SEBMO0Z0M0604 SOP IMCAUINITOAVIL; KOMATSU PC05-6,PC07-1 PC10-6,PC15-2 MACHINE MODEL SERIAL No. PCO5-6 11301 and up PCO7-1 10001 and up PC10-6 10501 and up PC15-2 10001 and up This shop manual may contain attachments and optional equipment that are not available in your aree. Please consult your local Komatsu distributor for those items you may required. Materials and specifications are subject to change without notice. efCONTENTS No. of page 10 STRUCTURE AND FUNCTION........................... 104 20 TESTING AND ADJUSTING ............ ceeeceeees 204 30 DISASSEMBLY AND ASSEMBLY ..................... 30-1 40 MAINTENANCE STANDARD ................... sees 40-1 00-2 @ 020M08020M06 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary ai ions be taken to these pages according to the table below. Wark Tndiestion | Aion required oO Page to be newly added Add e Page to be replaced Replace (| one to be dltea Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGES Mark Page Rimper [Mark Page Renner | Mark Page Firmner |Mark Page umber” . © |e 102 © 1065 © 2027 © 3020 ® ® 10-26 @® 1067 @ 20-28 ® 30-21 ® . @ © 1027 @ 1068 @ 2029 ® 30-22 @ 00.22 @® 10-28 ® 1069 @ 2030 @ 30-23 @ 10-29 @ 10-70 @® 20-31 @ 30-24 @ 10:30 @ 1071 ® 20-32 @ 30-25 @ 1031 ® 1072 © 2033 @ 3026 @ 1032 @ 1073 ® 20-34 @ 30-27 @ 10-33 @® 10-74 @ 20:35 ® 30-28 © 1034 @ 1075 ® 2038 ® 30:29 @ 1038 @ 10:76 ® 2038 ® 3030 @ 1037 @ 2039 ® 3031 ® @ 1038 © 20-1 ® 20-40 @ 3032 @ ® 1039 @ 22 © 2041 ® 3033 @ © 1040 @ 203° «@ 20-42 @ 3034 @ 1042 @ 204 @ 2043 @ 3035 @ 101 ® 1043 ® 25 @ 2044 @ 3036 ® 102 © 1044 @ 26 @ 2045 @ 3037 © 103 ® 1045 ® 27 ® 3038 © 04 © 1046 © 28 © 301 @ 3039 @ 106 @ 1047 ® 209 @ 302 @ 3040 ® 107 @® 1048 @ 20-10 @ 3203 @ 3041 @ 108 = ® 1049 @ 20-11 © 304 @ 3042 @ 109 @ 1050 © 20-12 © 305 © 3043 © 1010 ® 1051 @ 213 ® 306 @ 3044 @ 10-11 @ 1052 @ 20-14 @ 307 ® 3045 @ 1012 @ 1053 @ 2015 @ 308 © 3046 @ 10-13 @ 1054 ® 20-16 © 309 @ 3047 @ 1015 @ 1055 ® 2017 @ 30-10 @ 3048 © 10:16 @ 1056 ® 20-18 ® 30-11 © 3049 © 1017 @ 1057 @ 219 ® 30-12 ® 3050 © 1018 @ 1058 @ 2020 © 3013 @ 30-51 © 10-19 @® 1059 @ 20-21 @ 30-14 @ 3052 © * 10:20 © 1060 © 2022 @ 30-15 @ 3053 @ © 1021 @ 1061 @ 20-23 @ 3016 @ 3054 @ © 10022 @ 1062 @ 20-24 @ 3017 @ 3055 @ 10-23 © 1063 @ 20:25 @ 3018 @ 3056 @ 1024 @ 1064 @ 20:26 @ 30-19 @ 3057 © 00-2-1i Revision number Mark Revision umber Mark Page Rovsion umber ‘Mark Page Revirion| number Mork Pi Rvision number 3058 3059 30-60 3061 3062 3063, 30-64 30-65 30-68 30-67 3068 3069 30-70 30-71 30-72 30-73 30-74 30-75 000000000000000000 40-41 40-2 403 40-4 405 406 407 408 40-9 40-10 40-11 40-12 40-13 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-22 40.23 40-24 40-25 40-26 40-27 40-28 40-29 40:30 4031 40:32 40:33 40-34 98 G8 HH HHOHHHHHGHHGHGHHHHGHGHOHHGHHHOHHH GOHHHHHHHGHHHHHOOHOO 40-38 40:37 40-38 40:39 40-40 40-41 40-42 40-43 40-44 40-45 ©280908008 020M06A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols Mand “AX are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing « Always wear safety glasses when hitting parts with a hammer. © Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work 4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for ‘smoking. Never smoke while working. PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. if this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11. When removing the oil filer cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful Rot to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal firs. 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 @ hoist or crane and operate ‘slowly to prevent the component from hit- ting 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 on to 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 mini mum of gasoline when washing electrical parts. 00-4 19.Be sure to assemble all parts again in their al places. Replace any damaged parts with new parts. ‘© When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.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. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or Parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 26,Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the trackFOREWORD: This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements, Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of ‘components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting, TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volum Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models Electrical volume Attachments volume These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work. FILING METHOD 1 See the page number on the bottom of the page. File the pages in correct order. 2, Following examples shows how to read the page number. Example 1 (Chassis volume): 10-3 ltem number (10. Structure and Function} Consecutive page number for each item. Example 2 (Engine volume): 12-410 Unit number (1. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated by a hyphen (-)’and number after the Page number. File as in the example. Example: 10-4 12-203 10-4-1 12-203-1 10.4.2 }~Added pages E49 203.2 10-5 12-204 00-6 REVISED EDITION MARK (O®@ When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol | tem Remarks Special safety precautions are A nacessory when performing the wore Safety Entra special sfety precautions 4 are necessary when performing : the work because it is under internal pressure. Special technical precautions or other precautions for | Caution | preserving standards are Recessary when performing the work, Weight of parts or systems Caution necessary when (=>) | Weight | selecting hotsting wire, or when working postures important, ete “quan. [Places tat reue apo Gram | Tatton | Stenton forthe hteing 19 tOFqUe | torque during assembly. Places to be coated with = | Coat | adhesives and lubricants etc aces wher i water or ful Be | oi woter| masts essed ane the Copa Places where oil or water must Drain |be drained, and quantity to be drainedHOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AY Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with the symbol >) 1. If @ part cannot be smoothly removed from the machine by hoisting, the following checks should be made: = Check for removal of all bolts fastening the part to the relative parts. + Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or "S" twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 12 14 125 16 14 22 16 28 18 36 20 44 22.4 5.6 30 10.0 40 18.0 50 28.0 60 40.0 Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. 79% = 1% 1% 50064 3)Do not sling a heavy load with one rope alone, but sling with two or more ropes ‘symmetrically wound on to the load. BA Singing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4)Do not sting a heavy load with ropes forming a wide hanging angle from the hook. ‘When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150° Bf > The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Losd capacity 8 ea Lutting angle + F008 00-7STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. Thread diameter Width ae of bolt across flat (mm) (mm) kgm Nm 6 10 1.382015 13.2214 8 13 3.2403 31.4429 10 7 6740.7 65.7268 12 19 11.510 112498 14 22 18.0+2.0 177419 16 24 28.543 279+29 18 27 3924 383+39 20 30 56+6 549+58 22 32 76+8 745+78 24 36 94.5410 927+98 27 4 135415 1320+140 30 46 17520 1720+190 33 50 22525 2210240 36 55 280+30 2750+290 39 60 335435 32804340 1 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque. %* Nm (newton meter): 1Nm & 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque of bolt across flats —— (mm) (mm) kgm Nm 10 14 6740.7 65.7468 12 17 11541 112298 16 22 28543 279+29 00-8STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. ‘Thread diameter Width across flats Tightening torque rane otras, (mm) (mm) kgm Nm 14 19 25405 24549 18 24 5x2 402196 2 27 822 7852196 24 32 143 13734294 30 38 1823 1765294 33 a 2025 196.149 36 46 255 245.249 2 56 308 2942249 COATING MATERIALS a The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature | Komatsu code Applications LT-1A Used to apply rubber pads, rubber gaskets, and cork plugs. mo Used to apply resin, rubber, metallic and Adhesives ‘non-metallic parts when a fast, strong seal is needed, u1-2" Preventing bolts, nuts and plugs from loosening and leaking oi mS Provides an airtight, electrically insulating seal Used for aluminum surfaces. Let Used with gaskets and packings to increase sealing effect. rar Heat-resistent gasket for precombustion chambers and exhaus: piping. Gasket sealant roe Used by itself on mounting surfaces on the final drive and Wans- mission cases. (Thickness after tightening: 0.07 — 0.08 mm) ‘Used by itself to seal grease fittings, tapered screw LG-5 fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter. “Antifricion com- pound (Lubricant ae Applied to bearings and taper shafts to facilitate press-fitting and to including molybde- prevent sticking, burning or rusting. ‘num disulfide) Grease aa ‘Applied to bearings, sliding parts and oll seals for lubrication, rust (Cithium grease) prevention and facilitation of assembling work, Vaseline =_ Used for protecting battery electrode terminals from corrosion. *LT-2 is also called LOCTITE in the shop manuals. 00-9ELECTRIC WIRE CODE tsa 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: O5WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS Namie | —oaaa oe oratendy Casein] *HRS™ [Oume =H] Aopeabectut wae Pe te] ota CLASSIFICATION BY COLOR AND CODE 5 | 2 Color | Black & White] White & Red | Red & White |Green & White] Yellow & Red | Blue & White 3 Color |Black & Yellow] White & Black| Red & Black | Green & Red [Yellow & Black} Blue & Red naan Code BR WL RY GY YG uy ‘ Color | Black & Red | White & Blue | Red & Yellow [Green & Yellow ellow & Green| Blue & Yellow 5 Color - |WhiteéYellow| Red & Green | Green & Black | Yellow & Blue | Blue & Black as ee . Color ~|White & Green| Red & Blue [‘sreen Biue [Yetowewenite 00-10WEIGHT TABLE AX This weight table is a guide for use when transporting or handling components. Unit: kg Machine model PCO5-6 Pco7-4 PC106 Pcis.2 Serial No. 11301-11700 1 1701 and up | 10001 and up | 10501 and up| 10001 and up Engine assembly 123 | 123 me | 159 184 +Engine no | 110 110 130 155 “Engine mount - - - 12 12 “PTO 78 | 78 78 9 9 +Hydraulic pump 5.3 | 5.3 5.3 77 77 Radiator assembly 42 | 42 42 66 73 Revolving frame 130 | 200 262 338 478 Canopy as | 25 21.5 23 23 Operator's cab - | - - 155 155 Operator's seat 75 | 75 75 10 10 Fuel tank W ] 11 W 7 7 Hydraulic tank 20 i 20 20 34 34 1-spoo! control valve 430 | 43 - - - 2-spool control valve - | - - 6 6 5-spool control valve - | - - 14.5 14.5 6-spool control valve - as - 16 16 7-spool control valve 16 I 16 16 - - 8-spool control valve - { 18.5 18.5 - - ‘Swing-boom swing selector valve ‘Swing circle assembly w | 19 38.4 38.4 Swing motor assembly 13.5 | 13.5 13.5 7 28 Center swivel joint 71s | 78 15 78 75 00-12 © 020M06020M08. Unit: kg Machine model PCO5-6 PCO? PC106 PCI52 Serial No. 11301-11700 |11701 and up |10001 and up | 10501 and up |10001 and up Track frame assembly 257 184 187 359 398 “Track frame 90.5 905 93 223 262 idler 7.5x2 75x2 T5x2 20x2 20x2 + Idler cushion 7x2 7x2 7x2 1x2 x2 + Track roller 35x6 3.5x6 35x 6 6x6 6x6 *Sprocket 55x2 5x2 5.5x2 8x2 8x2 Travel motor assembly | 15x 2 15x2 15 x2 30x2 30x2 Track shoe assembly “Track shoe 70x2 785x2 | 785x2 136 x2 187 x2 “Track shoe with rubber nOD 2 - - - - + Rubber shoe 43x20 | 87x2 7x2 2x2 112 x2 Boom swing bracket esembly 45 | 148 18.5 37 a Boom assembly 384 | 384 39 73 88 ‘Arm assembly 19.4 | 19.4 23.2 40 40 Bucket assembly 19 L243 26.4 45 45 Blade assembly 30.4 39.5 40 108 109 Boom cylinder essenbly 10 10 107 18.5 20 Arm cylinder assembly 9 | 9 10.1 18.2 7 Bucket cylinder ae 85 85 85 145 145 Boom swing cylinder | assembly” 8 8 8 185 18.5 Blade cylinder assembly 63 | 65 65 98 98LIST OF LUBRICANT AND WATER AMBIENT TEMPERATURE CAPACITY (0) RESERVOIR tu “50 gE i FLUI 48 OE Specified | Refill —Teasroos: 3.65) PODS: 3.65 cngine ot EET INT sac go WEES. Tepe oO: 3 $5 POE: 3.65 gine oil pan | soon ae pero: 21 | Peto: 31 E10 = pois: 4.7 | pcis: 47 ons: 03 | Pc0s: 03 Final drive case Pco7: 0.3 | peo?: 03 (0200) | ine ol Pero: 08 | Pcto: 06 ngine oil Pers: 0.6 | PCtB: 06 ET ae Track roller (1 piece) oo2 | - Idler (1 piece) on2 = SSE Esa to EE TTT pcos. 200] cos: 10:3 set a a PCO?: 25.3] poor: 18.3 Hydraulic tank EEE Tama T pero: 46° | pero: 20 a ne toa ey "C'S | PS ~ ae Fabs: 25 ns Ast bers nod on Fuel tank Diesel fuet | ~ Pero: 38 | a] POIs: 35 BCOS: 3.6 Cooling system Water ‘Add antifreeze peor 33 | Pete: 39 34 ASTM D975 No.1 ASTM: American Society of Testing and Material SAE: — Society of Automotive Engineers 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. NOTE: (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic main- tenance hours described in operation and maintenance manual, Change oil according to the following table if fuel sulphur content is above 0.5%. Change interval of Fuel sulphur content | nena ini pan 0.5 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval 00-14 2 (2) When starting the engine in an atmospheric ‘temperature of lower than 0°C, be sure to use engine oil of SAE1OW, SAE10W-30 and SAE15W-40, even through an atmospheric temperature goes up to 10°C more or less in the day time. {3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. 020M06.10 STRUCTURE AND FUNCTION 020M08 Radiator . +610 2 Power tr : 10-6 Swing circle .. = 10-10 Track frame and recoil spring . 10-12 Hydraulic piping. ooo 10-15 Hydraulic circuit diagram . + 10-20 Hydraulic tank . . Hydraulic pump ... . 7-spool control valve 8-spool contro! valve . . 1-spool control valve 5-spool control valve . 10-29 = 10-31 10-36 = 10-38 = 10-40 1042 6-spool control valve ....... 10-44 2-spool control valve ..... » 10-46 Swing—boom swing selector valve ++ 10-47 Swing motor +++ 10-48 Travel motor +++ 1050 Center swivel joint 10-54 Hydraulic cylinder Valve control ..... Work equipment... Electric circuit diagram. 10-56 10-67 10-72 10-74 10-1RADIATOR PCOS-6, PCO7-1 1. Radiator 2. Cap 3. Radiator inlet hose 4, Radiator outlet hose 5, Drain valve SPECIFICATIONS + Type: + Fin pitch: + Cap Relief set pressure: Suction set pressure: + Capacity: F20M06001 cD-2 4.0mm 0.9 + 0.15 kg/cm? 0.05 kg/em? 1.352 020M06020M06. PC10-6 gp aene Radiator Cap Radiator inlet hose Radiator outlet hose Drain valve SPECIFICATIONS + Type: + Fin pitch: + Cop Relief set pressure: Suction set pressure: + Capa 20NFO6005 co-2 4.0mm. 0.9 + 0.15 kg/cm? 0.05 kg/em? 1.358PC15.2 Ogeens Radiator Cap Radiator inlet hose Radiator outlet hose Drain valve . Oil cooler (Hydraulic piping) SPECIFICATIONS + Type: + Fin pitch: + Cap Relief set pressure: Suction set pressure: + Capaci 20NFO6006 cp.2 4.0 mm 0.9 + 0.15 kg/cm? 0.05 kg/cm? 1.352 020M06* FOR MACHINE FOUIPPED WITH SWING- ROOM SWING SELECTOR PEDAL POWER TRAIN PCO5-6, PCO7-1 == swing == contrvaive F20M06057 1. Idler 6. Hydraulic pump 2. Center swivel joint 7. Swing-boom swing selector valve 3. Swingmotor — 8. 7-spool control valve 4, Travel motor 9. Swing circle 5. Engine o20mo6020M06. * FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL 20MFO6005 Hydraulic pump 8-spool contro! valve PCO5-6, PCO7-1 \ 2 3 4 ae [Se fetes tna) —— ca 7 1. Idler 5. Engine 2. Center swivel joint 6. 3. Swing motor 7. 4. Travel motor 8. ‘Swing circle 10-7 @* FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL PC10-6, PC15-2 10-8 Idler 5-spool control valve Center swivel joint Swing motor Travel motor F20M06058 2-spool control valve Engine Hydraulic pump ‘Swing-boom swing selector valve Swing circle 020M06:020M06 * FOR MACHINE WITHOUT SWING—BOOM SWING SELECTOR PEDAL, PC10-6, PC15-2 1203 4 5 6 \ | Ee ad \ Ar —— Q | 8 C4 : ened Be pe eye 8 = Swing 4 == en _ $8 20NFO6007 1, Idler 6. 2-spool control valve 2 epee! contra valve 3. Engine 3. Center swivel joint 8. Hydraulic pump 4. Swing motor 9. Swing circle 5. Travel motorSWING CIRCLE PCO5-6, PCO7-1 ‘90¢N0z0 20MF06006 1. Swing circle outer race 2. Ball bearing 3. Swing circle inner race 10-10020M08. PC10-6, PC15.2 —— wnt oe Section A—A 1. Swing circle outer race 2. Ball bearing 3. Swing circle inner race 20NFO6008 efTRACK FRAME AND RECOIL SPRING PCOS-6, PCO7-1 10-12 gpens . Idler Track frame . Sliding plate Travel motor . Sprocket eens . Track roller |. Track shoe 3. Recoil spring ). Guard F20M06002 020M06020M08 PC10-6, PC15-2 gaeone Idler . Track frame . Sliding plate . Travel motor . Sprocket @ruD 20NFO6009 . Track roller . Track shoe 3. Recoil spring Guard 10-13 e020M08. HYDRAULIC PIPING PCO5-6, PCO7-1 + FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL F20M06003 Bucket cylinder Arm cylinder Boom cylinder Boom swing cylinder Oil filter Hydraulic pump Travel motor ‘Swing—boom swing selector valve . Swing motor 7-spool control valve « Center swivel joint Blade cylinder 10-15 @®PCO5-6, PCO7-1 10-16 @ * FOR MACHINE EQUIPPED WITH SWING-BOOM SWING SELECTOR PEDAL, FLOW INCREASING CIRCUIT AND ADDITIONAL CIRCUIT F20M06004 4 . Bucket cylinder . Arm cylinder 1. Boom cylinder Boom swing cylinder 1-spool control valve Oil filter . Flow increasing pump . Hydraulic pump ). Travel motor |. Swing—boom swing selector valve . Swing motor . 7-spool control valve . Center swivel joint . Blade cylinder 020M06o20mo8. PCO5-6, PCO7-1 * FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL 20MFO6007 FS eprom sena Bucket cylinder Arm cylinder Boom cylinder Boom-swing cylinder Hydraulic filter Hydraulic pump Travel motor . Swing motor 8-spool control valve |. Center swivel joint . Blade cylinder 10-17 @* FOR MACHINE EQUIPPED WITH SWING-BOOM SWING SELECTOR PEDAL. PC10-6, PC15-2 PPNITSeN> 10. 1. 12. 13, 14. Bucket cylinder Arm cylinder Boom cylinder Boom swing cylinder R.H. travel motor Strainer Swing motor 2-spool control valve Hydraulic pump ‘Swing—boom swing selector valve LH, travel motor 5-spool control valve Center swivel joint Blade cylinder F20M06059 10-18 @ 020M06* FOR MACHINE EQUIPPED WITH SWING-BOOM SWING SELECTOR PEDAL Bucket cylinder cdddWGndacrad 3 2 g 8 PC10-6, PC15-2 ‘g0Ww0z0 10-19* FOR MACHINE EQUIPPED WITH SWING- BOOM SWING SELECTOR PEDAL HYDRAULIC CIRCUIT DIAGRAM oS Ri. ravel motor ‘Theoret devery 330.9cerev an, Meinretet veh FTL Setprersue 175kg/em* Boom swing evlndor (50% 930~ 2875) Blade onder (e60x 83060) Set pressure CCenterswivelioint £ Li > ‘Boom evinder (50% 990-9465) Bucket evindey (50% 00-385), ‘Ars eyinge (es0%930~442 Seugesnue Third valve igre 7 Beipressure tegen 8) Set oressue: ‘Yebxglem 77] Swing/Boom swing Swing motor Theoretical dolvery.195ce/to¥ Set pressure: Tésigiem" Setgressure, yaoi tank ry kg/cm! Engine rank capac i Maina vave Setpreseure'175kg/em! Hyareute pump ‘senes6. ‘Theoretical delivery: 6.446 4eciroe Rotou discharge volume: 11.93.1194 /min(¢t2.000rpm)_ F2OMOGOO5B 10-20 020M06020m06 PCOs-6 Blade cya (#60%$30~ 60) Boom evince (350 830 — 339.2) Bucket einder (#60%480-386), Arm evlinger (eB0x¢30—4421 Swing motoe Theoreveal delivery: 198ce/xev a ‘* FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL, FLOW INCREASING CIRCUIT AND ADDITIONAL CIRCUIT AML rave motoe ‘Theoretical delivery: 330 ecirey T-spoot control vatve | lan, Maio raat vive £7], Setpreeture:175kp/em* ‘Boom swing eyndee (gsoxgs0~267 5) Center swivel it E Third valve Hysreuie pum ‘son Theovetcal delivery: 8.781/min Rated dszharge volume B TSH (at 1.830 com) ‘Set prennre yout tank Frank capaci Goat 5072-214 M Jot mount 2.30 1808/24) | cee tatty ESE SS enzo F20MO6006A, 10-21* FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL PCOs-6 AH, wavel motor B-spool control valve Thooretcal delivery: 330-9ec/rev 7 Set pressure 175ig/em? Blade cylinder (60x #30 — 60) | set eessure TBskg/er | LH. travel motor Fonward) [fteverse Boom eviinder (65030 — 355) => 4 AHL eave at | ra ! XK | 1 ' t tt al { Bucket cvinder (@50°» 850385) Arm eylinder {850 «990 442) Leet rr Thi valve averse set pressure) “ekg/em| set possure B5kq/er set pressure: 85kg/en?| ——T Swing motor Theoretialdavery [> "9see/re Set prossure ‘a5tg/em| ‘Swing cylinder (50 7830 — 318) ‘karen Engine 9072.26 Hydraulic tank ‘Boom swing) Otlamount. 18.31 Wain relat vale Seton Pong Bit 180 mesh Hydraulic pume SBR 6+E ‘Theoretical delivery: 6.646.4ce/tew Rated discharge votume: 11.94 11.91/min (21 2,000 rom) F20M06091 10-22 020M06020M06 PCo7-1 * FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL BAH. travel motor ‘Theoretical delivery: 15.4 ee/rev Reduetion cation 25.26 px __7-sp00lcontl valve Main rae vai 77 Setpresse' 1 5tp/emt i Boom swing ender . Blade cvincer Set pressure "Bhg/em* rt Contr swivajoint F | | | Bucket ender ‘Swing: boom swing soictorvolve ‘Armeyinder set Peers: Sind 7 ‘Swing/Boom swing ‘Swng motor ‘Theoretical dalvay:244 celrev Hydrate tank Tank capacity: 2656 Onamount: 1830 Engine 5072-28 a Seat Moin reat vave Setpressure:178kg/em! arate pump Sene+e Theottica delivery: 6.446 4clrev Roted iochorge volume: 14,9 5 14:28/min (at 2,400 com) F20MO6005B 10-23 ®Pco7-1 8.sp00! control Main retiet valve [~]Set pressures 175 ka/em? Blade eylinder set 185 kglem’ Buckee| Boom cylinder PM. travel Forward Bucket cylinder ‘Arm eylinder La, travel Revers] set 185 kalo! set ‘35 kglem? Main relief valve Set pressure 175 Kain? * FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL Center swivel joint FE 1 t i 1 1! I ' J Swing cylinder Swing motor ‘Thooretcal dolvery: 2ad coltey Engine [sD72.2e Hygraute pamme /SBRG+6 Theoretical coivery: 6.4 + 8.4 ccirev Rated diicharge volume: 143+ 14.3 min (22,409 «pm) i Hydrautc tank Jolt amount: 18.3 2 20MFO6009 020M06020M08 * FOR MACHINE EQUIPPED WITH SWING-BOOM SWING SELECTOR PEDAL Pc10-6 Scapootconvolvane [Pe . ae W75kg/em* Bade cylinder teen ent _ a | sage | 7 ute eyinder ie | LL 2 "TT ae bere LY rho} Seepeynae Cantar int a U thd ve A wot i a | aefTh el bare Setoressure 2ichg/em™ Set pressure: 2Hokglom — SS ee 13 Set pressure: 175kg/em nen Ha Bisco hb | . \ soy 4 PATHE sme : athek se EBIglen a % M . 1E|C | a ‘Set pressure: [at ; sng weno 4A ce ‘Swing — boom swing]| ‘selector valve ‘Set pressure: yar Teoraeal devery: 85+0.5+6.4er/eay Rated fiw. 20.3¢203818.31/min (at 2,600 rpm) TTT F20MO6060A_ 10-25 @®* FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL pc10s ee a Wy Blade cylinder tls} a i iCal | a AAT TEX) iret -— a ++ al tas 7 oe | ae se LJ re Or 1 PASTE [Beigiens +1 oe ' i | ad mT Bot _] cana ste (Cg | * Lb apse omen — fiery "|, f 4 a . th ' ba ph 1 Bucket cylinder co ie re | Ae. 1 1 ae PL ' rt 1 | PARTITE, ro lorena: | | My ser renee: PAM EX 210 tae? | ‘Our Jot —— 9 ™ . & ‘Setpressure: 178 kglem? 7 L 2ave0! Mo tr = pene Eng 30752 | 5 M SEs svi can Lee Neds cclen pT EX To kaem* uy Ad LHL] RA kos | | M1 set] presure Ln as pd 138 lent pagel pmo t& * in) Raed dschogevolomer 21-221. 16 in ; a = FEES = 20NFO6011-1 ‘020M06020M06 C152 S-spool conuot vaio Pe = taint vate (71 Set pressure: 00kp/em* i ‘* FOR MACHINE EQUIPPED WITH SWING--BOOM SWING SELECTOR PEDAL = = tcc aT re] i= ' = = ep K Lower Set pressure: 3 BT 230Kg/em* ; Ir. eI Bucket cylinder ! i i + | ' a $1 pone ' es te 7 a 220.g/en" | . 7 4 a +o ate Le nama 7 = ke | er \ [2S] : ML ide rro4| (inet ' L_ | | fred | J at gt! rd td ee ¢ © 2 - 230kg/em? TI = "| | Ley I serene 11 et 230kq/em? t 4 i Iz | tedt be I i ‘Swing motor e2p00l contol vate MM Seen: tere onitone T eer ret | | yr ee : ' sera, | yy \ Hi ! Enaiea } | Ssh / \ sae TRS | | seers M | i ' ; tt | cod FE 1 Sang LL car - 1 Boom enting 0A Swing = boomenind 8 Ly one stg” 1 arte pa i : Rens com eerestee fo I Moeces S03 eI0 BES SU ms 600 rom) TAT ' 1 F20M06061A_ 10-27 ®‘* FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL PC15-2 convelveve pal . arn — | oe | 7 4 siesta swinging soon Gea AN | CaP] Lt 71 nee ene r | " | ec ET [eae | ASTER [Been \ a9 no fT Ea = cones 1 Ba) ! = | ie 4 it ' ' 1 ; Fomard Ir as Pins ” a El eigen Arm cylinder - _ a ongrol velve ovee[f come Pas apen! | Atte ot . Heal re | ES Swing motor t ‘a i Lana ‘Theoretical delivery: Ls set 1p 256 cclrev PETE U LH. RH. i ‘ ! ee SE ent My Tyga pump tS ep 8888 +bdcche iy —— al Repicieme Sores ais, - . : = in3ot0 od 20NFO6012-1 10-28 020M08020M06: HYDRAULIC TANK PCO5-6, PCO7-1 f it ¢ F20M06007 |. Hydraulic filter SPECIFICATIONS Hydraulic tank + Tank capacity : 26.52 Cover + Oilamount: 18.32 |. Strainer 9. Suction strainer Drain plug /. Sight gauge NOgeons 10-29 ®PC10-6, PC15-2 10-30 NOgeeNe ‘Sight gauge Hydraulic tank Cover Safety valve Hydraulic filter Suction strainer Drain plug SPECIFICATIONS + Safety valve 20NFO6013 1.05 £ 0.2 kg/em? 462 292 020M06.020M06. HYDRAULIC PUMP PCO5-6 Serial No. 11301 — 11700 Direction of revolution Exhaust 1. Drive gear 8. Drive gear 2, Bracket 9. Driven gear 3. Gear case 10. Coupling 4. Carrier 11. Driven gear 5. Bracket 12, Oil seal 6. Gear case 13, Snap ring 7. Cover _ 1B mou 10 20MF218 SPECIFICATIONS + Type: LARG6+6 + Theoretical delivery: 6.4 + 6.4 cc/rev. + Rated flow: 11.9 + 11.98/min, (at 2,000 rpm) 10-31 @HYDRAULIC PUMP PCOS5-6 Serial No, 11701 and up PCO7-1 |. Drive gear . Bracket . Gear case . Carrier Bracket . Gear case Cover 1 2. 3, 4. 5. 6. 7. 10-32 @ 8. Drive gear 9. Driven gear 10. Coupling 11, Driven gear 12, Oil seal 13, Snap ring 13 SPECIFICATIONS * Type: + Theoretical delivery: + Rated flow PCO5-6: PCO7-1: 10 F20MO06008-1 SBRE+6 6.4 + 6.4 cc/rev. 11.9 + 11.9.8/min, (at 2,000 rpm) 14.3 + 14.3 min, (at 2,400 rpm) 020M06020M08. 2. FLOW Exhaust %* FOR MACHINE EQUIPPED WITH FLOW INCREASING CIRCUIT INCREASING PUMP [A \ oO oO t ® nor << Intake O Q A 5 SectionA — A F20M06009 Bracket SPECIFICATIONS Side plate «Theoretical discharge: 7.9 cc/rev Drive gear «© Max. discharge pressure: 175 kg/cm? Cover Driven gear 10-33, ®PC10-6, PC15-2 3405 6 78 9 WoW WP Exhaust 20NFO6014. 1. Drive gear 11. Drive gear SPECIFICATIONS 2. Bracket 12. Cover SBRE+B+6 3. Gear case 13. Driven gear delivery: 8.5 + 8.5 +6.4 ce/rev. 4, Carrier 14, Coupling + Rated flow: 21 +21 + 16 L/min, 5. Bracket 15. Driven gear (at 2,000 rpm) 6. Gear case 16. Coupling 7. Drive gear 8 Carrier 9. Bracket 10. Gear case 10-34 @® 020M06* FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL 7-SPOOL CONTROL VALVE PCO5-6, PCO7-1 a. Az port (To swing—boom swing selector valve) b, As port (To arm cylinder bottom side) , As port (To L.H. travel motor B Port) d. As port (To blade cylinder bottom side) e, A3 port (To R.H. travel motor A port) f. Az, port (To bucket cylinder head side) g. Ai port (To boom cylinder bottom side} h. T port (To tank) i. Pr port (From hydraulic pump) 10-36 @ ie k. i. m. n °. P. qa. F20M06010 B1 port (To boom cylinder head side) Bz port (To bucket cylinder bottom side) Bs port (To R.H. travel motor B port) . Ba port (To blade cylinder head side) Bs port (To L.H. travel motor A port) Be port (To arm cylinder head side) B7 port (To swing—boom swing selector valve) PL port (From hydraulic pump) 020Mo6020M06 eNogsens * FOR MACHINE EQUIPPED WITH SWING- BOOM SWING SELECTOR PEDAL Section C —C Check valve spring . Check valve |. Main relief valve - Spool (Swing/Boom swing) . Spo! (Arm) |. Spool (LH. travel) . Center block . Spool (Blade) 1 Section D —D Section E—E F20M06011 |. Spool (R.H. travel) . Spool (Bucket) spool (Boom) . Main relief valve . Spool return spring . Safety-suction valve . Safety-suction valve 1. Safety-suction valve 10-37 @* FOR MACHINE WITHOUT SWING—BOOM SWING SELECTOR PEDAL 8-SPOOL CONTROL VALVE PLOS-6, PCO7-1 . () L 20MFO6010 @ As port (To boom swing cylinder bottom side) k. Bi port (To boom cylinder head side) b. Az port (To swing motor B port) 1. Bz port (To bucket cylinder bottom side) . As port (To arm cylinder bottom side) m, Ba port (To R.H. travel motor B port) d. As port (To L.H. travel motor B port) 1. Ba port (To blade cylinder head side) €. Aa port (To blade cylinder bottom side) ©. Bs port (To LH, travel motor A port) 4. As port (To R.H. travel motor A port) p. Bs port (To arm cylinder head side) 9. Az port (To bucket cylinder head side) q. B7 port (To swing motor A port) h. At port (To boom cylinder bottom side) r, Be port (To boom swing cylinder head side) i. T port (To tank) s. PL port (From hydraulic pump) J. Pr port (From hydraulic pump) 10-38 @ 020M06.020M06 * FOR MACHINE WITHOUT SWING~BOOM SWING SELECTOR PEDAL cae Section E - E Section FF 20MFO6011 1. Check valve 8. Spool (blade) 2. Check valve spring 9. Spool (R.H. travel) 3. Main relief valve 10. Spool (bucket) 4. Spool {boom swing) 11, Spool (boom) 5. Spool (swing) 12, Main relief valve 6. Spool (arm) 13. Spool return spring 7. Spool (L.H. travel) 14. Safety—suction valve 10-39* FOR MACHINE EQUIPPED WITH ADDITIONAL CIRCUIT 1-SPOOL CONTROL VALVE PCO5-6 Section - B b = os al re si _— : 73 Section - ¢ F20MO6012 .T port (To tank) . A port (To attachment) . B port (To attachment) |. P port (From hydraulic tank) Spool Spool return spring Safety-suction valve |. Check valve 5. Check valve spring . Safety-suction valve aege or pene 10-40 @ 020Mo08* FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL 5-SPOOL CONTROL VALVE PC10-6, PC15-2 As port (To arm cylinder head side) . Aa port (To L.H, travel motor A port) . Aa port (To R.H. travel motor A port) Az port (To bucket cylinder head side) Ai port (To boom cylinder bottom side) Pr port (Form hydraulic pump) . At port (To boom cylinder head side) exesaoge 10-42 @ he i, i k. 1 m. F20M06062 Az port (To bucket cylinder bottom side) As port (To R.H. travel motor B port) As port (To L.H, travel motor B port) As port (To arm cylinder bottom side) PL port (From hydraulic pump) To port (To tank) 020M06020M06 Pgrona * FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL «Check valve spring Check valve . Main relief valve Spool (Arm) . Spool (L.H. travel) . Spool (R.H. travel) F20M06063 Spool (Bucket) Spool (Boom) . Main relief valve 10. "1. 12. Spool return spring Safety—suction valve Safety valve 10-43 ®* FOR MACHINE WITHOUT SWING—BOOM SWING SELECTOR PEDAL 6-SPOOL CONTROL VALVE PC10-6, PC15.2 vere aoge ps e aN i As port (To arm cylinder heed side} As port (To L.H. travel motor A port) As port (To R.H. travel motor A port) Aa port (To bucket cylinder bottom side) Az port (To boom cylinder bottom side) Ai port (To boom swing cylinder head side) Pr port (From hydraulic pump) B1 port (To boom swing cylinder bottom side) epgrrrr 20NFO6O15 Bz port (To boom cylinder head side) Bs port (To bucket cylinder head side) Bs port (To R.H. travel motor B port) Bs port (To L.H. travel motor B port) Be port (To arm cylinder bottom side) PL port (From hydraulic pump) T port (To tank) 020m06020M06 * FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL Section D- D Check valve Check valve spring Main relief valve Spool (Arm) Spool (L.H. travel) Spool (R.H. travel) Spool (Bucket) Section A~A Section EE 10. i. 12 13. 14, 13 Section ¢ —¢ PE Section F — F Section G --G ‘20NFO6016 . Spool (Boom) Spool (Boom swing) Main relief valve Spool return spring Safety-suction valve Safety valve Suction valve 10-45, @2-SPOOL CONTROL VALVE PC10-6, PC15-2 Section B- B T port (To tank) Az port (To swing motor B port) At port (To blade cylinder bottom side) P port (From hydraulic pump} B1 port (To blade cylinder head side) 82 port (To swing motor A port) 10-46 @ NOSONS Section C—C ye Section D—D |. Spool (Swing) 2. Spool (Blade) . Main relief valve Spool return spring Safety-suction valve 1. Check valve 7. Check valve spring 20NFO6017 020M06020M06 + FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL. SWING—BOOM SWING SELECTOR VALVE pege oO} cc Oo oO Oo Oo B port (From swing/boom swing control valve) A port (From swing/boom swing control valve} D port (To boom swing cylinder head side) C port (To boom swing cylinder bottom side) F port (To swing motor A port) E port (To swing motor B port) SPN MF 2 4} O ; = oS 4 1 O 5 Section A — A F20M06013 Spool Detent spring Detent ball Body Cover 10-47SWING MOTOR PCOB-6, PCO7-1, PC10-6 Output shaft Flange Oil seal Roller bearing Main drive shaft Geroler star Valve drive shaft NOosene 10-48 10, M. 12, 13, 14, Disc valve Bolt Check valve Valve plate Geroler Geroler ring Flange mounting F20M05021 SPECIFICATIONS + Type PCOS. PCo7- 2-200D0HV-1E 2-250D0HV-1E 2-200CO4HV-E 195 co/rev 020M06020M06. PC152 z pr zl 16 at 4 3 12 iW 20NFO6O18 ‘Swing pinion 9. Cylinder SPECIFICATIONS Case (ring gear) 10, End cap + Type PC-100N-19-6-1027A, No.2 planetary 11. Valve plate + Theoretical delivery: 256 cc/rev carrier 12, Centerspring + Reduction ratio: 18.83 No.2 planetary gear 13, Swash plate No.1 planetary carrier. 14. Output shaft No.1 planetary gear 15, No.1 sun gear Hosing 16. No.2 sun gear PistonTRAVEL MOTOR PCO5-6, PCO7-1 1, MOTOR (WITH REDUCTION GEAR) 1 1 15 Cover No.2 plenetary gear No.1 planetary gear Ring gear Housing Piston Cylinder Valve plate PNOMaONn> 10-50 4 10. 1. 12, 13, 14, 15. 3 4 5 6 13 2 Brake valve Center spring Swash plate Output shaft No.1 sun gear No.2 planetary carrier No.2 sun gear 10 F20M06014 SPECIFICATIONS + Type PCO5-6: PH-100-25-0965A, PCO7-1: PH-100-25-0996A, + Theoretical delivery PCO5-6: 13.1 cc/rev PCO7-1: 15.4 cc/rev + Reduction ratio: 25.26 020Mo06020M06. 2, BRAKE VALVE F20M06016 Plug .. Spool return spring |. Check valve spring Check valve Spool gpene 10-51 @PC105, PC15-2 1, MOTOR (WITH REDUCTION GEAR) ly Cover No.2 planetary gear No.2 planetary carrier No.1 planetary gear No.1 planetary carrier Ring gear Housing Piston SN OTAaYNS 10-52 10. "1 12. 13, 14, 15, 16. i 4 Cylinder Brake valve Valve plate Center spring Swash plate Output shaft No.1 ring gear No.2 ring gear 13 2 W 10 20NFO6019 SPECIFICATIONS + Type: PH-200N-37-1019A + Theoretical delivery: 22.1 cc/rev + Reduction ratio: 36.51 020M06:020M06 2. BRAKE VALVE se ONe 20NF06020 Plug Spool return spring Check valve spring Check valve Spool 10-53 ®CENTER SWIVEL JOINT PCO5-6, PCO7-1 Shaft Back up ring Rotor O-ring Thrust washer Snap ring Flange NO MPYN> 10-54 A1.From L.H. travel control valve (A port) A2.To L.H. travel motor (A port) Bi. From R.H. travel control valve (B port) Bz. To R.H. travel motor (B port) C1. From L.H. travel control valve (C port) C2.To L.H. travel motor (C port) D1.From R.H. travel control valve (D port) 20MF221 D2.To R.H. travel motor (D port) E1. From blade control valve {E port) E2.To blade cylinder head side (E port) F1. From blade control valve (F port) F2.To blade cylinder bottom side (F port) G1. To hydraulic tank (G port) G2. From travel motor drain port (G port) 020M08020M06 PC106, PC15-2 PON O-ring Shaft Rotor Flange AL Ad. Br. Ba. C1. C2. From R.H. travel control velve {A port) To R.H. travel motor (A port) From L.H. travel control valve (B port) To LH. travel motor (B port) From R.H. travel control velve (C port) To R.H. travel motor (C port) Di. D2. E. Ee. Fa, Gi. G2. Section A — A 20NF2022 From L.H. travel control valve (D port) To L.H. travel motor (D port) From blade control valve (E port) To blade cylinder head side (E port) From blade control valve (F port) To blade cylinder bottom side (F port) To hydraulic tank (G port) From travel motor drain port (G port) 1 0-55 2HYDRAULIC CYLINDER 1. BOOM CYLINDER PCOS-6 \ el 2 \ oo F20M06017 1. Head side bushing 5. Rod packing 9. Piston 2. Bottom side bushing 6. Piston rod 10. Piston ring 3. Cylinder head 7. Cylinder 11. Wearing 4. Bushing 8. Plunger 12. Piston nut PCO7-1 F20MO6064 of g 020M06020M06. PC10-6 . Head side bushing . Cylinder head . Bushing |. Rod packing Pepe PC15-2 (WITH CANOPY) 5. Piston rod 9. 6. Cylinder 10. 7. Plunger 1. 8. Piston 12 F20M06065 Piston ring Wearing Piston nut Bottom side bushing WE F20M06066 10-57 22. ARM CYLINDER PCO5-6 1 2 F20M06018A 1, Head side bushing 5. Rod packing 9. Piston ring 2. Bottom side bushing 6. Piston rod 10. Wearing 3. Cylinder head 7. Cylinder 11, Piston nut 4, Bushing 8. Piston PCO7-1 F20M06067 10-58 co) 020Mo06.‘020M06 PC10-6 |. Head side tube . Bottom side tube Cylinder head |. Bushing PeNe PC152 9 Piston nut 5. Rod packing 6. Piston rod 7. Cylinder 1 8. Piston Db Oo WM / ° F20M06069 S}3. BUCKET CYLINDER PC05-6, PCO7-1 1 ‘er Pp aq 1 8 10 ! rh 1, Head side bushing 5. Rod packing 9. 2. Bottom side bushing 6. Piston rod 10. 3. Cylinder head 7. Cylinder iW. 4. Bushing 8. Piston PC10-6, PC15-2 10-60 @® F20M06019 Piston ring Wearing Piston nut F20M06070 020M06020M06. 4. BOOM SWING CYLINDER PCO5-6 Serial No. 11301 — 11700 1 1 2. 3. 4, F20M06020 . Head side bushing 5. Rod packing 9. Piston ring Bottom side bushing 6. Piston rod 10. Wearing it 7. Cylinder 11. Piston nut 8. Piston PCOS-6 Serial No. 11701 and up PCO7-1 1 ©) F20M06071 10-61 ©PC10-6, PC15-2 F20M06072 1, Head side tube 5. Rod packing 9. Piston ring 2. Bottom side tube 6. Piston rod 10. Wearing 3, Cylinder head 7. Cylinder 11, Piston nut 4. Bushing 8. Piston 8. BLADE CYLINDER PCO5-6, PCO7-1 | 2 T | y F20M06021 10-62 020M06020M06 PC10-6, PC15-2 1, Head side bushing 2. Bottom side bushing 3. Cylinder head 4, Bushing SPECIFICATIONS 5. Rod packing 6. Piston rod 7. Cylinder 8. Piston F20M06073 9. Piston ring 10. Wearing 11, Piston nut PCOS.6 (FOR MACHINE EQUIPPED WITH SWING-BOOM SWING SELECTOR PEDAL) Unit: ren Ovlinaer Boom Tam | ucket | Boom swing | elade ttem With canopy | With eab Piston rod oie dameey - 0 o | 20 Crliner inside diameter | 23, - 80 so |e 60 Piston stroke ee - a2 as | Que 60 Cylinder max ong wuz | - wore | nome | 88) 398 Cylinder min length &, - 708 oo | ar 333 Piston nut width across flat] 33, = 32 32 faa 2 {. }: 90° right boom swing specification. 10-63 @PCO5-6 (FOR MACHINE WITHOUT SWING—-BOOM SWING SELECTOR PEDAL) Unit: mm ame Boom Am Bucket | Boomswing | Blade trem With canopy | With cab Piston rod outside diameter 30 30 30 30 30 Cylinder inside diameter 50 50 50 50 50 60 Piston stroke 353 330.2 442 385 318 60 Cylinder max. length 988 9742] 1048 1,034 908 393 Cylinder min, length 635 635 706 649 590 333 Piston nut width across flat 32 32 32 32 32 32 Pco7-1 Unit: mm cael Boom Am Bucket | Boomswing | Blade ttem With canopy] With cab Piston rod outside diameter| 30 - 30 30 30 30 Cylinder inside diameter 60 - 55 50 50 60 Piston stroke 355 - 435 385 318 60 Cylinder max. length 982 - 441 1,034 808 393 Cylinder min, length 627 - 708 649 590 333 Piston nut width across flat 20 - 32 32 32 32 10-64 020M06.020M06 Pc10s Unit: mm ‘um Creer coe ane =“ Bucket | Boom swing | Blade Piston rod outside diameter] 35 38 40 25 35 35 Cylinder inside ciameter 70 70 10 60 70 70 Piston stroke 510 405, 475 480 520 195 Cylinder max. length 1,280 1,235 4.210 1.200 1,300 545, Cylinder min, length 770 770 735 70 780 410 Piston nut width across flat, 36 36 a 36 4 a Pc15.2 Unit: mm oe Boom ___ | arm Bucket | Boom swing | Blade Item With canopy [With cab Piston rod outside dismeter] 40 40 40 5 8 35 Cylinder inside diameter 70 70 70 60 70 70 Piston stroke 525 485, 478 480 520 1935 Cylinder max, length 1315 1.275 1.215 1.200 1,300 545 Cylinder min, length 790 790 740 720 780 410 Piston nut width across fat] 41 a 48 36 a “1 10-65 @020M06: & FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL, VALVE CONTROL PC05-6, PCO7-1 geene Blade control lever R.H. work equipment control lever R.H. travel control lever . LH, travel control lever L.H. work equipment control lever Sane F20M06022 . 7-Spool control valve Safety lock lever . Swing-boom swing selector valve |. Swing—boom swing selector pedal 10-67 @* FOR MACHINE EQUIPPED WITH SWING—ROOM SWING SELECTOR PEDAL AND ADDITIONAL CIRCUIT PCO5-6, PCO7-1 PO eONo 10-68 @ eqhitrovane RH torre 2 SN even { ieee y “nee | ; ie F20M06023 Blade control lever 7. Additional control pedal RH. work equipment control lever 8. 7-spool control lever RH, travel control lever 9. Safety lock lever LH, travel contro! lever 10. Swing—boom swing selector valve L.H. work equipment contro! lever 11. Swing—boom swing selector pedal 1-spool control valve 020Mo06‘020M06 * FOR MACHINE WITHOUT SWING-BOOM SWING SELECTOR PEDAL, PCOS-6, PCO7-1 PONS Bucket cum Boomrive = oom baer| Bucket ft wig Bide ie oe “saree 27 Seeing F20M06074 L.H. work equipment control lever 5. LH. travel contro! lever 6. Blade control fever 7. 8 Boom swing control lever R.H. travel control lever R.H. work equipment control lever . Safety lock lever 3. 8-spool control lever 10-69 @* FOR MACHINE EQUIPPED WITH SWING—BOOM SWING SELECTOR PEDAL PC10-6, PC15.2 Bucket dump <2 Boom raise Boom lower” / ‘Bucket cur Blade raise 1S LH sw nil roverse 9 5 ——T 10 9 8 F20M06075 1, LH. travel control lever 6. 2-spool control valve 2. R.H, travel contro! lever 7. Swing—boom swing control valve 3. R.H, work equipment control lever 8. Swing—boom swing control pedal 4. Blade control lever 9. 5.pool control valve 5. L.H. work equipment control lever 10. Safety lock lever 10-70 020M06020M06 * FOR MACHINE WITHOUT SWING BOOM SWING SELECTOR PEDAL PC10-6, PC15:2 geene LH. travel contro! lever . RH. travel control lever Boom swing control lever R.H. work equipment control lever |. Blade contro! lever Cerne F20M06076 LH. work equipment control lever . 2-spool control lever . spool control lever . Safety lock lever 10-71WORK EQUIPMENT PCO5-6, PC15-2 10-72 @® geen Bucket Bucket cylinder Arm Arm cylinder Boom Beene . Boom cylinder . Boom swing cylinder . Boom swing bracket . Blade cylinder . Blade F20M06024 020M08.PC10-6, PC15-2 90W0z0 20NFO6022 ‘Swing bracket Swing cylinder Blade cylinder Blade Bucket 6. 7. 8. 9. 10, SEESS3 caidivsELECTRICAL CIRCUIT DIAGRAM PCO5-6 Serial No. 11301 — 11700 Instrument pane! ae 23s Fuse box swe _ Starting switen 20a] 198, \ | | Horn awit Ba e Combination mp oko Ack aR 104, 208, 2 s alg] ala res as Satety ray Curent inter Heater signal lamp Service Lamp swith —S 5 Charging Inglestor 1 wg fe Ze a = omdaconsected) (Female connaetr STARTING SWITCH CONNECTING TABLE cr Gator | 8 | BR| R | Re] c | acc HEAT or 1 O oN 10-74 (Female connect Position of starting Key Switch OFF HEAT on stant ute raturn Fl 4 3 | Engine Alternator Stating motor Br io) Overaod warning unser selector ewitch Sa Battery avasan Water Oilpressure temperate ‘wlth te iow plug Hydrate pressure switch for ‘overland warning buzzer rol ) 208 F20M06025 020Mo08020Mo6 PCO5-6 Serial No. 11701 and up PCO7-1 Instrument penal _ . . (Femate connector) i —e, Engine Starting switch fad ce a S23 ae [Alternator | Combionation Heatersignal Servicemeter Lamp switch lamp tamp, Battory rch 12V43An Aas = bi 7 aa A gl ! 4 ! 38 [ Era za Water > eso] Oil pressure temperature Glow _ ose Sih” Sen "® Stow ptg | saawa f| ost 3| Te acid e Bea ut a [aw _J | 21s fee am fea L 1 i § Hom switeh Horn a an é ue mer urrent miter Charging Tine reat [Satety ry incator Working lamp ii (RF 3] at te" L (Female connector) (Female connector) Fest oy | ama male connector) : near OF om STARTING SWITCH CONNECTING TABLE Soe] B [eR] R | Re] c lace Stort HEAT oF | O i ON ie Auto retur START ‘oreturn F20M06077 Tuto return 10-75 ®PC10-6, PC15-2 Window washer (30) Wiper mator es ble, Room lamp ° I, 1? (Fema conecton) Service meter ese L258 aT ra a e ra om [h — =) crys “paren {1 6 eal Peele ‘(Female connector! fw Zee sur ae ee = q 1} 6/0 Obe Ti) ho fee Til (oo lh ify (Male connector) (Female connector) dsb Starting switch key poston ise oman cornet ere Heater switch 4 se 0000) bak 0" Working oesey be START a 432) a ‘nao reun Foor Starting motor ev Working Engine tome sp ‘Staring twitch connection tle Hom switeh 2 [er] m iydrotc pressure] ‘teh faa lev TOAn ° F20M06078 10-76 020M0620 TESTING AND ADJUSTING 020M06 Table of judgement standard value ..... 20- 2 Testing and adjusting tool list ......... 20-36 Adjusting valve clearance {PCO5-6, PCO7-1) .. Adjusting valve clearance {PC10-6, PC15-2) Measuring compression pressure (PCO5-6, PCO7-1) Measuring compression pressure (PC10-6, PC15-2) Testing and adjusting fuel injection timing (PCO5-6, PCO7-1) . Testing and adjusting fuel injection timing (PC10-6, PC15-2) ......++-44+ 20-43 Testing and adjusting hydraulic pressure (PCO5-6, PCO7-1) ........++ 20-44 Testing and adjusting hydrau pressure (PC10-6, PC15-2) . 20-45 20-1TABLE OF JUDGEMKENT STANDARD VALUE * FOR ENGINE Engine model 30722 Machine model P05-6 Standard | Permissible check item Conditions, ete Unit ae rales High idling rm | 2160260 | 2.150460 Engine speed Low iting tm | 900260 | 900260 Rated speed tm | 2,000%50 | 2.000250 Sudden acceleration Bosch index Exhaust gas color At high idling Bosch index| Valve clearance Intake valve (at 20°C) mm 0.20 = Exhaust valve (at 20°C) mm 0.20 = Oil temperature: 40 — 60°C, ; kg/em 30 Compression pressure | SAE3O oil w 36 ( ): Engine speed (rpm) (250) (250) by pressur Water temperature in operating range Blow-by pr e At high idling, SAE3O oil orld Woter temperature in operating range At high idling (SAE3O oil, Min. 80°C) kg/em? - _ Oil pressure At low idling (SAE3O oil, Min. 80°C) kg/cm? Min. 1.5 Min. 1.5 At high idling (SAE10W oil, Min. 80°C) | kg/cm® - _ At low idling (SAE10W oil, Min. 80°C) kg/cm? - - it temperature Whole speed range (inside oll pan) °c Max. 105 Fuel injection pressure | Nozzle tester kg/cm? 120 120—125 Fuel injection timing | Compression 8.7.0.C degree " an Slack when pushed with finger force Fan belt tension on mm 2 10-16 020M06020M06 3072-2 3075-2 ap78-1 Pco7-1 PC10-6 PCI15-2 Standard Permissible Standard Permissible Standard Permissible value value value value value value 2.570250 2,570:60 2,800::60 2,800%50 2,750%50 2,750:50 90050 900-50 90050 90050 90050 900450 2.400450 2,400+50 2,600 2,600 2,600 2,600 0.20 = 0.20 = 0.20 = 0.20 - 0.20 - 0.20 - 35 30 30 26 (250) (250) (250) (250) - - 35 30-40 35 30-40 Min, 1.5 Min. 1.5 Min. 1.0 Min. 1.0 = Min. 105 " - 16 - 16 S 12 10-16 10—~16 10-16* FOR CHASSIS Machine model Pc05-6 Serial No. 11301 — 11700 Standard | Permissible item Condition, ete. unit | Stenda risa Engine speed when | ¢ enn oeclaer semaine one pump circuit oil is in cocrect range 2.08050 2.08050 e | relief '* Engine oil pressure: 5 in correct range | pm & * Atone pump relief Engine speed when Bucket circuit reliot two pump circuit oil is] # Attwo pump relief: 2000880 | 2,000850 relief. Bucket and arm circuits reliet Boom control valve tialo fypalo Arm control valve Bucket control valve ___ | Swing — boom 1 2) CA | ea |h2od eae 3B |__ swing control valve | [Swing — boom : a J |__ swing selector valve mm @ | s Swing control valve ‘tr Boom swing control TPT PS valve Blade control valve 2}6}6]2\6le6 Travel control valve Neutral = Boom control lever ia 685 1775.4 3 | Arm contol ever Neutral = eas | 617-754 z In and out z Z| Bucket contro! ever eel 765 68.9842 5 eAtcenter of | Cutland dump § | ® Swing — boom lever knob ‘Neutral ~ g swing control lever_| © At tip of pedal LH. and P.H. swing 765 68.9 — 84,2 = * Measure at mm 3 | ® Swing — boom Swing — g |*S or pedal | endoftrave Suing 105 95-115 z swing selector pedal | , Endo wovel, : a 9 3 wing control lever | Stopped piri - - s iessesioy contol exe! PP LH. and P.H. swing| & [Boom swing control Neutral — _ _ EL tever LH. and RH, swing Neutrat— Blade control lever a 700 630—77.0 Note) %: For machine equipped with swing — boom swing selector pedal. +: For machine without swing — boom swing selector pedal 020M06PC05-6 Pco7-1 PCI0-6 11701 and up 10001 and up 10501 and up ‘Standard Permissible ‘Standard Permissible Standard Permissible value value value value value value 2,690 2,690 2,600 2,600 020M06 20] 6]}]6]2|6 |6]2|/6]|6)2}6)6]2]6|6}2/6}6 Max. 75 Max. 75 90 90 Mex. 80 Max. 80 98 105 Max. 70 Max. 70 90 Max. 80 Max. 80 70 N oo aEngine speed when | $ Qi semperature: 45 — 55°C & © At one pump relief: Boom control valve ! a b ! a b Bucket conta valve ® Swing — boom { A & ("suing conral valve 3 Newtre! 2ose73 & * Swing — boom | a Swing control valve ove C omroevey Raise and lower hed 3 [A aol In and out ou 2 a Neutral — z Bucket control lever One Curl and dump 95 § | * Swing — boom leverknob Neutral — E [Sting conel ver |» Atpcfindat Liana RH, swing ¢ Measure at mm = | ® Swing — boom Swing — g [_eumuscesorneds| Signe specs, om ang s swing contro! lever ‘Stopped leutral — 3 | * Swing controt LH. and R.H. swing] 108 z % Boom swing control Neutral — 90 Blade control lever Neutrals 70 Raise and lower Note) +: For machine equipped with swing — boom swing selector pedal. 4: For machine without swing — boom swing selector pedal 020M06020Mo06 Standard Permissible Standard Permissible Standard Permissible value value value value value value a t[alo a t[alo afo[t[alo nN 08 NMachine model P06. ‘Serial No. 11301 — 11700 Casa item Condition, ete unit | Standard” |” Permissibe * Atcenter of Neutral — Forward Teocteonoionr [Tartare 680 | 616-750 + Artipot peda S Measure at S100 mm} 145 [1305 —1885 Fuel control lever end of travel * '* Engine speed: Low idling — Sepped High ling Boom controltever | © Engine speed: High idling 15-28 | 1825 * Oiltemperature: 5 — 8c voltewer | © Hook pustrpul scala on ceca of = ~ oom oneal control lever knob to measure mae mae + Moaeure maximum value n Bucket control iever | * wees 14-24 | 14-20 | Sning— boom g swing contro! lever 14-24 14—24 3 Swing — boom 3 swing selector pedal 13.7— 184 13.7 —15.4 | # Swing cont lever - = § | i Boom ening cornet B | * lover - = £ | Blade control ever 13-23 13-23 8 Travel contol ever 15-25 | 18—25 Fue contol iever 25-35 | 25-36 Boom ereuit * Engine speed: High ing 175—180 | 178 — 180 2 Oiftemperature 45 — S880 —— 2 Pump relleved, other pump no an ae toad Bucket circuit 175—180 | 175—180 Boom swing crit e2—se | e2—ee Swing cruit e2—ee | e2—ee kas, 2 | Blade circuit em 175 — 180 175 — 180 3 2 | reave creuit 175—160 | 175—180 * Oiltemperature: a5 — 56°C * Dittrence ol reliet pressure Lowered hydraulic |" between at engine high ting and 5 pressure at engine a half speed. (Measure ° pressure when ove pur orout ol is relieved.) Note) 3: For machine equipped with swing — boom swing selector pedal. +: For machine without swing — boom swing selector pedal. 020M06020M06. P005-6 07. e108 11701 and up 10001 and up 10601 and up Standard] Permissible | Standard] Pommisssio | — Standard | Permisaie vale value wave vb value ‘alse ox. 75 Max. 76 eo 80 20 185 08-28 30 08-28 30 v2—25 | 12-28 08-28 30 os —25 30 ta—as | 12-28 08-28 30 08-28 30 12-28 | 12-28 oe—28 30 08-28 30 ta—as_ | 12-28 08-25 30 08-26 30 ta—as | 12-25 08-25 30 08-26 30 1a—as | 12-25 08-26 30 08-25 30 ta—as | 12-25 25-35 40 25-38 40 2548 | 2545 1st 17538 vst 17528 v7s"8 st st 17528 vet 17528 1758 et st 17848 ast 17528 1758 ast a 17525 vet 17628 1758 st ests e525 ast sis 1358 1358 1755 17825 vist 17888 175*8 758 1758 17528 ast 17525 175*8 vist max10 | Moxto | Maxt0 | Max 10 20-9 ®Machine model PoIs-2 Serial No. 10001 and up ae tem Condition, ete. Unit | Standard 5 © Atcenter of Neutral — Forward 8 fe) (ecco lever knob and reverse eo 38 * Attip of pedal = 332 # Measure at ong mm = Ss 3 Ep | Fuel control lever tend of travel E52 ‘Engine speed: Low idling — = Stopped High idling Boom control lever Engine speed: High idling 12-28 | 12-25 * Oil temperature: 45 — 55°C ea ‘© Hook push-pull scale on canter of pomeerene eeas 8 control lever knob to measure s Measure maximum value in > | Bucket control lever traveling 12-25 | 12-25 = | % Swing — boom 3 |__ swing control lever 3 [swing — boom B |__ swing selector pedal Z| & Swing contro! lever 12-25 | 12-25 3 | Boom swing contrat B | lever 12-28 | 12-25 Blade control lever 12-25 | 12-25 Travel control lever 12-25 | 12~25 Fuel control lever 25-45 | 25-45 Boom circuit ‘+ Engine speed: High idling 200*S 200°S Oil temperature: 45 — 55°C —— #1 pump relileved, other pump no 200°5 2008 load ° +5 +5 Bucket circuit 200*8, 200*§ e incu 5 +5 g | Boom swing circuit 200*S 200*S $ | swing circuit 138*8 i38*8 & kof, 3 | Blade circui om? +8 +8 3 | Blade circuit 178*8 178*5 E | travel circuit 2007S 200°S ° 0 * Oil temperature: 45 — 55°C * Difference oil relief pressure Lowered hydraulic between at engine high idling and at engine a half speed. (Measure o ° pressure pressure when one pump circuit oil is relieved.) Note) %: For machine equipped with swing — boom swing selector pedal. 3: For machine without swing — boom swing selector pedal. 20-10 ® ‘020Mo6.020M06 ‘Standard Permissible ‘Standard Permissible Standard Permissible value value value value value value 20-11Machine model PCOs-6 Serial No. 11301 — 11700 Classif. tem ‘cation Condition, ete. Unit Standard value Permissible value ‘Swing brake angle ‘© Measuring posture 20R5108 |oree ' Engine speed: High idlinig (mm) © Oil temperature: 45 ‘© Put match marks on the swing cir- BEPC cle outer race and the track frame. ‘Swing the upper structure 360°, then stop it. Measure the distance between the match marks after the upper structure comes toa stop. Max. 25 (Max. 109) Max. 25 (Max. 109) Time taken to start swing Swing © Measuring posture Engine speed: High idling * Oil temperature: 45 — 55°C ‘© Measure time taken for 90° 205108 Max. 2.4 Max. 2.7 sec. ‘and 180° swing from starting |180° point. Time taken to swing ‘© Measuring posture Engine speed: High idling Oil temperature: 45 — 55°C ‘© Measure time taken to swing for 5 ‘20RFS 108 sec, turns, after swinging one turn as ‘an approach swing, Max. 30 Max. 33 020M06020M06 Po0s-6 P07 rei0-6 11701 and up 10001 and up 10501 and up Standard] Permissible | Standard] Permissible | Stondord ] Permissible valve valve value value value valve Max. 20 30 20 80 D (Max. 105) Max. 24 Mox.2.7 Max 25 Mox.28 Max. 30 = = = = Max. 45 Maxaze | Mex3se | Mex337 | Maxs68 | Mex350 20-13Machine modal pcis.2 Serial No. 10001 and up Classif tem Condition, ete. Unit Standard value Permissible value Swing ‘Swing brake angle * Measuring posture Max. reach, * Engine speed: High idling Oil temperature: 45 — 55°C © Put match marks on the swing cir- cle outer race and the track frame. ‘Swing the upper structure 360°, then stop it. Measure the distance between the match marks after the Upper structure comes to a stop. Max. 25 (Max. 130) Time taken to start swing © Measuring posture so 90° ~ Max. reach oR 104 Max. 3.0 ‘© Engine speed: High idling il temperature: 45 — 55°C ‘© Measure time taken for 90° and 180° swing from starting point. 180°} Max. 4.5 Time taken to swing ® Measuring posture Max. reach 2oReSI04 * Engine speed: High idling Oil temperature: 45 — 55°C ‘* Measure time taken to swing for 5 turns, after swinging one turn as, an approach swing, Max. 35.0 020Mo8:020M08. Standard value Permissible value Standard vallue Permissible value ‘Standard value Permissible value 20-15 ®Machine mode! Pc0s-6 Serial No. 11301 — 11700 Classi. ‘cation hem Condition, ete. Unit ‘Standard value Permissible value Swing Hydraulic drift of swing © Measuring posture 20nF5105 * Engine speed: Stopped * Oil temperature: 45 — 55°C ** Stop the machine on 15° slope and ‘set boom at 45° angle across the slope. ‘* Write the mach marks on the swing circle outer race and track frame. After 15 minutes, measure the lag of match marks, degree’ (mm) Max. 90 Max. 90 Leakage from swing motor Engine speed: High idling © Oil temperature: 45 — 55°C «© Relieve oil in swing circuit 1/min| ‘Travel speed (1) * Measuring posture * Engine speed: High idling il temperature: 45 — 55°C * Raise one track off the ground, let it spin one revolution, then mea- Sure the time required for it to spi 5 revolutions. Repeat this proce- dure for the other track. Max. 28 Max. 30 Travel ‘Travel speed (2) ‘© Measuring posture 2ones107 * Engine speed: High idling * Oil temperature: 45 — 56°C © Ona flat surface, make an approache run of at least 10m, then measure the time required for the machine to travel 20 m, sec. Max. 39 Max. 41 20-16 020M06020M06 PCOs-6 Pco7-4 Pct0-6 11701 and up 10001 and up 10501 and up Standard Permissible ‘Standard Permissible ‘Stendard Permissible value value value value value value (Max. 180) (Max. 180) (Max. 180) (Max. 180) (Max. 180) Max. 28 Max. 35 Max. 28 Max. 35 3624 3628 Max. 37.6 Max. 43.7 Max. 37.6 Max. 43.7 374 3728 20-17 aMachine modet Pc16-2 Serial No, 10001 and up Classif. cation hem Condition, etc Unit Standard value Permissible value ‘Swing Hydraulic drift of swing © Measuring posture ‘* Engine speed: Stopped © Oil temperature: 45 — 65°C ‘© Stop the machine on 15° slope and set boom at 45° angle across the slope. © Write the mach marks on the swing circle outer race and track frame. After 15 minutes, measure the lag (of match marks. eegree’ (rum) (Max. 250) Leakage from ‘swing motor * Engine speed: High idling © Oil temperature: 45 — 55°C © Relieve oil in swing circuit t/min Travel speed (1) ‘© Measuring posture 20R#5 106 '* Engine speed: High idling * Oil temperature: 45 — 65°C ‘© Raise one track off the ground, let it spin one revolution, then mea- Sure the time required for it to spin 5 revolutions. Repeat this proce- dure for the other track. sec, 384 3848 Travel Travel speed (2) '* Measuring posture 20nF5107 * Engine speed: High idling * Oil temperature: 45 — 85°C * On a flat surface, make an approach run of at least 10m, then measure the time required for the machine to travel 20 m, sec 3744 3748 20-18 020Mo6.020M08 ‘Standard value Permissible value ‘Standard value Permissible value Standard vaule PermissibleMachine mode! PCOs-6 Serial No. 11301 — 11700 Classi —— nit | Standard | Permissible ‘ation ery ton ete eu value value ‘* Measuring posture — * Engine speed: High idling Oil temperature: 45 — 55°C © Ona fiat surface, make an approach run of at least 10 m,then | mm | Max. 500 Max. 550 travel another 20 m. Measure the travel deviation. Travel deviation 20m + Measure dimension f. '* Measuring posture Travel Hyrule ait 2onrs108 | mm | Max. 500 Max. 560 * Engine speed: Stopped © Oil temperature: 45 — 55°C ‘© Stop the machine on 30° slope with setting sprocket on uprill. ‘* Measure distance moved by machine in 5 min. ‘* Engine speed: High idling Oil temperature: 45 — 55°C © Relieve travel circuit. '* Measure leakage from travel motor with measuring cylinder. Leakage from travel motor |t/min. 20-20 ® 020M08:020M06 PCOs-6 Poort PcI0-6 11701 and up 10001 and up 10501 and up ‘Standard Permissible Standard Permissible Standard Permissible value value value value value value 500 550 500 550 Max. 500 Max. 550 Max. 100 8 esMachine model PC15-2 Serial No, 10001 and up Cassif me Condition, etc. Unit Standard Permissible value Travel deviation ® Measuring posture Engine speed: High idling * Oil temperature: 45 — 55°C © Ona flat surface, make an ‘approach run of at least 10m, then travel another 20 m. Measure the travel deviation. 20m ‘ Measure dimension t Max. 500 Max. 550 Hydraulic drift of travet ‘© Measuring posture 2065108 * Engine speed: Stopped © Oil temperature: 45 — 55°C * Stop the machine on 30° slope with setting sprocket on uphill. © Measure distance moved by ‘machine in § min, mm Max. 120 Leakage from travel motor ‘© Engine speed: High idling * Oil temperature: 45 — 55°C * Relieve travel circuit. © Measure leakage from travel motor ‘with measuring cylinder. lt/min. 020m06020Mo06 ‘Standard value Permissible value Standard value Permissible value ‘Standard value Permissible valuea Ss uaa tem Condition, et une | Standard | Permissibie g 22-26 22-26 SL Serfaty ngine speed: High idling | 19-23 | 19-23 z2 37-44 37-44 retracted “AO 8 | 5 ‘+ Engine speed: High idling 2 - - 3 icaenied) * Oil temperature: 45 — 55°C < aa 5 34—40 | 34—40 : 3 B | S| cylinder fully MN = |B | retractes = ye ae S aonesiny | & Cylinder fully 2 23-27 23-27 oyling ‘* Engine speed: High idling 3 pened * Oil temperature: 45 — 55°C ° Blade a we BF | osan | asus | CTT Is ytinder fully am | to-12 | 10-12 extended ‘* Engine speed: High idling 8 * Oil temperature: 45 — 55°C '® Measuring posture g Boom swing a "9 Post z g] | sscar | rear er aE 5 : < zorrsii3 | = ee 2] | seas | seas extended © Oil temperature: 45 — 55°C z 020Mo6020M06 PC05-6 Poort Pci0.6 19701 and up 10001 and up 10501 and up Saves | value | Swe | value | Swslve | value Max. 3.3 Max. 36 Max. 24 Max. 37 35205 3521.0 Max. 3.2 Max. 35 Max.29 Max. 32 27204 27208 Max. 45 Mex. 48 Mox. 45 Max. 4.8 51206 51812 Max. 3.2 Max. 35 Max. 35 Max. 38 39205 3921.0 Max. 39 Max. 42 Max. 34 Max. 37 38205 388.0 Max. 28 Max.3. Max. 24 Max.2.7 26204 26208 Mox.1.4 Max. 1.4 Max. 1.1 Max. 1.4 oss02 oatoa Max. 1.3 Mex. 1.6 Max. 1.3 Max. 1.6 09402 osz04 Max. 45 Max. 48 Max. 55 Max. 5.8 esi08 ese1.6 Max 5.1 Max. 5.4 Max. 6.7 Max 7.0 77409 77418 8 @% gMachine mode! pois-2 Serial No 10001 and up Classi tem Condition, ete Unit | Standard | Permissible boom * Measuring posture , a 35205 3.5410 Bucket teeth on nN z the ground | ——_ |. aowestoo | Cylinder fly | 6 Engine speed: High iting — | 8 2eso4 | 26408 '* Oil temperature: 45 — 55°C 2 wm * Measuring posture : = s1i06 | sista Cylinder fully e retracted | 5 zowsvio| © Cylinder fully * Engine speed: High idling = 3.720.5 3.741.0 itariaas) * Oil temperature: 45 — 55°C < # | ET oucun * Messuring posture 2 B/E 5 a7aos | 37410 = | 5] cwtinder tay \ s 2 | retracted =|? i sec 2\3} | sewn g * | yids: futy | 5 engine sped: High idling 3 26104 26208 extended * Oil temperature: 45 — 55°C ° © Measuring posture Blade y H oss02 | oetoa Blade on the ios round 4 Da! £ Cylinder fully 2oR5112| & 0940.2 0.9+04 & extended + Engine speed: High iding "| S * Oil temperature: 45 — 55°C © Measuring posture g Boom swing L 1g post = a 6.30.7 6.3414 Cylinder fly = retracted zi | g g cowsiia| cinder tuty | 6 engine speed: High iting | migoa | 71216 eateries * Oil temperature: 45 — 55°C = —L cS 20-26 020Mo06020M06 ‘Standard value Permissible value Standard value ermissible ‘Standard value | value Permissible value 38 ©8 NMachine mode! Pc0s-6 Serial No. 11301 — 11700 Ciasat Standard | Permissible Chaat Item Condition, ete unit | Stender aaa Entire work equip- | ° Measuring posture ment (Hydraulic drift at the tip of ee) ee oe bucket teeth) ~ Boom cylinder (Retraction of Max. 21 Max. 21 linger ae y 2ORFS114 € $ | Arm cylinder * Inthe posture shown above, mea- 8 | (Extension of sure the extension and retraction, | mm | Max. 24 Max. 24 2 | cylinder ‘of each cylinder as well as the & hydraulic drift at the tip of the = bucket teeth. + Work equipment rated loae: Bucket cylinder | © Flat level surface (Retraction of * Contra levers in neutral Max. 6 Max. 6 cylinder) + Engine: Stopped * Oil temperature: 45 — 55°C * Start measuring immediately after setting Blade (Hydraulic ‘* Measure the hydraulic drif: every 5 € drift at the tip of minutes, and make judgement Max. 12, Max. 12, 2 blade) atter 15 minutes, g * Measuring posture 3 aonesti6 8g * Engine speed: Low idling £ | Boom Oil temperature: 45 — 85°C sec. | Max.2.0 Max. 2.0 = * Measure the time it takes for the front of the machine to be ifted off the ground, starting from the time the Bucket contacts the ground, 20-28 020M06020M06 PCO5-6 Pco7-1 PC10-6 11701 and up 10001 and up 10501 and up Standard Permissible ‘Standard Permissible Standard Permissible value value value value value value Max. 175 360 Max. 175 360 Max. 400 2 42 24 42 Max. 20 Max. 22 24 48 24 48 Max. 15 Max. 17 6 12 6 12 Max. 10 Max. 11 Max. 5 Max. 6 ° Max.1 0 Max.1 Max. 5 Max. 5 20-29 D>Machine model Pcis.2 Serial No, 10001 and up Sassi item Condition ete. unit | Standard] Permissible Entire work equip: | ® Measuring posture ment (Hydrate drift at the tip of Max. 400 bucket teeth) Boom eylinder {Retraction of rowst14 Max. 25 Mox. 28 cylinder) 3 Arm cylinder | « inthe posture shown above, 5 | (Extension of ‘sure the extension and retraction mm Max. 15 Max. 17 3) cylinder of each eylinder as well asthe 3 hydraulic drift at the tip of the = bucket teeth. Work equipment rated toad Bucket ovinder | * Flat level surface eracion of | * Control levers in neutral Max. 10 Mox.11 cylinder) * Engine: Stopped * Oil temperature: 45 — 55°C * Start measuring immediately after setting «| | Blade Hydraulic | « Measure the hydraulic ih every 5 = | |dritattnetipot |” minutes, and make judgement Max. Max.6 z blade) ater 18 minutes i # Measuring posture 3 8 Engine speed: Low idling | Boom * Oiltemperature: 45 — 55°C sec. | Max. Max. 5 E # Measure the time it takes for the F front of the machine to be lifted off the ground, starting fom the time the Bucket contacts the ground. 20-30 020M06020M08 ‘Standard value Permissible value ‘Standard value Permissible value ‘Standard value Permissible value 20-31Machine modet PCO5-6 Serial No, 11301 — 11700 Classif Standard cation tem Condition, ete. Unit ae ‘© Measuring posture \ " Arm 20885117 Max. 2.0 Max. 2.0 * Engine speed: Low idling © Oil temperature: 45 — 55°C * Time required to momentarily stop the arm. ‘* Measuring posture Bucket 2onF6118 Max. 1.0 Max. 1.0 # Engine speed: Low idling © Oil temperature: 45 — 55°C Time required to momentarily stop the bucket, ‘Work equipment Time lag ‘© Measuring posture Blade 20RF5118 Max. 1.0 Max. 1.0 * Engine speed: Low idling © Oil temperature: 45 — 55°C ‘© Measure the time it takes for the rear of the machine to be lifted off the ground, starting from the time the blade contacts the ground. ach eylinder ee * Oil temperature: 45 — 55°C 5 co/ © Oil pressure: 175 kg/cm min ‘Swivel joint 020M06020M06 PCos-6 Pco7-1 PC10-6 11701 and up 10001 and up 10501 and up ‘Standard Permissible ‘Standard Pormissible Standard value value value value value ° Max.1 ° Max.1 Max. 5 Max. 5 ° Max. 1 ° Max. 1 Max. 4 Max. 4 ° Max.1 ° Max. 1 Max. 2 Max. 2 Max. 1.1 Max. 1.1 Max. 10 Max. 10 20-33 @am — cs | ans A = 2 | | sucker Max 4 Max. 4 $2 7ones118 gle 2 * Oil temperature: 45 — 55°C a cs | Fach cylinder * Oil temperature: 45 — 55°C Co i e3| © Oil pressure: 175 kg/cm? min. [==| Swivel joint Max. 10 Max. 10 20-34 ce 020M06020m06 ‘Standard value Permissible value ‘Standard value Permissible value ‘Standard value Permissible valueTESTING AND ADJUSTING TOOL LIST © FOR ENGINE No. Check item Too! Part No, Remarks 1 | enoine eed wurisacroneter | 7882084000 | oigtt ate §,€2— AOR 2. | Water and oi! amines) Thermistor kit 799-101-6000 | -50 — 1,200°C Anelog hydraulic 799-101-5000 | 25, 60,400, 600 kg/em? 3 | Oilpressure Digital hydraulic tester | 790-261-1100 | 500 kg/cm? Compression gauge | 796-502-1208 4 | compression pressure |* Ademter 0. 5 | 756-101-1860 | 0—70K9/en* * Adapter (3D78-1) 795-502-1530 8 | stow-by pressure | Blowsbychecker | 789-201-1508 | 0— 500mmii0 6 | Vove-teorance | Feeter gouge 020mm Handy smoke checker | 799-201-9000 | 5 :.-ctoration 0 — 70% 7 | Exhaust color With standard color Discoloration ‘Smoke meter Commercially | % x 1/10 = Bosch index) * FOR CHASISS No. Check item Too! Part No. Remarks 1 | Oil temperature Thermistor kit 799-101-6000 | -0 — 120°C Analog hydraulic, feoiee OI 799-101-5000 | 25, 60, 400, 600 kg/em* 2 | Oilpressure Digital hydraulic tester | 790-261-1100 | 500 kg/em* 3 | enoine pees Muisachonet | 788208-8000 | oii daley fy £2 — ADH. Commercially 4 | Operating force Push-pull scale ‘available - 5 | Stroke, hydraulic drift | Scale Commercially _ available 6 | Work equipment speed | Stopwatch Commercaty _ 5 | Pump performance | Flowmeter kit 790-303-1002 - 20-36 020M06:ADJUSTING VALVE CLEARANCE (PCO5-6, PC07-1) 1 Remove the cylinder head cover. Rotate the crankshaft in the normal direc- tion (clockwise as seen from the fan) and when No, 3 cylinder (flywheel end) is at compression top dead center, look through the hole in the flywheel housing, and align the line (TDC) on the outside of the fly- wheel with the position that can be seen. ‘* When the crankshaft is rotated, the intake and exhaust valves of the cylinder near the compression top dead center position do not move. If the intake and exhaust valves of No. 1 cylinder move, rotate further and set to the compression top dead center position. To adjust, loosen locknut (1), and turn ad: justment screw (2). Then insert specified feeler gauge A in clearance “c”” between the rocker arm and the valve stem and turn the adjustment screw until the clearance is a sliding fit. + To check, insert the feeler gauge between rocker arm (3) and valve stem (4) to check if the clearance (gauge thickness) is a sliding fit. Tighten the locknut to hold the adjustment serew in position, I Locknut: 2.6 £0.1 kgm * After tightening the locknut, check the valve clearance again. Rotate turn the crankshaft 240° each time, and use the same procedure to check and adjust the valve clearance of next cylinder according to the firing order. * Firing order: 3-1-2 20-38 078F201 020Mo06:020M06: ADJUSTING VALVE CLEARANCE (PC10-6, PC15-2) 4 Remove the cylinder head cover. Rotate the crankshaft in the normal direction (clockwise as seen from the fan) to align timing mark (a) with the top dead center (TDC) line (b) on the crankshaft pulley when No. 3 cylinder (at the flywheel end) is at compression top dead center. + When the crankshaft is rotated, the intake and exhaust valves of the cylinder near compression top dead center do not move. If the intake and exhaust valves of No. 3 cylinder move, rotate further to alilgn at the compression top dead center. To adjust, loosen locknut (1), and adjustment screw (2), insert feeler gauge A in clearance (C) between the rocker arm and the valve stem, and screw in adjustment screw (2) until the clearance is a sliding fit. % When checking, before loosening the locknut, insert feeler gauge between rocker arm (3) and valve stem (4), and check if itis a sliding fit. Tighten the locknut to hold the adjustment screw in position. =D Locknut 2.6+0.1 kgm % After tightening the locknut, check the clearance again. Turn the crankshaft 240° each time and check and adjust the valve clearance of the next cylinder in the firing order in the same way. x Firing order: 3 — —2 078F201 20-39MEASURING COMPRESSION PRESSURE (PCO5-6, PCO7-1) When measuring the compression pres- sure, be careful not to touch the exhaust manifold or muffler, or to get caught in the rotating parts. * Measure the compression pressure with the engine warmed up. (Oil temperature 40°C — 60°C) 1, Adjust the valve clearance, For details, see Adjusting valve clearance, 2. Disconnect the fuel injection pipe. 3. Remove the nozzle holder assembly (1) from each cylinder, * Be careful not to let or dust get inside. * If the nozzle holder assembly is removed, replace the seat gasket, 4, Install adapter A in the nozzle holder mount of the cylinder to be measured, and tighten to the specified tightening torque. SD Tightening torque: 5.2 + 0.2 kgm 5. Connect compression gauge A to the adapt- er. Place the fuel control lever at the NO INJECTION position, Crank the engine with the starting motor and measure the compression pressure at the point where the \dicator remains steady. AA If the fue! contro! lever is not placed at the NO INJECTION position, fue! will spurt out, * Leakage can be reduced if the adapter mount is coated with a small amount of oil, 20-40 oe 020M06.020M06 MEASURING COMPRESSION PRESSURE (PC10-6, PC15-2) A When measuring the compression pres- en sure, be careful not to touch the exhaust manifold or muffier, or to get caught in rotating parts. Measure the compression pressure with the ‘engine warmed up. (Oil temperature 40 — 60°C). . Adjust the valve clearance. %* For details, see ADJUSTING VALVE CLEARANCE. Disconnect fuel injection pipe. Remove nozzle holder assembly (1) from each cylinder. % Be careful no to let any dirt or dust get in, + If the nozzle holder assembly is removed, replace the seat gasket. Install the adapter in the nozzle holder mount of the cylinder to be measured. Connect the compression gauge to the adapter. Place the fuel control lever in the NO INJECTION position. Crank the engine with the starting motor and measure the com- poression pressure * Measure the compression pressure at the point where the pressure gauge indicator remains steady. Ay ithe fuet contro! lever is not placed in the NO INJECTION position, fuel will spurt out % Coat the adapter mount with a small amount of oil to make it more difficult for the pressure to leak out. 20-41 @TESTING AND ADJUSTING FUEL (PCO5-6, PCO7-1) 1. Disconnect the fuel injection pipe. Using crankshaft pulley mounting nut (1), rotate the crankshaft in the normal direction and stop the crankshaft at the point where the fuel level at the tip of the delivery valve holder starts to rise. When the fuel level at the tip of the deliv- ery valve holder starts to rise, check that the line (11° BTDC) on the outside of the fly- wheel is in the center of the peephole. If the injection timing is not correct, adjust the thickness of the shim (fuel injection timing adjustment plate) between the fuel injection pump and gear case. INCREASE shim thickness, to RE- TARD timing DECREASE shim thickness, to AD- VANCE timing * When adjusting, be careful of the follow- ing points, (1) The standard thickness of the shims used for adjusting the fuel injection timing is 0.5 mm. (2) The adjustment shims have a silicon coating, so use thinner to remove any oil on both faces of the shim or on the pump mounting surface. (3) A shim thickness of 0.1 mm changes the position by approx. 1°; the avail- able shim thicknesses are 0.2 mm and 0.3 mm. Adjustment shim, INJECTION TIMING P20M96003, ~ F20M06038 020M06020M06 TESTING AND ADJUSTING FUEL INJECTION TIMING (PC10-6, PC15-2) Disconnect fuel injection pipe (1). 2. Tobleedthe air, run the engine until no more bubbles come out from delivery valve holder (2). 3. Place the fuel control lever at the FULL position, and rotate the crankshaft slowly in the normal direction. Check the point where fuel starts flowing from the delivery valve holder, 4. Check that fuel injection timing line (b) on the crankshaft pulley and timing mark (a) are aligned at the point where the fuel starts flowing, BEYOND injection timing line: Timing RETARDED + BEFORE injection timing line: Timing ADVANCED Ifthe test shows that the fuel injection timing is not correct, adjust as follows. 1) Loosen the mounting nut of the fuel injection pump and adjust the mounting angle of the pump while watching timing lines (c) and (d) on the front plate. 2) Rotate the crankshaft slowly in the normal direction and adjust the mounting angle of the pump until fuel injection timing line {b) on the crankshaft pulley and timing mark (a) are alignerd correctly at the point where the fuel starts flowing. 3) Tighten the injection pump mounting nut. + Check the fuel injection timing again to confirm that the injection timing is correctly adjusted. 4) Make match marks. 20NFO8OS1 oree208