill Swing lock prolix switch mm
x4 1 Swing lock prolix switch F-5
X5 M 4 Swing lock switch E-l
20-216-2 Pc60-7
@
P2
r\ \ \
S 14
tit9
Ml8
Mil
\
X6
9
do ~12 M33
BWPO41I4
fC60-7 20-2 16-3

0
20-216-4 fuo-7
0
T18
T16
Tl
T17
Y6
T4
Pi3
M76
34
P44
92
St
\ -N76
Y77
\
T6
\
(tl3)
\
(Ml71
(Ii21
/
I
M31
(Hl)
Y27
+
Pc60-7 20-216-5
m
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No.
of
T X type connector
pins Male (female housing) Female (male housing)
TEWCiXZl TEwoo222
m 2
TEW00223 TEWO0224
TEW00226
20-217
0
No.
of
T SWP type connector
3 6
TEWO0235
4 8
TEWoO237
8 4
TEW00238
m
1
1 4
i __.__1-
0 5
12 0 5 8
9
9 12
BLwoO34 BLPOOO35
11 8 4 1
14
3 i io 14
14 ld i
TEWCKl240
1 4
5
16
9
BLpooO36 i6 BLFQw37
20-218
0
No.
of
T M type connector
2
E=
i
BLFUCO3B BLFucQ39
3 2
I,
3
Y @
1
I-
O TEW00243 TEWOOZM
;5 -
i
1 3
4
aI
2 4
TEww245 TEW00246
1 4 4 1
6
@
j 6 6 3
TEW00247 TEWC0248
1 4
4 BLFWO41
20-219
0
No.
of
T S type connector
4 8 TEWO0249
1 6
10
5 io
TEW00251
12
II Ii 5 EEL00114
20-220
0
No. S type connector

of
10
5 IO IO 5
EEL00117 EEL00118
1 6
BLmO043 TEW00254
12 5
8 1
16
7 16BLFCOO44 16 7 TEW00256
20-221
0
No.
of
T MIC connector
b
0
BLpoow8 F
8
7 w
13
13
17
21
lYrTY/ TEWCfQ59
20-222
0
No.
of
T AMP040 type connector
4 8
6 12 12 6
1' 7
ELKmO55 7 i BLPOOO56
8 16
16 8
16
9 1
1 9
BLmOO57 TEW00232
10 20
20 10
20
11 1
IL TEWOGW
20-223
0
No.
of
T AMP070 type connector
7 7 1
1
8
a-
6 4
BLPOOO59 6
1 9 9 1
12
20-224
0
No.
of
T L type connector
Etl
q
m
2
E.33
TEW00257 TEWOO258
20-225
0
No.
of
T Automobile connector
FB B
BLPoax5
6
b
1 2 2
ED
4' '3
BLFwoE7 BLPOOCM
BLPwo69
BLmco70
1 e
\8
ELF00072
20-226
0
TESTING AND ADJUSTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormai-
ity 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
[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 hy-
draulic or mechanical system.
If voltage is different from table (when normal) -+ go to appropriate troubleshooting (E-00) for
electrical system.
N
[Procedure 31
Carry out appropriate troubleshooting (YES/NO troubleshooting).
20-227
0
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
E-00 Troubleshooting of electrical system

H-00 ( Troubleshooting of hydraulic, mechanical system
M-00 Troubleshooting of machine monitor system
2. 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 (prob-
lem with the machine). (See Example (1))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing 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 sec-
tion 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 0
corner of the 0 is an index number; it does not indicate the order to follow.) 5
. Following the YES or NO lines according to the results of the check or measurement will z
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 equip-
ment 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 carry-
ing out the check inside the I .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) 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 con-
nector pin number and location for inspection and measurement of the wiring connector num-
ber appearing in the troubleshooting flow chart for each failure mode (problem).
20-228
0
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
0
E-6 Power mode cannot be changed
0
a) Work equipment speed is slow
when engine speed is middle and higher
0 Cause Remedy
2 YES Refer to the item H-l -

Are the resistsnce
YE vslues between V3
(male1 (1) and (2). -
and between (21 and
the chassisnormal? Defective mode select so-
lenoid teplace
* 20 - 60R. NO
* Between (2)-
chassis: 1MR or 3reaking wire or contact
higher. ailure in the wire harness
- Starting switch 5vs leplace the
)etween limit switch ter-
OFF. Is the resistance vire harness
between V3 (2) ninal H2f2) - chassis
and the chassis l Disconnect V3. YES value between tarth
a V3 (female) (1) Breaking wire or contacl
Is the resistance and S15 normal? failure in the wire harness
l Fuel lever full: 1V ieplace the
value between between V3 (female) (2) -
or lower. YE the limit switch _
l 1Q or lower. NO vire harness
* Starting switch OFF. H3flj - S15
* Starting switch terminals nor-
ON. - 3 mat? l Disconnect V3.
* Fuel lever full.
l Switch only.
between V3 (1) * ON side: Defective fuel limit switch
NO
and the chassis 1R or lower.
* OFF side: 1 MD or higher.
* Starting switch OFF.
Breaking wire in the wire
.20-30V * Disconnect the switch terminal. leplace the
harness between fuse2 -
* Starting switch vire harness
H3(4) - V3 (female) (1)
ON.
YES Refer to the item H-l -

1 r
Short-sircuit to the ground

and the chassis 2 YES in the wire harness bet. leplace the
Is the resrstance ween V3 (female) (2) - vire harness
l Fuel lever lowid- value between H3fl) - S12
ing: 20 -30V. - the limit switch
-
NO terminals nor-
* Starting switch
mal? Defective fuel lever limil
ON.
switch
= Fuel lever Switch only.
l NO
lowiding. * Full side: 1R or lower.
* Lowidling side: 1MR
or higher.
* Disconnect the switch
terminals.
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
TESTING AND ADJUSTING FAILURE MODES AND JUDGMENT TABLE
FAILURE MODES AND JUDGMENT TABLE

r Pump Control valve
Parts causing failure
!i
72
z
2
s
ii
.-E
Failure mode
s
-0
?!
*L
rz
Q z Speeds of all work equipments, travel and swing are
iog slow or lack of power 0
-
Remarkable drop in engine speed, or enqine stalls
i_; E
p All work equipments, travel and swin(l do not work H
iz.2 Abnormal sound (around the pump) -
: mo Fine control not carried out properly
E
Boom movement is slow, or no power -
? Arm movement is slow, or no power
k Bucket movement is slow, or no power -
5 Boom does not move
4 Arm does not move
Y Bucket does not move
Excessive hvdraulic drift
; Excessive time lag
In compound operations, work equipments, move-
ment of larger load side is slow
Zt
__ In compound operations, swing and boom, boom UP
j .z movement is slow
Fe In compound operations, swing and travel, travel
jg
>o
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
Curving in travel
forward and backward -
: In the different directions for
T forward and backward
k
z
Curving is larger at start -
2
Travel speed is slow, or no power -
Steering operation is difficult
i:
Travel speed selection unavailable -
Travel does not work (onlv one side) -
-
-
~~ -
-
-
Excessive shock when stopping - swing-
.E (One direction only) -
z Excessive abnormal sound when stopping swing
Excessive hydraulic When brake is ON
drift of swing When brake is OFF
Swing speed is faster than the specified speed -
$
Blade movement is slow, or no power -
_m Blade does not move -
m Excessive hydraulic drift of blade -
Troubleshooting mode in the electric system
20-230
0
TESTING AND ADJUSTING FAILURE MODES AND JUDGMENT TABLE
I Solenoid valve mob

Travel speed select PPC Hydraulic ll-
Swing brake solenoid node select solenoic
solenoid pressure lock solenoia
1) Connect a l-adapter 1) Connect a T-adapter 1) Connect a T-adapter ) Connect a T-adapter
to the swing brake to the travel speed to the PPC hydraulic to the mode select
solenoid V4. select solenoid V5. pressure lock sole- solenoid V3.
2) Operate the swing 2) Operate the travel noid Vl. 1Operate the fuel le-
lock switch with the speed select switch 2) Operate the PPC hy- ver with the starting
starting switch ON. with the starting draulic pressure switch ON.
3) Is the voltage be- switch ON. lock lever with the ) Is the voltage be-
tween (1) and 12) of 3) Is the voltage be- starting switch ON. tween (1) and (2) of
V4 as shown between (1) and (2) of 3) Is the voltage be- V3 as shown be-
low? V5 as shown between (1) and (2) of low?
low) Vl as shown be-
low?
(Normal) (Normal) (Normal; (Normal
~~~~~
I 0 I
I I
w
I I I
E-3 E-4 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 ..................................................................................................................................... 20-252

E-2 Work equipment 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
E-6 Power mode cannot be changed ....................................................................................................... 20-261
a) Work equipment speed is slow when engine speed is middle and higher.. ........................... 20-261
b) Excessive engine speed drop at engine speed middle and lower ........................................... 20-261
E-7 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
TROUBLESHOOTING E-l
E-l Work equipment does not move even when the PPC hydraulic
pressure lock lever is set to the DRIVE side
t 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 Remedy
2 YES -
Refer to the section H-3
Are the resistance
Yl values between Vl
(male) (11 nad (2). -
and between (2) and
chassisnormal? Defective PPC hydraulic
ieplace
l20-30R NO pressure lock solenoid
* Between 12) and
chassis: 1MR or Breaking wire in the wire
1 harness between lock
higher. Iepair or
switch terminal - S14 (2)
. Starting switch - M4 (5) -chassis ground, eplace
value between OFF.
* Disconnect Vl.
YES I
Is the resistance
value between or contact failure
harness between Vl ffe. lepair or
* Lock lever at male) (2) - M4 (7) - S14
DRIVE side: 1V or YEiS (1) - S12, or contact fail.
eplace
lower. ~~ ure
I
3
* Starting switch
ON. Defective PPC hydraulic
value between qeplace
* Lock lever at NO pressure lock switch
hioher.
DRIVE side. N Vl (1) and chas-
lRelease side: 1MSl or lower.

*20-3W . Disconnect the switch terminals. Breaking wire in fuse 2 -
lepair or
* Starting switch NO H3 14) - Vl (female) t 1I, OI
eplace
contact failure
ON.
E-l Related electric circuit diagram
ch-Dta
PPC hvdrau I ic
pressure lock
snitch
PPC hvdrau ~Iic
pressure I ock
ch-vl (x2) solenoid
TXPO2156
20-252 K60-7
0
TROUBLESHOOTING E-2
E-2 Work equipment does move even if the PPC hydraulic pressure
lock lever IS at the LOCK position.
Ir Before proceeding to the next step, make sure to restore removed connectors.
YES Refer to the section H-3 -

1
Is the voltage
value between Short-circuit to the
Vl (2) and the ground in the wire har-
2 YES ness vetween Vl (female)
chassis normal?
i A Is the resistance (2) - M4 (7) - S14 (1) -
l Lock lever at value of the PPC s12
- hydraulic pres- -
LOCK side: NO sure lock switch
20 - 3ov. normal? Defective PPC hydraulic
Replace
* Starting switch No pressure lock switch
*Switch only.
ON. Lock side: 1 MR or higher.
l
* Lock lever at Release side: 1MR or lower.

l
LOCK side. Starting switch OFF.

l
E-2 Related electric circuit diagram
Ct+Dt 8
PPC hvdraul ic
Pressure lock
switch
PPC hydraulic
pressure lock
ch-vl (x2) solenoid
TXP02156
Pc60-7 20-253
0
TROUBLESHOOTING E-3
E-3 Does not swing

Ir 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?
l 20 - 600. NO
* Between (2) and
Is the voltage body: 1MQ or
YE between V4 (1) higher. 6 YES
and the chassis l Starting switch
normal? OFF.
YE
l Disconnect V4. *
3(Conditions are 5
the same as the
item 2.
lock switch termi- * 20 - 3ov.
2 h % Conditions are the
chassis normal? same as the item 2.
L-t 1
Is the voltage C-l
ES * 20 - 3ov.
(4) and (2)
normal? % Conditions are the NO
same as the item
* 20 - 3ov.
l Start the engine,
and operate the
swing lever.
M Operate the lever YES
in the manner that ~ 9 YES
the machine does When a short 11
not swing.
x!Conditions are k
the voltage ior-
1 Is the voltage the same as the mal?

between Sl (1) item 2. s 1V or lower. NO
% Conditions are the
between C-l (1)
N0 and the chassis
normal? same as the item 2.
l20-3ov. YES
l Starting switch 10
* 20 - 3ov.
ON. Is the voltage
* Starting switch
ON. between Cl (3)
NO and (2) normal? 11 VES
1sthe remstance 1_
* 20 - 3ov. 1
l Starting switch NO
ON.
I
l 1MR or higher. NO
* Starting switch
OFF.
* Disconnect Cl.
NO
20-254 PC60-7
al
TROUBLESHOOTING E-3
I Cause Remedy
.______I 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 har-
ness between Sl (fe-
Repair or
I male) (2) -chassis

ground
Breaking wire or short-
circuit to the ground in
replace
Repair or
the wire harness bet- replace
ween Sl (female) (1) - H3
(2) -Cl (female) (3)
Replace
Repair or
replace
Breaking wire or contact

failure in the wire har- Repair or
ness between fuse2 - Cl replace
(female) (1)
20-255
0
TROUBLESHOOTING E-3
E-3 Related electric circuit diagram
Swns lock switch
Swine lock
GND
Pow r
source.24V
Pow r
source 24V CN-SP (X2) SWI~P Dressure
Controller
Ch-Cl (M4)
Power
source.24V &
CND
%;y;horessure
a--
SWIIIO brake
solenoid
CN-V4 (X2)
Sw~no Drolfx swatch
cNMF
CN-x3
Fuse 2 1 L 7 I1 TAP0098 I
20-256
0
TROUBLESHOOTING E-4
E-4 Swing brake does not work
* Before carrying out this troubleshooting, check for engagement failure at relating connectors.
ES
YES
I
YES
between V4 (1)
41
and the chassis and the chassis
normal?
* Wheb lever at .20 - 3ov. 6 YES

NEUTRAL: 1V or - starting switch disconnected, is
lower. ON.
a Starting witch mLever at NEU- YES
ON. TRAL. c
%(Conditons are
same as the value between Cl * 20 - 60R. NO
N item3. (female) (3) and l Between (2) -chassis:
switch normal? N
1MR or higher.
* Switch only. l Starting switch OFF.
l Switch OFF: 1Mn * 1MR or higher. - Disconnect V4.
or higher. * Starting switch 30
* Switch ON: ln or OFF.
lower. * Disconnect Cl
l Starting switch and Sl.
OFF.
* Disconnect the
switch terminal.
20-258
0
TROUBLESHOOTING E-4
~IRefertotheitemH-27 -
Defective timer Replace

I
>I Defective timer 1Replace
. Defective swing brake so- Repair or

lenoid replace
Short-circuit to the
ground in the wire haness
between Sl (female) (1) - Repace
H3 (2) -Cl (female) (3)
)I Defectwe prolix switch Replace
20-259
0
TROUBLESHOOTING E-5
E-5 Travel speed cannot be switched

Cause Remedy
al Cannot be switched to Hi
2 YES Refer to the item H-20 -

Arethe resistance 1 1
values between V5
Yf
hnalel Ill and (2). -
and between (2) and
the chassisnormal? Defective travel speed se
sorenoid
Ilect Replace
-20-6oR. NO
* Between (2) -
chassis: 1MR or IBreaking wire or contac
1
5 YES ; 1
higher. failure in the wire harness
* Starting switch Repair or
Is the voltage IDetween select switch ter
between V5 (2) OFF. 1Is the resistance 1 r Ininal (1) - M29(1) -M4(5 eplade
* Disconnect V5. YES value between
and the chassis - -chassis ground
- V5 (female) (2)
normal? 4 Breaking wire or contac
p and the switch
Is the resistance terminal normal? failure in the wire harnesl ?epair or
- Switch at Hi side: between V5 (female) (2)
1V or lower. YES value at the trav- * 1Q or lower. NC 1 .eplade
- Starting switch OFF. M4(10) - M29(2) - selec
* Starting switch el speed select l
* Disconnect V5 switch switch terminal

ON. 3 switch normal?
* Move the switch p terminal.
Is the voltage * Switch only. Defective travel speed se
to Hi side. NO Ilect switch Replace
between V5 (1) . Hi side: 1R or
and the chassis lower.
N
normal? * Lo side: IMR or
I 2 higher.
* 20 - 3ov
IBreaking wire in the win
* Starting switch
Iharness between fuse2 - qepair or
ON. NO IH3(4) - V5 (female) (1) .eplade
bl Cannot be switched to Lo
YES Idefer to the item H-20
l-iiz&lII
and the chassis 2 YES
1
Short-circuit to the grounc
In the wire harnass bet
\ween V5 (female) (2) - 3epair or
normal? eplade
Is the resistance IM4(10) - M29(2) - switch
* ~;~tc&&t Lo side: value at the trav- Iterminal (2)
NO el speed select
* Starting switch switch normal? IDefective travel speed se
ON. teplace
Ilect switch
- Move the switch * Switch onlv. NO
to Lo side. - Lo side: 1G;ln or
higher.
* Hi side: 1R or
lower.
* Starting switch
OFF.
E-5 Related electrical circuit diagram
CN-If3 (SB)
Tra speed select
swi
TAP00982
20-260
0
TROUBLESHOOTING E-6
E-6 Power mode cannot be changed

cause
a) Work equipment speed is slow
when engine speed is middle and higher
2 YES Refer to the item H-l -

Are the resistance
YE values batwaan v3
Imale) (1) and (21. -
and between (2) and
the chassisnormal7 Defective mode select
solenoid teplace
l20-60R. No
l Between (2) -
chassis: 1MR or Breaking wire or contact
1 higher. failure in the wire harness
5YEs tepair or
Is the voltage * Sdl;?ing switch between limit switch ter-
lo the resistance eplade
between V3 (2) minal -chassis ground
and the chassis l Disconnect V3. YES value between
normal? 4 V3 (female) (1) Breaking wire or contac
-
Is the resrstanca and S15 normal7 failure in the wire harness
Fuel lever full: 1V tepair or
l
yEs value between between V3 (female) (2) - eplade
or lower. l 1R or lower. NO
_ the limit switch _ H3(1) -s15
* Starting switch * Starting switch OFF.
terminals nor-
ON. 3 ma17 l Disconnect V3.
l Fuel lever full. * Switch only.
Is the voltage
. ON side: Defective fuel limit switch Ieplace
between V3 (1) _ NO
N and the chassis 1R or lower.
normal? * OFF side: 1MR or higher.
- l Starting switch OFF.
l20-30V l Disconnect the switch terminals. lepair or
harness between fuse2 -
l Starting switch eplade
No H3(4) - V3 (female) (1)
ON.
b) Excessive engine speed drop at engine speed middle and lower

YES Refer to the item H-l -
1 I
between V3 (2) I I Short-sircuit to the grounc

and the chassis 2 YES in the wire harness tepair or
Is the resrstance between V3 (female) (2) - eplade
value between s15
. Fuel lever low-
iding: 20 -30V. L the limit switch -
NO terminals nor-
l Starting switch Defective fuel lever limr
mal? teplace
ON.
switch
* Fuel lever low- * Switch only. NO
iding. * Full side: 1R or lower.
l At low-idling side:
1MD or higher.
. Starting switch OFF.
l Disconnect the switch
terminal.
Limit switch
Mode select
OFF ON cl+sl6 Ch-v3 (X2)
solenoid
00-J 3
_t
O- 3
Ch-H3 (98)
TXPO2167
Pc60-7 20-26 1
0
TROUBLESHOOTING E-7
E-7 Engine does not start

4 YES
81 Starter does not work Is the voltage bet-
Yf ween the terminal
. B of the starter -
and the chassis
normal?
* Starting switch ON. NO
. Approx. 24V.
Is there sound of
the starter pinion
6 YES
Is there continuity
YES between the ter-
- mmal C of the
5 starting switch
- and chassis?
Is there continuity * Turn the starting
between the ter- - switch to START. NO
minals S and R of
safty relay?
2 NO
YE! relay make a

sound when the 10 YES
starting switch is 1 IS there continuity r
turned OFF? .
YES between tne cnas-
* Starting switch - sis ground and the _
ON+OFF. 9 terminal E of bat-
Is the reslatancevar tery relay?
yes ue of the wire har-
- ass between BR of _ NO
the starting switch
8 and ER of tha bat-
ten, relavxzz!L
between the ter- * Between starting
Is the voltage and YES
m minal B and BR of - switch BR - bat- NO
specific gravity of 7 tery relay BR: lfl or lower.
the starting
switch? * Between harness -chassis: 1Mn or lower.
Is the voltage at
-* Turn ON the starting * Disconnect both starting switch and battery
the terminal B of relay ends.
l 24V or higher. the starting switch switch.
* Specific gravity: normal? * Remove the rermi- NO
1.26 or more. 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 PC60-7
0
TROUBLESHOOTING E-7
Cause Remedy
Defective starter Reolace
Contact failure in the wire

harness between (+) ter-
minal of battery - B-termi-
nal of battery relay - M- Replace
terminal of battery relay -
B-terminal of starter
Breaking wire or contact fai-

lure in the wire harness bet-
ween C-terminal of staning
switch - Hl (3) - M75 (1) - teplace
safty relay M75 (2) - Dll -
battery relay Wt. and B-ter-
minal of slaner - safty relay
-C-terminal
qeplace
Defective safty relay qeplace
Defective battery relay qeplace
Contact failure in the

wire harness between E-
terminal of battery relay 3eplace
-ground terminal of re-
volving frame
failure in the wire har-
ness between BR-termi-
nal of startin switch -
BR-terminal o B battery re-
lay
Defective starting switch
Replace
(between B - R)
Ftp,~~t~~~r,,~~~~~~t~~~~
ween I+) terminal of batteq
- B-terminal of battery relay Replace
- Ml5 (1) 12) - Hl (2) B-ter.
minal of stamng switch
(include fusible link)
Charge or
Lack of battery capacity
replace
20-263
0
TROUBLESHOOTING E-7
b) Engine stop solenoid does not work
2 YES Defective engine stop so-

1 Is the resistance II I lenoid
YES value between the
- engine stop solenoid -
terminal and the Breaking wire or contact
1 chassis normal? failure in the wire harness Repair or
Is the voltage between solenoid termi- replace
between the engine lla or lower. NO
_ * Starting switch OFF. nal -chassis
stop solenoid
terminal and the lDisconnect the solenoid Breaking wire or contact
chassis normal? terminal. 3 YES failure in the wire harness
between ACC terminal of Repair or
*20-30V Is the voltage replace
between the starting switch - Hl (4) -
* Starting switch solenoid terminal
- terminal ACC of the -
ON.
NO starting switch and
the chassis normal7 Defective starting switch
Replace
NO (berween B - ACC)
*20-30V
l Starting switch
ON.
E-7 b) Related electrical circuit diagram
Stsrtino switch
Ct+Hl 616)
Engine stop solenoid
77?
TAP00985
20-264
0
TROUBLESHOOTING E-8
E-8 Engine does not stop

Cause Remedy
YES Defective engine stop so-

1 I lenoid Replace
Is the voltage bet-

ween the engine
stop solenoid ter- 24V line contacts the wire
minal and the 2 YES Repair or
harness berween ACC-
chassis normal? Is the voltage bet- terminal of starting replace
ween the terminal switch - Hl (41 -solenoid
i*
1V or lower.
ACC of the start- -
*When turning ~0
ing switch and the
OFF the starting chassis normal? Defective starting switch
switch. Replace
(between B - ACC)
* 1V or lower. NO
* Starting switch
OFF.
l Disconnect the
ACC terminal.
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

Remedy
3 YES
Defective wiper motor Replace
Is the resistance
value between
y?, Ml8 (female) (2) _ Breaking wire or contact
and M31 (female) failure in the wire harness
Istheresistance ft t normal? between L terminal of Repair or
YES value between the - -NO wiper switch - Ml6 (2) - replace
- terminals 6 and L - . Tn or lower. M4 (15) - Ml7 (1) - M31
of the wiper . Starting switch OFF.
(female) (1)
switch normal? . Disconnect Ml6 and
1 - M31.
* Between B - L: . Defective wiper switch Replace
switch ON: NO
Is the voltage 1R or lower
between M31 (3) - swith OFF:
and (2) normal? 1MR or higher.
* 20 - 3ov. 4 YES failure in the wire harness Repair or
* Starting switch * between fuse4 - Ii1 (8) - replace
ON. M4 (female) (6)
Nz Does the buzzer -
sound normally?
. fuse4 is blown out Replace

NO
ctwoe (KES) Wssher
ir
TAP00986
20-266
0
TROUBLESHOOTING OF ENGINE (S MODE)
Method of using troubleshooting chart . . . . . .. . . . .. . . . . .. . .. .. . .. . . . .. . . . .. .. . . . .. . . .. . . .. .. . . . . . . .. . .. . . . . . .. . .. . . . . . . . . . . . . . . .. . .. . 20-302
s- 1 Starting performance is poor (Starting always takes time). ............................................... 20-306
s- 2 Engine does not start ............................................................................................................ 20-308
(I) Engine does not turn ...................................................................................................... 20-308
(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 (Follow-up is poor) ...................................................... 20-311
s- 4 Engine stops during operations ........................................................................................... 20-312
s- 5 Engine does not rotate smoothly (Hunting) ........................................................................ 20-313
S- 6 Engine lacks output (or lacks power) ................................................................................... 20-314
s- 7 Exhaust smoke is black (Incomplete combustion). ............................................................. 20-315
S- 8 Oil consumption is excessive (or exhaust gas is blue). ...................................................... 20-316
6 s- 9 Oil becomes contaminated quickly ...................................................................................... 20-317

z
z s-10 Fuel consumption is excessive ............................................................................................. 20-318
s-11 Oil is in cooling water, or water spurts back, or water level goes down.. ........................ .20-319
s-12 Oil pressure caution lamp lights up (Drop in oil pressure) ............................................... .20-320
s-13 Oil level rises (Water, fuel in oil) .......................................................................................... 20-321
s-14 Water temperature becomes too high (Overheating). ........................................................ 20-322
s-15 Abnormal noise is made ....................................................................................................... 20-323
S-16 Vibration is excessive.. .......................................................................................................... 20-324
20-301
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHART
This troubleshooting chart is divided into three

sections: questions, check items, and trouble-
shooting. The questions and check items are
used to pinpoint high probability causes that can
be located from the failure symptoms or simple
inspection without using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @I in the chart on the right cor-
responds to the items where answers can be
obtained from the user. The items in @I are
items that can be obtained from the user, de-
pending on the users level.
[Check items1
The serviceman carries out simple inspection
to narrow down the causes. The items under
@ in the chart on the right correspond to this.
The serviceman narrows down the causes
from information @ that he has obtained
from the user and the results of @ that he has
obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from IQuestions] and
[Check items].
20-302
0
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 verti-
cal column (Causes) that has the highest num-
ber of points is the most probable cause, so
start troubleshooting for that item to make final
confirmation of the cause.
%l. 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.
%2. Use the A in the Cause column as refer-
ence 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 nec-
essary to determine the order for
troubleshooting.
*1 Confirm recent repair history.
---I
r2 Degree of use Operated for long period AAA
20-303
0
. 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.
s-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
20-304
0
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
S-l Starting performance is poor (Starting always takes time)

Possible causes of the engine not starting though ex-
haust gas being discharged. I Causes I
. Electrical system is defective.
. Fuel supply is insufficient.
. Air intake is insufficient.
. Fuel selection is improper.
(Under the ambient temperature of -10C or lower,
use ASTM 0975 No.1
t Battery charging rate
temper*tre 100% 90 % 60 % 75 % 70 %
20C 1.28 1.26 1.24 1.23 1.22
0C 1.29 1.27 1.25 1.24 1.23
-10C 1.30 1.26 1.26 1.25 1.24
l A battery can be used if the specific gravity shows 70% or

higher charging rate shown in the above table.
l 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 dging from Questions and check items)

A: Possible causes due to th of use (used for a long period1
20-306
0
TROUBLESHOOTING S-l
Causes
20-307
0
TROUBLESHOOTING s-2
S-2 Engine does not start
(1) Engine does not turn I Causes

I
General causes why engine does not turn
. Internal parts of engine seized
* If internal parts of the engine are seized, carry

out troubleshooting for Engine stops during
operations.
. Defective electrical system

l 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 Horn does not sound

starting switch is turned
Ahl Horn volumr .- -
I
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

Q
move out 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
TROUBLESHOOTING s-2
(2) Engine turns but no exhaust smoke comes

out
(Fuel is not being injected)
General causes why engine turns but no exhaust smoke

comes out
. Supply of fuel impossible

. Supply of fuel is extremely small
. Improper selection of fuel (particularly in winter)
/ Causes I
t Standards for use of fuel
AMBIENT TEMPRATURE
KIND
VT
CI I ,,I7
nC rLlY -4 14 32 50 68 86OF
I -20 -10 b io 20 30C )
Legend
0: Possible 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 s-2
(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 electri-

cal system
. Insufficient supply of fuel
. Improper selection of fuel and oil
Legend
A: e to length of use (used for a long period)
20-310
0
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly

(Follow-up is podr) - Causes
General causes why engine does not pick up smoothly

. 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
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
. Seized parts inside engine
. Insufficient supply of fuel Causes
. 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)
e to length of use (used for a long period)
Condition when engine

stopped
Fuel tank is found to be empty

Replacement of filters has not been carried out according
tn Clnraratinn
Non-specified fuel is being used
When feed nump is operated, operation is too light or too heavy
<to fuel tank cap
hut stnns when nnwer train is nonrated
When control rack is pushed, it is found to be heavy, or

does not return
20-312
0
TROUBLESHOOTING s-5
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: Most probable causes (judging from Questions end check items.1
A: Possible causes due to length of usa (used for a long period)
0~ 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 I I I
Engine speed sometimes rises too far lolo
Enaine is sometimes difficult to stoo 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

. 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)
A: Possible causes due to length of use fused for a long period)
to Operation Manual
Non-specified fuel is being used QQ00
Dust indicator lamp is red Q
/ PI^^l,
08
Color of exhaust gas Oacn
?, lnzarl
Blue under ligl.. .._.. 6
I I 1-1 I 1 I 1 I I I I I
Noise of interference is heard from around turbocharger I lal I I I I I I I I I I
Blow-by gas is excessive 0 0
Engine pickup is poor and combustion is irregular 8 0 00
High idling speed under no load is normal, but speed
@@ 0
suddenly drops when load is applied
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
There is hunting from engine (rotation is irregular)
Clanging sound is heard from around cylinder head
High idling speed of engine is low
Leakage from fuel piping I
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 0
When compression pressure is measured, it is found to be low 0 0
20-314
0
TROUBLESHOOTING s-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black
Causes
Legend
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 1 1 1 1 1 1 1 I
Dust indicator lamp is red lel I
I I
I I
I
I
I I
I I
I I
I I
Blow-bv gas is excessive I Isl

I-I II II II II II II
Engine pickup is poor and combustion is irregular 01 1 181 I lololol 0
I I 1-n
Ir I When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low I
I I 5 Clanging sound is heard from around cylinder head
I When turbocharaer is rotated bv hand, it is found to be heaw IlI I I I I I I I
When control rack is pushed, it is found to be heavy, or

8
does not return
20-315
0
TROUBLESHOOTING s-a
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
Ir Do not run the engine at idling for more than 20 Causes
minutes continuously. (Both low and high idling)
General causes why oil consumption is excessive
l Abnormal combustion of oil

. External leakage of oil
l Wear of lubrication system
Legend
nd check items)
Amount of blow-by gas
1 When compression pressure is measured, it is found to be low 10 10 l l l I

When breather element is inspected, it is found to be
0
clogged with dirty oil
There is external leakage of oil from engine 0.0.
Pressure-tightness test of oil cooler shows there is leakage 0
I I I 144
Iii I
2 Excessive play of turbocharger shaft I I I I I
G
Inspect rear seal directly 1 IO
When intake manifold is removed, dust is found inside l
When intake manifold is removed, inside is found to be
0
dirty with oil
20-316
0
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
. Entry of exhaust gas due to internal wear

. Clogging of lubrication passage
. Improper fuel
. Improper oil used
l Operation under excessive load
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 A A A
.G_
$ Engine oil must be added more frequently Q
3 Non-specified oil is being used 0
Blue under light load 63
Color of exhaust gas
Black 0
Excessive Q 0 0 0 i
Amount of blow-by gas
E None 0 %
z 0
I 0
.4
C When 011filter is inspected, metal particles are found QO 0
2 When exhaust pipe is removed, inside is found to be dirty :
with oil Q
6 E
Engine 011temperature rises quickly Q 5
20-3 17
0
TROUBLESHOOTING S-IO
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive I Causes I

. Leakage 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 0
6 There is external leakage of fuel from engine 0
Engine oil level uses and smells of diesel fuel 0 QQ
Engine low idling and high idling speeds are high 0 0
20-318
0
TROUBLESHOOTING S-l 1
S-II Oil is in cooling water, or water

spurts back, or water level goes
/ Causes /
down
General causes why oil is in cooling water
. Internal leakage in lubrication system

. Internal leakage in cooling system
Legend
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 19
0
TROUBLESHOOTING s-12
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 oil selection
Selection of SAE No. according to Causes
Legend
0: Possible causes (judging from Cluestions and check items)
Condition when oil

pressure lamp lights up
20-320
0
S-13 Oil level rises (Water, fuel in oil)

* If there is oil in the cooling water, carry out trouble-
shooting 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 0
Defective contact with thermostat seal valve 0
Remove oil pan and check directly 00
8 $ ; 8 t; 8 z p: 8
% 2 U,m 2-m IO
Remedy 5PB=OtnLPB
dPdSPSL?SBd
20-321
0
S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes too Causes
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
* Carry out troubleshooting for chassis.
20-322
0
S-15 Abnormal noise is made

* Judge if the noise is an internal noise or an external
noise.
General causes why abnormal noise is made
. Abnormality due to defective parts

. Abnormal combustion
. Air sucked in from intake system
Degree of use of machine Operated for long period A

z 0 0
.g Condition of abnormal Gradually occurred
noise AA A
b: -----...,
P,,rlfirnl nrr,,rr&-4
__.._
vv
d Non-specified fuel is being used 00
Engine oil must be added more frequently @

I n, _ 0
----\t rrgr load
owe unoer
Color of exhaust gas fi A A
Black I 1-1I I I I I1 I I1
/ 1 I I 1 I
Metal particles are found in oil filter I@] ]@I 1 I 1
Blow-by gas is excessive I@/ I 1 I ) 1 1 I
Noise of interference is heard from around turbocharger 1 lo] I 1 / I I
Engine pickup is poor and combustion is abnormal I I I 101 I I I
Clanging sound is heard from around cylinder head I I I I

Leakage of air between turbocharger and head, loose clamo 1 1 I 1
Vibrating noise is heard from around muffler
I I I I 1-1 I I I I
I I I I I I I.1 I I I I
r I
Fan is deformed, belt is loose

Ic I When valve clearance is checked. it IS found to be outside
Remove cylrnder head cover and inspect directly I I I I I I /

II When muffler is removed, abnormal noise disappears
20-323
0
TROUBLESHOOTING S-16
S-16 Vibration is excessive

* If there is abnormal noise together with the vi-
/ Causes I
bration, carry out troubleshooting also for Ab-
normal noise is made.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)

. Improper alignment
. Abnormal combustion
Legend
0: Most probable csuses (judging from Questions and check items)
20-324
0
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 ............ ..20-35 2
H-2 Excessive drop in engine speed, or engine stalls ........................................................... 20-354
H-3 All work equipments, travel and swing do not move.. ................................................... 20-355
H-4 Abnormal sound is generated (around the pump) ......................................................... 20-355
H-5 Fine control ability is poor, or response is poor ............................................................. 20-356

Work equipment
H-6 Boom movement is slow or lacks of power.. .................................................................. 20-356
H-7 Arm movement is slow or lacks of power.. ..................................................................... 20-358

H-8 Bucket movement is slow or lacks of power.. ................................................................. 20-360
H-9 Work equipment (boom, arm, bucket) does not move
(but travel and swing are normal). ................................................................................... 20-361
H-10 Excessive hydraulic drift (boom, arm, bucket) ................................................................ 20-361
H-l 1 Excessive time lag (engine at low speed) ....................................................................... 20-362
Compound operations
6 H-12 In compound operations, work equipments, movement of one with
E;
w larger load is slow ............................................................................................................. 20-362
H-13 In swing + boom RAISE operation, boom RAISE movement is slow .......................... .20-363
H-14 In travel + swing operation, travel speed drop is excessive .......................................... 20-363
H-15 In travel + work equipment (boom RAISE) operation, travel speed drop is excessive ... 20-363
Travel system
H-16 Vehicle curves unintentionally during travel .................................................................. 20-364
H-17 Travel deviation is larger at starting ................................................................................ 20-364
.
H-18 Travel speed is low, or lacks of power ............................................................................ 20-364
H-19 Steering operation is difficult.. ......................................................................................... 20-367
H-20 Travel speed cannot be switched.. ................................................................................... 20-368
H-21 Travel does not work (one side only) .............................................................................. 20-368
Swing system
H-22 Does not swing (both sides, one side only) .................................................................... 20-369
H-23 Swing acceleration is poor ............................................................................................... 20-370
H-24 Excessive overrun when stopping swing (both sides, one side only) .......................... 20-372
H-25 Excessive shock when stopping swing (one direction only) ......................................... 20-373
H-26 Excessive abnormal noise when stopping swjng (one direction only). ....................... .20-373
H-27 Excessive hydraulic drift of swing (when the swing brake is released or activated). . 20-374
H-28 Swing speed is faster than the specified speed.. ............................................................ 20-375
H-29 Blade speed is slow, or lack of power ............................................................................. 20-375
H-30 Blade does not move ........................................................................................................ 20-376

. 20-376
H-31 Excessive hydraulic drift of the blade ..............................................................................
20-351
0
TROUBLESHOOTING H-l
H-l Speeds of all work equipments, swing and travel are slow or lack
of power.
Ir 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
oes t e pres-
n
I-
sure become
normal when the
PC valve is ad-
iusted?
- Referto the
section of NO
1 ZZ$&jH-
5 YES
YE
TESTING AND
mode select so- ADJUSTING.
lenoid normal? NO
c I
* 0.2 * 0.2MPa
12 * 2kg/cm3
* Engine at high
YE idling .
sure of the main
* Arm relief.
l 24.545 MPa 6 YES

1 Does the pres-
(2502 kg/cm?.
- Engine at high sure become
~Is the PPC setting normal when the -
idling.
pressure nor- N unload valve is
l Arm relief.
ma17 replaced?
I
I I
NO
f Referring to the
section of
TESTING AND
ADJSTING, check 1
and measure the NO
oil pressure in the
circuit.
20-352
0
TROUBLESHOOTING H-l
Adjustment failure of the Adjust

PC valve
Defective PC valve Repair or

replace
Defective piston pump Repair or

replace
Malfunction of the mode Rep,ace

select solenoid valve
_ Malfunction of the unload Repair or

valve replace
Malfunction of the main

Replace
relief valve
Defective the oil pressure

devices in the PPC setting Repair or
pressure circuit replace
(Refer to INSPECTION
AND ADJUSTMENT)
K60-7 20-353
0
TROUBLESHOOTING H-2
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 clog- 3 YES Defective PC valve, or idjust, or

ging in the throt- adjustment failure of the .eplace the PC
Does the condi-
PC valve lalve
YES don become nor-
2 - mal when the PC -
- valve is qeplace
Is the engine replaced) - Defective servo piston Piston pump
- spaed at arm NO sssemblv)
NO relief normal?
Refer to the troubleshoot- -

9 See the table
below. NO
1 ingof the engine fSI
% 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).
Table 1
Engine speed at
Model Serial No. Condition
arm relief

52374-57999 Min. 1,650 rpm
l Swing lock switch ON
PC66 - - With the arm dump at the stroke end, shift the
lever to the full side gradually, and read the
56001 and up Min. 2,000 rpm
value where the engine spead drop is largest.
20-354 Fc60-7
0
TROUBLESHOOTING H-3, H-4
H-3 All work equipments, travel and swing do not move
Cause Remedy
Defective PPC oil pressure

Replace
lock solenoid valve
YES Is the PPC setting
pressure
normal?
Defective self-reducing
pressure valve, or defec- Replace
Remove the NO tive control circuit
f+Jw,---
check v
comes out 01 YES Defective main piston Repair or
replace
-Crank thee
with the starter Is the PTO spline I pump
1
motor.
Repair or
Defective PTO spline replace
NO
6
z H-4 Abnormal sound is generated (around the pump)
z
Cause T Remedy
YE
Are there bub-
bles inside the
hydraulic oil
tank
2
When the engine
YES_ is stopped once,
do the bubbles
disappear?
3
YI
YES
NO
To the section 4
F=
Defective hydraulic oil I

Iqeplace
lydraulic oil
strainer clogged
1 Repair or
Defect inside the pump
Is the suction replace
Is the oil level in strainer clogged
+ZForeign matter: with metallic fer-
the hydraulic
tank normal? Cloth, etc. eign matters
n Or, are metal
chrps sticking to Recheck
the drain plug? Operate for a short time (depending of
and observe for any the change in
change in conditions conditions)
Refill the
Lack of hydraulic oil
hydraulic oil
NO
20-355
0
H-5 Fine control ability is poor, or response is poor
I Cause Remedy
1 YES Clogging in the LS circuit Clean

throttle
Is the throttle in
the LS circuit
clogged?
Defective LS valve, or de-
Replace
fective servo piston
NO
H-6 Boom movement is slow or lacks of power 6

2
Lu
Ir When the travel and swing speeds are normal.
YES Is the leak

amount from the
5- hydraulic cylin- -
- der normal?
YES With the boom
UP relief, is the _ *Max. 15cc/min. NO
4 -
- pump relief pres- Engine at high idling.
l
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
3 compensation idling.
- valve move . 24.5 iMPa
Does the spool smoothly?
YES_ of the control _ - 250 $ kgcm2)
valve move NO
2 smoothly?
Is the output
YES pressure of the
PPC valve nor- - NO
1 mal?
* 2.9 + 0.5MPa
lief, is the pump (30 + 5 kg/cm? I
relief pressure is . Engine at high
idling.
1250$ kg/cm?
* Engine at high ND
idling.
20-356
0
TROUBLESHOOTING H-6
Cause Remedy
IMalfunction of the regen- 3eplace

,aration valve
IDefective hydraulic cylin- Zorrect or

,der gasket eplace
IMalfunction of the suctior

3eplace
valve
Defective pressure corn.

pensation valve, or mat Zorrect or
function of the pressure ,eplace
comprensation valve
Corrector
Malfunction of the contro
valve spool replace
IDefective PPC valve leplace
Iblalfunction of the safety

- ! /abe and the suctiom teplace
I falve
20-357
0
TROUBLESHOOTING H-7
H-7 Arm movement is slow or lacks of power
* When the travel and swing speeds are normal.
5 YES
Is relief pressure
XES of pump normal
when arm circuit
Is the pressure is relieved?
compensation
~66 V&e nOrmal?
- Does the pressure - NO
3 compensation
- valve move
~66 Does the spoof snoothly?
r of the control _
valve move NO
2 smoothly?
Is the output
YES pressure of the -
PPC valve nor- NO
1_ mal?
* 2.9 + 0.5MPa
_ (30 + 5 kg/cm)
pump relief pres- * Engine et high NO
sure is normal? idling.
* 24.5b;cMPa
I250 so kg/cm)
* Engine at high NO
idling.
6 YES
A Is leakage from
arm cylinder nor- _
mal?
- Max. 15cclmin NO
* Engine at high idling
* Make it relief at the
stroke end
20-358
0
TROUBLESHOOTING H-7
Cause
To A
Malfunction of the suction

valve
Defective pressure corn

pensation ;alve. or mal Repair or
function of the pressure replace
comprensation valve
Malfunction of the contra Repair or

valve spool replace
=I Defective PPC valve

Replace
I
Malfunction of the safeb
and suction valve Replace
Malfunction of the regen Repair or

eration valve replace
Defective arm cylinder Repair or

piston gasket 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.
YES Does spool of

3 YES
To A
F--t=
- the control valve -
2 nove smoothly?
YES IS the OUtpUt Malfunction of the control Repair or
pressure of the- NO valve spool replace
1 PPC valve nor-

- mal?
With the arm re- -
lief, is the pump * 2.9 * 0.5MPa x Defective PPC valve Replace
relief pressure is - 00 f 5 kg/cm} NO
normal? . Engine at high
- idling.
* 24.5 *iMPa Defective the safety valve
and the suction valve Replace
1250 2 kg/cm) ND
l Engine at high
idling.
5 YES Malfunction of the suction

valve Replace
YES Is the leak
Defective bucket cylinder Repair or

Prom .A. -m[-i !$r!~~~L~~ yis;;;t;k;;ess.,. com_ replace
stroke end.
pensation valve, or mat- Repair or
NO function of the pressure replace
compensation valve
20-360
0
H-S Work equipment (boom, arm, bucket) does not move (but travel
and swing are normal)
* When the boom, arm or bucket is operated independently.
Cause Remedy
1 YES Defective control valve Repair or

spool replace
Is the output
L_
pressure of the
PPC valve nor-
ma17
* 2.9 + 0.5MPa
(30 * 5 kg/cm)
* Engine at high
NO
Defective PPC valve Replace
idling.
H-10 Excessive hydraulic drift (boom, arm, bucket)
b .X Because the safety valve and the suction valve

0
commonly serve for the boom, arm and bucket, if
5
excessive hydraulic drift occurs equally for boom,
z
arm and bucket, it can be judged that the cause is
defective safety valve or suction valve.
Cause Remedy
2 YES Malfunction of the suc- Replace

Does the condition valve
YES tion become nor-
1 - mal when the -
suction valve is
replaced? Defective oil tightness of
Replace
from the hydrau- - -NO the control valve spool
lit cylinder nor- -
* Refer to the Defective hydraulic cylin-

Replace
section of . der piston gasket
TESTING AND
ADJUSTING.
* Max. 15cc/mtn.
* Engine at high idling.
* Make it relief at the
stroke end.
20-36 1
0
H-l 1 Excessive time lag (engine at low speed)
* When the speeds of the work equipments are normal.
Cause Remedy
Clean or
Defective suction valve
replace
Engine at low idling tsec)
Time lag
Boom ) Max. 3.9
I Arm 1 Max. 1.0 1
Bucket Max. 1.0
H-12 In compound operations, work equipments, movement of one with

larger load is slow I-
O
s
Ir Engine at full speed z
Table 1
Cause Remedy
Malfunction of the pres- Replace (Replace the pressure compen-

sure compensation valve sation valve of the smaller load side)
Weplace as the valve stack assembly.)
Combination of compound 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
TROUBLESHOOTING H-13, H-14, H-15
H-13 In swing + boom RAISE operation, boom RAISE movement is slow
Ir When the machine works normally in independent operations of swing and boom UP.
Malfunction of the LS se- Repair or

replace
/ lect
vave
H-14 In travel + swing operation, travel speed drop is excessive
Ir When the machine works normally in independent operations of swing and travel.
Cause Remedy
H-15 In travel + work equipment (boom RAISE) operation, travel speed

drop is excessive
* When the machine works normally in independent operations of the work equipment (boom UP)
and travel.
Cause Remedy
Malfunction of the pres-

~$t~~~~~~~~~a,$ve Repair or
replace
(Pressure compensation
valve for travel)
20-363
0
TROUBLESHOOTING H-16
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 F3epair or
Defective final drive
r eolace
t
boes the pres-
YE sure compensa-
tion valve of the
curving side
move smoothlv?
I3efective pressure corn.
sensation valve, or mal. F7epair or
berween output -I iunction of the pressure r eplace
presswes of the left (:ompensation valve
and right travel PPC
valves normal?
* Output pressure -[ Iefective travel PPC valve I3eplace

difference for
Is the lever of the
totWard and
backward travel:
0.2MPa (2kg/cm2jN
or lower.
I4djustment failure of the
! I4djust
-t ravel lever linkage damp
* Enaine at hiah NO :r
idlhg. -
l Travel relief.
5 YES Iefective control valve FIepair or
When the left and ;pool r eolace
right hoses between
the control valve
and the swivel are FReplace the
From A - interchanged.does -
6 YES 3efective swivel joint gar ,- ,-
yasket, or
the vehicle curves
to the opposite di- ket replace the
Is the drain
rection? assembly
amount of the
Defective travel motor
NO travel motor nor- -
mal? internal leakage, brake,
counterbalance valve, Repair or
NO
I or check valve replace
* Max. 5Umin.
* Engine at high
idling.
. Travel relief.
20-364
0
b1 Curving side is different for forward and reverse travel
YES Defective swivel joint Repair or

gasket replace
Does the contorol
valve spool at the
slower side move
smoothly? Malfunction of the control Repair or
NO valve spool replace
Fig. 1 Location of defective swivel joint packings and direction of travel deviation
Forward
TI (Drain)
Rioht forward onlr
Forratd
(Rioht
I Al
forward) _ Rioht forward and f
forward Reverse
B, (Rioht right reverse
\ Riaht reverse and reverse)
Forward Reverse
left forward C, (Left
forward) Left forward and
Reverse Forward
D, (Laft left reverse
Left reverse only reverse) /
Reverse
(Travel
I El
seeed)
Reverse
Bottom
Direction of deviation is defferent Direction of deviation is same

in forward and reverse in forward and reverse
TDP00987
20-365
0
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 in
the section H-16 Vehicle curves unintentionally during travel first.)
F=
Cause Remedy
Replace the
2 YES Malfunction of the control
control valve
IS the phenomenon valve spool
interchayed whenthe assembly
ys left and r~ ht hoses _
between(1 e comrol
Is the phenomenon - valveandthe swivel Replace the
joint are interchanged? Defective swivel joint
interchangedwhen gasket, or
the left and right has- _ gasket
NO assembly
es between the swi-
vel joint and rhe no-
mr ars interchanged?
Defective travel motor Replace the
f Refer to the
(Malfunction of the travel motor
section of LO countervalance valve) assembly
TESTING AND
ADJUSTING.
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 trouble-
shooting in the section H-16 Vehicle curves unintentionally during travel first.)
* When the work equipment speed is normal.
Cause Remedy
2 YES
Defective PC valve Replace
~~ Refer to the troubleshoot- -

ing for the engine (S)
I I Defective main relief

- 24.5*i.rMPa valve, or adjustment fai- Adjust or
(250 ::kg/cm). lure of the main relief
- Engine at high valve
idling.
20-366
0
H-19 Steering operation is difficult
Cause Remedy
2 YES Defective travel motor

Repair or
servo piston or center
swivel joint replace
Both sides j=H-

Malfunction of the travel
speed select solenoid Repair or
- 2.9 z 0.5MPa NO valve replace
(30 f 5 kg/cm)
for both left and * Engine at high
idling. Defective pressure com-
YES pensation valve or mal- Repair or
RI
L
function of the pressure replace
compensation valve
become normal
when the left and
One side only right pressure com-
4YES Malfunctron of the suc-
peSatlO valves Repair or
tion velve of the control
replace
valve
when the sucdon
valves of the control
valve are inter-
defective check valve of Replace
the travel motor
(Low, High )
20-367
0
H-20 Travel speed cannot be switched
I Cause Remedy
1 YES Malfunction of the travel

speed select servo piston Replace
Is the output of the travel motor
pressure of the
travel speed se- -
lect solenoid Malfunction of the travel
valve normal7 speed select solenoid Repair or
- 2.9 + 0.5 MPa NO valve replace
(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
iepair or
Defective final drive
eplace
ters come out of 3 YES Malfunction of the suc-

tion valve of the control leplace
the fimal drive
valve
Malfunction of the coun-

leplace
terbalance valve
NO
- Max. 5 e /min. so.LL_ travel motor teplace

. Engine at high
idling.
- At travel relief.
20-368
0
H-22 Does not swing (both sides, one side only)
a) Does not swing to either left or right
Cause Remedy
3 YES Defective swing machin- Repair or

ery replace
YES
eH--
2
Defective swing holding Repair or
YES Is output pres- L
brake or swing motor replace
sure of swing
- brake solenoid -
,_
1 valve normal?
Defective operation of
Are two of swing Repair or
* 2.9 + O.SMPa swing brake solenoid
oil pressure replace
- (30 f 5 kg/cm? NO valve
switchs normal7 + Operate swing lever.
* Turn swina lock switch ON flock).
lEngine at high idling. Defective swing oil pres
Replace
sure switch
NO
b) Does not swing in one direction
Cause Remedy
1 YES
To A
Is swing oil pres-
sure switch nor- -
mat?
Defective swing oil pres-
leplace
5ure switch
3 YES Defective swing motor

leplace
-II safety valve
YE
2
Defective operation of lepair or
control valve spool eplace
From A put pressure no-
0.5 MPa Defective PPC valve Ieplace
* Operate Swing lever.

. Turn swing lock switch ON flock).
20-369
0
H-23 Swing acceleration is poor
2 YES
7 Both sides {Ftl
NO
6 YES
1Does the condition 1 r
I;ri$ioroneside YES
. Engine at high
41
Is the output I
idling.
YES ressure of the
- FPC valve tat
shuttle block
Is the output
* Conditions are
pressure of the
- One side only - - same as the item5.
PPC valve nor-
% Remove the inlet NO
mal?
hose of the PPC shuttle
. 2.9 * 0.5MPa block, fit an adapter
(30 + 5 kg/cm? and block the tip.
* Enaine at full
NO
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
Remedy
Repair or
replace
Defective pressure com- Replace

pensation valve
Defective swing motor

safety valve Replace

suction valve
Repair or
.~I zam;;o,; of the control
replace
Malfunction of the PPC Connect or

shuttle valve (for swing) replace
Defective PPC valve
20-371
0
H-24 Excessive overrun when stopping swing (both sides, one side only)
a) One direction only
Cause I Remedy
2 YES
t Is woblem re- I I

Replace
safety valve
Defective operation of Correct or

control valve spool replace
b) Both directions
Table 1
I Cause I Remedv
1 Defective swina motor 1 ReDair or replace I
20-372
0
H-25 Excessive shock when stopping swing (one direction only)
I Cause I
I
Rem-b I
I
1 YES
Defecttve PPC valve Replace
Does contorol
valve spool
move smoothly
Defective operation of Correct or
control valve spool replace
NO
H-26 Excessive abnormal noise when stopping swing (one direction

6
z only)
z
I Cause Remedy

YES Replace
safety valve
1

YES Replace
suction valve
2
oes condition
ecome normal _
rhen suction 3 YES Defective swing machin Repair or
en/ replace
A Is dirt found in
- swing machin- -
NO cry?
Defective back pressure : Repair or
7 vave
20-373
0
H-27 Excessive hydraulic drift of swing

(when the swing brake is relased or activated)
a) When the swing brake is released
I Cause 1 Remedy 1
2 YES Defective swing motor Replace

Is the phenomenon safety valve
reversed when left
One side only - and right safety -
valves are inter-
changed? Defective swing motor Repair or
suction valve replace
NO
3 YES Defective oil tightness of

the control valve spool Replace
Is the drain
Both sides - Of the
atTIOUtIt -
motor normal?
Defective swing motor Repair or
* 7 e /min. NO replace
* Engine at high
idling.
* At swing relief.
b) When the swing brake is activated
Cause Remedy
1 YES ~rdfmtiOn of the SWhg Repair or
Is the output replace

pressure of the
swing brake sole- -
noid valve nor-
mal? Malfunction of the swing Repair or
_ brake solenoid valve replace
* 0.2 + 0.2 MPa NO
(2 t 2 kg/cm?
l Swing lock switch ON (LOCK).
20-374
0
H-28 Swing speed is faster than the specified speed
Cause Remedy
Malfunction of the LS
3place
valve
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 Defective blade valve Adjust or
(relief valve, safety valve) replace
Is the leak
amount of the
blade cylinder
normal? Defective blade cylinder
piston gasket Replace
- Max. 15cc/min. NO
- Release it at the stroke end.
20-375
0
H-30 Blade does not move
* When the blade is operated independently
Cause Remedy
Defective control valve

Replace
Malfunction of control Correct or

valve spool replace
H-31 Excessive hydraulic drift of the blade
Cause
1 YES Defective oil tightness of

Replace
_ the blade valve spool
Is the leak
amount of the
blade cylinder
normal? Defective blade cylinder
piston gasket Replace
- Max. 15cc/min. NO
- Engine at high idling.
- Release it at the stroke end.
20-376
0
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
(Bsecond self-check is not carried out either) ..................................................................... 20-403
M-2 All the lamps remain lighting-up after 3-second self-check completed after
the starting switch turned ON .............................................................................................. .20-403
M-3 Some lamps do not light up during self-check (all lamps lights up for 3 seconds)
upon starting switch ON ........................................................................................................ 20-404
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
does not light up .................................................................................................................... 20-405
M-5 When turning ON the power (before engine starting), engine oil pressure
caution lamp does not light up. ............................................................................................ 20-405
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
(engine oil pressure is normal) ............................................................................................. 20-407
M-9 Charge caution lamp lights up while engine running.. ...................................................... -20-407
M-10 Abnormality in engine water temperature gauge .............................................................. .20-408
a) Indicator remains in the lowest level (white range) and does not rise
after engine started. ........................................................................................................ 20-408
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
M-11 Abnormality in fuel gauge ..................................................................................................... 20-409
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
M-12 Malfunction of the buzzer ...................................................................................................... 20-411
a) Buzzer does not sound .................................................................................................... 20-411
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
M-15 Illumination does not light up ............................................................................................... 20-413
a) Illumination at gauge section does not light up. ......................................................... .20-413
b) Illumination at the service meter section does not light up
(Service meter itself do work normally) ........................................................................ 20-413
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 ..................................................................................................... 20-414
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
Strrtine switch sitnr
..
)
CN-BR
,Tl 6 Horn
TAP009aa
20-402 FC60-7
0
TESTING AND ADJUSTlNG ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM
Boo
swi
Window
rasher
Diode
Wiper switch
-I Room
I IlD
A.yX p7
Coolant temp.
sensor
I
Start in0 mot
Glow simal
DI I
TXPOZI 68
20-402- 1
0
TROUBLESHOOTING M-l, M-2
L.

(3-second self-check is not carried out either)
F
Cause Remedy
YES Defective monitor panel Replace

1
Is the voltage
Breaking wire or connec-
between Pl tfe-
tion failure in the wire
male) (1) (2) and 2 YES harness between Pl (1) Repair or
(3) (4) normal? j (2) - fusel, or between Pl replace
- Is the fuse2 nor- (3) (4) - H2 (2) chassis
* Starting switch ,_ mal (not blown - - ground
ON. NO off)? Check for cause
* 20 - 3ov. 6 Blown-off fuse or fuse blown
NO off, and replace
the fuse
M-l Related electrical circuit
CN-nl I
CN-Pl
c To the battery relay
Monitor Panel
TAP00989
M-2 All the lamps remain lighting-up after 3-second self-check com-
pleted after the starting switch turned ON
* Check the fuse before this troubleshooting.
Cause Remedy
- Defective monitor panel Replace
20-403
0
TROUBLESHOOTING M-3
M-3 Some lamps do not light up during self-check (all lamps lights up
for 3 seconds) upon starting switch ON
a) All gauge lamps do not light up

(caution lamp does light up)
Cause Remedy
Iefective monitor panel teplace
b1 Swing lock, auto-greasing failure or preheat does not

light up (all gauge lamps light up)
1 YES
Defective light bulb leplace
Is there breaking
wire in the bulb
of the item that -
;o;s not light
P Iefective monitor panel leplace
*Visual check for NO
breaking wire in
bulbs.
c) Charge caution lamp does not light up
1 YES breaking wire in the

:harge caution bulb leplace
- Visual check for

breaking wire in
the bulb.
d) Engine oil pressure caution lamp does not light up

!nglne oil pressure Ieplace
:aution bulb
Is there breaking
wire in the bulb 7
To the item M-5

- Visual check for NO
breaking wire in
the bulb.
20-404
0
TROUBLESHOOTING M-4, M-5
M-4 When turning ON the power (before engine starting), charge cau-
tion lamp does not light up
* Before carrying out this troubleshooting, check for en-

gagement failure at relating connectors.
* Before proceeding to the next step, make sure to restore Cause I Remedy
removed connectors.
t Check for the breaking wire in the bulb (lamp) before this
troubleshooting.
YES Replace
Defective monitor panel
1
Is the voltage
between Pl (10) Breaking wire or contact
and Pl (3) 2 YES failure in the wire harness Repair or
normal? Is the voltage bet- between Pl (10) - Hl (7). replace
ween R-terminal M5 (alternator R-terminal)
* Starting switch
- M5 of the afterna- -
ON.
NO tor and the chassis
- o-5v. ground normal?
Defective alternator Replace
lStarting switch NO
ON.
lo-5v.
terfiinal
M-4 Related electrical circuit
CN-P I CN-Hl CN-M5
- I\ 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 en-

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
YES between Pl ffe-
1 - male) (91 and Pl -
- gay7aleale,
(3) nor- Breaking wire in the wire
Is the continuity Repair or
between the ter- harness between Pl (9) - replace
minal pl3 and the _ * Disconnect Pl. NO Hl (10) -terminal P13
chassis ground * Starting switch
normal? ON.
l 0 - 5R or lower.
* Starting switch Defective engine oil sen-
ON. sor
No
* 0 - 5R or lower.
M-5 Related electrical circuit diagram

I
Monitor panel
Terminal
Hl (S16) CN-P13
Engine oil
@ Pressure
sensor
TXPO2159
PCoo-7 20-405
0
M-6 At preheating, preheating indicator does not light up

+ 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
Is the voltage
between Pl (13) Breaking wire or contact
and 13) normal? failure in the wire harness
between Pl (female) (13) Repair or
. Set the starting -TlO Matting switch Rl) replace
or defective starting
switch to the
switch
HEAT psition.
-20 - 3ov.
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 en-
1
removed connectors. *
2 YES I
I
failure m the wire her-
ness between Pl (female)
Repair or
(12) - Hl (9) - M4f3) - X5
(female) (1). or between
X5 Warnale (2) - M4 15) -
chassis ground
* ursconnect X3. Defective swing lock Rep,ace

l Swing lock switch
switch ON.
M-7 electrical circuit diagram Swine lock ssitch
Ch-Hl
CM-X6
Monitor oansl
5

)W
III 0
I%I
-., .._
CL-Y9
nl/
TAP00993
20-406 Pctm-7
0
TROUBLESHOOTING M-8. M-9
(engine oil pressure is normal)
Remedy
* Before proceeding to the next step, make sure to restore
removed connectors.
YES Defective engine oil pres-

1 Replace
sure sensor
Does the engine

oil pressure cau- _
tion lamp go off7 2 YES
4 Defective monitor panel Replace
- Are Pl Ifemale)
* Remove the ter- (9) and the chas-
. ;t~;:~~~ngine,~o ;;ey70und insu- Wire harness between ter.
minal P13 - Hl (10) - Pl Repair or
(female) (9) touches the replace
. Continuity check NO
chassis ground
between Pl (female) (9)
and chassis ground.
*lMR-mR.
Monitor Panel
Terminal
I I
Pl (04Oi6) Hl (S16) CN-Pls 3
1
Eneine oil
Pressure
a= sensor
TXPO2169
M-9 Charge caution lamp lights up while engine running

Cause Remedy
removed connectors.
2 YES
Is the voltage bat-
YES wean Pl (female)
1- (10) and (3) nor- Wire harnass between Pl
Is the voltage bet- ma17 (10) - Hl (7). M5 (alterna- Repair or
waan MI hnale) (1) _ - tor R-termmal) touches replace
(alternator R-termi- - lEngine stmt. No
the chassis ground
nail and the chassis l20-3ov.
ground normal?
. Disconnect M5.
* ~~$f$$ ,9,t~:ner~ Replace
l Engine start. NO
l 20 - 3ov.

terminal
CN-Pl CN-H I CN-ML
Q Al ternatar
R-terminal
Monttor panel
TAP00990
Pc60-7 20-407
0
TROUBLESHOOTING M-10
M-10 Abnormality in engine water temperature gauge
t Before proceeding to the next step, make sure to restore removed connectors.
a) Indicator remains in the lowest level (white range) and

does not rise after engine started.
YES Defective engine water
1) Replace
temperature sensor
Level rises by
one step, and fi- Breaking wire or contac
failure in the wire harnesr
nally all seg- 2 YES between Pl (female) (6) - Repair or
ments go off. replace
p Ii1 (5) - P7 ffamale) (1) or
* Starting switch one step, and fi- batwaan Pl (female) (2) -
ON. chassis ground
:t a short NO nallv all seg-
l Conm ments go off.
crrcun connector Defective monitor panel Replace
to P7 (female). * Starting switch ON. NO
Make a shortcircuit
l
between Pl (6) and

(3).

Indicator goes in the red range though overheat does not
occur. 2 YES
Is the resistance
YES value between P7
1 - (male) (1) and (21
normal?
Defective engine water Replace
_ *Disconnect P7. NO temperature sensor
* Engine start.
1earth normai? * Resistance: 4kR
_ or higher. eontact failure between Pl
* Engine start. Check and
Ifemale) (3) - H2 (2) - chas-
* O.lV or lower. NO sis ground
repair
cl Engine water temperature gauge lamp goes off

YES Iefective engine water
Beplace
:emparature sensor
Does the lowest

level lamp light
up? 2 YES
hfactive monitor panel Beplace
Is the resistance
* Starting switch value between Pl
-_. 1
UN. (female) (6) and
l Disconnect P7
NO Nire harness between Pl
(3) normal? female) (6) - Hl (5) - PI qepair or
female) (1) touches the ,eplace
* Disconnect Pl. NO
:hassis ground, or teaks
l Resistance: 1kR
or higher.

CN-Ii1
Coolrnt
W-P7
Monitor Mncl
M-l 1
- tenverrture seneor
W-q K
CN-HP
rfr
TAP00994
20-408 PC60-7
0
M-11 Abnormality in fuel gauge
Cause Remedy
a) All segments of the fuel gauge go off.

YES Ilefective fuel sensor
Mode of braking wire is qeplace
1;
)ut of order)
Does the fuel
gauge indicates 3reaking wire or contact
FULL fall seg- ailure in the wire harness
2 YES aetween Pl (female) (7) - 3epair or
ments llight up)? -
- Does the fuel -13 (6) - P5 (female), or bet- .eplace
* Starting switch _ gauge indicates _ Neen P6 (male) -chassis
ON. NO FULL fall seg- around
* Connect P5 ffe- ments llight up)?
male1 and P6 Defective monitor panel Seolace
h-nale). *Starting switch ON. NO
-Wait for about 1 * Make a short-circuit bet-
minute. ween Pl (7) and (3).
l Wait for about 1 minute.
b) Fuel gauge indicates FULL though the level is low

3 YES
&%e harness between Pl

[female) (7) - H3 (6) - P5 Repair or
[female) (1) touches the replace
chassis ground
between P{(3) * Remove the sensor. Defective fuel sensor Replace

- * Moving the float by NO
and the chassis hand, measure the resistance bet-
ground normal? ween P5 (male) and P6 (female).
*At position F: 1OQ or higher.
* Engrne start. . At position E: 85R or higher. Contact failure in Pl ffe-
Check and
* O.lV or lower. male) (3) - HZ (2) -chassis
NO repair
ground
c) Fuel gauge does not indicate FULL though the tank is full
YES
1 T-
Is the resistance
value of the sen- _
Contact failure between
sor normal? 2 YES Check and
Pl (female) (3) - H2 (2) -
- Is the voltage chassis ground repair
* Measure the re- between Pl (3)
g$farkfeFc$s;rsNO and the chassis
ground normal?
(female). Defective fuel sensor Replace
. At postion F: 10R = Engine start. NO
or lower. * O.lV or lower.
20-409
CD
M-l 1 Related electrical circuit diagram
Ck-Pl ch-HJ CN-P6
Monitor Dane1
TAP00995
20-410
0
M-12 Malfunction of the buzzer
Cause Remedy
a) Buzzer does not sound
YES Defective monitor panel

1 Replace
When Pl (fe-
male) (15) and
(3) are connect- -
ed. does the 2 YES failure in the wire harness Pepair or
buzzer sound? : between P4 (female) (1) - replace
- Is the voltage Pl (female) (151, or defec-
* Connect Pl (fe- between P4 (2) _ tive buzzer
;;fe (15) and N~-J and chassis
ground normal? failure in the wire harness PePair or
* Start ing switch
between fuse2 - P4 (fe- raPface
ON. * Start ing switch NO
male) (21
ON.
* 20 - 3ov.
1
b) Buzzer does not stop sounding
Cause Remedy
YES
Does the buzzer
when Pl IS dis-
Wire harness between P4
, (female) (lb- Pl (female)
- Disconnect Pl. NO (15) touches the chassis
* Starting switch ground
ON.
Ml2 Related electrical circuit diagram
CN-P4 Buzzer
Monitor Panel
To the battery relay

TAP00996
20-411
0
M-13 Service meter does not work while the engine is running
+ Before carrying out this troubleshooting, check for en-

removed connectors. Cause Remedy
al When the charge caution lamp does not light up
1 YES
Is the voltage
between Pl (fe-
male) (10) and (3)
mormal? Breaking wire or contact
failure in the wire harness Repair or
* Engine start. NO between Pl (10) - H7 M5 replace
* 20 - 3ov. (alternator R-terminal)
b) When the charge caution lamp lights up, refer to the item M-9.

terminal
CN-PI CN-Hl CN-M6
TAP00990
M-14 Auto-greasing abnormality alarm lights up (Auto-greasing control-

ler is normal)

Cause Remedy
removed connectors.
, YES Defective monitor panel Replace
Is the voltage
between Pl (11)
and Pl (3) nor- Breaking wire or contact
2 YES failure in the wire harness Repair or
mal?
- Is the voltage between Pl (11) - Hl (13) - replace
* Start ing switch between P44 (4) P44 (female) (41
ON. NO and the chassis
* 18 - 30V. ground normal? Refer to the troubleshoot-
ing of the auto-greasing Replace
* Start ing switch NO controller
ON.
* 18 - 30V.
CN-Pl CN-Hl ch-P44

Auto-ereasino controller
TAP00997
20-412
0
M-15 Illumination does not light up
a) Illumination at gauge section does not light up.
Breaking wire in the il-

YE Replace
lumination lamp (inside
1 the monitor panel)
Is the voltage
L_
between Pl He-
failure in the wire harness Repair or
male) (16) and between Pl (female) (16) replace
2
(3) normal? - P2 (female) (3)
1Is the voltage 11
l Starting switch
ON. i . between P?(3) _
Light switch ON. / and the chassis 3 YES
Defective light switch Replace
l
* 20 - 3ov. ground normal? Is the voltage

I
* Starting switch _ between P2 (4)
ON. NO and the chassis Breaking wire in the wire
* Light switch ON. ground normal? harness between P2 (fe- Repair or
.20 - 3ov. male) (4) - fuse4, or replace
* Startina switch NO
ON. - blown-off fuse
* 20 - 3ov.
z
w b) Illumination at the service meter section does not light up (Service meter itself do work normally)
Cause Remedy
- Defective monitor panel Replace
To the work Iieht
Monitor Dsnsl a>J Lioht srltch
To the battery relay

TAP00998
20-413
0
M-16 Heater does not work

t Before proceeding to the next step, make sure to restore
removed connectors.
a) Both Hi and Lo do not work

2 YES Refer to the troubleshoot-
Is the continuity ing of the heater
:ES between P3 (4) _
and the body Breaking wire or contact
Are continuities of earth? failure in the wire har-
the heater switch ness between P3 (female)
(between male _ * Starting switch NO
(4) - body earth
terminals of P3) as OFF.
shown in Table 17
* Starting switch
ON. Defective heater switch
NO
* Disconnect P3.
Table 1
Terminals of
Switch position
continuity
Lo 1 Between (3) - (4)
Cause Remedy
Hi 1 Between 12) - (4)
b) Lo only does not work

2 YES Refer to the troubleshoot- -
:E between Ml2 (fe- _
male) (2) and the Breaking wire or contact
Is there continu- body earth? failure in the wire har- Repair or
ity between P3 _ l Disconnect M12. NO ness between P3 (female) replace
(male) (3) and 13) - Ml2 (female) (2)
* Starting switch
(4)7 OFF.
* Heater switch Lo.
. Disconnect P3.
Defective heater switch Replace
* Starting switch NO
OFF.
- Heater switch Lo.
c) Hi only does not work

2 YES Refer to the troubleshoot- -
:E between Ml2 (fe- _
, male) (3) and the Breaking wire or contact
Is there continu- body earth? failure in the wire har- Repair or
ity between P3 _ * Disconnect M12. NO ness between P3 (female) replace
(male) (2) and (2) - Ml2 (female) (3)
* Starting switch
(4)? OFF.
* Heater switch Hi.
* Disconnect P3.
Defective heater switch Replace
- Starting switch NO
OFF.
l Heater switch Hi.
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 is displayed.. ....... ..20-45 2
D-2 [Alternate blinking of [El and [bll Abnormality in depressurization is displayed.
[Alternate blinking of [El and [cl] Abnormality in pressure detection is displayed. ........... ..20-45 4
D-3 [Alternate blinking of [El and IO]] Abnormality in controller setting is displayed.................20-45 4
D-4 Abnormal sound is generated from the work equipment pin, though no abnormality
is displayed on the monitor panel and greasing controller.. .................................................. 20-456
D-5 All LEDs on the greasing controller goes off ........................................................................... 20-458
D-6 Pump does not run even though the start-up switch is pressed.. ......................................... .20-458
20-451
0
TROUBLESHOOTING D-l
D-l [Alternate blinking of [El and [all Abnormality in pump pressuriza-

tion is displayed
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 reconnect-
ing 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
Is there grease
leakage from the
NO mating face of the
distributor valve?
4
I Is ttte greasecar- 1
NO
1 tridge loosening
due to insufficient
Is there grease re- tightening? I
maining in the YES
grease cartridge?
rAfter
N i
~~~~N~~~~
PONENT OF AUTO-
GREASING SYSTEM
in the TESTING
AN0 ADJUSTING.
20-452
0
TROUBLESHOOTING D-l
Cause Remedy
I.oosening in joints, or de
7ghten the
-I ective main piping or nip
Dints, or replace
I3le
IDefective distributing valve seplace
I nsufficient tightening 01
t he rease cartridge
Re Ber to the section of.
AIR BLEEDING FROM Tightening and
EACH COMPONENT OF Bir bleeding
AUTO-GREASING SYS-
TEM in the TESTING
i AND ADJUSTING
9 YES I3efective pump
tinternal leakage)
yES Is the voltage bet-
8 - ween (21 and (3) of -
- the motor normal?
YES Is there continuity l - IIefective controller qeplace

_ between (2) and - * 20 - 3Ov. NO
7 (3) of the motor? * Turn ON the starting
Is the reistance
switch, and then turn IDefective pump
- ON the start-up switch.
value between (1) -Startingswitch OFF. Breaking wire or contact
Replace
NO
- and (2) of the failure in the motor or
I the wire harness
pressure detecting
switch normal?
Defective pump
. Max. 1R. Breaking wire or contact
* Turn OFF the start- qeplace
failure in the pressure
ing switch once NO detecting switch or the
and turn it ON again, then
turn ON the starvup switch. wire harness
. Disconnect the connector for
the pressure detecting switch.
deration in the main pipng -
Aeration in the pump -
IEmpty grease cartridge Replace
20-453
0
TROUBLESHOOTING D-2, D-3
D-2 [Alternate blinking of [El and [bll Abnormality in depressurization

IS displa ed.
[Alterna Ye blinking of [El and [cl] Abnormality in pressure detection
IS displayed.
Ir 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.
Ir 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 cor-
rected).
Cause Remedy
2 YES Defective controller

Replace
YES !s the depressuriz-
, - mg spool indicator -
- mormal?
Is the resistance Defective pump
value between (1) lD&,;tive depressurizing Replace
and (2) of the _ . Refer to the section NO
pressure detecting of CONFIRMATION METHOD
OF THE DEPRESSURIZING
switch normal?
SPOOL INDICATOR in the
TESTING AND ADJUSTING Defective pump
* Max. 1MQ.
pot;tive depressurizing Replace
: ~~;/~;~;t; ,o,Nn:NO
nectar for the pres-
sure detecting
switch.
D-3 [Alternate blinking of [El and [O]] Abnormality in controller setting

IS displayed
* 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).
1 YES I
Replace
Reset
20-454
0
TROUBLESHOOTING D-4
D-4 Abnormal sound is enerated from the work equipment in,

though no abnorma 9ity is displayed on the monitor pane Pand
greasing controller.
YEiS
the greasing
troller
con-
correct?
YE S
1
J
1Is theregrease leak-
age from the piping
there any crush in
I
2
Does
delivery
grease
out of the pump
port?
come
YE
out of the delivery
YES
port of the distribut-

ing valve, or is the
delivery amount of
the distribting valve
* Start-up
ON.
switch
Does grease
I.
NO
come
out of the end of
the bearing
the lateral
side of
piping?
- Supply grease by a
grease gun to the
fitting of the dis-
tributing valve.
YES
-
-
I
NO
Is the voltage
ween
(2) normal?
-20 - 3ov.
* Boom RAISE
bet-
P44 (5) and
relief.
6
-
YES
NO
8
w
* Start-up switch
ON.
* Disconnect the
hose under the
pump.
20-456
al
TROUBLESHOOTING D-4
Cause Remedy
I
7 YES Defective bushing Replace
Is there clogging Incorrect setting

Refer to the section of
- in the grease hole - CHANGING PROCEDURE
of the bushing? OF SETrING VALUES OF
THE GREASING CON- Modification
TROLLER in the TEST-
NO ,I ING AND ADJUSTING I
Defective Pressure switch, or

breaking wirs or contact fai-
. $~~$e,f~$,~~$~ p& Replace
(female) (5)
~1~~ jBleeding
Aeration in the lst?ral Piping
1 Defective distributing 1Replace
Replace
Incorrect setting
Refer to the section of
CHANGING PROCEDURE Reset
OF SElNNG VALUES OF
THE GREASING CON-
TROLLER in the TEST-
I ING AND ADJUSTING I
20-457
0
TROUBLESHOOTING D-5, D-6
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.)
Cause Remedy
2 YES Defective controller

Replace
Defective controller fuse Replace
.Max.10.
* Disconnect P44
and Hl.
NO
failure in the wire harness
between P44 (female) (1)
- Hl (female) (14). or P44
(female) (6) - Ii1 (female)
(41
Replace
D-6 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.)
Cause Remedy
1 YES
Defective pump Replace
Are the voltagesbet-
ween 12)and (3) of
the mot&. and bet- _
w*en (1) and I21of
the pressuredetect-
ing switchnormal? Defective controller
* 20 - 3ov. NO
*Start-up switch
ON.
20-458
0
TROUBLESHOOTING D-l, 2,3,4, 5,6 RELATED ELECTRICAL CIRCUIT DIAGRAM
D-l, 2,3,4, 5, 6 Related electrical circuit diagram
ch-s4 (xi?) Boom RAISE ~ressurc switch
Chassis
around
Auto ~reas~no controller
ch-i44 (swP6)
Monitor Panel
_-f-Y Black
..v
L
TAP01000
20-459
0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................30-3 SWING MOTOR. SWING MACHINERY

PRECAUTIONS WHENCARRYING Removal and Installation ....................... 30- 47
OUT OPERATION ...................................... 30-4 SWING MOTOR
SPECIAL TOOLLIST ................................. 30-6 Disassembly ........................................... 30-47-1
SKETCHESOFSPECIAL TOOLS ..............30- 9 Assembly ............................................... 30-47-5
*STARTING MOTOR SWING MACHINERY
Removal and Installation ....................... 30- 12 Disassembly ............................................ 30- 48
*ALTERNATOR Assembly ................................................ 30- 51
Removal and Installation ....................... 30- 13 REVOLVING FRAME
* FUEL INJECTION PUMP Removal .................................................. 30- 54
Removal .................................................. 30- 14 Installation .............................................. 30- 55
Installation .............................................. 30-16 SWING CIRCLE
*WATER PUMP Removal and Installation ....................... 30- 56
Removal and Installation ....................... 30- 18 IDLER. RECOIL SPRING
* NOZZLE HOLDER Removal and Installation ....................... 30- 57
Removal and Installation ....................... 30- 19 RECOIL SPRING
*THERMOSTAT Disassembly ............................................ 30- 58
Removal and Installation ....................... 30- 20 Assembly ................................................ 30- 59
*ENGINE OIL COOLER CORE IDLER
Removal .................................................. 30- 21 Disassembly ............................................ 30- 60
Installation .............................................. 30- 22 Assembly ................................................
61 30-
CYLINDER HEAD TRACK ROLLER
Removal .................................................. 30- 23 Removal and Installation ....................... 30- 63
Installation .............................................. 30- 28 Disassembly ............................................ 30- 64
ENGINE. MAIN PUMP Assembly ................................................
66 30-
Removal .................................................. 30- 31 CARRIER ROLLER
Installation .............................................. 30- 37 Removal and Installation ....................... 30- 68
RADIATOR. HYDRAULIC COOLER TRACK SHOE
Removal .................................................. 30- 38 Removal and Installation ....................... 30- 69
Installation .............................................. 30-40 HYDRAULIC TANK
FUEL TANK Removal .................................................. 30- 70
Removal and Installation ....................... 30- 41 Installation .............................................. 30-71
CENTER SWIVEL JOINT MAIN PUMP
Removal .................................................. 30- 42 Removal .................................................. 30- 72
Installation .............................................. 30- 43 Installation ..............................................
73 30-
Disassembly and assembly ...................30- 44 MAIN PUMP INPUT SHAFTOIL SEAL
SPROCKET Removal and Installation ....................... 30- 74
Removal and Installation ....................... 30- 45
TRAVEL MOTOR
Disassembly and assembly..................30-46-2
.
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 COUNTERWEIGHT
Removal .................................................. 30- 75 Removal and Installation....................... 30- 122
Installation .............................................. 30-76 MONITOR
Disassembly ............................................ 30- 78 Removal and Installation....................... 30- 123
Assembly ................................................ 30- 82 SWING CONTROLLER
MA1N RELIEF VALVE Removal and Installation....................... 30- 123
Disassembly and assembly ...................30- 86 AUTO-GREASING CONTROLLER
SOLENOID VALVE Removal and Installation....................... 30- 124
Removal and Installation ....................... 30- 87 AUTO-GREASING PUMP
WORK EQUIPMENT LEFT SIDE PPC VALVE Removal and Installation....................... 30- 124
(FOR ARM. SWING CONTROL)
WORK EQUIPMENT RIGHT SIDE PPC VALVE
(FOR BOOM. BUCKET CONTROL)
WORK EQUIPMENT PPC VALVE
(FOR BOOM. ARM. BUCKET. SWING CONTROL
PPC VALVE)
Disassembly ............................................ 30- 90
Assembly ................................................ 30- 91
TRAVEL PPC VALVE
Disassembly and assembly ...................30- 94
BOOM CYLINDER
Removal .................................................. 30- 96
Installation .............................................. 30- 97
ARM CYLINDER
Removal .................................................. 30- 98
Installation .............................................. 30- 99
BUCKET CYLINDER
Removal .................................................. 30-100
Installation .............................................. 30-101
BLADE CYLINDER
Removal .................................................. 30-102
Installation ..............................................
103 30-
HYDRAULIC CYLINDER
Disassembly ............................................ 30- 104
Assembly ................................................ 30-107
WORK EQUIPMENT
Removal .................................................. 30-110
1 ..............................................
Installation 11 30-
BUCKET
Removal .................................................. 30- 11 2
Installation .............................................. 30- 113
ARM
Removal .................................................. 30- 114
Installation ..............................................
11 30- 5
BUCKET ARM
Removal .................................................. 30- 11 6
Installation .............................................. 30- 117
BOOM
Removal .................................................. 30-118
Installation ..............................................
119 30-
BLADE
Removal and Installation ....................... 30-120
OPERATOR'S CAB
Removal and Installation ....................... 30-121
30-2 PC60-7
8
DISASSEMBLY AND ASSEMBLY METHOD 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
for the removal operation; the order of work for the installation operation is not given.
12) Any special techniques applying only to the installation procedure are marked a, and the
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
a . .. . . . .. .. . . .. . . . . .. .. . . .. .. . .. .. . . .. . . . . .. . . . . . . .. . . . . . .. . .. .. . . Precautions related to safety when carrying out the
operation
1. XxXx (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step in operation
* .. . . . .. .. . . .. .. . . . . .. . .. . . . . . . . . . . . . . . . . . . . .. . .. . . . . . .. . . . . . . . Technique or important point to remember when
removing XXXX (1).
2. AAAA (2) . .. . .. . . . . . .. . .. . . . . . . .. . . .. . . . . . . .. .. . . . . .. . a Indicates that a technique is listed for use dur-
ing installation
3. J U U U assembly (3)
b
. .. . . . .. . . . .. . .. .. . . . . . . ... . . . . . . . . .. . . . .. . . .. . .. . .. . . . See Lubricant and Coolant Table
.(.
INSTALLATION OF 0 0 0 0 ASSEMBLY.... Title of operation
. Carry out installation in the reverse order to removal.
p .... .... ........ ............. ..... ......... ... .... Technique used during installation
. . . .. ... . . . .. ... . .. .. . .. .. . . . .. . . . . . .. . . . . . .. . . . . . . . . . . Technique or important point to remember when
installing AAAA (2).
. Adding water, oil . . . . .. .. . . . .. . .. .. .. . . . . . . .. . . Step in operation
* . . . . .. . .. . .. .. .. . .. . . . .. . . . . .. . . .. .. . . .. . . .. . . .. . .. . . . . Point to remember when adding water or oil
Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of

units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to fol-
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
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
(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
manufactured according to the sketch.
30-3
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. 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 install-
ing.
. 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 it during disassembly operations.
1) Hoses and tubes using sleeve nuts
6
Nommal number Plug (nut end) Sleeve nut(elbowend): Usethetwo Items belowasa set z
02 07376-50210 07221-202lO(Nut),07222-00210 (Plug) G
03 07376-50315 07221-20315 (Nut),07222-00312 (Plug)
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)
2) Split flange type hoses and tubes

Nommalnumber Hange(hoseend) Sleeve headitubeend) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
30-4
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. 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.
-s.
. 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.
* 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 proce-
dure.
3. Precautions when completing the operation

l If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
l If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
. fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
l 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.
l Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
30-5
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

Tools with part number 79OT-000-0000 cannot be supplied (they are items to be locally manu-
factured).
Necessity: n .. . . . .. . . Cannot be substituted, should always be installed (used)
0 .. . . . .. . . Extremely useful if available, can be substituted with commercially available
part
New/remodel: N .. . .. .. .. Tools with new part numbers, newly developed for this model
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,
Component
remarks
Disassembly, assembly
Removal, installation of
of swin
assemb 9 y
machinery Push tool
IW lo collar
Compressor B 141 I I
B
of recoil sprrng assembly
790-101-1600
1791-616-1030 Remover & installer IW 1 1 1 1

track shoe assembly
hydraulic
bly
pump assem- 01 2 11 ( 796T-297-1110 Push tool Ml lo Replacement of oil seal
for pump shaft
Multi-wrench
Wrench assembly n 1
Disassembly, assembly I III
of hydraulic cylinder E
Socket (width
assembly
across flats: 80) n
Socket (width
across flats: 70) n l
installation of
Socket (wrdth
across flats: 60) n 1
Socket (width
across flats: 65) n 1
Expander 1.1 11 /
30-6
0
Nature of work T
Symbol Part No. Part Name !; Uv A
New
ske
tch
Nature of work,
remarks
796-720-l 670 Ring 0 1

Blade
07281-01279 Clamp 0 1
t
796-720-1660 Ring 0 1 _ Boom, Installation of
5 arm piston ring
07281-01159 Clamp 0 1
796-720-l 650 Ring 0 1
Bucket
07281-01029 Clamp l I
790-201-1702 Push tool KIT n 1
790-201-1811 l Push tool 1
Blade
790-101-5021 l Grip 1
01010-50816 - Bolt 1
790-201-1702 Push tool KIT Imi1) )

790-201-1781 l Push tool 1
Arm
790-101-5021 l Grip 1
01010-50816 l Bolt 1 Press fitting of

r- 6
0 coiled bushing
790-201-1702 Push tool KIT ,B 1
;;
sf Disassembly, assembly
of hydraulic cylinder E 790-201-1771 l Push tool 1
Bucket
assembly
790-101-5021 l Grip 1
01010-50816 l Bolt 1
790-201-1702 Push tool KIT 11
790-201-1791 l Push tool 1

Boom
790-101-5021 l Grip 1
.
01010-50816 l Bolt 1
790-201-1500 Push tool KIT I 1
790-201-1620 l Plate 1
, Blade
790-101-5021 l Grip 1
01010-50816 l Bolt 1
790-201-1500 Push tool KIT n 1
790-201-1610 l Plate 1 Insertion of

7 Boom
dust seal
790-101-5021 l Grip 1
1 01010-50816 1 Bolt
l
I Ill I I
pi Bucket
30-7
0
Nature of work,
Nature of work
remarks
I I 790-201-1500 I Push tool KIT 11.1 I I

Disassembly, assembly Insertion of
of hydraulic cylinder E
assembly
I 1-1 I 790-441-1810 I *Sleeve I I l l lo
work equipment
assembly
I 1-2 I 792-900-1530 I Screw I Ill I
1-3 01803-13034 Nut 1 Pulling out of boom foot
F pin
1-4 01643-33080 Washer 1
Removal, installation of 1-5 796-900-1 240 Adapter 1
boom assembly
I 2 I 790-101-4000 I Puller (50ton long) I I 1 I I
I 3 I 790-101-1102 I Pump I Ill I
Removal, installation of Wrench (angle Tightening of cylinder
1 790-331-1 110tightening wrench) 1 head bolt
engine cylinder head c
u
assembly 2 795-799-1130 Gear .I Barring
Removal, installation of 1 795-799-1390 Puller I. Removal of drive gear
fuel injection pump H
assembly 2 795-799-1130 Gear .I Barring
Removal, installation of Pulling out of nozzle
nozzle holder assembly 795-799-1 170Puller I. holder
1 790-501-5200 Unit repair stand 1
2 790-901-2110 Bracket 1 Disassembly,
assembly of motor
3790-901-1371 Plate 1 0
4 790-901-1 390 Plate 1 0
2 I 799-301-1600 I Oil leaktester KIT I I 1 I I t Pulling out brake piston
of swing motor Removal, installation of
cylinder block spring
Press fitting of oilseal
Press fitting Push tool

of main kit No.
bearing 790-1 - 01
outer race 5001
I
I I
Press fitting of main

6 796-126-1
140 Push tOOI 1 0 bearing inner race
30-8 PC60-7
8
DISASSEMBLY
SPECIAL
AND ASSEMBLY TOOL LIST
Nece- NewSke Nature of work,

Nature of work Symbol Part No. Part Name QV
ssiv mriel
tch remarks
7 796-126-1 130Push tool Press fitting of sub
bearing inner race
Disassembly, assembly P I 01435-00816 Bolt 1 Measurement of
of swing motor turning torque of drive
8
Commercially Torque wrench 1 shaft
available
PC60-7 30-8-1
8
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A. Push tool
fU
___________-
3
1
!
v)
a;
JO CAP03570
l-J-d HEAT TREATMENT MATERIAL

STKM13A
B2. Spacer
4
_
0. 5
co.5
L 200 -I
CAP03571
HEAT TREATMENT MATERIAL

I STKM13A
30-9
0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
D2-1. Push tool
-
1
E
I
cy
d
e --- _-
Cl
.7-Z
=
=:
s
CI
I
L
c2 Cl
CAP03572
D2-2. Spacer
I
-_.
eo.
co.
CAP03573

s43c
I PART NAME
SPACER I
QTY
1
790-201-2730 A
30-10
0
DISASSEMBLYAND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Fl-1. Sleeve
z
CAP03574
03 PLATE SS41P 1
02 HANGER SS41B 1
01 PIPE STKM13A 1
SYM.1 PART NAME i MATERliL 1 (IWISET

I SEE DWG
K60-7 30-l 1
0
W
?
@ 2 w
2
I
2 L 544
285
-I
r
lr 1 185 I 1
190
269 130
75. 25-75. 75 88.9-89. 3
' 7 2 2. 5 - 7 2 7. 5 :1 ..
- b
P 0
0
W
-
r
W
DISASSEMBLY ANDSKETCHES
ASSEMBLY OF SPECIAL TOOLS
P3-3.
Washer
-P
rr
DWPOl633
TREATMENT
HEAT MATER I AL
SS400B
796T-266-1120 A
P4-1.Push tool
0
Lo
8
- l b I TREATMENT
HEAT I
DWPO I634
MATERIAL
SS400B
v 796T-266-1110 A
30-11-3 PC60-7
8
DISASSEMBLY AND SKETCHES
ASSEMBLY OF SPECIAL TOOLS
P4-2. Spacer
A
I
W N
. w. B 3
w
- 0
I I __
coco
. .
LDLD
co. 5 i -
co. 5
i
1
co. 5
100
i -
co. 5
I
DWPOl636
1225001400
7 9 0 - 2 10 - 2 7 2 0 a
P6.Push tool
-
LD
I /I /
LD
cu
W e - 0
0 I O
a 0 %
LD
D N
-a
1
i \
a 1
c1. 5- 5
I 100 I
DWPO1636
HEAT TREATMENT MATER I AL
1124001900 STKMl7A
PARTNAME
PUSH TOOL
I 796-126-1140 A
PC60-7 30-11-4
@
->
>
4.
i
-1421. 3-421. 7
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING MOTOR ASSEMBLY

Serial No. : 52374 - 57999
Disconnect the cable from the negative(-) ter-

minal 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 re-

moval.
Starting motor assembly mounting bolt:

43 f 6 Nm (4.38 f 0.61 kgm)
30-12 PC60-7
@
DISASSEMBLV AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR ASSEMBLY

Serial No. : 52374 - 57999
A Disconnect the cable from the negative H ter-

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 dis-
tinguish the mounting position.
4. Remove clamp (4) of heater hose.
5. Using wrench 0, raise tensioner (5) and remove I

fan belt (6).
A Be extremely careful not to get your fingers
caught when removing the belt.
6. Remove alternator mounting bolt (7) and spacer

(8). m
7. Remove mounting bolt (9) of alternator mount-

CBP02805
ing plate, then remove alternator assembly (IO).
m
INSTALLATION OF ALTERNA-
TOR ASSEMBLY
Serial No. : 52374 - 57999
l Carry out installation in the reverse order to re-

moval.
w Alternator assembly mounting bolt (71, (9)

: 43 f 8 Nm t4.38 4 0.61 kgm}
I . CBP02807
K60-7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION PUMP

ASSEMBLY
Serial No. : 52374 - 57999
g Disconnect the cable from the negative (-1 ter-

2. Remove washer tank (I) together with bracket,

and move towards main pump.
3. Remove oil filter assembly (2) together with

bracket, then move towards main pump. If
4. Remove intake hose cover (31, then remove in-

take hose (4).
5. Remove fan guard (5).

* Clamp (6) of the fuel control cable is also tight-
ened with one of the fan guard mounting
bolts.
6. Disconnect fuel control cable (71, then remove to-

gether with bracket (81, and move towards radia-
tor.
* 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 ter-
minals are used.
* Spacers (12) are used on two of the bracket I Ii 7 CBPO2810
mounting bolts. a
8. Disconnect fuel inlet hose (13) and return hose

(14).
t Fuel will flow out when the hoses are discon-
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
block. 11
II. Disconnect delivery tube (18). m
30-14
0
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 ro-
tate 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 . CBPO2814 CBPO2815
15. Using tool Hl, pull drive gear of fuel injection

pump, and loosen from shaft.
Pcoo-7
DISASSEMBLYAND ASSEMBLY FUEL INJECTIONPUMP
16. Remove 4 nuts (251, then remove fuel injection

pump assembly (26). 115)
NSTALLATION OF FUEL INJEC-

TION PUMP ASSEMBLY
Serial No. : 52374 - 57999

moval.
a
Ir Coat one of the 3 mounting bolts (marked z
in the diagram on the right) of the oil filter
assembly bracket with gasket sealant.
\
6 Oil filter assembly bracket mounting bolt : CRPO')AlA
Gasket sealant (LG-7)
a
. Length of mounting spacer (12) :
Ll = 12.0 mm, L2 = 44.5 mm
m
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)
pzJ
. Install the fuel injection pump assembly as
follows.
1) Check that the No. 1 cylinder is at compres-
sion 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 CBPO2620 CBPO282 1
the pointer tooth.
30-16 Pc60-7
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
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 install-
ing.
m Temporary tightening of nut (23) :
12.5 + 2.5 Nm Il.27 + 0.25 kgm}
Ir 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 Plug (27) : 14.7 Nm U.5 kgm1
8) Tighten drive nut (23) of fuel injection pump

fully.
w Nut (23) : 95 f 10 Nm (9.7 + 1.02 kgm1
9) For remaining installation, carry out in reverse

order to removal.
CBPO2825
Pcoo-7 30-17
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
Serial No. : 52374 - 57999
1. Drain coolant.
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).
A Beextremely careful not to get your fingers

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 re-

moval.
w Tensioner mounting bolt :

43 + 6 Nm 14.38 k 0.61 kgm)
If
QEI Water pump assembly mounting bolt :
24 + 4 Nm t2.45 f 0.41 kgm)
l Refilling with water

Add water through the water filler to the speci-
fied level.
Run the engine to circulate the water through the
system. Then check the water level again.
30-18
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER

ASSEMBLY
Serial No. : 52374 - 57999
Open engine hood.
Disconnect delivery tube (1) at nozzle holder as-

sembly end. a
Remove spill tube (2). m
Remove nozzle holder assembly (3). m

+ If it is difficult to remove the nozzle holder as-
sembly, 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
CBP02831

moval.
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}
I
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 as-
sembling. Tighten the mounting bolts gradu-
ally in turn and be careful not to tighten un-
evenly.
PC&7 30-19
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT ASSEMBLY

Serial No. : 52374 - 57999
1. Drain coolant.
2. Remove alternator assembly.

For details, see REMOVAL OF ALTERNATOR AS-
SEMBLY.
3. Disconnect radiator inlet hose (1).
4. Disconnect bypass hose (2).

CBP02832
5. Remove alternator bracket (3).
6. Remove thermostat housing (4).
7. Remove thermostat (5).
INSTALLATION OF THERMO-
STAT ASSEMBLY
Serial No. : 52374 - 57999

moval.
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 K60-7
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE
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 AS-
SEMBLY.
4. Remove muffler drain pipe (I).
5. Remove fire prevention cover (2).
6. Remove 4 nuts (4) of exhaust manifold pipe (3).
7. Remove muffler (5) together with exhaust mani-

fold pipe (3).
8. Remove intermediate clamp (6) of heater hose.
9. Remove exhaust 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

moval.
m Oil cooler assembly mounting bolt :

24 + 4 Nm (2.45 + 0.41 kgm)
30-22 FcbO-7
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
a Disconnect the cable from the negative (-) ter-
1. Drain coolant.
2. Open engine hood assembly (1).
I
I CBPO2840
3. Remove muffler drain pipe (2).

-
4. Remove fire prevention cover (3).
5. Remove 4 nuts (5) of exhaust manifold pipe (41, 7. = 5.- - B-

then remove muffler (6) together with exhaust
manifold pipe. a
6. Remove intake hose (7).
7. Remove water temperature sensor connector

from oil filter assembly bracket (81, then remove I
oil filter assembly (8) together with bracket, and
move towards counterweight. a
30-23
0
9. Remove fan (1 I) and move towards radiator.
10. Using wrench 0, raise tensioner (12), then remove

fan belt (13).
A Re extremely careful not to get your fingers

I
11. Remove radiator inlet hose (14).
12. Remove intermediate clamp, and disconnect

heater hose (15) and electrical intake air heater
wiring (16).
30-24
0
13. Remove tensioner (17) together with bracket (18).

a
14. Remove 3 mounting bolts of alternator holder

bracket (19), then move alternator assembly to-
wards partition plate.
15. Remove exhaust manifold (20). a
6
z CBPO2849
I?
16. Disconnect water temperature sensor connector

(21).
17. Remove clamps (22) and (23) (2 places), then re-

move delivery tube (24). m
18. Disconnect engine stop solenoid mounting

bracket (25) from head.
19. Remove spill hose (26) and tube (27) between in-
jection pump and fuel filter block. m
20. Remove intermediate clamp (28), then remove

tube (29) between fuel supply pump and fuel fil-
ter block. m
30-z
0
21. Remove intake commector (30).
22. Remove fuel filter assembly (31).
23. Remove intermediate clamp (33), (34) for spill tube

(32).
24. Remove spill tube (35).
25. Remove nozzle holder assembly (36).
26. Remove head cover (37).
27. Remove rocker arm assembly (38). m

* Loosen the locknut and turn the adjustment
screw back 2 - 3 turns.
30-26
0
28. Remove push rod (39).
CBPO2856
29. Remove cylinder head mounting bolts in order Intake side

shown in diagram on right. m
Q-Q-8
Exhaust side DBP00511
30. Lift off cylinder head assembly (40).
I+ kP Cylinder head assembly : 36 kg
31. Remove cylinder head gasket (41).
CBPO2858
30-27
0
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
moval.
w Exhaust manifold pipe mounting nut (5) :

37 - 49 Nm (3.8 - 5 kgm)
a
+ Coat one of the 3 mounting bolts (marked %
in the diagram on the right) of the oil filter
assembly bracket with gasket sealant.
w CflPO281Fi
& Oil filter assembly bracket mounting bolt:
Gasket sealant (LG-71
m Tensioner 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.
Exhaust manifold (20) mounting bolt :
43 f 6 Nm (4.38 + 0.61 kgm}
I CEPO2922
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
m 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 and cylin-
der head assembly as follows.
Ir Check that there is no dirt or dust on the cyl-
inder mount surface or inside the cylinder.
Set cylinder head gasket (41) to cylinder block. 1

t Check that the gasket is aligned with the holes 1
in the block.
Raise cylinder head assembly (40) and set to
cylinder block.
Assemble push rod (39).

6 Add engine oil to the push rod socket por-
tion.
-_. I
4. Fit rocker arm assembly (381, and tighten mount-
ing 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.
30-29
0
Tighten cylinder head mounting bolts in order

Intake side
shown in diagram.
& Put engine oil (SAE15W-40) on the seat
surface and thread of the mounting bolts.
m Cylinder head mounting bolt :

1) 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 @ - @ Exhaust side nRPnri II
to 120 + 5 Nm (12.24 & 0.51
kgm}.
* Check that the long bolts in Step (2)
are tightened to 120 + 5 Nm I12.24 +
0.51 kgm1.
G-1
3) 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
Cl POl6?0
tighten bolt a further 90.
Tighten rocker arm assembly mounting bolts (di-

ameter: 8 mm). marks
under head
w Rocker arm mounting bolt (diameter: 8 and bal
4
mm) : 24 k 3 Nm I2.45 + 0.31 kgm)
Adjust valve clearance.

For details, see TESTING AND ADJUSTING, Ad-
justing valve clearance.
Refilling with water

Add water to the specified level, and run the en-
gine to circulate the water through the system. DKP00451
Then check the water level again.
CLPOl522
30-30
0
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP
REMOVAL OF ENGINE, MAIN PUMP

ASSEMBLY
Serial No. : 52374 - 57999
A Lower the work equipment completely to the

ground and stop the engine. Then loosen the
oil filler cap slowly to release the pressure in-
side the hydraulic tank.
A Disconnect the cable from the negative (-1 ter-
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.
- t Hydraulic tank : Approx. 68 f?
2. Drain coolant.
3. Remove engine hood (I).
CBPO2840
4. Disconnect hose (2) from reservoir tank.
2- CEPO2861
5. Disconnect hose (3) of window washer tank and

wiring 14).
s- CBPO2882
fC60-7 30-3 1
0
6. Remove counteweight assembly (5).

For details, see REMOVAL OF COUNTERWEIGHT
ASSEMBLY.
7. Remove undercover under engine and under-

cover under pump.
8. Remove muffler cover (6) and partition plate (7).
9. Remove starting motor side cover.
10. Remove cover (8) at intake hose portion, then re-

move intake hose (9) and intermediate clamp (10).
11. Disconnect ground connection ( 11) from pump.
CBPO266f
30-32 PC60-7
0
12. Disconnect suction tube (12). LS pressure inlet

hose (13), and LS pump pressure inlet hose (14).
13. Disconnect main pump outlet hose (15), drain

hose (16), mode selector pilot pressure hose (171,
and blade sensing pilot pressure hose (18).
6
z
z
14. Disconnect fuel control cable (19) together with

bracket (20).
15. Disconnect 2 stop solenoid wires (211, water tem-

perature sensor connector (22), and engine oil
pressure sensor wiring (231, then remove inter-
mediate clamps (24) (2 places).
16. Disconnect fuel supply hose (251, fuel return hose

(261, and spill hose (27).
18. Remove fan (29). and move towards radiator.
19. Using wrench 0, raise tensioner (30) and remove

fan belt (31).
(g Be extremely careful not to get your fingers

20. Disconnect electrical intake air heater wiring (32)

and heater hose (33), then remove intermediate
clamp (1 place).
21. Remove radiator inlet hose (34).
30-34
0
22. Remove 2 alternator wires (351, then remove al-

ternator assembly (36).
23. Remove alternator mounting bracket (37).
24. Remove radiator outlet hose (38).
25. Disconnect heater hose (39), then remove heater

hose mounting elbow (40).
39 30 CBPO2876
26. Disconnect 3 starting motor terminal C wiring (41).

a
CBPO287
27. Disconnect starting motor terminal B wiring (42)

and wiring connector (43). a
.
28. Sling engine and main pump assembly, and

loosen engine mount bolts (44).
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 pip-
ing has been disconnected, and be careful not
to hit any other parts when lifting off.
I+ kg Engine, main pump assembly : 465 kg
30-36
0
INSTALLATION OF ENGINE, MAIN

PUMP ASSEMBLY
Serial No. : 52374 - 57999

moval.
m Starting motor assembly, terminal C

mounting nut (dia.: 5mm):
2.5 - 3.0 Nm IO.25 - 0.31 kgml
w Starting motor assembly, terminal B

mounting nut (dia.: IOmm):
15.7 - lg.6 Nm (1.6 - 2.0 kgm)
@j
* Set the engine mount rubber as shown in the
diagram on the right, then install the engine
and main pump assembly.
w Engine mount mounting bolt:
277 +-31.9 Nm (28.25 +_3.25 kgml
l Refilling with water Front of chassis Rear of chassis

Add water through water filler to the specified DBP00512
level.
l 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 Hydraulic tank : 68 k?(SAElOW-CD)
l Bleeding air.
Bleed the air from the fuel system.
Bleeding air.
K60-7 30-37
0
REMOVAL OF ENGINE, MAIN PUMP

ASSEMBLY
a Lower the work equipment completely to the

a Disconnect the cable from the negative

(-) ter-

to stop oil.
+ When not using tool 01, remove the drain
and piping.
& Hydraulic tank : Approx. 68 i?
2. Drain coolant.
3. Remove engine side cover.
4. Remove two heat insulation panels (I), then re-

move muffler (2).
5. Disconnect air intake hose (3).
6. Disconnect following hoses from main pump.

0 Drain hoses (4) and (5)
l Mode selector solenoid pressure input hose (6)
0 Main pump discharge hose (7)
l LS pump pressure input hose (8)
+ LS pressure input hose (9)
0 Suction tube (I 0)
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 PC60-7
0
7. Disconnect ground wire (11) from main pump.
8. Disconnect two wires (12) from alternator.
PC60-7 30-37-Z
0
14. Disconnect two engine stop solenoid wires (19).
15. Remove fuel control lever limit switch (20) and

bracket as one unit.
16. Disconnect two starting motor wires (21).
17. Disconnect fuel control cable (22). EG

+ Before disconnecting this cable, check its fit-
ting dimension.
18. Disconnect fuel feed hose (231, fuel return hose

(24), and spill hose (25). n
* If the fuel feed hose is disconnected, fuel flows
out. Accordingly, prepare a wooden plug, etc.
in advance.
19. Disconnect two heater hoses (26).
20. Disconnect radiator inlet hose (27) and outlet hose

(28).
22. Remove air conditioner compressor assembly

(OP) from engine assembly according to follow-
ing 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 assem-
bly (30).
* When removing compressor assembly with-
out releasing refrigerant (R134a):
1) Loosen two lock bolts (32) and one mount-
ing bolt (33) of the air conditioner com-
pressor to remove air conditioner com-
pressor belt (34).
2) Remove air conditioner compressor as-
sembly (30) and air conditioner piping to-
gether, then secure them out of engine
with ropes, etc.
30-37-3 PC60-7
0
23. Sling engine and main pump assembly tempo-

rarily and remove four engine mounting bolts 135).
24. Lift off engine and main pump assembly (36).

* Check that the all wiring and piping have been
disconnected and the assembly WIII not inter-
fezwith the machine body and radiator.
[kg/ Engine and main pump assembly:
370 kg
INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY

moval.
/
* Adjust the fuel control cable. For details, see
TESTING AND ADJUSTING, Adjusting fuel
control cable.
N Fuel hose joint bolt :

29.4 t+ 4.9 Nm {3.0 i 0.5 kgml
l Refilling with water

Add water through water filler to the specified
level.
Run the engine to circulate thewater through the

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the sys-
tem. Then check the oil level again.
Hydraulic tank : 68 e (SAElOW-CD)
l Bleeding air.
Bleed the air from the fuel system.
Bleeding air.
l Charging air conditioner with gas

Using tool X, charge the air conditioner circuit with
refrigerant (R134a).
PC60-7 30-37-4
0
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
REMOVAL OF RADIATOR, HYDRAULIC

COOLER ASSEMBLY
Serial No. : 52374 - 57999
A Lower
ground
the work equipment completely to the
and stop the engine. Then loosen the
a Disconnect the cable from the negative

(-1 ter-

CBPO2833
to stop oil.
* When not using tool Dl, remove the drain
and piping.
- : Hydraulic tank : Approx. 68 t
2. Drain coolant.
3. Remove engine hood.
4. Remove counterweight assembly.

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).
PCBPO12883
30-38
0
8. Remove frame (7).
\ , I
CEPO2884
9. Disconnect hydraulic cooler inlet hose (8) and

outlet hose (9).
10. Remove fan guard (IO).

* Clamp (11) of the fuel control cable is also
tightened with one of the fan guard mount-
ing bolts.
11. Remove fan (121, then move it towards radiater.
PC60-7
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 dam-
age the core, and stop to remove the fan dur-
1
ing the removal operation.
I II I--
- CBPO28
INSTALLATION OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY
Serial No. : 52374 - 57999

moval.
. Refilling with water

fied level.
. Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified level.
@ Hydraulic tank : 68 t (SAElOW-CD)
30-40 Pcoo-7
0
REMOVAL OF RADIATOR, HYDRAULIC

COOLER ASSEMBLY
g Lower the work equipment completely to the

li!L
A Disconnect the cable from the negative (-) ter-

1. Remove hydraulic tank strainer, then use tool Dl CBPO2833

L
to stop oil.
Ir When not using tool Dl, remove the drain
I
and piping.
2. Drain coolant.
Remove engine hood.
Remove CounterJveight assembly.

ASSEMBLY. CBPO2882
Remove 3 fuse connectors (4) from air cleaner

bracket, then remove battery relay assembly (5).
6. Remove air cleaner bracket (6).
I
I-------b CBPO2883
7. Remove frame (7).
' ' ' CBPO28184
Pc60-7
8. Disconnect hydraulic cooler inlet hose (8) and

outlet hose (9).

+r Clamp of the fuel control cable is also tight-
ened with one of the fan guard mounting
bolts.
IO. Remove fan (12), then move it towards radiater.
11. Disconnect 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 dam-
age the core, and stop to remove the fan dur-
ing the removal operation.
INSTALLATION OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY

moval.
Refilling with water

fied level.
Refilling with oil (hydraulic tank)

Hydraulic tank : 68 e (SAElOW-CD)
30-40-2 PC60-7
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK ASSEMBLY

+ Turn the chassis 45 to the right and lower the

work equipment completely to the ground.
1. Drain fuel.
- : Fuel tank : Approx. 130 !Z(when full)
2. Open engine hood. 2

I
3. Remove handrail (1).
4. Remove right side cover (2).
5. Disconnect 2 fuel level sensor wiring connectors

(3).
6. Disconnect fuel return hoses (4).
7. Disconnect fuel return hose (5) at fuel tank end.
8. Disconnect fuel supply hose (6).

f;
;3 9. Remove mounting bolts, and lift off fuel tank as- CEPO289 I
z sembly (7). a
LO
rz?l Fuel tank assembly : 55 kg
INSTALLATION OF FUEL TANK

ASSEMBLY
moval.
CBP02893
& Thread of fuel tank mounting bolt :

Thread tightener ILT- 2)
w Fuel tank mounting bolt :

176.5 f 19.6 Nm (18 + 2 kgm}
l Refilling with oil (fuel tank)
Ia Fuel tank : Approx. 130 e (when full)
. I // CBP02894
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
3
oil filler cap of the hydraulic tank slowly to re-
lease the pressure inside the hydraulic tank.
* 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
off center swivel joint assembly (9). (m
CBPO2897
30-42
0
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
moval.
& Thread of swivel joint mounting bolt :

Thread tightener (LT-2)
m Swivel joint mounting bolt :

110.25 + 12.26 Nm (11.25 f 1.25 kgm)

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
+ Bleed the air from the travel motor.
Bleeding air.
30-43
0
DISASSEMBLY OF CENTER SWIVEL JOINT

ASSEMBLY
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 oil seal (7)

and slipper seal (8).
CBP0357E
ASSEMBLY OF CENTER SWIVEL

JOINT ASSEMBLY
1. Assemble slipper seal (8) to swivel shaft (5).
2. Using push tool 0, press fit oil seal (7) to swivel

rotor (41, then install snap ring (6).
& Lip of oil seal : Grease (G2-LI)
3. Set swivel shaft (5) to block, and using push tool,

tap swivel rotor (4) with a plastic hammer to in-
COP03576
stall.
* Be extremely careful not to damage the lip of
the oil seal and slipper seal when installing
the rotor.
Yi!3f
I
4. Install ring (3) and secure with snap ring (2).

I
5. Fit O-ring and install cover (1).
CLIP03577
30-44
0
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
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 bolts, and pull out sprocket (1)

slightly. a
4. Set eyebolt and nut to mounting bolt hole, and CBPO3578

lift off sprocket (I 1.
&I km Sprocket : 25 kg
INSTALLATION OF SPROCKET
ij
z l Carry out installation in the reverse order to re-
2 moval.
m
& Thread of sprocket mounting bolt :
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 OF SPROCKET.

2. Remove cover (I 1. m
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 I
seal surface of the hose mount.
& kg Travel motor assembly : 95 kg
INSTALLATION OF TRAVEL MO-

TOR ASSEMBLY

moval.
& Thread of cover mounting bolt :

m Cover mounting bolt :
65.7 + 6.9 Nm I6.7 + 0.7 kgml
6 Thread of travel motor mounting bolt :

m Travel motor mounting bolt :

276.85 + 31.85 Nm (8.25 + 3.25 kgm}
Ir Bleed the air from the travel motor (hydraulic

tank).
Bleeding air from travel motor.

* Add oil through the oil filler to the specified
again.
30-46
0
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 PC60-7
8
DISASSEMBLY
SAFETY
TYPES AND MEANING OF WARNING TERMS

The four warning terms shown in the following table are used in the maintenance manual according
to the degreeof expected danger (or the scale an
of expected accident).
Understand the meaning of these warning terms and observe the instructions given together with
these terms.
WARNING TERM MEANING
1 DANGER I This term means that there is an imminent danger and is used when
neglecting the given procedure or instructioncan cause death or seri-
ous injury.
1 WARNING I This term means that there is a latent danger and is used when ne-
glecting the given procedure or instruction can cause death or serious
injury.
1 CAUTION I This term means that there is a latent danger and is used when ne-
glecting the given procedure or instruction
dium or light degree or damage
can cause injury of me-
of equipment or devices.
This symbol is used to draw the

readers 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
SECTIONAL DRAWING, SINGLE VIEW DRAWING, AND PARTS

LIST
SECTIONAL DRAWING OF ASSEMBLY
127 130 126

123 137
173 121
A-A
I68
I52
I74
I44
I78
0-0
DWP02120
30-46-4 PC60-7
8
DISASSEMBLY
SINGLE VIEW DISASSEMBLY DRAWING OF REDUCTION GEAR ASSEMBLY

21
28 I
21
30
5 1
DWPOZ 122
30-46-6 PC60-7
8
DISASSEMBLY
SINGLE VIEW DISASSEMBLY DRAWING OF HYDRAULIC MOTOR ASSEMBLY
DWPOP I23
PC60-7 30-46-7
@
BLY AND ASSEMBLY
TRAVEL
DISASSEM MOTOR
PARTS LIST
- -
Sym bc Part named Qtj
- Sym bc Part named
-
37)
REDUCTION GEAR ASSEMBLY 1 HYDRAULIC MOTOR 1

Rear flange kit 1
1 Hub 1
101 Rear flange 1
123 Spool 1
Spindle kit 1
144 Hexagon socket headplug 3
Spindle assembly 1
152 Plug 2
2 * * Spindle 1
154 Hexagon socket headplug 6
3 * * Hold flange 1
174 O-ring 2
19 Reamer bolt 3
178 Orifice 1
37 Expander 1
179 Filter 1
199 Nameplate 1
RV gear assembly 1
RV gear kit 1 102 Shaft 1
4 * * RV gear A 1 103 Swash plate 1
5 * * RV gear B 1 104 Cylinder block 1
9 Crankshaft 3
Piston kit 1
12 Spacer 6
Piston assembly 9
22 Tapered roller bearing 6
105 Piston 1
23 Needle roller bearing 6 1
106 Shoe
6 Input gear 1 107 Retainer plate 1
108 Thrust ball 1
Spur gearkit 1 109 Timing plate 1
7 Spur gear 3 110 Washer 2
112 Piston 1
8 Cover 1 113 Spring 8
114 Spring 1
F seal kit 1 115 Friction plate 2
10 Distance piece 1 116 Mating plate 2
1 121 Plug 1
31 Floating seal
124 Plug 2
1 125 Spring retainer 2
11 Collar
3 126 Plug 2
14 Distance piece
127 Va Ive 2
15 Coupling 1
128 Spring 2
16 Shaft 1
130 Spring 2
17 Pin 24
132 Oil seal 1
18 Ring 1
135 O-ring 1
20 Snap ring 136 O-ring 2
21
I
t: Above 1.90 up to 1.95
k A t interval of 0.05>
t: Above 2.45 up to 2.50
Ball bearing
I 3
2
1
137
139
141
142
143
145
O-ring
O-ring
Parallel pin
Parallel pin
Hexagon socket headbolt
THS snap ring
2
1
2
2
8
1
24 C-type snapfor shaft
25 C-type snapfor shaft 3 149 Deep groove ball bearing 1
26 Steel ball 1 150 Deep groove ball bearing 1
27 O-ring 2 151 Roller 3
28 O-ring 1 153 Thrust plate 1
29 O-ring 1 Piston assembly 1
30 O-ring 1 161 b Piston 1
33 Hexagon socket head plug 3 162 b Shoe 1
30-46-8 PC60-7
@
DISASSEMBLY
TOOLS
1. Standard tools
Applicable parts
(Index No.in structural/ Name TypeIStandard Q'ty
disassembly drawing)
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 1 set
Cleaning of products and parts Washing brush 1
Cleaning of products and parts Wire brush 1
Draining of lubricating oil Container Vat for general use 3
and hydraulic oil
Steel ball receiver W450 x D300 x H I 20
For match marks Paint marker White oil paint 1
17 Wire netting basket 2 pcs.
11 Rubber mat 1
149 Leather gloves 1 pair
Supply of oil Jug For hydraulic oil and lubricating oil 2
33 Sealing tape 1
PC60-7 30-46-9
@
DISASSEMBLY
2. Devices
Applicable parts
(Index No. in structural/ Name Type/Standard Qty
Disassembly, assembly Work tablefor general 1 set
of products 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. 100C 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
3 Lathe 1 set
3. Measuring tools
Applicable parts
(Index No. in structural/ Name TypeEtandard Qty
For adjustment of thickness Thickness gauge Measurement range: 0.04- 0.3 mm 2
of snap ring (20)
For adjustment of thickness Outside micrometer Measurement range: 0 - 25 mm 1
of snap ring (20) Min. division: 0.01
For adjustment of preload on Unit-type depth Measurement range: 0 - 25 mm 1
ball bearincl (21) micrometer Min. division: 0.01
30-46-10 PC60-7
@
P cn)
I I
*I
0
r
N
0
0
-
P
P
w
0
D 0 0
r r r
N N N N
0 0 0 0
0 0 0 0
-
CTI
-
P
P
0 ID m
2
0
-
* r
0
0
r
N
0
0
-
ln
P
DISASSEMBLY
TIGHTENING TORQUE
Applicable part BoWNut to be used Width across Tightening torque

(Structural drawing) Name I Nominal size flats(mm) (Nm (kgml)
19 I Reamer bolt I M20 P2.5 27 I 41.16{4.2)

33 Hexagon socket headplug PT3/8 8 3.92 (0.4)
124 Plug M30 PI.5 36 35.28 (3.6)
126 I Plug I M24 P1.5 I 10 I 12.74(1.3)
143 I Hexagon
socket
head bolt I M I 0 P1.5 I 8 I (0.59)
5.78
144 I Hexagon
head
socket plug I PT1/8 I 5 I 1.23(0.125)
121 Plug M20 26 5.88 (0.6)
152 Plug 6 PF1/4 2.94 (0.3)
154 Hexagon socket headplug GDL-1/16-S 4 0.98 (0.1)
WEIGHT TABLE
Applicable part
Name Weight (kg)
(Structural drawing)
I Travel motor assembly I Approx. 90

1
2
101 11.85 Rear
I Spindle
Hub
flange assembly
21.75
26.65
PC60-7 30-46-15
8
DISASSEMBLY
DISASSEMBLY
1. Preparation
Beforedisassemblingthetravelmotor,pre-
pare 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, con-
sider the inspection items, characteristics of
the detected trouble, etc. and then work ac-
cording 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 bro-
ken. 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 mois-
ture and dust. Accordingly, if it is obliged to
interrupt the work, take rust-preventive mea-
sures 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 dis-
assembled, as a rule. Accordingly, prepare
the all replacement seals before disassem-
bling.
30-46-16 PC60-7
@
DISASSEMBLY
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
CLZOO11i7
installed) is filled with soil and sand,

clean it very carefully.
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 work-
table carefully.
1
CLZOO159
2) Fix the travel motor to the worktable with two

hexagon socket head bolts.
CLZOO160
PC60-7 30-46-17
8
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.

4) Removehexagonsocketheadplugs(33)(3
pieces) from cover (8) and drain the lubricat-
ing oil.
a When draining the lubricating oil, place
a container under the worktable.
\ \ CLZOOf 6 2
6. Removal of cover
2) Make match marks on the mating faces of hub
(1) and cover (8) withan oil paint marker.
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 PC60-7
G9
DISASSEMBLY
I Closed. gap Cover Ring
Hub
DWPO21 I 1
4) Make a hole 2 m m i n diameter with an elec-
z'
tric drill from outside of hub (1) toward ring
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

out above cover(8).
(18) is pushed
0167
6) Hold the tipof ring (18) pushed up above cover

(8) with the hands and remove ring (18) from
the ring groove of hub
(1).
PC60-7 30-46-19
8
DISASSEMBLY
7) Tighten the eyebolts for PT into the screw

holes for hexagon socket head plugs (33) of
cover (8). (2 places)
PT
8) Install hooks and wires to the eyebolts for
and lift off cover(8) with a crane.
a If cover(8) cannot be removed easily be-
cause 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 (8).

a Do not reuse removed O-ring (29).
7. Removal of input gear

1)RemoveC-typeshaftsnaprings (24) f r o m
shaft (1 6).
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

a The following work is executed to re-
move the plugs easily when the inside
of the rear flange needs to be disas-
sembled. 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.
I73
2) Loosen plugs (124) (2 pieces). I
3) Loosen plugs (126) (2 pieces).

a 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) (8

pieces).
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
7) Remove parallel pin (142) from spindle (2).
CLZOO I 7 7
8 ) Remove O-ring (30) from spindle (2).

a Do not reuse removed O-ring (30).
9. 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 screw- CLZOO179
driver is inserted between the mating
faces, the matingfaces will be damaged
and oilwill leak. Accordingly, do notuse
such a sharp tool. \ /
3) Removeparallelpin(141)fromrearflange
(101).
30-46-22 PC60-7
@
\
w
0
V V
0 -
- 0
0 ) -
cn
DISASSEMBLY
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 sud-
denly, 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 thor-
oughly. 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 Do not reuse removed O-rings (135) and
(1 39).
PC60-7 30-46-25
8
DISASSEMBLY
14. Disassembly of hydraulic motor

a If the travel motor is laid on itsside, the oil
flowsout.Accordingly,place a container
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 tosepa-
*
rate shoe (106)from thrust plate(153).
If cylinder block (104)is pulled out with-
out performing the above action, shoe
(106)is left on swash plate (103)and the
parts sticking to cylinder block (104)(pis-
ton, 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 mat-
ing 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 cyl-
inder 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 spheri-
cal 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 (here-
inafter, referred toas the piston assem-
bly) and replace the 9 sets (hereinafter,
referred toas the piston kit).
Pull piston assemblies (105)and (106)(9 as- CLZOO194
semblies) out of retainer plate(107).
CLZOOl96
30-46-26 PC60-7
@
DISASSEMBLY
8) Take thrustball (108) out of cylinder block

(104). 108
- IO4
I 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
101 98
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 H o l d e r 11)
*
force is lost.
If the press is released suddenly, the
spring may jump out to hurt you. Accord-
ingly, release the press slowly.
i
n l DWP02 1 12
PC60-7 30-46-27
8
w
0 w
Y
0
r
N
0 - \ 0 - -
0 0 N 0 0 0
N N N N W
0 0
N -
4) Take 2 pivots (176) and 2 parallel pins (177)
*
out of spindle (2).
At the following step, the 2nd-speed se-
lector piston assembly may jump out and
hurt you because of compressed air. Ac-
cordingly, put a protective cover over the
2nd-speed selector pistonassembly.
5) Supply compressed air to the passage of
spindle (2) totake the 2nd-speed selector pis-
ton assembly (piston and shoe) and spring
(185) out of spindle (2).
L
Piston (161)
Piston assembly
Shoe (162)
a 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 spheri-
cal part of the piston.It is impossible to
separate piston (161) and shoe (162)
from each other without damagingpis-
ton (161). If either or both of them need
to be replaced, replace them as a set
(hereinafter, referred toas the pistonas-
sembly).
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
102
put shaft (102) i n it. aD
2) Push the shaft end with the press to remove
deepgroove ball bearing (149)from theshaft.
a Do not reuse the deep groove ball bear-
ing.
DWP021 I 3
18. Removal of spur gears

When the snap ring is removed, it may
come off the pliers nose and fly out.
Take
care.
2) Remove C-type shaft snaprings (25) (3 pieces)
from crankshafts (9).
PC60-7 30-46-29
8
DISASSEMBLY
3) Remove spur gears (7) (3 pieces) from crank-

shafts (9).
00206
4) Remove distance pieces (14) (3 pieces) from

crankshafts (9).
19. Removal of hold flange

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 set-
ting 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. 1
08
4) Remove snap rings (20) (3 pieces) from hold

flange (3).
30-46-30 PC60-7
@
DISASSEMBLY
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 ream-
ing 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 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 install-
ing 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.)
PC60-7 30-46-31
8
w N
P
0 P 0 Iu
v Y Y
w
DISASSEMBLY
22. Removal of ball bearing, RV gear assembly, and

pin
Y
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), 17
RV gear B (5),crankshaft (9), tapered roller
bearing (22),needle roller bearing (23),and
spacer (12)]and pin (17)are removed, too.
a When removing ball bearing (21),hit 3 -
4 points on the periphery of the pin end u
21
DWPOZ I 14
lightly so that the bearing will not be
slanted.
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 assem-
bly can be separated from crankshaft (9).
a Remove tapered roller bearing
needle roller bearing
(22),
(23),and spacer (12)
from crankshaft (9) onlywhen they need
to be replaced.
23. Removal of ball bearing and collar

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 re-
moved, they fall from hub (1). Accord-
ingly, placea rubber mat under the work II
table to protect those parts.
21
I DWPOZI 16
PC60-7 30-46-33
8
DISASSEMBLY
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 lubri-
cating oil films. In thiscase, hit thecen-
ter of the mounting hole of the spindle
(2) lightlywith an aluminumbar, and the
oil films are broken and the outerraces .I
can be takenout easily.
.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
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 be-
come loose and float.
27. Finish cleaning

1) Put the parts and kerosenein the finishclean-
ing container and clean them carefullyto their
inside, turning them slowly.
2) Wipe kerosene off the parts withclean cloths.
a 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), hy-
draulic motorparts, and RV gear assem-
bly 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.
PC60-7 30-46-35
8
DISASSEMBLY
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).
Standard value Allowable value

Part No. Part name Trouble
Standard dimension) (Criterion)
Spindle kit
Spindle Part surface hasvisible serious
damage.
Hold flange Part surfaceis scuffed or worn
easily.
Reamer bolt
RV gear assembly
RV gear (A) RV gear tooth surface is worn
RV gear (B) unevenly.
Crankshaft When crankshaft (9) is revolved,
Tapered roller bearing each part does not move
Needle roller bearing smoothly.
10 Distance piece Sliding surface has flaw.

Sliding surface is worn abnor-
mally.
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 Moving part against spool (123)
has flaw.
Clearance between rear flange Clearance Clearance
and spool is large. 12-18~ 23 c1
Contact face againstvalve (127)
has flaw.
Depth to contact face against
valve (127) is large.
Spool Outside sutface has flaw.
Outside sutface is worn unevenly.
30-46-36 PC60-7
@
DISASSEMBLY
Part No. Part name Trouble Standard value Allowable value

Standard dimension) (Criterion)
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.
Piston assembly
Piston There is axial clearance between

piston (105) and shoe (106).
Shoe Clearance: Clearance:
Shoe isworn abnormally. 0.15 mm
0.05 mm
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 Both end faces are worn un- 3raking torque: 3raking torque:
evenly. 82.38Nm{8.4kgm} 82.38Nm{8.4kgm}
116 Mating plate
Specified torque is not produced.
Plate is seized.
127 Valve Seat surface has flaw.
149 Deep groove ball There is bruise.

bearing
Surface is flaked.
150 Deep groove ball
Surface is worn unevenly.
bearing
163 Valve Outside surface has flaw.
PC60-7 30-46-37
8
ASSEMBLY
Carry out assembly in the reverse order to disas- 3. Assembly procedure
sembly, as a rule.
1. Preparation
a If any part is replaced before assem-
bling, the preload on the ball bearing
Prepare a worktable, tools, and materials for dis- and thickness of the snap ring may
assembling, similarly to preparation for disassem- need to be adjusted. Accordingly,see
b Iy. if any of the following part has been
2. General precautions for work replaced before assembling.
1) Observe the same general precautions with 1)Replacementpartswhichrequiread-
disassembly. justment of preload on ball bearing
2) Removeallmetalchipsandforeignmatter Hub (I), spindle (2), collar (II),hold
from theall parts andcheck that any part does flange (3),ball bearing (21)
not have a burr, bruise, etc. before assem- 2) Replacementpartswhichrequiread-
bling. If thereis any burr or bruise, remove it justment of thickness of snap ring
with an oilstone.
3) Replace the O-rings, oilseals, and floatingseal
a Spindle (21, hold flange(3),crankshaft
(9),spacer (12), tapered roller bearing
with new ones. (22), snap ring (20)
4) Replace the reamer bolts with new ones, as a If any of the above part is replaced be-
rule. If it is obliged to reuse one, remove all fore assembling, be sure to use only
adhesive from it with a brush. If boltseat has the adjusted parts. If a part which has
any flaw, removeit with an oilstone and then not been adjusted is used, the travel
degrease the reamer bolt. motor will malfunction and cause
5) Since the reamer bolt holes of spindle (2) and breakage soon. Accordingly, observe
threaded parts of reamer bolts (19) are to be this precaution.
coated with adhesive when they are as-
sembled, degrease them.
6 ) When fitting the O-rings, oil seals, and float-
ing seals, take care not to damage them. (Ap-
ply 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 malfunc-
tion.)
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 PC60-7
@
DISASSEMBLY
4. 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, ad-
just the preload on the ball bearing be-
fore 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 care-
fully.
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 bear-
ing (21) and hit it lightly witha hammer
all round to fit the bearing little by little.
00229
PC60-7 30-46-39
8
DISASSEMBLY
7) Apply grease to O-ring(28) and fit O-ring(28)

to the O-ring groove of hub (1).
II I
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, 0-
ring (28) may be broken causeto oil leak-
age. 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
and apply grease thinly all round 0-
seal
the
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).
sling spindle(2) with the crane and insert it in
hub (1) slowly.
17" \ ' CLZOO214
30-46-40 PC60-7
@
0
<
2
DISASSEMBLY
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 ham-
mer @ 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 bear-
ing (21) in hub (1).
a When fitting hold flange(3) to ball bear-
ing (21), set the match marks on spindle
(2) and crankshaft(9) to the positions be-
fore disassembly.
If hold flange (3) does not enter the in-
ner race of ball bearing (21) smoothly,
hit it evenly and lightly with a plastic
hammer.
t \ I CLZOO241
30-46-42 PC60-7
@
DISASSEMBLY
7. Tightening of reamer bolts

1) Apply anti-seizure lubricating oil to the ream-
ing parts of reamer bolts (19) and apply ad-
hesive 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. / 1 CLZOO242
3) Tightenreamerbolts(19) (3 pieces) to the
specified torque.
Reamer bolts (19):
a 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 tight- 3
ened first, hold flange (3) will slant and
ball bearing (21) will not be fitted accu-
rately 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. \ I 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 If any of the above parts has not been
replaced, go to the next step. If any of
20
the above parts has been replaced, ad-
just the axial clearance of tapered roller
bearing (22) before going to the next
step.
PC60-7 30-46-43
8
DISASSEMBLY
a When replacing only snap rings (20), se-

lect 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 positionsbe-
fore disassembly, matching them to the
match marks on hold flange (3). When
using new snap rings (20), select ones
having the thickness selected in thepre-
vious process.
3) Install distance pieces(14) (3 pieces) to crank-
shaft (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 crank-

shaft (9), matching their match marks
S e tm a t c hm a r k s
bunch oles) of
s p u rg e a r s to
(punch holes) as shown in the figure t h e s ep o s i t i o n s .
below.
Hold flanae
I DWP01916
2) Install C-type shaft snap rings (25) (3 pieces)

to thesnap ring grooves of crankshaft(9).
30-46-44 PC60-7
G9
DISASSEMBLY
IO. Press fitting of oil seal

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 heat-
ing tank andheat it at 100 & 10C for 10 min-
utes and then insertit in shaft(102).
a Put on leather gloves to insert the bear-
ing and take care not to get burnt.
Insert deep groove ball bearing (149)
until it is fitted to the flange of(102).
shaft
CLZOO251
2) Fit parallelpins(177)(2pieces9tothepin
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.
6) Fit shaft (102) to spindle (2).

a Fit shaft (102) to spindle (2) slowly, tak-
ing care that it will not damage the lip of
oil seal (132) fitted in spindle (2). If the
102
lip is damaged,oil will leak and the travel
motor will be broken soon.
PC60-7 30-46-45
8
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 2
spindle (21, match its steel ball holes t o
steel balls (167)(2 pieces) fitted to
spindle (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
@
P
I
n
DISASSEMBLY
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 0-
rings (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 ad-
hesion 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
a 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 hydrau-
* lic 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 bycon-
tact, internal leakage will occur after as-
sembly and the performance of the travel
motor will lower. CLZOO266
6) Fit O-rings (136) to plugs (124).

a Apply grease to O-rings (136).
PC60-7 30-46-49
8
DISASSEMBLY
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
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 oper- 164
ated 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 bear-
rear flange(101).
ing (1 50)and fit it to 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 Install timing plate (109)
flange (101).
until it fits torear
The timing plate must be fitted so that it

will not fall from the rear flange when it
is installed to spindle (2).
PC60-7 30-46-51
8
DISASSEMBLY
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 leak-
age, 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), match- r
ing its pin holesto parallel pins

(142) (2 pieces)
fitted to spindle(2).
a 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
@
rc
It
:
S
(L1
3 ?
v
m
DISASSEMBLY
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
and hub (1) to install them to the posi-
(8)
tions before disassembly.

Install cover (8) by hitting its periphery
lightly with a plastic hammer. If it is in-
stalled 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.
Hexagon socket head plugs (33):

39.2 f 14.7 Nm (4 f 1.5 kgm)
a Wind the sealing tape onto each hexa-
gon socket headplug (33)at least2 turns.
Tighten each hexagon socket head plug
(33) until the number of threads pro-
jected from the endof cover (8) becomes
*I.
30-46-54 PC60-7
@
DISASSEMBLY
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

a Install 2 eyebolts symmetrically to the
screw holes of spindle (2).
remove the travel motor from the work table
with thecrane.
0289
PC60-7 30-46-55
8
DISASSEMBLY
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 re-
placed, assemble the parts temporarily and
check the preload according to the follow-
1
ing procedure.
If the GM motor is assembled without check-
ing the preload, it will malfunction and will
be broken soon.
Parts which affect preload on ball bearing
CLZOO290
Hub ( I ) , spindle (2), hold flange (31, ball bear-
ing (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.
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
DWPO2 1 1 9
30-46-56 PC60-7
@
DISASSEMBLY
4) Obtain dimension "D" of hold flange (3).
5) Adjust hold flange(3) by the following meth-

ods, depending on the measurement in 2) -
4) above.
tVFace
I
E
Dimension "C" is the standard dimension of

the hold flange.
i) Whenthemeasureddimensionofhold
flange (3) is smaller than the standard di-
mension
Cut face E of hold flange(3) with a lathe,
etc. to the standard dimension.
ii)Whenthemeasureddimensionofhold
flange is within the tolerance of the stan-
dard dimension
Use the hold flangeas it is.
iii) When measured dimension D of hold
flange (3) is larger than the standard di-
mension
Replace the spindle assembly with new
one.
New hold flange (3) has an adjustment al-
lowance.
a Since the hold flange and spindle
are used together, they are made in
an assembly. Accordingly, it is im-
possible to replace only the hold
flange.Replace bothholdflange
and spindle together. The assem-
bly of the hold flange and spindle is
called the spindle assembly.
When replacing the spindle assembly,
execute the disassembly and assem-
bly 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
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 ad-
justing the thickness of snap ring (20). If the
GM motor is assembled without adjusting
the axialclearance of the tapered roller bear-
ing, it will malfunction and will be broken
soon.
Spindle (21, hold flange (31,crankshaft (9),
spacer (12), snap ring PO), tapered roller
bearing (22)
I I CLZOO296
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 bear-
ing.
1) Lightly hit the outer race of tapered roller bear- 20
ing (22) installed tocrankshaft (9) with a ham-
mer and holder(IV).
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).
3) Lightly hit the peripheryof snap ring (20) with
the hammer and holder (IV).
a Check that the RV gear assembly is in-
serted securely in spindle(2).
I I I CLZOO295
30-46-58 PC60-7
@
DISASSEM
TRAVEL
BLY AND ASSEMBLY MOTOR
4) Insert a thickness gauge between snap ring

(20) and tapered roller bearing (22) to mea-
sure the clearance.
5) Measurem ent of snap ring thickness

Set thickness of snap ring (Max.) 20
Max. = (Thickness of thickness gauge) +
(Thickness of snap ring fitted at present)
Set thickness of snap ring (Min.)
Min. = (Thickness of thickness gauge) + 22
(Thickness of snap ring fitted at present)
-
(0.05 mm) /J CLZ0029t
6) After the snap ring thickness is decided, se-
lect one from the 12 types and install it to the
hold flange.
(See 23. Dimensions table of clearance adjust-
ment parts.)
7) After installing the snap ring having the de-
cided thickness, go to8.2.
00299
PC60-7 30-46-5 9
8
DISASSEMBLY
DIMENSIONS TABLE OF CLEARANCE ADJUSTMENT PARTS

GM Model
No.
Part name
GM09VL2
-
1 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
@
DISASSEMBLY
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 pcs.
I 2 I Measuring cylinder (For 5 liters) I 1 PC.
3 Stopwatch 1 PC.
2. Test procedure
and
..................... Install the GM motor to the machine body (sprocket) and pipe it.
piping of GM Do not install the track, however [sincethe performance test of the GM
motor motor (no-load operation) is executed].
Notes) 1. 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.
Running-in of ..................... I Operating time I

1 minute or
Right/Left more foreach
3 Performance
confirmation test
on GM motor
I1I ..........
Preparatory operation beforetestn.Operate until temperaturerises to thefollowing points.
Outside temperatureof hubof reduction gear assembly:
40 - 80C
-
2 Confirmation test
-
........................................
I I
Criteria
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. 4
Acceptable Rejected
J( JI
Install track. Disassemble and adjust again.
PC60-7 30-46-61
8
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY
REMOVAL OF SWING MOTOR,

SWING MACHINERY ASSEMBLY
side the hydraulictank.
a An accumulator is not installed,
sleeve nut of the hose slowly and
so loosen the
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 machin-

ery and swing motor assembly ( 6 ) ,and use forc-
ing screwCiJ t o remove.
* When removing the swing machinery and
swing motor assembly, lift off slowly and be
00
careful not to damage the wiring or piping.

& Swing machinery and swing motorassem-
bly : 70 kg
INSTALLATION OF SWING MO-

TOR, SWING MACHINERY AS-
SEMBLY
moval.
Swing machinery case mating surface :

Swing machinery and swing motor assem-
bly 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
again.
*
Bleeding air
Bleed the air from the swing motor.
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
7 5
1) Loosenplug (2).
\ \ /J
*
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).
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
P2 IO
*
brake piston (IO).
Air pressure: 0.39 MPa (4 kg/cm2}
a If the air pressure is too high, the brake pis-
ton jumps out. Take care.
I DWPOI 643
30-47-1 PC60-7
8
2
W
-m
3
Q
n
v)
0
2) Disassembly of cylinder block and piston as-

sembly
Pull piston assembly(19) out of cylinder block
(18) and remove retainer guide (20) and
*
preload pins (21).
When the cylinder block and piston
sembly is removed from the shaft
as-
assem-
bly or when the piston assembly is pulled
out of the cylinderblock, 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 PC60-7
8
2) Remove bearing (30)from shaft (29)with push

tool (2).
30
DWPO 1 6 5 2
11. Plate
,I2
*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.
12. Oil seal and outer race

1) Remove snap ring (31) from motor case 12
and then remove oilseal (32).
2) Remove outer race (33).
Y
DWPO1664
13. When theabove disassembly work is not neces-

sary 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 oilseal 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
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.) 33
1. Motor case
1) Press fit outer race (33)with tool P5. I PI !2
2) Set tool P I to motor case (12).
I DWPOl657
2.Shaftassembly
1) Press fit bearing (30)to shaft (29) with toolP6
P6
*
to form them into shaft assembly (17).
Press the end of the bearing inner race
with tool P6 until the bearing fits to the
I7
* shaft end.
Press fitting load:
1,834 - 7,119 N (187 - 726 kg} 30
Press fitting surface of bearing: 29
Lubricating oil (EOIO-CD)
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 mo-
tor case, turn it to the right and left to
check that it is installed accurately.
17
30-47-5 PC60-7
8
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 assem-

bly
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 pis-
*
ton assembly (16).
Match the splines of the cylinder block
and retainer guide toeach other. I DWPO1648
4) Install cylinder blockand piston assembly (16)
*
to motor case (12). I
Take care sufficiently that the preload pins

will not fall.
I' 1 DWPO1660
PC60-7 30-47-6
@
4. Plate, disc, and piston
*
1 ) Install plate (13)and disc (14)in order.
Do not clean the disc with trichloroethyl-
ene 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
P7
* 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) DWPOl663
2) Installspacer (5) and outer race (4)to end
*
cover (3).
Installthespacerwhichhasbeenre-
moved.
3) Install valve plate (9) to end cover (31,match-
*
ing it to the dowel pin.
Check that the valve plate does not inter-
* fere 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.) DWPOl664
30-47-7 PC60-7
@
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
5) Push the shaft end with puller 0 to shift the
*
shaft toward the end
Pushing out load:
cover.
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
8.
*
gauge
End play: 0.05 - 0.25 m m
I DWPO1666
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
n
table.
Thickness (mm) Spacer tobe used
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 DWPO1667
70s-7T-12390 2.1
--
70s-7T-12460 2.2
iv) Install the selected spacer and assemble
the parts again according to steps 5-2) - I 7
5-6) and measure the end play.
v) After adjusting the end play, remove the
end cover. I-\
6. Endcover assembly
1) Install relief valve (7)and spring (6) in order
I v v
I
and then fit the O-ring and tighten plug (2)
temporarily.
I DWPOI 6 6 8
PC60-7 30-47-8
8
2) Install brake spring (8).
3) Fit the O-ring to the motor case and install

end cover (3) horizontally, matching it to the I DWPO1669
*
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.
Mating face of motor case:

Gasket sealant
[LG-7 or LG-5 (LOCTITE 572/575)]
m Mounting bolt: I I
110.3 f 12.3 Nm {11.25 f 1.25 kgm} DWPO1670
4) Tightenplug (2).
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) DWPO1671
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}
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). DWPO1672
30-47-9 PC60-7
8
DISASSEMBLYAND ASSEMBLY SWING MOTOR
CONTACT CHECK OF CYLINDER BLOCK,

CY I i n d r!r b l o c k C e n t e Vtr oianol gvl e plate
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 cylin-
der block or valve plate is a spare or is re-
paired.
If the contact is improper, correct it by lap-
ping the parts on a surface plate. DWPO I 6 7 3
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.
I a seal
*
Degrease the parts to be checked.
Do not wipe the parts with a cloth.
Set the tool and apply check paint to the cyl-
*
inder 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 origi-
nal position. Repeat this motion 2- 3 times.
Remove the valve plate and transfer the con- I V aCl vyel i np dl ae tr e block
DWPO I 6 7 4
*
tact surface onto a tape and check it.
The standard contact area is as follows.
Sealing part a
Valve platec. Min. 80%

I Cylinder
blocke. I Min. 80% I
* For the details of the work procedure,
guide to parts judgment.
see the
2. Valve plate and end cap

1) Remove all oil and grease from the parts to Valve P
*
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
there
plate go", then turn itback to the original po- and
sition. Repeat this process 2 or3 times. more
4) Remove the valve plate, transfer the contact I DKP00664
surface to a tape, and check the contact sur-
*
face.
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.
PC60-7 30-47-10
@
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLY OF SWING MACHINERY

ASSEMBLY I
1. Draining oil
Loosen drain plug and drain oil from swing ma-
chinery.
- : Swing machinery case : Approx. 1.5 e
2. Swing motor assembly

Remove swing motor assembly (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 fol-

lows.
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
4. 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).
CBPO3586 CBPO3587
2) Disassemble No. 2 carrier assembly as fol-

I11 17 I6
lows.
i) Remove snap ring (161, then remove I9
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
20
(21).
iii) Remove thrust washer (23) from carrier
21
(24).
7. 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 col-
lar 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 shaftassem-
bly (28) with press.
2) Remove bearing (25).
. CBPO3591
30-49
0
3) Set shaft assembly to press, then using push

tool 0, remove bearing (29) and collar (30)
from shaft (31 I.
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 outer races

(35) and (36) from case (34).
CBP03594
30-50
0
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 CBPO3595 CEPO3596
Using push tool, press fit outer races (35) and (36)
to case (34).
3. Shaft assembly
1) Install collar (30) to shaft (31).
2) Using push tool 8, press fit bearing (29) with

press.
s
Lu
CBPO3597
3) Set case assembly (37) to shaft assembly (28).
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
kg}
- Ir Press fit the bearing slowly while rotating
the case.
CBPO3696 1 1 CBP03599
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.
CBP03600 CBPO3601
4. Dust seal
Using push tool @, press fit dust seal (32).
* Replace the dust seal with a new part.

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 be-
tween the shaft and carrier is less than
0.2 mm.
iv) Assemble thrust washer (20), bearing (19). CBPO3568
gear (18), and thrust washer (17), then in-
stall snap ring (16).
2) Install No. 2 carrier assembly (15) to shaft and

case assembly.
6. Ring gear
Install ring gear (14).
6 Ring gear mating surface :

Gasket sealant (LG-4 or LG-6)
7. No. 2 sun gear

Install No. 2 sun gear (15).
CBP03566 CBPO3567
30-52
0

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 be-
tween the shaft and carrier is less than
0.2 mm. CBPO35B5
iv) Assemble thrust washer (8), bearing (7),

gear (6), and thrust washer (5), then in-
stall snap ring (4).
CEPO3584
2) Install No. 1 carrier assembly (3).

3) Install No. 1 sun gear (2).
9. Swing motor assembly CBPO3583
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)
10. Refilling with oil, adding grease

Tighten drain plug and add engine oil through oil
filler.
I& Swing machinery case : Approx. 1.5 fi
& Swing machinery case : CEPO3582

Grease fG2-LB Approx. 110 cc
PC60-7 30-53
0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING FRAME

ASSEMBLY
Serial No. : 52374 - 57999

.
1. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIPMENT
ASSEMBLY.

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 boom cylinder assembly (3).
r&lLO Boom cylinder assembly : 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). 11
CEPO2003 CBPO2904
30-54 Pc60-7
0
11. Raise block 0, set between wire and frame, then

sling, taking care that wire does not contact en-
gine.
12. Remove mounting bolts, then lift off revolving

frame assembly (14). (x
* 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 re-
maining bolts, and lift off.
A When removing the revolving frame assem-

bly, 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 - 57999

moval.
& Mating surface of swing circle :

& 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)

t Add oil through the oil filler to the specified
again.
l Bleeding air
Ir Bleed the air from the swing motor.
Bleeding air.
Fc60-7 30-55
0
REMOVAL OF REVOLVING FRAME

ASSEMBLY

1. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIPMENT
ASSEMBLY.

For details, see REMOVAL OF COUNTERWEIGHT 1 CBP03220
ASSEMBLY.
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).
CrlPO2903 CfJPO2904
L
9. Raise block 0, set between wire and frame, then

sling, taking care that wire does not contact en-
gine.
,.- -
CBPO2905
30-55-l PCbO-7
0
10. Remove mounting bolts, then lift off revolving

frame assembly (14). (f
* 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 re-
maining bolts, and lift off.
A When removing the revolving frame assem-

bly, be careful not to hit the center swivel
joint assembly.
6 La Revolving frame assembly : 2300 kg
INSTALLATION OF REVOLVING
FRAME ASSEMBLY

moval.
6 Mating surface of swing circle :

& Thread of revolving frame mounting bolt

: Thread tightener (LT-2)
m Revolving frame mounting bolt :

277.5 + 32.4 Nm (28.3 f 3.3 kgm)

again.
. Bleeding air
Ir Bleed the air from the swing motor.
Bleeding air.
Pcbo-7 30-55-2
0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE ASSEMBLY

1. Remove revolving frame assembly.
For details, see REMOVAL OF REVdLVlNG FRAME
ASSEMBLY.
2. Lift off swing circle assembly (1). m
rel kg Swing circle assembly : 110 kg
INSTALLATION OF SWING
CIRCLE ASSEMBLY race
zone
Outer race soft zone
l Carry out installation in the reverse order to re- DBP00513
moval.
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 bolt : Thread tightener (LT-2)
m Mounting bolt :
276.85 f 31.85 Nm (28.25 f 3.25 kgm)
30-56 PC60-7
0
DISASSEMBLY AND ASSEMBLY IDLER, RECOIL SPRING
REMOVAL OF IDLER. RECOIL SPRING

ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
2. Sling idler and recoil spring assembly (11, and pull

out to the front to remove.
Idler, recoil spring assembly : 95 kg

I+ kP
3. Disconnect recoil spring assembly (3) from idler

CEiPO3606
assembly (2). a
&I kg Idler assembly : 60 kg
- &I kg Recoil spring assembly : 35 kg
INSTALLATION OF IDLER, RE-

COIL SPRING ASSEMBLY
moval.
6
CBPO3606
z I
m
z
6 Thread of recoil spring assembly mount-
ing bolt : Thread tightener (LT-2)
30-57
0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
CBPO3607
1. Remove lock plate (11, then remove seat (2) and I

lubricator (3).
2. Remove yoke piston assembly (5) from recoil

spring assembly (4). I
3. Disassembly of recoil spring assembly

1) Set recoil spring assembly (4) to tool B.
A The recoil spring is under large installed

load, so be sure to set the tool prop-
erly. Failure to do this is dangerous.. I -
Ir Installed load of spring : - CBPO3606
I
42.63 kN (4,350 kg}
2) 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.
4. Disassembly of yoke piston assembly

I) Remove wear ring (12) from yoke piston (11).
2) Remove snap ring (13), then remove U-pack-
ing (14).
30-58
0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY OF RECOIL SPRING ASSEMBLY

1. Assembly of yoke piston assembly
1) Assemble U-packing (14) to yoke piston (ll), IO
and secure with snap ring (13).
2) Assemble wear ring (12).
2. Assembly of recoil spring assembly

,Y
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. CBPO3609
* Installed length a of spring : 322 mm
6 Thread of nut :
Anti-friction compound (LM-P)
(4) from tool Fill with

4) Remove recoil spring assembly
OreaSe
B.
3. Fill inside of cylinder with a minimum of 120 cc of

grease.
& Inside cylinder : Grease (G2-LI)
4. Assemble yoke piston assembly (5) to recoil

6 spring assembly (4).
;; a Voke piston sliding portion wear ring : OLPOO453
z Grease (G2-LI)
5. 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 AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER ASSEMBLY

1. Remove dowel pin (I 1, then remove support (2).
2. Remove floating seal (3) from support (2) and idler

(4).
3. Pull out idler (4) from shaft (5) and support as-
sembly (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 pin (8). then remove support (7)

from shaft (5).
6. Remove bushings (9) and (IO) from idler (4).
CBPO36 12
CBPO3611 DBPOO236
30-60
0
ASSEMBLY OF IDLER ASSEMBLY

1. Press fit bushings (9) and (10) to idler (4).
DBP00238
I
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 CBPO3617
z
4. Assemble shaft (5) and support assembly (7) to

idler (4).
CtlPO3618
5. Add oil between shaft 15) and idler (4).
Q Oil : 60 cc (SAE3OCD)
DBPOO241
30-61
0
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 4 3
dust get stuck to it.
Ir Remove all grease and oil from the contact
surface of the O-ring and the floating seal. 3
CBPO3620
7. Install O-ring, then install support (2) with dowel

pin (1).
CBPO3621
30-62
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER ASSEMBLY

1. Lower work equipment to ground, then loosen
lubricator (11, and relieve track tension. a
g The adjustment cylinder is under extremely

high pressure, so never loosen the lubrica-
tor more than one turn. If the grease does
not come out easily, move the machine back-
wards and forwards.
2. Remove mounting bolts of track roller, then

swing work equipment 90, jack up machine with
work equipment, and remove track roller assem-
CBP03622
bly (2) towards outside of machine. a
DBP00245
INSTALLATION OF TRACK
ROLLER ASSEMBLY
moval.
- a
Ir Adjust the track shoe tension.
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 chas-
sis, 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 OF TRACK ROLLER

ASSEMBLY
I
1. Remove pin (I 1, then remove collar (2). I 2
2. Remove floating seal (3) from collar (2) and roller

(4).
DBP0024
3. Pull out roller (4) from shaft (5).

Ir It is filled with 75 - 85 cc. of oil, so drain the
oil at this point or lay a cloth to prevent the
area from becoming dirty.
DBP00247 I DBP00248
DBP00249 I DBP00250
30-64
0
4. Remove floating seal (6) (on opposite side) from

roller (4) and shaft (5).
5. Remove bushings (7) and (8) from roller (4).

5
CBPO3629 CBPO3630
30-65
0
ASSEMBLY OF TRACK ROLLER ASSEMBLY

1. Using push tool 0, press fit bushings (9) and (IO)
to roller (4).
2. Assemble coliar (8) to shaft (51, and install pin (7).
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.
DBPD0252 CEPD363?
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 shaft (5) to roller (4).
CBPO3634 CBPO3635
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 precau-
tions marked + for Step 3.
CBP036 CEPO3638
30-66
0
9. Assemble 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),
and relieve track tension. m
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 posi-

tion where carrier roller assembly can be re-
moved, then remove carrier roller assembly (2). CBPO3622
m
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
CBPO3640
moval.
@?4 Adjust the track tension

Testing and adjusting track tension.
a Thread of carrier roller assembly mount-

ing bolt : Thread tightener (LT-2)
30-68
0
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Lower work equipment, then loosen lubricator (I),
and relieve track tension. I
& 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. Move machine forward so that position of mas-

ter pin is at front of idler, and set block @ in posi- CBPO3622
tion.
3. Using tool C, pull out master pin. a
4. Remove tool C, and pull out temporary pin, and

remove dust seal, then drive machine in reverse
to lay out track (2). a
CEPO3641
INSTALLATION OF TRACK
SHOE ASSEMBLY
moval.
u
a
It Adjust the track tension.
For details, see TESTING AND ADJUSTING, Test-
ing and adjusting track tension.
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 AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
around and stop the engine. Then loosen the
1. Drain oil from hydraulic tank.
- : Hydraulic tank : Approx. 68 fl
3. Remove handrail (1).
4. Remove right side cover (2).
5. Remove rubber hose clamp (3).
6. Remove hose clamp (4). then disconnect hose (5).
7. Disconnect hoses (61, (71, (81, and (9).

Ir Make match marks before disconnecting.
CRPO2906 CBPO2907
8. Lift off hydraulic tank assembly (10). a
r+ kn Hydraulic tank assembly : 70 kg
CBPO3223
30-70
0
DISASSEMBLY AND ASSEMBLV HYDRAULIC TANK
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
moval.
& Thread of hydraulic tank mounting bolt :

w Hydraulic tank mounting bolt :

176.5 + 19.6 Nm I18 f 2 kgml

Ia Hydraulic tank : 68 b?(SAEIOWCD)
. Bleeding air
Bleeding air from hydraulic tank.
For details, see TESTING AND ADJUSTING, Bleed
the air.
Pc60-7
30-71
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP
REMOVAL OF MAIN PUMP

ASSEMBLY
Serial No. : 52374 - 57999

around and stop the engine. Then loosen the
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 cePo2833
tank and inside the system.
- : 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).
\ 1 6cspo*910
7. Disconnect main pump outlet hose (7).
8. Disconnect main pump drain hose (8).
9. Disconnect power mode select pilot pressure

hose (9).
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
13. Disconnect ground cable (13).
14. Sling main pump assembly (141, and using forc-

ing screws @ to remove main pump assembly.
a
&I km Main pump assembly : 56 kg
INSTALLATION OF MAIN PUMP UJ CBPO29l3 I
ASSEMBLY
Serial No. : 52374 - 57996

moval.
6 Mating surface of pump case :

l Refilling with oil (PTO gear case)

Add engine oil through the oil filler to the speci-
fied level.
Q PTO gear case : 0.35 e (SAESOCDI
9 Refilling with oil (hydraulic tank)

Q Hydraulic tank : 68 l (SAElOWCD)
l Bleeding air
Bleed the air from main pump.
Bleeding air.
Pc60-7 30-73
0
REMOVAL OF MAIN PUMP

ASSEMBLY
a Lower the work equipment

ground and stop the engine.
completely to the
Then loosen the
I. 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.
2. Drain cooling water.
3. Remove engine side cover.
4. Remove two heat insulation panels (I), then re-

move muffler (2).
5. Disconnect air intake hose (3).
6. Disconnect following hoses from main pump.

* Drain hoses (4) and (5)
Mode selector solenoid pressure input hose
l
f6t
- Main pump discharge hose (71
- LS pump pressure input hose (8)
l LS pressure input hose (9)
l Suction tube (IO)
g 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
@
7. Disconnect ground wire (11) from main pump
8. Sling main pump assembly (141, and using forc-

ing screws I to remove main pump assembly.
!
Main pump assembly : 60 kg
INSTALLATION OF MAIN PUMP

ASSEMBLY

moval.
&I, Matrng surface of pump case :

Refilling with oil (PTO gear case)

Add engine oil through the oil filler to the speci-
fied level.
I& PTO gear case : 0.35 e (SAEBOCD)
Refilling with oil (hydraulic tank)

% Hydraulic tank : 68 !Z(SAEIOWCD)
Bleeding air
Bleed the air from main pump.
Bleeding air.
PC60-7 30-73-2
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP IN-

PUT SHAFl= OIL SEAL
1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP AS-
SEMBLY
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
moval.
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.
* Use tool D2 to press fit oil seal (4).
30-74 PC60-7
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL VALVE

ASSEMBLY
g An accumulator is not installed, so loosen the

sleeve nut of the hose slowly and check that
no oil spurts out before removing.
+ Make match marks before removing the
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 fol-
lows: blade, bucket, arm, boom, R.H. travel,
L.H. travel, swing.
3. Disconnect hoses (6), (71, and (8).
4. Remove clamp (9).
5. Disconnect hoses (IO), (11). (12) and (13).
6. Remove U-bolt mounting bracket (14) for secur-

ing oil cooler inlet hose.
h CBPO2917
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
moval.

level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
l Bleeding air
t Bleed the air from the circuit between the
valve and the hydraulic cylinder.
Bleeding air.
30-76
0
DISASSEMBLY OF CONTROL VALVE ASSEMBLY

+ The set pressure of the safety valve cannot 1) Remove case (5). then remove spring (6)
be adjusted when it is installed on the ma- and retainer (7).
chine, so do not disassemble. 2) Remove plugs (8) and (11) from spool
* Except for the R.H. and L.H. travel, the (141, then remove spring (9) and valve
spools and pressure compensation valves (IO).
are not interchangeable, so always mark t Plug (8) is for the RAISE valve and
them before removing them. plug (11) is for the LOWER valve.
Ir Loosen the plug with the spool still as-
sembled in the valve body. 5. Arm control valve
1) Remove case (5), then remove spring (6)
1. Remove main relief valve assembly (I), and retainer (7).
safety valve assembly (21, LS select valve as- 2) Remove plug (8) from spool (151, then re-
sembly (3). and unload valve assembly (4). move spring (9) and valve (IO).
2. Swing control valve 6. Bucket control valve

1) Remove case (5), then remove spring (6) 1) Remove case (51, then remove spring (6)
and retainer (7). and retainer (7).
2) Remove plug (8) from spool (121, then re- 2) Remove plug (8) from spool (16).
move spring (9) and valve (10).
7. Blade control valve
3. Travel control valve I) Remove case (51, then remove spring (6)
I) Remove case (51, then remove spring (6) and retainer (7).
and retainer (7). 2) Remove plug (8) from spool (17), then re-
2) Remove spool (13). move spring (9) and valve (IO).
6
E
4. Boom control valve
w
LOVER
Blade
TILT
Bucket
Arm
LOWER
Boom
REVERSE
R. Ii. travel
L.It.
travel REVERSE
DAPDD514
30-78
0
8. Pressure compensation valve 5) For bucket

1) For swing i) Remove plug (18), then remove valve
i) Remove plug (18). then remove valve (32), spring (20), and valve (33).
(19). spring (20). and valve (21). ii) Remove piston (34) from valve (33).
ii) Remove piston (22) from valve (21). 6) For blade
2) For travel i) Remove plug (18), then remove valve
i) Remove plug (18), then remove valve (35), spring (20), and valve (36).
(23), spring (20), and valve (24). ii) Remove piston (37) from valve (36).
ii) Remove orifice (25) from valve (23).
3) For boom 9. Remove suction valve (38).
i) Remove plug (18), then remove valve
(26), spring (20), and valve (27). 10. Remove plug (39), then remove spring (40)
ii) Remove piston (28) from valve (27). and check valve (41).
4) For arm
i) Remove plug (18), then remove valve 11. Remove plug (43) from body (42), then re-
(29), spring (201, and valve (30). move springs (44) and (45) and poppet (46).
ii) Remove piston (31) from valve (30). + The springs are different so be careful to
distinguish them.
12. Remove plugs (47) and (48).
CAP0371
9
30-79
0
CAP03720
30-80
0
I 6
CAP03721
30-8 7
0
ASSEMBLY OF CONTROL VALVE ASSEMBLY

* Except for the R.H. and L.H. travel, the 5) For travel
spools and pressure compensation valves i) Assemble orifice (25) in valve (23).
are not interchangeable, so always mark ii) Assemble valve (23) spring (20), and
them before disassembling them. valve (24) in body, then fit O-ring and
install plug (18).
. Before assembling coat the sliding surface 6) For swing
with engine oil. i) Assemble piston (22) in valve (21).
ii) Assemble valve (21), spring (20). and
1. Fit O-ring and backup ring and install plugs valve (19) in body, then fit O-ring and
(47) and (48). install plug (18).
m Plug : 39.2 + 4.9 Nm I4 + 0.5 kgm)
2. Assemble poppet (46) and springs (45) and

(44) to body (42), then fit O-ring and install
plug (43).
m Plug : 127.4 & 19.6 Nm I13 + 2 kgm}
3. Assemble check valve (41) and spring (40) to

body, then fit O-ring and install plug (35).
m Plug : 29.4 + 4.9 Nm i3 + 0.5 kgm}
4. Fit O-ring and install suction valve (38).
m Plug : 44.1 + 4.9 Nm I4.5 + 0.5 kgm}

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
install plug (18).
3) For arm
install plug (18).
4) For boom
ii) Assemble valve (27). spring (20), and
install plug (18).
CAP03722
30-82
CAP03721
30-83
6. Blade control valve 3) Assemble retainer (7) and spring (6),

1) Assemble spool (17) in body. then fit O-ring and install case (5).
2) Assemble valve (10) and spring (9), then 10. Travel control valve
fit O-ring and install plug (8). I) Assemble spool (13) in body.
2) Assemble retainer (7) and spring (6),
w Plug :
then fit O-ring and install case (5).
17.15 + 2.45 Nm il.75 * 0.25 kgm)
3) Assemble retainer (7) and spring (6), then 11. Swing control valve
fit O-ring and install case (5). 1) Assemble spool (12) in body.
2) Assemble valve (IO) and spring (9), then
w Case mounting bolt :
fit O-ring and install plug (8).
11.27 f 1.47 Nm il.15 + 0.15 kgm}
3) Assemble retainer (7) and spring (6).
* The tightening torques are the same
for all the valves, so refer to the
12. Fit O-ring and install unload valve assembly
tightening torque for the blade valve
when tightening the other valves. (4).
w Unload valve :
7. Bucket control valve 166.6 f 19.6 Nm (17 + 2 kgm}
1) Assemble spool (16) in body, then fit O-
ring and install plug (8). 13. Fit O-ring and install LS select valve assem-
2) Assemble retainer (7) and spring (6), bly (3).
w LS select valve :
127.4 f 19.6 Nm {I3 k 2 kgm} 6
8. Arm control valve
1) Assemble spool (15) in body. 6
14. Fit O-ring and install safety valve assembly z
2) Assemble valve (10) and spring (9), then
fit O-ring and install plug (8). (2).
3) Assemble retainer (7) and spring (6), w Safety and suction valve :
then fit O-ring and install case (5). 98 * 9.8 Nm {IO f 1 kgm)
9. Boom control valve 15. Fit O-ring and install main relief valve as-
1) Assemble spool (14) in body. sembly (1).
2) Assemble valve (10) and spring (9), then
w Main relief valve :
fit O-ring and install plugs (11) and (8).
53.9 f 4.9 Nm 15.5 + 0.5 kgm)
Sr Plug (8) is for the RAISE valve and
plug (11) is for the LOWER valve.
2 LOWER
Blade
TILT
OunP
IN 8
t
OUT
RAISE
R. Ii. travel w
L.H. travel
Swine 2 c
CY
FORWARD
FORWARD
RIGHT
I DAP00511
30-84
A-- 46
Y
16
16
CAP03720
30-85
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY 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 pro-
trusion dimension of adjustment screw (2)
from the end face of the nut.
2. Remove snap ring (6) from sleeve (5), then re-

move valve (7) and spring (8).
3. Remove backup ring (9) from sleeve (5).
ASSEMBLY OF MAIN RELIEF
Assemble backup ring (9) and O-ring to sleeve

(5).
Assemble spring (8) to valve (71, and assemble

in sleeve (51, then install snap ring (6).
Assemble poppet (4) and spring (3) in sleeve

(5).
Screw adjustment screw (2) into sleeve (51, ad-

just so that protrusion dimension from end face
of locknut (I) is the same as when it was disas-
sembled, then secure with locknut (1).
w Locknut : 88.6 + 9.8 Nm I7 + 1 kgm}
+ Check and adjust the relief pressure.

Testing and adjusting pressure in work CAP03723
equipment, travel, swing circuits.
30-86
0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID
VALVE ASSEMBLY
A Disconnect the cable from the negative H ter-
2. Remove 4 solenoid wiring connectors (I) from

clip, then disconnect. m
t Record the connection number and the
connectiong position of the wiring.
3. Disconnect 9 hoses (2).

* Mark the connecting position of the hoses
with tags before disconnecting.
4. Remove mounting bolts (31, then remove sole-

noid valve assembly (4).
When removing solenoid valve as individual part

Remove nut (51, then remove solenoid valve (6).
a
INSTALLATION OF SOLENOID
VALVE ASSEMBLY
moval.
Check the connector 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 EQUIP-

MENT LEFT SIDE PPC VALVE
ASSEMBLY
(FOR ARM, SWING CONTROL)
A Lower the work equipment completely
to the

1. Remove boot (2) from cover (11, raise to top,

then remove lever (3).
* Check the direction of the lever. CEPO3646
2. Disconnect clamp (4).

* Remove the mounting bolts and move to-
wards rear.
4. Remove mounting bolts of PPC valve assembly

(5). then raise PPC valve assembly, and discon-
nect 6 hoses (6). m
5. Remove PPC valve assembly (5). m
INSTALLATION OF WORK
EQUIPMENT LEFT SIDE PPC
VALVE ASSEMBLY
(FOR ARM, SWING CONTROL)
moval.
m Hose joint bolt :

39.2 f 4.9 Nm I4.0 f 0.5 kgm)
t If there is excessive play in the control le-

vers, adjust the PPC valve. For details, see
TESTING AND ADJUSTING, Adjusting PPC
valve.
30-88
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT RIGHT SIDE PPC VALVE

MENT RIGHT SIDE PPC VALVE
ASSEMBLY
(FOR BOOM, BUCKET CON-
TROL)
g Lower the work equipment completely to the
1. Remove boot (2) from cover (11, raise to top,

CBPO3649
then disconnect wiring of horn, and remove le-
ver (3).
Ir Check the direction of the lever.
It Move cover (1) up.
2. Disconnect wiring clamp.
3. Remove mounting bolts of PPC valve assembly

(5), then raise PPC valve assembly, and discon-
nect 6 hoses (4). m
4. Remove PPC valve assembly (5). a

6
E
CEPO3650
2
EQUIPMENT RIGHT SIDE PPC
VALVE ASSEMBLY
(FOR BOOM, BUCKET CON-
TROL)
w in the reverse order to re-
l Carry out installation
moval.
m Hose joint bolt :

39.2 * 4.9 Nm t4.0 * 0.5 kgm)
Ir If there is excessive play in the control le-

vers, adjust the PPC valve. For details, see
TESTING AND ADJUSTING, Adjusting PPC
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 re-
placed.
3. Remove seal (6) and collar (7).
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 in-
stalling.
5. Pull out valve (13) from body (14).
30-90
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
ASSEMBLY OF WORK EQUIP-

MENT PPC VALVE ASSEMBLY
(FOR BOOM, ARM, BUCKET,
SWING CONTROL PPC VALVE)
1. Assembly valve (13) to body (14). 7. Assemble boot (3) and disc (2), and tighten
with nut (1).
2. Assemble shim (12) and spring (11) to valve
m Nut: 112.7 i 14.7 Nm Ill.5 + 1.5 kgm}
(13).
* When assembling spring (111, set the end * After assembling the disc, adjust the
with the small coil diameter (inside diam- height of the disc.
eter) at shim (12) end. For details, see TESTING AND ADJUST-
ING, Adjusting PPC valve.
3. Assemble spring (101, retainer (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 on the

bottom of the valve body.
& Piston : Grease (GZ-LII
* When assembling piston (8). coat the out-

side of the piston and the inside of the hole
in the body with grease.
- 5-7.1
4. Fit O-ring to collar (7) and assemble in body
(141, then install seal (6).
5. Install plate (5).
w Mounting bolt :
13.23 f 1.47 Nm II.35 2 0.15 kgm)
6. Install joint (4)
w Sliding portion of joint : Grease (G2-LI) CLIP03652
QZI Female thread of body :

Ir Coat two places on the female thread with

one drop each of Loctite as shown in the
diagram.
w 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
1. Remove floor mat.
2. Remove bottom cover.
3. Remove levers (1). a
4. Remove cover (2). a
5. Remove covers (3), then remove springs (4).
6. Disconnect 6 PPC hoses (51, and remove travel

PPC valve assembly (6). a
INSTALLATION OF TRAVEL PPC CBPO3654
VALVE ASSEMBLY
moval.
+ Adjust the travel lever.

Adjusting travel lever.
m Cover mounting bolt :

19.6 f 1.96 Nm I2.0 * 0.2 kgm)
w Hose mounting joint bolt (width across

fiats: 30mm) :
39.2 ? 4.9 Nm I4.0 + 0.5 kgm}
w Hose mounting joint bolt (width across
flats: 22mm) :
29.4 rt:4.9 Nm I3.0 + 0.5 kgm}
30-92
0
DISASSEMBLY OF TRAVEL PPC
1. Remove cover and cam assembly (I), then re-

move shims (2).
t Check the number and thickness of shims
(2) for each mounting position, and keep in
a safe place.
2. Remove plate (3).
3. Remove seal (4) and collar (5).
4. Pull out piston (6). and remove retainer (7),

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. Assemble shims (10) and spring (9) to valve

(II).
Ir Assemble the same number and thickness
of shims (IO) as was removed during disas-
sembly.
Standard shim thickness : 0.3 mm
* Spring (9) is not symmetrical at the top and
bottom, so assemble with the small coil di-
ameter (inside diameter) at the shim end.
3. Assemble spring (8), retainer (7). and piston (6).
&& Outside circumference of piston, body hole

: Grease fG2-LI) CBPO3656
L
4. Fit O-ring to collar (5) and assemble in body
(II), then install seal (4).
5. Assemble plate (3)
6. Fit cover and cam assembly (I) and assemble

shims (21, then tighten with bolt.
xII1, Sliding portion of shaft, connecting por-

tion of lever and piston : Grease (G2-LI)
30-94
0
* Assemble the same number and thickness of

shims (2) as was removed during disassembly.
m Mounting bolt (a) :

27.93 ? 3.43 Nm (2.85 * 0.35 kgm}
m Mounting bolt (b) : b

30.87 f 3.43 Nm (3.15 + 0.35 kgm)
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 posi-
tion.
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 pis-

ton 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 An accumulator is not installed, so loosen the

4. Disconnect left and right hoses (5).

CBPO3659
6. Remove plate, and remove bottom pin (61, then

remove boom cylinder assembly (2). 1121
t There are shims installed, so check the
place.
& kg Boom cylinder assembly : 105 kg
30-96
0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOM CYL-

INDER ASSEMBLY
moval.
& Inside surface of bushing when assem-

bling pin : Anti-friction compound (LM-PI
& Greasing after assembling pin :

Grease (LM-G)
A When aligning the position of the pin hole,

never insert your fingers in the pin hole. DBPOOE.15
Ir Adjust the shim thickness so that the clear-

ance between cylinder rod (7) and plate (8)
is below 1 mm.
Ir Standard shim thickness : 1.0 mm


Grease (LM-G)
6
E
never insert your fingers in the pin hole.
z Ir Adjust the shim thickness so that the clear-
ance between cylinder bottom (9) and
bracket (10) is below 1 mm.
Ir Standard shim thickness :
1 .O mm, 2.0 mm
l Bleeding air
Ir Bleed the air from the cylinder.
Bleeding air from hydraulic cylinder.

Ir Add oil through the oil filler to the specified
level.
30-97
0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
a Curl the bucket and arm in, lower them onto a
block, then set the safety lock to the LOCK po-
sition.
1. Sling arm cylinder assembly.
2. Disconnect grease tube (I).
3. Remove head pin (2).

lock plate, then remove
m
Ir There are shims installed, so check the
place.


sleeve nut of the hose slowlv and check that
7. Raise arm cylinder assembly, remove plate, then

remove bottom pin (51, and remove arm cylinder
assembly (6). /EJ
* There are shims installed, so check the
place.
c+ kll Arm cylinder assembly : 80 kg
30-98
0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM CYLIN-

DER ASSEMBLY
moval.


Grease (LM-G)

never insert your fingers in the pin hole. DBP00517

ance between cylinder rod (7) and bracket
(8) is below 1 mm.
Standard shim thickness : 1 .O mm
Inside surface of bushing when assem-

bling pin : Anti-friction compound (LM-P)
Greasing after assembling pin :

Grease (LM-G)
6 A When aligning the position of the pin hole,

5 never insert your fingers in the pin hole.
2 * Adjust the shim thickness so that the clear- DBP00518

* Standard shim thickness : 1 .O mm
l Bleeding air
Ir Bleed the air from the cylinder.
w

level.
30-99
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET CYLIN-

DER 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 link and arm.
3. Sling bucket cylinder assembly.

CBPO3667
4. Remove lock bolt (1). a
5. Remove lock plate, then remove head pin (21, and

tie piston rod with wire to prevent it from coming
out. a
A If pin (2) comes out, link (7) will fall, so be

careful that block @ does not come out.
place.

UJ CBPO3666

8. Raise bucket cylinder assembly, remove plate,

then remove bottom pin (51, and remove bucket
cylinder assembly (6). a
place.
ILIkm Bucket cylinder assembly : 60 kg A 3 CBP03669
30-l 00
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKET
o
moval.
.@j=
-- ------
---.---- --
Ir When tightening the locknut, tighten so that
the clearance between the plate and nut is _-
0.5 - 1.5 mm. 0. 5-l. 5un
CEP00059
6 Inside surface of bushing when assem-
xTI1, Grease after assembling pin:

Grease (LM-G) I Max Inn

* Adjust the shim thickness so that the clear-
ance between link (8) and link (7) is below 1
mm.
Standard shim thickness :
1.0 mm, 2.0 mm
Inside surface of bushing when assem- D0P00519
Grease after assembling pin: I
Grease (LM-G)

Ir Standard shim thickness : 1 .O mm
l Bleeding air
Ir Bleed the air from the cylinder. DBP00520
For details, see TESTING ADN ADJUSTING,

level.
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

head mounting pin (2). m
place.

Q, An accumulator is not installed, so loosen the

4. Disconnect hoses (3).
5. Remove bottom pin (41, and lift off blade cylinder

assembly (1). m
place.
r9 LP Blade cylinder assembly : 50 kg
30-102
0
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER
INSTALLATION OF BLADE CYL-

INDER ASSEMBLY
moval.
(XI

* Assemble the shims securely to their origi-
nal position.
l Bleeding air
+ Bleed the air from the cylinder.

level.
30-l 03
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
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.
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) Remove piston assembly (5) and retainer

(6).
l Retainer (6) is used for the boom and
arm cylinders only.
4) Remove plunger (7).
l Boom and arm cylinder only
5) Remove collar (8) and head assembly (9).
I CBP03677
30-104
0
6) Remove cap (12), pull out 9 balls (101, then

remove plunger (11).
l Arm cylinder only
I CBPO3678
Boom, arm, bucket cylinder

3. Disassembly of piston assembly
I) Remove wear ring (13).
2) Remove piston ring (14).
fl:
6
s
w CBPO3679
Blade cylinder
ti:
CtlPO3680
30-105
0
Boom, arm, bucket cylinder

4. Disassembly of cylinder head assembly
1) Remove O-ring and backup ring (15).
22
2) Remove O-ring (17). I5
3) Remove snap ring (18). then remove dust
seal (19). 21
4) Remove rod packing (20).
5) Remove buffer ring (21).
6) Remove bushing (22). 20 17
I
CBP03661
I I
,Blade cylinder ,
20
22
19 111
I CBPO3662 1
30-l 06
0
DISASSEMBLV AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
Ir Be careful not to damage the packings, dust
seals, and O-rings.
Ir Do not try to force the backup ring into position.
Warm it in warm water (50 - 60C) before fitting
it.
I, Assembly of cylinder head assembly
I) Using tool E6, press fit bushing (22).
2) Assemble buffer ring (21). CAP03683 ' CAP03684
3) Assemble rod packing (20).
47 Using tool E7, install dust seal (197, and se- 22

cure with snap ring (18). I5
57 Install backup ring (15) and O-ring. 21
6) Install O-ring (17). 20 I7
I9
Ia CBPO3681
2. 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, and compress piston

ring (14).
CAP03688 CAP03687
3) Assemble wear ring (13).

Ir Be careful not to open the end gap of
the ring too wide.
6 Ring groove : Grease (G2-LII
CBPO3879
30-l 07
0
3. 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 head assembly (9).
3) Fit O-ring and backup ring, and assemble

collar (8).
l Boom and arm cylinder only CBPO3678
4) Assemble plunger (71.

l Boom and arm cylinder only
5) Assemble retainer (61.

l Boom and arm cylinders only
6) Assemble piston assembly (5).
7) Set piston rod assembly (2) to tool El.
8) Using tool E3, tighten nut (4).
A Nut : Thread tightener (LT-2) I CBPO3677
m Nut:
21 2597 f 259.7 Nm (265 * 26.5 kgm)
Bucket 2156 f 215.6 Nm 1220 f 22 kgm} I

Blade 3969 f 399.9 Nm (405 f 40.5 kgm)
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

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

MENT 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 posi-
tion.
1. Disconnect grease tube (I 1.
2. Sling boom cylinder assembly (2). remove lock

plate, then remove head pin (3). m
place.
3. Lower boom cylinder assembly onto stand.

4. Disconnect hoses (4) and (51, and secure to

valve with rope.
* Install blind plugs at the male end and in the
disconnected hoses.
I
5. Disconnect
lamp.
wiring connector (6) for working
I 5 CEPO3666
6. Disconnect grease hose (7).
7. Raise work equipment assembly, remove plate,

then remove foot pin (8) using tool F, and remove
work equipment assembly (9). B
+ There are shims installed, so check the
place.
r%ke Work equipment assembly : 1000 kg
CBPO36.99
CBPO3690
30-110
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
EQUIPMENT ASSEMBLY
moval.

& Grease after assembling pin :

Grease (LM-G)

DBP00521
ance between cylinder rod (IO) and bracket
(11) is below 1 mm.

Grease after assembling pin :

Grease (LM-G)

never insert your fingers in the pin hole. 0BP00522
t Adjust the shim thickness so that the clear-

ance between boom (12) and bracket (13) is
below 1 mm.
* Standard shim thickness :
0.5 mm, 1.0 mm
l Bleeding air
* Bleed the air from the cylinder.

level.
30-111
0
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET ASSEM-

BLY
a 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 posi-
tion.
1. Remove rings (1 I and (2).
2. Pull out pin (31, and remove connecting pin (4)

between link and bucket. a
Sr There are shims installed, so check the
number and thickness, and keep in a safe CBPO3691
place.

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
place.
5. After raising work equipment, swing to discon-

nect bucket assembly (8). 3694
&I kg Bucket assembly : 215 kg
COP03695
30-112
0
DISASSEMBLY AND ASSEMBLY BUCKET
INSTALLATION OF BUCKET AS-

SEMBLY
moval.


Grease (LM-Gl
A When aligning the position of the pin hole, I * DBP00523

ance between bucket boss (9) and link (IO)
is below 1 mm.
Standard shim thickness : 1.0, 1.6, 3.2 anti-friction
mm

bling pin, inside surface, end face of spacer
(12) : Anti-friction compound (LM-P)

Grease (LM-G) / -11 DBPOO524

Ir Insert the O-ring at the end face of the
bucket boss securely.
ance between arm top (11) and spacer (12)
is below 0.5 mm.
Ir Standard shim thickness : 0.5 mm
30-l 13
0
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY

1. Remove bucket assembly.
For details, see REMOVAL OF BUCKET ASSEM-
BLY.
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 posi-

tion.
CBPO3696
4. Set block @ between arm cylinder and boom.
6. Remove lock plate, then remove arm cylinder

head pin (3). m
place.
7. Start engine,and retract piston rod, then tie pis-

A An accumulator
the sleeve
is not installed, so loosen
nut of the hose slowly and
CBPO3699
check that no oil spurts out before remov-

ing.

disconnected hoses.
10. Remove elate, then remove connecting _.pin (6) be-

tween arm and boom. m
place.
ll After raising boom, swing to remove arm and

bucket cylinder assembly (I).
& ks Arm, bucket cylinder assembly (including

link) : 240 kg
30-l 14
0
DISASSEMBLY AND ASSEMBLY ARM
INSTALLATION OF ARM ASSEMBLY

moval.


Grease (LM-G)

(8) is below 1 mm.
* Standard shim thickness : 1.0 mm
a Inside surface of bushing when assem-


Grease (LM-G)
A When aligning the position of the pin hole, Max. 0. 5hm

+ Adjust the shim thickness so that the clear-
ance between boom top (9) and arm bottom
(10) is below 0.5 mm.
Ir Standard shim thickness :
0.5 mm, 1.0 mm
l Bleeding air
4 For details, see TESTING AND ADJUSTING,

+ Add oil through the oil filler to the specified
level.
30-l 15
0
DISASSEMBLY AND ASSEMBLY BUCKET l ARM
REMOVAL OF BUCKET l ARM

ASSEMBLY
a Curl the bucket and arm in, lower them onto a
block, then set the safety lock to the LOCK po-
sition.
A Loosen the oil filler cap slowly to release

pressure inside the hydraulic tank.
the
1. Set block @ between arm cylinder and boom.
3. Remove lock plate, then remove arm cylinder

head pin (2). m
place.

g An accumulator is not installed, so loosen

the sleeve nut of the hose slowly and
ing.
CBPO3704

disconnected hoses.
7. Remove lock plate, then remove connecting pin

(5) between arm and boom. a
8. After raising boom, swing to remove bucket

and arm assembly (6).
place.
& LP Bucket, arm assembly : 450 kg
30-116
0
DISASSEMBLY AND ASSEMBLY BUCKET. ARM
INSTALLATION OF BUCKET l
ARM ASSEMBLY
moval.
6 Inside surface of bushing when assem-


Grease (LM-GI
a When aligning the position of the pin hole, DEP00517

(8) is below 1 mm.
* Standard shim thickness: 1.0 mm


Grease WI-GI
A When aligning the position of the pin hole, DBP00525

ance between boom (9) and arm bottom
(IO) is below 0.5 mm.
0.5 mm, 1.0 mm
l Bleeding air
For details, see TESTING AND ADJUSTING

level.
Run the engine to curculate the oil through
30-l 17
0
DISASSEMBLY AND ASSEMBLY BOOM
1. Remove bucket and arm assembly.

For details, see REMOVAL OF BUCKET, ARM
ASSEMBLY.
2. Lower boom assembly completely to ground,

and set safety lock lever to LOCK position.
4. Sling boom cylinder assembly (27, and remove

lock plate then remove head pin (3). m
place.
5. Lower boom cylinder assembly onto stand.
A An accumulator is not installed, so loosen

the sleeve nut of the hose slowly and
ing.
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.
5 CBPO3688
7. Disconnect wiring connector (6) for working

lamp.
9. Raise boom assembly and remove plate, then

remove foot pin (8) using tool F.
10. Lift off boom assembly (9). a

place.
& km Boom assembly (with arm cylinder) : CBPO3689
445 kg
CBPO3706
30-118
0
DISASSEMBLY AND ASSEMBLY BOOM
INSTALLATION OF BOOM AS-

SEMBLY
moval.


Grease (LM-G)
A When aligning the position of the pin hole, DBPDO521

(11) is below 1 mm.


Grease (LM-G)
A When aligning the position of the pin hole, DBPD0522

ance between boom (12) and bracket (13) is
below 1 mm.
0.5 mm, 1.0 mm
l Bleeding air

+ Add oil through the oil filler to the specified
level.
30-119
0
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE ASSEMBLY

A Swing the work equipment
equipment to the ground,
45. lower the work
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.
A 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.
CBPO3707
2. Sling blade cylinder assembly (lb, and remove
bottom pin (2). m
* Start the engine, retract the blade cylinder
rod, then lower it onto a block.
place.
3. Sling blade assembly, and remove left and right

pins (3). m
place. 6
5
CEPO3708 z
4. Remove blade assembly (4).
&I kg Blade assembly : 350 kg
INSTALLATION OF BLADE AS-

SEMBLY
moval.

Ir Insert the shims securely.

t Assemble the shims securely to their origi-
nal position.
30- 120
0
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
REMOVAL OF OPERATORS
CAB ASSEMBLY
1. Remove floor mat.
2. Disconnect speaker wiring (I), room lamp wir-

ing (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.
CBPO3709
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 operators cab assembly (6).
& ha Operators cab assembly : 250 kg
INSTALLATION OF OPERATORS CBPO3710
CAB ASSEMBLY
moval.
CBPO3
CBPO3712
PC60-7 30-121
0
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
Serial No. : 52374 - 57999
2. Remove cover (I) at intake hose side.
3. Disconnect reservoir tank hose (2).
2- CBPO2920
4. Disconnect window washer tank hose (3) and

connector (4).
5. Set eyebolts @ to counterweight assembly (51,

and sling.
3- CBPO292 1
6. Remove 4 mounting bolts (4), then lift off coun-

terweight assembly (5). (.
r+ kg Counterweight assembly : 650 kg
INSTALLATION OF COUNTER-
WEIGHT ASSEMBLY
Serial No. : 52374 - 57999

moval.
If
& Thread of counterweight bolt :
mounting
m Counterweight mounting bolt :

549.2 + 58.8 Nm I56 & 6 kgm)
* When installing the counterweight, adjust

so that the clearance and stepped difference
is uniform on the left and right.
30-122 FCbO-7
0
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
1. Remove engine hood.
2. Disconnect reservoir tank hose (I 1.
3. Remove air intake hose (2).

Ir Disconnect clamp (3).
5. Remove window washer rank (5) from bracket.
6. Set eyebolts @ to counterweight assembly (6),

and sling.
7. Remove mounting bolts, then lift off counter-

weight assembly (6). 1111
&I kg Counterweight assembly : 715 kg
INSTALLATION OF COUNTER-
WEIGHT ASSEMBLY
* Carry out installation in the reverse order to re-

moval.
6 Thread of counterweight mounting bolt :

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
MONITOR
DISASSEMBLY AND ASSEMBLY SWING CONTROLLER
REMOVAL OF MONITOR AS-

SEMBLY
A. Drsconnect the cable from the negative
(-) ter-
1. Remove boot (2) from cover (1). raise to top,

then remove lever (3).
* Check the direction of the lever.
2. Disconnect horn wiring. .
3. Remove
(4).
cover (lb, and disconnect 3 connectors e CBPO3713
4. Remove monitor assembly (5) from cover (I 1.

m
INSTALLATION OF MONITOR
ASSEMBLY
6 movaf.
;5
r m
w Mounting nut of monitor assembly :

8.33 + 0.49 Nm (0.85 _+0.05 kgmf
TROLLER ASSEMBLY
A Disconnect the cable from the negative
t-j ter-
- CBPO3715
1. Tip operators seat over to front, then discon-
nect wiring connector (I 1 under operators seat.
2. Remove mounting bolts, then remove controller

assembly (2).
INSTALLATION OF SWING
CONTROLLER ASSEMBLY
W moval.
30-123
0
AUTO-GREASING CONTROLLER
DISASSEMBLY AND ASSEMBLY AUTO-GREASING PUMP
REMOVAL OF AUTO-GREASING
CONTROLLER ASSEMBLY
2. Disconnect 3 wiring connectors (1).

connecting.
3. Remove 2 mounting bolts, then remove control- CBP03716
ler assembly (2).
INSTALLATION OF AUTO-
GREASING CONTROLLER AS-
SEMBLY
moval.
PUMP ASSEMBLY
A Disconnect the cable from the negative (-) ter-
2. Remove 2 wiring connectors (1). and disconnect

hose (2). m
3. Remove 2 mounting bolts, then remove pump

assembly (3).
GREASING PUMP ASSEMBLY
moval.
a
+ Bleeding air inside circuit
For details, see Bleeding air from auto-
greasing device.
30-124
0
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. Check item Criteria Remedy
Standard clearance Clearance limit

1 Clearance between bear- Replace
ing and circle 0.3 1.2 2.0
PC60-7 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
Horizontal width of idler

2 guide
40-4
MAINTENANCE STANDARD IDLER
IDLER
Unit: mm
Standard size Repair limit

Outside diameter of
protrusion of idler 460 452
2 Outside diameter of tread

415 407
I of idler
Rebuild or
3 Width of protrusion of idler 43 37 replace
4 Overall width of idler 100 92
5 Width of tread of idler 28.5 32
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
6 Clearance between shaft
and bushmg
44 -0.250 +0.062 0250 - 1.5 Replace
-0.290 0 0.352 bushing
7 Play of idler in axial

Repair limit :1.5
direction I
Thickness of idler tread Rebuild or
8 (thickness at tread surface) 12 8 replace
PC&7 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 149
Overlay or
2 Outside diameter of tread 120 113 replace
3 Width of flange 43 36.6
4 Overall width 129
Width of tread Overlay or

5 43 47.3 replace
Basic Allowance Standard Allowable

dimension Shaft Hole clearance clearance
Clearance between shaft
6 and bushing
0.250 +0.075 0.225
38 0.270 0.025 0.345 1.5

dimension Shaft Hole interference interference Replace
Interference between roller
7 and bushing
+0.117 +0.030 0.057
48 +0.087 0 0.117
Standard clearance Allowable clearance

Side clearance of track
8 roller (Each side) 0.38 0.73 1.5

Thickness of tread Overlay or
9 replace
(at center of width of tread) 36 32.5
40-6 PC60-7
(11)
MAINTENANCE STANDARD TRACK ROLLER
Serial No.: 60157and up
Unit: mm
No. Item Criteria Remedy

projected part 139
Overlay or
2 Outside diameter of tread 110 103 replace
3 Width of flange 43 36.6
4 Overall width 136.6
Width of tread Overlay or

5 46.8 51.1 replace

dimension Shaft Hole clearance clearance
Clearance between shaft
6 and bushing
0.250 +0.165 0.230
40 0.270 0.020 0.435 1.5

dimension Shaft Hole interference interference Replace
Interference between roller
7 and bushing
+0.150 +0.025 0.075
44 +0.100 0.020 0.170
Standard clearance Allowable clearance

Side clearance of track
8 roller (Each side) 0.53 1.06 1.5

Thickness of tread Overlay or
9 replace
(at center of width of tread) 33 29.5
PC60-7 40-6-1
(11)
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
_
/
/
/;,-*
-..--_I ,*
1
~,.________. ..-._-__- _-----------. _________\-:
_------------ 7___.___~____________-.I__._.._..--~\
/,5 <_J
;/
I I\
SKP03173
Unit: mm

Rebuild or
1 Outside diameter of tread replace
82 78
2 Width of tread 100 - Replace

3 :,he-k$ness of carrier roller Rebuild or re-
10 8 place
PC40-7 40-7
0
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
TRIPLE SHOE, SWAMP SHOE
I \
9
Swamp shoe
SLPO3174
40-8 Pc60-7
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
Check item Criteria Remedy
Standard size I Reoair limit I

1 Link pitch
154.25 157.25
Turn or
replace
41.2 37.2
bushing
Triple 20 12
3 Height of It is possible to
grouser carry out lug
welding or re-
Swamp building until
repair limit has
been reached.
4 Height of link 74 70
Tolerance Standard
Standard
size Shaft 1 Hole interference
5 interference between
bushing and link If it exceeds
interference
limit, replace
6 Interference between
regular pin and link
If it is less than in-

Interference between
7 - terference limit, re-
master pin and link placewith oversize
8 Protrusion of bushing Adjust
Tightening torque of shoe Default : 118 * 20 Nm Tighten

g bolt (12 f 2 kgm, additional tightening : 90 f 103
Standard clearance I Clearance limit
26 18
Weld lug or
rebuild
14 4
Rebuild or
20 16 replace
. Turn or
12 Thickness of bushing 8.4 4.4 (Heavy) replace
PC60-7 40-9
0
MAINTENANCE STANDARD RUBBER SHOE
RUBBER SHOE
fi_------__+_j
\
f \\ j___il i .j, j
A
A-A SKPO3175
Unit: mm

1 Wear of lug height
30 5
2 Wear of roller guard 101 81

Replace
3 Wear of meshing portion

of sprocket 3 -2
4 Wear of roller tread height 28.5 23.5
40-10
HYDRAULIC PUMP
HYDRAULIC PUMP
0 0
El
CJ
0
Y
0
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 E
D ---I
SKP03177
40-l 2 PC60-7
HYDRAULIC PUMP
7-SPOOL OIL PRESSURE ASSIST TYPE (STANDARD + 1 SERVICE VALVE)
-c
l-l-GA D---l
I c
SKP03178
(STANDARD SPECIFICATION)
A-A
SKP03179
Unit: mm

Freelengthx OD Installedlength Installed load Free length Installed load Re@acf!
1 Cooler bypass valve spring - sprmg if
185.3 N damaged or
231.4 N
50.2 x 21.6 33 118.9 kg} deformed
123.6 kg} -
40-14
0
MAINTENANCE STANDARD HYDRAULIC PUMP
(STANDARD + 1 SERVICE VALVE)
A-A
SKP03180
Unit: mm

Freelengthx OD Installedlength Installed load Installed load
Replace
Free length
1 Cooler bypass valve spring I . spring if
. damaged or
231.4 N 185.3 N
50.2 x 21.6 33 (23.6 kg1 (18.9 kg) deformed
-
40-15'
I I
I 3
I 3
I I
I I
SKP03181

x OD InstalledlengthInstalledload
Freelength Free length Installed load
, Spool return spring
(work equipment, travel) 34.3 N 27.4 N
41.1 x 19.3 40.5 Replace
(3.5 kg) - 12.6 kg1 spring if
damaged or
2 Spool return spring 61.7 N 49 N deformed
(swing) 42.3 x 19.2 40.5 16.3 kg) - (5 kg}
54.9 N 44 N
3 Spool return spring -
(boom, arm) 42.3~ 19.2 40.5 (5.6 kg) 14.5 kg1
40-16
I I
I 3
1 3
I I
I I
2 2
.
B-0
SKP03182
Unit: mm
Spool return spring

(work equipment, travel)
139.7*22.1Nm
(14.25*2.25krml
140:22Nm
f14.25*2.251oml
SKP03183
Unit: mm
No Check item Criteria Remedy
Freelengthx OD Installedlength Installed load Free length Installedload

Pressure compensation
1
valve spring
13.7 N 11 N
28 x 14.4 14.5 Replace
Il.4 kg) - Il.12 kg)
spring if
damaged or
Pressure compensation 56 N 44.7 N deformed
2 valve spring 33.4 x 14.4 21.5 15.7 kg} - 14.56 kg)
-
Pressure compensation 27.7 N 22.2 N
3 -
valve spring 30.85 x 5.2 20 (2.82 kg} 12.26 kg)
-
40-18
139.7*22.lNm
(14.25*2.25bd
402 22Nm
4.25*2.25ksml
c-c
SKP03184
Unit: mm

Free length x 00 Installed length Installed load Free length Installed load
Pressure compensation
1
valve spring
13.7 N 11 N
28 x 14.4 14.5 {1.4 kg) Replace
- il.12 kg)
spring if
damaged or
56 N 44.7 N deformed
2 valve
Pressure
spring
compensation 33.4 x 14.4 21.5 15.7 kg) - (4.56 kg)
4
27.7 N 22.2 N
3 Pressure
valve compensation
spring 30.85 x 5.2 20 i2.82 kg) - (2.26 kg}
40-l 9
D-D SKP03185
Unit: mm

I
Standard size Reoair
r--- limit
-~ -
Replace
Freelengthx CID Installedlength Installed load Free length Installed load
Check valve spring spring if
damaged or
3.9 N 3.14 N
27.2 x 6.9 22 deformed
(0.4 kg} - (0.32 kg)
40-20
D-D
SKPO3186

x OD installedlength Installed load
Freelength Free length Installed load Re@ac?
sprmg If
1 Check valve spring
3.14 N damaged or
3.9 N deformed
27.2 x 6.9 22 (0.4 kg) - IO.32 kg}
PC60-7 40-21
SXPO7104
No. Check item

I
Criteria I Remedy

lengthInstalledload
FraelangthxOD Installed Free length Installed load Re@acf!
1 Lift check valve spring _ spring If
36.3 N 29 N
damaged or
55.7 x 22.3 44.9 - 12.96 kg)
deformed
13.7 kg)
40-22 Pc60-7
0
M-M
SXPO7105
PC60-7 40-23
0
MAINTENANCE STANDARD SELF-PRESSURE REDUCING VALVE
SELF-PRESSURE REDUCING VALVE
SXPO7106
40-24 Pc60-7
0
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
Unit: mm
I I
I
I I
I
Free length x OD Installedlength installed load Free length Installed load
, Spring
(reducing valve main)
19.6 N 17.7 N
19.2 x 7.2 16.1
G kg) - il.8 kg}
2 ZLZing 16.5 x 7.2 12.7 20.6 N 18.6 N

valve pilot) {2.1 kg} - Replace
il.9 kg}
spring if
damaged or
3 Spring 71 x 18 52 316.5 N 294.4 N deformed
(sequence valve large) (32.3 kg} - t30 kg)
Spring 149.9 N 133.3 N

4 (sequence valve small) 63x 10 54 i15.3 kg) -
I I I (13.6 kg)
.
5 Spring (safety valve)
PC60-7 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
Standard size Standard clearance Clearance limit

, Clearance between rotor
and shaft Replace
60 0.056 - 0.105 0.111
PC60-7 40-27
0
MAINTENANCE STANDARD CENTER SWIVEL JOINT
31.4*2.9Nm
~3.2~0.3knl
SFPO6909
Unit: mm

Clearance between rotor
1 Replace
and shaft 60 0.056 - 0.105 0.111
40-28 PC60-7
0
BLADE SPECIFICATION MACHINE

Serial No. : 52374 - 57999
=
-
-
=
-
-
I
I
.
-
D
T
SKP03193
Unit: mm

, t$cyhnc; between rotor
Replace
70 0.056 - 0.105 0.111
pC60-7 40-28-l
0
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

, Clearance between rotor
and shaft Replace
70 0.056 - 0.105 0.111
40-28-2 PC&7
0 0
MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
C-C D-O
SXPO7109
Unit: mm

x OD InstalledlengthInstalledload
Freelength Free length Installed load
1 Centering spring Replace
108N 86 N spring if
48.1 x 15.5 32.5 111 kg1 - 18.8 kg} damaged or
deformed
17 N 14N
2 Metering spring 26.5 x 8.15 24.7 {1.7kg} - t1.4 kg)
40-30 PC60-7
0
MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
NO. Check item Criteria Remedy

Free length x OD Installedlength Installed load Free length Installed load
1 Centering spring Replace
124.5 N 100.0 N spring if
33.6 x 15.3 28.4 {12.7 kg) - (10.2 kg1 damaged or
deformed
2 Metering 16.7 N 13.7 N
spring 22.7 X 6.1 22.0 Il.7 kg} - Il.4 kg}
40-3 1
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
A-A E-E
J-J
N-N
F-F
K-K
SLPO3837
40-32
Unit: mm
\ No. r Check item Criteria

1
Remedy
Standard Tolerance T Standard Clearance

Clearance between bush- size Shaft Hole clearance limit
1 ing and mounting pin of
revolving frame and boom - 0.030 +0.174 0.130 -
65 -0.100 +O.lOO 0.274 1.0
*
Clearance between bush-
ing and mounting pin of +0.174 0.130 -
2 1 60 1 :;:f;; +O.lOO 0.274 1.0
boom and arm
ing and mounting pin of - 0.225 - 0.062 0.105 -
3 50 - 0.285 -0.120 0.223 1.0
boom and arm
- Replace
ing and mounting pin of -0.225 - 0.062 0.105 -
4 50 - 0.285 .-0.120 0.223 1.0
boom and arm
+0.149 0.325 -
5 +O.lOO 0.434 1.0
+0.173 0.130 -
6 +O.lOO 0.273 1.0
-
. Clearance between bushing
and mounting in of track -0.225 +0.142 0.105 -
7 frame and bla Be 50 -0.287 +0.080 0.229 1.0
(blade specification machine) 1
40-33
DIMENSIONS OF WORK EQUIPMENT

1. Arm
40-34 PC60-7
(11)
Unit: mm
PC60-7
No. Allowance
Measuring point Basic dimension
Shaft Hole
1 60 0.030 + 0.100
0.100 0
Arm side 71.5 + 1.0
0
2
Cylinder head side 70 1.2
3 60 0.030 + 0.100
0.100 0
Boom side 220 + 0.5
0
4
220 0.5
Arm side 1.0
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 50 0.225 0
0.285 0.150
1.0
Link side 200 2.0
18
+ 2.0
Bucket side 200 0
19 50 0.225 0
0.285 0.150
20 Arm as individual part 188 0.5
1.0
When pressfitting 0.5
21 200 1.4
bushing
Min. 1,055 1.5
22
Max. 1,765
PC60-7 40-34-1
(11)
2. Bucket
i
A-A
SKP03838
Unit: mm
NO. PC60-7 NO. PC60-7
1 309.8 12 71
2 [ 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 16 0115
6 1 143.7 I 17 I 95
71 - 1 18 1 75
8 60' 19 60
9 050 20 60
10 200 21 211
11 I 40 1 22 ] 24
40-35
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
l The diagram shows the boom cylinder.
m y; :961i96. lNm(98*9. aknl ~2. 6OiO. 26Nm(265*26. 5kPml (Width across f lats:70mml
:785*76.5Nm(ao*a. Okml :2. 65iO. 26Nm(270*27kPnl (Width across flals:65mm)
Bucket:See below Bucket:2. 16*0. 22Nm(220*22krmt (Width across flats:60mm)
Blade :981*9a. ONm(lOO* 10. Okml
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 Criteria Remedy
I I
-
Name of Standard Tolerance Standard Clf?yr$ce
cylinder size Shaft Hole clearance
- -
Boom 65 0.030
- 0.070 +0.250
+0.055 0.085 0.326 0.426
Clearance
1 between piston Arm -0.030 +0.151 0.024 - Replace
rod and bushing 60 -0.076 +0.006 0.227 0.327 bushing
- -
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
-
- 0.030 +0.174 0.130 -

Clearance Arm 60 -0.100 +O.lOO 0.274 1.0
2 between piston
rod support shaft
and bushing - 0.030 +0.174 0.130 -
Bucket 50 -0.100 +O.lOO 0.274 1.0
- -
Blade 70 0.030
-0.104 +0.174
+O.lOO 0.130 0.278 1.0
- Replace pin
and bushing
-
Boom 65 -0.030
-0.100 +0.174 ,
+O.lOO 0.130 0.274 1.0
- -
Clearancecylinder
between Arm 55 0.030
-0.100 +0.174
+O.lOO 0.130 0.274 1.0
3
bottom support
shaft and bushing -0.030 +0.142 0.130 -
Bucket 50 -0.100 + 0.080 0.274 1.0
- -
Blade 70 0.030
-0.104 +0.174
+O.lOO 0.130 0.278 1.0
-
40-36
50 OTHER SPECIFICATION
PC60-7 (For Norway) . .. . . . . .. .. . . . .. . .. . .. .. . .. . .. . .. . . 50- 3
PCbO-7 50- 1
0
PC60-7 (For Norway)
MACHINE MODEL SERIAL NUMBER
PC60-7 55720 and up (For Norway)
. This section contains only information related to the Norway specification.

For other information, see the PC60-7 Shop Manual.
PC60-7
CONTENTS
GENERAL
Dimension .............................................................................................................................................. 50- 5
Specifications ......................................................................................................................................... 50- 7
Weight table ........................................................................................................................................... 50- 9
Table of oil and coolant capacity ......................................................................................................... 50-l 1

Work equipment pin automatic grasing system (OPT) ..................................................................... 50-13
Electrical allocation diagram ............................................................................................................... 50-26
Electric circuit diagram ........................................................................................................................ 50-30
Machine monitor system ..................................................................................................................... 50-32

Connector types and mounting locations ..._........__............................. .... ....... ... .... ....... ............. ......... 50-35
TROUBLESHOOTING
Troubleshooting of machine monitor system . . .. . .. .. . . . .. . . . . . . . . . . . . . . . . .. . . . .. . . . . .. .. .. . ... . .. . . .. . .. . . . .. ... ... . .. . .. . . .. . . 50-41

Auto-greasing controller (OPT) .. . . . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . .. . . . . . . .. . . . . . . . ... . . . .. . . . .. .. . . .. . . . . .. . . .. . .. . . . .. .. .. .. .. . .. .. . . . .. 50-54
Auto-Greasing pump (OPT) .. . . .. .. . . . .. . . . .. . .. . . .. . . . .. . .. . .. . . .. . .. . . . . . . .. .. . . . . . ... . . . .. . . .. . . .. . .. . . . . .. . . .. . .. . . . .. ... . .. ... .. . .. . . .. 50-54
50-4 Pc60-7
0
GENERAL GENERAL
GENERAL
DIMENSION
.
* The vallues maked C%are for blade specification only.
Pao-7 50-5
0
GENERAL GENERAL
WORKING RANGE
Ir The vallues maked % are for shovel operations.
SVPO6836
50-6 PC60-7
0
SPECIFICATIONS
PC60-7
Machine model
Blade specification
Serial Number 55720 and up
Bucket capacity m3 0.25
Operating weight kg 6,700
Max. digging depth mm 4,100
Max. vertical wall depth mm 3,505
Max. digging reach mm 6,360
Max. reach at ground level mm 6,200
Max. digging height mm 7,150
Max. dumping height mm 5,015
Max. lifting height of blade mm 410
Max. lowering depth of blade mm 270
Max. digging force kN {kg) 47 (4,800)
Swing speed rpm 12
Swing max. slope angle deg. 20
Travel speed Km/h Lo 2.8 Hi 4.5
Gradeability deg. 35
Ground pressure
kPa fkglcm? 30.40 iO.31)
(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, counterweight mm 750
Min. ground clearance mm 350
Tail swing radius mm 1,750
Min. swing radius of work equipment mm 1,750

mm 5,460
swing radius
Length of track on ground mm 2,130
Track gauge mm 1,700
Height of machine cab mm 1,750
Blade width x height mm 2,260 x 470
Pao-7 50-7
0
I
PC60-7
Machine model
Blade specification
Model 40102
Type 4-cycle. water-cooled, in-line, vertical, direct injection

No. of cylinders-bore x stroke mm 4- 102 x 120
Piston displacement e (cd 3.92 (3.9201
Flywheel horsepower W/rpm (HP/mm 44X5/1,750 {54.2/l ,750)

0
c Max. torque lljrpm (kgm/rpm 246/l ,200 c75/1,200}
[ Max. speed at no load rpm 1,950
t Min. speed at no load 950
rpm
t
Min. fuel consumption g/kWh fg/HPhI 230 (1721
Starting motor 24V. 4.5kW

Alternator 24V. 35A
Battery 12V. 70Ah x 2
Radiator core type CWXQ
Carrier roller (each side) 1

Track roller (each side) 5
Track shoe Assembly-type triple grouser, 39 (each side)
Type x No. Variable displacement piston type x 1

Discharge amount Umin 155
Set pressure MPa (kg/cm? 24.5 (250?
Type x no. 6-spool type x 1

Control method 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 Air cooled (CFT-1)
50-8 KtW-7
0
WEIGHT TABLE
These weights are for reference when handling or transporting components.
Unit: kg
PC60-7
Machine model
Blade specification
Engine assembly (excl. water, oil) 382

PTO (coupling) assembly 6
Serial No.: 55720 59774 31

Radiator, oil cooler assembly
Serial No.: 59775 and up 36
Revolving frame 638
Operators cab 260
Operators seat 20
Fuel tank (excl. fuel) 50
Hydraulic tank (excl. hydraulic oil) 58
Serial No.: 55720 58000 685

Counterweight
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 1,342

Track frame 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)
Unit: kg
PC60-7
Machine model
Blade specification
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 PC60-7
3
TABLE OF OIL AND COOLANT CAPACITIES

SELECTION ACCORDING TO AMBIENT TEMPERATURE CAPACITY ()
RESERVOIR KIND OF
FLUID 30 20 10 0 10 20 30 40C Specified Refill
SAE 30CD
SAE 10WCD
Engine oil pan 14.5 13
SAE 10W-30CD (11.0) (10.5)
SAE 15W-40CD
PTO case 0.5(0.35) 0.5(0.35)

Swing machinery 1.5 1.5
case SAE 30CD
Final drive case Engine oil
(left and right, 1.7 1.7
each)
Idler (left and SAE 30CD 0.06

right, each)
SAE 10WCD
SAE 10W-30CD 90 57
Hydraulic system SAE 15W-40CD
Hydraulic HO46-HM (Note 1)

oil
ASTM D975 No. 2 130

Fuel tank Diesel
fuel
1
0.21
Track roller 0.23
(each) Gear oil GO 140 <0.16
0.18>
Carrier roller 0.047

(each) ALBANIA EP-2
0.052
Cartridge for Grease Cartridge

automatic NLGI No. 2 : 0.5
greasing system +
(Note 2) NLGI No. 2 NLGI No. 0 (Note 3) Piping
: 1.5
Cooling system Coolant Add Komatsu genuine Super Coolant (AF-ACL) 16(10.3)
1: ASTM D975 No. 1 ( ) : Serial Number 58001 and up
< > : Serial Number 60157 and up
PC60-7 50-11
(11)
FUEL, OIL
Select the fuel and oil according to the ambi-
ent 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 indi-
cates the amount of oil added when the oil is
changed for normal inspection and mainte-
nance.
When starting the engine in ambient tempera-
tures of below 0C. even if the daytime tem-
perature rises to IOC, always use SAElOW
or SAElOW-30.
Note 1: For hydraulic oil H046-HM, use the oil rec-
ommended 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 Op-
eration 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 lubri-
cating performance.
ANTI-FREEZE
Komatsu genuine Super Coolant (AF-ACL) is
added at a proportion of 30% to the cooling wa-
ter, so there is no need to change the density for
temperatures down to -1 OC.
If the temperature goes below -lOC, adjust the
density according to the table below.
* Use tap water for the coolant.
5042 PCoo-7
0

WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
(OPT)
SLPO3625
1. Flow divider valve (0, @I, @I,@, 0) l Automatic greasing points

2. R.H. work equipment control lever No. 1 Greasing point
(boom RAISE) 1
1 @ 1 Arm, bucket connecting pin
3. Flow divider valve (@J,0, @I>,
4. Monitor panel 1@ I Arm, link connecting pin I
5. Hydraulic pump
6. Grease cartridge
7. Controller
9. Boom RAISE oil pressure switch 1 -6.J 1 Arm cylinder foot pin -7
10. Flow divider valve (@I>,
10 I Boom cylinder rod pin I
1@ I Boom cylinder foot pin I
@ Boom foot pin
I
PC60-7 50-13
0
1. SYSTEM DIAGRAM
Electric Ilresse
-,-
DURD
-
,I
&?I ;z
Main valvckelf-Pressure reducino valve)
I
SIartina switch
I I Pressure
RAISE oil
switch
Automatic
oreasine
1
m controller
I
Betters
THLT#-&
_--
t
m
a Monitor Panel
/
Flow divider valve Flow divider low divider valve
SKP04235
50-14 fC60-7
Co
2. OPERATION OF SYSTEM
. The automatic greasing system adds the . The amount of grease for each work equip-
hours of operation of the equipment, and ment pin is set according to the load on the
every time the total reaches 5 hours, it car- pin.
ries out greasing.
. The boom RAISE oil pressure switch signal
is used to detect operation of the work equip-
ment.
-_-_-_-______-__-_
Calculation ON ---
Susmnsion of
calculation calculation
oom, arm connecting pin
PC60-7
3. COMPONENTS OF SYSTEM
1) Controller
SLPO3826
1. Connector Input/output signals

2. Controller
CN-P44
3. Fuse
Specification
Model: LC2MP
4 1 Abnormality signal I output

1 5 1 Boom RAISE sianal I lnout I
6 Starting switch ON signal Input
50-M PCbO-7
0
2) Electric grease pump
SLPO3827
1. Motor Specification
2. Grease cartridge Model: LD05CP
3. Air bleed plug
4. Pump
5. Pressure switch
6. Connector
Pao-7 50-17
0
Operation
1. Greasing, pressurizing
l When motor (I) rotates in the normal direc-
tion, eccentric shaft (2) rotates counterclock-
wise and pump piston (4) is operated in a re-
ciprocal 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 dis-
charge 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 pres-
sure switch (11) is turned OFF, motor (I) starts
again and the pressurized condition is main-
tained.
SKP03829
50-18 PC60-7
0
. If abnormal pressure is generated in the cir-

cuit at discharge port P end, safety valve (12)
opens and releases the pressure to return cir-
cuit 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) ro-
tates clockwise.
. Pressure release spool (7) is moved to the left
( ) by pin (8) of eccentric shaft (2) and pres-
T
sure release hook (9). 1111,/1,,,,,,,
lZl~~~1,,,,,,,
11111/1,,,/,,,
. As a result, discharge port P and return cir-
cuit T are interconnected, and the pressure in
the circuit is released to cartridge (5). 1
. When this happens, pump piston (4) moves
in a reciprocal motion, but the discharged
grease flows to return circuit T, so the pres- 0
sure does not rise. 7
. When the pressure in the circuit drops, indi-
cator (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.
fC60-7 50-19
0
3) Flow divider valve

Type installed to revolving frame
b
SBPOI480

b. To boom cylinder foot pin @I
50-20 PC60-7
@j
Type installed to boom
b C d f
SBPO1461

b. To left boom foot pin @
c. To right boom foot pin @
d. To arm cylinder foot pin @J
e. To boom cylinder rod end pin @
f. To arm flow divider valve
P&50-7 50-2 1
CD
Type installed to arm
b C d e f
SBPOl462
a. From boom flow divider valve

b. To bucket cylinder foot pin @
c. To arm, link connecting pin @
d. To arm, bucket connecting pin @)
e. To boom, arm connecting pin @
f. To arm cylinder rod end pin @
50-22 PC&7
0
Structure A. Discharge port

B. Discharge port
C. Measurement chamber
D. Piston chamber
E. Oil passage
F. Supply port
1. Measurement piston
2. Head
3. Body
4. Spring
5. Spring retainer
6. Pilot piston
SAP01469
Operation
11 Supply
. When grease from the pump is supplied to I
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 measure-
ment piston (1) from oil passage E.
SAP01463
Pc60-7 50-23
0
. Measurement piston (I) is pushed down by

the grease in piston chamber D, and the
grease in measurement chamber C is dis-
charged 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) Resetting
. When the pump enters the pressure release
mode, measurement piston (I) is pushed back
up by spring (4).
l When this happens, the grease in piston
chamber D passes from oil passage E through
the inside of pilot piston (61, and enters mea-
surement chamber C to reset the system to
the initial stage in preparation for the next
time of actuation.
u SAP01465
50-24 Pc60-7
0
STFWCTURE AND FUNCTION WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
3) Boom RAISE oil pressure switch
a---
---
-
_
I
I
I
I
1
I Structure of circuit
SLPO4237
1. Plug Specifications
2. Switch Structure of contact : N.O. contact
3. Connector 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}
F3c60-7 50-25
0
ELECTRICAL ALLOCATION DIAGRAM (l/2)
+
SVPO6837
50-26 PC60-7
0
\
21
\
25
27
/ I 28
29
+
SVPO6838
PC60-7 50-27
0
(l/2)
INSIDE CAB
34
33
\
.36
37
SVPO5B39
50-28 PCbO-7
0
1. Front lamp
2. Working lamp
8. Additional light (Front)
9. Room lamp
10. Additional light (Rear)
11. Starting motor
12. Antenna
13. Glow plug
16. Window washer
18. Alternator
19. Fusible link
20. Battery relay
21. Battery
22. Electric grease pump (OPT)
23. Automatic greasing controller (OPT)
26. Heater unit
27. Additional light relay
28. Wiper motor
29. Horn
30. Horn switch
31. Speaker
32. Monitor panel
33. Fuel control dial
34. Starting switch
35. Fuse box
36. Swing lock prolix switch
37. Additional light switch
38. Radio
39. Wiper switch
40. Swing lock switch
41. PPC lock limit switc
42. Travel boost switch
(blade specification machine)
43. One-touch slow-down switch
44. Glow resistance
45. Alarm buzzer
46. Swing holding brake controller
50-29
Co

PC60-7 Serial No. 55720 and up for Norway.
t For details of this page, see page W-23.
:I
2::
, :I
_:
HEATER ER ELECTRIC CIRCUIT DIAGRAM
@ CONTOROL SWITCH
@I F/C ACT
SVPO5841
PC60-7 50-31
0
MACHINE MONITOR 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 ma-
chine. 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 warn-
ing when any abnormality is found in the
machine.
2. The pilot portion, which displays the op-
eration and the condition of the machine
3. The gauge portion, which always displays
the condition of the machine
l Switches for electrical attachments are also
installed inside the monitor panel.
50-32 PCbO-7
0
1. MONITOR PANEL
CN-PI
CN-P2
W-P3
Iit- Ch-K7
SLPO3154
Outline Input/output signals

l The monitor panel has a monitor display CN-Pl (monitor Dane11
function and switches for electrical compo- No Name of signal No Name of signal $ut,tt
nents.
. It has a built-in CPU (Central Processing Unit)
which processes the data and outputs the
display.
l A liquid crystal display is used for the gauge
display; lamps are used for the monitor dis- 15 I Starting signal IInput I
play. 1 6 1Coolant tempersture I Input )
CN-P2 (light switch) CN-P3 (heater switch)
PC60-7 50-33
0
STRUCTUREAND FUNCTION MACHINE MONITOR SYSTEM
12 II IO 9 6 7 6 SKP03155
1. Service meter 7. Heater switch (al)

2. Coolant temperature gauge 8. Preheating pilot lamp
3. Fuel level gauge 9. Automatic greasing caution lamp (~2)
4. Light switch 10. Swing lock pilot lamp
5. One-touch slow-down pilot lamp 11. Charge caution lamp
6. Fuel control dial 12. Engine oil pressure caution lamp
Symbol Display item Display range Display method
Engine oil Below When the starting switch is turned ON with the engine
0 b pressure 49kPaI0.5 kg/cm 1 running, the display is as follows:
Sp1po0520
Normal : OFF
-+ When there is Abnormal: ON (buzzer sounds if abnormality occurs
Charge amount defective charging
f3
C.-=.+ when engine is running)
a Automatic When there is Normal : OFF

abnormality *2
SKPO3168 greasing Abnormal: ON
el (left) lights up,
One-touch decel
Heater switch - Lo : Heater fan Lo %l

Hi : Heater fan Hi
Z3 Light switch - 1. Monitor panel lights up

sllm31u 2. Monitor panel, head light and work lamp light up
~1: The switch is installed, but it cannot be used.
~2: Works only on machines equipped with the automatic greasing system (Option).
50-34 tC60-7
0
STRUCTURE AND FUNCTION TESTING AND ADJUSTING

* Address column in the table indicates the addresses in the connector location diagram (3D drawing).
Ml2 KESl 3 -
Ml4 L 2 Fusible link
MJ L 1 2 1 Fusible link I Q-5 I

D8 IKESII 2 I Diode Ml61 1 1 1 Horn
DII 1~~~11 2 I Diode I-

DA1 I 1 4 I Diode (Solenoid) I-
DA2 4 Diode (Solenoid) -
El1 1 Heater relay in P-8
El2 I I I I Heater relay coil I- M22 1 1 1 I Horn switch I A-4

I
El3 1 Heater relay out -
El4 1 Ribbon heater -
FB1 I 6 I Fuse box 1 F-7

Hl ( 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 M 2 Optional power source -
K7 SWP 4 Fuel control motor F-7 M31 KESO 4 Wiper motor M-l
K33 2 Deceleration indicator - M32/ l-~i-1 Decceleration

~~ switch I D-1
I
K34 2 Deceleration indicator - M331 111 Decceleration switch t D-l t
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 light (Rear) 1 N-9 M40 1

;rr;;l boost pedal switch (for
c-1
( ( 1 ( B-terminal of starting motor ( P-2 ;~zJ~I boost pedal switch (for

Ml M41 1 C-l
1
M2 1 1 1 ( C-terminal of starting motor I P-3 M66 - 6 Wiper motor intermediate Q-2
M3 1 Engine stop solenoid Q-8 M67 - 2 Additional light switch F-4
M4 S 16 Intermediate N-2 M68 - 6 Additional light relay P-3
M5 1 R, E-terminal of alternator a-7 iiGl --T--i] Additional light intermediate I Q-3 I

M8 1 Light M-l M751 x I 2 I Sefty relay (s, R-terminal) I p-2 I
MC-M I I I Working lamp 1 K-9 M76 1 Sefty relay B-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 TESTING AND ADJUSTING
f, !jgi$.d Mounting location 11
Pl IAMd 16 1 Monitor panel 1 A-81 x3 - 1 Swing lock prolix switch F-6

P2 lKESl/ 4 1 Monitor panel I B-8I x4 I - I 1 1 Swing lock prolix switch I F-6
~3 IKESI~ 4 I Monitor panel I C-81x5 I M I 4 I Swing lockswitch ) E-l
P4 M 2 Buzzer K-4
P5 1 Fuel sensor M-9
P6 1 Fuel sensor M-9
P7 x 2 Water temperature sensor P-8
P13 1 Engine oil pressure switch Q-8
P44 SWP 6 Auto-greasing controller (OPT) B-3
Sl x 2 Swing pressure switch Q-3
s2 x 2 Swing pressure switch Q-4

Boom RAISE pressure switch
I 1 I
PPC hydrauirc lock swrtcn,
Sl4 M 2 intermediate F-2
T2 I-1 1 IG round to revolving frame I Q-6 I

T4 - 1 Alternator, B-terminal Q-8
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
T8 I I 1 I Battery relay, E-terminal I Q-7 I

VI I x I 2 1 PPC hydraulic lock solenoid 1Q-91
v3 x 2 Mode selection solenoid o-9
v4 x 2 Swing holding brake solenoid O-9
v5 ix 2 Speed selection solenoid o-9
50-36 PC60
0
STRUCTUREAND FUNCTION TESTING AND ADJUSTING
Pc60-7 50-37
0
STRUCTUREAND FUNCTION TESTINGAND ADJUSTING
SVPO5843 -t
50-38 Pao-7
0
(Y4)
MB
PC60-7
TROUBLESHOOTING
TROUBLESHOOTING OF MACHINE MONITOR
SYSTEM (M MODE)
Electric circuit diagram of the machine monitor systme.. ................................................................... 20-40

(3-second self-check is not carried out either) ....................................................................... 20-41
M-2 All the lamps remain lighting-up after 3-second self-check completed after
the starting switch turned ON ................................................................................................. 20-41
M-3 Some lamps do not light up during self-check (all lamps lights up for 3 seconds)
upon starting switch ON.. ........................................................................................................ 20-42
a) All gauge lamps do not light up (caution lamp does light up) ...................................... 20-42
b) Swing lock, auto-greasing failure or preheat does not light up
(all gauge lamps light up) ................................................................................................. 20-42
c) Charge caution lamp does not light up ........................................................................... 20-42
d) Engine oil pressure caution lamp does not light up.. ..................................................... 20-42
M-4 When turning ON the power (before engine starting), charge caution lamp
does not light up ...................................................................................................................... 20-43
M-5 When turning ON the power (before engine starting), engine oil pressure
caution lamp does not light up ............................................................................................... 20-43
M-6 At preheating,preheating indicator does not light up.. ........................................................ 20-44
M-7 Though the switch is operated, swing lock does not light up .............................................. 20-44
(engine oil pressure is normal) ............................................................................................... 20-45
M-9 Charge caution lamp lights up while engine running.. ........................................................ .20-45
M-10 Abnormality in engine water temperature gauge ................................................................. 20-46
a) Indicator remains in the lowest level (white range) and does not rise
after engine started ........................................................................................................... 20-46
Indicator goes in the red range though overheat does not occur. ............................... .20-46
Engine water temperature gauge lamp goes off ............................................................
c) 20-46
M-l 1 Abnormality in fuel gauge ....................................................................................................... 20-47
a) All segments of the fuel gauge go off .............................................................................. 20-47
b) Fuel gauge indicates FULL though the level is low ........................................................ 20-47
c) Fuel gauge does not indicate FULL though the tank is full.. ......................................... .20-47
M-12 Malfunction of the buzzer ........................................................................................................ 20-49
a) Buzzer does not sound ...................................................................................................... 20-49
b) Buzzer does not stop sounding ........................................................................................ 20-49
M-13 Service meter does not work while the engine is running ................................................... 20-50
a) When the charge caution lamp does not light up ........................................................... 20-50
b) When the charge caution lamp lights up, refer to the item M-9.. ................................. .20-50
M-14 Auto-greasing abnormality alarm lights up (Auto-greasing controller is normal). ........... .20-50
M-15 Illumination does not light up.. .............................................................................................. .20-51
a) Illumination at gauge section does not light up. ............................................................ 20-51
b) Illumination at the service meter section does not light up
(Service meter itself do work normally) ......................................................................... .20-51
PC60-7 50-41
0
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR

SYSTEM
CN-P44 (SWP6)
Boon UP switch I Power aource:24V 1
fi
--I slensl
Wiper switch
iii
I I
Noni tar Dene

Power rourre24V
Pore1 rourcr.24v
GND
GND
Start aisnal
Ctolull InI. ,1,01
Fuel level aeeser
Alarm buzzer
Illunination
(KESI)
Lloht
PIMI illumination
Power source .24v I u CN-HZ (L2) ( ( 1
IKESU_
Heater Hi
Heater Lo
Heater GND 1 , - .
-
N76
Horn snitch
Horn
SVPO5845
50-42 PC60-7
0
TROUBLESHOOTING M-l, M-2

(3-second self-check is not carried out either)
Cause Remedy

1* Replace
Is the voltage
between Pl (fe- Breaking wire or connec-
tion failure in the wire
male) (1) (2) and 2 YES Repair or
harness between Pl (1)
13) (41 normal? (2) - fuse2, or between Pl replace
- Is the fuse2 nor- (3) (4) - H2 (2) chassis
* Starting switch ,_ ma, ,not b,own _
ground
ON. NO off)? Check for cause
* 20 - 3ov. or fuse blown-
Blown-off fuse
NO off, and replace
the fuse
M-l Related electrical circuit
CN-Ml I
CN-P I I
* To the battery relay
Monitor Panel
APO0989
M-2 All the lamps remain lighting-up after S-second self-check com-
pleted after the starting switch turned ON
+ Before carrying out this troubleshooting, check for engagement failure at relating connectors.
t Before proceeding to the next step, make sure to restore removed connectors.
Ir Check the fuse before this troubleshooting.
Cause Remedy
PC60-7 50-43
0
TROUBLESHOOTING M-3
M-3 Some lamps do not light up during self-check (all lamps lights up
for 3 seconds) upon starting switch ON
al All gauge lamps do not light up

(caution lamp does light up)
Cause Remedy
befective monitor panel teplace
bl Swing lock, auto-greasing failure or preheat does not

light up (all gauge lamps light up)
1 YES
defective light bulb 3eplace
Is there breaking
wire in the bulb
of the item that -
zo;s not light
P lefective monitor panel 7eplace
-Visual check for NO
breaking wire in
bulbs.
c) Charge caution lamp does not light up
1 YES Ireaking wire in the

harge caution bulb 7eplace
Is there breaking
wire in the bulb ?
To the item M-4

l Visual check for NO
breaking wire in
the bulb.
d) Engine oil pressure caution lamp does not light up

engine oil pressure 3eplace
:aution bulb
Is there breaking
wire in the bulb 7
To the item M-5

* Visual check for NO
breaking wire in
the bulb.
50-44 fJc60-7
0
M-4 When turning ON the power (before engine starting), charge cau-
tion lamp does not light up
Ir Before carrying out this troubleshooting, check for en-

* Before proceeding to the next step, make sure to restore Cause Remedy
removed connectors.
Ir Check for the breaking wire in the bulb (lamp) before this
troubleshooting.
YES
1 , Defective monitor panel
between Pl (101
Breaking wire or contac
2 YES failure in the wire harnes Repair or
Is the voltage bet- between Pl (10) - Hl (7: replace
ween R-terminal 2115(alternator R-terminal
* Starting switch
M5 of the alterna- -
ON. -
N6 for and the chaws
.o-5v.
ground normal
_.^ Defective alternator Replace
* Startmg switch NW
ON.
* 0 - 5v.
M-4 Related electrical 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 proceeding to the next step, make sure to restore Cause Remedy
removed connectors.
* Check for the breaking wire in the bulb (lamp) before this
troubleshooting.
-2 YES
.-_ Defective monitor panel Replace
Is the continuity
YE iS between Pl (fe-
1 male) (9) and Pl -
FaT?ale) (3) nor-
I
Repair or
between the ter- harness between Pl (91 -
* Disconnect Pl. NO replace
minal P13 and the ii1 (101 -terminal P13
* Starting switch
ON.
l 0 - 5R or lower.
* Starting switch Defective engine oil sen.
Replace
ON. N0 sor
-0 - 5R or lower

lerninrl
CN-P 1 CN-H 1 CN-Pl3
QEnoine oil
Pressure sensor
Monttar panel
.
TAP0099 I
PC60-7 50-45
0
M-6 At preheating, preheating indicator does not light up

+ Before proceeding to the next step, make sure to restore
removed connectors. Remedy
* If the lamp does not light up also during the self-check
upon power ON, refer to M-2.
1 YES
Is the voltage
between Pl (13) - Breaking wire or contact
and (3) normal? failure in the wire harness
between Pl (female) (13) Repair or
Set the starting NO -TlD (starting switch RI) replace
switch to the ct;tcsctive starting
HEAT psition.
* 20 - 3ov.
I
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 en- Cause Remedy
removed connectors.
2 YES
Is the continuity
YES between Pl (fe-
, c male) (12) and -
failure in the wire bar.
the chassis
ness between Pl (female1
Is the continuity ground? Repair or
112) - Hl (9) - M4t3) - X5
between X5 _ *Disconnect Pl. NO [female) (1). or between replace
(male) (1) and *Swing lock X5 (female (2) - M4 (5) -
switch ON. chassis ground
* Disconnect X5. Defective swing lock

Replace
* Swing lock NO switch
switch ON.
M-7 Related electrical circuit diagram Swine loch switch
Won itor
TAP90993
50-46 PC60-7
0
(engine oil pressure is normal)

Cause Remedy
removed connectors.
YES Defective engine oil pres-

Replace
1 sure sensor
Does the engine

oil pressure cau- _
tion lamp go off? 2 YES
1 Defective monitor panel Replace
p Are Pl (female)
* Remove the ter- (9) and the chas-
minal P13. NO sis ground insu-
* Start the engine. Wire harness between ter-
lated? minal P13 - Hl (101 - Pl Repair or
(female) (91 touches the replace
- Continuity check NO
chassis ground
between Pl (female) (9)
and chassis ground.
- lMR-~4.

Terminal
ch-Pl Ch-H 1 ch-PI3
@Enoine oil
oressure Sensor
Monitor Panel
TAP00991
M-9 Charge caution lamp lights up while engine running

Ir Before proceeding to the next step, make sure to restore
removed connectors.
2 YES
Defective monitor panel qeplace
Is the voltage bet-
YES ween Pl (female)
1- 110) and (3) nor- Wire harnass between Pl
Is the voltage
bbt- mal?
Ween M5 (ma,e) ,,) , (10) - H1 (7), M5 (alterna. qepair or
tor R-terminal) touches ,eplace
R-termi-
(alternator - * Engine start. NO the chassis ground
nalt and the chassis * 20 - 3ov.
ground normal?
* Disconnect M5. Insufficient power gener
Xeplace
* Engine start. NO ation of the alternator
* 20 - 3ov.

terminal
CN-P I CN-H I CN-MB
@ A ternator
R- termanal
Monitor Panel
1
TAP00990
PC60-7 50-47
0
M-10 Abnormality in engine water temperature gauge
Cause Remedy
a) Indicator remains in the lowest level (white range) and

does not rise after engine started.
VES Defective engine water
Replace
1 temperature sensor
Level rises by
one step, and fi- Breaking wire or contac
nally all seg- 2 YES Repair or
between Pl (female) 16) -
Hl (5) - P7 (female) (1) or replace
* Starting switch one step, and fi- between Pl (female) (2) -
ON. chassis ground
NO nally all seg-
* Connect a short- ments go off.
circuit connector Defective monitor panel Replace
to P7 (female). * Starting switch ON. NO
. Make a-shortcircuit
between Pl (6) and
(3).

Indicator goes in the red range though overheat does not
occur. 2 YES
. II Defective monitor panel Replace
ts tne resrstance
Is the voltage
1 rl
YES value between P7
(male) (1) and (2) H
normal?
II
Defective engine water Replace
between Pl (3) _ Disconnect P7. NO
l
temperature sensor
and the body * Engine start.
earth normal? * Resistance: 4kR
or higher. Contact failure between Pl
*Engine start. Check and
* O.lV or lower. (female) (3) - H2 12) - chas- repair
NO sis ground
cl Engine water temperature gauge lamp goes off
VES Defective engine water

Replace
lA temperature sensor
Does the lowest

level lamp light -
up? 2 YES
Defective monitor panel ?eplace
- Is the resistance
* Starting switch L value between Pl
ON. NO (female) (6) and
. Disconnect P7 Wire harness between Pl
(3) normal? (female) (6) - Hl (5) - P7 qepair or
(female) (1) touches the ,eplace
* Disconnect Pl. NO
l Resistance: 1kR chassis ground, or leaks
or higher.

C&H 1
Coolant
Manlitor Panel
Ct+HP
rh
TAP00994
50-48 Pc60-7
0
M-11 Abnormality in fuel gauge
+ Before carrying out this troubleshooting, check for engagement failure at relating connectors.
Cause Remedy
a) All segments of the fuel gauge go off.

YES Defective fuel sensor
11 (Mode of braking wire i!
out of order)
Does the fuel
gauge indicates Breaking wrre or contact
FULL (all seg- - failure in the wire harness
2 YES between Pl (female) (7) - qepair or
ments llight up)? .
- Does the fuel H3 (6) - P5 (female), or bet- ,eplace
* Starting switch _ gauge indicates ween P6 (male) -chassis
ON. ground
. Connect P5 (fe_ NO FuLL ca.seg-
ments llrght up)?
male) and P6 Defective monitor panel qeplace
(male). * Starting switch ON.NO
*Wait for about 1 . Make a short-circuit bet-
minute. ween Pl (7) and (3).
*Wait for about 1 minute.
b) Fuel gauge indicates FULL though the level is low

3 YES
Defective monitor panel qeplace
YES Do all segments
- of the fuel gauge -
2 go off7 Wire harness between Pl
female) (71 - H3 (6) - PE qepair or
YES Is the resistance female) (1) touches the eplace
l Disconnect P5. NO
,- value of the sen- - :hassis ground
* Starting switch ON.
1 sor normal? *Wait for about 1
I -I minute.
between Pl (3) * Remove the sensor. Defective fuel sensor qeplace
* Moving the float by NO
and the chassis hand, measure the resistance bet-
ween P5 (male) and P6 (female).
- At position F: 10R or higher.
* Engine start. - At position E: 85fJ or higher. Zontact failure in Pl ffe-
:heck and
* O.lV or lower. nale) (3) - HZ (2) -chassis
h epair
yound
cl Fuel gauge does not indicate FULL though the tank is full
YES
, , Iefective monitor panel leplace
I
(Iontact failure between
LrzzA)&
. Measure the re-
YES
I1 (female) (3) - H2 (2) -
c:hassis ground
:heck and
epair
$~tfa~~ap;rars~~NO and the chassis

1 ground normal?
(female). 1Iefective fuel sensor leplace
* At postion F: 1OQ . Engine start. NO
or lower. . O.lV or lower.
PC60-7 50-49
0
TROUBLESHOOTING M-l 1
M-l 1 Related electrical circuit diagram
ch-PI Ch-HI ch-P6
Monitor bane
TAP00995
50-50 PC60-7
0
M-12 Malfunction of the buzzer
Remedy
a) Buzzer does not sound

11 Replace
When Pl (fe-
male) (15) and
(3) are connect- - Breaking wire or contact
ed, does the 2 YES failure in the wire harness
Repair or
buzzer sound? between P4 (female) (1) -
- Is the voltage replace
Pl (female) (15). or defec-
* Connect Pl (fe- between P4 (2) tive buzzer
;;;fef (15) and NO and chassis
ground normal? failure in the wire harness Repair or
* Start ing switch
ON. between fuse2 - P4 (fe- replace
* Start ing switch NO
ON. male) (2)
* 20 - 3ov.
I
b) Buzzer does not stop sounding

Cause Remedy
1 YES
Does the buzzer
stop sounding
when Pl is dis-
Wire harness between P4
connected?
(female) (1) - Pl (female) Repair or
l Disconnect Pl. NO (151 touches the chassis replace
- Starting switch ground
ON.
Ml2 Related electrical circuit diagram
PC60-7 50-51
0
M-13 Service meter does not work while the engine is running
Before carrying out this troubleshooting, check for en-

removed connectors. Remedy
When the charge caution lamp does not light up
1 YES
Is the voltage
between Pl (fe-
male) (101 and (31
mormal? Repair or
* Engine start. NO between Pl (10) - Ii7 M5 replace
* 20- 3ov. (alternator R-terminal)
b) When the charge caution lamp lights up, refer to the item M-9.

terminal
CN-Pl CN-H 1 Cly-M6
o Al ternatnr
0 R-terminal
Monitor Dane1
TAP00990
M-14 Auto-greasing abnormality alarm lights up (Auto-greasing control-

ler is normal)
* Before carrying out this troubleshooting, check for en- Remedy

Ir Before proceeding to the next step, make sure to restore
removed connectors.

1* Replace
Is the voltage
between Pl (1 lb
and Pl (3) nor- Breaking wire or contact
2 YES failure in the wire harness Repair or
mal? reolace
- Is the voltage between Pl (ll)-Hl (13)-
* Starting switch _ between P44 (4) P44 (female) (4)
l 18 - 30V. ground normal? Refer to the troubleshoot-
ing of the auto-greasing Replace
* Start ing switch NO controller
C-IN
-. .
M-14
*18-3ov.
Related electrical circuit diagram

I
ch-PI CN-H 1 ch-P44
Monitor Panel Auto-oressin controller
TAP00997
50-52 Pc60-7
0
M-15 Illumination does not light up
a) Illumination at gauge section does not light up. Cause
YES Breaking wire in the il-

lumination lamp (inside leplace
1 the monitor panel)
Is the voltage
Breaking wire or contacl
between Pl (fe- _
YES failure in the wire harness :epair or
male) (16) and
2 between Pl (female) (161 eplace
(3) normal? - P2 (female) (3)
- Is the voltage
* Starting switch
_ between P2 (3) _
, eii, swirch ON NO and the chassis 3 YES
teplace
* 20 - 3ov. ground normal? Is the voltage
* Starting switch _ between P2 (4) _
* Light switch ON. ground normal? harness between P2 ffe- lepair or
* 20 - 3ov. * Starting switch NO male) (4) - fuse4, or eplace
ON. blown-off fuse
* 20 - 3ov.
b) Illumination at the service meter section does not light up (Service meter itself do work normally)
Cause Remedy
Defective monitor panel leplace
To the work Iisht
Lioht switch
To the battery relsr
TAP00998
PC60-7 Xl-53
0
AUTO-GREASING CONTROLLER
TROUBLESHOOTING AUTO-GREASING PUMP

CONTROLLER ASSEMBLY (OPT)
dh Disconnect the cable from the negative f-1 ter-
2. Disconnect 3 wiring connectors (I 1.

connecting.
3. Remove 2 mounting bolts, then remove control-

ler assembly (2).
GREASING CONTROLLER AS-
SEMBLY (OPT)
moval.
PUMP ASSEMBLY (OPT)
A Disconnect the cable from the negative
(4 ter-
Open engine hood.
Remove 2 wiring connectors (I 1, and disconnect

hose (2). m
Remove 2 mounting bolts, then remove pump

assembly (3).
~o;;~SING PUMP ASSEMBLY

moval.
@?r Bleeding air inside circuit

For details, see Bleeding air from auto-
greasing device.
50-54 PC60-7
0
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. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Hydraulic tank
6. R.H. travel motor
7. Hydraulic pump
8. Control valve
9. Oil cooler
10. L.H. travel motor
11. L.H. work equipment PPC valve
12. R.H. work equipment PPC valve
13. Center swivel joint
14. Travel PPC valve
15. Blade cylinder
(blade specification machine)
17. Swing lock solenoid valve
SLPO3044
90-3
Serial No. : 52374 - 57999
1. Hydraulic tank
2. Hydraulic filter
I 3. Strainer
I A- 4.
5.
Breather
Hydraulic pump
6. Control valve
6A. Safety 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
7. Self-pressure reducing valve
8. Boom cylinder
9. Arm cylinder
10. Bucket cylinder
11. Blade cylinder
12. Center swivel ioint
13. Travel motor (i.H.)
14. Travel motor (R.H.)
15. Swing motor
16. R.H. PPC valve
17. L.H. PPC valve
18. Travel PPC valve
19. PPC shuttle valve
20. Solenoid valve
21. Oil cooler
90-5
$.
STANDARD SPECIFICATION
SOLENOID
---- V4LVE
PUMP PRESSURE
DETECTION PORT
[ } j BUCKET CYLINDER
/-SPOOL CONTROL VALVE 1 ?r LS

r----- w-1
L
I@----+ ARM CYLINDER
._----__________
RIGHT PPC VAtYE,:
~~--~._.___._..______________________-_-_____ IBUCKET DUMPI PA6
, 1 ,Nl -BOOM CYLINDER
PI1
(REVERSE) TRAVEL HOTOR

PI.7
_----._______________________________________ (BUCKfi CURL) PBS
_---..______,
P7
.___TL__~_________----______________ (BOOM LOWER) PB4
(ARM I Nl PB5
- (ARM OUT) PAS PA4

4----._________. I!! I
------!
_pR________________.___._____~,_____~
,[+& LEFT : 7
,
FORIAROI PA2 :
(REVERSE)
:LE
:TR
LS SELECT VALVE
SETTING
PRESSURE:
SELF-PRESSURE BRAKE
REDUCING VALVE RELEASE
PRESSURE:
p__
HYORAUL IC PUMP: LPV90
LS PRESSURE 1
DETECTION I-
;________________________________________..._.___________________~
ISUING TO LEFT1
CAP
p=-y BACK
CRACKING
PRESSURE VALVE
PRESSURE:
BYPASS
CRACKING
CHECK VALVE
PRESSURE:
SAFETY VALVE - 2. 9WPM 4.9WPI 0 13YPI 0 91YPI
SETTING PRESSURE : I30ko/cmI iSOk@/Cdl I I. 3k#/C.l Id. 3kdCll
0 03ato. OIsYPa (FOR PEAK CUII
IO. 39to. lske/cdI
CHECK VALVE )__
CRACKING PRESSURt
O-O. 004SYQa I__
IO-O. 046to/cmI
SUCTION BYPASS RETURN L_________________________________________

STRAINER STRAINER FILTER
PC&l-7 90-5-2
BLADE SPECIFICATION PUMP PRESSURE
:
Serial No. 58001 and up IJETECTlOh PC;RT
SLENO I D YAL%;E .____-__________-____________----------_-.__-.__.--_..__--.---.__.___.__

------1
B-SPOgL CONlR9t VALVE \ i LS

)I(
-1
/ @ j ARM CYLINDER
PA
___
BLADE PPC VALVE
RAlSE
LOWER
BUCKET 1 ,
._--*..__________
RIGHJ PPC VALVE,:
(REVERSE1 TRAVEL MOTOR
WJCKET CURL1 PBI
; i it-t-h I A4 ;_ [I
: I
III I
BOOM c) [r
,___.._________._____L~~_~. (ARM 0T) PAS
; l_P3k_..______________ P3B
1--.------ mDnmLswA4
RIGHT) PA1
(R(G9J
JIAYEL
___,---.,_46._._.______________________
---._P_L___..___________________. (R,GIJ JgAyEL
FOR1ARO~PA3
-_"______._________________-. JLfF, ,RAYEL
:LE (REVERSE)
;TR REVERSE1 P82
LS SELECT VALVE
SETTING
PRESSURE:
ELF-PRESSURE
19. IYPl BRAKE
EDUCING VALVE
l195kS/C~I RELEASE
_^___ __
LS PRESSURE/
DETECTION
----
[SUING TO LEFT1 :I ;:0
i__________..___....________~~____________________~_~
: ;--_______-____________________---_______-________________,
; :
CAP BACK PRESSUR; VALVE 8YPA;S CHECK VALVE :
SAFETY VALVE ;,R,XpKJNC PRESSURE: CRACKING PRESSURE:
2.9WPS ,.QYPl 0.81YPa
SETTING PRESSURE-
l30tD/CD'l 15Otr/cm'J (1. 3kdCdl (8. 3k0/CdI
0 03.9fO.015YP8
IFOR PEAK CUT1
io.39*0. !Skl/C.'l
CHECK VALVE
CRACKING PRESSURi
o-0.0045MPa
l0-0.046kO/Cn'I
SUClloN 0YPAjS RET.URN ~.._____---------_._____________________~

STRAINER STRAINER FILTER
K60-7
90-5-4
OTHERS OVERALL SYSTEM DIAGRAM
OVERALL SYSTEM DIAGRAM (l/5)

WHEN ALL CONTROL VALVES ARE AT HOLD
SKP04205
90-7
OVERALL SYSTEM DIAGRAM (2/5)

WHEN SWING IS OPERATED INDEPENDENTLY
I SKP04206
90-9

WHEN LEFT AND RIGHT TRAVEL ARE OPERATED AT SAME TIME
___-_-_ _-_---_-.-___
r---- t 1
1
I
I
I J
t
IB
- I
I
iT=
,
/I
L________.________ ___-__
I ----k--------
L SKP04207
90-11

WHEN BOOM + ARM ARE OPERATED AT SAME TIME
r r-
-_-_---_-_-_
-t
-_.___----_-_
1
,b
,. 1
I
r-
SKP04208
90-13

WHEN BOOM RAISE + SWING ARE OPERATED AT SAME TIME
r-
-Pr
I SKP04209
90-M
OTHERS ELECTRICAL ALLOCATION DIAGRAM
J
ELECTRICAL ALLOCATION DIAGRAM
19. Front lamp

20. Working lamp
26. Room lamp
27. Antenna
30. Glow plug
31. Starting motor
32. Window washer
34. Air conditioner compressor (option)
35. Alternator
36. Battery relay
37. Fusible link
38. Battery
40. Automatic greasing controller
43. Air conditioner unit
44. Wiper motor
45. Horn
SLPO3143
90-l 7
ELECTLIC CIRCUIT DIAGRAM
Serial No. : 52374 - 57999
SWING PRESSURf
ANTENNA
RADIQ
SWING LOCK
CO LE
II I PRESSURE SWITCH
IH LA
SPEAKER
INDICATOR
TRAVEL ALARM
ATER
r---------,
BATTERY
RELAY CND
1
HORN SWITCH
II
SWING RELEASE
STARTING
SWITCH
I TRAVEL ALARM ;
I____--__-_-_ -I
cw-P.
1 ALARM BUZZER
(BOdB) (A)
MOTOR RELLAY
CONTROLLER
pC60-7
90-19
3:
ELECTLIC CIRCUIT DIAGRAM
CAD!0 CONNECTjii
CONNECIIQN TABLE
:RhYEL SiLEClOR
PEDAL SiYJTCH ASS'Y
IFOR BLADE1
i------ 1
EL SPEED
I-__ 1
WIPER
INDICATOR
TRAVEL ALARM
r---------7
I BATTERY
RELAY GND
I
2:' :::J FUSE RING
SWITCH
1172
STARTING
SWITCH
i TRAVEFALARM /
PC&7 90-21
PC60-7 Serial No. 55720 and up for Norway.
PC60-7 90-23
OTHERS CONNECTOR TYPES AND MOUNTING LOCATIONS
Serial No. : 52374 - 57999
\ T4
I
Y76
Y26
M6
PC60-7 90-201
A
DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186
DATE: FOR INTERNAL USE ONLY -- No. PMR
NAME OF COMPANY: CITY:
) STATE OR PROVINCE::
DEPARTMENT: COUNTRY:
; NAME: FAX NO:
ANUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service
ANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:
ANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:
SOOK DESCRIPTION
IACHINE MODEL 8 S/N:
IANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS:
ROBLEM:
,ttach photo or sketch.

more space is needed, use another sheet.
FOR INTERNAL USE ONLY
:ORRECTIVE ACTION:
m
PROPFREV.WPD 071:

SM PC60-7 Sebd010911

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Copyright:

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SM PC60-7 Sebd010911

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Copyright:

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SEBM010911

Copyright 2004 Komatsu

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

00-1 (11) 10-3 10-43 (3) 10-85 10-119

30-46-40 (6) 30-67 (2) 30-121 (2) 50-7 (3) 90-9

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

Used to prevent rubber gaskets, rub-

Holtz Used as heat-resisting sealant for re-

Features: Silicone type, heat resist-

LM-G 09940-00051 60 g Can Used as lubricant for sliding portion

SYG2-400CA Used for normal temperature, light

Molybdenum Used for heavy load portion

SUNSTAR Used as primer for cab side

SUNSTAR "S" is used for high-tempera-

SUNSTAR Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 14.7 1.2 1.5

16 24 235 285 23.5 29.5

27 41 1150 1440 118 147

6 10 5.9 9.8 0.6 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 4.9 2.5 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 63 {3.5 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 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

CLASSIFICATION BY COLOR AND CODE