‘SEBM021TA103 SOW IMCA\INTUZA\ IL KOMATSU PC1600-1 MACHINE MODEL SERIAL No. PC1600-1 10001 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. + PC1600-1 mount the SA6D140 engine For details of the engine, see the 60140-1 Series Engine Shop Manual Printed in Japan 00-1 06-89(01)00531 310 20 30 40 CONTENTS No. of page STRUCTURE AND FUNCTION....................... 10-1 TESTING AND ADJUSTING .....................08. 20-1 DISASSEMBLY AND ASSEMBLY ................... 30-1 MAINTENANCE STANDARD ... o21TAto21Tat ‘The affected pages are indicated by the use of the following marks. I is requested that necessary actions be taken to these pages according to the table below. T ] Mark | Indication Action required | Page to be newly added Add : © | Page to be replaced Replace ho (}] Page to be deleted Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGES . or 8 ms on os ‘oe or I A 7 on rose | i ioe oe oa ‘ow ia _ oo oe oa mo ioe ote i oo sos08 oo 1020 noe iss 0108 oo ine tose = rose = tose rose os iat toa 1080 v0 ‘ome bo 1038 1080 1087 os oo ‘030 oa ro0e or 00-2-1 3Mark Page TIME F| mark Page Tot | mark Poe TUTE OF | Mark Page LTE Ot| mark Page [me of 10.128 + soa G 20.38 27% 212 10.129 s0.172 wa a 2mm 20.126 10.130 10.173 20: 38 ra 20125 10131 10.4174 ee rear © 20128 ©) ro.132 20-40 roa 127 0.4133 20-4) mas 20.18 sors 20.1 2-42 ma orm) 10195 22 4 roa 4) 2-88 20190 10.196 m3 o 20-48 ne prs a 10138 24 1 20.48 @ 2-88 noi) 10139 25 D |e m4 @ 20-90) 213 OD 10.140 20. 6 |. ma 9 2-91 wim roa 27 > | 2049 m2 201% ro142 | me 9 | m5 4 mos 2138 s0149 mo T |e mn @ 296 roi roa 20.10 20-52 20-95 20-138 ros 20.11 20-53) 298 ma 10-146 20.12 20-54 97 8 100 so447 20.13 20.85 2098 2 roaar 10.148 | 2014 20.56) 20.99 20182) r0149 j> B =o 2057 201004 2018 10160 Higteoo ea 20: 58 200012 20846 10351 } ma 20.89) 20102 20185) 10182 | m1 20-602 20102 201884 10182 20.19 4 61 20:08 20487 10184 | w20 4 2062 201082 20.08 10-185 a 2-632 20107 249 © 10-158 20.22 2066 20.108 2150 10157 | 23 4 20-654 20408 2181 10.159 20-241 20-65 21102 ror 10-160 ozo ede eecer ee 2011 20153 @ 10161 20: 26 20- 68 20.4112 2158 @ 10-162 20. 27 20. 69 20.119 20185 10163 20.28 20: 70 214 1 20188 10.164 wo 1 | wn 2152 20187 @ 10-165 20.201 20.72 2116“ 20188) 10-168 20-98 20-73 aout a 20188 2) s0167 20. 92 20% 4 zone 20160 @ 10-168 20.33 20:78 4 roars“ 20162 10-169 34 1 |» 20-76 20120 ors @ 10.170 20:35 | zm 20821 20164 @ 00-2-2 021TAI21TAt Mark Pane TimeF | saark Page TimEOH) atark rage TIMES] mark Page Tne St| Mark Page Teaton, 201681 soa 30. 44 308s 4 301764 rors @ we 4 30.45 30-88 win 20.168 ws aoa 30871 soi za 4 | wee © goa 4 30. 88 so van @ | eT ao4e soa} 20.130 zone 20 8 ao49 A sos worst 20.173 we 9 30:50 soo w012 @ zoam 2 so 1 wos A seer gorse 20175} won 1 20. 82 30-93, 20138 wie 2 | wt ass soot 20138 D ran @ 013 woes 1 oes 1 20137 2oame 2 4 30887 so9 4 30138 zoarre i | 2068 so97 7 019 row 7 | 18 I wos? 30981 sora 2 ronan 30-17 30. 58 so 1 wore 20183 | wow I 0: 59 a0100 oe 2018s 20:19 30: 60 sow wos © 200883 2020 1 gost so102 sone © 200873 2} 20: 62 so10s 204s © m1 3 20221 26 sot0e 2048 zoo 1 | 30-23 I a6 30108 soner 20190 1 30:24 206 30-108 3018 zoasr 30: 25 20: 68 30107 sora + n102 3 30-28 67 soa0e s0.150 + 201993 3027 2068 3009 so181 + 218 3 3078 2069 sore D wise «20195 3 07 3070 soa soass + 70196 3 30. 20 vo i soa so1s¢ = m197 3 wet 30.72 sos aorss 20198 | 30:32 30.731 sore sorss zor 2 | ss so 4 3018 gorsr 20200 2 036 20: 75 30-116 gorse = 20201 3 3035 20: 78 soa17 sorss © 70002 3 3036 om sore aoaso noma 2 wa i woe | 20.19 soar © «20206 3 381 a0 30120 30162 202052 09 380 | aorar 30463 30. 40 aoa aor 30-164 a0: 41 0: 82 30.123 gores we moat soe sor sores D 2 v.43 woes s0128 aoasr_ee ee ee ee wns @ oa 20100 D wa | 2018 1 sos | | 30176 D 40-9 \ | 30178 D 4040 | 320179, D D 40-18 | sow | 40-13 30184 D r 40-16 | Seta ea woes ea wwe 0 oa seas rr aor | ® 40-24 see On| a woe 0 i mmo woot wore won aca00 fee mas 0 mas | 0-2-4 3 o21TAtA 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 AM and "AX" are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous, Read the Operation and Maintenance Manual carefully BEFORE operating the machine 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine 2.When carrying out any operation, always wear safety shoes and helmet, Do not wear loose work clothes, or clothes with buttons missing. « Always wear safety glasses when hitting parts with a hammer, © Always wear safety glasses when grinding parts with a grinder. etc. 3.If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work 4. When carrying out any operation with two ‘or more workers, always 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 keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking, Never smoke while working, PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling, In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work 10. Remove all mud and oil from the steps or other places used to get on and off the machine, Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned, Wait for the oil and water to cool before car- rying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use 2 hoist or crane Check that the wire rope, chains and hooks, are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any art still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on. opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or ail drips on to the floor, wipe it up immediately. Fuel or oi fon 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 mini- mum of gasoline when washing electrical parts. 00-4 19. 20. 24 22 23 24, Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts * When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed When assembling or installing parts, always use the specified tightening torques. When. installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements, Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates 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 accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity This shop manual mainly contains the necessary technical information for operations performed in a service workshop, For ease of understanding, the manual is divided into 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 serves as reference material for troubleshooting. 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” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts, NOTICE The specifications contained in this shop manual are 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 carrying out repairs, They are divided as follows: Chassis volume: Engine volume: Issued for every machine model Issued for each engine series Each issued as one volume to cover all models Electrical volume Attachments volume These various volumes are designed to avoid du- plicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment 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 order 2. Following examples show how to read the page number. Example 1 (Chassis volume) 21-3 Unit number (2. Power train} tem number (1. Structure and Function) Consecutive page number for each item Example 2 (Engine volume) 12-410 TTT Unit number (1. Engine) I Item number (2. Testing and Adjusting) |_| Group No. (4. Fuel systern — Consecutive page No. [Page 10 of Group 3. Additional pages: Additional pages are indicated by a hyphen () and number after the page number. File as in the example 00-6 REVISED EDITION MARK (@2@-~) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the UIST OF REVISED PAGES on the between the title page and SAFETY page SYMBOLS So that the shop manual can be of ample practical vse, important places for safety and quality are marked with the following symbols, Symbot | item Rornarks Special safety precautions are A necessary when performing the work Sotety Extra special safety precautions are necessary when performing the work because itis under internal pressure ‘Special technical precautions or | other precautions for IK | Caution | preserving standards are | necessary when performing the work Weight of parts or systems, Caution necessary when selecting hoisting wire, or when working posture is important, (ie) | Weight oe Grae) | Tighten ing torque Places that require special attention for the tightening torque during assembly Places to be coated with adhesives and lubricants ete Places where oil, water or fuel Oil, water | must be added, and the capacity Places where oll or water must Drain |e drained, and quantity to be drained,HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Ad Heavy parts (25 kg or more} must be lifted with a hoist ete. In the Disassembly and As sembly section, every part weighing 25 kg,or more is indicated clearly with the symbol 1. Ifa part cannot be smoothly removed trom 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 adequate ropes depending on the weight of parts to be hoisted, referring to the table below Wire ropes (Standard "2" or "S” twist ropes without galvanizing) Rope diameter (mm) | Allowable load {tons} 10 | 10 112 14 125 16 14 22 16 28 18 36 20 44 224 56 30 100 40 180 50 280 60 400 ‘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 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. BOG 4 4 007% Bs 7% 41% 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 may cause turning of the load during hoisting, untwisting of the rope, oF slipping of the rope from its original winding position on the load, which can result in a dangerous accident 4} Do not sling a heavy load with ropes forming @ wide hanging angle from the hook ‘When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles, The table below shows the variation of allowable load (ka) when, hoisting is made with two ropes, each of which Js allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 ky of total weight can be suspended. This weight becomes 1000 kg when two ropes make @ 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at alifting angle of 150° Littag angie: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, Exceptions are given in sections of ‘Disassembly and Assembly” Thread diometer win ‘ibon cross ft ( a : . _ kam ] Nm § vo seers meee [eee soon 8 13 a2+03 | 314229 10 Ww 67+07 | 65.7468 2 19 ls=10 Nax98 14 2 18020 | 17819 16 24 28523 | 27928 18 27 gona | 393.39 20 30 s6+6 54958 22 32 768 7145078 2 36 oast0 92798 27 a1 138215 1320140 30 46 17520 17202190 33 60 225+25 | 22104240 36 56 28030 2750:+290 39 60 395435 3280340 This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque. 4+ Nm (newton meter: 1Nm = 1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts Thread diameter Width Tightening torque of bolt across flats - + — (mm) eam) kam | Nm 10 14 67407 | 65.7468 12 7 11521 112498 16 22 28543 279429, 00-8STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared Thvepa diameter | With across ats tig o] _ — tr tr tam New 14 19 25405 | 245+49 18 2 52 9196 2 2 se2 785196 24 2 aes | 13734294 30 36 1823 1765294 33 a 2008 196.1 #49 36 46 2845 2452449 a 88 3025 | 294249 COATING MATERIALS (iw ‘The recommended coating materials prescribed in Komatsu Shop Manuals are listed below Nomenclature Adnesives uaa Used to apply ber pads, rubber gaskets, and cork plugs ‘Used to apply resin. rubber, metallic and ronsmetaie parte when sft trong sels needed Preventing bolts, outs and plogs trom loosening an leaking of Provides an Used for at Ngee nang sea Used with gaskets aa packings to increase seating Lina gosto 2 fet = iG (Thickness after tightening 0.07 — 0.08 mm) Tas] testo get grease fon tnared sro ngs Bnd apse oS {fittings in hydraulic circuits of less than 50 mm in diameter. touncaet ee owe vege an toe [tition grease prevention an felitation af asserting work Vaseline Used for protecting battery electrode terminals trom corrosion. *LT-2is also called LOCTITE in the shop manuals 00-9ELECTRIC WIRE CODE aay 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: SWB indicates a cable having a nominal imber § and white coating with black stripe CLASSIFICATION BY THICKNESS 5 65 032 | 523 46 ~ a7 Charging and signal 45 a4 045 3.36 70 59 Starting (Glow plug) 40 35 | 080 42.73 114 135) Starting 700 [a1 | 080 | yea P| 280 sim CLASSIFICATION BY COLOR AND CODE Greue Prot | gaa chovaig | Ground | Starting Lighting | instrument Signal thee y few peop wd 3 = v.16 T mary FGoior| white Block Black ed Yellow Green Code | wR = aw aw vA ow iw Color] White & Red Black & White | Rede White | Yellow & Red | Green White | Bive & White cose] wa we ae ve Gl tw a fore] _WS - — a ‘nun| Color] white x Biack | | Binck # Yellow | Rea Ainck | Yetow Alack| Gween&Aed | Bes Rea tev Code] wi = aR wy ve aw v White & Bloe = Black & Red | Red 8 Yellow | Yatlow & Green | Green & Yeliow | Alue & Yellow we 5 me | wo ry 5 [ee 6 - o o Colo | White & Green Rea Green | Yeliow & Blue [Green & BlacN | (Blue Black Code = 5 5 Re Ww ao 6 L —|- = — —— Color 5 5 Reda Blue |Yelow A White| (Green & Blue) = 00-10WEIGHT TABLE AL This weight tabieis a guide for use when transporting or handling components. Unit: kg Machine mode! PC1600-1 Serial No, 10001 and up Specification BACK HOE LOADING SHOVEL Engine assembly 2,606 2,608 + Engine 1,620 1,620 + PTO (including lubrication piping) 520 520 + Main piston pump 4ag (147 + 164+ 137)|448 (147 + 164 137) + Tandem gear pump 177 177 Radiator assembly (Excluding radiator guard) 646x2 646 x2 Oilcooler assembly 112x2 1122 Hydraulic oll tank (Excluding hydraulic oi) 1,390 1,390 Fuel tank (Excluding fuel) 1,415 1415 Revolving frame (Including LH. and RLH. platform) 38,000 38,000 Operator's cab ‘600 600 ‘Swing machinery 870x2 870x2 ‘Swing motor 122x2 122x2 Travel motor 180x4 180 x4 ‘Swing control valve 110 110 LH. 5-spool control valve 245 x2 245 x2 RH. 4-spool control valve 240 x2 240 x2 ‘Center swivel joint assembly 69 69 ‘Counterweight (Excluding mounting bolt) 21,000 21,000 Track frame assembly + Track frame 23,000 x2 23,000 x2 + Cartier roller 0x6 70x6 + Track roller 280x16 280x16 + Idler cushion assembly 885x2 885x2 + Idler 1,110 x2 | 1,110 x2 + Final drive assembly 2,810 x2 i 2,810x2 + Swing circle assembly 2,740 2,740 + Center frame assembly 14,000 14,000 00-12 021TAI021TAI Machine model PC1600-1 ‘Serial No, 10001 and up ‘Specification BACK HOE LOADING SHOVEL Track shoe assembly + Standard shoe (810 mm) 16,940 16,940 +_ Optional wide show (1,010 mm) 20,960 20,960 Boom assembly (Excluding piping) 14,300 9,350 ‘Arm assembly (Excluding piping) 5,650 6,630 Bucket assembly (Excluding piping) = 17,100 ‘Boom cylinder assembly 1,860 1,830 ‘Arm cylinder assembly 1,255 995 Bucket cylinder assembly 820 1,005 Bottom dump cylinder assembly = 335 00-13LIST OF LUBRICANT AND WATER AMBIENT TEMPERATURE CAPACITY (2) 43250 BB <0 0 tee RESERVOIR | KIND OF FLUID soecitied | Refi Tar Engine oi pan (eseh) 335 SAE 10050. SAE Towa0) SAE PTO case (each) Engine oi ‘Swing machinery cate (each) inal drive case (each) SAE IO) aa Ke 1m Hydraulic system RE Ae SAE 16020) 026-098 | 02-098 1.08 1.15 | 1.05 = 1.18 Carrier roller (each) tata “rack roller (ezen} rater (een) Fuel tank Diesel fuel ASTM DDE Naa) Cooling system (eeeh) Water Add antifreeze 18 ASTM 0975 No.1 note: (1) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric tem- change ot inthe of pan svery perodie mano: perature of lower than O°, be sure to se engine nance hours descbadin the mance oirof SAETOW, SAETOW-20 and SAETSWe0 henge ol according tothe folowing tbl ua tven tough on stmosphete temperature goes up suphor Sontentis above 0 Sie to 10°C more orlssin th dy tne (3) Use API classification CD as engine oil and if API valat oi Fuelsuphurcontet | Chengeinerysl of tin clssfeston C6. reduce the engine ol change - tevl oat 051010% | 1/2 ofreguar interval Avowe 1.0% | 1/4 oregularintavel ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers ‘Specified capacity: Total amount of cil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. 00-14 021TAt10 STRUCTURE AND FUNCTION O21TA1 PTO (Power Take-Off) PTO lubrication system Radiator and oll cooler Auto-deceleration system Power train Travel and brake system ‘Swing system Track frame Idler cushion Idler Track roller Carrier roller Track Airsystem Airgovernor ‘ir tank Safety valve oe ‘Solenoid valve (for lubrication, horn) Grease pump Greasing system Hydraulic piping diagram Hydraulic circuit diagrm Work equipment control ‘Automatic work equipment control system Hydraulic tank 10- 10- 10- 10- 10-13 10-14 10-28 10-52 10-53 10-56 10-57 10-57 10-58 10-59 10-60 10-60 10-61 10-61 10-62 10-63 10-66 10-68 10-71 10-79 10-87 Main pump. Hydraulic ol filter Charging and PTO lubricating pump 2-stage and 3-stage mode selector OLSS. Control valve : PPC valve PPC shuttle valve ‘Accumulator Pilot relief valve Safety lock valve Hydraulic cylinder ‘Work equipment Electrical circuit diagram Electronic components of 3-stage mode selector OLSS . Electronic components of automatic work equipment control system EVMS (Electronic Vehicle Monitoring System) 10-88 10-108 10-110 10-111 10-128 10-138 10-144 10-145 10-146 10-148 10-150 10-154 10-156 . 10-159, 10-164 10-168 10-1PTO (Power Take-Off) Driven gear (No. of teeth: 46) PTO case Drive gear (No. of teeth: 51) Input shaft Connecting plate 6. Driven gear (No. of teeth: 41) 7. Driven gear (No. of teeth: 43) pPene Volume of lubrication oil 10.0 (Erigine oil CLASS-CD SAE3O) Reduction ratio: 1Pv20 + 90 pump shot =£2-= 0849 vev60 pump anti = #8 0902 SAL63 +8 pump shaft =<1-= 0.804 10-2 Section A= A, 2rTAFO1001 209F3002 o21TAto21TAt PTO LUBRICATION SYSTEM opens PTO case Lubrication piping Dividing block ‘Charging and PTO lubrication pump (SAL63 + 8) iltank 21TAFO1002 OUTLINE The lubrication oil from lubrication oil tank (5) goes. to tandem gear pumps (4), The oil passing through gear pump SAL8 is sent to the upper dividing block (3), and from here it is divided and sent to all parts of the PTO to lubricate and cool al parts of the gear. 10-3RADIATOR AND OIL COOLER ‘The fan is driven by a V-belt between the fan pulley land the engine pulley. The fan is a suction type which ‘sucks in the outside air through the radiator core an il cooler and sends it forcibly to the engine. Radiator outlet tube Fan pulley Radiator inlet hose Fan guard Pressure valve Fan Radiator upper tank Radiator core Oil cooler inlet tube Cit cooler core Oil cooler outlet tube Radiator lower tank h J Radiator drain valve Section A—A WONORRENS asrs 21TAFO1003 10-4 021TAIo21TAt * FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM. AUTO-DECELERATION SYSTEM Engine running, all control levers at “Neutral” ‘Accumulator Semromsene 1 12. 00m Bucket RH travel LH. rave Charging pump Solenoid valve Decelerator cylinder Loose spring Engine control governor lever Fue! control lever Control box Auto-deceleration switch PPC oll pressure switch LH. PPC valve Travel PPC valve RH, PPC valve 'SA6D140 engine 5 © GS] deceleration ‘© The diagram shows one unit. 21NF01003 FUNCTION ‘When all the control levers are at “neutral”, such as when waiting to start work, the auto-deceleration system automatically moves the engine governor lever back to the “middle idling” position ("DECELER- ATION” position) even if the fuel control lever is at the “Full speed” position. This reduces the engine speed and also reduces fuel consumption and noise. 10-5%* FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM OPERATION 1. Engine running, control levers at NEUTRAL 1) When fuel control lever (6) is set to the FULL position and the control levers are returned to NEUTRAL, the hydraulic pressure in the PPC circuit does not act on oil pressure switch (8), so the switch is closed. For this reason, an electric current flows to contro! box (7) and the control box sends out an electric current to excite SOL A (2) When the solenoid valve is switched, pres- sure oil from charging pump (1) acts on decelerator cylinder (3). The cylinder extends and engine control governor lever (5) is moved back to the No. 1 deceleration post tion. Fig. 1) When this happens, loose spring (4) is com- pressed, so fuel control lever (6) is not moved back: The engine speed at this point is 1,850 — 1,950 rpm (No. 1 deceleration speed) 2) When 0.25 seconds have passed after the levers were moved to NEUTRAL, the electric signal from control box is cut, and solenoid valve (2) is switched. When the solenoid valve is switched, the pressure oil from charging pump (1) and the drain oil from the decelerator cylinder (3) are shut off, so engine control governor lever (5) is held at No. 1 deceleration position for about 4 seconds. 10-6 ‘Accuruator F21Noi001A 1 [ saso120 Accurotor F21N01002A o21TAt021TAI ‘* FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM 3) 4 seconds after levers are placed in NEU- RAL, the control box sends out the electric current to switch solenoid valve (2). When the solenoid valve is switched, the pressure cil from charging pump (1) acts again on decelerator cylinder (3). The cylinder extends. and engine control governor lever (5) is moved back to the HALF-OPEN (decelera- tion) position. (Fig. 3) ‘When this happens, loose spring (4) is com- pressed, so fuel control lever (6) is not moved back. The engine speed at this point is 1,200 — 1,500 rpm (deceleration speed). Engine running, control levers being operated If the work equipment control levers are operated with fuel control lever (6) at the FULL position, the pressure oil in the PPC circuit acts on oil pres- sure switch (9) and opens the switch. If either of these switches is opened, control box (7) sends an electric signal to excite SOL B (2). As a result, the pressure oil from the charging pump does not act on decelerator cylinder (3) The oil at the bottom end of the cylinder is drained, so the force of the cylinder return spring ‘and the force of the loose spring move the engine control governor in the direction of the FULL position. (Fig. 4) ‘Accumustor F21No1001A 11 [Saep120 | 9) CH Sane” LR Ful F21NO10034, Fig 10-7% FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM OPERATION TABLE [ Opraion nae Cperuion | eee ¥ seo : Decelerator Not operation Not Jeceleration Not operation condition ae deceleration a ° Engine speed | ree eae crag toriced | 11200-1800 19m | cnange tora lever at "Ful" 2 1,980 rpm | 1200-~ 1500 10 omen sove fav eee W), wave ° Y Pear county | | LI ° VM eae eee 10-8 0.25 second 3.9 seconds o21TAt021TAI 1 DECELERATOR CYLINDER * FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM Cylinder Piston Return spring Bushing Nut ‘Stopper Air bleeding plug Noaeens 21TAFO1008 A. To solenoid valve B. Drain 10-9%* FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM 2. SOLENOID VALVE [ 8 oF 6 3 View lO fo) 1. Cap 8. Spring ‘A. From charging pump 2. Grommet 9. Body B. To tank 3. Cable 10. O-ring P. Todecelerator cylinder 4. Plug 11. Spring 8. Core 12. Plunger FUNCTION 8. Coit 13. Coil The solenoid valve is installed on top of the PTO. itis 7. Plunger 14, Core actuated by the electric signal from the control box and switches the flow of hydraulic oll from the charg- ing pump. 10-10 o21Tat021TA1 * FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM OPERATION 1. SOL A excited (engine running, control levers at NEUTRAL} When the control levers are set to NEUTRAL, the electric signal is sent from the control box for the period indicated by T, (approx. 0.25 seconds), and coil (13) is excited for the period indicated by the hatched lines in Fig. 1. Plunger (12) is pulled in to the left, and ports A and P are connected. ‘When this happens, coil (6) is deactivated, so plunger (7) is pushed into body (9) by spring (8). For this reason port B is closed, and the pressure oil sent to decelerator cylinder, then engine con- trol governor lever is returned to No. 1 DECELER- ATION position. baad sou 8 iz Z soa Lever neutral Lever operation Fiat 20720194 2. SOLA, B deactivated (engine running, contro! levers at NEUTRAL) After 0.25 seconds when the control levers are set to NEUTRAL, for the period indicated by T, in Fig. 2, coils (6) and (13) are deactivated, so plun- gers (7) and (12) are pushed into body (9) by spr- ings (8) and (11). This makes ports A, P and B independent. aay = soe iY SOL A 7 Le Lever neutral Lever operation Fig.2 207F20148 3. SOL B excited (engine running, control levers operated) When the control levers are operated, the electric, signal is sent from the controller, and coil (6) is, excited. Plunger (7) is pulled in to the right, and, ports P and B are connected. When this happens, coil (13) is deactivated, so plunger (12) is pushed into body (9) by spring (11). For this reason, port A is closed, and oil in decelerator cylinder is drained, then engine con- trol governor lever is pulled back to FULL posi tion, Lay = sou. 2ey SOL A Lever neutral Lever operation io. 207F2015A 20503056 20503058 20503060 10-11* FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM 3. OIL PRESSURE SWITCH 1. Plug (PT1/8) 2. Diaphragm 3. Connector oe 2082024 4, AUTO-DECELERATOR SELECTOR SWITCH Prema ay 21TAFO1008 1. Connector 2. Wire 3. Switch 10-12 o21TAto21TAt POWER TRAIN OUTLINE ‘The mechanical power from the engine is con- verted to hydraulic power by No. 1, 2, 3, 4 main pumps and swing pumps. 10 MH 12 ter . Saving motor (front) . Center swivel joint ‘Swing motor (rear) Final drive Travel motor Engine (front) Engine (rear) . PTO 10. No.4 mein pump (P4) | 11. No. 2 swing pump (PS2) 412. No. 3 main pump (P3} 13. No. 2 main pump (P2) i 14, No. 1 swing pump (PS1) 15. No. 1 main pump (P1) 16. Swing machinery 17. Swing circle V1: No. t control valve (4-spoo!) V2: No. 2 control vaive (5-spool V3: No.3 control valve (4-spool) Va: No. 4 control valve (5-spoo!) airaroroos VS: Swing control valve eexrorren~ The hydraulic power from main pumps is divided to each actuator by control valves, it then goes to travel motor and swing motor, ‘and is converted back to mechanical power. This actuates travel and swing. . 10-13TRAVEL AND BRAKE SYSTEM 1. TRAVEL CONTROL CIRCUIT 21TAFO1007 10-14 021TAT021TAI OUTLINE ‘The travel system consists of the following systems and components. © Travel circuit: There are two main circuits (the left travel circuit and the right travel circuit), and these normally form independent circuits for the left and right. © Straight-travel system: When the machine is traveling in a straight line, land the work equipment is operated, the straight- travel system works to interconnect the left and right travel circuits and to prevent the machine from deviating, © Parking brake’ ‘A disc type parking brake is equipped, so when parking on slopes, there is no hydraulic drift in the travel system, © Travel brake valve The hydraulic brake action of the travel brake valve prevents the machine from running away ‘on downhill slopes. 10-15,2. STRAIGHT-TRAVEL SYSTEM This system acts to prevent the machine from deviating when the machine is traveling (FOR- WARD and REVERSE), and the operator uses the boom, arm or bucket circuits. LH.PPCvaive RH. PPC valve Stan tere sivigen™ [nro trot nae 60 iva. Le Ip Sekece| Sega Front engine iva) [lo va psorkri6o > FUNCTION © When the machine is traveling in a straight line and the work equipment is operated, the straight- travel valve operates to prevent the machine from deviating. OPERATION © When the travel system is operated, the pilot pressure oil from the LH. travel PPC valve passes through the PPC shuttle valve and enters the pilot port of the travel shuttle valve to switch the travel shuttle vaive. 10-16 21TAFO1008 If the work equipment is operated when this is happening, the pilot pressure oil from the PPC shuttle valve passes through the straight-travel shuttle vaive and travel shuttle valve and enters the pilot port of the straight-travel valve to switch the straight-travel valve. When the straight-travel valve is switched, the 5-spool control valve and 4-spool control valve are interconnected, so the flow of oil to the LH. and RH. travel motors is made equal and straight-travel is maintained. 021TAIo21TAt (1) TRAVEL SHUTTLE VALVE Cover Body Spool Spool return spring Po port (To straight-travel valve) T port (To tank) :-P, (From PPC shuttle valve) P, (From PPC shuttle valve) ao ge Rene 209F2018 ‘SPECIFICATION ‘Spool switching pressure: 3.4 + 0.5 kg/em? 10-17,FUNCTION © The travel shuttle vaive is installed to the left deck stand of the control valve. When the ma- chine is traveling, it takes the pilot pressure from the RH. travel PPC shuttle valve and switches the spool to send the pilot pressure from the swing arm or boom PPC valves to the straight- travel valve. OPERATION When operating with independent travel systems © When the travel system is operated, pilot pres- sure flows from the RH. travel PPC shuttle valve to port P, and pushes spool (3). When this happens port P, and port P, are inter- connected by the groove in the spool, and they are also connected to the straight-travel valve. However, there is no pilot pressure oil from the work equipment PPC valve, so the straight-travel, valve is not actuated Simultaneous operations © If the arm and travel systems are operated at the same time, pressurized oil flows from the RH. travel PPC shuttle valve to port P, and pushes spool (3) to the right. © At the same time, when the arm is operated, pilot pressure oil from the arm PPC shuttle valve flows to port P,. It passes through the groove of the spool, goes to port Ps, then flows to the straight-travel valve to switch the straight-travel valve. © The flow of the pilot pressure oil is the same when the any of the other work equipment sys- tems are operated, 10-18 ram wave Pee inutte ey 20902003, ce peal HEE ~y t eal toon Pach tisrne toe | | l j ee Shnfevate” [a { From bucket From arm PPC sndlpoam PPC hurtlevave 20903004 o2iTAto21Tat (2) STRAIGHT-TRAVEL VALVE (Equipped on 4-spool control valve) Section —C Section 8-8 209F3020, Orifice Check valve with orifice Spring Spool return spring Body Spool Piston Cover @ryEgsens Pe port (From travel shuttle valve) P, port (To 5-spool control valve "LH. travel”) P; port (From 5-spool control valve inlet) Pr port (To tank) P, port (To arm-Hi) P} port (To boom-Lo and bucket-Lo} P port (From 4-spool control vaive inlet) 10-19FUNCTION ‘© Normally if the travel system is operated at the ‘same time as the boom, arm, or bucket systems, the flow of pressurized oil to the left and right travel circuit is divided and sent to the boom, arm, or bucket circuits. The supply of oll to the motor in the travel circuit where the oil is divided becomes less than the flow of oil in the undivided travel circuit, so the speed of the motor on that side drops and the machine starts to deviate. © However, by switching the straight-travel valve to interconnect the left and right travel circuits, the supply of oil to the left and right travel motors can be kept equal. As a result, both the left and right motors rotate at the same speed, and this prevents the machine from deviating. OPERATION When operating with independent travel systems '® No pilot oil flows from the work equipment PPC. shuttle vaive, so no pilot pressure oil flows from the travel shuttle valve to the straight-travel valve. ‘© For this reason, port P, and port P, are not inter- connected and the circuits remain independent. wultaneous operations @ When the travel system is operated at the same time as the boom, arm, or bucket systems, the pilot pressure oll from the PPC shuttle valves of ‘the simultaneously operated circuits passes through the travel shuttle vaive and flows to the piston end of the straight-travel valve to push spool (6) to the right © Asa result, port P, and port P, are interconnect- ed, and the supply of oil to the left and right travel motors becomes equal, so the left and right travel motors rotate at the same speed and the machine does not deviate, 10-20 To bucket and To LH. travel boom comtrel From §-spoc! contiolvaive valve contr valve net From 4: spool control valve inlet 209030084, To bucket ang To L.M. travel boom contrat From §-exognene 2rTaror022 Oo Sraase can Boom foot pin Boom cylinder bottom pin ‘Swing circle Boom cylinder rod pin Boom point pin ‘Arm cylinder bottom pin ‘Arm cylinder rod pin Bucket cylinder bottom pin Main distributor (boom foot) Chassis distributor (front face of revolving frame) Boom distributor Arm distributor 10-63LOADING SHOVEL SPECIFICATION ‘Grease Grease gun Hose ree! ape =F. WEF Stopper vaive aia o gue | Lean ches ne Dum ‘Grasse can Work equipment —e—A-e Chassis Boom foot pin Boom cylinder bottom pin, ‘Swing circle Boom cylinder rod pin Boom point pin ‘Arm eylinder bottom pin Arm cylinder rod pin Bucket cylinder bottom pin ‘Arm-link connecting pin Main distributor (boom foot) Chassis distributor (front face of revolving frame) Boom distributor Arm distributor 1 2. 3 4 5 6 7 8 9 A 8 c. °. ‘ 2 B 3 21TAFO1023 10-64 o2iTAt021TAI FUNCTION OF EQUIPMENT Greasing switch When greasing, turn the switch on to actuate the ‘grease pump. Solenoid valve The electrical signal from the greasing switch ‘opens or closes the air circuit, thereby opening oF closing the supply of air to the grease pump. Grease pump This is @ reciprocel type pump which is driven by air. It generates a grease pressure forty times the air pressure, During greasing, the grease pressure gauge should read 60 — 200 kg/em. + If itis below 50 kgiemé, it means that the grease can is empty. + If itreads more than 200 kg/em?, chack the indicator of main distributor A at the top of the boom foot. If the plunger is out, the tine is clogged. Stop vaive When the grease can is being used to pump in (grease, this tighten this valve to cut the automat- ie greasing tine. When not using the grea to OPEN, Hose ree! This is used to store the grease can hose (au- tomatic wind-in} Grease gun This is used for greasing (pins around bucket, parts of radiator fan, track tension, etc! Distributor This is @ valve to distribute the grease coming from the pump to each line. The amount of grease sent to gun, always set spool % The spool is @ sequential action type (the grease does not flow simply to the low pres- Sure areas, but a fixed amount of grease is supplied properly to each line). So if the line to even one point becomes clogged, the pressure in that line will rise and the system will stop. 10-65HYDRAULIC PIPNG DIAGRAM BACK HOE SPECIFICATION 1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Hydraulic tank 5. Return oil filter 6. No.3 control valve (4-spool) 7. No control valve (5-spool) 8 Oilcooler 9. No.1 control valve (4-spool) 10. No.2 control valve (5-spoo!) 11. No.2 swing pump 12. No.4 main pump. 13. No.3 main pump 14. No.1 swing pump 18. No.2 main pump 16. No.1 main pump 17. Line oit filter 18. Swing control valve 19. Swing motor 2rrarov024 10-66 oziTAtHYDRAULIC CIRCUIT DIAGRAM © BACK HOE 10-68 2rTAF01028 o2tTat© LOADING SHOVEL 021TAI 2rTAFo1026 10-69021TAt WORK EQUIPMENT CONTROL 10. " 12, 13, 14, 16, 16. 17, 18, 19, 20. 21 22. 23. @orarren BACK HOE Boom and bucket PPC shuttle valve ‘Swing control valve RH. 5-spool control valve RH. 4-spool control valve LH. 8-spoo! control valve LH, 4-spool control valve Pilot oil filter Accumulator Charging and PTO lubrication pump (rear) Safety lock valve Charging and PTO lubrication pump (front) ‘Swing PPC shuttle valve ‘Arm PPC shuttle valve LH. travel PPC shuttle valve RH. travel PPC shuttle valve LH. PPC valve Safety lock lever LH. control lever Travel PPC valve LH. travel control lever RU. travel control lever RH. PPC valve RH. control lever Fartaoior2 OUTLINE @ To reduce the operating force of the contro! levers, all the controls use PPC valves. ‘© Use of the safety lock valve means that operation of one lock lever cuts the pressure to the PPC. valves and locks the action of all the PPC valves. 10-71(Boom control lever operated to RAISE) 1, BOOM CONTROL LOWER — naise Lvitzo 20903028 '* The diagram shows the operation of one unit {front or rear) 10-72021TAI 10. 1. 12. 13, 14, 15. 16. 17. 18. 19. 20. 21. weroraena . Accumulator Safety lock valve Pilot relief valve RH. PPC valve (Boom) . Boom and bucket PPC shuttle valve Line oit fitter Engine PTO No.2 or No. 4 pump 92, Front pump 9b. Rear pump No. 1 or No. 3 pump 102. Front pump 10b. Rear pump, Charging pump Pilot of filter Check valve Return oil filter Oilcooler Check valve Hydraulic tank Boom cylinder ‘4-spool control valve (V1 or V3) 198. Main relief valve 19b. Boom-Lo control valve Check valve 5-spool control valve (V2 or V4) 21a, Main relief valve 21b. Boom-Hi control valve OPERATION 1) Boom control lever operated to RAISE: ‘® When the boom control lever is operated to the RAISE position, the spool of PPC valve (4) inter- connected with the control lever is actuated Pilot pressure oll flows from charging pump (11) to the pilot case at the spool end of boom-Lo control vaive (196) and boom-Hi control valve (216), and moves the spool ‘@ The pressurized cil from No. 2 (or No. 4) front pump (88) and No. 1 (or No. 3) front pump (10a) ‘merges, then passes through boom-Lo control valve (19b) and enters the bottom end of boom vlinder (18) AAs the same time, the pressurized oil from No. 2 (or No. 4) rear pump (9b) and No. 1 (or No. 3) rear pump (1Ob) merges, then passes through boom-Hi control valve (21b) flows also to the bottom end of boom cylinder (18) ‘¢ All the oil returning from the head end of boom cylinder (18) flows to boom-Lo control valve (19b), passes through return oil fitter (14) and hydraulic oil cooler (15), and is then drained to hydraulic tank (17) 2) Boom control lever operated to LOWER. © When the boom control lever is operated to the LOWER position, the spool of PPC valve (4) inter- connected with the control lever is actuated. Pilot pressure oil flows from charging pump (11) to the pilot case at the spool end of boom-Lo control valve (196) and boom-Hi control valve (21), and moves the spool. © The pressurized oil from No. 2 (or No. 4) front pump (9a) and No. 1 (or No. 3) front pump (10a) merges, then passes through boom-Lo control valve (19b) and enters the head end of boom cylinder (18) At the same time, the pressurized oil from No. 2 (or No. 4) rear pump (9b) and No. 1 (or No. 3) rear pump (10b) merges, then passes through boom-Hi control valve (21b) and flows also to the head end of boom cylinder (18). © The circuit to the boom-Hi control valve is closed by check valve (20), so all the oil returning from the bottom end of boom cylinder (18) flows to boom-Lo contro! valve (19b), passes through return oil filter (14) and hydraulic oil cooler (15), and is then drained to hydraulic tank (17) 10-732. ARM CONTROL (Arm control lever operated to ARM IN) ARMOUT —~ ARMIN ' The diagram shows the operation of one unit (front or rear) *20009022 10-74 o21TAIo2iTAt @ervannene 10. u 12. 13, 14, 16, 16. 7 18 19, 20. 24 22. |. Accumulator Safety lock valve . Pilot relief valve LH.PPC valve (Arm) ‘Arm PPC shuttle valve Line ol filter Engine TO No. 2 or No. 4 pump 9a. Front pump 9b. Rear pump No. 1 or No. 3 pump 10a. Front pump 10b. Rear pump Charging pump Pilot of filter Check valve Return oil fiter Oil cooler Check valve Hydraulic tank Arm eylinder Slow-return valve Check valve 4-spoo! control valve (V1 or V3) 21a. Main relief valve 21b. Arm-Hi control valve 5-spool control valve (V2 or V4) 22a. Main relief valve 22b. Arm-Lo control valve OPERATION 1) Arm control lever operated to ARM IN: ‘© When the arm control lever is operated to the ‘ARM IN position, the spool of PPC valve (4) inter connected with the control lever is actuated. Pilot pressure oll flows from charging pump (11) to the pilot case at the spool end of arm-Lo con- ‘rol valve (2b) and arm-Hi control valve (21b), ‘and moves the spool © The pressurized oil from No. 2 (or No. 4) rear pump (9b) and No. 1 (or No. 3) rear pump (10b) merges, then passes through arm-Lo control valve (22b) and enters the bottom end of arm cylinder (18) [At the same time, the pressurized oil from No. 2 (or No. 4) front pump (9a) and No. 1 (or No. 3) front pump (10a) merges, then passes through ‘arm-Hi control valve (21b) and flows also to the bottom end of arm cylinder (18). (© The flow of oil returning from the head end of arm cylinder (18) is controlled by siow-return valve (19). The circuit to arm-Hi control valve (21b) is closed by check valve (20), so all the oil flows to arm-Lo control valve (2b), passes through return oil filter (14) and hydraulic oil cooler (15), and is then drained to hydraulic tank a7) © Slow-retumn valve (19) acts to prevent any time lag and to prevent the arm from lowering suddenly 2) Arm control lever operated to ARM OUT: © When the arm control lever is operated to the ‘ARM OUT position, the spool of PPC valve (4) i terconnected with the control lever is actuated. Pilot pressure oil flows from charging pump (11), to the pilot case at the spool end of arm-Lo con trol valve (2b) and arm-Hi control valve (2b), and moves the spool. ‘© The pressurized oil from No. 2 (or No. 4) rear pump (9b) and No. 1 (or No. 3) rear pump (106) merges, the passes through arm-Lo control valve (2b) and enters the head end of arm cylin- der (18). At the same time, the pressurized oil from No. 2 {or No. 4) front pump (9a) and No. 1 (or No. 3), front pump (10a) merges, then passes through arm-Hi control valve (216) and flows also to the head end of arm cylinder (18) ‘© The oil returning from the bottom end of arm cylinder (18) flows to arm-Lo control valve (226) and arm-Hi control valve (21bl, passes through return oil filter (1.4) and hydraulic oil cooler (15), and is then drained to hydraulic tank (17) 10-753. BUCKET CONTROL {Bucket control lever operated to CURL) UMP — cURL 20903090, ‘The diagram shows the operation of one unit (front or rear! 10-76 021TAI021TAt Seregren 10, u 12. 13, 14, 168, 16. 17, 18, 19, 20. 21 Accumulator Safety lock valve Pilot relief valve . RH. PPC valve (Bucket) Boom and bucket PPC shuttle valve Line oil filter Engine PTO No.2 or No. 4 pump 92. Front pump. . 9b. Rear pump No. 1 or No. 3 pump 10a. Front pump 10b. Rear pump Charging pump, Pilot of filter Check valve Return oil filter Oil cooler Check valve . Hydraulic tank Bucket cylinder Slow-return valve 4-spool control valve (V1 or V3) 20a. Main relief valve 20b. Bucket-Hi control valve 5-spool control vaive (V2 or V4) 21a, Main relief valve 2) 21b, Bucket A . . OPERATION 1) Bucket control lever operated to CURL: When the bucket control lever is operated to the CURL position, the spool of PPC valve (4) inter- connected with the control lever is actuated. Pilot pressure oil flows from charging pump (11) to the pilot case at the spool end of bucket-Lo control valve (21b) and bucket-Hi control valve (20b), and moves the spool. The pressurized oil from No. 2 (or No. 4) rear pump (9b) and No. 1 (or No. 3) rear pump (106), merges, then passes through bucket-Lo control valve (21b) and enters the bottom end of bucket cylinder (18), At the same time, the pressurized oil from No. 2 (or No. 4) front pump (9a) and No. 1 (or No. 3) front pump (10a) merges, then enters bucket-Hi control valve (20b), but the circuit is closed, so the oll does not flow. The flow of oil returning from the head end of bucket cylinder (18) is controlled by slow-return valve (19). It flows to bucket-Lo control valve (21) and bucket-Hi control valve (206), passes through return oil filter (14) and hydraulic oil cooler (15), and is then drained to hydraulic tank (17. Bucket control lever operated to DUMP: When the bucket control lever is operated to the DUMP position, the spool of PPC valve (4) inter- connected with the control lever is actuated. Pilot pressure oil flows from charging pump (11) to the pilot case at the spool end of bucket-Lo control valve (21b) and bucket-Hi control valve (20), and moves the spool. The pressurized oil from No. 2 lor No. 4) rear pump (9b) and No. 1 (or No. 3) rear pump (10b), ‘merges, then passes through bucket-Lo control valve (21b) and enters the head end of bucket cylinder (18), ‘At the same time, the pressurized oil from No. 2 (or No. 4) front pump (Sa) and No. 1 (or No. 3) front pump (10a) merges, then passes through bucket-Hi control valve (20b) and flows also to the head end of bucket cylinder (18). All the oil returning from the bottom end of bucket cylinder (18) flows to bucket-Lo control valve (216), passes through return oil filter (14) and hydraulic oil cooler (18), and is then drained to hydraulic tank (17), 10-77o21TAI + FOR MACHINE EQUIPPED WITH AUTO-DECELERATION SYSTEM AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM 1 BASIC CIRCUIT \ Shenae Pectmiometer Shutie OUTLINE This system carries out automatic control of the bucket height when carrying out horizontal digging ‘and when raising the boom in all opeations using the loading shovel. This enables the operator to carry out efficient and accurate operations. 10-79‘* FOR MACHINE EQUIPPED WITH AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM. g - g E z é 8 S 3 z é 5 s z enien Qed torong Gez ‘onion Jad woog "Bez ONIPA Ddd HY EZ OMA Dd UY "27 OMA Odd HT Ze ¥3MO7 pus agivel NOOR 405 YouNE aunssesd oHneIpAH “LZ, dina pue und SYONG 'NI WHY 40) YouNs aunssaid ouneuPAH “Oz LAO IBY 104 4UIMS eunssasd ONEIDA “GL tviizo xoqjoau09 ‘81 {Youms 10709488 yuowenOUL FONG “Z| ‘duind BuiB2e49 “91 ‘onjen gga woos "st ene 985 3990"8 “PL elon on3n4s Y3MOTNOOR ‘EL jen opinys gNG 13x9NA "Zi (@°0Ns0 1 ON) dnd yuosy “1 (v 0N 20 z-0N) dundwuo14 “OL (€°0N20 | ON) dund swey 6 (ON 20 2 ON} duind se9y °g etotoveizs qyun @uo smoys weIBeIp 94, @ AURA ERAS RGS AIA EPSP RE DS SROETS ATAATALTTUCGA ROLLEI Say } susaRSGESStenIaesesesy th ‘anjea jostuos oy-wo0g “9, ‘anjen jonuoa ov-r¥9NG “QL AIBA JONUOD HUY “eZ {EA 20 1A) alen joxqucd oods-y “¢ ‘nen JoRUOD IH-WoEg “99 anjeA joRUOD OT-Wy “49 ‘@njen jonUoO IH-19y9NG “2 (pA.10 ZA) eaten jostU09 jo0ds-g s9puyo woos sepuyo way s9pudo ioxone s9}owonUs}od woog, sajewonuajod wiy Kadded re mE Spy ay SS _ eT = 10-8021TAI v 2) ‘+ FOR MACHINE EQUIPPED WITH AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM |. CONTROL FUNCTIONS Horizontal digging compensation function During ARM OUT operations, the BOOM LOWER Control is carried out so that the height of the arm top pin moves horizontally and parallel to ‘the machine. The link is used to keep the bucket angle the same. U Bucket angle compensation function During BOOM RAISE operations, when the height of the arm top pin goes above approx. 5.8 m, the BOOM RAISE speed and BUCKET DUMP speed are made proportional. This controls the BUCKET DUMP operation so that the load inside the bucket does not spill back towards the opera~ tor's cab. ‘21TAFO1033 2rTAFO1034 10-81* FOR MACHINE EQUIPPED WITH AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM 4, HORIZONTAL DIGGING COMPENSATION FUNCTION '® The diagram shows the operation of one unit (front or rear) FarTaoto1a 10-82 o2iTAt021TAI * FOR MACHINE EQUIPPED WITH AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM. 5. BUCKET ANGLE COMPENSATION FUNCTION tpl) | Fromboam €°¢ vahe FarTaoi015. 10-83* FOR MACHINE EQUIPPED WITH AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM ‘Arm potentiometer Boom potentiometer Arm cylinder Boom cylinder 5-spool control valve (V2 or V4) Sa. Arm-Lo control valve 5b. Boom-Hi control valve 6. 4-spoo! control valve (V1 or V3) 6a. Arm-Hi control valve 6b. Boom-Lo control valve 7. Rear pump (No.2 or No. 4) 8. Rear pump (No. 1 of No. 3) 9. Front pump (No. 2 or No. 4) 10. Front pump (No. 1 or No. 3) 11. BOOM LOWER shuttle valve 12. Boom EPC valve 13. Charging pump 14. Bucket movement selector switch 18. Control box 16. Hydraulic pressure switch for ARM OUT 17. LH. PPC valve 17aArm PPC valve 18. RH.PPC valve 18. Boom PPC valve 18b, Bucket PPC valve faeNe 10-84 FUNCTION ‘© When the bucket movement selector switch in the operator's cab is switched to HORIZONTAL DIGGING Mode or HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION Mode, and the lever is operated to ARM OUT, the BOOM LOWER movement is controlled so that the height of the arm top pin moves parallel to the horizontal level of the machine. OPERATION @ Boom and arm potentiometers (1), (2) input the angles of the work equipment to control box (18). In this way, control box (15) can always calculate height H of the arm top pin 2o0ra219 When the lever is operated to ARM OUT, the amount to lower the boom in order to maintain height H must be calculated. To carry out this ‘movement, control box (15) sends electric cur- rent to EPC valve solenoid (12) to lower the boom. In this way, EPC valve (12) is actuated and pressurized oil from charging pump (13) passes through shuttle vaive (11) and actuates boom-Lo control valve (6b) to lower the boom. o21TAt021TAI 10. u 12 13. 14, 15, 16. 7, 18, + FOR MACHINE EQUIPPED WITH AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM ‘Arm potentiometer Boom potentiometer Bucket cylinder Boom cylinder 5-spool control valve (V2 or V4) 5a. Bucket-Hi control valve 5b, Boom-Hi control valve 4-spool control valve (V1 or V3) 6a, Bucket-Lo control valve 6b. Boom-Lo control valve Rear pump (No. 2 or No. 4) Rear pump (No. 1 or No. 3) Front pump (No. 2 or No. 4) Front pump (No. 1 or No. 3) BUCKET DUMP shuttle valve Bucket EPC valve Charging pump Bucket movement selector switch Control box Hydraulic pressure switch for BOOM RAISE and LOWER LH.PPC valve 17a. Arm PPC valve RH. PPC valve 18a. Boom PPC valve 1b. Bucket PPC valve FUNCTION @ When the bucket movement selector switch in the operator's cab is switched to HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION ‘Mode, and the lever is operated to BOOM RAISE, the bucket is controlled so that when the height of the arm top pin is above 6.8 m, the bucket moves to the DUMP direction to prevent the load. in the bucket from spiling towards the cab. OPERATION ‘© Boom and arm potentiometers (1), (2) input the angles of the work equipment to control box (15) In this way, control box (15) can always calculat heightH of the arm top pin. kL ——.-if C=O. ‘© When the lever is operated to BOOM RAISE, and height H is above 5.8 m, control box (15) sends electric current to EPC valve solenoid (12) to move the bucket to the DUMP direction to ‘match the BOOM RAISE speed. In this way, EPC valve (12) is actuated and pressurized oil from charging pump (13) passes, through shuttle valve (11) and actuates bucket- Lo control valve (6a) to move the bucket to the DUMP direction, 10-85* FOR MACHINE EQUIPPED WITH AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM 6. EPC VALVE (Electric Pressure Control valve) Le» Con Return spring Retainer Valve body Spool Base Push rod Coil Iron core Connector @evaneens 10-86 Section A-A 20972216 FUNCTION The EPC valve consists of a hydraulic valve and a proportional control solenoid. ‘The signal current sent from the control box flows to coil (7), and excites base (5) and iron core (8). As a result, variable core (8) is pushed to base (5), and generates a thrust to the left. This thrust is proportional to the signal current. Because of this, Pi port and Pe port open. {weve | s| 3 | g 3 Inoutcurent 1) o21TAto21TAt HYDRAULIC TANK Hydraulic tank Filler cap Strainer Oil evel sensor Suction strainer Breather SectionA—A BREATHER Sectione—C 2rarot027 ‘© Relief cracking pressure: 0.7 + 0.07 kg/em* ‘© Suction cracking pressure: 0.02 + 0.002 kg/cm? 10-87MAIN PUMP 1. No.2, 4PUMP ASSEMBLY (HPV90 + 90 WITH TVC VALVE AND CO- NC VALVE ASSEMBLY) (CO-NC valve output pressure Peen(Al CO-NC valve output pressure PeentF} OUT pert we Ru. travel main Pot LH travel main valve outet pressure Pra pressure Pov pressure PR pressure Pe \ \ ’ . J settemosoutet wt stor ote euneoroue! LJ] preturePa'Nipor pre 6: IN por FNS Non Jetsensor outer press Fein Sort Sing pump dachare promuie Pav Nipor 209F3056A 1. Front pump, OUTLINE 2. Front pump servo unit assembly ‘© No. 2, 4 pump assemblies consist of two 3. Rear pump servo unit assembly variable-displacement —swash-plate piston 4. Rear pump pumps, front servo unit assembly, rear servo unit assembly and impeller pump (built in between the front pump and the rear pump). ‘© The front pump serves 4-spool control valve. @ The rear pump serves 5-spool control vaive. 10-88 o21TAt021TAI 2. No. 1,3 PUMP ASSEMBLY (HPV90 + 90 WITHOUT TVC VALVE AND CO- NC VALVE ASSEMBLY) Pepe aq i a yl Pilot pressure Psv Front pump Front pump servo valve Rear pump servo valve Rear pump CO:NC valve ourput pressure CONC valve output pressure Peentf) IN port Peenif IN part CO-NC valve output pressure CO-NC valve output pressure Peenlfl pickup port Pent pick-up port 209F3057A OUTLINE No. 1, 3 pump assemblies consist of two variable-displacement swash-plate type piston pumps, front servo valve, rear servo valve and impeller pump (built in between the front pump and the rear pump] The front pump serves 4-spool control valve. ‘The rear pump serves 5-spool control valve. 10-893. FRONT PUMP, REAR PUMP AND IMPELLER PUMP No, 2,4 PUMP EB B Disenaige por Discharge or {rovt V2 control vate {To v2.or va control valve) ye |e > sd3} ne be z eee (charging pump presure Port PSV ‘Pump discharge pr ° ‘Charging pump pressure port PSV2 Pump discharge pressure port PAZ Pump discharge ‘Servo valve output port PSV1B- “Pump discha promure port Pas \ i pum decharge a ‘Servo valve output port PSV28 pressure port PAT servo vate output phy Sere ave output port PSA aoe FAL port PSv2A, bw 2) er" viewY 209F3058A, 10-90 o21Ta1o21TAt 1. Front shaft 2. Front cradle 3, Front case 4, Rocker cam 5. Piston 6. Cylinder 7. Valve plate 8. Frontend cap 9. Impeller 10. Coupling 11, Rearend cap 12. Rear case 13, Rear cradie 14, Rear shaft 15. Servo piston 10-914, FRONT PUMP, REAR PUMP AND IMPELLER PUMP No. 2 PUMP Discharge por Disenarge por (ovi'er V3 conte! vate) rover V8 contol valve) \ i i A A 8 8 = ez Suction por Charging pump resue por Pov Pump dachre ree port Pa ag CMBING DUE Pens por Pav ume dicharge pressure port Paz ’ Sewo ive oupu \ eure dscrarae resura port baa / servo wave output revsure Dor PSV 18 \ mo dacharge prenure port PA / poor Pave \ J | servo vave output por Paving Lf / en view oe 2093060 10-92 021TA1o21TAt Section ©— ¢ 1. Front shaft 6. Cylinder 11, Rear end cap 2. Front cradle 7. Valve plate 12. Rear case 3. Front case 8. Front end cap 13. Rear cradle 4. Rocker cam 9. Impeller 14. Rear shaft 5. Piston 10. Coupling 15, Servo piston 10-93,10-94 Shaft (front) Cradle (front) Rocker cam Suction port Piston Cylinder barret Valve plate Impeller 10. Joint 15. Sevo piston 16. Shoe On ooENe 20903022, 20902031 The tip of piston (5) is spherical. Shoe (16) is swaged around the ball at the piston tip to form ne unit with the piston. Piston (5) and shoe (16) form a spherical bearing. Rocker cam (4) has surface A. Shoe (16) is always pushed against this surface and slides in acircle on surface A. Rocker cam (4) slides on the concave face of cradle (2) which is fixed to the case. Pistons (5) move in an axial direction inside each cylinder of cylinder barrel (6). Cylinder barrel (6) rotates while pushing valve plate (7). This seals the oil while rotating, The oil inside each cylinder chamber on the rotat- ing side (cylinder barrel (6)) goes in and out of the ports on the fixed side (valve plate (71). Impelter (9) is connected to shaft (1), and rotates together with the shaft. It sends the oil sucked in from the suction port to the cylinder chamber by centrifugal force to make it easier to suck in. Delivery control (Rocker cam angle control Servo piston (15) changes the angle of the rocker cam. Servo piston (15) moves in a recipro- cal linear movernent according to the commands of the servo valve, This linear movernent moves rod and swings rocker cam (4). Rocker cam (4) slides around the spherical surface of cradle (2) o2iTato21TAt OPERATION Operation of pump. 1 v 2) When shaft (1) rotates because of the x engine, cylinder barrel (6) also rotates. Shoe (21) rotates on face A of rocker cam (4). When rocker cam (4) moves on concave face B, the angle @ of rocker cam (4) chamges. ais called the rocker cam angle. When rocker cam (4) has a rocker cam angle 4, piston (5) reciprocates inside cylinder barrel (6). As a result, 2 difference between / volume E and volume F inside cylinder barrel (6) appears. When this happens, an amount of oll equal to this difference in volume is sucked in from port & , and the same amount of oilis pumped out from port &) In other words, cylinder barrel (6) rotates and volume F gradually becomes. smaller. While the volume F approaching volume E, cil is pumped out. After it passes the situa- tion in volume E and approaches volume F, the oils sucked in 20820774 142F0368 When the angle of rocker cam (4) is 0, there is no difference between volume E’ and x 4 volume F', s0 no oil is sucked in or pumped / ‘out. (no pumping action) \ 10-955. SERVO UNIT ASSEMBLY ¢ No. 2,4 FRONT PUMP SERVO UNIT ASSEMBLY Servo valve dain RerOUr pore ‘Servo actuator port heraeg pam presure — ‘Swing pump discharge pressure _/PAS IN port Pump discharge pressure PAT IN port ~ Bump discharge pressure PAzIN port ~~ Servo setustor port “¢ “\TVC valve output pressure Pe ER connecting port ~Jet sensor outlet pressure Ps FR connecting port TVC valve co+Nc Connector Servo valve fe assembly RORS 10-96 2093062 021TAI021TAI No.2, 4 REAR PUMP SERVO UNIT ASSEMBLY AND SWING PUMP SERVO UNIT ASSEMBLY TVG valve ourput pressure _——PeIN'por ump aisenarge pressure _ PaziN port _--Servo valve drain Per OUT port Pump discharge pressure Charging pump pressure PSV IN port PATINeor = aid " ‘Servo actuator port —_ Serve actuator port TVG valve output presure Pe EReonnecting port 12093063 1. CO*NC valve assembly 2. Servo valve 10-97