SEBM02010607 SOW" IMTAINIUZA\ Io KOMATSU PC60-6 PC6OL-6 PC90-1 MACHINE MODEL SERIAL No. PC60-6 28001 and up PC6OL-6 8001 and up PCg90-1 1001 and up © This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require Materials and specifications are subject to change without notice. ‘* PC6O, GOL and PC80 mount the 4D9SL-1 engine For details of the engine, see the 95 series engine Shop Manual. @CONTENTS 10 STRUCTURE AND FUNCTION 00... 0000 ton 20 TESTING AND ADJUSTING ........... seiseweveun@4 30 DISASSEMBLY AND ASSEMBLY Si 40 MAINTENANCE STANDARD ........c00. ssecessseess 404 020106020106 The affected pages are indicated by the use of the following marks. t is requested that necessary actions Indication Action required be taken to tase pages according to the table below. ial 7 Page to be newty added age tobe reolaced ‘Page to be doloted Pages having no marks are those previously revised! ‘or made additions, LIST OF REVISED PAGES Wen oe Mipset|wen toe Rie |wemn roe Seagh|ven tom Rinse wer] Ravan ware page MeNBCC Tomar rage ROMEO] wae Page “ex Pom Revber]min rege Sevton]wam rece Savhah|wan rome Rava" rae Memerl aan page Rewer oor gg 1021 © 10-53 | 1082 ® 2010 @ 02 2 1022 @ 10-54 1088 ® 20-11 ® © 021 F 10-23 10-55 1087 © 2042 OD © 0022 oO 1024 ® 10-56 1088 20-13 @ 00.3 1025 @ 1057 @ 1088 20-131 @ 00-4 10-251 6 10571 @ 1090 @ 2014 @ 00.8 10.252 © 10572 © | 1091 ® 2015 00-6 10.28 @ 10873 6 | 1092 20-15 @ 00.7 10.27 @ 10574 @ 1093 © | © 217 @ 00-8 | 1028 @ 1058 @ | 1094 20-18 O 00-9 10-29 ® 10-59 | 1095 @ 20-19 @ 00.10 | 10.291 © 10-60 1098 ® 2020 00-12 10-292 © 10-61 1097 © 2021 ® © 0013 @ | 1030 1081-1 @ | 1098 20.211 00-14 | toa 10612 6 1099 20-22 ® | 10-32 10813 @ 10.100 © 20-23 ® tor @ | 10.33 tose @ | 0101 © 20-24 @ 10-2 | 10.38 10-62 @) 20-25 @ 03 o 10.35 1062 @ 201 © 2028 @ 04 10-36 10-64 © 22 © 2027 @ 05 «© | 10.37 jos © 8 3 OD 20.28 ® 106 =O 10871 © 1066 © «© 24 20:29 @ 107 OD 10.372 © 1087 @ e205 Oo 20:30 @ 108 6 O 10:38 10-68 206 20:31 @ 09 O 10-39 1070 @ 0 27 20-32 @ to10 © 10-40 1071 208 © 20:33 ® O11 1041 ® 073 © | 29 ® 20-38 ® 1012 10.42 1074 «© 2091 © 20:35 tors 3 | toes 1% | 2082 @ | os @ 1014 @ 10-44. ° 107% @ 2033 © 20:37 ® 1015 OD 10451 © | ¢ 1077 @ 2094 @ 20.38 @ 1017 © | 10452 © | @ 107 @ © 2095 @ 20:39 ® ore © 1048 som @ |e wes 9] we 6 wis @ | 1047 © 108 2097 ® 20-41 ® ro-191 @ | 10.48 2 1081 G @ 2038 & 20-42 ® so1s-2 © | 10-49 108-1 @ 209.8 © 20-44 @ > 1018.3 @ 10.50 1081-2 @ , 208-10 © 2045 ® 1019-4 © , 10-81 10-82 @ | © 20911 @ 20.46 @ 1020 © | 1062 108 «| @ 20912 @ 20.47 ® 00-2-1Mark Poye REVEION storm Page REVECT| trash Page Rewser| tart Page Parent Poge Rewcion 20-48 20.105 soe & 30.602 © 404 2049 @) 20198 3081 20603 € 40.5 2050 4) 20-107 309 2 30-804 46 2091 20.108 x10 30-50.5 407 2051 @ 20-109 3011 8 30-50.8 40-8 2053 @ 20.110 3012 > 30-50-7 408 2053.1 @ 20111 @ | 3043 | 508 @ | 40-10 20.54 20-112 7 2014 509 8 4019 20.55 | 20113 @ 3015 2 30-50.10 © 40-12 20.58 20114 @ , 316 @ 20.60.11 & a0.18 20.87 2015 @ | 3017 ® 40.15 20.68 20.116 & gaia g & 40-16 20.58 2017 @ | 3019 6 4017 208) 20-118 } 3020 ® ® | 4018 20.82 20.119 9 | 90-21 @ |e 4019 % © 2063 7 20120 % | 3022 2 40191 & 2064 20121 @ | 9023 2 4020 6 2065 & 20122 2 | 3024 2 40-21 2066 4 20.123 4 3025 3 > 40.21-1 & 2067 4 20-124 4 30.28 > | « D 40.212 6 2068 20.128 30:27 3 | 4022 8 2070 4 | 20128 & 3028 | © 2 | 40-23 27 6g | (20827 @ 3028 >| 40231 ® 2072 20-128 3030 a 40232 @ © 20% 20429 a | 3091 2 1024 © 20:75 20130 4 2032 © @ Z| 40.26 en) 20131 4 | 30321 @ | @ % | 40-261 § ©2077 o 20432 4 | 30322 © 30631 7 10.25.2 20-78 @ 20133 | 3032.3 & 3063.2 7 | 4025.3 # 2079 go134 6 | 30924 & 30633 y | 40.254 & 2080 «@ 20135 @ 30325 30034 7 | 40255 8 2081 @ 20136 9 | 30326 % 30-66 | 40-25-6 2082 20-137 «@ | 30927 % ges 2 | 4026 & 2083 a 20138 20328 © 3085 > | 4027 2084 20.139 4 20:32 3087 2 aoa) & zoe? a | 2011 3038 7 3069 > 4028 8) 20.88 4) 20142 5038 > | @ 3070 > 40.29 ® 2089 aw 20183 2037 30-71 g 40-29-13 20:80 @ 20144 so38 6g | 3072 & 40.292 2081 20445 6 3039 2 | O73 dD 40293 7 282 & 20146 goao | 078 10.294 © 2092 2 20147 soar og | 9075 8 0-30 gh 2094 20148 3042 | 3076 40.31 @ 2095 4 3043 2 3077 5 40.22 2098 @ | @ 301 304a 30-78 3 40330 2087 @ | © 302 @ 3045 30-739 3 40-34 2098 @ | 3030 2 2046 & 3080 > 40-35 20-100 g | 304 oD 3047 | 3081 8 20101 @ | 305g 3048 5 20-102 308 2 30493 | @ aor 20-103 3081 8 3050 40.2 20.108 4 307 30801 # 404 00-2-2 020106Ay IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. ‘The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose To prevent injury to workers, the symbols QM and “A are used to mark safety pre- cautions in this manual, The cautions accompanying these symbols should always be followed carefully. if any dangerous situstion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the ation. A SAFETY GENERAL PRECAUTIONS Mistakes in operation ate extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1.Before carrying out any greasing or repairs, read oll the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet Do not wear loose work clothes, or clothes with buttons missing * Always wear safety glasses when hitting parts with a hammer. «Always wear safety glasses when grinding parts with a grinder, etc 3.1 welding repairs are needed. always have a trained, experienced welder carry out the work When carrying out welding work, always weer welding gloves, apran, glasses, cap and other clothes suited for welding work 4.When carrying out any operation with two ‘or more workers, alweys agree on the op- erating procedure before starting. Always inform your fellow workers before starting ‘any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them. 6 Decide a place in the repair workshop to keap tools and removed parts Always keep the tools and parts in their correct places, Always keep the work area clean and make sure that there 1s no ditt or oil on the floor Smoke only in the areas provided for smoking. Never smoke while working PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8.Before starting work. lower blade, ripper, bucket or any other work equipment to the Ground. If this is not possible, insert the safety pin or use blocks to prevent the work, equipment from falling. In advition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling. sup- port the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oi! from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when geting on or off the machine Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11 When removing the off filer eap, drain plug ue hydrauhe pressure measuring plugs, sen them slowly to prevent the oil trom urting out Setore discoaneeting oF removing compo: nents of the oll, water or air circults, first remove the pr jetely from the ure comp circu. 42 The water and oil in the circuits are hot when the engine 1s sieaped, so be caretul not to get burned Wait for the oi! ond water to cool betore car ying out oneuits, ry work on the oll C€ weter starting work, remave the leads from the battery Always ramove the lead trom the negative (—) terminal firs 14 When ‘aising heavy components. use a horst or crane Check that the wire rope, chains and hooks ae free from damage Always use lifting equipment which has ample capacity fastal the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component fram hit ting any other part. Do net work with ai part still raised by the hoist or crane 15 When removing covers which are under i= ternal pressure or under pressure from a spring, always eave two bolts in position on opposite sides, Slowly release the pressure, then slowly loosen the bolts to remove. 16 When removing components, be caratul not to break or Gamage the wiring Damaged wining may cause electrical fires. 17 When removing piping, stop the fuel or oil from spilling out. If any fue! or ail dps cn to the floor, wipe it up immediately, Fuel ar oil fon the floor can cause you to slip, oF car even start fires 18.As a general rule, da not use gasoline to wash parts. In particular, use only the mai rum of gasoline whon washing electrical parts 00-4 18.Be sure to assemble all parts again in their orginal places Replace any damaged parts with new parts © When installing hoses and wares, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated 20 When installing bigh pressure hoses. make twisted, Damaged tubes are dangerous, $0 be extremely cate: ful when installing tubes for high pressure Cicuits Also, check that connecting paris are correctly installed sure that they are 21 When assembling or i Salling parts, always use the specified tightening torques. When Installing protective parts such as guards. parts which vibrate violently or rotate at high speed, be particularly caretul to check thot they are installed correctly, 22. When aligning two holes, never insert your fingers or hand Be careful not to get your fingers caught in a hole. 23 When messuring hydraulic pressure, check that the measuring taal 's correctly assem bled before taking any measurements. 24 Take care when semoving oF installing the tracks of track: type machines When removing the track, the track sepa- sajes suddenly, so never let anyone stand at either end of the track.FOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an gccurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. ‘This shop manual mainly contains the necessary technical information for eperations performed in a service workshop For ease of undersianding, the menual is divided into chapters for each main group of components, these chapters are further divided into the following sections STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also setves as reference material for troubleshooting, TESTING AND ADJUSTING This section explains checks to be made before end aft adjustments to be made ‘Troubleshooting charts correlating “Problems” to “Causes performing repairs, as well ay ¢ completion of the checks and repairs, ar@ also nolucied in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as weil as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards whon inspecting disassembled parts. NOTICE The specifications coatained in this shop manual sre subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES: Shop manuals are issued as a guide to carry: ing out repairs. They are dividect as follows Chassis volume: Issued for every machine motiel Engine volume: Issueu for aach engine series | Each issued as ane volume to cover ail models Etectrical volume | Attachments volume : | These various volumes are designed 10 avoid Guplicating the seme information Therefore to deal with all repairs fer any model, at is neces- sary that chassis, engine, electrical and attach- ment volumes are ready DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work FILING METHOD. 1 See the page number on the bottom of the page File the pages in correct orser 2. Following exemples shows how to read the page number Example + (Chassis volume): — item number and Furetion! L__ Consecutive page number tue each item 10. Structure Example 2 (Engine volume) 12-410 - Unit number (1. Engine) Item number {2 Testing and Adjusting] Group No. (4. Fue! system! Consecutive page No. [Page 10 of Group 4) 3. Additional pages Additional pages are in- aicated by a hyphen |-) and number after the page number, File as in the example. Example teed 12-208 te ce 12-203-1 16-4. bAdded pages {7 5 3°593 9 10-5 12-204 00-6 REVISED EDITION MARK [260 1) When @ menual is revised, an edition mark is recorded on the bottom outside corner of the pages REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. symeos So thet the shop manual can be of ample orectical use, important places for safety and quality ara marked with the following aymbols. ier Remarks Special salery precautions are necessary when performing the work anf Safety Extra special sefety precautions ace necessary when performing the work becouse its under | Spacial weednical precautions or {otter precautions for proserving stanuaeds are necessary when performing the wou “{ Weight af pacts or syst Caution necessary when Waight selecting hoistna wire, ar when working nostureis important ete * “- Cautio = hgnten- a ng Uer. | attention tor the tghterung More eo rgue during as sembly ae | coat Places to be costed with adhesives and lubricants ete Places where oi, water oF fuel Oi, water |must be added and the | capacity. ad Places where oil or water muse (Brain [ibe drained, and cuaat ty 10 be | drainedHOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AA Heovy parts (25 kg or more) must be lifted with 2 hoist etc. In the Disassembly and Assembly section, every part weigh= ing 25 kg or more is indicated clearly with the symbol ~ yy 1. If @ part cannot be smoothly removed from the machine by hoisting, the following checks should be made # Check for removal of all bolts fastening the part to the relative parts. + Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1)Use adequete ropes depending on the weight of parts to be hossted, referring to the table below Wire sopes (Standard "2" or “S” twist ropes. without galvanizing) Rope diameter (mm) | Allowable load (tons) 14 22 16 28 18 36 20 a4 22.4 | 58 30 t 10.9 ao 180 50 28.0 60 \ 40.0 a The allowable load value \s estimated to be one-sixth or one-seventh of the breaking strength of the rope used 2) Sling wire ropas from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result Hooks have maximum strength at the middle portion, 3)Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load A. Binsing with one rope moy cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the foad, which can result ina dangerous accident 4)Do not sling a heavy load with ropes forming a wide hanging engle from the hook When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the vanation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically. at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This waight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are Subjected to an excessive force as large as 4000 kg if they sling @ 2000 kg load at « lifting angle of 150°, Lifting angie 5STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1, STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptians are given in sections of “Disassembly and Assembly” Thread diameter width ‘of bolt actoss flat J (am) (mm) Xs 5 a kom | 6 10 135-015 8 13 32203 2 v7 67207 12 19 115-10 14 2 180%20 16 28523 | iB 39 | 20 56:6 22 768 24 94.510 a a 138218 13204140 30 46 175-20 1720-190 33 50 22525 2210240 36 685 280-30 27504290 39 60 335435 3280 #:340 — This torque table does not apply to the bolts with which nylon packings or other non ferrous metal washers ate to be used, or whic recuire tghtening to othorwise spacified torque. * Nm [newton meter): Nm & 0.1 kam 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these tarques for split flanga bolts Thread diameter Width Tightening torque ‘of bolt across flats - - lin immi kgm Nm ae 10 14 6.7407 eo 7+68 12 v7 1641 112=9.8 16 22 28562 279423 00-8STANDARD TIGHTENING TORQUE Seaing surtace a 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared — ~ FS00E8 Thread diameter | Wwieth across tars | Tightening torque of rut pare Dtrmetpere jes . tnd ime) | tom twa 14 19 25605 2a 5249 ” 18 24 522 492196 22 2 | ge2 7852196 2a 2 | 1as3 13732294 30 38 tars 17652294 33 4 2025 | 196.1249 35 46 2545 245.2249 az 85 g0%8 294249 COATING MATERIALS Nomerctsture Komatsu code “Applications. Used to appv cutber pace, rubber gaskals, and cork plugs Used to voeiy resin fubber, metalic and pon-metalle ports whens fest sword seal y reeded. Agheswes Preventing bolts, nutsand plugs from loosening and leaking a) Frodtes an aiid, slgctricay meuating Spd tor atau surtaces said coar plugs Ipire shaped bow shapedl are halen ana mating portion of shalt Used with gaskets an packings to increase nealing effect “Teal eater gbaketTorBiecombasTan ohabes Used by sfelt on minting eurtacee on the Waal arve and anemic cneee (Thyeknets after tgntening 0.07 — 9.08 mm by sell 10 se ai grease fittings, ‘epeved scraw rings and tapered ydeaule cucuite-o¢ tees than 80 shen in oarmater Sealent goake' Sinzon base type weed n combination with LG-1 ond LG-4. “Ward master carag wae fan (C6, and caver to.pe01 of “Kniiiciion compound (atest inelucing moiynderum diculfcieh Grease Gu ‘Tpaued te bean ngs shaing parts and ol seal Yor lubrication, ast iin tease) levennion and faciitavonot assembling work ‘ing ang to ae ‘Applic to beutings and taper shatis to faci tate pre prevent sticking, Burning or ‘usting Veseline [scatter retectina tater eloctoda termina om comasion “LT-2 ts alsceated LOCTITE in tha shoo manuals. 00-9ELECTRIC WIRE CODE ELECTRIC lo the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires This wire cose table wil help you understand WIRING DIAGRAMS, Example CLASSIFICATION BY THICKNESS ELECTRIC WIRE CODE SWE indicates a cable having 9 nominal number § and white coating with black stripe Norner stands Copper wre ‘i of strane] Crags seahon tab oo. il sang, signal et Changing ava signa CLASSIFICATION BY COLOR AND CODE 1 He hese | ons fiona |} vane |] nature | sign omar 4 Ww a @ ® t ¥ c t : wie | aaa Bee | eon fae we | aw a aw wo ey ve , a wn * Tce | Color] Waite # Back oc 4 Yelow Yalow iach | Gwen’ fed | Given Moa wary Cone vei cy Ve wd wv S| reef 2 aC a 00-10WEIGHT TABLE a This weight table is a guide for use when transporting or handling companents _ 7 Unit:_kg Machine Mode! | PC806 PC6OL 6 Pcs. Serial Numbers | 2001 andup | 8001andup | 1001 andup 310 | 310 310 Engine assembly (excluding water and oii) fa 20 OF and Of cater assembly 27 | 2 a “TRevane frame - Ty oS a5 oa Operator's cab oo 7 240 ag Operator's seat | 2 22 “Hydraulic tenk ard fuel tank enemy | 2512 30 texcluding oi ard fuel) i Counterweight 700 | 1,a00. Hyaraulie pump assemaly - a nr L.H. 6 spon! contra! valve RH. 5 spo0) control valve ‘Swing cirele assembly ‘Swing mach inery essembly ‘Swing motor Center swivel joint frame assembly © Track frame © Idler © Idler cushion © Carrier roller Track roller Travel motor Sprocket 718 535x2 36.5 x 2 x2 142%10 915 x2 28x2 x2 ea | 142% 12 182 x2 2x2 6B5x2 S2x2 112 19.3x 12 167 x2 29x2 00-12 020106020106 Unit: kg Machine model PC60-6 PCBOL-6 PC90.1 Serial Numbers 28001 and up 8001 and up 1001 and up Hh HH Track shoe assembly Tripie shoe [450 mm) 800x2 - - Triple shoe (480 mm) — - 1185 x2 Wide triple-shoe (600 mm) 9702 1,080 x 2 1,616 x2 Wide triple-shoe (700 mm} + 1,200.2 1,790 x2 Flat shoe (480 mm) 1.1402 1,380 x 2 Swamp shoe (700 mm) 980x2 1,090x2 — Swamp shoe (750 mm) - - 1.585 x2 Rubber shoe (450 mm) 403. x2 Boom assembly 419 419 530 Arm assembly 157 157 213 Link assembly 55 58 55 Bucket assembly 2u 201 236 Blade 360 - Boom cylinder assembly 109 108 127 Arm cylinder assembly 80 toa Bucket cylinder assembly 6 61 61 Blade cylinder 48 = 2s 00-13LIST OF LUBRICANT AND WATER NDF AMBIENT TENPERATURE CAPACITY if) RESERVOIR és FLUID 6% 8 SBE Specie Reta Engine oil pan PTO case | (SAE tow, 80 70 SAE 10W-30 | mm ome er sore | ea oa Swing mac inery case seis 24 24 Final drive case (ezchi pe A poe: ir) Pew be POsOL.90; 3° | PCOOL|0. 3 a | siydemiie eyetom PC6D.6OL. 109 | POSO.6OL: 67 tS aa Pcoo: 105 Pee. 7 ‘eer (each) [Peso.60L-008 | Peco.s01: 0.05 Poa: | pean 0.120-0.136) 0.120-0.195 “Trike roller (1 place) Jeceneou: 0.08 | ecso,601:; 0.08 pa Poo0 | © 100-0.118 0100-0115 Carrie role (1 ites) | | oor oor hi i ASTM 0875 No. 2 Pca: 200 | “ Ls epeseeee micah CCoeting system water |Add antiteeeze 0 | ASTM 0075 No.1 NOTE: ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum institute Specified capacity: Total amount of oi/ including oil tor components and oil in piping, Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. (1) When fuel sulphur content is less than 0.5%, change oil in the of pan every periodic tenance hours described in this manual. Change oil according to the following table If fuel sulphur content is ebove 0.5%, Charge avtervat of oi ia engine ext pen Fuel sutohur coment | 0.5 101.0% 1/2 of rrguler intevval Abou co 1.4 of reguist interval 00-14 (2) When starting the engine in an atmospheric temperature of lower than O°C, be sure to use engine vil of SAE1OW, SAE10W-30 and SAETSW-40 ever’ though an atmospheric temperature goes up to 10°C more or less in the day time. 13) Use AP) classification CD as engine oil and vf API classification CC, reduce the engine cil change interval to half 0201110 STRUCTURE AND FUNCTION 020106 Engine mount and engine related BOHS ceenpeeecenn en 2 Radiator and oil cooler . 3 PTO 4 Powertrain... 5 Swing circle. 7 Swing machinery « a Track frame +10: 9 Idler... +1012 Idler cushion 2510-12 Carrier foller ...s.eeeee eee 10-13 ThaekeFAMEr ce scerw ences 10-13 Track shoe 2 10-14 Hydraulic piping . - : 10-17 Hydraulic circuit diagram .. 10-19 Hydrualic tank and fuol tank » 10-19-4 Hydrualic pump ajagaiens 1020 Blade pump... 0.00 10-29-2 LH 6-spool control valve =. +++. 10-30 RH. 6-spool control valve. Blade control valves. .-+ ++ Swing motor .. 2... Center swivel joint. . Travel motor... sseseeeeeeee Boom safety valve... 2... Valve control PPC valve Solenoid valve assembly . Safety lock valve Shuttle valve «6... Hydrualic cylinder 7 Work equipment ....... Electrical wiring diagrain Electrical circuit diagram Engine control. cee Total contral system... EMMAC (Electronic Monitor and Control Console}... 6.0 .e ee 10-1ENGINE MOUNT AND ENGINE RELATED PARTS. 5 2 Je a ; a 1 4 § ’ 8 ae Ee al 201F06007 2. Front engine mount 6 Rubber pads: 10-2 020108020106 RADIATOR AND OIL COOLER Nomson- Drain vaive Sub tank Oil cooler Radiator Fan guard Radiator inlet hose Radiator outlet nose 201F 06008 SPECIFICATIONS Radiator’ PC60 Serial No. 2800131195 PC6OL Serial No. 8001-8047 PC90 Serial No. 1001-1232 cD-3 PC6O Serial No. 31196 and up PC6OL Seria! No. 8048 and up PC90 Serial No. 1233 and up cCWX.3 Oil cooler: SACS 10-3P.T.O. Section A~ A 1 Coupling 2 Sati 3. Breather and lubricating plug 4 Case 8 Oil level plug 201F 08010 920106020108 POWER TRAIN PC60, GOL-6 1 2 a 4 5 & \ ea eae 1 i | ta: : yh f ' 10 3 W Ww : 20108011 1. idler 7. Hydraulic pump. 2. Center swivel joint B Engine 3. AH. 5-spool control valve 9. LH. 6-spool control valve 4. Swing brake solenaid valve 10. Swing motor 5. Travel speed solenoid valve 11. Swing machinery 6. Travel motor and final drive 12. Swing circlePCgo-1 1 taer 2. Centar swivel joint 3.R.H.5 spool control valve 4. 2-stage reliel solenoid valve ©. Swing brake solenoid valve 6. Travel speed solenoid valve 7. Travel| motor and final drive 10-6 201 F080! 2 8. Hydraulic pump 9 Engine 10 LH. -spool control valve 11, Swing metor 12. Swng machinery 13 Swing circle 020106020106 SWING CIRCLE ‘Swing circle outer race Ball bearing ‘Swing circle inner race (80 teeth) Inner race soft zone “s” Quter race soft zone“s” a's Section A— A 201F06013 SPECIFICATIONS 80 _ Reduction ratio: 82 = 6.154 Grease volume: 5 { (grease G2-L1] 10-7SWING MACHINERY Section A Swing pinion (13 teeth) Cage Planet carrier Ring gear (77 toath) Bearing holder Drive gear (22 teeth} [18 teeth] ‘Swing motor Cover 9. Driven gear (73 teeth) [77 teeth] and sun gear (16 teeth) 10. Planet gear (30 teeth) 11. Oil level gauge 12. Drain plug £1 Pcg0.1 evenaurss 10-8 A é 2o1FO601a SPECIFICATIONS PC6O, 60L-6 Reduction rao: 23x 1+ 72 |= 49.286 2 16 PC90-1 24.865 Reduction ratios 22x 1+ 18 20106020106 TRACK FRAME Pce0.6 1 1. Idler 2. Track frame 3. Carrier roller 4. Travel motor exos 201F06015 Sprocket Track shoe Idler cushion Track roller 10-9PCEOL-6 1 tales 2 Track frame 3. Carrier roller 4. Travel motor 10-10 1 201F06016 Sprocket Track shoe later cushion Track roller 020106020106 PC90-1 Idler Track frame Carrier roller Travel motor evox 20106017 Sprocket Track shoe Idler cushion Track roller 10-17 1IDLER ® The drawing shows PC60,80L 6 Idle Floating seat 3. Support 4. Idler shatt 5 Bushing 1 201FOBO1E IDLER CUSHION * The drawing shows PC60,60L-6 Yoke Rod Front support (eylinder) Recoil spring Wear ring Packing Rear support Lubrivator Drain plug 1 2 woues 1 2 9 4 § § 7 B SPECIFICATIONS a Grease volume. 160ce (PCEO, GOL} Grease volume, 180ce (PC3O) G2.u1 201F06019 10-12 1 020106CARRIER ROLLER Lubricating plug Carriar rotier Bushing Floating seal Collar Shaft eoserna 201F06115 020106 TRACK ROLLER 4% The drawing shows PC90-1 1. Floating seal Track roller Shatt Bushing Collar DLR 9202033028 10-13 4TRACK SHOE Regular bushing Regular pin Regular dust seal Master bushing Master pin Master dust sea Shoe Shoe bolt Link eoryensons 10-14 4 + The drawing shows PC90-1 202F 05018 SPECIFICATIONS (Standard shoe) PC6O 450mm triple-shoe Link Pitch: 154mm Number of shae, 74 Pcé6oL, 600mm tripie-shoe Link pitch: 154mm Number of shoe, 82 cao 480mm triple-shoe Link pitch 175mm Number of shoe. 76 020106SELECTION OF TRACK SHOE - Select the most suitable track shoe from the folloiwng table. PC6O-6 PCBOL-6 PC90.4 Specifications oe Specitications | Ge Specifications | a 450 mm triple shoe A 600 mm triple shoe B 480 mm triple shoe | A 600 mm triple shoe |B a 7900 mm wipleshoe BTS ~ = | = |timetoeae | 6 |iionspsae Te 700 mm swamp shoe | € | 700mmswampshoe | C | 760mmawempanos |G 480 mm flat shoe | D = ~ 480 mm flat shoe dD + Category oe Use | Precautions when using 020106 A | Rocky ground, normal river | + Travel in Lo when traveling on rough ground with obstacles soi such 8s lerge boulders and fallen trees, + Cannot be used on rough ground where there are large obstacles such as boulders and falien trees, B | Normal soil, soft lend + Travel in Hi spaed only on flat ground, and when itis, impossible to avoid traveling over obstacles, lower the travel speed to approx, half of Lo speed. + Use only for ground where “A"' and “B" sink and are possible to use. Extremely soft ground Cannot be used on rough ground where there are large c obstacles such as boulders and felien trees (Swampy ground) + Travel in Hi spead only on flat ground, and when it is impossible to evoid traveling over obstactes, lower the ‘ravei speed 10 approx. half of Lo speed, D Paved surface + The shoes are flat, so they have low gradeability, % Categories "BY and "C” are wide shoes, so When selecting the shoe width, select the There are restrictions on thei use. There- narrowest shoe possible within the range fore, botore using, check the restrictions and thet will give no problem with flotation and consider carefully the conditions of use ground pressure before recommending a suitable shoe width. fa wider shoe than necessary is used, there If necessary, give the customer guidance in will be a large load on the shoe, and this their use may lead to bending of the shoe. cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems. 10-15 1HYDRAULIC PIPING 1017 ‘sHYDRAUUC CIRCUIT DIAGRAM020108 HYDRAULIC TANK AND FUEL TANK Section A--A Section B—- B. 20106026 1, Dram Plug (Hydraulic tank) SPECIFICATIONS 2. Filler cap (Hydraulic tank} Hydraulic tank 3. Pressure valve © Tank capacity. 954 4. Fuel tank © Oil amount, 674 5. Filler cap (Hydraulic tank) © Pressure valve 6. Strainer Relief set pressure 0390.15 kg/em? 7, Fuel ievel sensor Suction sei pressure Q- 0.046 kg/cm? 8, Hydraulic tank + Bypass valve set pressure, 1,080.20 kg-em? 9. Return oil filter (Hydraulic tank) 10. Bypass valve Fue! tank 11. Sight gauge (Fuel tank) * Tank capacity 160¢ (PC60, 6OL) 12. Sight gauge (Hydrauhe tank) © Tank capacity 2001 (PCO) 13 Straner 14 Drain valve (Fuel tank)10-19-4 & HYDRAULIC PUMP PC6O, 60L-6, PC90-1 020108 201F06027 a. Power set signal pressure PmF port b. Power set signal pressure Pm port Front main pump Front servo valve Rear servo valve Rear main pump Charging relief vaive Charging pump onawne10-20 3 PC60-6 (WITH BLADE) 020106 201 Fo8A 12 Power set signal pressure Pme port Blade sencing pressure Par port Power set signal pressure Pma port Blade sencing pressure Per port Front main pump Front servo valve Rear servo valve Rear main pump. Charging relief valve Charging pump OOAeno10-21 5 1. FRONT MAIN PUMP AND REAR MAIN PUMP (HPV035+035) 020108 20106028 Rear main pump discharge Paz por: m. Front main pump discharge Pav port Front main pump disenarge Pat port 1 Servo valve output pressure PSv2a port a Front main pump disenerge PAt port fh Charging pump pressure Psvt port b. Rear main pump discharge PA2 port i. Servo valve output pressure PSV1A port Suction PS port i. Servo vaive output pressure PSV2A port 4 Drain port k. Charging pump pressure P8v2 port ©. Servo vaive output pressure PSv18 port | Rear main pump discharge Pa2 port ' 410-22 1 020106 MoOonons 3d $e6 7 8 8 wn 13a is 16 17 18 Air bleeding plug Drain plug Front drive shaft Front cradle Front pump case Front rocker cam Front piston Section ~ B 8 Front cylinder 9 Front vaive plate 10. End cap 11. Couphiag 12. Rear valve seat 13. Rear cylinder 14 Rear piston 201F06029 18. Rear rocker cam 16. Rear pump case 17. Rear cradle 18 Rear drive shatt 19. Servo piston10-23 2. SERVO VALVE PC6O. 6OL-6, PCSOL-1 % The drawing shows the servo valve for the front main pump. appeal dL & ‘ible, he a 920108 Soction DD Section EE Section FF SectionG—G Section H —H ia) es GectionJ—J Section K — K Section — L10-24 wg 020106 201FO6030 Power set signal pressure Pm port Front main pump discharge inlet Pat port Rear main pump discharge iniet Pa2 port Servo valve output pressure Psv1a port Charging pump pressure inlet Psv1 port Servo valve output pressure Psvia port Section A — A 1. Screw 2 Plug 3 Sleave 4, Guide spool 5. Spring 6. Plug 7, Serew 8. Body 9. Rod 10. Spring 11, Seat 201F06031 12. Spring 13 Seat 14. Pin 15. Arm 16. Control piston 17. Sleeve 18. Piston 19. Sleeve 20 Piston 21 Piston 22. Sleeve10-25 @ PC60-6 (WITH BLADE) 4 The drawing shows the servo valve for the front main pump. 02010610-25-1 6 s $ a b ¢ 4. e. f 8 Section A—A Power set signal pressure Pat port 1 Blade sencing pressure Par port 2 Front main pump discharge inlet Pat port 3 Rear main pump discharge inlet Paz port 4 Servo valve output pressure Psvia port 5 Charging pump pressure iniet Psv1 port 6 Servo valve cutput pressure Psvve port 7 8 9. 10 W 12. Screw Plug Sleeve Guide spoo! Spring Plug Serow Body Rod Spring Seat Spring 13, 14. 15, 16. 17. 18. 19. 20. 24 22. 23 24 201 FUG4IS 201Fo8a14 Seat Pin Arm Control piston Sleeve Piston Sleeve Piston Piston Steeve Piston SleeveOPERATION 1) S mode {for normal operation), No load on moin pump * When the power set switched is pressed to select S mode, signal pressure Perc from the power set solenoid valve does not enter port f of the servo valve * Tho charging pump output pressure Poa enters ports b of spool (4) When there is no load on the pump port by and port ¢ are connected, so the pressurized oil from the charging pump enters chamber A of servs piston (23) and pushes serve piston. (23) to the right in the direction of the arrow When this happens, the pump delivery amount is maximum Pump discharge volume (‘enn 10-25-2 ® Power sat g solenoid valve ower Set sivitch tS mode) F20106004 8 made L mode’ Pump discharge pressure {kg/em@) (g.1) 20106005 020106020106 10-26 2) S mode, Load on main pump (front pump) * When the load on the frent main pump increases and the delivery pressure becomes farger, delivery pressure PA1 of the front main pump enters port d and pushes piston (18) to the left in the direction of the arrow. As a result, piston (16) is pushed to the lett in the direction of the arrow and arm (15) uses servo piston (23) as a fulerum to push spool (4) to the left in the direction of the arrow When this happens, port b and port a of spogl (4) are connected, and the pres. surized oil PGA from the charging pump enters chamber B of serve piston (23), and pushes sorvo piston (23) to tha left in the direction of the arrow Power set soleneid valve Pon ae nich | ek a zt tt | Controiter 20106008 © Arm (15) uses pin (14) as a fulcrum and rotates clockwise to move guide spool (4) to the right. Servo piston (23) stops at a position where the connection between porta and port bis cut. © In this way, the discharge volume from the front main pump is reduced according to the discharge pressure, and ts controlled as shown in the graph for the S mode in Fig 13) L mode, (for light load operations) Power set solenoid valve al | © When the power set switch set to L mode The power set solenoid valve is switched, and signal pressure Prec enters port f and pushes piston (21) to the left in the direction of the arrow. As a result, piston (16} is pushed to the left in the direction of the arrow. and arm (15) uses servo piston (23) as a fulerum to push spool (4) to the left in the direction of the arrow. When spool (4) is pushed to the left, port b and port a are connected, and pressurized oil Pga from the charging pump enters chamber B of servo piston (23), and pushes servo piston (28) to the ‘eft in the direction of the arraw 20106007 Arm (15) uses pin (14) as a fulcrum and rotates clockwise 19 move guide spool (4) to the right: Servo piston (23) stops at a position where the connection between porta and port bis cut In this way, springs (70) and (12) are comprassed, and become greater than the set pressure, so the main pump is controlled as shown in the graph for the L mode in Fig 1 02610610-28 1 920108 4) When blade is operated (for machines with blade specifications) egatrot * For machines equipped with blade, the absorption torque of the main pump is reduced in accordance with the foad on the blade pump to prevent the engine from stalling when the blade is used * Toachieve this, the discharge pressure of the blade pump goes to the pilot port of the servo vaive, and the load an the blade pumps taken by piston (23), By pushing control piston (16) to the left in accordance with the load, the absorption torque of the main pump is reduced. * When there is no load on the blade pump, the pump absorption torque is near the digging mode curve (light mode curve for light mode) in the diagram on the right, and as the load rises, it is reduced and moved towards the blade mode cutve So when the blade pump is at maximum load. the Working mode solenoid valve va Working mooe | “To tiade Pump discharge volume —= Iconieaier ul 201 FOE 1S Pump discharge pressure feg/ern®) 20) FoSa16ee ee eee ee eae 10-29 3. CHARGING PUMP (BARO20) AND RELIEF VALVE = PSN | easuetion biseharge 8 g \ 8 = © Section A A 201F06036 1. Body SPECIFICATIONS 2. Driven gear Type: BARO20 3. Cover Theoretical detivery: 20.9 ce/rev 4. Drive gear Set pressure: 30 kg/em* 5 Relief valve 6. Filter10-29-1 ® BLADE PUMP PC60-6 (WITH BLADE) Discharge 020108 Bracket Drive gear Housing Cover Driven gear geens 20106617 SPECIFICATIONS Type: SBL21 Theoretical delivery 21.0 cc/rey Set pressure 210 kg/em?L.H. 6-SPOOL CONTROL VALVE PC6O, B0L-6 ze-sance 10-29-2 5 h 9 Pa3 port {irom LH. PPC valve) Pas port (from LH. PPC valve) P1 port (from tear main pump) Aa port {T- svsing motor MA port] As por: (To arm cylinder bottom side} As por (To LH. travel motor A port) P2 port (From straight travel vaive) Ts port (To tank} ge ave 20\FO6O37 Bs port |To arm cylinder head side) 83 port (To swing motor MB port) Bz port ITo boom cylinder battom side) Paz port (From HH. HPC valve) P83 port (From {H. PPC valve} Pea port (From swing brake solenoid valve) Pas port (From LH. PPC valve} T port (To tank) 020106' BO POP 1G RF. EVEL INGhOn Ss pers 10-30 020106 1, Main relief valve 2. Spool (service) 3. Spool (boom-Hi) 4. Spoal (swing) 5. Spool {arm-Lo} 6 Spool {L_H travel) Section C Section HH 201F06038 7. Spool return spring 8 Check valve 9. Check vaive spring 10. Safety-suction valve 11. Spool (swing priority}Pe9o-t one ec PR port (From 2-stage relief solenoid valve) Pao port (Fram LH. PPC valve} Pas port (From L1H. PPC valve) P1 port (From rear main pump} A3 part [Ta swing motor MA port} As port [To arm cylinder bottom side) AG port (To LH. travel motor A port) P2 port (From straight-travel valve) soneange evesg-77 Mey OMe ma, Mt aye ng h aag ws bo vire pa 2o1ro8039 Bé port (To LH. 1ravel motor B port) Bs port (To arm cylinder head side) B3 port (To swing motor MB port) 82 port (To boom cylinder bottom side} Paz port (From RH. PPC valve) Pp3 port (From L.H. PPC valve) Pad port (From swing brake solenoid valve} Pes port (To LH. PPC valve} 10-317 020106HS por ho taney 10-32 920108 Main relies valve Spool (service) Spool (boom-Hi) Spool (swing) Li PARES Se SER ee STH WU Section — 0 Section 8 Section H—H. Section — C 201F06040 7. Spoo! return spring 8 Check valve 9. Check vaive spring 10. Safety-suction valve 11, Spool! {swing priority)ER ERE Ae See ere 10-33 SWING PRIORITY VALVE FUNCTION © When operating the swing and arm at the same ume, most of the oll flows to the arm, which has less load. The flow of ol to the swing circuit is reduced so the arm speed is faster than ihe swing speed. This makes combined operations difficult © To prevent this, the swing priority vaive is switched by the pilot pressure from the swing holding brake solenoid valve to restrict the flow of pressure oil to the arm-Lo control vaiue This restricts the arm speed and makes 2 easier to operate the arm and swing at the same ume. GREBATION Beisfeawe_| When swing at neutral * When ihe swing is at neutral, no pitot pressure oil flows from the solenoid valve The swing priority valve 18 not actuated, 96 sg, GE the pressurized oi! from the front main pump —satersidvoivel passes through gort P1 and flows to the arm. gf! uN Le control valve 20108 When swing is operated © When the swing is operated, spool (11) af she swing priority valve 1s pushed to the right by the pilot pressure from the solenoid vaive, Because of tus, the pressunzed oll flowing front main pump to the arm Le central valve 1s throttled by the swing priority valve and the arm speed |s controlled so the simultaneous operation pertd ance is. improved 201FO604210-34 3 020106 MAIN RELIFE VALVE (PC90-1) 201F06049 FUNCTION © The main relief valve is in the circuit between the pump and the contro! vatve. This valve acts to protect the pump from damage from any abnormal oi! pressure. When abnormal pressure is produced or when the hydraulic cylinder reaches the end of its stroke during operations, the oi! sent from the pump is telievad through the main relief valve (It sets the maximum high pressure in the cireuit during operations.) OPERATION ‘© Chamber A forms a pump circuit and chamber € forms @ tank drain circuit, The oil flows into chamber B through the main vaive (1) orifice to keep the chamber tilled Poppet vaive (3) is set in the sleeve (5). © If the pressure in chamber B reaches the pilot valve spring force (set pressure), the poppet valve {3) moves, allowing the oil in chamber B to fiow into chamber C through orifice. in addition, the oll flows from chamber & to B through orifices. If the oil flows through the orifice of main valve (1), @ differential pressure occurs between the chambers A and B, moving main valve (1) to the right. This allows the oil in chamber A to flow into chamber © + When the travel is operated, the 2-stage relief solenoid valve is actuated, so oil is shut to chamber E, and pushes piston (6) to the left, The set pressure is raised by compressing arenes: ehsiree HES. Main valve Main valve spring Poppet valve Poppet valve spring Sleove Piston Adjustment sleeve Adjustment plug PNOMEEN= Set pressure When work equipment and swing oper: ated: 325 ka/em? (at 27 L/min) When traveling operated: 355 kg/cm? (at 24 /min) 5 7 From 2-stage ‘lie! solenoid valve 201F 6050 From 2-stage reliet \ solenoid valve 201 F06051 § rom 2 \ { From 2-stage raiet {sotonoie valvea ee ee 201F 06082 10-35 R.H. 5-SPOOL CONTROL VALVE PC60, 60L-6 8 zl rol aed 8 oo€ & 8 fy w® 4 b ua ‘ . . 201F 08043, Pa port (From staight-travel valve) a PBS port (From RH. PPC valve) As port (To arm cylinder bottom side} bh Pa4 port (From RH PPC valve} m © Pas port (From LH. PPC valve} 6. Aaport (Ta boom cylinder head side) «Pt port From front main pump) 2, Aa port (To bucket cylinder bottom side} Bi port (To RH, travel motor A port) 9, A2 port (From rear main pump) f Ba port {To LH. travel control valve) 21 Pe port (Te arm Hi control valve) g: B3 por (To bucket cylinder head side) 1 At port (To RH. travel motor B port} Ba port (To boom cylinder bottom side ) s, Paz port (From straight travel solenoid valve| Bs port (To arm cylinder head side} 1 Paa ort (From RH, PPC valve) Ts port {To tans) Pa port (From RH PPE valve)TAS POC IT TOET LAY. Eke WANES kT port (To tank) 10.36 020106 Section C ~ Section H— Jo1Fosoaa 1. Main relief valve 6. Spool (arm-Hi) 2. Spool return spring 7. Check vaive 3. Spool (RH travel) 8. Check valve spring 4 Spool (bucket) 9. Satety-suction vaive 5. Spool (boom-Lo} 10. Spool! (straight-travel)PC60-6 (WITH BLADE} Pas port (From R.H. PPC valve) Pea port (From R.H. PPC valve) Pas port (From LH. PPC valve} 1 port (From front main pump} B1 port (To R.H. travel motor A port) Bz port {To LH. travel control valve) Bo port (To bucket cylinder head side) Be port (To boom cylinder bottom side) Bs port (To arm cylinder head side) 10-37 cal 020106 2orFo6s1a) Ps port (From straight-travel valve) . As port (To arm cylinder head side) As port {To boom cylinder heed side) As port (To bucekt cylinder bottom side} ‘Az port (From rear main pump} P2 port (To eem-Hi control valve) At port (To RH travel motor 8 port) Paz port (From straight-travel selencid valve) Pas port (From 8.H. PPC valve) He ey oe geet* k ae ee T port (To tank) 10-37-1 6 020106 vy Pas port (From LH. PPC valve} SectionH—H_ Section JJ Section ¢~C 2o1F 05419 1. Main relief valve 6. Spool (arm-Hi} 2 Spool return spring 7. Check valve 3. Spool (R.H. travel) 8. Check valve spring 4. Spool (bucket) 9. Satety-suction valve 5, Spool boom: Lo) 10. Spool (straight-travel)PC90-1 Pa port (From 2-stage relief solenoid valve} Pas port (From RH. PPC valve) Psa port (From RH PPC valve) Pas port (From LH. PPC valve} P1 port (From front main pump) B1 port {To R.H. travel motor A port) B2 port (To LH. travel control valve) Bs port (To bucket cylinder head side) Bs port (To boom oylinder bottom side} Bs port (To arm cylinder head side} Ts port (To tank) » 201FO6048 3 port (From straight-travel valve) As port (To arm cylinder bottom side} ‘Aa port (To boom cylinder head side) 3 port (To bucket cylinder bottom side) ‘A2 port (From rear main pump) P2 port (To arm-Hi control valve} At port (To RH. travel motor B port} Paz port (From straight-travel solenoid valve} Pa3 port (From R.H. PPC valve} Pad port (From RH. PPC valve) 10-37-2 6 020106T part (To tank) w. Pas port (From L.H. PPC valve) 10-38 020106 Section CC Section HH. 20106045 1 Main relief valve 6. Spool (arm-Hip 2. Spool return spring 7 Check valve 3. Spool (P.H. travel) 8 Check valve spring 4. Spool (bucket) 9. Safety-suction valve 5. Spoo! (boom-Lo} 19, Spool (straight-travel)STRAIGHT TRAVEL VALVE FUNCTION © While operating the swing, boom, arm, oF bucket when traveling, the pressure oil flowing to the RH, and LH. travel circuits branches into the swing, boom, arm, or bucket circuit, Since the supply of pressure oil in a branched travel circuit is less than that in the circuit before the branch, the motor naturally slows down, resulting in a turn © When the straight-travel valve is switched ‘over to establish continuity between the RH and L.H. travel circuits, this undesired turning is prevented by equalizing the supply of pressure oil to the RH. and LH. travel motors $0 that they rotate at the same speed. OPERATION ‘When traveling only: * Since ro pilot hydraulic o1l flows trom solenoid valve, the travel-straight vaive is not operated © Therefore, the circuit between port PR (RH travel circuit) and port PL {LH. travel circuit) remains closed and both circuits remain independent. During simultaneous operation ‘+ When operating the work equipment or swing while traveling, spoot (10) is pushed to the Fight in the direction of the arrow by the pilot pressure from the straight-travel solenoid vatve. © Because of this, port PR and port PL then become connected to each other and an equal amount of pressure oi! is supplied ta the RH. and L.H. travel motors, allowing both motors to rotate at the same speed The machine travels thus in a straight line my Eline wie! 110 Bucher aint Bucket Boom vo 2o1Fo8047 | FE On tawet 10-39 020106ES 10-40 BLADE CONTROL VALVE PC60-6 (WITH BLADE) 020106 Section 8-8 201F08420 a, B1 port (To blade cylinder haad side) 1. Spool (Blade) b, Ar port {To blade cylinder bottom side) 2. Main relief vaive ¢. T port (To tank) 3. Spool return spring dP port (From bialde pump) 4 Check valve 5. Check valve spring 6 Satety-suction valveSWING MOTOR S por B port (From swing brake solenoid vaiva) T port (To tank} MB port (From LH. 6-spool control valve} MA port (From LH. 6-spoo! control valve) 201706053 SPECIFICATION Type: KMF40AB.2 Theoretical delivery: 40.2ce/rev Safety valve set pressure: 236% kg/cm? (PC6O, 60L) +5 oO Rated speed: 1.585 rpm (PCO, 60L) 1 80) 21075 kavem# (PCO) 10-41 3 02010610-42 020106 Re ae Max. 14 kg/cm? 1, Drive shatt 2. Cover 3. Housing 4. Disk 5. Plate 6. Brake piston 7. Brake spring 8. End cover 9. Piston 201F 06054 10. Cylinder 11, Valve plate 12. Air bleeding plug 13, Center shaft 14, Center spring 18. Safety valve 16. Check vaive 17. Check valve springSWING HOLDING BRAKE OPERATION 1) 2) When swing brake solenoid valve is deactivated When the swing brake solenoid valve is deactivated, the pressurized oil from the charging pump is shut off and port B is connected to the tank circuit Because of this, brake piston (6) is pushed down in the direction of the arrow by brake spring (7), so dise (4) and plate (5) are pushed together and the brake is applied When swing brake solenoid valve is excited When the swing brake solenoid valve is, excited, the valve is switched and the pressurized oi! from the charging pump enters port B and flows to brake chamber a The pressurized oll entering chamber a overcomes the force of brake spring (71, and brake piston (6] is pushed up in the direction of the arrow. Because of this, disc (4) and plate (5) separate, and the brake is releesed Deactivated MEPL Charging eump wd 10-43 [Swing brake | solenoid valve 202F08048A, 020106 Swaine broke solenoid valve 202F0S060A,CENTER SWIVEL JOINT opens 10-44 Cover Body ipper seal Oil seal Shaft 201#06085 A1.From R.H. 5-spool control valve A1 port A2,To RH. travel motor B port 8), From A.H. 5-spool control valve 81 port Ba. To RH. travel motor A port C1, From LH. 6-sp00l control valve As port 2, To LH. travel motor port ©). From LH. 6-spool control valve Bs port D2, To LH, travel motor B port E1, From travel speed solenoid valve £2, To LH. and RH, travel motor D port 02010610-45-1 5 020106 T2 From LH and RH travel motor © port PC60-6 (WITH BLADE) Cover Body Slipper seal Oil seat Shaft . From R.H, 5-spool control valve A1 port . To RH. travel motor B port From R.H. 5-spool control vatve B1 port To RH. travel motor A port From LH. 6-spool control valve As port ToL.H. travel motar & port Se eal dl tenn ett lal oes inte 201706421 E1, From blade control valve B1 port E2 To blade cylinder head side F 1 From blade control valve A1 port F2. To blade cylinder bottom side G1. From travel speed solenid valve G2.ToL.H. and RH. travel motor D portD2, To LH. travel motor B port Ta. From LH. and RH. travel moter € port 10-45-2 " TRAVEL MOTOR PC60-6 bees PE 20108056 a. C port (To tank} SPECIFICATIONS b. A port (From travel contro! valve) Type: GMOSVL-D c. D port (From travel speed solenoid valve) Hydraulic motor 4. B port (From travel control valve! Theoretical delivery: Lo 37.2 cc/rev Hi 26.7 cc/rev Rated pressure. 320 kg/cm* Reted speed: Lo 1,897 rom Hi 2.689 1pm Parking brake releasing pressure: 9 kg/cm? Hi-Lo switching pressure: 30 kg/cm? Final drive Reduction ratio: 48 Rated speed: Lo 39.6 Hi 66.5 02010610-46 020106 SSeeavanmsans Check valve spring Check valve Safety valve spring Satoty vaive Counterbalance valve Return spring End cap Regulator vaive Spring Brake piston Cylinder 12 13. 14 15 16 7 18 19 20 21 22. {it fi | PE YLAN 330320 0 aD) 8 B25 A922 Piston Rocker com Crankshaft RV gear RY gear Cover Driven gear Drive gear Drain plug Shatt Coupling 23. 24, 25 26 27. 28. 29. 30. 31 32 33 201F08057 Center shaft Case Regulator piston Spindle Floating seal Plate Disk Broke spring Vaive plate Spring Chack valvePCBOL-6 aoge C port (To tank) A port (From travel control valve) D port (From travel speed solenoid valve) B port (From travel control vaive) Ia rAL 201F06088 SPECIFICATIONS Type: GM17VY-E Hydraulic motor ‘Theoretical delivery: Lo 37.2 cc/tey Hi 25.7 ce/rev Rated pressure: $20 kg/emt Rated speed: Lo 1.897 rom Hi2,717 rem Parking brake releasing pressure: 10 kg/cm’ Hi-Lo switching pressure: 30 kg/cm? Final drive Reduction ratio: 53.5 Rated speed: Lo 35.6 rpm Hi 50.9 rpm 10-47 02010810-48 020106 SSeanonsons Check valve spring Check valve Salety valve spring Safety valve Counterbatance valve Return spring End cap Rogulator valve Spring Brake piston Cylinder 12 13 14 15. 16 17. 18. 19. 20, 2 22 Piston Rocker cam Crankshaft RY gear RY gear Cover Driven gear Drive gear Drain plug Shaft Coupling a M08 80 0 | wu bn LV EV YAY wm ha hh 201F06059 23. Center shat 24, Case 26 Regulator piston 26 Spindie 2? Floating seal 28 Plate 29 Disk 30 Brake spring 31 Valve plate 32. Spring 33 Cheek valvePCa0-1 eecs © port (To tank) A port [From travel cantrol vaive) D port {From travel speed solenoid valve) B port (From travel controt valve} 10-49 020108 201F06060 SPECIFICATIONS Type GMI7VIL-F Hydraulic motor Theoretical delivery: Lo 86.3 cc/rev Hi 55.3 ce/rev Rated pressure: 350 kg/cm? Rated speod: Lo 965 rpm Hi 1,491 pm. Parking brake releasing pressure: 10 ka/em* Hi-Lo switching pressure: 30 kg/cm? Final drive Reduction ratio: 29.1 Rated speed: Lo 33.2 rpm Hi 81.2 rpm10-50 020106 ZSeevaonawns Check vaive spring Check valve Safety valve spring Safety valve Counterbalance valve Return spring End cap Regulator vaive Spring Brake soncg Brake piston 12. 13. 14 15 16. 17 18. 19 20 21 22 1 8 8 19 11 12 13 14 18 16 17 1 49 20 Cylinder Piston Rocker cam Crankshait RY gear RV gear Cover Driven gear Drive gear Drain plug Center shaft 3110 29 28 27 23 24 25 26 27, 28 29 30 31 1 l | Bea 2D 20106081 Case Regulator piston Spindie Floating seal Plate Disk Valve plate Spring Check valveMOTOR OPERATION 1) At Lo speed (motor rocker cam angle at maximum) | droke vaive © Tho solenuid vave % deactivated, so the pilet pressure oil om the charging pump does not How te port D. For ths reason, regulator valve (Bt is pushed fo the dell on the diction of the arrow by spring (9) Because of ti , rd the mary pressure oil from the contrat pushes check valve (2 valve ta end cover (7) 16 closed for equator valve (By © The pressurized oil in chamber aot requlal piston (24) at the bottom passes through orifice bins regulator valve (B) end 1s drained 202FOSO5SA a rasult, rocker cam (14) moves in the maximum swash plate angle direction for main pressure oll in cylinder chamber P, the: and the mater capacity becomes maximum system is set to Lo speed. 10-51 02010610.52 at minimum) —— cecal Ay ||| iy! | i Brake valve Travel speed Travel contol } solenoid vaive vaive Hi) T 020106 Fs 202FOS0S5A, # The solenoid vaive is excited, so the pilot pressure oll from the charging pump flows Je port D, and pushes regulator valve (8) is pushed to the right in the direction of the arrow * Because of this, the main pressure oil from the control valve passes through passage ¢ in regulator valve (8}, enters regulator piston (24) at the bottom, and pushes regulator piston (24) to the left in the direction of the arrow # As a result, rocker cam (14) moves in the minimum swash plate angie direction, the motor capacity becomes minimum, and the system 1s set to Hi speedPARKING BRAKE OPERATION 1) When starting to travel When the travel iever is operated, the pressurized oi] from the pump actuates counterbalance valve spoo! 16), the circuit 10 the parking brake is opened, and opened check valve (31) and the oil flaws into chamber a of brake piston (11), overcomes the force of spring (10}, anc pushes pision (12) 10 the left in the direction of the arrow When thes happens, the force pushing plato (27) and cise (28) together is lost, 20 plate (27) and disc (28) separate and the brake 15 released 2) When stopping travel When the travel lever is placed in netval counterbalance valve spool (5) returns te tne neutral position and the cwreurtto the parking brake is closed The pressurized ot! in chamber a of brake piston (11) is drained to the case from the orifice of check vaive (31) in the brake pistcm, and brake piston (11) 15 pushed to the right in the direction cf the arrow by spring (19). As a result, plave (27) and dise (28) are pusted togerher, and the brake is applied 10-53 Wd FB \ | fe 2o2Fos0s68, 020108 bk = 2 contol vatve10-54 020106 BRAKE VALVE * The brake valve consists of a check valve, counterbalance vaive, and safety valve in a circuit as shown in the diagram on the right. ig.1) * The function and operation of each compo- ‘nent is as given below. 1) Counterbalance vatve, check valve Function ‘* When traveling down a slope, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without jad and will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according 10 the ‘engine speed (pump discharge volume). Operation when pressure is supplied * When the travel lever is operated, the pressurized oil from the control valve is Supplied to port PA. It pushes open check valve (2a) and flows from motor intet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (2b) and spool (5), so the pressure at the Supply side rises. (Fig. 2) © The pressurized oil at the supply side flows from orifice Et in spool (5) to chamber $1, and when the pressure in chamber $1 goes above the spool switch- ing pressure, spool (5) is pushed to the right in the direction of the arrow. AS a result, port MB and port PB are connected, the outlet port side of the motor is opsned, and the motor starts to rotate. (Fig. 3) 20ZFOS0S78 fi contro! vah iFig.1) 202F95058 da (Fig 2) 202FO805SOperation of brake when traveling downhill © If the machine (ries to run away when traveling downhill, the motor will turn under ne load, 50 the pressure at the motor inlet port will drop, and the pressure in chamber $1 through orifice Et will also drop When the pressure in chamber $1 drops below the spool switching pressure, spool (5) \s returned to the left in the direction of the arrow by spring (8), and outlet port MB is throttled AS @ result, the pressure at the outle} port side Fises. resistance is generated 10 the rotation of the motor, and this prevents running away In other words, tne spool is moved to a position where the pressure at outlet pert port MB baiances the pressure at the intet port and the force generated by the weight of the machine I throttles the outlet post sircurt and controls the speed aceordmg to the discharge volume. of the pump. (Fig. 4) 2} Safety valve Function * When travel is stopped (or when traveling doverhill, the circuit at the inlet and outlet ports of the motor are closed by the counterbalance valve, but the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and damage the motor oF piping. The safety valve acts to release this abnormal pressure and sent tto the inlet port side of the motor to prevent damage to the equipment Operation When stepping travel (or when traveling downhill), chamber a (or chamber b)in the outlet port ciréult 1s closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia (Fig 5) When the pressure goes above the set pressure, the pressurized oil in chamber a overcomes the force of spring (3), pushes spool (4) 1a the right in the direction of the arrow. so the pressurized «il flows to chamber b on the opposite side (When the pressure in chamber @ is high} (Fig. 8) When ihe pressure goes above the set pressure the pressurized oil flows into chamber d through orifice ¢ in spool (4). It overcomes the force of spring (@), pushes spool (4) to the right in the direction of the arrow, so the pressurized oi flows to chamber a on the opposite side ig.) 202FO5060 10-55 Lees) 4 ” 2e2=08081 eg ” 8 2 2o2r0saesESOMEEY SORE POOR ent WC PMrMENeS OP Tee Cage 4 3 (Fra, 7) fg 202-5054 10-56 BOOM SAFETY VALVE PC60-6 (WITH BLADE) oom 2 . | | 2 ea 3 8 201F06422 a, Cy port (Boom cylinder head circuit) OUTLINE b. Thort (To tank) © The boom safety valve is in the circuit between the LH. 5-spo0! contro! vaive 1. Block and boom eylinder head, and is installed 2. Safety-suction valve to the tip of the rovolving frame.VALVE CONTROL PC60-6 Serial No.: 28001~34100 PCEOL-6 Serial No.: 80018075 PC90-1 Serial No. 1001-1403 Bucket duine we Beam loner Hydraulic pump 2. LH. 6-spoo! conirol valve RH. 5-spool control valve 3. 4, Shuttle valve g g 8 8 20706008 7. LH, work equipment control lever 8 LH, travel contro! lever 9. RH. travel contral lever 10. R.H. PPC valvea SED Tae So ee aa eee 6 LH, PPC valve 10-57-1 BS PC60-6 Serial No.: 34101 and up PC6OL-6 Serial No.: 8076 and up PC90-1 Serial No.: 1404 and up 920106 7 20106303 1, Hydraulic pump 7. LH, work equipment control laver 2. LH 6-spool contro! vaive 8. LH. travel control lever 3. A.H. 5-spool control valve 9. RH. travel control leverSee eee 5. Safety tock valve 6. LH. PPC valve eR ee 11. RH. work equipment control PC60.6 (WITH BLADE) Serial No.: 28001 ~-34100 io 1 Hydraulic pump 2. LH. 6-spool control valve 3. AH. 5-spool control valve 4 Shuttle valve eee ee ee 1 8. LH. work equipment control lever 9. LH. travel control lever 10. RH, travel control lever 41. RH, PPC valve Se ei a gS Acc lever 10-57-2 5 Fr0106304 020106work equipment control lever 7H PPC valve 10-57-3 é PC60-6 (WITH BLADE) Serial No.: 34101 and up # Blode lower Bucket dump . 020106 1 eormais Wh io f 7 a 8 Fro1083is 1. Hydraulic pump 8 LH. work equipment control lever 2. LH. 6-spool control valve 9. LH. travel contro! lever 3.A.H. 5-spool contro! valve 10. R.H, travel control lever 4. Shunte valve 11, LH PPC valve 5 Blede control valve- 19 Blade cantral lever6. Safety look valve 13. R.H. work equipment control fever 7. LH PPC valve 10-57-4 % PPC VALVE PC60-6 Serial No.: 28001-34100 PC6OL-6 Serial No.: 8001—8075 PC90-1 Serial No.: 1001—1403 g S 20208086 a. Pport (trom charging pump) FUNCTION b. Tort {To tank) * The PPC valve supplies pressure oil from the we. Fe port (LR, arm in/RLH., bun sarse) charging pump to the side face of the spac! dd) Paport(L KH: RK. swing/R-H. bucket dump) ol each control valve according to the amount1 10. 20106 Py port (LH. arm out/R.H., boom lower) Ps port (LH LH. swing/RH. bucket curl) 58 & Section C ~C 1. Spoot 2, Metering spring 3. Centering spring 4, Damper piston 5. Damper spring 6. Piston of travel of the control lever This pressure oll actuates the spool 202F05067 7.Disk 8. Lever 9. Joint 10. Plate 41. Collar 12. Body10-59 OPERATION 1) Controi fever at neutral Ports Pt and P2 of the PPC valves in circuits A and B of the conisol valve are connected todrain chamber B through fine contro! hole Fin spool (1). (Fig. 4) 2) Control lever operated trol) When piston (8) starts to be pushed by dise (7), retainer (13) § pushed. Spool (1) 1s also pushed by spring (2) and moves down aay When this happens, fine control hale t « Lng contrat vaive shut off from drain chamber D At almost a the same time it is conrwsted te pump Fiot 202F08066 pressure chamber Pp, and the pilot pressure ‘of the control valve is sent through fin control hole f to port Pt, When the pressure a1 port P1 rises, spool |1) is pushed back Fine control hole fis shut off from pump. pressure chamber Pp. A: almost the same ume its connected 0 drain chamber D, $9 the pressure at port P1 escapes 10 drain chamber D Spool (1) moves up and down unt) the force of metering spring (2| is balanced with the pressure of port Pt The relationship of the positions of spoal (1) and body (12) (fine control hale fis in the middle between drain hele D and pump pressure chamber Pp} does not change unul damper piston (4) conzacts piston (6) Therefore, metering spring(2) seompressed ‘9 propertian te the travel of the control lever, 9 the pressure at port Pt also rises in proportion to the travel of the contro! lever The spool of the contral valve moves to a position where the pressure of port A (same a8 pressure at port Pr and ihe force fo the sein ipin aralilcn, i Gi Leaps norton Addie 020106(Fig 10-60 020106 2) 3) During fine control (control lever returned} When dise (7) starts to be returned, spooi (1) 1s pushed up by the force of cemering (2) and the pressure at port Pa Because of this, fine control hole f is connected t drain chamber D, and the pressurized oil at port P1 is released if the pressure at port P1 drops too much, spool (1) is pushed up by metering spring (2), 80 tine control hole 4 1s shut off from drain chamber D. At almost the seme time it is connected to pump pressure chamber Pp, so the pressure at port P1 supplies the pump pressure until the pressure recovers (0 @ pressure aquivatent to the position of me lever. When the contral valve spool returns, oil in drain chamber D from fine control hole of the valve on the side that is not moving folws through pori Pz and goes to chamber B, so the oil 1s 1s charged. (Fig. 3) 4) At full stroke Disc (7) pushas down piston (6), but damper piston (4) also follows this and pushes down spool (1). Fine contro! hole Fis shut off from drain chamber D, and is connected to pump pressure chamber Pp. Therefore, the pilot pressure oil from the charging pump passes through fine contral nole f and flows to chamber A trom port Pt 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 With damper piston |4) that was following piston (6), the pressurized oil in the spring chamber flows out from orifice a, and damper piston (4) and spool |1) are pushed back by the force of metering spring (2) and the hydraulic pressure at port Pt The time lag when the lever 15. suddeniy operated 1s prevented by damper piston (4) (During fine control, damper piston (4) does not follow piston (6), so the fine control reve | ge Fig 2 202F05063 202F05070 Control vaive Ee an + ig 4)performance is maintained,| (Fig. 4) AR ne 10-61 PC60-6 Serial No.: 34101 and up PC6OL-6 Serial No.: 8076 and up PC90-1 Serial No.: 1404 and up 3 g 8 ll . a | 5) 4 | / f : @ 2orFo ‘002 P port (Fram charging pump) T port (To tank’ P2 port LH: Arm dump/R.H. Boom lower) Pa cort iL. H = Swing left/R.H.: Bucket curl)10-61-1 s 9010704. Piston 5 Disc OPERATION 1) Atneutral Ports A and B of the control valve and ports P7 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool 1) (Fig, 1) 2). During fine contro! (neutral fine control) When piston (4) starts to be pushed by disc |S), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down When this happens, fine control hole f is shut off from drain chamber D, and at slmost the same: ume, it is connected to pump pressure chamber Pe, so pilot pressure oil from tha charging pump. passes through fine contro! hole Fand goes from port Pr te por A When the pressure at port Pr bacomes tugher sp00| (1) 1S pushed back and fine control hole fis shut off from pump oressure chamber Pr At almost the same time, it is connected to drain chamber D fo release the pressure at port P1 When this happens, spool {1} moves up or down 0 hat the force of mataring spring (2} is balanced with the pressure at port Pt. The relationship ‘8 the position of spool (1) and body 10} (tine gonitol hole Fis at a point micway nerween drain hole D and pump pressure: chamber P| dees not change until retaimer (9) contacts spool (1) Theretore, metering soring (2) 1s compressed proportionally to the amount of movernent of the: zon rol lever, sothe pragsure at port Pr alsa rises in propertion to the traval of the conteat lever. In this way, the eantrol valve spool moves toa position where the pressure in chamber A (the ines: 10, Body a 2oTFo1D4s 2oTFOoas 8 g 8CINE | Cine FP EES BE BE EY ES TENE: TE of the control valve spol return spring are balanced (Fig. 2) 10-61-3 3 020106 3) During fine controt {when contro! lever is 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 Pa When this happens, fine control hole £ is connected to drain chamber D and the pressure oil at port Py is released. If the pressure at port P1 drops 100 far, spool (1) is pushed down by metering spring (2), and fine contrat hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber Pr, and the pump Pressure is supplied until the pressure at port Pt recovers to 4 pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in trom tine control hofe f* in the valve on the side that is not working. The cif passes through port P2 and aniers chamber 8 to fill the chamber with oil. (Fig. 3) 4) At full stroke When disc (5) pushes down piston (4), and telainar (9) pushes down spool (1), tine contrat hote fis shut off from drain chamber D, and is, connected with pump pressure chamber Pp, Therefore. the pilot pressure ail from thecharging bump passes through fine control hale and flows te shomber A from port P1, and pushes the control valve spool The oil returning from chamber B passes from port P2 through fine control hole #” and flows 10 drain chambar D (Fig. 4) a 20TFO 1085 93) in 4 a f pe © mag] Control valve PGB 20TFo108? (Fig ay10-61-4 SOLENOID VALVE ASSEMBLY PC6O, 6OL-6 FOR TRAVEL SPEED, SWING BRAKE, POWER SET AND STRAIGHT-TRAVEL 070106 201606063 T port (To tank} 1. Block P port (From charging pump) 2. Travel speed sotenoid vaive Tr port 3, Swing brake solenoid valve Te port 4, Power set solenoid valve Ts port 5. Swaight-travel solenoid valve Ax port (To LH. and RH. travel motor) Az port (To swing priority valve and swing motor) Aa port (To front and rear servo valve) tha port Ifo: etraichttravel vale)10-62 i PC90-1 FOR TRAVEL SPEED, SWING BRAKE, POWER SET STRAIGHT-TRAVEL AND 2-STAGE RELIEF 0201068 201F0606a T port (To tank) 1. Block P port (From charging pump) 2. Travel speed solenoid valve T1 port 3. Swing brake solenoid valve T2 port 4, Power set solenoid valve ‘T3 port 5. Straight-trevel solenoid valve 6 At port (To LH. and R.H. travel mator} A2 port (To swing priority valve and swing motor) As port (To tront and rear servo vaive) Aé port (To straight-travel vatve) 2-stage relief solenoid vaive -sesepange— a ne Cannector Plunger Coil Push pin Spool Spring Block Neosens Section A 202FOSO75 OPERATION Solenoid deactivated © No signal current flows from the controller, so solenoid (8) is deactivated. As @ result, spool (5] is pushed to the left in the direction of the arrow by spring (6) Because of this, port A is closed, and the pressurized oil from the charging aump does not ilow to the actuator At the same time, the oil from the actuator flows from port B to port © and is drained to the tank 3 a § 202708076 Solenoid excited * When the signa! current flows from the controller to solenoid (3), solenoid (3) is excited As a result, Spool (5) is pushed to the left in the direction of the arrow by push pin (4) Because of this, the pressurized oil from the charging pump passes from prot A through the inside of spool (5), flows to port B and then flows to the actuator. At the same time, port C is closed, so the oil does not flow to the tank Actuator |202F 08077 10-64 020108, SAFETY LOCK VAVLE Lever Body Seat Ball End cap 1 2 3. 4 5 201F 06087 SHUTTLE VALVE FOR WORK EQUIPMENT OIL PRESSURE SWITCH AND SWING OiL PRESSURE SWITCH Plug Bady Ball Ps port (LH. swing) Ps port (F.H. swing) P? port (Arm in) Pa port (Arm out) Pt port (Boom raise) Pa port (Bucket dump} P2 port (Boom lower) |. Ps port (Bucket curl) Bs port {installed hole of work equipment oil pressure switch) B2 port (Installed hale of swing oil pressure switch)201F06068 10-65 1 HYDRAULIC CYLINDER 1. BOOM CYLINDER 201F06070 3. BUCKET CYLINDER 02010610-66 7 020106 4. BLADE CYLINDER (PC60 WITH BLADE) 201F06071 1, Rod side bushing 2. Piston rod 3. Cylinder head 4. Rod packing 5. Buffer ring 6. Wear ring 7. Cylinder SPECIFICATIONS 8. Head side tube 9. Casting ring 10. Piston ring 11. Wear ring 12, Piston 13. Piston nut 14, Bottom side tube 201F 08826 15, Bottom side bushing 16. Bottom side cushion plunger 17. Ball 18, Collar 19, Head side cushion plunger Unit: am = Cyuncer Boom arm ce Fe60 P80 po80, ao. | p0«0 sae = PC6OL ee PCEOL, pean PcaG WITH BLADE) Cylincer insice diameter 10 | 110 a0 108 390 130 | | Piston tod outside dlamener ws | | 60 | 6 % | 70 T ‘Stroke 1,005 1,000 870 910 710 150 Masiniom le pass | 2ase | 2201 | 2207 | 1023 | 600 Mint oath vaso | tas | vast | ager | ain | ao Piiton fat widen acres Mate nm | | 6 | | o | oWORK EQUIPMENT 1 Bucket 2. Bucket cylinder 3. Arm 4. Arm cylinder Smal! swing specification (PC60, 6OL) * By changing the position of the pin in the mounting hole at the boom cylinder bottom on the revolving frame, itis possible to change to the smali swing specification by raising the boom higher than normal * For details of the values, see the Speci- fication Dimension Drawing 10-67 8 8 8 2orFoBea? 5. Boom 6, Boom cylinder 7. Blade cylinder {PC6O WITH BLADE} 8. Blade |PCGO WITH BLADE) Sag py im (Py Boom eyhnder es / Sinall swing Standard swing position postion snarcenecea:10-68 3 ELECTRICAL WIRING DIAGRAM. COV MpENs 10. W 12 14, +5 Monitor panel Swing lock switch Horn switch Starting switch Fuel control dial Cigarette lighter Buzzer Service meter Radio Swing lock prolix ewitoh System controller Engine throttle controller Heater Glow plug resistor Jinan bathe 18, 19. 20. 2 22. 23 2a. 26. 26. 2 oR Detail A Speaker Heater Hi relay Fuse box Working lamp, 2-stage relief solenoid valve (PC90- 1 only) Straight-travel solenoid valve Power set solenoid valve Swing brake solenoid valve Travel speed solenoid valve Room lamp. Pispenveert irene: 31 32 33 34. 35. 36. 37. 38. 39 40 a ao 0106011 Conant temperature sensor Swing oil pressure switch Work equipment oti ressure switch Fusible link Battery relay Battery Alternator Engine oil pressure switch Wiper motor LH. travel limit switch RH. travel limit switch Horn. 02010616 Wipor retay 29, Glow plug 43, Fuel level sensor 17 Heater Lo relay 30. Starting motor 44, Head |amp 10-70 wortENGINE CONTROL020106 5 View Z F20106018 1, Starting seritch OUTLINE 2 Fuel comtrel dial * Tho engine can be storted and stopped simply 3. Governor motor by using the starting switch 4. Staring motor © The engine speed can be controlied using @ 5 Battary relay dial contro! system for the fuel control 6. Battery * The engine throttle controller also controls 7. Engine throttle controller the engine speed at the same time using 8. Fuel injection pump signals from the system controier. For detail, see TOTAL CONTROL SYSTEM 10-75 i GOVERNOR MOTOR LINKAGE020106 F20100331 1. Governor lever 2. Spring assembly 3. Governor motor 10-76 7 1. OPERATION OF SYSTEM Starting engine When the starting switch is turned to the START position, the start signat fiows to the starting | s motor, and the starting moter turns to start the EES engine 7 AL When this happens, the engine throttle con: ' teoller checks the signal voltage from the fuel control dial and sets th engine speed to the set speed, Fuck contrat diet «2 zoar0B0g?Engine speed control The fuel control dial sends 2 signal valtage 10 fuer contri sai fA" the engine throttle controller according to the a position of the dial The engine throttle controller caiculates the angle of the governor motor according to this signal valtage, and drives the governor motor 30 that it 18 Set to that position When this happens, it detects the operating angie of the governor motor using @ potent! ometer and observes the governor motor Engine woe 020106 Stopping engine — When the engine trate controller detecte that iy the starting switch is at the STOP position, it dees the governor mator to set itto the ac Z injection positon, and stops the engine Se When this happens. to maintain the electric a power in the system until the engine sions completely, the engine throttie controller sel drives the battery relay. { 2oar0so89 10-77 7 2. COMPONENT EQUIPMENT OF SYSTEM. 1) ENGINE THROTTLE CONTROLLER