PC650-5 S Sebm000607 PDF

‘SEBM000607 SOW IMLB\INTOA\ IL KOMATSU PC650-5 PC7105 MACHINE MODEL SERIAL NUMBER PC650-5 20001 and up PC650SE-5 20001 and up PC6S5OLC-5 20001 and up PC710-5 10001 and up PC710SE-5 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. ¢ PC650-5 and PC710-5 mount the SA6D140-1 engine. For details of the engine, see the 140 Series Engine Shop Manual © 1996 KOMATSU All Rights Reserved 00-1 Printed in Japan 02-96(01/00251 a01 10 20 30 40 CONTENTS GENERAL .. STRUCTURE AND FUNCTION TESTING AND ADJUSTING....... DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD 020905020905 The affected pages are indicated by the use of the following marks. itis requested that necessary actions Mark Indication Action required| be taken to these pages according to the table below. © | Page to be newly added Add © | Page to bo replaced Replace ( } | Page to be deleted Discard Pages having no marks are those previously revised or made additions, LIST OF REVISED PAGE Mark Page [orion] Mark Page MEE] Mark Page TIME! wank Page TE] mark Page Ast om Ft ors) wor 1035 1064 Ona lie one ay ws2 1036 065 © ona eo om7 F r0-10 037 1066 + 00-22 soe F to 10:38 1087 + 23 © orto tore 1039 1068 2 24 2 on 019 040 1069 0. 25 son wou oer 1070 + m3 os f 1015 104 ron © oe o om 10-16 roe 072 + 0s 2 os 1017 10-45 1073 + m6 oe ro-19 r04s vom + 7 ov w2 3 roar 1075 + 08 ove wa ross 1076 + 09 ons war 1050 1077 = 10 01-20 wor. 0st 1078 + on san s022 1082 1079 © oot oe E 1022 1059 1080 © oo ro2 rose wos + oo. 1025 oss 1082 + 0035 wr © 1026 1086 1089 + 0036 102 1027 ws @ rose +0037 103 022 ws D 108s roe 1028 wos GZ 1086 ws 1030 ws2 @ oer eo ep 106 wn ® 10-60 wes @ or 6 10-7) ws D 1061 1089 oa 108 1039 1062 0 @ oa 8 09 rox 1069 wD 0-2-1Mark Page [Ersion| Mark Page Tim H mak Page TIMES!) wank Page Tomscn| Mark Page Time of we @ |. wie @ wou ® nO 2 © srr @ | + wom @ wows @ nz O ne @ 22 © | + wns D ws ® na nO) wns D]e wi. © wus nu DD rs @ ware @ win D wis wD wes OD oss D ons @ wis @ 22D 28 ® wot 2 wos 2 wise @ na DO v6 © wor 2 wn 2 rissa 28D ws ® woser 2 tone D w01ss1 we 20 @ + 8 tons wise D 20D nn © © 81 wor worss D wD wr © o 10952 wi D v2 D a @ ws 2 wm f wr oD ws wn ® ws 2 ws 2 pe o ue ws & ws 2 worm 2 w21 @ 23D 26 @ wo92 2 wos g 222 @ wD wn ® toss 2) ws 20-23 ws D nna © tose 2 wr @ wee @ we D ne @ 0100 J wis 2 w25 Dd ne OD 281 @ wor D wore 226 D wo D 27D wow 8 wor 227 ® we DB |e m0 wows 8 wor 228 @ wa ® |» nmr @ rors wae ns wa D | + 02 ® worse 8 worss Z ws ® wu @ 203 @ + 11033 2 worse D ws ® ns ps4 D wor034 8) ors we ® we 20s ® + wie 2 wis 2 27 OD wr D |e wn @ torr wuss © ws @ ww D |e wr ® wore2 @ wor wo ® wo D |. m2 D rors D wor D nw @ ws we @ wwi084 BD wor @ wn @ nO) ne @ wrs wou @ we @ ws QO |. war @ wis @ wwe D 23 @ ws O | + waz © 10.105 wus D wu nse O | + 23 © os08 wrs1 @ nw @ ro) 204 @ wir D wu @ zs @ ws @ re @ ors 2D wus @ nn ws @ ws @ wo ous @ we © ws 851 ® wn ® 1081 ® ww ws =O |» 252 ® win @ wu ® 20 @ wo O |. 2659 ® 0-2-2 020905020905 Mark Page [Essa] Mork Page TINE tT atark Page Time Hl sare page MEHL ark Page Hapdel 2 006% wim @ p13 @ 7 @ wont 2086 3 wi © rou @ 20188 O sou @ we 3 |e mim ® us @ zo ws | zoe D 20.15 ® ous @ z190 @ soe we 2 | + wwe ww 8 2191 © wow wer 8 |e mm gg owe @ ww @ ww g we | 6 tm ww n193 ww 2 wee & | «more & zoo wie @ x20 9 6 | 8 om 20182 @ 2015 sox 3 ww S v3 D n-96 x2 nor 8 |e om wos oar OD wD ws 8 | 6 man 2 20156 zor8 wu ver 6 | + miss voisr 20199 wD 20982 8 pi rosa 2020 3026 woes 6 | «mm zoo 2201 @ 2027 wo 3 | 6 mor & are © nm @ 3028 woo i |e zona 2 wwe @ 20203 @ 20.29 20-101 pis PD ns a 20 @ 3030 ww I 18 216 ns @ 2031 20.103 20.1351 206 @ 20 OD om 20-108 20.1352 J 2187 20207 D 3033 20-106 20.183 z0188 @ 20208 D soa 20107 2.184 pis 2020 30.98 pws 3 | + mw rom w20 @ 30.6 20-109 ww win @ wan 3037 pio GF fe mw & win @ 22 @ 2028 win 3 pina & 2173 @ 3039 wu D |. mm & nan @ wr @ 3040 wis fF | ower Z wos S v2 @ 3041 wm f | + mre we @ ws ® woe vous zor D wn @ me wa wwe 2 2.10902 @ zoe os D woe wir 2 2193 @ wos @ ws OD wus zorma 3 rime G 10 =O a) wus pana zw @ wre oe ® wo wows 3 nour wow = @ ws ® oD rie S ww wie ww © ww =O none I nus & ror G wn @ ws ror i roar rows © on ® ws porwr 21032 & rows D rr @ ws ODMark Page [aos] Mark Page TimEH mark Page Time ot] mark Page femsion| Mark Page Time of 3053 wa so133 worst D #3 © 3054 we G soi s0182 woe 3085 3098. 3018 sos os 2056 nO) 2016 301584 “06 ws D wD sort 20155 or sess 38 soe @ 20-186 we soso i wo sors D 30.1862 D 9 woo i 3010 sow sora) 4010 ws sow sour -D sorsee D on wed wr wre D aoses 2 won sess wd sous 301566 2 sons 2064 sore sou 30.1567 @ won 20.68 20105 wus 301568 D 405 woes |G sos 30.48 20187 wow S wer sow @ 30-1461 sors ® won soe 30108 30-1462 so1ss 2 som we T so D 30163 0160 sora wmf sono 30-464 wr @ sone on wan 20-1465 182 ® song wr son 30-1466 30169 ® 40.20 2073 sons 301467 wre ® on 3074 som ® 2068 sos won 2075 sons 201469 sors soz 30.76 wore @ 30-46-10 sor 4026 son soar @ wen @ sore @ 10% 3078 sone @ sous @ 30-1681 @ won 2078 song 3014613 © 301682 @ 4028 30.60 ww sous @ 301683 © 02 = ® 308 wor @ w0.e15 @ so-1684 @ 0 @ 3082 wore 20-4616 © sors @ wor @ sa so @ soe © s0-1686 © on @ se | som soe18 @ 30-1667 @ wou ® a) sos 20-46-19 @ sor no) 3086 sos @ 20.4620 @ wm O | + wx @ 3087 wi @ 30-4621 © win @ |e or @ sos sows @ s0-08.22 © wr @}e we ® we so19 wow © + 0 © 30-90 130 @ wwe DO + 00 sor son @ sous wor @ le on @ se D soz soso 402 o me © 00-2-4 6 20805020905 Mark Page 7,1] Mark Page TIM °F! Mark Page TIME Of Mark Page Time of] mark Page Time of See op eaaeey ws 00-2-5SAFETY SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe, Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose To prevent injury to workers, the symbot is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal withthe situation. GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. + Always wear safety glasses when hitting parts with a hammer. + Always wear safety glasses when grind- ing parts with a grinder, ete 3. If welding repairs are needed, always have a trained, experienced welder carry out the work, When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for weld ing work. 4, When carrying out any operation with two or more workers, always agree on the oper ating procedure before starting. Always in- form 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 alll 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 smok. ing. Never smoke while working, PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and. block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15, When removing covers which are under 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 oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 19, 20. 21. 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 machine 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 assembled 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 GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. 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. Use the specifications given in the book with the latest date 00-5FOREWORD 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: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attach- ‘ment volumes be available. Electrical volum Attachments volume: DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. 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}: 10 - Item number (10. Structure and Function) Consecutive page number for each item Example 2 (Engine volume) 12-5 l Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-} and number after the page number. File as in the example. Example: 10-4 12-203 10-415 12.203-1 y0-4.2}~ Added pages —[_19.293.2 105 12-208 00-6 REVISED EDITION MARK When a manual is revised, an edition mark (2G...) is recorded on the bottom of the pages. REVISIONS Revised pages are shown in the LIST OF RE- VISED PAGES next to the CONTENTS page. ‘SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quality portions are marked with the following symbols. Symbol Remarks necessary when performing the work, Special technical precautions fr other precautions for pre serving standards are neces: sary when performing the work Caution Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, et Weight Places that require special at tention for the tightening torque during assembly. ‘Tightening torque Places to be coated with ad: Coat | hesives and lubricants, ate Places where oil, water or fuel must be added, and the capacity. i, water Places where oil or water must be drained, and quan: tity to be drained, DrainFOREWORD HOISTING INSTRUCTIONS. HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or more, is indicated clearly with the symbol C57) « If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed, WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "2" or *S* twist ropes without galvanizing) Rope diameter Allowable load mm KN tons 10 98 1.0 W2 137 14 125 187 16 4 216 22 16 275 28 18 35.3 36 20 43.1 44 22.4 | 549 56 30 98.1 10.0 40 176.5 18.0 50 | 2746 28.0 60 392.2 40.0 ‘* The allowable load value is estimated to be one-sixth or one-seventh of the break- ing 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. ( QO U 100% 88% © 79% + «= 71% = 41% 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. B Binging with one rope may cause turning of the load during hoisting, tuntwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes form- ing a wide hanging angle from the hook When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load KN {kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 KN (1000 kg} vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 19.6 KN (2000 kg) of total weight can be suspended. This weight becomes 9.8 KN (1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 KN (4000 kg} if they sling a 19.6 KN (2000 kg) load at a lifting angle of 150°, 300-0 120180 nee) sap0480FOREWORD COATING MATERIALS COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Category [Komatsu code | Pant No | Gry | Container ain appiications, features Dado preven rubber oaks, rubbor Tans, elit Eres td Tube | and cork plugs from coming out ales Used in places requiring an immediatly efec : 209 | Pranic |" tive: srong ochesive Used for plots except Lt-18 | 790-129-9060! ‘ix2) | container | polyethylene, polypropylene, tetrafluoroethylene, |__Sne'iny enone rebar, etal and mon meal T Plastic’ | Features: Resistance to heat, chemicals ur | oso1n-conso | sg | Plastic, | Ghar antioosenny and seslontsurposes for Adhesive [_ potts and plugs. : = | Usd a seater sein Tor ea aS PTE rao o-oo | Tor mata as, ia (Set of ane ra Jardin] arceing] can | 2900 [:300 9 I Cra | eo-aa-sow | asm g | PES, | Wied 0 ln’ or machined Poles Fania: Rantance To oat, Chas tocite 648-50] 79A-129-0110| soce | — | * Used at joint pontns subject to igh tempers ie ia 7 "Used"as adhesive or sealant for gaskets and Lt | 790-126-9010 | 2009 | Tube _| "packings of power train case, etc Features: Resistance to heat * Utea'assestan for flange suraces and bots at high temperature locaton, used to prevent ser wea |reorzssom] rKy | can | at tem i + Used as seta fr heat esitnt gasket or high | ‘temperature locations such as engine precombustion Chamber exhaust poe Features: Resistance to water, i |> Useas seaint for flange sua, threos ice | 90-1 uve |* Also possible to use ae seslant for Hanges with Gasket sealant] 7 ee . large clearance Used salat for mating surfaces offiral rive cove, fanamson case = + Used a5 sealant for various threads, pipe joints, Prustic |" anges tes | r90-r29-s080 | 1 K5 | coiainer + Used a8 sealant for tapered pgs, elbows, nip bles of hydrate ping |F Features Sifcon based, reitance To eat oid uc-s | opo40-o00rs | 2509 | Tube > Use a salon for lange srtare, thread {Utada selantfor ol ba, fie! dive case. ot Features: Siteon based, quick hardenig ye uc-7 | oeezo-oor80 | 1509 | Tube |: Use a selan for iwhee! housing, rake oni foidsat pan, nermosa housing, se BE ENSR] we | esoranor | soo | can | Ua ber or ting pr Fo olyedenvm Used to prevent some or euing oT head Gisulonae'u'| ume | 09040-0000 | 200.9 | Tube |” wnen pres iting o shank tung brant Used os lubricator inkage, boangs Sye-3500 > General purpose type sye-s00 unmgwee| —oz-u |Sve-atatt-a | venous | voous sve-ten Sveaocnu| S562 400CA | ed tr normal Temperate Wg Tod Bearing Sye2-2s0ca |" staces im contact wih water ot stan calcumgrease] Gz-ca | svez-oca-a) Various | Various sye2-10008 | SvGA-TOONCA Molybdenum 7 Used Tor places with heavy Toad Gisvpnie — | svaz-aoom | #2°.9 | otows wpe tel perce 00-8FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section of DISASSEMBLY AND ASSEMBLY. 1 Kgm = 9.806 Nm Thread diameter Width of bolt | across fats — mm. mm Nm kam 10 | 13.2818 1.3540.15 13 | 31.4429 3.2203 10 a 65.7268 67207 2 19 112498 11.541.0 1“ 2 177419 18.042.0 6 28 279429 28.543 18 2 38339 3924 20 30 549458 5626 2 32 745+78 7628 24 36 927+98 94.5210 2 a 13204140 135215, 30 46 17204190 175420 33 | 50 2210240 225425 36 55 2750290 280+30 38 | 60 | 32804340 336435 + This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening to otherwise specified torque.FOREWORD TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. STANDARD TIGHTENING TORQUE Thread diameter [Width Tightening torque mm mm : = kgm 0 4 65.7268 2 ” 112198 16 2 27929 TIGHTENING TORQUE FOR FLARED NUTS Use these torques for flared part of aut Thread diameter | Width across flats of nut part of nut part Tightening torque mm mm) Nm I kgm aa 1“ 9 25248 25205 18 24 49+19.6 542 2 7 7851196 822 24 32 137.3429.4 1443 20 36 17651294 1823 33 i 4 196.1449 2025 36 | 46 245.2449 2525 2 55 294.2449 305FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS Copper wie MBE! | Number a oi of aronesCrogs secon) “Mat”: [MMAI™"®) —Apliabie eu | osz | 209 31 20 | Lighting, signal ete 8 6 | 0a 5.23 46 3 Charging and signal 15 : 84 0.45 13,36 7.0 59 ‘Starting (Glow plug) a fo | aes | na 135 | Starting 60 7 127 | 0.80 63.84 13.6 178 Starting oe 100 a7 | oso | tsa 178 230 | staring CLASSIFICATION BY COLOR AND CODE Prior ewes Charging | Ground | Starting | Lighting | instrument | Signal Other Ww 3 A Y S c ' Ce ee : k eas lw ee ow aw ve ow Ww Color] wit & Real sack & white Rea a white [Yotow & Rea Green & White Blue & White code] we By ae ve GR iF * | cotorfwnite& slack} — lack & Vetiow] Rea & Black [Yelow & Back|Greon & Red] Blue & Red _ 7 ae Sate] we [= or |v YG ov wv '°Y Color| White & Blue| Black & Red [Red & Yellow/Yellow & Green|Green & Yellow/Blue & Yellow code] we | = nG ve 3 6 © | Cotorfiie & Greed —|ped & Green fYetiow & Blue(Groen & Blac Blue & Black | Code _ _ ae RL Yw GL — : Color] [ = ae Red & Blue [Yellow & White|Green & Blue| =FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ‘+ Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as \, then draw a horizontal line from @. (2) Locate the number § in the row across the top, take this as \8, then draw a perpendicular line down from ®. (3) Take the point where the two lines cross as (©). This point ©) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 50 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert §5 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches 1mm = 0.03937 in 0 1 2 3 4 5 6 7 8 9 o jo 0.039 | 0.079 | 0.118 | 0.157 | 0.197/| 0.236 | 0.276 | 0.315) 0.354 10 | 0.394 | 0.433 | 0.472 | 0.512 | 0.551 | 0.591!| 0.630 | 0.669 0.709 | 0.748 20 | 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984/| 1.024 | 1.063 | 1.102) 1.142 30 | 1.181 | 1.220 | 1.260 | 1.299 | 1.339 | 1.378:| 1.417 | 1.457 | 1.496 | 1.536 40 | 1.575 | 1.614] 1.654 | 1.693 | 1.732 | 1.72'| 1.811| 1.850 | 1.890 1.929 © .89....|..1,969. | 2.008 | 2.047 | 2.087 | 2.126 |[2.165] 2.205 | 2.244) 2.283/ 2.323 60°)" 2:362")"2.402 [2.441 ) "2.480" 2.520") 2.559 | 2.598 | 2.638 | 2.677 | 2.717 70 | 2.756 | 2.795 | 2.835 | 2.874 | 2913 | 2.953 | 2.992 | 3.032| 3.071) 3.110 80 | 3.150) 3.189] 3.228 | 3.268 3.307 | 3.346 | 3.386 | 3.425 3.465 | 3.504 90 | 3.543) 3.583) 3.622 3.661 3.701| 3740) 3780| 3819) 3.858 3.898 00-12FOREWORD Millimeters to Inches CONVERSION TABLE 11mm = 0.03987 in : ° 1 2 3 4 5 fa 8 9 7 o 0 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.236 | 0.276 | 0315 | 0.356 10 0.394 | 0.433 | 0.472 | 0612 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748 20 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 1.181 | 1.220 | 1.260 | 1.299 | 1.339 | 1.378 | 1.417 | 1.457 | 1.496 | 1.536 40 1.875 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 50 1.969 | 2.008 | 2.047 | 2087 | 2.126 2.165 | 2.205 | 2.244 | 2.283 | 2.323 60 2.362 | 2.402 | 2.441 | 2.480 | 2520 2.559 | 2.598 | 2.638 | 2.677 | 2.717 70 2.756 | 2.795 | 2.835 | 2.874 | 2913 2.953 | 2.992 | 3.032 | 3.071 | 3.110 80 3.150 | 3.189 | 3.228 | 3.268 | 3.307 3.346 | 3.386 | 3.425 | 3.465 | 3.504 90 3.543 | 3.583 | 3.622 | 3.661 | 3.701 | 3740 | 3.780 | 3.819 | 3.858 | 3.898 \ Kilogram to Pound 1 kg = 2.2046 Ib o 1 2 3 4 5 6 7 8 9 ° ° 220| 441| 661) 882) 11.02] 1323| 15.43) 17.64) 19.86 10 22.05 | 24.25] 26.46| 28.66| 30.86) 33.07) 35.27| 37.48] 39.68| 41.89 20 44.09| 46.30, 4850] 50.71| 5191) 55.12| 57.32) 59.53] 61.73| 63.93 30 66.14| 6834 7055] 7275| 7496| 77.16) 79.37] 81.57| 83.78| 85.98 40 88.18| 90.39 92.59] 9480| 97.00 | 99.21] 107.41 | 103.62 | 105.82 | 108.03 50 110.23 | 112.44 | 114.64 | 116.85 | 119.05 | 121.25 | 123.46 | 125.66 127.87 | 130.07 60 132.28 | 134.48 | 196.69 | 138.89 | 141.10 143.30 | 145.51 | 147.71 | 149.91 | 152.12 70 154.32 | 186.53 | 158.73 | 160.94 | 163.14 | 165.35 | 167.55 | 169.76 | 171.96 | 174.17 80 176.37 | 178.87 | 180.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 | 194.01 | 196.21 90 198.42 | 200.62 | 202.83 | 205.03 | 207.24 | 209.44 | 211.64 | 213.85 | 216.05 | 218.26 00-13FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1¢ = 0.2682 US. Gal 0 1 2 3 4 5 6 u 8 9 ° 0 0.264 | 0.528 | 0.793 | 1.057 | 1.321 | 1.585 | 1.849 | 2.113 | 2.378 10 2.642 | 2.906 | 3.170 | 3.434 | 3.698 | 3963 | 4.227 | 4.491 | 4.755 | 5.019 20 5.283 | 5.548 | 5.812 | 6.076 | 6:340 | 6.604 | 6869 | 7.133 | 7.397 | 7.661 30 7.925 | 8.189 | 8.454 | 8.718 | 8.982 | 9.246 | 9.510 | 9.774 | 10.039 | 10.303 40 10.567 | 10.831 | 11.095 | 11.359 | 11.624 | 11.888 | 12.152 | 12.416 | 12.680 | 12.944 50 13.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.322 | 15.586, 60 15.850 | 16.115 | 16.379 | 16.643 | 16.907 | 17.171 | 17.435 | 17.700 | 17.964 | 18.228 70 18.492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 20 | 21.134 | 21.398 | 21.662 | 21.926 | 22.190 | 22.455 | 22.719 | 22.983 | 23.247 | 23.511 90 | 23.775 | 24.040 | 24.304 | 24.568 | 24.832 | 25.096 | 25.361 | 25.625 | 25.889 | 26.153, Liter to U.K. Gallon 1 = 0.21997 UK. Gal 0 1 2 3 4 5 6 7 8 9 ° 0 0.220 | 0.440 | 0.660 | 0.880 | 1.100 | 1.320] 1.540| 1.760 | 1.980 10 2.200 | 2.420 | 2.640) 2.860 | 3.080| 3.300] 3.520| 3.740| 3.950} 4.179 20 4.399 | 4.619 | 4.839 | 5.059 | 5.279| 5.499| 5.719| 5.939| 6.159 | 6.379 30 6.599 | 6.819 | 7.039 | 7.259 | 7.479| 7.969| 7.919] 8.139| 8.359 | 8.579 40 8.799 | 9.019 | 9.239 | 9.459 | 9.679 | 9.899 | 10.119 | 10.339 | 10.559 | 10.778 50 10.998 | 11.261 | 11.438 | 11.658 | 11.878 | 12.098 | 12.318 | 12.528 | 12.758 | 12.978 60 13.198 | 13.418 | 13.638 | 13.858 | 14.078 | 14.298 | 14.518 | 14.738 | 14.958 | 15.178 70 15.398 | 15.618 | 15.838 | 16.058 | 16.278 | 16.498 | 16.718 | 16.938 | 17.158 | 17.378 80 17.598 | 17.818 | 18.037 | 18.257 | 18.477 | 18.697 | 18.917 | 19.137 | 19.367 | 19.577 90 19.797 | 20.017 | 20.237 | 20.457 | 20.677 | 20.897 | 21.117 | 21.337 | 21.957 | 21.77 00-14FOREWORD CONVERSION TABLE kgm to ft. Ib 1 kgm = 7.233 ft lb ° 1 2 3 4 5 6 7 8 9 ° 0 72) 145) 217) 289| 362| 434| 506] 579] 651 10 723| 796) 868) 940| 1013 | 1085 | 115.7) 1230 | 1302 | 197.4 20 1447 | 1519 | 159.1} 166.4 | 1736 | 1808 | 1881 | 195.3 | 2025 | 2098 30 217.0 224.2 | 2315 | 2387 | 245.9 | 2532 | 260.4 | 2676 | 2749 | 282.1 40 209.3 | 296.6 | 3038 | 3110 | 3183 | 3255 | 3327 | s400 | 347.2 | 3544 50 361.7 | 368.9 | 376.1 383.4) 3906 | 3978 | 405.1 | 4123 | 4195 | 4268 60 4340 | 4412 | 448.5 | 455.7 | 4629 | 470.2 | 477.4 | 4946 | 491.8 | 499.1 70 506.3 | 5135 | 5208 | 528.0 | 595.2 | 542.5 | 549.7 | 5569 | 5642 | 571.4 80 578.6 | 685.9 | 593.1 | 600.3 | 607.6 | 614.8 | 622.0 | 629.3 | 6365 | 643.7 90 651.0 | 658.2 | 665.4 | 6727 | 679.9 | 687.1 | 694.4 | 7016 | 7088 | 716.1 100 | 7233 | 730.8 | 737.8 | 745.0 | 7522 | 7595 | 766.7 | 7739 | 781.2 | 788.4 110 | 795.6 | 8029] 810.1) 817.3 | 8246 | 9318 | 839.0 | 8463 | 9535 | 860.7 120 | 68.0 | 875.2 | 8824 | 889.7 | 696.9 | 904.1 | 911.4 | 9186 | 925.8 | 933.1 130 | 940.3 | 947.5 | 954.8 | 962.0 | 969.2 | 9765 | 983.7 | 9909 | 998.2 | 1005.4 140 | 1012.6 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 1070.5 | 1077.7 150 | 1084.9 | 1092.2 | 1099.4 | 1106.6 | 1113.9 | 1121.1 | 11283 | 1135.6 | 11428 | 1150.0 t60 | 1157.3 | 11646 | 1171.7 | 1179.0 | 1186.2 | 1193.4 | 1200.7 | 1207.9 | 1215.1 | 1222.4 qo | 1129.6 | 12368 | 1244.1 | 1251.3 | 1258.5 | 1265.8 | 1273.0 | 1280.1 | 1287.5 | 1294.7 180 | 1301.9 | 1309.2 | 1316.4 | 1323.6 | 1330.9 | 1338.1 | 1345.3 | 13526 | 1369.8 | 1367.0 190 | 1374.3 1981.5 1988.7 | 1396.0 | 1403.2 | 1410.4 | 1417.7 | 1424.9 | 1432.1 | 1499.4 | 00-15FOREWORD CONVERSION TABLE kg/em? to Ib/in? 4.2233 Ibn? o 1 2 3 4 5 6 7 8 9 o o | 142| 24] 427| 569] 71.1] 953] 996| 1138 | 1280 10 142.2 | 1565 | 170.7 | 1849 | 199.1 | 213.4 | 227.6 2418| 256.0) 270.2 20 2845 | 2987 | 3129 | 327.1 | 341.4 | 3556 369.8 | 3840 | 3983 | 4125 30 4267 | aso | 455.1 | 4694 | 4896 | 497.8 | 6120 | 5269 | 5405 | 554.7 40 568.9 | 5832 | 597.4 | 611.6 | 625.8 | 640.1, 654.3 | 6685 | 6827 | 696.9 50 711.2 | 725.4 | 739.6 | 7538 | 768.1 | 7823 | 796.5 | 810.7 | 825.0 | 839.2 60 a53.4| 2676 | 881.8 | 8961 | 9103 | 9245 | 938.7 | 953.0 | 967.2 | 9814 70 9956 }1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 go 1138. | 4152. | 1166 [1181 | 1195 | 1209 | 1223. | 1237 | 1252 | 1266 90 | 1280 | 1294 | 1309 | 1323 | 1337 | 1351 | 1365 | 1380 | 1394 | 1408 too | 1422 | 1437 |1451 | 1465 | 1479 | 1493 | 1508 | 1522 | 1536 | 1550 110 }1565 | 1579 |1593 | 1607 | 1621 | 1636 | 1650 | 1664 | 1678 | 1693, 120 |1707 | 1721 |1735 | 1749 | 1764 | 1778 | 1792 | 1806 | 1821 | 1835, 130 | 1849 | 1863 |1877 | 1892 | 1906 | 1920 | 1934 | 1949 | 1963 | 197 140} 1991 | 2005 | 2020 | 2034 | 2068 | 2062 | 2077 |2091 | 2105 | 2119 150 }2134 | 2148 |2162 | 2176 | 2190 | 2205 | 2219 | 2233 | 2247 | 2262 160 2276 | 2290 | 2304 | 2318 | 2333 | 2347 2361 | 2375 | 2389 | 2408 qo |2418 | 2432 | 2446 | 2460 | 2475 | 2489 | 2503 | 2518 | 2532 | 2546 190 | 2560 | 2574 | 2589 | 2603 | 2617 | 2631 | 2646 | 2660 | 2674 | 2688, 190 }2702 | 2717 | 2731 | 2745 | 2759 | 2773 | 2788 | 2802 | 2816 | 2830 200 | 2845 | 2859 | 2873 | 2887 | 2901 | 2916 | 2930 | 2944 | 2958 | 2973 210 | 2987 | 3001 | 3015 | 3030 | 3044 | 3058 | 3072 | 3086 [3101 | 3115 220 | 3129 |3143 [3158 | 3172 |stes | 3200 | 3214 | 3229 | 3243 | 3267 230 3271 |3286 | 3300 |3a14 | 3328 | 3343 | 3357 | 2371 | 3285 | 3209 2ao [aera | 3428 [3442 | 3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542FOREWORD CONVERSION TABLE Temperature FahrenheitCentigrade Conversion ; 8 simple way to conven a Fahrenheit temperature reading into a Centigrade tempera ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures reler to the temperature in either Fahrenheit or Centigrade degrees, It it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the columa at the left, If it is desited to convert from Centigrade to Fahrenheit degrees, consider the center colurnn as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right C= 23 T “ ef ec} | + of | ec - -s04 | 40 | 00 | x7 | | sig] 7¢ | as | rus} a2!) #1 | ive -72 | 5 | aro | 11 | 2 | sas | aa] a | se6 | 278 | a | r96 -ata | -30 | -220 | 106] 19 | ssa | 09 | a8 | 1194] 203 | 03 | te14 317 25 | -13.0 10.0 14 87.2 94 49 120.2 28.9 84 183.2 -29 | -20 | -10 | -94| 1 | 590 | 100 | so | 1220 | 204 | 95 | 1850 -203| 9 | 22] -9| 16 | cos | 106 | 51 | 1232] 300 | s6 | 1068 sae | 12 | -o4| 03 | w | c26 | ma | se | 1256 | 306] o7 | 1086 cara. | av | 14 | re} te | cea | an7 | sa | are | ara | ee | 1904 27 | 16 | 32 | -72| 1 | 062 | 122] sa | raz] 217 | 09 | 1922 -61 | -18 | 50 | -27| 20 | 680] 128 | ss | 1310 | 222 | 9 | 1940 -as6|-«4 | oa | -61| 2 | oe | 133] s6 | 1228 | 220 | 91 | 1058 -0 | 13 | a6 | -s6| 2 | 716] 139| s7 | 1346] 223 | 92 | 1976 saa | 12 | roa] so] 22 | 734] tae] 5a | ra64 | 339 | 93 | 99% waa) | w2| -a¢ | 2 | 752 | 150 | so | 1382 | 304 | o¢ | 2or2 233 40 | wo | -39| 25 | 70] 155) 60 | 1400 | 350) 95 | 2020 -ze 9 | we| -23| 2 vee | 161 | 6 rie | 356] 96 | 2048 22.2 8 ws | 28 | 27 | a6} 167) 62 1436 | 361 | 97 | 2066 7-7 roa | 22 | 28 | aza | 172 | 63 1454 | 367 | 98 | 2084 saa) 6 | aa | a7! 29 | e42| ve] oe | raz] a2 | 99 | 202 -206 | 6 | 230] -11| 30 | e6o| 13 | 6 v490| 378 | 100 | 2120 200 -4 | 28 | 06) 31 78 | 19 | 66 | 1508} 406 | 105 | 221.0 <4 3 | 266] 0 | a2 | o6 | t94| 67 1526] 433 | 110 | 2300 9 2 =a | 06 | a3 | 914 | 200 | oe | rss | 461 | 115 | 2390 -13 | 4 302 | 11 a4 | 932 | 206] 69 | 562] 29 | 120 | 2480 178 0o 32.0 17 | 35 | 95.0 214 70 158.0 51.7 | 125 257.0 16.7 ba 35.6 28 37 98.6 22.2 2 161.6 57.2 | 136 275.0 “16.1 3 374 33 38 | 104 | 228 73 | 1634 | 600 140 | 2840 15.6 4 39.2 39 39 102.2 23.3 4 165.2 62.7 | 145 293.0 aso | 5 410 | 44 | 40 | 1040] 239) 75 | 1670 | 656 | 150 | 2020 ua] 6 | ze} 50 | 41 | 1052 | 24 | 76 | t688 | 063 155 | 3110 39) 7 | 46 | 56 | 42 | ro76 | 250 | 77 | 06 | 712 | 160 | 3200 m3 |e | aa | 61] a | roe] 256 | 7a | 724 | 739 | 105 | 2200 size} 9 | 42] 67 | a | a2] 261 | 79 | a2 | 767 170 | 3380 “a2 | | soo} 72) © | 30} 27 | so | 60] m4 ms | a001 GENERAL 020905 Assembly drawing Specifications Weight table List of lubricant and water 01-2 01-10 01-16 01-22ASSEMBLY DRAWING BACK HOE PC650-5 Unit: mm —s— oe Py jee | it z poo 1} ae ee —_—s — r SS ons i /f ae | | /K péedsx a / SAHRA fea) NES i di / Kw \\\o | i | )\N / Be {| 5) : a oe 01-2 6 020905,020905, PCESOSE-5 209F05008 209F05005,PossoLe-s Le Sf 020905 soroosesPC710-5 Unit: mm 01-6 1 202F 08006 209F05007 (020905020905 PC710SE-5 Unit: mm 209F0S009LOADING SHOVEL Unit: mm. oer] es 20905010 20905011 020905SPECIFICATIONS BACK HOE Machine Model PossO PeROSES Peasoies Serial No 200% and vo | 20001 and-up | 20001 and vp Operating weight a [7080 7980 cosu0 Bucket caacty (8) 25 25 2A | Maximum signa depth mmr | 886 7a00 3986 jg) Moximu vertical wal depth (mm) 7310 21s ra70 je desman gerne esha amy | ra708 1198 13.788 || Meximum digging height (me) 12490 11078 12,490 3] | Meximum dumping height_ (mm) 2:05 1210 2.305 ) Maximum digging force (kNikg)! 253(25,800) '338(34,500) 253(25,800) fl Swing speed (rom) 87 57 57 | Maximum owing slope angle (eg) 0 0 10 | Travel speed thew) | Lo: 2.7, His 4 Lo: 27, Hi at | Lo:27,His4.1 Gradetiiy (aes 2s % 2% | voround pressure (mPatkg/em")) 0.107(1.09) 0.108(1.107) 0.076(0.780) _Istandard shoe width: 12 fet) ise] T vera oath wom | r40%0 72900 14.040 | vera with (mm 4.008 4.006 410 | Overall width of crawler (mm) 3.910 3,910 4,110 | overt neigh tm 820 5588 520 Height of machine tom | ers 2978 2978 ‘aes tm saa 1322 1532 E) Minimum ground clearance (mm) o20 a20 exo | Minimum swing ie ty 100 100 4.100 por awe (eas ot (mm) 6,176 5,721 6,176 work eavipment orm telah at coin naa (mm) 10,765, 9,668 10,765 owing rae Lena of ack on ground mm) 4300 4500 020 Track gouge tom | 3300 3.00 2200 | acing ab mig tm 2540 3540 aso 01-10 020905020905 Machine model PCBSOS POBSOSES POSSOLES Serial No. 20001 and up| 20007 and up 70001 and up Model SAGDI40-1 | type -eycle, water cooled in-line venical direct injection type with turbocharger and aftercooler No. of cylinders - bore x stroke (mm) 6-140 x 165 Total displacement (ce) 15,240 Flywheel horsepower (kWIHPIirom) -306(410/1,800 | Maximum torque (Nmtkgmyepm) 1,804(184)/1,400, 2 High idling speed (rpm) 1.980 Low idling speed pm) 700 | Minimum fuel consumption ratio | (g/kW.nigiHP.n)) eee Starting motor 24V, 7.5 kW | Alternator 24V, 50 A Battery 12, 170 an x2 | Carrer roller (each side) 3 3 2) reck ler (each sie) 8 3 8) track shoe (each side) | Assembled double grouser shoe, | Assembled double z 47 on each side grouser shoe, 5 7°on each side Type, No. Vorable deplacement tandem piston pump x2 Variable displacement single piston pump x 1 Fixed displacement tandem gear pump x1 i 3 | Discharge flow (timo) 419 2 ¢ 916 + 157 8 set pressure apategierm Piston type: 3.4(320) 2) Gear type: 2.9130) '2| Te. No. ‘-sp00! type x 1 e|3| spool type x 1 Sig) S-spool type x 1 2/8 | operating method Hydraulic assist 33) Travel motor Piston type (with brake valve) x 2 £ | 2) swing motor Piston type (with safety valve x 2 4 Sena vp ¥ | Hydraulic cylinder Hydraulic tank Hydraulic line filter Hydraulic return filter Hydraulic cooler Double acting piston type Box type with breather Outlet port of pump Tank return side Air cooledMachine Mode! PoTI0- POTIOSE Serial No. 10001 and wp | 10001 and up eet - 70.540 70540 oo ot 26 35 Maximum digging depth | mm 3.380 7.300 | Meximum verieal wall depth] mm 6.035 2s Z| ttrimum canoe reach 2| yy 13380 | tnaas g = Maximum digging height. mm 12,000 11,075, 2 |__| Maximum dumping height | _mm 8,300 7.270 Serer Kika) | 2727-800) 38834.500) é ‘Swing speed pm 57 57 ee ee 140 140 Travel speed km/h Lo: 2.7, Hi: 4.1 | Lo: 2.7, Hi: 4.1 Gradeability | deg 35 | 35 ee wPaugens] ornate) — | ostatsen ee i610) 16101 Overall length om 13870 12.800 Overall width 7. 4.008 4.008 | overal wiath of erawlar 3910 3910 Overal height lon 5.130 5.585 Height of machine | omm 3,540, 3,540 Sec caso nm | 0 1s 5 | Minimum ground clearance mm 880 880 i Manimum swing rade at mm 4.100 4100 Mermamrig atin ct | mm | aan om | Arm height t minimum mm 10.830 s.608 4.500 4.500 | Track gauge mm 3,300 3,300 Machine cab height i 3500 3500 20908020905 Piston type(with safety valve} x 1 Machine Mode pono rorases | Serial No 70001 and up | 10007 and up Wael SABDTaO1 Tyee cycle, water cooled inne vertical, direct injection type with turbocharger and akercooler No.of liners ~ bore x suoke | mm 6140 x 168 | Total displacement | cc 15,240 Fiywhee! horsepower AWIHPYrpm 206(410)/1,600 2 | Maximum torque kgm 1,808(180)1.400 E igh icing speea . 1.980 i tom 700 oe 201 a gun 48) Starting motor 24v, 75K Alternator 24,504 [Battery 12,170 ah x2 3) Carver rolier (each side) 7 3) rack ote each sie 3 | Track shoe (each side) Assembled double grouser shoe, . 1 on each side oe Variable displacement tandem piston pump x2 iE Varable displacement single piston pump ® 1 a] Fixed eisplacernent tandem gear pump 1 bischarge ow timin 19942 +316 +187 [Bi sot pressure Pa, Piston type: 31.1320) =| | tkgiem*y Gear type: 2.9130), ype, No ] ‘spool type «1 : | Eapo0l pe a1 g eee ia © 5 loperating method a. 3 3) B) Travel motor Piston typetwith brake valve) x2 Bla] 2 4) swing motor Hydraulic cylinder Hydraulic tank | Hydraulic line filter Hydraulic return filter Hydraulic cooler Double acting piston type Box type with breather Outlet port of pump Tank return side Air cooledLOADING SHOVEL 8 | Meximum digging reach (mm) 9.961 i ae reach at (im) 8897 g 5 Maximum digging height = (mm) 10,647 2, _| Maximum dumping height (mm) 6.956 é ‘Swing speed (rpm) 57 cession ofeanpen” | ean oo el ie 5} Minimum ground clearance (mm) 880 | weoremarie et! ay | 5 See lll | | oa o1-14 02090520305 Machine model CEOS Serial No, 20001 and up | Model ‘SAD 140-1 Type ‘eye, ate cole ining eral, det inecton ype wah turboenager and srcaoler No. of cylinders - bore x stroke (mm) | 6 -140x 165 Total displacement (ce) 15,240 2 | Flywheel horsepower (kWIHPIirpm) | — 306(410V/1,800 | Maximum torque Nmikgmiepm | 1,804(184)/1,400 “| High idling speed (rpm) 1,980 | Low idling speed (om) 700 | Minimum fuel consumption ratio | (g/kW.hig/HP.h)) raat | Starting motor 24-V, 7.5 kW Alternator 24V, 504 Battery 12.V, 170 Ah x2 | Cartier roller (each side) 3 £ | Track roller (each side) 8 § | Track shoe (each side) | Assembled double 3 sgrouser shoe, 5| 47 on each side | Type. No. arate dsslacerent =| tandem pston pure x2 Fal \arale displacement single 2 fison pup x 1 | Fred displacement tandem 3| gear pur x1 \3| Discharge flow (f/min) | 419 x 24314 + 157 =| set pressure (MPa(kgicm?)) Piston type: 31.4(320}] el Gear type: 2.9(30) 22] Type, No, 1-spool type x 1 8 4:spool type x 1 2/2 5-spool type x 1 2 |S | Operating method Hydraulic assist 2) E) Travel motor Piston type (with e) brake valve) x 2 Swing motor Piston type (with = safety valve) x 2 Hydraulic cylinder Double acting piston ype Hydraulic tank Box type with breather Hydraulic line filter Outlet port of pump Hydraulic return fiter Tank return side Hydraulic cooler Air cooledWEIGHT TABLE BACK HOE ee ves v0 vss ees = ase roe 01-16 020905020905 Unit: kg Machine model PC85O-5 PC6SOSE-S PCESOLC-5 Serial No. 20001 and up 20001 ~ 2016320164 and up 20001 and up. Track shoe assembly 610 mm double grouser shoe 7,560 7860 | 7.560 = 710 mm double grouser shoe — | s20 ~ 810 mm double grouser shoe 8,880 - - 9.630 1.010 mm double grouser shoe 9,360 7 7 10,160 1.110 mm double grouser shoe = = 7 11,740 Boom assembly (excluding piping) 6.380 6,160 | 6310 6,380 ‘Avr assembly (excluding piping) 2,280 2510 | 2,760 2.280 Bucket assembly (excluding piping) 2,320 2,980 | 3,000 2,320 Boom cylinder assembly 790 x2 790x2 | 7902 790 x2 ‘Arm cylinder assembly 861 sei | 861 861 Bucket cylinder assembly 386 os | 704 586 Boom foot pin 45242 452x2 | 45.2x2 45242 Boom cylinder bottom pin 338x2 338x2 | 338x2 3382 Boom cylinder head pin 257 x2 251x2 | 255x2 257 x2 ‘Boom, arm connecting pin 918 915 | 105 918 ‘em eylinder bottom pin a 4 6 a Arm eylinder head pin 31 Ee 31 Link, arm connecting pin 50 50 | 56a 50 Link, bucket connecting pin 563 sea | 622 583 Bucket cylinder head pin 50 so | 561 50 Boom cylinder bottom pin 345 sas | 449 345 ‘Arm, bucket connecting pin 637 ea7 | oe 637 Link assembly 378 a8 | ate 378Unit: kg Machine Model Peri0-s PCTIOSES Serial No. 10001 and up 10001 and vp Engine assembly 2487 2487 + Engine 1475 147s + PTO (including lubricating piping) 543 543 + No. 1 pump 164 164 + No. 2 pump ur ur + Swing pump 137 137 + Charging and PTO lubricating pump 17 7 Radiator assembly 646 646 . Oil cooler assembly 154 154 Hydraulic tank (excluding oi a a ticluding laf and right decks) 18.150 18.180 Operator's cab 280 780 Swing machinery 385 265 Swing motor wz 12 Travel motor 0x2 220x2 ‘Swing control valve 355 355 LH. S-sp00! control valve 245 245 ALM, &-sp00! control valve 240 240 Center swivel joint a oy fincluding reounting bots) 10.600 10.600 Track frame assembly 18.435 18435 + Center frame 4763 4763 + Track frame 2487 x2 2487 x2 + Carrer roller T18x6 n8x6 + Track roller 136 x 16 136 x 16 + Idler cushion assembly 782.x2 792 x2 + later 490x2 450x2 + Final drive 147 x2 17 x2 + Swing circle 1.335 1336 01:18 020905020908 Unit: ko Machine Model PCT10-5 PCTI0SE-S Serial No. 430001 and up [iin EH | Hand ap Track shoe assembly 610 mm double grouser shoe 7560 7860 | 7.560 710 mm double grouser shoe 8.240 8200 | 0.240 810 mm double grouser shoe 1,010 mm double grouser shoe 1.110 mm double grouser shoe Boom assembly (excluding piping) 6.600 6.160 | 6310 Arm assembly (excluding piping) 2.580 2510 | 2.760 Bucket assembly (excluding piping) 2.550 2980 | 3.000 Boom cylinder assembly 790.x2 7902 | 790%2 ‘Arm cylinder assembly 361 ast | 861 Bucket cylinder assembly 586 70s | 704 Boom foot pin 452x2 452x2 | 452%2 Boom cylinder bottom pin 3382 338x2 | 338x2 Boom cylinder head pin 255 x2 25.7 x2 | 25x2 Boom, arm connecting pin 105 915 | 105 ‘Arm eylinder bottom pin 6 44 “6 ‘Aem cylinder head pin 30 Sie eral Link, atm connecting pin 561 so | 564 Link, Bueket connecting pin 622 563 | 622 Bucket cylinder head pin 36.1 so | 861 Boom cylinder bottom pin 368 45 | 449 Arm, bucket connecting pin ona ea7 | ota Link assembly 2 378 | 6LOADING SHOVEL es ve eae ell so 01-20 208052005 Unit: kg Machine model PCE50-S Serial No. 20001 and up Track shoe assembly 610 mm double grouser shoe 7,860 810 mm double grouser shoe 8.880 1,110 mm double grouser shoe 9,630 Boom assembly (excluding piping) #007 ‘Arm assembly (excluding piping) 2,725 Bucket assembly (excluding piping 5524 Boom cylinder assembly 568 x2 ‘Arm cylinder assembly 862 ‘Bucket cylinder assembly 526 x2 Bottom dump cylinder assembly 134 x2 Boom foot pia 435 x2 Boom cylinder Bottom pin 32x 2 Boom cylinder head pin 252x2 Boom, arm connecting pin 45 x2 ‘Arm cylinder bottom pin 55a ‘Arm cylinder head pin 554 Link, arm connecting pin 35.3x2 Link, bucket connecting pin 36.7 x2 Bucket cylinder head pin 36.8 x2 Boom cylinder bottom pin 35.3x2 ‘Arm, bucket connecting pin S18x2 Link assembly 440 01-21LIST OF LUBRICANT AND WATER “AMBIENT TEM "3 KINO OF eerie CAPACITY ( ¥) RESERVOIR IND Paiaree Ms BSS BBE soecitea [ren = SAE 30 == oo - « 3 is wa Engine oi ss awa PTO case ne E SAE 10W it a (each) ” 0.63 = ‘Track roller (each) Gear oil be RMS eT es 0.48 = Carrier role (each 073} Swing machinery case 7 a _ Sarina machinery a Final drive case (each) v ay Engi 2 = SEA 10W — Hydraulic system, SAE 10W-30 860 480 ie LE oe oo owe | oS Coating system | Water | Aad antireeze a *¥ ASTM 0975 No. 1 ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute NOTE: (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic mainte- ance hours described in operation & maintenance manual Change oil according to the following table if fuel sulphur content is above 0.5%, Change interval of oil in engine oil pan Fuel sulphur content 05 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval (2) When starting the engine in an atmospheric tem- erature of lower than 0°C, be sure to use engine oil of SAE 10W, SAE 10W-30 and SAE 1SW-40, even though an atmospheric temperature goes up to 10°C more or less in the day time, 01-22 ® Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. (3) Use API classification CD engine oil and if API Classification CC, reduce the engine oil change interval to halt. (4) There is no problem if single grade oil is mixed with multigrade oil (SAETOW-30, 15W-40), but be Sure to add single oil that matches the tempera. ture in the table on the left. (5) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applica: tions. 02090510 STRUCTURE AND FUNCTION 020905 PTO (Power Take-Off) rune 10- PTO lubrication system nnn 1H Radiator and oil cooler Power train . Swing machinery . ‘Swing circle Final drive. Track frame Idler cushion Idler... Track roller Carrier roller. Track shoe ... Air piping... Air circuit diagram Air compressor Air governor Ale tank wn Safety valve Horn valve Grease pump o : Hydraulic unit location. 10-19 Hydraulic circuit diagram . ioe Hydraulic tank nn senses 22 No. 1 pump ae sn 1023, No. 2 pump ‘Swing pump Charging and PTO lubrication pump ... Line oil filter Pilot oit filter... Return oil filter Drain oil filter : LH. 5:spool control valve A.M. 4-spool control valve ... ‘Swing control vaive ... Center swivel joint Travel motor Control relief vaive Safety lock vaive Accumulator... PPC valve... ea Solenoid vaive assembly. EPC valve : Auto-deceleration cylinder ... PPC shuttle vaive ... Hydraulic cylinder Work equipment... ee Electrical wiring diagram... Electrical circuit diagram Engine control Machine control system .. Machine monitoring system 10-43 10-49 10- 64 10> 55, 10- 85, 10-56 so 10> 86 110+ 68 10> 60 10- 65 10-72 10. 73 10> 80 10. 81 10- 83 10-92-1 10-923 10-924 10. 93 10- 95 se 10> 96 10-100 10-105 10-107 10-141PTO (Power Take-Off) Section AA Driven gear (No. of teeth: 46) PTO case |. Drive gear (No. of teeth: 51) Input shaft Connecting plate Driven gear (No, of teeth: 41) Driven gear (No. of teeth: 43) HeVv90+90 shat canter HPV90+00 shaft center ‘SALG3+8 shatt center 209Fos010 sPecircarions Volume of ubreation oi 1 (SAE30 Reduction rate HPVa0 «80 pump shat « $3. 0849 ‘s HPV160 pump shaft = 0.902 SAL63 + 8 pump shaft = 41 = 0.804 020905020905 PTO LUBRICATION SYSTEM Hydraulic circuit diagram Dividing block PTO lubrication pump SALE. Surainer Hydraulic piping PTO case Dividing block Lubrication piping Charging and PTO lubrication pump (SALE3 + 8) 5. Oil filter PTO case +209F3003 209F05011 OUTLINE In the PTO, the SAL8 of charging and PTO lubrication pump (4) is used to send the lubricating oil inside the PTO case through oil filter (5) to the top dividing block (2). From here, it is divided and sent to each art of the PTO and lubricates and cools all the gears. 10-3RADIATOR AND OIL COOLER 20905012 1. Radiator outlet tube SPECIFICATIONS. 2. Fan pulley 1. Fan 3. Radiator inlet hose Outside diameter: 1,350 mm 4, Fan guard No. of blade: 8 5. Pressure valve Fan speed: Standard 890 mm 6. Fan (At engine rated rpm: 1,800 rpm) 7. Radiator upper tank 8. Radiator core 2. Radiator 8. Oil cooler inlet tube Core type: D7 10. Oil cooler cole Fin pitch: 4mm 11. Radiator lower tank Pressure valve set pressure: 0.75 = 0.1 kg/cm? 12. Radiator drain valve Vacuum valve set pressure: 0 ~ 0.07 kgiem? 3. Oil cooler Core type: J Fin pitch: 3mm 10-4 020905020905 POWER TRAIN W 3 —r ‘Swing control valve | pe eee 18 20905013 . Idler . Center swivel joint ‘Swing motor LH. S-spoo! control valve RH. 4-spool control valve Final drive and sprocket Travel motor Engine PTO No. 1 pump |. Charging pump and PTO lubricating pump . Swing pump . No. 2 pump ‘Swing control valve ‘Swing brake solenoid valve Travel speed solenoid vaive 7. Swing machinery 1. Swing circleSWING MACHINERY 10-6 Section AA 209F05014 |. Swing pinion Housing No. 2 sun gear (13 teeth) No. 2 ring gear (80 teeth) No. 1 ring gear (160 teeth) No. 1 planetary carrier Cover 9. Swing motor 10. No. 1 sun gear (23 teeth) 11, No. 1 planetary gear (36 teeth) 12. Oil level gauge 13. No. 2 planetary gear (33 teeth) 14. No. 2 planetary carrier SPECIFICATIONS Reduction ratio: 23+ 160 , 13480 23 3 Continuous rotating speed: 5.3 rpm Volume of lubrication oi: Upper 37 £ (Engine oil SAE30) Lower 6 (Grease G2:LI) 36 x SB -37655 020905020905 SWING CIRCLE 1. Swing circle outer race 2. Ball bearing 3, Swing circle inner race SPECIFICATION Grease volume: 95 (G2-LI) 209F3039FINAL DRIVE 10-8 ‘200F0s015 |. Level plug . No. 1 planetary carrier Drain plug No. 2 planetary carrier 3. Cover 3. No. 1 sun gear (15 teeth) 7. No. 2 sun gear (12 teeth) 3. No. 2 planetary gear (43 teeth) 1. No. 2 ring gear (99 teeth) Spacer . No. 1 ring gear (77 teeth) . No. 1 planetary gear (29 teeth) . Floating seal . Housing Travel motor . Retainer . Hub Sprocket ‘SPECIFICATION Reduction ratio: 171+ 18 yx (ee 99 +12 - Be” det 55.733 Volume of lubricating oil: 35(SAE30) 020905TRACK FRAME PC650-5 PC650SE-5 10-9-1 6 1 2 3 4 6. 6 1 8 Idler Idler cushion Carrier roller Center frame Track frame Travel motor Track roller Guard 209F05016, 020905020905 PCESOLC-5 Idler Idler cushion Carier roller Center frame Track frame Travel motor Track roller Guard 30700989IDLER CUSHION 1. Idler 2 Cylinder 3. Piston IDLER 10-10 4 5. 6 Recoil spring Rod Lubricator § SectonaA-A 209F05017 Lubricating plug 2. Floating seal Bushing I. Idler shaft Bearing support Idler 020905020905 TRACK ROLLER |. Roller Shaft Bushing Floating seal Support CARRIER ROLLER 2osFoso1e Shaft Collar Floating seal Roller Cover 3. Lubricating plug 209F05019 10-11TRACK SHOE 1 i 3 4 T TASES aEoy ( D [oO [O} oO}, } T Td} ld} i | 2 A) (4 : : 2 |\ 209F3331 1. Regular pin 7. Regular dust seal (spacer) 2. Regular bushing 8. Regular dust seal (washer) 3. Master pin 9. Link 4. Master bushing 10. Shoe nut 5. Master seal (washer) 11, Shoe 6. Master dust seal (spacer) 12. Shoe bolt 10-12 020905020905 AIR PIPING Grease gun Grease ree! Grease pump Air horn |. Horn valve 6 7. 8 9 Air compressor Air governor Safety valve Air tank 209F05020 10-13AIR CIRCUIT DIAGRAM Governor Gur oft pressure: 7.3 + 0.2 kglem* Grease un Gut in pressure: 6.3 0.3 kgiem™ Greate reet, c Grease ump roo IAS) ey re 5 T t Ig mH wees CT iS —— Ac compresor | Set pressure 70200 rom | 9.7 8. ugiem? Unloader valve Ar tank oe | i fo bet - Check vaive 72 3 : cm ea 209F2048 AIR COMPRESSOR * See ENGINE SHOP MANUAL. 10-14 020905020905 AIR GOVERNOR AIR TANK Valve seat Diaphragm Body Sleeve Adjustment screw Spring Cover 209F2048 | dq © | | 209F3050 10-15SAFETY VALVE Cover Sleeve Spring Pin Cap Valve Nipple 5 SPECIFICATION : Set pressure: 9.7 9s kglom? 209F3051 HORN VALVE Spring Magnet, Wire Wire Coit Cover Piston Body 200115, 10-16 020905020905 GREASE PUMP Silencer Valve Cover Follower plate Grease tank = Grease discharge port 20905021HYDRAULIC UNIT LOCATION BACK HOE 8 10, u 12 13, 14 16, 16. 1. 18, 19. 20. 21. 22, 23, 24. 25. 26. 31 32, 3, 3g ‘209F 08022 27. 28. 23. 30. Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Swing motor Return oil filter RH. 4-spool control valve Gil cooler LH. 5-spool control valve Auto-deceleration cylinder Line oit filter ‘Swing pump ‘Auto-deceleration solenoid valve Charging and PTO lubricating pump Pilot oil filter No. 1 pump No. 2 pump Drain oil filter Control relief valve Safety lock valve Travel motor Heavy lift solenoid vaive Machine push up solenoid valve Straight-travel solenoid valve Free swing solenoid valve Swing brake solenoid valve Travel speed solenoid valve Swing control valve Accumulator LH. PPC valve « Conter swivel joint Travel PPC valve RH. PPC valve 10-19 @LOADING SHOVEL 13. 20905012 10-20 @ Bottom dump cylinder Bucket cylinder ‘Arm cylinder Boom cylinder ‘Swing motor Hydraulic tank Roturn oil filter RH. 4-spool control valve |. Oil cooler LH. 5-spool control valve Auto-deceleration cylinder Une oil filter - Swing pump . Auto-deceleration solenoid valve . Charging and PTO lubricating pump Pilot oil filter 7. No. 1 pump No. 2 pump . Orain oil filter Control relief valve . Safety lock valve . Travel motor |. Bottom dump close solenoid valve Machine push up solenoid vaive . Straight-travel solenoid valve . Boom EPC valve Bucket EPC valve Bottom dump open solenoid valve 1. Swing brake solenoid valve ). Travel speed solenoid valve Boom shuttle valve . Bucket shuttle valve ‘Swing control valve . Accumulator LH, PPC valve Travel PPC valve Center swivel joint |. RAH. PPC valve (020905HYDRAULIC CIRCUIT DIAGRAM BACK HOE PPC ot (a) OI INO} (HO INO 1 209F05023, s060z0LOADING SHOVEL 10-21-1 @ 20905019 020905* FOR MACHINE EQUIPPED WITH WORK EQUIPMENT CONTROL SYSTEM LOADING SHOVEL sosozoHYDRAULIC TANK 10-22 Hydraulic tank Strainer Filler cap Pressure valve il level sensor . Suction strainer Drain valve Mes = Section 8-8 Section A= A 209F2085, ‘SPECIFICATION Relief set pressure: 0.39 + 0.15 kg/em? Suction set pressure: 0 - 0.046 kg/em* 020905020905, No. 1 PUMP CO- NC valve output pressure Pecn (rest), cue G9; NC ve oto pressure Peen trond Servo source pressure Pav supply port lla of a5 po = ~ Jet sensor Jet sensor Suction port Jet sensor output pressure Pd | IN por u it pressure ouput pressure uiput pressure ‘brinpor PdiNport PLN Dor ‘Swing pump pressre Pas piled taenaid 102039 4 5 6 7 Drain Pars port Discharge Pas port Discharge Pas port Drain Pd: port 209F05024 1. Front pump 5. Rear servo valve 2. TC valve 6 Rear CO*NC valve 3. Front CONC valve 7. Rear pump. 4. Front servo valve1 MAIN PISTON PUMP (HPV90 + 90) | | = E ) By a View2 Discharge port Discharge pont rane dchre nin port brain por pressure Pu pat. Serv valve source Pump discharge» Pressure Ps. BO" Servo valve source ume decharge pressure pressure Par port. Servo vaive output pres t pee: ae _Pswie port Ne Pum discharge pressure Sane ton aunt SS Servo vole output fe Fora po On Seven ‘ Seno pon ora esse (ye * " oQ o Vio x 20905025, 10-24 020905020905, Front shaft Front cradle Front case Rocker cam Piston 42 1 4 6 7. 8 9. 10. Cylinder Valve plate Front end cap Impetier Coupling nn. 12. 13, 4 18. 209F0s026 Rear end cap Rear case Rear cradle Rear shaft ‘Servo piston 10-252. SERVO VALVE cl tc Pe ‘oP P Sof vA a! \ He} co-ncvave 9 ar port Main pump pressure Pas OUT le °Q.| [_9. Section J—J Seetionk—K 20905027, 020905020905, Section A= A 209F206 1. Lock nut 7. Pin 13. Sleeve 2. Cover 8. Control piston 14, Guide spool 3. Plug 9. Lock nut 18. Spring 4 Spring 10. Plug 16. Plug 5. Body 11. Lock nut 17. Cover 6. Arm 12. Cover 18. Lock nut FUNCTION + Delivery amounts of two main piston pumps are controlled separately by the respective servo valve. + The stroke of the actuator (servo piston) which changes the delivery of the variable displacement pump. is controlled by the pump servo vaive. ‘The relationship between the delivery amounts Qs (or Q.) of the pump and the input signal pressure Pecn to the servo vaive is as shown in the graph on the right. The stroke of the actuator (servo piston) is proportional to the oil pressure — from TVC valve, in other words, delivery amounts ‘CO-NC valve output pressure iks/em*) 1 (or Qs) vary in direct proportion to Pecn. Lit Pump delivery amount lec/rev) 10-27OPERATION 11 Operation for increasing pump discharges (rocker cam angle changes to the large) 448 8 5 ! \A : | aire 7 see | Os ae Ne valve : a 5 covane 6 000008 ; | Go000 8 M + Charging pump pressure Psv is sent to port a, Signal pressure Peen from the NC valve is sent from port b to chamber ¢. + As signal pressure Pecn rises, the pressure in ‘chamber ¢ pushes control piston (8) to the left in the direction of the arrow. The piston stops in a Position where it is balanced with the force of springs (4) and (4A), At the same time, arm (6) uses serve piston (19), as a fulcrum, moves to the left in the same way a8 control piston (8), and while fluctuating, moves. Quide spool (13) to the left 10-28 aL 209F05028 ‘The movement of guide spool (13) closes port a and port d, and connects port d with drain chamber e. As a result, servo piston chamber f is also connected to chamber e through port g and port d. ‘At the same time, port a and port h are con- ected, and the flow passes through port i to servo piston chamber j to push servo piston (19) to the left in the direction of the arrow. The rocker cam angle of the main piston pump be: comes larger, and the pump discharge volume increases. Because of the movement of servo piston (19), ‘arm (6} rotates clockwise around pin (7), moves guide spool (13) to the right, and closes port a, port d, and port h, so the discharge volume increases only by an amount corresponding to signal pressure Peen. 020905020905 : oh = y 1 = \ afi 2 \ — ' i St cE | ee si pa c NC valve. —f L4 = 6 OO0000: Go eilaaa ovale f » i ! Te valve 209F05029 When signal pressure Pecn drops, control piston At the same time, port a and port d are con- (8) moves to the right in the direction of the ar- nected, and the flow passes through port g to row to a point where the hydraulic pressure of ‘servo piston chamber f to push servo piston (19) chamber ¢ is in balance with the force of springs to the right in the direction of the arrow. The (4) and (4A) rocker cam angle of the main piston pump be- At the same time, arm (6) uses servo piston (19) comes smaller, and the pump discharge volume {as a fulcrum, moves to the right in the same way decreases. ‘as control piston (8), and while fluctuating, moves guide spool! (13) to the right. + Because of the movement of servo piston (19), arm (6) rotates counterclockwise around pin (7), ‘The movement of guide spool (13) closes port a moves guide spool (13) to the left, and closes and port h, and connects port h with drain Port a, port d, and port h, so the discharge vol- chamber e. As a result, servo piston chamber j is lume decreases only by an amount corresponding also connected to chamber e through port i and to signal pressure Pecn. port h.3. TVC VALVE ‘Main pump pressure Servo source ‘Main pump pressure pressure Psv IN port Par! port oe Fu PavIN port \ / = Hq \ oleeee i eo ° = 2 Ka Secon ¢ / iN o > Ve vate output pressure Re vane dan PE) g— Peau port Par OUT port [ov ore rq Section = a A Kho EK el o © T Ei | © © > kek sh K — ump pressure Section K ~ Pooh por Oo ° a © oc SecionB-8 Secon E-€ Section F=F SecionG—G Section Section 1? ete agg ; ep | FES pH / oH ° ) gee Erbe +H zosF05030 1. Spring 6. Piston 2) Spool 7. Piston 3. Piston 8. Body 4 Sleeve 9. Solenoid 8. Piston 10-30 020905020905 FUNCTION AND OPERATION When command current from controller in H mode is small * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS v M Wve wale i / A ie 2) | fea @| lex 2 < Pew Peal ne’ | cg . valve | valve ee > Servo valve db Sere piston Ld LES FUNCTION When the OLSS mode is set to H mode, the discharge flow from the pump is controlled to the ‘optimum by the command current from the controller to match the change in the engine speed, In § mode or L mode, and when the prolix switch is ON, the pump discharge flow is controlled to match the pump discharge pressure (load) by hydraulic sensing in accordance with a constant pump absorption torque. For details, see MACHINE CONTROL SYSTEM. te a , aa. OPERATION + Because of the command current sent from the controller, solenoid push pin (10) moves, and piston (2) also moves. When this happens, it stops at a point where the sum of the force of spring (1) and the force of push pin (10) and the force of TVC output pressure Pe acting on piston (3) is in balance. At this point, the command current is small, so piston (2) is balanced at the bottom. As a result, ports a and b are both almost completely open, and almost all the pressure oil from the charging pump output as TVC output pressure Pe. For this reason, the pump discharge volume becomes the maximum.2) When command current from controller in H mode is large * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS VC valve Pecn| yo co valve Servo valve Servo piston Decreases =— UT increases Protx switch ee Controle nt 209F05092 + Because of the command current sent from the controller, solenoid push pin (10) moves, and piston (2) also moves. When this happens, it stops at a point where it is balanced with the force of spring (1), At this point, the command current is large, so piston (2) is balanced at the top. As a result, the flow of the oil sent from the charging pump is throttled at port a and port b, and at the same time, the area of the opening at @ port b and port ¢ (drain port) becomes larger. For this reason, the TVC valve output pressure Pe {drops and the pump discharge volume is reduced. 020905020905 3) In $ mode (When in L mode or prolix switch is ON) and load on pump is small oe ve vane BR, ora bess vl ny | a a ets | ae) SL aa Psy eee ee Es jl =o || —a ] a Servo valve Pay serve piston ur PA2| ae decreas TT Tarenses =] GE] & ra, = all, Ha at PA PAs] H Protx switch Pe MB | conn 4 a Resistor - ae + If the setting is changed to S mode (L mode of prolix switch ON), solenoid push pin (10) is Pushed up; this makes the set pressure of spring (1) larger, and this condition is maintained, + AS a result, the absorption torque of the pump. becomes constant, and TVC output pressure Pe Jump discharge flow) is controlled by the pump. discharge pressure. 209F05029 Main pump discharge pressures PA1, PA2 and PA3 are low, so spool (2) is pushed down by spring (1). As a result, charging pump discharge pressure Psv and TVC valve output pressure Pe are equal. At this point, the TVC valve output pressure Pe becomes the maximum, and the main pump dis: charge volume is also the maximum. 10-334) In $ mode (When in L mode or prolix switch is ON) and load on pump is large VC valve Pen, Ne co. valve Servo valve. Servo piston Decreases == Up] increases Protx ewiten controler ON! Resistor 209Fo50e + When main pump discharge pressure PA1 (or PAZ or PA3) increases, spool (2) is moved up by piston (4) (or piston (6) or piston (7)). As a result, the flow of the oil at port a and port b is throttled by the notch in the spool, and at the same time, the area of the opening at port b and port ¢ (drain port) becomes larger. For this reason, the output pressure Pe of the TVC valve drops and the main pump discharge volume is reduced, 10-34 020905020905 4. CO-NC VALVE Heavy it solenoid valve pressure PeN port Jet sensor output FFA pressure PLN port / oa 5 Nese : 5 CO:NC vane ouput ( | | reser Pan eee a Lf LE bs ae | Bore Pov OUT port Tie vane cae] (| sere souce Nevane pene © 4D Pa fo ol eeeese ew pon ‘output pressure. ao PPR IONS Pein port somacion O)MO) \ €O-NC vane drain eZ) | Per 9 ir ‘port wWevave dain | ° 4) if i eral « eeu Maa] @—1 | sin our esse Main pumoorssre| ° | | oer Psi OUT port, 9 a 4 Section €~ € Main pump pressure Pas INport Section H— 209F05095CO VALVE Plug Piston Spring Spool Piston Plug 209F05036, 10-36 NC VALVE 2 10. " 12. Plug Sleeve Piston Spool Spring Plug 020905,020905 FUNCTION AND OPERATION OF CO VALVE 1) When main pump discharge pressure is below relief pressure Ne valve Reavy iit ed) AT fr Servo valve Servo piston Decreases FUNCTION + If the load increases during operation, and the main pump discharge pressure rises and comes close to the relief pressure, the CO valve carries out the cut-off function to reduce the pump discharge volume and decrease the relief loss. + At the same time, the pilot pressure of the heavy lift solenoid valve also has the function of canceling the cut-off + The CO valve is controlled by balancing the spring with the sum of the main pump discharge pressure PA and CO valve output pressure Pec, 209F0S037 OPERATION Spool (4) is pushed down by spring (3). As a result, port a and port b are fully open, and TVC valve output pressure Pe is equal to CO valve output pressure Pec. For this reason, CO valve output pressure Pee becomes the maximum, and the main pump discharge volume also becomes the maximum,2) When main discharge pressure is close to relief pressure S toleold vate mom] at A —J Deactivated 1 Peca| ne 4 valve Pel tc {Psu =F Te, Servo valve, Peel Decreases =— LTinareases 5 209605028, + As the load increases and main pump discharge pressure PA comes close to the relief pressur main pump discharge pressure PA pushes piston (5). At the same time, CO valve output pressure Pec pushes piston (5), and spool (4) moves up. As a result, the flow from port @ to port b is throttled by the notch in the spool, and the area of the opening of port b and port ¢ (drain port) becomes larger. For this reason, CO valve output pressure Pec drops and the pump discharge flow becomes the minimum, 10-38 020905020905 3) When cut-off function is canceled by heavy lift solenoid valve COvaWe op Is Heavy ite solenoid valve ea) T. = ae | valve Pel rc {Es | a valve Servo valve Ped Decreases LJ = tren Ns Id + When the heavy lift solenoid valve is switched, its pilot pressure goes to port Pe, and piston (2) is pushed down. Asa result, the set pressure of spring (3) becomes larger, so even when main Pump discharge pressure PA rises and reaches the relief pressure, spool (4) is not actuated, and CO valve output pressure Pec remains at the 203F05039 10-39FUNCTION AND OPERATION OF NC VALVE 1) Control valve at neutral et sensor Servo valve ‘Serve piston Decreases —— Ly] increases M FUNCTION + The NC vaive controls the main pump discharge volume according to the amount of operation of the control valve spool, and carries out the function of controlling the oil flow to reduce the neu tral loss and fine control loss. + The NC vaive is controlled by balancing the sum of jet sensor output pressure Pt and NC valve output pressure Peen with the sum of the force of NC valve spring (12) and jet sensor output pressure Pd. + The jet sensor detects the flow of return oil pass ing through the control valve and returning to the tank, and takes it as NC valve Pt and Pd. 10-40 Pee Psv vane | TV eowave | vale 20905040, OPERATION The differential pressure (Pt ~ Pd) of the jet sensor reaches the maximum and jet sensor output, pressure Pt acting on piston (10) becomes gr than the sum of the force of spring (12) and jet ‘sensor output pressure Pd acting on the lower end of spool (11). As a result, spool (11) is pushed downward, ‘causing a restriction of the oil flow between port and port b and in turn opening port b and port @ (drain port). Output pressure Peen of the NC valve is then reduced to the minimum and the main pump discharge is also reduced to the minimum with the ‘swash plate angle minimized through the opera: tion of the servo valve. 020905020905 2) When the control valve is operated Jet sensor Control Servo valve Servo piston Decreases LJ —= Inereases| M + With the jet sensor differential pressure (Pt - Pd) reduced according to the operation of the control valve, spool (11) is pushed upward, fully opening port ¢ and port b. Thus, the NC valve output pressure Peen increases. Together with the increase in the main ump swash plate angle through the servo valve operation, the main pump discharge is also in. ceased. That is to say, the pump discharge increases as the stroke of the lever increases. NC valve 209F0s081020905 No, 2 PUMP CO-NC valve output pressure Peen (tront] CONC valve output pressure Pecn (reer CO- NC valve output pressure CO + NC valve output pressure Pecn iran piexup port een (ear! pick-up por I —“O) oO ©) ) 0° 96, C0 0 ne é é =P 8 TUl 2o9Fos042 Front pump Front servo valve Rear servo valve |. Rear pump,1. MAIN PISTON PUMP (HPVS0 + 90) Drain por Discharge port Discharge port Drain port / i Servo valve source pressure Pos port Pump discharge \ presture Pu port Servo valve source , ressure Pov port / Pump discharge WN Z_prassure Pas port e ZT Serv stn uot BAO “SL saree aa ae e view x 10-44 a Pump discharge pressure Pas port Pump discharge pressure Pas port, Suction port Servo valve source _ pressure Poa port Servo piston outout | >> pressure Psa port we Servo valve output &:|_—~pressure Pum port ¢ view x) 209F05042 020908020905 Section A A Front shaft Front cradle Front case Rocker cam Piston 6. Cylinder ". 7. Valve plate 12, 8, Front end cap 13. 9. Impeller 7 10. Coupling 15, zooroeoee Rear end cap Rear ease Rear cradle Rear shaft Servo piston 10-452. SERVO VALVE at pt BAe OTE ae Sr, Serve actuator p01 “Pump aiseharge pressure En —— p=] Paz IN port ump discharge pressure De rT {charging pump or Psv IN port ble Section D = D 10-46 * For details of the operation, see No. 1 PUMP. Servo actuator port 209F2066 020905020905 Plug Lock nut Body Control piston Arm Pin 15 Seeton A= A 7. Spring 8. Plug 9. Cover 10. Lock nut 11, Lock nut 12. Cover 209F2067 13. Plug 14. Spring 18. Guide spool 16. Sleeve 11. Cover 18. Lock nut 10-47020905 Drain port Jet sensor output bressure Pd IN port ‘Servo source pressure supply port Jet sensor output TVC valve output pressure Pe IN por pressure PEIN port (from No. 1 main pump servo! TVC valve output pressure pick-up 1 2 G3 Suction port 2osros04s 1. Main pump + For details of the structure and operation of the 2. COmNC valve servo valve, see NO. 1 PUMP. 3. Servo valve1. MAIN PISTON PUMP (HPV160) rain port Discharge port Servo valve Pov output port \ Servo source \ pressure Pov per 2 _ servo vatve output Pa port r al! iE a. Suction port 209F05047 10-50 020905,020905 1. Shaft 2. Cradle 3. Case 4. Rocker cam 5. Piston 6. Cylinder block 7. Valve plate 8. End cap 8. Impeller 10. Block 11. Servo piston Section ~ ¢ 2o9Fso4e2. CO-NC VALVE ‘charging pump pressure Pav OUT port a Tvc valve ba gree fh % For details of the operation of the CONC valve, see NO. 1 PUMP. set sensor ‘guter pressure PeiN'per “5 %)_CO-NC valve output -pressure Peen OUT | Bort | Crarsing pume ‘resure PSV IN port ee) — S ©) |. cane mle tran 7 1 Fo SSiten TVC valve F i e ° e Pump discharg o Sl output i {> pretute Pat IN port oaks der sense age Pump dishare pum dserarge ciergreure La fume asoareprenure PatiNeot — PAzIN port ae eee if ali c ale ery cai Onn Oe ° f pS 22 o FO tc a J Seon =D Seton EE Sesion —F Sesion@-G Section = 10-52 209F3069 020905020905 cOveve NC valve CO valve A TES 7 Do HT D i t B t q = section B= 8 ee CO VALVE NC VALVE 1. Plug 10. Plug 2. Cover 11. Sleeve 3. Seat 12, Piston 4 Spring 13. Spool 5. Seat 14, Body 6. Spool 15. Seat 1. Piston 16. Spring 8. Sleeve 17. Plug 9. Pug 18. Cover Section = € 2092070 10-53CHARGING AND PTO LUBRICATING PUMP SALES +8 Discharge om mW 10 | H Charging pumo PTO lubrication ISALeaI umplSALB! 200F3073, 1 gear OUTLINE 2. Bracket In this tandem gear pump, the SAL63 is for the PPC 3. Gear case and OLSS charging, and the SAL8 is for PTO lubrica 4. Cover tion, 5. Coupling 6. Drive gear ‘SPECIFICATIONS. 7. Bracket ‘Theoretical delivery: SAL63_ 63.1 coirev. 8. Gear case SAL8 85 co/rev. 9. Cover Max. delivery pressure: 210 kglem? 10. Driven gear 11. Driven gear 10-54 020905020905 LINE OIL FILTER 3 1. Body 2. Element 3. Cover PILOT OIL FILTER a of? 209F2074 209F05048 1. Bracket 2. Cartridge 3. Element 10-55RETURN OIL FILTER |. Cover Spring Bypass valve Bypass valve spring Element Housing = 209F05050, DRAIN OIL FILTER 10-56 Bracket Safety vaive Cartridge Element 209F3206-1 020905,L.H. 5-SPOOL CONTROL VALVE BACK HOE s060z0 Pe pon p Pepon Pupon — 209F05081 10-58020905 Section BB Section F =F Lt/ LET *r Section G-G 20905015, Main relief valve 6. Spool (LH. travel) 11, Throttle valve Spool (Service) 7. Spool return spring 12, Check valve spring Spool (Boom-Hi) 8 Body 13. Check valve Spool (Arm-Lo) 9. Jet sensor orifice 14. Safety-suction valve ‘Spool (Bucket-Hi) 10. Jet sensor relief valve 18. Suction valve 10-59 3LOADING SHOVEL F20905016 10-59-1 2 020905020905 —s 2 a Ls : 5 Wy 5 a! Sees ° 2 8 Section 8-8 / \ 4 1 9 ‘ Section A= A Xv /, TS fiacy Section ¢~¢ Section D- 0 Section G - G 20906017 Main relief valve 6. Spool (LH. travel) 11. Throttle valve ‘Spool (Bottom dump) 7. Spool return spring 12. Check valve spring ‘Spool (Boom-Hi 8. Body 13. Check vaive Spool (Arm-Lo} 9. Jet sensor orifice 14. Safety-suction valve ‘Spool (Bucket-Hi) 10. Jet sensor relief valve 18. Suction valveR.H. 4-SPOOL CONTROL VALVE 1 [D oe s060z0 Prport Pre port Per port [0 7 lal li U r I 9-0 | | 203F05053 10-60020905 Section € ~ € |. Main relief vaive . Spool (RLH. travel) ‘Spool (Boom-Lo) Spool (Bucket-Lo} Spool (Arm-Hi) Section F — F 209Fo5054 6. Spool! return spring 11. Check valve spring 7. Body 12. Straight-travel valve 8 Jet sensor orifice 13. Suction valve 9. Jet sensor relief valve 14, Safety-suction valve 10. Check valve 18. Safety-suction valve 10-61STRAIGHT-TRAVEL VALVE (To arm) __-Port Pe f Ps (To bucket, boom) Port Ps s060z0 209F3019 10-62020905 ial Section 8 @ Section - ¢ 208F05055 Orifice Check vaive Spring ‘Spool return spring Body Spool CoverFUNCTION + Ifthe boom, arm, or bucket are operated at the same time as the travel, the pressure oil flowing to the LH. and RH. travel circuits is divided and sent to the boom, arm, or bucket circuit, The travel circuit on the side where the oil flow is divided will have a smaller flow of oil to the motor than the travel circuit on the side which is Not divided, so the flow in the motor circuit will drop and the machine will deviate to one side. + To prevent this, the straight-travel valve is switched to interconnect the LH. and RH. travel circuits, thereby ensuring and equal supply of oil to both the LH. and RH. travel motors. This keeps both the LH. and RH. motors rotating at the same speed, and prevents any travel deviation, OPERATION When operating only travel circuit (st solenoid valve deactivated) + The straight-travel solenoid valve is deactivated, 80 the pilot pressure does not flow, and spool (6) remains pushed to the left. + Because of this, port Pr (LH. travel circuit) and Port Ps (RH. travel circuit) are not interconnected, but are kept as independent circuit. Travel and work equipment circuits operated at the same time (straight-travel solenoid valve excited) + The straight-travel solenoid valve is excited, so pilot pressure flows and spool (6) is pushed to the right. + When this happens, port Pr and port Ps are interconnected to ensure an equal flow of oil to the LH. and RAH. travel motors. The LH. and RH. travel motors rotate at the same speed, so there is no travel deviation. 10-64 LH wave RH. ¢sp00! LH. Sspoot tH valve vave RH. travel Strsightaravey solenoid va Deactivated aoseosne ft p00! Li. spot LM eve fin. val UF. ed Suraighttravel Selendis valve Exci 20905057 020905SWING CONTROL VALVE 06020 209F3034 10-6510-66 Section A= A I a ef tT. Section = Body Main relief valve Spool return spring Spool Section 8 = 8 209F2035 Suction valve Jet sensor Check vaive spring Check valve 020905JET SENSOR 2093036 @ aff] SA Cy - e) | ©9 10-67 QI wile] s060z0SWING MOTOR Tort Spon Ha MA port Cron ‘SPECIFICATIONS Type: Theoretical delivery: Safety vaive set pressure: Rated speed: Brake releasing pressure: 10-68 203F05058 KMF160AB-2 160.7 corey 280 kgicm* 2,106 rpm 16 + 2 kgicm* 020905020905 1. SWING MOTOR { | / \ 10 Section A= & 20905059 * 1. Housing 7. Center shaft 2. Brake spring 8. Valve plate 3. Brake piston 9. Piston 4, Plate 10. Cylinder block 5. Disc 11, Output shaft 6. Brake case 10-6910-70020905 ‘SWING MECHANICAL BRAKE OPERATION 2) When swing brake solenoid valve is deactivated When the swing brake solenoid valve is deactivated, the pressurized cil from the charging pump. is shut off and port B is connected to the tank circuit Because of this, brake piston (3) is pushed down in the direction of the arrow by brake spring (2), so disc (5) and plate (4) are pushed together and the brake is applied. When swing brake solenoid valve is excited When the swing brake solenoid vaive is excited, the valve is switched, and the pressurized oil from the charging pump enters port B and flows to brake chamber a, ‘The pressurized oil entering chamber a overcomes the force of brake spring (2), and brake piston (3), is pushed up in the direction of the arrow. Be- cause of this, disc (5) and plate (4) separate, and the brake is released, ‘Swing brake solenoid valve ay Deactivated 203F05061 Excited] Swing brake solenoid valve 209Fos062CENTER SWIVEL JOINT 10-72 Cover Body Slipper Oil seal Shaft 209F3021 020905020905 TRAVEL MOTOR Motor Selector valve and reducing valve Counterbalance vaive Safety valve 209F05069 ‘SPECIFICATIONS. Type: HTM550G1 Theoretical delivery Max. (at Low speedi: 552 ecirev Min. (at High speed!: 361 ccirev Rotating speed Max. (at Low speed): 751 rpm (8068 /min) Min. (at High speed): 1,150 rpm (4068 /min) Parking brake releasing pressure: 10 kg/cm? Pilot spool switching pressure: 15 kg/cm? 10-731. MOTOR, SPEED SELECTOR VALVE AND PARKING BRAKE 10-74 2 3 4 18 ” Retainer Flange Piston (high speed) cam Piston (low speed) Piston Shoe 5 6 7 8 Lf = x 16 15 4 13 12 8. Orifice 18. 9. Valve plate 16. 10. Spring 1”. 11. Check valve 8. 12. Cover 18. 13. Brake spring 20. 14, Brake piston 21 W 209F05064 Dise Plate Cylinder Housing Valve body Selector valve Reducing valve 020905020905 2. BRAKE VALVE i | pode \ oe Safety valve 10-75OPERATION OF MOTOR 1). At low speed (travel speed solenoid valve deactivated, motor swash plate angle at maximum) | —20 =a Brake vawve Travel speed solenoid valve q Al, Deactivated + When the travel speed solenoid valve is deacti vated, the pressure oil from the charging pump does not flow to pilot port ¢ of selector valve (20), 50 selector valve (20) is kept pushed down in the direction of the arrow by the spring, + Because of this, the pressure oil sent from the main pump by check valve (11) passes from pas- ‘sage a of selector valve (20) through passage b, enters chamber e of piston (3), and pushes piston (3) to the right in the direction of the arrow. 10-76 BE] travel control valve [7 M 20905065, When piston (3) is pushed, cam (4), which is connected to the piston, moves. The swash plate of the motor is set to the maximum angle (maxi mum displacement), and the travel speed is set, to low speed. 020905020905 2) At high speed (travel speed solenoid valve excited, motor swash plate angle at minimum) ry MB. Brake valve Travel speed solenoid valve iva Excited + When the travel speed solenoid vaive is excited, the pressure oil from the charging pump flows to pilot port ¢ of selector valve (20), and selector valve (20) is pushed up in the direction of the arrow. + Because of this, the pressure oil sent from the main pump by check valve (11) passes from pas- ‘sage @ of selector valve (20) through passage d, enters chamber f of piston (5), and pushes piston (6) to the left in the direction of the arrow. EE] Teaver contol vatve [a M 209F05066 ‘When piston (5) is pushed, cam (4), which is con- ected to the piston, moves. The swash plate of the motor is set to the minimum angle (mini mum displacement), and the travel speed is set to high speed,OPERATION OF BRAKE VALVE + The brake vaive consists of a counterbalance valve (61, check valve (1) and safety vaive (7) in a circuit {as shown in the diagram on the right (Fig. 1) + The function and operation of each component is, as given below. 1) Counterbalance valve, 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 load and will run away, which is extremely dangerous. To prevent this, these valves act to make the ‘machine travel according to the engine speed (pump discharge volume). 1m! when pressure is supplied + When the travel lever is operated, the pressu. rized oil from the control vaive is supplied to port PA. It pushes open check valve Cs and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve C2 and spool (1), so the pressure at the supply side rises. (Fig. 2) + The pressurized oil at the supply side flows from orifice D1 in spool (1) to chamber Es, and when the pressure in chamber E1 goes above the spool ‘switching pressure, spool (1) 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 opened, and the motor starts to rotate. (Fig. 3) 10-78 Fig 20905067, SS swing holding brake function Travel speed selection function Straight-travel ON (Automatic) 2-mode or 3-mode pump torque control Cutoff control Flow control OFF oN oFF (Digging improvement mode} oN (Machine push-up mode) OFF (Swing holding brake} ON (Swing lock) Lo (Low speed) Hi (High speed 209Fo5008TOTAL SYSTEM DIAGRAM BACK HOE ‘* FOR MACHINE EQUIPPED WITH 2-STAGE MODE SELECTOR OLSS Br Gam gay Que Teauatr TRaguator SIV: Safety vaive PIS: Oil pressure switeh F 20805039 10-108 2 020905,020905 BACK HOE ‘* FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS AND AUTO-DECELERATION GB LH. travel RH travel Cylinder £} swing motor motor motor Tr Z | Regulator Regulator SIV: Satety valve | © Buckerto Bs B) i! See [Boomehi S| |e Ri travel fo PIS: Ol pressure switch (ree swing) Z1;1 a | swien_f| | rl | a , wureatng 80m fh; | Auto-deceleration LSS controler JS re See, ee 20905095, 10-109 2LOADING SHOVEL ‘* FOR MACHINE EQUIPPED WITH 2-STAGE MODE SELECTOR OLSS ae Be Ca” SI: Satery valve /S: Oi pressure switch Solenoid vave Bottom dum close © Buceette = eeante amis bs 2 Monitor panel 10-110 2 20205040 020905020905 LOADING SHOVEL * FOR MACHINE EQUIPPED WITH 3.STAGE MODE SELECTOR OLSS AND AUTO-DECELERATION = i aos aM a rl Grinder Q ae 2 cor ‘SIV: Safety vave SS = === SS /S: Oi pressure switch ryeenwot Solenoid valve ef UH travel | | Monitor panel tT! iss comroner ‘See next page! fF 20905081 10-111 2RELAY CIRCUIT DIAGRAM. BACK HOE ‘The machine control system uses 11 relays, and the structure of the circuits is as shown below. (The travel speed solenoid system does not pass through the relay circuit: the switch and solenoid are connected directly.) PC650-5: 20001 - 20096, 20099 ~ 20103, 20106 - 20108 PC710-5: 10001 - 10085 Solenoid valve Swing LA.uivel RALtavel —Suaght Swing ee saci Wea wane eg en) ears fh ey a w a @ ee i ee a | | ARM IN-bucket_ ou “S ere oe? |, [ei 7 lon-a1 | ‘Swing brake | oY | Sing ek | | qe { 75a | Sonne | wares a fen A jet | pee eeeeetae & ee ) | | = 8, | | RS3TF $f] Straight travel eee | Eds f+-9¢ | PHidlone. ae? Brel | LJ Jour nie © 7B] Auedecteraton 5 © eas Lo aaluneoan cnr (st: Power source (-24V) 2osrosos6 Ch Ground 10-112 020805020905 LOADING SHOVEL The machine control system uses 12 relays, and the structure of the circuits is as shown below. (The travel speed solenoid system does not pass through the relay circuit: the switch and solenoid are connected directly.) PC650-5: 20001 - 20096, 20099 - 20103, 20106 - 20108 PC710.8; 10001 - 10088 LH RA, straight Swing Machine fem Bugket Bopm Swing wage) anes SHNQTY Sra washine h | K a a as . fs = 2/3] (lg) (8) GE) El] Ele E —s isis) | ee & @2POPOa® fe . Hee He Hees | | ane Swing lock amp a Swing brake aa EJ) Lew ) Swi en tay UE Swing tock ea $ aa Free ret cea Lop lrciay? Machine push ‘ree swing oS = es) tooth i: cur 26) cn - RS 32 % Horizontal digging J aay Sign vave SEB en-ro 3 enor | gen. a0 Bele i ) erat reay ae RS-2 relay” jerk — testemen| (ams f eee [Brener f [ORL] Hoan Fh Susiom 7 ere |sena ae (Eg a ee [SF auto - deceleration aS-1 is Ol eater zo [Oa] Machine push up CN =A? OFS| sate © Power source (24V) ©: GrounsBACK HOE ‘The machine control system uses 11 relays, and the structure of the circuits is as shown below. (The travel speed solenoid system does not pass through the relay circuit: the switch and solenoid are connected directly.) PC650-5: 20097, 20098, 20104, 20105, 20109 and up Pc7t0 Solero vale fm Bucket Boom Swing LM. travel Ravel Staght: Swing thn active travel grate’ ‘suingl Heavy push up foe aT ea aS es ls] IE id] lz -le] [+f iz § 3} ile 5 5 @ le je je fe fe [P29 PPR ERREES l + dn ivovchet Con tio Swing ek time Swing lock omic of], PA ouput ae ie a 800m relay swing brake | Swing lock em seg coor = 1, Sng lok rel | je { ase | Senne tm essere) | ee Free swing Seon-ne pray | tee pe a = RS-3] ff cnr | Phe Henny it aay [4-92 p Swing holding }CN-F10, este. (fas? os OF eae in EHS f © sensi aS Machine push (+h Power source (s24¥) Cr Ground! 10-113-1 Be 2osrosis2 020905020905 LOADING SHOVEL The machine control system uses 12 relays, and the structure of the circuits is as shown below. (The travel speed solenoid system does not pass through the relay circuit: the switch and solenoid are connected directly.) PC650-5: 20097, 20098, 20104, 20105, 20109 and up PC710-5: 10086 and up ‘Ae Suchet Boom Swing ware rogel «Serna ra? Breit Ete 0 fee 3 3 zis) (Big) (ea) Giz Be a ® fo le e é aneeeee ARM IN bucket relay 8 1} Swing tok tomp pee Swing brake ime oui LL neat 200m relay =P N Ri eae relay Machine push Up eisy, Free swing a rea | each”? oN=F2 —Seien=n9 Ewite ° oF arent! donna relay as-ar} ight travel 5 IKE, —— bet en aro aa tT ® | i ‘Swing holding +26) en - a0 Soe woe 5 jecsleration relay oe S-2 relay” See _ é aoe (ee Sot sen ‘deceleration a o OER] Machine push up cN-A? OES | Sonter ©: Power source (24V) ©: Ground soroossr 10-113-21. AUTO-DECELERATION FUNCTION % FOR MACHINE EQUIPPED WITH.AUTO-DECELERATION z a Bucket Swing LH. travel RH. travel ALA A ‘Auto-deceleration switch : Ee (Switch signa ee a W po —— ae -—foved lw Coe four (rea ee | =~ (car Crea tren Auto-deceleration + OLSS controller (eceleration signal (Drive signal) Fuel controll {rive signal) ‘Auto-deceleration solenoid valve SoA : SOL B lr ‘Charging, PTO lubrication pump J Engine ttson| OY a 2ooresoa? ourune Fuel contol tver st speed + When athe control levers ore at neutral, suchas when waiting for work, the engine speed is auto- be matically lowered to a mid-range speed (decel- 100, eration speed) to save fuel and fo reduce noise. + When work is started again, the engine speed immediately rises to the set speed : No.2 deaterston g se can Max. 2 Mon Jj ett teed fe i Lever at neta Time Lever operated 2osFosoae 10-114 2 020905020905 OPERATION + When fuel control lever is at high idling and auto-deceleration switch is ON Operated Neutral | Operated XY kK y Control lever Ly ae pec PPC. oro aera ares |_2av : f i Sg | sotenoida | oy $2 2av 3° | sornoid | gy I ' Becelration | Gisgon” ___Notactaa [no deveson]| No.2 carton | Ret Enaine seed | High ising | 2000-2050 9m | 1280-1450 pm | High iting + Autoeceleraton solenoid valve For deals of the structure ond operation, see SOLENOID VALVE ASSEMBLY. + Altodeceerton oinaer For details ofthe structure and operation, see AUTO-DECELERATION CYLINGER 10-1152. ELECTRONIC OLSS FUNCTION * FOR MACHINE EQUIPPED WITH 2-STAGE MODE SELECTOR OLSS oS PTA un sapct — | Coentapaat} 1 {Jeanna vave eoniolvahe | 11 raver ami] | Lt [Buckeri Bucketto | | LO] swing cor Ht [ame come | | Swing 1 11 [Boom An wavet | | Traain reer it valve Ht [Serie Svaightarave] | 11 Tamra tiie! | 1 [tate valve ' it ' Fuel control lever (rive signal SL Mode select ouss ©-——a—_ OUTLINE The electronic OLSS (Electronic type Open center Load. Sensing System) controls the angle (discharge vol- lume) of the swash plate type variable displacement pump, to reduce the various type of hydraulic loss that occur during operation, and to improve the ease Of fine control. This system also maintains the optimum matching between the engine and the pump to. reduce fuel consumption. 10-116 2 Ccherging pump Fos0so4s {tis possible to set the pump absorption torque to two or three stages, 2-stage: S mode, L mode, + 3-stage: H mode, $ mode, L mode, By selecting the L mode during light operations, it is possible to further reduce the fuel consumption. 020905020805 + FOR MACHINE EQUIPPED WITH 3.STAGE MODE SELECTOR OLSS : roa un sseco | Fp Jeomratvave 1 i eet cor) i 1 [ete hatte a 11 Tamas Boome Swine I 11 eeom noel T i Pin at Lt [semen Sraeneevl ‘ive i (tees ai at ty valve fe. i i Engine Potentiometer [=] 4 ral Engine s ee 801) ous = tem DM prt yu i : 31 ero i 3] seh a) 3? EF OLSS controler charging pump 2o9F0s102OPERATION * FOR MACHINE EQUIPPED WITH 2-STAGE 1) Mode selection pump torque control function MODE SELECTOR OLSS +H mode: Engine speed sensing control * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS The engine speed set by the governor (potentiometer) and the actual engine speed (engine speed sensor) are detected, and based on these, the controller carries out controls so that the pump absorption torque always matches at the engine rated output Point. In other words, even if there is @ change in the load during operations, the Pump absorption torque is changed so that the work can always be carried out at the engine rated output point. +S mode: Hydraulic sensing control ‘The pump absorption torque is set to @ lower Pump discharge pressure P constant than with the H mode, and hydrau- Frosos04s, lic sensing control is carried out according to that absorption torque. ‘% Hydraulic sensing (pressure compensation) ‘The discharge amount is controlled to match the discharge pressure according to the con- H mode stant pump absorption torque that has been set. +L mode: Hydraulic sensing ‘The pump absorption torque is set to an even lower constant than with the S mode, and hydraulic sensing control is carried out according to that absorption torque. + When protix switch is ON + FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS If any abnormality should occur in the controller, the prolix switch can be turned ON to set the pump absorption torque to a lower constant than in H mode, and hydraulic 20905103 sensing is carried out according to that absorption torque. Pump discharge volume Q * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS Protx switeh ON k mode Pump discherge volume Pump discharge pressure P 2) Flow control function + The discharge flow is adjusted according to the travel of the control lever (flow needed by control valve) to improve the ease of operation and to reduce the fuel consumption. + When the levers are at neutral, the pump discharge volume is set to the minimum to reduce any waste flow of oil. When the lever is operated, the discharge amount is set according to the travel of the lever, and this reduces any waste flow during fine control operations, and also improves the response of the work equipment when the lever is op- Travel of lever L erated to the full position. ee ect eee erga Pump discharge volume Q 10-118 2 020905020905 3) Cut-off function + Ifthe load becomes large during operation, and the pump discharge pressure comes close to the relief pressure, the pump dis. charge volume is reduced to reduce the relief loss. + Its also provided with a cancel function to cancel the cut-off function when the main relief pressure has been raised by using the heavy lift function, TVC valve For details of the structure and operation, see NO. 1 PUMP. CONC valve For details of the structure and operation, see NO. 1 PUMP. Jet sensor For details of the structure and operation, see SWING CONTROL VALVE. Servo valve For details of the structure and operation, see No. 1 PUMP. Pump discharge volume O Pump discharge pressure P Relief pressure 209051083. HEAVY LIFT FUNCTION BACK HOE LH. Sspoot LD] controt vaive ‘boom eyiner RH, &spoo! oni valve (Havel fever Hi al Boomto Xe LOWER Main relief valve oy ZI Boom Arm Bucket ie (Switen RR oy crt OUTLINE + This function increases the lifting force of the boom by approx. 10%, + Itis actuated only when the boom RAISE is operated independently. If the arm IN or bucket CURL is operated at the ‘same time, it is automatically canceled. 10-120 2 [7 swine pump : tit Charging pump Frosososs 20305020905 OPERATION Lever operation Main relief “Sten” [Boom RAISE |g Atm ar legurd ave "abe aes | CO vaive | U8 | Remar OFF | Operated | - | Deoctwatea | 320 | Acwuned | Noval Neural | ates | 380 | Canceled | 10% up ON | Operated Wie am Wo: ane CURL ope Sones | tern Macrae ete | Noma Heavy lift solenoid valve Condition as when the switch is tured OFF. For details of the structure and operation, see SOLENOID VALVE ASSEMBLY. * CO valve For details of the structure and operation, see NO. 1 PUMP. Main relief valve For details of the structure and operation, see LH. 5-SPOOL CONTROL VALVE,4, MACHINE PUSH UP FUNCTION faecal {00m evinder LOT] cael ve WO] Shei ie tno fr | | am Bucret Hi FB foal b ra 7 a esse cr) a . i i evel i sin elit Be | Nos Front Ly pump RAM, 1 Machine push up PT Seam fe OUTLINE * This function switches the pushing force of the ‘boom to increase the pushing force and the dig ging efficiency by reducing the digging resistance of the boom. This helps to increase the ease of operation in cutting roots, digging square holes, twist swing, and escaping from soft ground, 10-122 2 Frov0s0a7 20905020905 OPERATION + This function is carried out by switching the set pressure of the safety valve at the boom cylinder head end of the R.H. 4-speo! control valve boom-Lo to two levels: low pressure (190 kgicm*) and high pressure (340 gfe’ + For details of the operation, see the following table. Mowe | Machine push | Mine uh op | Safty valve oat [up switch | solenoid valve _|pressure (kg/cm cea By reducing the push force of the boom, the boom is automatically able to escape square holes, twist swing, or escaping from soft ground, Digging in the RAISE direction. This means that eae 190 | the boom needs to be operated inthe made: | | RAISE direction less frequently, thereby |_ enabling digging tobe carries out smoothy | By increasing the thrust fore for Machine ‘boom LOWER, the ease of operation is push up. ON Excited =f 340 increased for cutting roots, digging mode | ‘Machine push up solenoid For details of the structure and operation, see SOLENOID VALVE ASSEMBLY. * Boom safety valve For details of the structure and operation, see RH. &.SPOOL CONTROL VALVE,5. SWING LOCK, SWING HOLDING BRAKE FUNCTION 00m buetet Suing 3/5 aa} sie i ii (Swit signal) ipmentsignall Swing brake timer Engine OUTLINE + A swing lock (manual type) and swing mechanical brake (automatic type) are employed to allow the swing to be locked at the desired position and to prevent hydraulic drift after the swing is stopped. 10-124 2 dd Ald ON OFF = ' Relay circuit eee Swing lock amp FSwing, work I) ‘Swing brake solenoid valve Charging pump 20905107 02090520905 OPERATION Swing lock | Swing lock | Swing brake 3 Mode switch =| == lamp [solenoid valve | Operatios When the swing and work equipment levers are al placed at neutral, the swing brake is actuated Stier a delay of approx. 4 sec if any of the swing of other work equipment control levers are operated, the swing brake is released and the upper structure can swing freely swing | Tine chan co holding | OFF ee eee a Geese cern = brake sl Control Nesta | ny | Sotenoia ose cia vow Plezed Aosied | 20905108, Tho swing is locked by the swing brake, so even Swing lock | ON ON | Deactivated | if the swing lever is operated, the swing brake | | is not released and the upper structure cannot swing. % Swing brake solenoid valve For details of the structure and operation, see SOLENOID VALVE ASSEMBLY. * Swing motor For details of the structure and operation, see SWING MOTOR, 10-125 26. TRAVEL SPEED SELECTION FUNCTION RH. travel motor Regulator Travel switch Engine OUTLINE (or %* By switching between low speed (2.7 km/h) and” high speed (4.1 knvh), it is possible to obtain @ travel speed to match the jobsite conditions. LH. travel moter Regulator Travel speed solenoid valve Li Charging pump 209F05109 OPERATION Travel speed ] Travel speed ] Travel motOr | travel soos ar switch | solenoid vaive |swash plate angle) T’@vel speed bali Low speed | Suitable for moving short distances Lo |_ Deactivated mae (2.7 km/h) _|_and when drawbar pull is needed ql in, High speed le for movin, jistances Hi Excited Mi (et kun) | Suitable for moving long dist ‘* Travel speed solenoid valve For details of the structure and operation, see SOLENOID VALVE ASSEMBLY. * Travel motor For details of the structure and operation, see TRAVEL MOTOR, 10-126 2 020905020905 7. STRAIGHT-TRAVEL FUNCTION LM. travel motor RH. wavel motor w OS LIT] Bsp001 tava [ Bucerrifs | amie | efscommrfs eae Straight | el sevice ia “Titan rete Engine 800m Arm Buckes GE, ay Aguas ro 2 OP 9 I Relay circuit i aa OUTLINE If the boom, arm, or bucket are operated at the same time as the travel, the pressure oil flowing to the LH. and RL, travel circuits is divided and sent to the boom, arm, or bucket circuit. The travel circuit on the side where the oil flow is divided will have a smaller flow of oil to the ‘motor than the travel circuit on the side which is not divided, so the flow in the motor circuit will drop and the machine will deviate to one side, 7 swing pump 2 - {Drive signal, 209F05110 + To prevent this, the straight-travel valve is switched to interconnect the LH. and RLH. travel circuits, thereby ensuring and equal supply of oil to both the LH. and RH. travel motors. This keeps both the LH. and R.H. motors rotating at the same speed, and prevents any travel deviation.OPERATION LH. RH. | Work equipment] Straight-travel | Straighttravel meee travel levers levers _| solenoid valve | __valve Poa LH, and R.H. travel motor circuits are tral vated | Not actuate ee Newt Deactivated | Not ectuated | [;1, 2nd RH ose oy ‘Actuated | LH. and RH. travel motor circuits are actuated ‘* Straight-travel solenoid valve For details of the structure and operation, see SOLENOID VALVE ASSEMBLY. * Straight-ravel valve For details of the structure and operation, see RH. SPOOL CONTROL VALVE. 10-128 2 20805(020905 8. COMPONENTS OF SYSTEM 1) AUTO-DECELERATION + OLSS CONTROLLER * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS AND AUTO-DECELERATION CN-10~ t ONAL 1. Self-diagnostic display Input/output signals 7 cN-10 i Ro Signal [recovoa) ; 1 | Power source (24V) | 2 GNO =| | Mode: input | “| Engine speed sensor od input Ll '5| Engine speed sensor (-) = | PotentiometerGNOL = T | Potentiometer (Si input | Potentiometers) faite: | Deceleraton solenoid (SOL 8) | Output 10] Deceleration solenoid (SOL 8-1 | — 11] Oil pressure switen I+} {Output 12] Oil pressure switeh (+) 7 sa] = 7 NAT fe, ‘Signal reson 1] WE solenoid in) ‘Output | TVE solenoid 1 = 3] Deceleration solenoid (SOL, A=) | Output ‘41 Deceleration solenoid (SOL. A -1 = ‘S| Model selection (1 input 6] Mode! selection 2h Input 7 eae ‘| GND FUNCTION ‘Auto-deceleration portion + This receives the signal from the control levers, and when they are in the deceleration condition, it carries out the timer function. Based on this, it drives the auto-deceleration solenoid valve, Electronic OLSS portion + In the H mode, it receives the signal from the potentiometer and engine speed sensor, and carries out the engine speed sensing function. Based on this, it drives the TVC vaive. + In the S and L modes, it drives the TVC valve with a constant current to match the pump absorption torque that has been set. 20905111 Self-diagnostic portion + The controller itself observes the input signal, output signal, and self function, and always displays the normal actuation or the location of the problem with the red and green LEDs on the self diagnostic display. (For details, see TROUBLE. SHOOTING)2). POTENTIOMETER + FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS 1. Potentiometer (variable resistance) 3) ENGINE SPEED SENSOR ones Composition of circuit 209605112 FUNCTION + This is interconnected with the injection pump governor lever of the engine, and detects the set speed of the engine. ‘* FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS Magnet Terminal Case Boot 1 2 3. 4 —f cn-es o7stc Composition of eicuit 205F0s1se8 FUNCTION + This is installed to the engine flywheel, and detects the actual speed of the engine. 020905020905 4 PROLIX RESISTOR * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS 1. Resistor SPECIFICATION Resistance value: 20 2 FUNCTION Compostion ofcieuit This ig installed in the prolix circuit of the electronic OLSS, and when the prolix switch is turned ON, it generates a constant current to the TVC solenoid, ‘SWING BRAKE TIMER 209F05113 Inpuvoutput signal ime char ONC24V) § ec Input —QFE_[- 1 thever signaty ON Isoteno ourout DEE ——]_1Setenoiad Z 2o9F05114 FUNCTION + This receives the signal from the work equip: ment and swing control levers, carries out the timer function, and drives the swing brake solenoid valve, 10-131 26) PPC OIL PRESSURE SWITCH 5 6 N75 ~ cN6 Plug Diaphragm Backup ring Pin Guide pin Movable contact 10-132 1 SS ee) Ugp i) Composition of circuit SPECIFICATIONS Actuation pressure: 5.0 + 1.0 kg/em? Reset pressure: 3.0 + 0.5 kgicm? FUNCTION There are 12 switches in: stalled in the pilot circuit be- ‘tween the PPC valve and the control valve, and these de- tect if each lever is being operated or is at neutral. 02090520805 7) STRAIGHT-TRAVEL « AUTO-DECELERATION RELAY (RS-1) SWING HOLDING BRAKE + AUTO-DECELERATION RELAY (RS-2) STRAIGHT-TRAVEL CANCEL RELAY (RS-3) BOOM RELAY (RS-4) ARM IN + BUCKET CURL RELAY (RS-5) [BACK HOE] ARM IN « BUCKET RELAY (RS-5) [LOADING SHOVEL] ARM OUT RELAY (RS-6) [LOADING SHOVEL] Composition of circuit F090so4e 8) BOTTOM DUMP OPEN RELAY (RS-7) [LOADING SHOVEL} BOTTOM DUMP CLOSE RELAY (RS-8) [LOADING SHOVEL] He Faoa0sos98) SWING LOCK RELAY (CN-R1) FREE SWING RELAY (CN-R2) HORN RELAY (CN-R3) ‘STOP MOTOR RELAY (CN-R4) WORKING LAMP RELAY (CN-RS) HEAD LAMP RELAY (CN-R6) 10) AUTO-DECELERATION RELAY (CN-R7) ‘SWING LOCK RELAY (CN-R8) MACHINE PUSH UP RELAY (CN-R9) HEAVY LIFT RELAY (CN-R10) [BACK HOE] HORIZONTAL DIGGING RELAY (CN-R10) [LOADING SHOVEL] T ' 77 ' [25 Pe : E23 10-134 2 Composition of circuit 20905050, Composition of circuit z090s051 020905020905 WORK EQUIPMENT CONTROL SYSTEM LOADING SHOVEL + FOR MACHINE EQUIPPED WITH WORK EQUIPMENT CONTROL SYSTEM ‘SYSTEM DIAGRAM §} Boom potentiometer LH. Sspoo! octet EF oe Beet & Work equipment i i i 1 |_ No.2 pump ' i 1 1 i i 1 | sem oom aust 1 t t ‘witch witch | 6.2) Relay cieut 20905062 RELAY CIRCUIT See MACHINE CONTROL SYSTEM. 10-135 2HORIZONTAL DIGGING COMPENSATION FUNCTION OUTLINE 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, OPERATION The boom and arm potentiometers input the an. gles of the work equipment to the controller. In this way, the controller can always calculate height H of the arm top pin, + When the lever is operated to ARM OUT, the amount to lower the boom in order to maintain hheight H must be calculated. To carry out this movement, the controller sends electric current to the boom EPC valve solenoid to lower the boom. In this way, the boom EPC valve is actuated and Pressurized oil from the charging pump passes through the shuttle valve and actuates the boom: Lo control valve to lower the boom. 10-1 36 209F3210 2083219 020905020905 2 BUCKET ANGLE COMPENSATION FUNCTION OUTLINE During BOOM RAISE operations, when the height, Of the arm top pin goes above approx. 4.8 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 operator's cab. OPERATION The boom and arm potentiometers input the an. gles of the work equipment to the controller In this way, the controller can always calcul height H of the arm top of pin. When the lever is operated to BOOM RAISE, and height H is above 48 m, the controller sends electric current to the bucket EPC valve solenoid to move the bucket to the DUMP direction to match the BOOM RAISE speed. In this way, the bucket EPC valve is actuated and pressurized oil from the charging pump passes through the shuttle valve and actuates the bucket: Lo control valve to move the bucket to the DUMP. direction. 20932113. COMPONENTS OF SYSTEM 1) WORK EQUIPMENT CONTROLLER cn25 ® 1. Adjustment trimmer window 2. Self-diagnostic display window FUNCTION + This receives the work equipment angle signal from the boom and arm potentiometers, calcu: lates the height of the arm top pin, and outputs the drive signal to the boom and bucket EPC valves when pushing the arm and when raising the boom. diagnostic portion +. The controller itself monitors the input signal, output signal, and its own functions. It uses four red and green LEDs on the self-diagnostic display to show to the outside that the equipment is working normally, or to indicate the location of any failure. (For details, see TROUBLESHOOTING.) input/output signals 20805063 CN-25 ca Signa aaa 1] Power sour 10) a 2] GND a 31 Horizont digging swith Teput 5] Boom EC solenoid Oupat | Boom EFC solenoid -) ‘Output 7 Bucket EPC solenoid (1 ‘Output B Bucket EPC solenoid (=) ‘Output N26 te ‘Signal Tapatonoa] 1 | Boom poteatiometer = 2 [Boom potentiometer (5) input '3| Boom potentiometer (1 = “41 Arm potentiometer I = | Arm potentiometer (S) Tnpat | Arm potentiometer (1 = 7 = = @ : Z 2 7 = 10] Arm OUT ol pressure switch | Taput 11] Boom oi pressure swten input 2] Arm IN «bucket oi pressure sith | Input 020905020905 2) 3) 4) 5) BOOM POTENTIOMETER ARM POTENTIOMETER * See MACHINE CONTROL SYSTEM, BOOM EPC VALVE BUCKET EPC VALVE * See EPC VALVE, OIL PRESSURE SWITCH * See MACHINE CONTROL SYSTEM, RELAYS * See MACHINE CONTROL SYSTEM,020905 MACHINE MONITORING SYSTEM Monitor pane! Relay Electrical part —=8= Solenoid valve Sensor Banery 209F05115 + The machine monitoring system observes the + Various modes selector switches are built into condition of the machine through the sensors the monitor panel, and it acts as the control installed to various parts of the machine, and portion of the machine control system. processes this information quickly. The system informs the operator of the condition of the machine by displaying the condition on the panel. ‘The content of the panel displays can be broadly divided into the following, 1. Monitor portion that gives warnings when any abnormality occurs in the machine, 2. The gauge portion (coolant temperature, fuel level) that always informs the condition of the machine,REGULATION OF EC INCLUSION Monitor panel Sensor + The machine monitoring system observes the condition of the machine through the sensors installed to various parts of the machine, and processes this information quickly. The system informs the operator of the condition of the machine by displaying the condition on the panel. The content of the panel displays can be broadly divided into the following. 1. Monitor portion that gives warnings when any abnormality occurs in the machine. 2. The gauge portion (coolant temperature level) that always informs the condi the machine. fuel ion of 10-141-1 s Relay Electrical part —=8 = i Solenoid vaive Buzzer serous? Various modes selector switches are built into the monitor panel, and it acts as the control portion of the machine control system, 020905SWITCHES AND MONITOR BACK HOE + FOR MACHINE EQUIPPED WITH 2-STAGE MODE SELECTOR OLSS 10-142 2 HEAVY LIFT | AS) MACHI, PUSH UP 20908054 ‘SWITCHES. ‘Mode selector switch Lamp switch Wiper switch Travel speed switch Heavy lift switch Machine push up switch ‘Swing lock switch MONITOR ICHECKS BEFORE STARTING items] 8 Coolant level 9. Engine oil level 10. Hydraulic oil level [CAUTION items} 11. Hydraulic filter 12. Engine oil pressure 13. Coolant level 14, Coolant temperature 15. Hydraulic oil temperature 16. Charge [PILOT items} 17. Preheating 18. Swing lock [GAUGE items} 19. Coolant temperature 20. Fuel level 21. Service meter 020905BACK HOE * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS AND AUTO-DECELERATION SWITCHES. 1. Mode selector switch Lamp switch Winer switch Travel speed switch Heavy lift switch Auto-deceleration switch Machine push up switch Swing lock switch MONITOR. ICHECKS BEFORE STARTING items] ‘9. Coolant level 10. Engine oil level 11. Hydraulic oil level [CAUTION items} 12. Hydraulic filter 13, Engine oil pressure 14, Coolant level 15. Coolant temperature 16. Hydraulic oil temperature 17. Preheating Piscean ce cane) sce sen |S) [PILOT items} 19. Coolant temperature [GAUGE items} 20. Coolant temperature 21. Fuel level 22. Service meter 20908116BACK HOE %* FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS AND AUTO-DECELERATION REGULATION OF EC INCLUSION. 10-143-1 ¢ SWITCHES Mode selector switch . Lamp switch Wiper switch Travel speed switch Heavy lift switch Auto-deceleration switch Machine push up switch ‘Swing lock switch MoniToR ICHECKS BEFORE STARTING items} 9. Coolant level 10. Engine oil level 11, Hydraulic oil level ICAUTION items] 12. Hydraulic filter 13. Engine oil pressure 14, Coolant level 18. Coolant temperature 16, Hydraulic oil temperature 17. Preheating [PILOT items} 18. Preheating 19. Coolant temperature IGAUGE items} 20. Coolant temperature 21. Fuel level 22. Service meter 020905LOADING SHOVEL * FOR MACH HINE EQUIPPED WITH 2-STAGE MODE SELECTOR OLSS 10-144 oF lon MACH. PUSH UP SWING LOCK OF Jon oFF o Froa050s5, ‘SWITCHES. 1. Mode selector switch Lamp switch Wiper switch Travel speed switch Horizontal digging switch Machine push up switch ‘Swing lock switch MONITOR ICHECKS BEFORE STARTING items] 8. Coolant level 9. Engine oil level 10. Hydraulic oil level ICAUTION items} 11. Hydraulic filter 12. Engine oil pressure 13. Coolant level 14. Coolant temperature 15, Hydraulic oil temperature 16. Charge (PILOT items) 17. Preheating 18. Swing lock {GAUGE items] 19. Coolant temperature 20. Fuel level 21, Service meter 02080520905 LOADING SHOVEL * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS AND AUTO-DECELERATION ‘SWITCHES. 1. Mode selector switch 2. Lamp switch 3. Wiper switch 4. Travel speed switch 5. Horizontal digging switch 6. Auto-deceleration switch 7. Machine push up switch 8 Swing lock switch MONITOR [CHECKS BEFORE STARTING items} 9. Coolant level 10. Engine oil level 11. Hydraulic oil level [CAUTION items} 12. Hydraulic filter 13. Engine oil pressure 14. Coolant level 18. Coolant temperature 16. Hydraulic oil temperature 17. Charge (PILOT items} 18, Preheating 19. Swing lock [GAUGE items} 20. Coolant temperature 21. Fuel level 22. Service meter ‘SWING LOCK, 20905056INDICATION ON MONITOR PANEL ta Condition for eeplaying axon [Symbol tem dition f Deseriotion nel sbnormaltan pug LE _| coon Beiowiow vet nines when ping te Haring ge2 switch to ON before storing the engine Se Tow Te EEE | Q | enoine ot ive Below lowievel | itis normal tne ee ae aes an abnormality the lamp Tashes, © Ft | wvarautcoitiever | Below low level | HH | Hyarautic ot fiter Above specified pressure 3 8 Indicates while the engine i running Engine ol pressure | Below apected pressure 9 Or cee es and the starting switch is set 0 ON, 5 ton cares ee ifit ie normal, the lamp goes off Its 5 | an abnormality, the lamp flashes and g Above specified temperature| the buzzer sounds. Coolant temperature i . Tw level, the buzzer dows not sound 8 avi ol temperature_| Above specified vemperature 2 a . but the lamp flashes. 3 [es | charge revel When caging stem fis When the starting switch is turned to | HEAT position, this pilot lights for 36 5 oe Whan preheating (Peres seconds, then flashes (for 16 seconds) z to indicate the preheating i finished fo When sing lock switch ON nea] pose HLT esae FL sre” | appropriate place ‘one place only | Coolant temperature | ren||f—ai-ere | Aneto ore White a I | Fo202131 s rue 3 7 & 7 3 |B | Festive | : All light up below appropriate level 3 ; ot |EMPTY Hy | senice meter ae Operates while the engin oil pressure is normal © | service meter indicator The lamp flashes while the service meter s working 020905020905 INDICATION ON MONITOR PANEL REGULATION OF EC INCLUSION oy eaten at [Symbol item Coneltion for deplaying Description icon Coolant level Below low level Indicates when placing the starting Engine oil level switch to ON before starting the engine. en senteul If it is normal, the lamp goes off. If itis CHECKS. BEFORE, | Hydraulic oil level ‘an abnormality the lamp flashes. Below low level 7 STARTING e\s/a)d Hydraulic oil filter Above specified pressure Engine oil pressure Indicates while the engine is running Below speci and the starting switch is set to ON, 1d pressure Coolant level Below low level it is normal, the lamp goes off. If itis Coolant temperature jalde IL | Hvaaute oi temperature = CAUTION MONITOR GROUP | EB | chorge ever | Above specified temperature ‘an abnormality, the lamp flashes and the buzzer sounds. In case of an abnormality in charge level, the buzzer does nat sound but the lamp flashes. Ahove specified temperature {above tos) When charging system fais Engine preheat, PILOT @ When the starting switch is turned to HEAT position, this pilot lights for 36 | seconds, then flashes (for 16 seconds) to indicate the preheating is finished. When preheating H® | swing lock When swing lock switch ON | | GI | cootant temperature | | ea] HET itosse Appropriate place (one place only) Green| | | lights up. we | | woe’) aa | Fo202139 | oe ee] 2 | 2 7 Green || EE | | BD | Fuel tever : | AY or ue now promi ev 8 | a | | ed emery | obi | | ] | | 8 | Sere mae 099850 nous | Operate while the engine ol resi is norma | | Service meter indicator | The ae flashes while the service meter ae is working 10-146-120305 1. MONITOR PANEL 1) UPPER PANEL (Pan S a oN aes S| g ‘on-Pi0 si 7 ey =| cnr | ones. 5 Inputioutt signa ce cn-Pa cnP3 209808117 fe ease fl Signal eaaaaa] “tons Ourou 1 | Power sores tv =| F | Convo Ouro Z| eno 7 3 | Gontater on 3 | Staring signal Tout 4 [omer sous 7 2 Toh ing [Coolant Tea input NPS & | Engine ot vet input > - Sa T [Hyatavie or eat [Cirost on = ae BL ryarauie iter input He = | Engine of pressure ing a ge ERERESe = | Hysraue of enoaratae inp [Power sous 0) fesse i PPE ol resure Ta [i2|-Oveross warn input cN-P6 cNn-P9 fe rae fa Sarat Troaoaa ‘T= = 1 | Cosiant Temperate input | Read tmp. working amp relay — | Out Z[Fur nut ‘Manor panel. a coniioner paral] Output 3 Preneating input [Power sores Vr =I a [Bune Suiput cue? cnPt0 fe Sin ronacaa 3 Signal aaa] "War mar Outbut [Ching Sona ev input 2 ower sour 20 = tereno: tower woe oy om awash Ouibu cup fe] “Signal rr} "Power sour 0 5 7 [ong sana aVT iow TT GN 7 Deve agra ehane aT prea) —| Tat1) UPPER PANEL REGULATION OF EC INCLUSION NPS | NPA 5 | |S al cues —_| || 8) cN-P7 —T] NPs Input/output signals nen NPS CN-PB fa Saal a far Sgn aa 7 | Conaer GR ‘Susp 1 Power sare ae 7 3 [Conver Oat a] GND 7 [3 conrete Out 3] Seng san nga (aL poner source Br : a] Chae co [cota eet Tan cN-P5 Tin of va ca a aE Fane of ea Tapa Rey Saal - | Rraaie Tier Tit ue - 3 [Engine oi pene ing 2 ae cae Tol myers a emperor Tt 2 | Tae ined S TPP st presure nba ral Onroad warning Tap cN-P6 cN-P9 fo Saar aaa i Saal aa 1 7 1 | Coote Temper input Zi ane ry —| Baa 2] Faster input 5 ‘rr eoravone baal] Oubit 3] Prenestng Tapa oars a 7 ap boner oat cn-P7 cN-P10 a a ieee fs Sigal a] Wipe maar Out 7 [ aking agra Tat 7 Powers 7 zn [Comers oy ui aha Oust cn-pn1 i] arar a | Power sure a 7 [oghing sna 207 i a Teno : i gal eine wane — 10-147-1 s cN-P10 0209082) LOWER PANEL %* FOR MACHINE EQUIPPED WITH 2-STAGE MODE SELECTOR OLSS BACK HOE Heavy Jift switch fl a 2. Machine push up switch 3. Swing lock lamp a es 4. Swing lock switch MACH, PUSH UP SWING Lock _© 4 fe) 20908057 LOADING SHOVEL 1. Horizontal digging switch 4 2. Machine push up switch 3. Swing lock lamp HORIZONTAL DI ee 4. Swing lock switch MACHI, PUSH UP SWING Lock © 20805058 02090520905 * FOR MACHINE EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS AND AUTO-DECELERATION Back woe plop signa oun : ree : cw Power souree 0) ‘GND. H moe Hi = ct + Rear 4 [-}aursaecneaion — Susur 9) [EL Maehine poh up [ouput ef =| Pears sara a onp3 209F05118 REGULATION OF EC INCLUSION fe Signal Router 1) Power source GA) 2] NO s | Swing Teekay uigat cN-P3 rm Signa ean + Power source (00) : 2 GNO = 3 | Horaontal aaa Surat | Auto-deceieration ‘Output 5 | Maenine push vp Output fer = | WignT gral Tra CN-P3 cN-PILOADING SHOVEL Input/output signal CNP fel _——sgaa Tero 3 ° ere ae : @ 3 Sangean —t oar cura fo|_——sgrat “Tre torre aa ws 10K a = caro ian aga [oar lo 7 Raocneneen —[ Gabat bine pat op Oat a ° ara aT Tea 10-149-1 cnr 209052. SENSORS + The signals from the sensors are input directly to the panel. (The signal from the hydraulic filter sensor system is input through the timer.) + For the contact type sensors, one side is always connected to the chassis ground. When the contact is closed and the signal wire is connected to the chassis, the panel judges that this is the nor- ‘mal signal. Display nsor metho 0 norm fen abnorm caaaae Type of sensor ‘Sensor method | Wher 1al_ | When abnormal CHECKS |__coolant level Contact ‘ON OFF, BEFORE | Engine oil level Contact ON OFF, STARTING [Hydraulic oll level Contact ‘ON OFF Hydraulic fier [_Comect [ON OFF, Hydraulic oil temperature ae on ace CAUTION low temperature) Engine oil pressure Contact ON OFF Hydraulic oil temperature a thigh temperature} ee on i Coolant temperature Resistance = = GAUGE | Fuel level Resistance = = 1) COOLANT LEVEL SENSOR sf i kA \ ©) OR q ' Composition of circuit 12 Section AA 208Fo5118 1. Shaft 2. Float 3. Switch 4. Plug 10-150 2 020905020905 2 ENGINE OIL LEVEL SENSOR ones 3 HYDRAULIC OIL LEVEL SENSOR ons Composition of circuit 205F 05167 | Composition of circuit zosrosiea. 1. Bracket 2. Float 3. Switch 1. Plug 2. Switch 3. Float4) HYDRAULIC FILTER SENSOR. i 2. High pressure inlet port ? owas Low pressure outlet port : 1. Block Ci [/ OF oS 2 sensor i : SPECIFICATIONS a OFF pressure: 10 + 0.2 kglem? [poeeaaso) ate ® © Composition of circuit LS ° aosrosizo + HYDRAULIC OIL TEMPERATURE SENSOR (LOW TEMPERATURE) 1. Plug 2. Seneor ON temperature: 13°C +—" specirications \ OFF temperature: 20 = 5'C 2 oy S + HYDRAULIC FILTER CLOGGING TIMER 20905121, Pocsoenuemeeeas 1 a Timer O° Inpuvoutout signal time chart | om FUNCTION | f\ input PEE tom sensor «When the OFF signal is re- = ceived from the hydraulic fi outpu—EEF——— To monitor __ter sensor, the timer function is carried out, and then the On| signal to the monitor is aac switched OFF. 209F05122 10-152 2 020905020905 ELECTRIC CIRCUIT FOR HYDRAULIC FILTER MONITOR SYSTEM FUNCTION + Immediately after starting the engine, the oil temperature is low and the oil viscosity is high. As a result, resistance is generated in the filter, so the hydraulic filter sensor is switched OFF. To cancel this electrically, a hydraulic oil temperature (low temperature) sensor is installed, and at low temperatures, this hydraulic oil tem- erature sensor is switched ON. + There may also be cases when the filter sensor is switched OFF because of momentary changes in the oil pressure. To cancel this electrically, a timer is installed which gives a 5:second delay in the display. OPERATION 1) When starting engine Immediately after starting the engine, the oil temperature is low and the oil viscesity is high. As a result, resistance is generated in the filter, so the hydraulic filter sensor is switched OFF. However, the temperature sensor, which is connected in parallel to the filter sensor, is ON, so the signal to the timer is switched ON, and the ‘monitor does not give any display (Fig. 1). 2) When engine running and oil temperature rise When the oil temperature rises and the viscosity of the oil becomes lower, the flow of hydraulic, oil becomes smooth and the filter sensor is turned. ON, ‘At the same time, when the oil temperature rises, the temperature sensor is switched OFF (Fig. 2). 3), When filter is clogged + When the filter becomes clogged, the filter sensor sends an OFF signal to the timer (Fig. 23). + When the timer receives the OFF signal from the filter sensor, it starts the timer in order to judge if the signal is a momentary phenom- enon. If the filter sensor is not turned back fon within 5 seconds, it sends an OFF signal to the monitor. + When the monitor receives the OFF signal from the timer, it lights up the hydraulic filter monitor lamp (Fig. 4). ‘Temperature sensor Fiter sensor Temperature sensor Filter sensor Temperature sensor Fiter sensor Temperature sensor Filter sensor Timer Monitor a 20905129, Timer Monitor a 209F05124 Timer Monitor Bi 20905125, 209F08126 10-153 2ELECTRIC CIRCUIT FOR HYDRAULIC FILTER MONITOR SYSTEM REGULATION OF EC INCLUSION FUNCTION + Immediately after starting the engine, the oil temperature is low and the oil viscosity is high. As a result, resistance is generated in the filter, 80 the hydraulic filter sensor is switched OFF. To cancel this electrically, a hydraulic oil tem- erature (low temperature) sensor is installed, and at low temperatures, this hydraulic oil tem: erature sensor is switched ON. + There may also be cases when the filter sensor is switched OFF because of momentary changes in the oil pressure. To cancel this electrically, a timer is installed which gives a S-second delay in the display. OPERATION 1) When starting engine Immediately after starting the engine, the oil temperature is low and the oil viscosity is high. As a result, resistance is generated in the filter, 0 the hydraulic filter sensor is switched OFF. However, the temperature sensor, which is con: nected in parallel to the filter sensor, is ON, so the signal to the timer is switched ON, and the monitor does not give any display (Fig. 1) 2) When engine running and oil temperature rise When the oil temperature rises and the viscosity of the oil becomes lower, the flow of hydraulic oil becomes smooth and the filter sensor is turned ON. At the same time, when the oil temperature rises, the temperature sensor is switched OFF (Fig. 2) 3) When filter is clogged + When the filter becomes clogged, the filter sensor sends an OFF signal to the timer (Fig. 3). + When the timer receives the OFF signal from the filter sensor, it starts the timer in order to judge if the signal is a momentary phenom. enon. If the filter sensor is not turned back fon within 5 seconds, it sends an OFF signal to the monitor. + When the monitor receives the OFF signal from the timer, it lights up the hydraulic filter monitor lamp (Fig. 4). 10-153-1 3 Temperature sensor Filter sensor Temperature sensor Filter sensor Temperature sensor Filter sensor Temperature sensor oh Filter sensor Monitor Monitor Timer (sl Timer loll Timer ll 209055) ENGINE OIL PRESSURE SENSOR 1. Plug eta) gues 2. Diaphragm \ / San < 4 SPECIFICATIONS ON pressure: 1.3 + 0.3 kglem* Composition of circuit OFF pressure: 0.5 *83kgiem? 20905127, 6) HYDRAULIC OIL TEMPERATURE SENSOR (HIGH TEMPERATURE) : 1. Sensor , ont 2. Plug / srtcincaTions 7 ON temperature: 98 = 30 ——} OFF temperature: 102 + 30 rosrosien 7) COOLANT TEMPERATURE SENSOR CN-ES 1 - 1. Plug 2. Sensor Composition of eicuit 205081704 10-154 2 020905020905 8) FUEL LEVEL SENSOR aN (0 Q 4 \ ) 1. Float 2. Cover 3. Variable resistance Composition of circuit 2 3 Section AA 208F05171 10-155 220 TESTING AND ADJUSTING 020905 Table of judgement standard value : Standard value table for electrical system... Tools for testing, adjusting and troubleshooting Measuring engine speed... Measuring intake air pressure (boost pressure) Measuring exhaust gas temperature .. Measuring exhaust gas color Adjusting valve clearance 7 Measuring compression pressure ... Measuring blow-by pressure Testing and adjusting fuel injection timing Measuring engine oil pressure Testing and adjusting alternator belt tension . Testing and adjusting fan belt tension Adjusting fuel control linkage Adjusting engine speed sensor Checking swing circle bearing clearance Testing and adjusting track shoe tension Testing and adjusting work equipment, swing, travel circuit pressure Testing and adjusting control circuit pressure... Testing and adjusting piston pump control pressure Measuring stroke of servo piston Testing and adjusting travel deviation Measuring oil leakage Checking locations causing hydraulic drift of work equipment . Measuring PPC valve output pressure ae Adjusting work equipment, swing PPC valve Measuring solenoid valve outlet pressure Bleeding air Releasing remaining pressure in hydraulic circut Troubleshooting Bi betore performing inspection, adjustment or feufinding, park the machine on level ground and check the satety pin and chock When preforming joint work, make apporpriate signals and allow only authorized personnel near the machine When checking the water lev, allow the engine to cool down before removing the radiator cap to prevent the risk of being scalded by hot water which may spurt out ifthe engine is hot Take great care to avotd geting caught in rotating parts such asthe fan, ectTABLE OF JUDGEMENT STANDARD VALUE © FOR ENGINE P8505 Machine model Pomog Engine saspiéo hem Measurement condition | Unit Standard valve Permissibe value High idling om 1.900 = 60 11980 + 50 Engine speed Low iating tom 700 = 50 700 = 60 fated specs om 1.000 : Intake aie pressure At rated output mmig Min. 1.100 880 Exhaust gos pressure tastoay amet oees c Max. 700 ‘Max. 700, ‘A sudden accalrtion | BoReD Max. 60 12 Exhaust ges color | At hgh iting Bosch Mex. 20 20 Vaive clearance eeie vate Ge oe . (rormattemperature) — | enauat valve oe os i 01 temperature: 40 ~ 60°C |kgiem* 32 2 Compression pressure (Ske 010 (Engine speed (oom) (180 - 200) (180 - 2001 (Coolant temperature: Operating range) Blow by pressure ces ‘ (SAE 30 oil 7 Cid “0 | Atrated output (Coolant temperature: i Operating range) i pressure high iin gion : i, pressure At high ating ha 25-50 18 Atom ing (SAE 30) |g 12 or At tow iting (SAEIOW! | ems a 07 aes All speed range z Oi tome (inside i pan . oo18 0 Fuel injection timing Br.0.c. eo 221 wet | Datiesion whan pressed Atternator belt tension | with finger fore oF mm 10 e-2 aprox Bg Fan bet tension Protrusion of ajusement bolt | mm sea . 020905020908 ‘¢ FOR CHASSIS (FOR MACHINE EQUIPPED WITH 2-STAGE MODE SELECTOR OLSS) % The standard values and permissible values shown in this table are all values when mode selector switch is at S mode. ‘ ros80.5 Machine mods! rosso as tem Measurement condition | Uni | Standard value Permissible value fat rent pues reel | vaauie ot tempera = At sront panes sycroue o tempea min reo | 1830 [Ayton and rear BOMBS] «encine coo fea _ ate gre cola! vempuaure ae a Eten aca |” MR soo ge + Engine ol pressure: os % ' z | Atewing pump reiet |" Game ol restore || ap Min. 1990 0 i 7 Get heow Wf swish ON Atheavy lit relit | Rttonly BOOM RAISE relief | ee ee ‘a gutarcraion | Fm conti a hap ina z z tos 1 aifconot eves tse Boome contol vave ela ered | eases ee oom contol valve [eer Arm contol valve Arm contol valve | Bacteria conta vave 3 “+ fe eteeU ea aes eee ane B | suctec cont vatve Have conto ave | R. H. travel control valve) Service valve orem | | Simp contol wave Neural = | coor cont! tver ost eso L + as conter of _Ralee, Lower iver tnoe ] | Arm contro lever ett eT e210 66210 | + Manu at eng "Out | otra a Bucket cont levee Nawal e210 cs t0 + Engine stopped = E | sui trol lever Neutral bas 10 64210 E | swing comrot eve ota : : 8 Neutral : = 2 Tevet contol ever Nera | Ves M5215 zt 5 | Sater lock ever Lock + Fe 300 = 20 300 = 909 ; tom ing <= : : Wor : : equipment eae on7 Pray ofconvol ever Travel 0-20 0-20Machine mode! Posso-s Peesase-s coe tern | Measurement condition | Unit ‘Standard value Permissible valve Boom contro lever | + Engine at high iting 24208 + yar oi temperature: ea sse Arm contol lever | + For contro eve, ft push 24208 | Pull scate to canter af knob {o measure Bucket contol lever | + For contol pedal ft push 21208 21208 Dulseale top of pedal to | yg Swing control lever | + Measure max. valve to end 21208 2a oftrove. control lever 25208 25208 Fuel control lever 55-7 58-7 [At heavy 1k 20 switch OFF 320720 rote At ey i = Swatch ON 30 0 Boom AE mashing push we | 75218 2738 ‘ower mache 10 push wp 220210 20 Seton ON "20 0 arm + Hyeraui il temperature: 30210 2013? Bose + Engine a high iting Bucket { Rebeve aniieweut be 20210 0732 mmescured [trove 2 220°] 5 29 20 | swing Kolem 280 200 g ° | ° 40 ! s 5 3 | conver | 203 nt ee a2 Min. 18 + Engine st “Boom vase ots a ee righ ing rer pressure saapaee | sat Min. 18 Min. 18 | ahaa ste 12522 2 foam ase ie * Wveraulc of Lever at nae moue temperature: neural Pressure Boo perenne “Engine st Rewraa nn in in high ing Sommers oe ea "+ ‘Measure atthe NC valve, but neither the NC valve nor the CO vaive are actuated, so the measurement is the pressure of he TVG * When measuring ot BOM RAISE relief, do not operate tothe end of the stroke, Relieve the circuit before the end of the stroke {At the end of the RAISE stroke, the pision valve opens.) 20-2-2 020905020905 ‘Machine mode! Pcss0-s PossOSe-s Case stem Measurement condition Unit Standard value | Permissible valve 2 Hydra Lever at Difference | nevtral pressure of + Hysraulic ol temperature: 45 ~ §5°C Engine at high idling + Control lever at neutral 18220 Min. 15, Laver at end of travel 7 Hydraulic ol temperature: «86ST + Engine at high idling + Contr lever at end of travel (Pump discharge pressure 35 desired) kgiem? Max. 2.0 Max. 20 Lowered hydraulic pressure + Hydraulic ol temperature: 65 - 55°C + Difference oi rele! pressure between at engine full speed and at engine Tow speed itwo pump rele Max. 20 20 ‘Swing brake angie ‘Measuring posture Max reach + Engine at high ising * Hyérauiie ail temperature: 45 ~ 55°C + Stop atter swinging one turn and ‘measure distance that swing ctele +N Distance of movement on 0. circumference of swing eicle 9. (om Max. 45 san 775) Max. 60, (Mae 1.040) Swing Time taken to stort suing ‘Measuring posture eo ava 80" i eee ETAT Max. re0ch 44-53 Max. 56 + Engine at high iling * Hydrautie 01 temperature wesc + Time taken from starting position | te swing 90 and 180) 180" 70-86 Max 9.0 Time taken to swing ‘Measuring posture Max. reach + Engine at high idling + Hydrautie ot temperature: Bosse + Swing one turn, and measure time taken fo'swing next turns 500-560 Max. 58 20-2-3Machine model 650-5 Pcssose-s Css feston Mi surement condition Unit ‘Standard value ‘Swing Hydraulic dit of swing + Eegine stopped + Hydraulic el temperature: 48 - 55°C * Set machine on'TB. slope, and set Upper structure at 90" to the side, “Make match marks on swing evele ‘outer race and trank frame, + Measure distance that match marks move apart after § minutes, Leakage of swing motor Engine at high idling + Hydraulic oil temperature: 45 - 55°C + Siwing lock switen ON + Relieve ewing circuit ein Max. 5 Max. 10 Travel ‘Travel speed (1) Measuring posture bo | ST. i ‘st ic ns- B18 B10 900 735- ars. a10- ‘900 205F2427/ + Engine at high icing + Hyaravite oll temperature: a 55 + lise track on one side ata time, rotate one tur, then measure time taken for hext 5 turns s90- 580 550- ‘50 490- 580 550- 650 Travel speed (2) le 265 - ‘Bao 249 - ‘300 255 - 330 + Engine at high idling _208°2409| + Hyerauite ol temperature: a 55 + lun up for at least 10 m, and ‘measure time taken to travel ‘ext 20 m on flat ground 4 160- 190 180 - 210 160- 190 180- 210 020905020905 Pces0-s Machine model BeeEDS Cass tem ‘Measurement condition Unit | stonderd value | Permissible value | Measuring posture | em aN eo YS eet | + Engine at high idling a * Hyaraue of temperature: 45 ~ 55¢ Travel deviation “Rump fora Teast 10m. andmeasure | mm | Max. 200, Max 220 Gevition wen traveling next 0m On {ts roune + Urea hard noszontal sutace 20m | = | | 2osr2402 | # Measure dimension ¢ | Measuring posture rl | i] | £ | | | | rare it ot os ° : | *2ov03007 | | + Engine stopped { fivrauie of temperature: 45 —s5°¢ 1 Slop machine on 1 slope with sprocket | facing straight up the slope | + Meature in tstance the machine moves | | Ines nates | Leakage of travel tumin | tox. 10 Max. 20 Lock pin | 'F20703008 | Engine at high ising | Hygraute oi temperature: 45 ~ 56°C {Coax shoes and veteve travel creut 20.2-5 >css0-5 Machine mods Pessost-s ca Gis tem Measurement condition nit | standard vatue | Permisinie value Measuring posture BACK ]IDADING| BACK LOADING ies woe |'Stovec | HSE [Stove Teal work tecmeert || dite ari ax || fiydiat Y Max. 1200 | Mas 1200| Max 1800| Max. 1500 teat Al i mex. +200 LOADING SHOVEL tarsount ot jaa fo Wax 99 retraction of (35) Max. 180) ax, 50) Sinden mm + Poe in above posture and m um eyinder teeraion or reaciton of Cyage and down Atm lind tard movement a ip of beset eth cea + Bucket” Rated load 185 | max. ao | Max: 250 ‘a oe BACK HOE: 4.500 kg (PCE50) 70) Max. 1051 5 | 300 1g (peasosey i LoAoING SHOVEL “60 tp e + Horizontal at round 2 «eee tal z Bucket cylinder | + Engine stopped : Bucaateyinder | * Rodrouc temperature: 45 55 2 levees * ‘atter setting, 52 | Max.e | Max 25 cylinder! é ae oy ee ‘notes, and judge Hom reat or 13 mines. CM Bucet no lad aa Measvring posture ee 3 Bucket teeth in ns Sasos/anece| : | conte th 2 ‘round ko toad | 7 ARE, oe |g TT | Stinger tuty | Engine ation iting | IY |S Jaczou| - = E | ehended Liver oftempednure: «6-560 | | : | Measuring pone E | am Pe 2 | cinder ey ‘ sos asso) - S| reractes Saatee| eee Saas Fully exened 3 a7z04| 27203] - - + Engine at high iting + Hydraulic oil temperature: 45 — 55°C 20-2-6 3 (020905

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