Komatsu PCMR 2, Pc30mr 2, Pc35mr 2, Pc40mr 2, Pc50mr 2 Shop Manual
Komatsu PCMR 2, Pc30mr 2, Pc35mr 2, Pc40mr 2, Pc50mr 2 Shop Manual
Komatsu PCMR 2, Pc30mr 2, Pc35mr 2, Pc40mr 2, Pc50mr 2 Shop Manual
• 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.
© 2007
All Rights Reserved 00-1
Printed in Japan 04-07(02) (11)
CONTENTS
No. of page
01 GENERAL ................................................................................................................01-1
90 OTHERS ....................................................................................................................90-1
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
! Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
! For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
! Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
PC35MR-2
Item Unit PC27MR-2 PC30MR-2 PC35MR-2
(High altitude spec.
S/No. 6736 and up )
Canopy specification 3,170 3,435 3,815
Operat- <2,980> <3,245> <3,655>
ing kg
weight 3,310 3,550 3,990 4,005
Cab specification <3,120> <3,360> <3,855> <3,845>
Bucket capacity m3 0.08 0.09 0.11
Komatsu Komatsu Komatsu Komatsu
Engine model — 3D82AE-5M 3D84E-5N 3D88E-5P S3D84E-5PBA
Diesel engine Diesel engine Diesel engine Diesel engine
Rated engine output kW{HP}/rpm 18.9 {25.3} 20.6 {27.6} 21.7 {29.1} 23.9 {32.5}
/ 2,600 / 2,500 / 2,400 / 2,400
A Overall length mm 4,320 4,630 4,850
B Overall height mm 2,530
C Overall width mm 1,550 1,740
D Shoe width mm 300
855 950
Tail Canopy specification <775> <870>
E swing mm
radius Cab specification 885 950
<885> <885>
F Overall length of track mm 1,950 2,105
Distance between tumbler cen-
G ters mm 1,485 1,650
5,160 5,325
Operat- Canopy specification <4,910> <5,075>
ing kg
weight Cab specification 5,245 5,410
<4,995> <5,160>
Bucket capacity m3 0.14 0.16
Komatsu
Engine model — 4D88E-5X
Diesel engine
PC35MR-2
Working range (mm) PC27MR-2 PC30MR-2 PC35MR-2
(High altitude spec.
S/No. 6736 and up )
A Max. digging radius 4,700 5,150 5,360 5,360
B Max. digging depth 2,650 2,910 3,170 3,170
C Max. digging height 4,500 4,950 5,010 5,010
D Max. vertical wall depth 2,185 2,475 2,720 2,720
E Max. dumping height 3,230 3,450 3,530 3,530
Swing radius of work equipment 1,910 2,010 2,080 2,080
F
<Values in ( ) are boom swing radii> (1,510) (1,510) (1,590) (1,590)
G Max. reach at ground level 4,550 5,060 5,225 5,225
H Blade lifting height 360 360 360 360
I Blade lowering depth 315 310 390 390
SPECIFICATIONS
PC27MR-2
Machine model
Canopy specification Cab specification
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specification are shown.)
a Values in < > are for the X-weightless specifications.
a Values in [ ] are for the X-weightless and steel shoe specification.
a Operating weight of machine with full tank of fuel and an 75kg operator (ISO 6016).
PC27MR-2
Machine model
Canopy specification Cab specification
Travel motor
Hydraulic
PC27MR-2
Machine model
Canopy specification Cab specification
Stroke mm 460
Hydraulic system
PC30MR-2
Machine model
Canopy specification Cab specification
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specification are shown.)
a Values in < > are for the X-weightless specifications.
a Values in [ ] are for the X-weightless and steel shoe specification.
a Operating weight of machine with full tank of fuel and an 75kg operator (ISO 6016).
PC30MR-2
Machine model
Canopy specification Cab specification
Travel motor
Hydraulic
PC30MR-2
Machine model
Canopy specification Cab specification
Stroke mm 490
Hydraulic system
PC35MR-2
Machine model
Canopy specification Cab specification
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specification are shown.)
a Values in < > are for the X-weightless specifications.
a Values in [ ] are for the X-weightless and steel shoe specification.
a Operating weight of machine with full tank of fuel and an 75kg operator (ISO 6016).
PC35MR-2
Machine model
Canopy specification Cab specification
Travel motor
Hydraulic
PC35MR-2
Machine model
Canopy specification Cab specification
Stroke mm 490
Hydraulic system
PC35MR-2
(High altitude spec.)
Machine model
Cab specification
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specification are shown.)
a Values in < > are for the X-weightless specifications.
a Values in [ ] are for the X-weightless and steel shoe specification.
a Operating weight of machine with full tank of fuel and an 75kg operator (ISO 6016).
PC35MR-2
(High altitude spec.)
Machine model
Cab specification
Travel motor
Hydraulic
PC35MR-2
(High altitude spec.)
Machine model
Cab specification
Stroke mm 490
Hydraulic system
PC40MR-2
Machine model
Canopy specification Cab specification
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specification are shown.)
a Values in < > are for the X-weightless specifications.
a Values in [ ] are for the X-weightless and steel shoe specification.
a Operating weight of machine with full tank of fuel and an 75kg operator (ISO 6016).
PC40MR-2
Machine model
Canopy specification Cab specification
Travel motor
Hydraulic
PC40MR-2
Machine model
Canopy specification Cab specification
Stroke mm 580
Hydraulic system
PC50MR-2
Machine model
Canopy specification Cab specification
a Values are common to all specifications, unless otherwise specified. (The values of the rubber shoe specification are shown.)
a Values in < > are for the X-weightless specifications.
a Values in [ ] are for the X-weightless and steel shoe specification.
a Operating weight of machine with full tank of fuel and an 75kg operator (ISO 6016).
PC50MR-2
Machine model
Canopy specification Cab specification
Travel motor
Hydraulic
PC50MR-2
Machine model
Canopy specification Cab specification
Stroke mm 580
Hydraulic system
WEIGHT TABLE
k This weight table is a guide for use when transporting or handing components.
Unit: kg
PC27MR-2
Machine model
Canopy Cab specification Canopy Cab specification
specification specification
Serial number 15001 – 17667 17668 and up
Engine assembly (without oil, water) 182 182 182 182
• Engine 135 135 135 135
• Engine mount 7 7 7 7
• PTO 10 10 10 10
• Hydraulic pump 30 30 30 30
Cooling assembly (excluding coolant and oil) 22 22 22 22
Battery 19 19 19 19
Revolving frame 311 311 311 311
Floor frame 125 — 125 —
Canopy assembly 118 — 84 —
Handrail 6 — 6 —
Operator's cab (with floor frame) — 356 — 356
Operator's seat 12 12 12 12
Fuel tank (without fuel) 5 5 5 5
Hydraulic tank (without hydraulic oil) 35 35 35 35
Control valve 36 36 36 36
Counterweight 300 300 300 300
X-weight (Additional counterweight) 190 190 190 190
Swing motor (with brake valve) 14 14 14 14
Swing machinery 19 19 19 19
Track frame assembly (without track shoe) 572 572 579 579
• Track frame 278 278 285 285
• Idler assembly 26 x 2 26 x 2 26 x 2 26 x 2
• Recoil spring assembly 14 x 2 14 x 2 14 x 2 14 x 2
• Carrier roller assembly 4x2 4x2 4x2 4x2
• Track roller assembly 6x8 6x8 6x8 6x8
• Travel motor (with reduction gear) 37 x 2 37 x 2 37 x 2 37 x 2
• Sprocket 10 x 2 10 x 2 10 x 2 10 x 2
• Swing circle 37 37 37 37
• Center swivel joint 9 9 9 9
Unit: kg
PC30MR-2 PC35MR-2
Unit: kg
PC35MR-2
PC40MR-2
(High altitude spec.)
Machine model
Cab specification Cab specification Canopy Cab specification
specification
Serial number 6736 – 9241 9242 and up 8001 – 11974
Engine assembly (without oil, water) 227 227 254 254
• Engine 179 179 205 205
• Engine mount 7 7 12 12
• PTO 10 10 8 8
• Hydraulic pump 31 31 29 29
Cooling assembly (excluding coolant and oil) 21 21 32 32
Battery 19 19 24 24
Revolving frame 384 384 561 561
Floor frame — — 125 —
Canopy assembly — — 127 —
Handrail — — 6 —
Operator's cab (with floor frame) 356 356 — 356
Operator's seat 12 12 12 12
Fuel tank (without fuel) 5 5 31 31
Hydraulic tank (without hydraulic oil) 35 35 35 35
Control valve 45 45 45 45
Counterweight 621 621 567 567
X-weight (Additional counterweight) 160 160 250 250
Swing motor (with brake valve) 14 14 15 15
Swing machinery 19 19 26 26
Track frame assembly (without track shoe) 705 608 950 950
• Track frame 403 396 539 539
• Idler assembly 26 x 2 26 x 2 46 x 2 46 x 2
• Recoil spring assembly 14 x 2 14 x 2 16 x 2 16 x 2
• Carrier roller assembly 4x2 4x2 3x2 3x2
• Track roller assembly 6x8 6x8 10 x 8 10 x 8
• Travel motor (with reduction gear) 37 x 2 37 x 2 50 x 2 50 x 2
• Sprocket 10 x 2 10 x 2 12 x 2 12 x 2
• Swing circle 37 37 59 59
• Center swivel joint 15 15 18 18
Unit: kg
PC40MR-2 PC50MR-2
Unit: kg
PC27MR-2
Machine model
Canopy Canopy
specification Cab specification specification Cab specification
Unit: kg
PC30MR-2 PC35MR-2
Unit: kg
PC35MR-2
PC40MR-2
(High altitude spec.)
Machine model
Canopy
Cab specification Cab specification specification Cab specification
Unit: kg
PC40MR-2 PC50MR-2
— — — — — —
242 x 2 242 x 2 242 x 2 242 x 2 242 x 2 242 x 2
— — — — — —
274 x 2 274 x 2 274 x 2 274 x 2 274 x 2 274 x 2
— — — — — —
285 x 2 285 x 2 285 x 2 285 x 2 285 x 2 285 x 2
101 101 101 101 101 101
160 160 169 169 169 169
70 70 84 84 84 84
28 28 28 28 28 28
105 105 121 121 121 121
216 216 216 216 216 216
41 41 41 41 41 41
36 36 40 40 40 40
25 25 29 29 29 29
35 35 39 39 39 39
31 31 31 31 31 31
SAE 30
PC30, 35MR:
Cooling system Coolant Add antifreeze 3.3
PC40, 50MR:
7.3
* 1 : ASTM D975 No.1
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs a high-
pressure fuel injection device to obtain good fuel con-
sumption and good exhaust gas characteristics. For
this reason, It requires high precision for the parts
and good lubrication.
If kerosene or other fuel with low lubricating ability is
used, there will be a big drop in durability.
REMARK
• When fuel sulphur content is less than 0.5%,
change oil in the oil pan according to the periodic
maintenance hours described in this manual.
Charge oil according to the following table if fuel
sulphur content is above 0.5%.
PTO .......................................................................................10- 2
COOLING SYSTEM ..............................................................10- 3
POWER TRAIN .....................................................................10- 5
SWING CIRCLE ....................................................................10- 7
SWING MACHINERY ............................................................10- 8
TRACK FRAME.....................................................................10- 12
IDLER CUSHION ..................................................................10- 13
IDLER .................................................................................... 10- 14
TRACK ROLLER ...................................................................10- 16
CARRIER ROLLER ...............................................................10- 18
SPROCKET...........................................................................10- 19
TRACK SHOE ....................................................................... 10- 20
HYDRAULIC COMPONENTS LAYOUT DRAWING..............10- 28
HYDRAULIC TANK ...............................................................10- 30
CENTER SWIVEL JOINT......................................................10- 33
TRAVEL MOTOR...................................................................10- 35
HYDRAULIC CYLINDER.......................................................10- 43
SOLENOID VALVE ................................................................ 10- 49
MULTI-CONTROL VALVE .....................................................10- 53
HYDRAULIC PUMP ..............................................................10- 54
CONTROL VALVE .................................................................10- 70
CLSS .....................................................................................10- 91
OPERATION FOR EACH FUNCTION AND VALVE..............10- 94
SWING MOTOR ....................................................................10-136
PPC VALVE ...........................................................................10-145
WORK EQUIPMENT .............................................................10-153
DIMENSIONS OF EACH PART OF WORK EQUIPMENT ....10-156
FLOOR .................................................................................10-165
AIR CONDITIONER .............................................................10-166
ENGINE CONTROL .............................................................10-167
ELECTRIC CONTROL SYSTEM ..........................................10-169
COMPONENT PARTS OF SYSTEM.....................................10-177
MONITOR SYSTEM ..............................................................10-178
MONITOR PANEL .................................................................10-179
SENSORS ............................................................................. 10-181
PTO
a This diagram shows PC27MR, 30MR, 35MR.
1. Boss
2. Spring pin
3. Rubber
4. Cover
5. Hydraulic pump
COOLING SYSTEM
PC27MR-2
SPECIFICATIONS
POWER TRAIN
PC27MR, 30MR-2
SWING CIRCLE
a This diagram shows PC27MR, 30MR, 35MR.
SWING MACHINERY
PC27MR, 30MR, 35MR-2
Unit: mm
PC40MR, 50MR-2
Unit: mm
TRACK FRAME
PC27MR-2
* 1 : PC30MR, 35MR-2
* 2 : PC40MR, 50MR-2
IDLER CUSHION
a The following figure shows the PC27MR, 30MR and 35MR with the rubber shoe specification.
Unit: mm
2. Rod SPECIFICATIONS
3. Cylinder
Grease G2-LI
4. Recoil spring
5. Rear support Amount of grease 120
6. Nut
7. Lubricator
IDLER
a This diagram shows PC27MR, 30MR, 35MR.
Unit: mm
TRACK ROLLER
a This diagram shows PC27MR, 30MR, 35MR.
Unit: mm
CARRIER ROLLER
a This diagram shows PC27MR, 30MR, 35MR.
Unit: mm
SPROCKET
a This diagram shows PC40MR, 50MR.
Unit: mm
TRACK SHOE
RUBBER SHOE
a This diagram shows PC40MR, 50MR.
Unit: mm
Unit: mm
ROAD LINER
PC27MR, 30MR, 35MR-2
(If equipped)
Unit: mm
14 Tightening torque of shoe bolt 130 – 145 Nm {13 – 14.5 kgm} Retighten
Unit: mm
PC40MR, 50MR-2
HYDRAULIC TANK
PC27MR, 30MR, 35MR-2
PC40MR, 50MR-2
Unit: mm
PC30MR, 35MR-2
Unit: mm
PC40MR, 50MR-2
Unit: mm
TRAVEL MOTOR
a This diagram shows PC40MR, 50MR.
SPECIFICATIONS
PC27MR-2 PC40MR-2
Model PC30MR-2 PC50MR-2
PC35MR-2
Hi 12.2 19.11
Theoretical delivery
(cm3/rev)
Lo 22.1 33.08
Hi 2,988 2,670
Rated speed (rpm)
Lo 1,650 1,540
Brake cracking pressure 2.0 0.76
(MPa {kg/cm2}) {20} {7.8}
Speed changing pressure 3.4 0.86 ± 0.1
(MPa {kg/cm2}) {35} {8.8 ± 1}
OUTLINE
• Swash plate (1) has two rear faces x and y, and
ball is supported by the ball (2).
• The travel speed is switched by pressurized oil
from control chamber a acting on control piston
(3). This switches the angle of swash plate (1)
between the maximum angle and minimum
angle to determine the travel speed.
OPERATION OF MOTOR
At low speed (When motor swash plate angle is at maximum)
a This diagram shows PC40MR, 50MR.
Automatic change of travel speed from low speed (Low) to high speed (High)
HYDRAULIC CYLINDER
BOOM CYLINDER
a This diagram shows PC40MR, 50MR.
ARM CYLINDER
a This diagram shows PC40MR.
BUCKET CYLINDER
a This diagram shows PC40MR.
BLADE CYLINDER
a This diagram shows PC40MR, 50MR.
PC27MR-2
Unit: mm
Tightening torque
4 Bucket 569 ± 57.0 Nm {58 ± 5.8 kgm}
of cylinder head
Arm 912 ± 91.0 Nm {93 ± 9.3 kgm} (Width across flats: 46 mm)
Tightening torque
5 Bucket 412 ± 41.0 Nm {42 ± 4.2 kgm} (Width across flats: 36 mm)
of cylinder piston
Boom swing 647 ± 64.5 Nm {66 ± 6.6 kgm} (Width across flats: 41 mm)
Blade 1.08 ± 0.11 kNm {110 ± 11.0 kgm} (Width across flats: 50 mm)
PC30MR-2
Unit: mm
Tightening torque
4 Bucket 677 ± 67.5 Nm {69 ± 6.9 kgm}
of cylinder head
Arm 912 ± 91.0 Nm {93 ± 9.3 kgm} (Width across flats: 46 mm)
Tightening torque
5 Bucket 785 ± 78.5 Nm {80 ± 8.0 kgm} (Width across flats: 46 mm)
of cylinder piston
Boom swing 647 ± 64.5 Nm {66 ± 6.6 kgm} (Width across flats: 41 mm)
Blade 1.08 ± 0.11 kNm {110 ± 11.0 kgm} (Width across flats: 50 mm)
PC35MR-2
Unit: mm
Tightening torque
4 Bucket 677 ± 67.5 Nm {69 ± 6.9 kgm}
of cylinder head
Arm 1.25 ± 0.13 kNm {127 ± 12.7 kgm} (Width across flats: 50 mm)
Tightening torque
5 Bucket 785 ± 78.5 Nm {80 ± 8.0 kgm} (Width across flats: 46 mm)
of cylinder piston
Boom swing 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (Width across flats: 55 mm)
Blade 1.08 ± 0.11 kNm {110 ± 11.0 kgm} (Width across flats: 50 mm)
PC40MR-2
Unit: mm
Tightening torque
4 Bucket 785 ± 78.5 Nm {80 ± 8.0 kgm}
of cylinder head
Arm 1.67 ± 0.17 kNm {170 ± 17.0 kgm} (Width across flats: 55 mm)
Tightening torque
5 Bucket 1.08 ± 0.11 kNm {110 ± 11.0 kgm} (Width across flats: 50 mm)
of cylinder piston
Boom swing 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (Width across flats: 55 mm)
Blade 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (Width across flats: 55 mm)
PC50MR-2
Unit: mm
Tightening torque
4 Bucket 863 ± 86.5 Nm {88 ± 8.8 kgm}
of cylinder head
Arm 1.67 ± 0.17 kNm {170 ± 17.0 kgm} (Width across flats: 55 mm)
Tightening torque
5 Bucket 1.08 ± 0.11 kNm {110 ± 11.0 kgm} (Width across flats: 50 mm)
of cylinder piston
Boom swing 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (Width across flats: 55 mm)
Blade 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (Width across flats: 55 mm)
SOLENOID VALVE
PC27MR, 30MR-2
A: To PPC valve
B: To 2nd travel speed selector valve
P: From hydraulic pump
T: To hydraulic tank
Solenoid valve
3. Coil (ON/OFF type)
4. Push pin
5. Valve spool
6. Return spring
7. Valve body
A: To PPC valve
B: To 2nd travel speed selector valve
P: From hydraulic pump
T: To hydraulic tank
MULTI-CONTROL VALVE
Operation pattern selection drawing (The port names correspond to the symbols in the drawing).
HYDRAULIC PUMP
PC27MR, 30MR-2
Type: LPV30 + SBR8.5
MAIN PUMP
FUNCTION STRUCTURE
• The engine rotation and torque transmitted to the • Cylinder block (7) is supported to shaft (1) by
pump shaft is converted into hydraulic energy, spline a, and shaft (1) is supported by the front
and pressurized oil is discharged according the and rear bearings.
load. • The tip of piston (6) is a concave ball, and shoe
• It is possible to change the delivery amount by (5) is caulked to it to form one unit. Piston (6) and
changing the swash angle. shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface A. Shoe (5) is
kept pressed against the flat surface A and it
slides circularly on flat surface A. Rocker cam
(4) slides around ball (11).
• Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
• Cylinder block (7) seals the pressure oil to valve
plate (8) and carries out relative rotation. This
surface is designed so that the oil pressure bal-
ance is maintained at a suitable level. The oil
inside each cylinder chamber of cylinder block
(7) is sucked in and discharged through valve
plate (8).
• Hole number of cylinder block (7) is an odd num-
ber. So, it is suited to groove of valve plate (8).
VALVE ASSEMBLY
T : Drain 1. Locknut
GH : Gear pump HI signal (a2) 2. Plug
GL : Gear pump LO signal (b2) 3. Spring
P1 : Pump signal pressure 4. Spool
PE : Control piston pressure 5. Sleeve
PH : Pump shuttle pressure (Pump pressure) 6. Piston
P1L : Pump pressure input 7. Seat
PLS : LS pressure input 8. Plug
PAVE : Pump average pressure (Pump pressure) 9. Lever
10. Spool
11. PC valve
12. LS valve
FUNCTION 2. PC valve
1. LS valve • When pump discharge pressure P1/PAVE rises,
• The LS valve controls the discharge of the pump the stroke of the control valve spool is increased
according to the stroke of the control lever, or the and the opening area is increased and pump dis-
demand flow for the actuator. charge Q is increased. At this time, the PC valve
• The LS valve calculates the demand flow for the limits pump discharge Q according to discharge
actuator from differential pressure PLS pressure P1/PAVE so that the pump absorption
between pump discharge pressure P1L and con- horsepower will not exceed the engine horse-
trol valve outlet pressure PLS, and controls power. In other words, the PC valve performs
pump discharge Q. approximate constant-horsepower control.
(P1L is called the pump discharge pressure, • That is, if the load on the actuator is increased
PLS called the LS pressure, and PLS called and pump discharge pressure P1/PAVE rises
the LS differential pressure.) during operation, the PC valve reduces pump
• That is, the pump discharge is controlled accord- discharge Q. If the pump discharge pressure
ing to the demand flow for the actuator by the fol- lowers, the PC valve increases pump discharge
lowing method; The pressure loss made when Q.
the oil flows through the opening of the control • The relationship between pump discharge pres-
sure P1/PAVE and pump discharge Q is shown
valve spool (LS differential pressure PLS) is
below.
sensed and pump discharge Q is so controlled
• When the machine swings, since the swing
that the pressure loss will be constant.
pump and main pump are installed tandem, the
torque absorbed in the main pump is lowered by
the part absorbed in the swing pump.
• When the swing pump operates, the total of the
main pump absorption torque and swing pump
absorption torque is the total absorption torque
(100%)
PC35MR-2
Type: LPD25 + 25 + SBR8.5 + 5
MAIN PUMP
PC40MR, 50MR-2
Type: LPD25 + 25 + DNP21 – 14.1 + 5.2
MAIN PUMP
PC40MR, 50MR-2
Type: LPD25 + 25 + DNP21 – 14.1 + 5.2
FUNCTION STRUCTURE
• The engine rotation and torque transmitted to the • Cylinder block (7) is supported to shaft (1) by
pump shaft is converted into hydraulic energy, spline a, and shaft (1) is supported by the front
and pressurized oil is discharged according the and rear bearings.
load. • The tip of piston (6) is a concave ball, and shoe
• It is possible to change the delivery amount by (5) is caulked to it to form one unit. Piston (6) and
changing the swash angle. shoe (5) form a spherical bearing.
• It have two discharge port and it enable to supply • Rocker cam (4) has flat surface A. Shoe (5) is
the pressure individually in every one. kept pressed against the flat surface A and it
slides circularly on flat surface A. Rocker cam
(4) slides around ball (11).
• Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
• Cylinder block (7) seals the pressure oil to valve
plate (8) and carries out relative rotation. This
surface is designed so that the oil pressure bal-
ance is maintained at a suitable level.
• The oil inside each cylinder chamber of cylinder
block (7) is sucked in and discharged through
valve plate (8).
Hole number of cylinder block (7) is an even
number. So, it is suited to two groove by valve
plate (8) alternately.
VALVE ASSEMBLY
T : Drain 1. Locknut
GH : Gear pump HI signal (a2) 2. Plug
GL : Gear pump LO signal (b2) 3. Spring
P1 : Pump signal pressure 4. Spool
PE : Control piston pressure 5. Sleeve
PH : Pump shuttle pressure (Pump pressure) 6. Piston
P1L : Pump pressure input 7. Seat
PLS : LS pressure input 8. Plug
PAVE : Pump average pressure (Pump pressure) 9. Lever
10. Spool
11. PC valve
12. LS valve
PC40MR, 50MR-2
• The LS valve controls the pump discharge
according to the stroke of the control lever, or the
flow rate required by the actuator.
• This valve determines the flow rate required by
the actuator from differential pressure PLS
between main pump discharge pressure P1L
and control valve outlet pressure PLS, then con-
trols main pump discharge Q.
(P1L is called the pump pressure, PLS LS pres-
sure, and PLS LS differential pressure.)
• To put it concretely, the LS valve senses the
pressure loss (= LS differential pressure PLS)
caused by the flow of oil from the pump through
2. PC valve
• When pump discharge pressure P1/PAVE rises,
the stroke of the control valve spool is increased
and the opening area is increased and pump dis-
charge Q is increased. At this time, the PC valve
limits pump discharge Q according to discharge
pressure P1/PAVE so that the pump absorption
horsepower will not exceed the engine horse-
power. In other words, the PC valve performs
approximate constant-horsepower control.
• That is, if the load on the actuator is increased
and pump discharge pressure P1/PAVE rises
during operation, the PC valve reduces pump
discharge Q. If the pump discharge pressure
lowers, the PC valve increases pump discharge
Q.
• The relationship between pump discharge pres-
sure P1/PAVE and pump discharge Q is shown
below.
• When the machine swings, since the swing
pump and main pump are installed tandem, the
torque absorbed in the main pump is lowered by
the part absorbed in the swing pump.
• When the swing pump operates, the total of the
main pump absorption torque and swing pump
absorption torque is the total absorption torque
(100%)
CONTROL VALVE
a The control valve is an add-on type where one
service valve each can be added, so it is possi-
ble to add valves or remove valves if necessary.
a The service valve is installed additionally between
the top cover and lower valve.
a As for the 9-spool valve, only the parts different
from the 8-spool valve are shown.
PC27MR-2
C : To oil cooler
T : To tank
A1 : To R.H. travel motor
A2 : To L.H. travel motor
A3 : To boom cylinder head
A4 : To arm cylinder head
A5 : To bucket cylinder head
A6 : To boom swing cylinder head
A7 : To blade cylinder head
A8 : To swing motor MA port
B1 : To R.H. travel motor
B2 : To L.H. travel motor
B3 : To boom cylinder bottom
B4 : To arm cylinder bottom
B5 : To bucket cylinder bottom
B6 : To boom swing cylinder bottom
B7 : To blade cylinder bottom
B8 : To swing motor MB port
LS : To pump LS valve
P1 : From main pump to variable pump
P2 : From main pump to gear pump
S1 : To swing motor S port
PA1: From R.H. travel FORWARD PPC valve
PA2: From L.H. travel FORWARD PPC valve
PA3: From boom LOWER PPC valve
PA4: From arm OUT PPC valve
PA5: From bucket DUMP PPC valve
PA6: From boom swing R.H. PPC valve
PA7: From blade RAISE PPC valve
PA8: From swing L.H. PPC valve
PB1: From R.H. travel REVERSE PPC valve
PB2: From L.H. travel REVERSE PPC valve
PB3: From boom RAISE PPC valve
PB4: From arm IN PPC valve
PB5: From bucket CURL PPC valve
PB6: From boom swing L.H. PPC valve
PB7: From blade LOWER PPC valve
PB8: From swing R.H. PPC valve
PP : To pump LS valve
PPPC : To solenoid valve P port
PS : To swing motor BR port
TS : To tank
1. 8 spool valve
(1/5)
(2/5)
Unit: mm
(3/5)
Unit: mm
(4/5)
Unit: mm
(5/5)
Unit: mm
2. 9 spool valve
Unit: mm
PC30MR-2
C : To oil cooler
T : To tank
A1 : To R.H. travel motor
A2 : To L.H. travel motor
A3 : To boom cylinder head
A4 : To arm cylinder head
A5 : To bucket cylinder head
A6 : To boom swing cylinder head
A7 : To blade cylinder head
A8 : To swing motor MA port
B1 : To R.H. travel motor
B2 : To L.H. travel motor
B3 : To boom cylinder bottom
B4 : To arm cylinder bottom
B5 : To bucket cylinder bottom
B6 : To boom swing cylinder bottom
B7 : To blade cylinder bottom
B8 : To swing motor MB port
LS : To pump LS valve
P1 : From main pump to variable pump
P2 : From main pump to gear pump
S1 : To swing motor S port
PA1: From R.H. travel FORWARD PPC valve
PA2: From L.H. travel FORWARD PPC valve
PA3: From boom LOWER PPC valve
PA4: From arm OUT PPC valve
PA5: From bucket DUMP PPC valve
PA6: From boom swing R.H. PPC valve
PA7: From blade RAISE PPC valve
PA8: From swing L.H. PPC valve
PB1: From R.H. travel REVERSE PPC valve
PB2: From L.H. travel REVERSE PPC valve
PB3: From boom RAISE PPC valve
PB4: From arm IN PPC valve
PB5: From bucket CURL PPC valve
PB6: From boom swing L.H. PPC valve
PB7: From blade LOWER PPC valve
PB8: From swing R.H. PPC valve
PP : To pump LS valve
PPPC : To solenoid valve P port
PS : To swing motor BR port
TS : To tank
1. 8 spool valve
(1/5)
(2/5)
1. Safety valve
2. Suction valve (boom bottom)
3. Suction valve (arm bottom)
4. Suction valve (bucket bottom)
5. Suction valve (blade bottom)
6. Suction valve (boom swing head)
7. Suction valve (bucket head)
8. Suction valve (boom head)
9. Spool (swing)
10. Spool (blade)
11. Spool (boom swing)
12. Spool (bucket)
13. Spool (arm)
14. Spool (boom)
15. Spool (L.H. travel)
16. Spool (R.H. travel)
17. Main relief valve
Unit: mm
(3/5)
Unit: mm
(4/5)
Unit: mm
(5/5)
Unit: mm
2. 9 spool valve
Unit: mm
1. 8 spool valve
(1/6)
(2/6)
Unit: mm
(3/6)
Unit: mm
(4/6)
Unit: mm
(5/6)
(6/6)
1. Spool (Swing)
2. Swing relief valve (For gear pump)
3. Safety valve
4. Pressure relief plug
2. 9 spool valve
Unit: mm
CLSS
OUTLINE OF CLSS
FEATURES STRUCTURE
CLSS stands for Closed center Load Sensing Sys- • The CLSS consists of a variable capacity single
tem, and has the following featues. piston pump, control valve, and actuators.
• Fine control not influenced by load • The pump body consists of the main pump, PC
• Control enabling digging even with fine control valve and LS valve.
• Ease of compound operation ensured by flow
divider function using area of opening of spoll
during compund operations
• Energy saving using variable pump control
1. Unload valve
Set pressure : LS pressure + 3.4 MPa
{35.0 kg/cm2}
2. Main relief valve
Set pressure : 24.5 MPa {250 kg/cm2}
3. Self pressure reducing valve
4. Pilot relief valve
Set pressure : 2.90 MPa {30.0 kg/cm2}
5. Self pressure sequence valve
Set pressure :
2.90 to 3.40 MPa {30.0 to 35.0 kg/cm2}
6. Pressure compensation valve
7. Safety valve
Set pressure : 27.9 MPa {285 kg/cm2}
8. Suction valve
9. Pilot pressure check valve
10. Check valve
11. Back pressure check valve
Set pressure : 0.34 MPa {3.5 kg/cm2}
12. Swing relief valve
(for gear pump)
Set pressure : 21.1 MPa {215 kg/cm2}
2. 9 spool valve
PC30MR-2
1. 8 Spool valve
1. Unload valve
Set pressure : LS pressure + 3.70 MPa
{38.0 kg/cm2}
2. Safety valve
Set pressure : 27.9 MPa {285 kg/cm2}
3. Main relief valve
Set pressure : 26.0 MPa {265 kg/cm2}
4. Self pressure reducing valve
5. Pilot relief valve
Set pressure : 2.90 MPa {30.0 kg/cm2}
6. Self pressure sequence valve
Set pressure :
2.90 to 3.40 MPa {30.0 to 35.0 kg/cm2}
7. Pressure compensation valve
8. Suction valve
9. Oil cooler bypass valve
Set pressure : 0.40 MPa {4.0 kg/cm2}
10. Pilot pressure check valve
11. Check valve
12. Back pressure check valve
Set pressure : 0.34 MPa {3.5 kg/cm2}
13. Swing relief valve
(for gear pump)
Set pressure : 21.1 MPa {215 kg/cm2}
2. 9 spool valve
PC35MR-2
1. 8 spool valve
1. Unload valve
Set pressure :
LS pressure + 2.45 MPa {25.0 kg/cm2}
2. Safety valve
Set pressure : 28.0 MPa {285 kg/cm2}
3. Main relief valve
Set pressure : 26.0 MPa {265 kg/cm2}
4. Merge-divider valve
5. Logic valve
6. Pressure compensation valve
7. Suction valve
8. Pilot pressure check valve
9. Check valve
10. Back pressure check valve
Set pressure : 0.34 MPa {3.5 kg/cm2}
11. Oil cooler bypass valve
Set pressure : 0.39 MPa {4.0 kg/cm2}
12. Swing relief valve
(for gear pump)
Set pressure : 21.6 MPa {220 kg/cm2}
13. Boom lock valve
2. 9 spool valve
PC40MR, 50MR-2
1. 8 spool valve
1. Unload valve
Set pressure :
LS pressure + 2.45 MPa {25.0 kg/cm2}
2. Safety valve
Set pressure : 28.0 MPa {285 kg/cm2}
3. Main relief valve
Set pressure : 26.0 MPa {265 kg/cm2}
4. Merge-divider valve
5. Logic valve
6. Pressure compensation valve
7. Suction valve
8. Pilot pressure check valve
9. Check valve
10. Back pressure check valve
Set pressure : 0.34 MPa {3.5 kg/cm2}
11. Oil cooler bypass valve
Set pressure : 0.39 MPa {4.0 kg/cm2}
12. Swing relief valve
(for gear pump)
Set pressure : 21.6 MPa {220 kg/cm2}
13. Boom lock valve
2. 9 spool valve
UNLOAD VALVE
PC27MR, 30MR-2
1. When control valve is at neutral
1. Spool
2. Spring
FUNCTION
• When the control valve is at neutral, pump dis-
charge amount Q discharged by the minimum
swash plate angle is released to the tank circuit.
When this happens, pump discharge pressure
PP is set at 3.43 MPa {35 kg/cm2} by spring (2)
inside the valve. (LS pressure PLS : 0 MPa {0
kg/cm2}.
OPERATION
• Pump discharge pressure PP is acting on the left
end of spool, and LS pressure PLS is acting on
the right end.
• When the control valve is at neutral, LS pressure
PLS is 0, so only pump discharge pressure PP
has any effect, and PP is set only by the load of
spring (2).
• As pump discharge pressure PP rises and
reaches the load of spring (2) (3.43 MPa {35 kg/
cm2}), spool (1) is moved to the right in the direc-
tion. Pump discharge pressure PP then passes
through the notch a of spool (1) and is connected
to tank circuit T.
• In this way, pump discharge pressure PP is set
to 3.43 MPa {35 kg/cm2}.
1. Spool
2. Spring
FUNCTION OPERATION
• When the control valve is in the fine control • When fine control is carried out on the control
mode, if the demand flow for actuator is less than valve, LS pressure PLS is generated and acts on
the value corresponding to the minimum swash the right end of spool (1).
plate angle of the pump, pump pressure PP is When this happens, the area of the opening of
set to LS pressure PLS + 3.43 MPa {35.0 kg/ the control valve spool is small, so there is a big
cm2}. If the difference pressure between pump difference between LS pressure PLS and pump
pressure PP and LS pressure PLS becomes discharge pressure PP.
equal to the load of spring (2) (3.43 MPa {35.0 • When the differential pressure between pump
kg/cm2}), the unload valve opens. Accordingly, discharge pressure PP and LS pressure PLS
LS differential pressure PLS is (3.43 MPa reaches the load of spring (2) (3.43MPa {35 kg/
{35.0 kg/cm2}) at this time. cm2}, spool (1) moves to the right in the direction
of the arrow, and pump circuit PP and tank circuit
T are connected.
• In other words, pump discharge pressure PP is
set to a pressure equal to the spring force (3.43
MPa {35 kg/cm 2}) + LS pressure PLS, and LS
differential pressure PLS becomes 3.43 MPa
{35 kg/cm2}.
1. Spool
2. Spring
3. Actuator circuit
FUNCTION
• When the control valve is operated, if the
demand flow for actuator exceeds the value cor-
responding to the minimum swash plate angle of
the pump, the outflow to tank circuit T is shut off
and all of pump discharge amount Q is sent to
the actuator circuit.
OPERATION
• When the control valve is operated to a bigger
stroke, LS pressure PLS is generated and acts
on the right end of spool (1). When this happens,
the area of the opening of the control valve spool
is large, so the difference between LS pressure
PLS and pump discharge pressure PP is small.
• For this reason, the differential pressure between
pump discharge pressure PP and LS pressure
PLS does not reach the load of spring (2) (3.43
MPa {35 kg/cm2}), so spool (1) is pushed to the
left by spring (2).
• As a result, pump circuit PP and tank circuit T
are shut off, and all the pump discharge amount
Q flows to the actuator circuit (3).
1. Spool
2. Spring
FUNCTION OPERATION
• When the control valve is at neutral, pump dis- • Pump discharge pressure PP1, PP2 is acting on
charge amount Q discharged by the minimum the left end of spool (1), and LS pressure PLS1,
swash plate angle is released to the tank circuit. PLS2 is acting on the right end.
When this happens, pump discharge pressure • When the control valve is at neutral, LS pressure
PP1, PP2 is set at 2.45 MPa {25 kg/cm 2 } by PLS1, PLS2 is 0, so only pump discharge pres-
spring (2) inside the valve. (LS pressure PLS1, sure PP1, PP2 has any effect, and PP1, PP2 is
PLS2 : 0 MPa {0 kg/cm2} set only by the load of spring (2).
• As pump discharge pressure PP1, PP2 rises and
reaches the load of spring (2) (2.45 MPa {25 kg/
cm2}), spool (1) is moved to the right in the direc-
tion of the arrow. Pump discharge pressure PP1,
PP2 then passes through the notch a in spool (1)
and is connected to tank circuit T.
• In this way, pump discharge pressure PP1, PP2
is set to 2.45 MPa {25 kg/cm2}.
1. Spool
2. Spring
FUNCTION OPERATION
• When the control valve is in the fine control • When fine control is carried out on the control
mode, if the demand flow for actuator is less than valve, LS pressure PLS1, PLS2 is generated
the value corresponding to the minimum swash and acts on the right end of spool (1).
plate angle of the pump, pump pressure PP1, When this happens, the area of the opening of
PP2 is set to LS pressure PLS1, PLS2 + 2.45 the control valve spool is small, so there is a big
MPa {25.0 kg/cm2}. If the difference pressure difference between LS pressure PLS1, PLS2
between pump pressure PP1, PP2 and LS pres- and pump discharge pressure PP1, PP2.
sure PLS1, PLS2 becomes equal to the load of • When the differential pressure between pump
spring (2) (2.45 MPa {25.0 kg/cm2}), the unload discharge pressure PP1, PP2 and LS pressure
valve opens. Accordingly, LS differential pres- PLS1, PLS2 reaches the load of spring (2) (2.45
sure PLS is (2.45 MPa {25.0 kg/cm2}) at this MPa {25 kg/cm2}, spool (1) moves to the right in
time. the direction of the arrow, and pump circuit PP1,
PP2 and tank circuit T are connected.
• In other words, pump discharge pressure PP1,
PP2 is set to a pressure equal to the spring force
(2.45 MPa {25 kg/cm 2 }) + LS pressure PLS1,
PLS2 and LS differential pressure PLS
becomes 2.45 MPa {25 kg/cm2}.
1. Spool
2. Spring
FUNCTION
• When the control valve is operated, if the
demand flow for actuator exceeds the value cor-
responding to the minimum swash plate angle of
the pump, the outflow to tank circuit T is shut off
and all of pump discharge amount Q1, Q2 is sent
to the actuator circuit.
OPERATION
• When the control valve is operated to a bigger
stroke, LS pressure PLS1, PLS2 is generated
and acts on the right end of spool (1). When this
happens, the area of the opening of the control
valve spool is large, so the difference between
LS pressure PLS1, PLS2 and pump discharge
pressure PP1, PP2 is small.
• For this reason, the differential pressure between
pump discharge pressure PP1, PP2 and LS
pressure PLS1, PLS2 does not reach the load of
spring (2) (2.45 MPa {25 kg/cm2}), so spool (1) is
pushed to the left by spring (2).
• As a result, pump circuit PP1, PP2 and tank cir-
cuit T are shut off, and all the pump discharge
amount Q1, Q2 flows to the actuator circuit.
1. Spool
2. Spring
FUNCTION
• When the machine travels, the swash plate
angle of the pump becomes maximum. At this
time, the oil flow is controlled according to the
opening rate of the spool.
OPERATION
• When the travel control valve is operated singly,
the control valve is separated by the junction
valve.
• As a result, the unload valves on PP1 and PP2
sides operate according to the opening rate of
the travel spools on both sides.
INTRODUCTION OF LS PRESSURE
PC27MR, 30MR-2
1. Work equipment valve (boom, arm, bucket, boom swing, travel)
FUNCTION OPERATION
• The LS pressure is the actuator load pressure at • When spool (1) operated, pump pressure PP
the outlet port end of the control valve. flows from flow control valve (2) and notch a in
• With the control valve, it actually reduces pump the spool through bridge passage b to actuator
pressure PP at reducing valve (3) of the pres- circuit A.
sure compensation valve to the same pressure • At the same time, reducing valve (3) also moves
as actuation circuit pressure A, and sends it to to the right, so pump pressure PP is reduced by
the LS circuit PLS. the pressure loss at notch c, and then applied
though LS circuit PLS to spring chamber PLS1.
• When this happens, LS circuit PLS is connected
to tank circuit T from LS bypass plug (4) (see the
section on the LS bypass plug).
• The actuator circuit pressure A acts on the left
end of reducing valve (3). The reduced pump
pressure PP acts on at the other end.
• As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure A and
the pressure of spring chamber PLS1 are the
same. Pump pressure PP reduced at notch a
becomes actuator circuit pressure A and is taken
to LS circuit PLS.
FUNCTION OPERATION
• The LS pressure is the actuator load pressure at • When spool (1) is operated, pump pressure PP3
the outlet port end of the control valve. flows from flow control valve (2) and notch a in
• With the control valve, it actually reduces pump the spool through bridge passage b to actuator
pressure PP3 at reducing valve (3) of the pres- circuit A.
sure compensation valve to the same pressure • At the same time, reducing valve (3) also moves
as actuation circuit pressure PA (=A), and sends to the right, so pump pressure PP3 brought from
it to the LS circuit PLS3. orifice c has its pressure reduced by the pres-
sure loss at notch c. It goes to LS circuit PLS3,
and then goes to spring chamber PLS'.
• When this happens, LS circuit PLS3 is con-
nected to tank circuit T from LS bypass plug (4)
(see the section on the LS bypass plug).
• The actuator circuit pressure A acts on the left
end of reducing valve (3). The reduced pump
pressure PP3 acts on at the other end.
• As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure A and
the pressure of spring chamber PLS' are the
same. Pump pressure PP3 reduced at notch a
becomes actuator circuit pressure A and is taken
to LS circuit PLS3.
LS BYPASS PLUG
PC27MR-2
FUNCTION
• This releases the residual pressure of LS pres-
sure PLS.
• It makes the speed of the rise in pressure of LS
pressure PLS more gentle. In addition, with this
discarded throttled flow, it creates a pressure
loss in the throttled flow of the spool or shuttle
valve, and increases the stability by lowering the
effective LS differential pressure.
OPERATION
• The pressurized oil for LS circuit PLS passes
from filter a of bypass plug (1) through orifice b
and flows to the tank circuit T.
PC30MR-2
FUNCTION
• This releases the residual pressure of LS pres-
sure PLS.
• It makes the speed of the rise in pressure of LS
pressure PLS more gentle. In addition, with this
discarded throttled flow, it creates a pressure
loss in the throttled flow of the spool or shuttle
valve, and increases the stability by lowering the
effective LS differential pressure.
OPERATION
• The pressurized oil for LS circuit PLS passes
from clearance filter a (formed by the clearance
between LS bypass plug (1) and the valve cover
(2)) through orifice b and flows to the tank circuit
T.
FUNCTION
• This releases the residual pressure of LS pres-
sure.
• It makes the speed of the rise in pressure of LS
pressure more gentle. In addition, with this dis-
carded throttled flow, it creates a pressure loss in
the throttled flow of the spool or shuttle valve,
and increases the stability by lowering the effec-
tive LS differential pressure.
OPERATION
• The oil in LS circuit PLS flows through filter a
and orifice b to the tank circuit.
PC30MR-2
OPERATION
• If the load pressure of the other actuator (right
side) becomes higher during compound opera-
tions, the oil flow in actuator circuit A on this side
(left side) tries to increase.
• If this happens, the LS pressure PLS of the other
actuator acts on spring chamber PLS', and
reducing valve (1) and flow control valve (2) are
pushed to the left.
• Flow control valve (2) throttles the area of open-
ing between pump circuit PP and spool upstream
PPA, and pressure loss is generated between
PP and PPA.
• Flow control valve (2) and reducing valve (1) are
balanced in position where the difference in
pressure between PLS and PA acting on both
ends of reducing valve (1) and the pressure loss
between PP and PPA on both sides of flow con-
trol valve (2) are the same.
• In this way, the pressure difference between
upstream pressure PPA and downstream pres-
sure PA of both spools used during compound
operations is the same, so the pump flow is
divided in proportion to the area of opening of
notch a of each spool.
FUNCTION
• The pressure compensation valve determines
the compensation characteristics by carrying out
fine adj ustment of the area ratio (S 2/S 1)
between area S2 of reducing valve (1) and area
S1 of flow control valve (2) to match the charac-
teristics of each actuator.
PC30MR-2
FUNCTION
• If the other actuator is relieved during compound
operations, LS introduction throttle b of reducing
valve (1) divides the flow and sends more oil to
the side receiving compensation.
PC30MR-2
OPERATION
• If the other actuator (right side) is relieved during
compound operations, each circuit pressure
(PPA, PA) of the other actuator becomes the
same as the pump circuit pressure (PP = relief
pressure).
• In this case, spring chamber PLS2 of the other
actuator becomes the same as pump circuit
pressure PP because of the balance of reducing
valve (1).
• PLS2 passes through LS introduction throttle b
of reducing valve (1) and becomes PLS. PLS is
connected to the tank circuit T from LS bypass
plug (4), so pressure loss is generated at LS
introduction throttle b (the condition becomes
PLS<PLS2).
• As a result, even if the other actuator is relieved,
a pressure differential is created between PP
and PLS, so more oil flows to actuator circuit A
on this side (left side).
FUNCTION OPERATION
• To compensate for any difference in the oil flow • When left and right travel spools (1) are oper-
in the left and right travel circuits when traveling ated, the pump discharge flows from pump cir-
in a straight line, the junction circuit opens when cuit PP and circuits PA to actuator circuits B.
the left and right travel spools are operated. • When traveling in a straight line, to make actua-
• In this way, the flow of oil to the left and right tor circuits PA equal, left and right reducing
travel motors is almost the same when traveling valves (2) are pushed to the right by the same
in a straight line, so there is no travel deviation. amount, and notch a and the travel junction cir-
• When steering the machine, the difference in the cuit are opened.
load pressure returns the reducing valve of the • In this way, the left and right travel actuator cir-
travel valve on the inside of the turn and the cuits are interconnected by the travel junction cir-
opening of the notch in the travel junction valve cuit, so if any difference occurs in the flow of oil
spool becomes smaller, so the machine can be to the left and right travel motors, the compensa-
steered. tion is carried out to prevent any deviation in
travel.
OPERATION
• When traveling in a straight line, if left travel
spool (L. H. 1) is returned to the neutral position
and the steering is operated, a difference (R. H.
B > L. H. B) is generated in the load pressure of
left and right travel actuator circuits PA, and LS
pressure PLS becomes the same pressure as R.
H. B.
• As a result, flow control valve (3) on the left travel
side is pushed to the left by LS circuit PLS.
Because of this, the opening of the left notch a is
made smaller, so it becomes possible to operate
the steering when traveling.
• Damper b is provided in the circuit to damper
any excessive characteristics in the opening or
closing of the travel junction circuit if the spool is
operated suddenly.
FUNCTION
• An interconnection circuit is installed to correct
the flow error in both travel circuits during
straight travel.
• With this circuit, the flow rates in both travel
motors become almost the same during straight
travel to reduce travel deviation.
• Dampers b are installed to ease the transient
characteristics of sudden opening and closing of
the interconnection circuit when the machine is
steered and the spools are operated sharply.
OPERATION
• Bridge circuits PA of both travel circuits are con-
nected to each other by interconnection circuit L.
Accordingly, if there is difference between the oil
flow rates in both travel motors, it is corrected to
reduce the travel deviation.
OPERATION
• When the right travel spool (R. H. 1) is returned
to the neutral position to steer the machine in the
straight travel state, the load pressures in both
travel actuator circuits PA become different (L.
H. A > R. H. A).
• Since the main pump is separated at this time, oil
flows in both travel motors according to the
opening area of the spool.
FUNCTION OPERATION
• This valve reduces pump discharge pressure PP • Unload spool (1) moves and pump discharge
and supplies the pilot main pressure of 2.90 MPa pressure PP is set to 2.90 MPa {30.0 kg/cm 2}.
{30.0 kg/cm2} to the PPC valve. (See the explanation of the unload valve.)
• When the actuator circuit pressure is low, the • Pump discharge pressure PP is reduced to 2.90
self-pressure sequence valve is closed to raise MPa {30.0 kg/cm 2 } by self-pressure reducing
pump discharge pressure PP to secure the pilot spool (2) and self-pressure reducing pilot relief
main pressure. valve (3), and the main pressure oil is supplied
through the PC port to the PPC valve.
OPERATION
• Unload spool (1) moves to the left and pump dis-
charge pressure PP becomes higher than the LS
pressure by the LS differential pressure. (See
the explanation of unload valve.)
• When pump discharge pressure PP is higher
than 2.90 MPa {30.0 kg/cm 2 }, it is reduced to
2.90 MPa {30.0 kg/cm2} by self-pressure reduc-
ing spool (2) and self-pressure reducing pilot
relief valve (3), and the pressure oil is supplied
through the PC port to the PPC valve.
• At this time, self-presser sequence valve (4) is
kept open.
OPERATION
• When pump discharge pressure PP is below
2.90 MPa {30.0 kg/cm2}, self-pressure sequence
valve (4) moves to the right to reduce the open-
ing area between PP and actuator circuit (5).
• As a result, differential pressure is made between
PP and actuator circuit (5) and PP is raised to
above 2.90 MPa {30.0 kg/cm2}, then it is reduced
to 2.90 MPa {30.0 kg/cm 2 } by self-pressure
reducing spool (2) and self-pressure reducing
pilot relief valve (3), and the pressure oil is sup-
plied through the PC port to the PPC valve.
STRUCTURE
• The swing and blade sections are the open cen-
ter valves of the gear pump. They are arranged
tandem, with the swing section ahead of the
blade section.
OPERATION
Swing section
• If pressure is applied from the PPC valve to the
PA8 port, the spool moves to the left and oil
flows in the A8 port.
• If pressure is applied from the PPC valve to the
PB8 port, the spool moves to the right and oil
flows in the B8 port.
• Load check valve (2) is installed in each spool,
corresponding to ports A and B of each valve.
• Relief valve (1) for the gear pump is installed to
the swing section.
Blade section
• If pressure is applied from the PPC valve to the
PA7 port, the spool moves to the left and oil
flows in the A7 port.
• If pressure is applied from the PPC valve to the
PB7 port, the spool moves to the right and oil
flows in the B7 port.
• Load check valve (2) is installed in each spool,
corresponding to ports A and B of each valve.
STRUCTURE
• The swing and blade sections are the open cen-
ter valves of the gear pump. They are arranged
tandem, with the swing section ahead of the
blade section.
OPERATION
Swing section
• If pressure is applied from the PPC valve to the
PA8 port, the spool moves to the left and oil
flows in the A8 port.
• If pressure is applied from the PPC valve to the
PB8 port, the spool moves to the right and oil
flows in the B8 port.
• Load check valve (2) is installed in each spool,
corresponding to ports A and B of each valve.
• Relief valve (1) for the gear pump is installed to
the swing section.
Blade section
• If pressure is applied from the PPC valve to the
PA7 port, the spool moves to the left and oil
flows in the A7 port.
• If pressure is applied from the PPC valve to the
PB7 port, the spool moves to the right and oil
flows in the B7 port.
• Load check valve (2) is installed in each spool,
corresponding to ports A and B of each valve.
FUNCTION
• This system resets the swing holding brake by
using both swing PPC pressures and arm IN
PPC pressure as signals.
OPERATION
• The left and right swing PPC pressure and the
arm IN PPC pressure each pass through check
valve inside spring case, are output to port BR
from PS port, and the swing holding brake is
canceled. (The highest pressure is output to port
BR.)
• The arm and swing are connected by the pilot
circuit inside the control valve.
LOGIC VALVE
PC35MR, 40MR, 50MR-2
FUNCTION
• This valve changes the pilot pressure to change
the merge-divider valve.
OPERATION
1. When divided
• If only the travel PPC pressure is applied to port
b, it is applied to output port c of the pump
merge-divider valve as it is. This pressure sets
the pump merge-divider valve in the division
mode.
2. When merged
• If the work equipment PPC pressure (excluding
the swing pressure) is applied to port a, the pres-
sure in output port c of the pump merge-divider
valve is connected through spool (1) to spring
chamber d and used as seal drain pressure.
• Accordingly, the pump merge-divider valve is not
changed but kept in the merging mode. Even if
the travel PPC pressure is applied under this
condition, spool (1) is kept pressed and the valve
is kept in the merging mode.
MERGE-DIVIDER VALVE
PC35MR, 40MR, 50MR-2
1. When machine travels singly
FUNCTION
• When the machine travels singly, the merge-
divider valve spool separates pump pressures
PP1 and PP2.
OPERATION
• When the machine travels singly, the travel port
pressure is applied through the logic valve spool
to the right side of merge-divider valve spool (1).
If this pressure exceeds the force of spring (2),
merge-divider valve spool (1) is pushed to the
right and left to separate pump pressures PP1,
PP2 and PP3.
• At this time, LS pressures PLS1, PLS2 and
PLS3 are also separated from each other. The
pump pressure is output to output pressure PLS
applied to the pump LS valve.
2. When “work equipment is operated” and when “machine travels and work equipment is operated
simultaneously”
FUNCTION
• When the work equipment is operated and when
the machine travels and the work equipment is
operated simultaneously, the merge-divider
valve spool merges pump (discharge) pressures
PP1 and PP2.
OPERATION
• When the work equipment is operated, the logic
valve spool is changed by pump pressure PP2
output by the throttle valve and the oil for chang-
ing the pump merge-divider valve is drained into
the tank.
• Accordingly, pump merge-divider valve spool (1)
is pressed to the right by the force of spring (2)
and pump pressures PP1, PP2 and PP3 are
merged. At this time, LS pressures PLS1, PLS2
and PLS3 are merged, too.
• When the machine travels and the work equip-
ment is operated simultaneously, the travel port
pressure is not applied to the pump merge-
divider valve, since the logic valve spool is
changed. Since the oil for changing the pump
merge-divider valve is drained into the tank, the
oils are merged.
• When the control lever is in neutral, the spring
force of the pump merge-divider valve spool is
larger because of the valve changing force made
by the travel PPC pressure. Accordingly, the oils
are merged.
SWING MOTOR
PC27MR, 30MR, 35MR-2
Type: LMF16
SPECIFICATIONS
Model PC27MR-2 PC30MR, 35MR-2
Type LMF16
Theoretical discharge cc/rev 16.1
Rated speed rpm 1,160 1,114
Rated discharge amount l/min 19 18
Suction valve cracking pressure MPa {kg/cm2} Max. 0.04 {0.45}
Safety valve set pressure MPa {kg/cm2} 17.2 {175} 19.1 {195}
PC27MR-2
PC30MR, 35MR-2
Unit: mm
PC40MR, 50MR-2
Unit: mm
2. Principle of operation
• The oil sent from the hydraulic pump goes from
valve plate (7) and enters cylinder block (5).
• The structure of the motor takes in the oil at one
side only of the Y - Y line joining the top and bot-
tom dead centers of the stroke of piston (4).
• The pressure oil entering one side of cylinder
block (5) generates force F1 (F1N{kg} = P
MPa{kg/cm2} x x/4 D2cm 2) pushing each piston
(4) (3 or 4 pistons).
• This force acts on thrust plate (2), but thrust plate
(2) is secured at a certain angle ° to output
shaft (1), so the force is divided into force F2 and
F3.
• Of the divided forces, the radial force F3 gener-
ates the torque (T = F3 x ri) for line Y - Y joining
the top and bottom dead centers.
The combined force of this torque {T = (F3 x
ri)} goes as a rotating force through the piston to
rotate cylinder block (5).
• Cylinder block (5) is joined to the output shaft by
a spline, so the output shaft rotates and trans-
mits the torque.
OPERATION
1. When circuit pressure is P0
• The relief valve does not operate.
SWING BRAKE 2. When swing and arm control levers are oper-
ated
PC27MR-2 • The PPC output pressure flows through port B
OPERATION into brake chamber a. The oil in chamber a
1. When swing and arm control levers are in presses down brake spring (13). As a result,
neutral brake piston (12) moves down and disc (14) and
• Since the PPC output pressure is 0 MPa {0 kg/ plate (15) are separated, thus the brake is
cm2 }, brake piston (12) is pushed up by brake released.
spring (13). As a result, disc (14) and plate (15)
are pressed and the brake works.
PC30MR, 35MR, 40MR, 50MR-2 2. When swing and arm control levers are oper-
ated
OPERATION
• The PPC output pressure flows through port B
1. When swing and arm control levers are in
into brake chamber a. The oil in chamber a
neutral
presses down brake spring (13). As a result,
• Since the PPC output pressure is 0 MPa {0 kg/
brake piston (12) moves down and disc (14) and
cm2 }, brake piston (12) is pushed up by brake
plate (15) are separated, thus the brake is
spring (13). As a result, disc (14) and plate (15)
released.
are pressed and the brake works.
PPC VALVE
1. For work equipment, swing
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
Unit: mm
14 16.7 N 13.7 N
Metering spring 26.5 x 8.20 24.9 —
{1.70 kg} {1.40 kg}
2. For travel
a For operation, see the sections of the work equipment and swing PPC valve.
1. Piston
2. Plate
3. Collar
4. Body
5. Valve
6. Metering spring
7. Centering spring
8. Bolt
11 16.7 N 13.3 N
Metering spring 22.7 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
11 16.7 N 13.3 N
Metering spring 22.7 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
WORK EQUIPMENT
a This diagram shows PC40MR.
Unit: mm
Clearance PC27MR-2
between mounting PC30MR-2
– 0.025 + 0.142 0.105 –
9 pin of track frame PC35MR-2 35 1.0
and blade and – 0.087 + 0.080 0.229
PC40MR-2
bushing PC50MR-2
Unit: mm
PC27MR-2
No.
Tolerance
Measuring point Standard size
Shaft Hole
– 0.025 + 0.039
1 — 35 – 0.064 0
+1
Arm side 46
0
2
0
Cylinder head side 45
– 0.5
– 0.025 + 0.039
3 — 40 – 0.064 0
+ 0.5
Boom side 124
0
4
0
Arm side 123.5
– 0.5
5 — 261 ±1
6 — 163.9 ±1
7 — 266.3 ±1
8 — 1,111 ±3
9 — 8.1 ±1
10 — 174 ±1
11 — 6 ±1
12 — 265.5 ± 0.5
13 — 250.5 ± 0.5
14 — 200 ± 0.2
15 — 659 —
– 0.170 – 0.050
16 — 35 – 0.209 – 0.089
0
Link side 143.5
– 0.5
17
Bucket side 145 ±1
– 0.170 – 0.050
18 — 35 – 0.209 – 0.089
0
Arm side 143.5
– 0.5
19
Bucket side 145 ±1
Min. 806 ±1
20
Max. 1,350 —
Unit: mm
PC30MR-2
No.
Tolerance
Measuring point Standard size
Shaft Hole
– 0.025 + 0.039
1 — 40 – 0.064 0
+1
Arm side 51
0
2
0
Cylinder head side 50
– 0.5
– 0.025 + 0.039
3 — 40 – 0.064 0
+ 0.5
Boom side 124
0
4
0
Arm side 123.5
– 0.5
5 — 256.3 ±1
6 — 138 ±1
7 — 263 ±1
8 — 1,260 ±3
9 — 89.8 ±1
10 — 163.6 ±1
11 — 4.5 ±1
12 — 280 ± 0.5
13 — 256 ± 0.5
14 — 194.6 ± 0.2
15 — 754 —
– 0.170 – 0.050
16 — 35 – 0.209 – 0.089
0
Link side 143.5
– 0.5
17
Bucket side 145 ±1
– 0.170 – 0.050
18 — 35 – 0.209 – 0.089
0
Arm side 143.5
– 0.5
19
Bucket side 145 ±1
Min. 780 ±1
20
Max. 1,270 —
Unit: mm
PC35MR-2
No.
Tolerance
Measuring point Standard size
Shaft Hole
– 0.025 + 0.039
1 — 40 – 0.064 0
+1
Arm side 51
0
2
0
Cylinder head side 50
– 0.5
– 0.025 + 0.039
3 — 40 – 0.064 0
+ 0.5
Boom side 130
0
4
0
Arm side 130
– 0.5
5 — 256.7 ±1
6 — 120.2 ±1
7 — 335 ±1
8 — 1,350 ±3
9 — 173.7 ±1
10 — 163.4 ±1
11 — 9.6 ±1
12 — 280 ± 0.5
13 — 256 ± 0.5
14 — 194.6 ± 0.5
15 — 754 —
– 0.170 0
16 — 35 – 0.209 – 0.040
0
Link side 143.5
– 0.5
17
Bucket side 145 ±1
– 0.170 0
18 — 35 – 0.209 – 0.040
0
Arm side 143.5
– 0.5
19
Bucket side 145 ±1
Min. 780 ±1
20
Max. 1,270 —
ARM SECTION
PC40MR, 50MR-2
a The following figure shows PC40MR.
Unit: mm
PC40MR-2
No.
Tolerance
Measuring point Standard size
Shaft Hole
– 0.025 + 0.1
1 — 45 – 0.064 0
+1
Arm side 55.5
0
2
0
Cylinder head side 55
– 0.5
– 0.025 + 0.039
3 — 50 – 0.064 0
+ 0.5
Boom side 163
0
4
– 0.3
Arm side 163
– 1.0
5 — 167.7 ±1
+1
6 — 155
0
+1
7 — 347.2
0
8 — 1,431.6 —
9 — 1,395 ±1
10 — 193.5 ±1
11 — 8.4 ±1
12 — 330 ± 0.5
13 — 303 ± 0.5
14 — 230.3 ± 0.5
15 — 871 —
– 0.170 – 0.050
16 — 45 – 0.230 – 0.089
+ 0.7
Link side 168
+ 0.2
17
Bucket side 170 ±1
– 0.170 – 0.050
18 — 45 – 0.230 – 0.089
+ 0.7
Arm side 168
+ 0.2
19
Bucket side 170 ±1
Unit: mm
PC50MR-2
No.
Tolerance
Measuring point Standard size
Shaft Hole
– 0.025 + 0.1
1 — 45 – 0.064 0
+1
Arm side 55.5
0
2
0
Cylinder head side 55
– 0.5
– 0.025 + 0.039
3 — 50 – 0.064 0
+ 0.5
Boom side 163
0
4
– 0.3
Arm side 163
– 1.0
5 — 180.5 ±1
+1
6 — 161.5
0
+1
7 — 393.1
0
8 — 1,632 —
9 — 1,389 ±1
10 — 193.6 ±1
11 — 6.3 ±1
12 — 330 ± 0.5
13 — 303 ± 0.5
14 — 230.3 ± 0.5
15 — 871 —
– 0.170 – 0.050
16 — 45 – 0.230 – 0.089
+ 0.7
Link side 168
+ 0.2
17
Bucket side 170 ±1
– 0.170 – 0.050
18 — 45 – 0.230 – 0.089
+ 0.7
Arm side 168
+ 0.2
19
Bucket side 170 ±1
BUCKET SECTION
PC27MR-2
Unit: mm
PC27MR-2
No.
Measuring point Standard size Tolerance
1 — 199.9 —
2 — 6.3 —
3 — 567 —
4 — 42 —
5 — 42 —
6 — 45° —
7 — 45° —
8 — 13.5 —
9 — 145 ±1
10 — 51 —
11 — 36 —
12 — 221 ±1
13 — 60 —
14 — 60 —
– 0.050
15 — 35 – 0.089
PC30MR-2
Unit: mm
PC30MR-2
No.
Measuring point Standard size Tolerance
1 — 194 —
2 — 13.6 —
3 — 653 —
4 — 40 —
5 — 40 —
6 — 49° —
7 — 45° —
8 — 13.5 —
9 — 145 ±1
10 — 51 —
11 — 36 —
12 — 221 ±1
13 — 60 —
14 — 60 —
– 0.050
15 — 35 – 0.089
PC35MR-2
Unit: mm
PC35MR-2
No.
Measuring point Standard size Tolerance
1 — 194.6 ± 0.5
2 — 0 —
3 — 609.5 —
4 — 50 —
5 — 50 —
6 — 45° —
7 — 45° —
8 — 13.5 —
9 — 145 ±1
10 — 51 —
11 — 36 —
12 — 221 ±1
13 — 60 —
14 — 60 —
0
15 — 35 – 0.040
PC40MR, 50MR-2
Unit: mm
PC40MR, 50MR-2
No.
Measuring point Standard size Tolerance
1 — 230.3 ± 0.5
2 — 0 —
3 — 719.6 —
4 — 55 —
5 — 55 —
6 — 45° —
7 — 45° —
8 — 13.5 —
9 — 170 ±1
10 — 60 —
11 — 42 —
12 — 258 ±1
13 — 85 —
14 — 85 —
– 0.050
15 — 45 – 0.089
FLOOR
TILT FLOOR
a The following figure shows PC40MR with the canopy specification.
(Except PC27MR-2, Serial No. 17902 and up, and PC35MR-2, Serial No. 9242 and up for North America
with the canopy specification.)
AIR CONDITIONER
AIR CONDITIONER PIPING
a This diagram shows PC40MR, 50MR.
ENGINE CONTROL
1. Battery
2. Starting switch
3. Fuse box
4. Engine stop solenoid
5. Lock lever
6. PPC lock switch
7. Neutral-engine start relay
8. Safety relay
9. Starting motor
10. Fuel control lever
Starting engine
• If starting switch (2) is set to the ON position,
engine stop solenoid (4) sets the governor stop
lever to the RUN position. Accordingly, if the
electric system has a failure, the engine stops,
that is, a fail-safe mechanism is formed.
• If starting switch (2) is set to the START position
while lock lever (5) is in the LOCK position, the
start signal flows in starting motor (9) and the
engine starts. If lock lever (5) is in the FREE
position, neutral-engine start relay (7) operates
to shut off the start signal to starting motor (9),
thus the engine does not start.
Stopping engine
• If starting switch (2) is set in the OFF position,
engine stop solenoid (4) sets the governor stop
lever in the STOP position to stop the engine.
1. Battery
2. Starting switch
3. Fuse box
4. Monitor panel
5. 2nd travel speed selection solenoid relay
6. Lock lever
7. PPC lock switch
8. PPC lock solenoid relay
9. 2nd travel speed selection solenoid valve
10. PPC lock solenoid valve
11. Right work equipment PPC valve
12. Travel PPC valve
13. Left work equipment PPC valve
14. Boom swing PPC valve
15. Blade PPC valve
16. Travel motor
17. Travel pressure switch
18. Travel alarm
19. Engine
20. Hydraulic pump
20a. Servo valve
20b. LS valve
20c. PC valve
21. Control valve
21a. Self-reducing pressure valve
1. Battery
2. Starting switch
3. Fuse box
4. Monitor panel
5. 2nd travel speed selection solenoid relay
6. Lock lever
7. PPC lock switch
8. PPC lock solenoid relay
9. 2nd travel speed selection solenoid valve
10. PPC lock solenoid valve
11. Right work equipment PPC valve
12. Travel PPC valve
13. Left work equipment PPC valve
14. Boom swing PPC valve
15. Blade PPC valve
16. Travel motor
17. Travel pressure switch
18. Travel alarm
19. Engine
20. Hydraulic pump
20a. Servo valve
20b. LS valve
20c. PC valve
21. Control valve
21a. Pump merge-divider valve
1. Battery
2. Starting switch
3. Fuse box
4. Monitor panel
5. 2nd travel speed selection solenoid relay
6. 2nd travel speed selection solenoid valve
7. Left travel motor
8. Right travel motor
9. Control valve
10. Engine
11. Hydraulic pump
12. Travel pressure switch
13. Travel alarm
PC40MR, 50MR-2
2nd travel speed selection
Low speed High speed
switch
2nd travel speed selection
OFF ON
monitor
2nd travel speed selection
OFF ON
solenoid valve
Motor capacity (cm3/rev) 33.08 19.11
1. Battery
2. Starting switch
3. Fuse box
4. Lock lever
5. PPC lock lever
6. PPC lock solenoid relay
7. PPC lock solenoid valve
8. Left PPC valve
9. Right PPC valve
10. Travel PPC valve
11. Boom swing PPC valve
12. Blade PPC valve
13. Engine
14. Hydraulic pump
15. Control valve
FUNCTION
• The PPC lock switch is interlocked with the lock
lever. If the lock lever is set in the LOCK posi-
tion, the PPC lock switch is turned OFF.
• If the PPC lock switch is turned OFF, the current
flowing to the PPC lock solenoid valve is shut off.
Then, the work equipment and machine unit do
not move even if any control lever or pedal is
operated.
MONITOR PANEL
a See MONITOR SYSTEM.
MONITOR SYSTEM
MONITOR PANEL
OUTLINE
• The monitor panel has the monitor display function, gauge display function, and service meter function.
• The monitor switch section consists of 2 flat-type sheet switches. Each time either switch is pressed, the
machine condition changes.
• There is a CPU (Center Processing Unit) in the monitor panel to process, display, and output the informa-
tion.
• If the monitor panel has a failure, it does not display normally.
OPERATION
SENSORS
• The signal from each sensor is input to the panel directly.
• The sensors are classified into contact type and resistance type.
• Either side of a sensor of contact type is always connected to the chassis ground.
Category of display Name of sensor Type of sensor When normal When abnormal
Caution Engine oil pressure Contact OFF (Open) ON (Closed)
Coolant temperature Resistance — —
Gauge
Fuel level Resistance — —
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
FUNCTION
• The engine oil pressure sensor is installed to the engine cylinder block and its diaphragm senses oil pres-
sure. If the oil pressure lowers below the set level, the switch is turned ON.
1. Connector
2. Plug
3. Thermistor
FUNCTION
• The coolant temperature sensor is installed to the engine cylinder block. It senses changes of temperature
as changes of resistance of the thermistor in it, and then generates signals according the measured temper-
ature.
FUNCTION
• The fuel level sensor is installed to the side of the fuel tank and its float moves up and down according to the
fuel level in the tank. The movement of the float operates the variable resistor through the arm, and then
signals are generated according to the change of the resistance.
Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
Engine 3D82AE-5M
Oil temperature Whole speed range (inside oil pan) ºC Max. 120 Max. 120
Engine 3D84E-5N
Oil temperature Whole speed range (inside oil pan) ºC Max. 120 Max. 120
Engine 3D88E-5P
Oil temperature Whole speed range (inside oil pan) ºC Max. 120 Max. 120
PC35MR-2
Applicable model
(High
S/No. 6736 and up)
altitude spec.
Engine S3D84E-5PBA
Oil temperature Whole speed range (inside oil pan) ºC Max. 120 Max. 120
Engine 4D88E-5X
Oil temperature Whole speed range (inside oil pan) ºC Max. 120 Max. 120
is relieved range
• Engine coolant temperature: Within oper-
rpm
ating range
Speed when 2 • Relief of 1 pump: Relieve bucket circuit.
• Relief of 2 pumps: Relieve bucket and Min. 2,100 Min. 2,100
pumps are relieved
swing circuits.
N o CURL,
Bucket control lever 80 ± 10 80 ± 10
DUMP
Stroke of control lever and pedal
N o Swing to
Swing control lever 80 ± 10 80 ± 10
LEFT, RIGHT
• Stop engine. N o Swing
Boom swing control • Measure at center of boom to LEFT, 25 ± 5 25 ± 5
pedal lever grip. RIGHT
• Measure at pedal tip. mm
• Read max. value to N o RAISE,
Blade control lever 50 ± 5 50 ± 5
stroke end (excluding LOWER
neutral play). N o FOR-
Travel control lever WARD, 100 ± 10 100 ± 10
REVERSE
SLOW i
o FULL
Fuel control lever 160 ± 20 160 ± 20
THROTTLE
Work equip-
Max. 5 Max. 5
ment, swing
Play of control lever
Travel Max. 5 Max. 5
+ 0.98 + 0.98
24.5 – 0.49 24.5 – 0.49
Arm relief pressure + 10 + 10
{250 – 5 } {250 – 5 }
• Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle and measure 24.5
+ 0.98
24.5
+ 0.98
Bucket relief pres- – 0.49 – 0.49
relief pressure (Relieve only circuit to be
sure + 10
{250 – 5 }
+ 10
{250 – 5 }
measured).
• Measure pump outlet pressure.
MPa
Oil pressure
Bucket cylinder
(Retraction of • Measure hydraulic drift every 5 minutes Max. 20 30
cylinder) for 15 minutes.
mm
• Stop engine
• Hydraulic oil temperature: 45 – 55°C
• Bucket: Rated load
Boom swing cyl- (Rated load: 1,422 N {145 kg})
inder (Retraction • Set machine in above position on slope Max. 20 30
and extension of of 15 degrees with upper structure at
cylinder) right angle to its body and measure
retraction and extension of cylinder for
15 minutes.
Work equipment
• Stop engine
Blade (Hydraulic • Hydraulic oil temperature: 45 – 55°C
drift of blade tip) • Measure hydraulic drift of blade tip from Max. 30 45
maximum raising height for 15 minutes.
aFor measuring posture, see Fig.
H at end of this section.
• Run engine at full throttle. RAISE 2.4 ± 0.3 3.0
• Hydraulic oil temperature: 45 –
55°C
Boom speed • Measure time required to move
cylinder between extension
stroke end and position at which LOWER 2.4 ± 0.3 3.0
bucket tooth is in contact with
Work equipment speed
ground.
aFor measuring posture, see Fig.
I at end of this section. IN 2.8 ± 0.3 3.4
• Run engine at full throttle.
• Hydraulic oil temperature: 45 – sec
Arm speed 55°C
• Measure time required to move
cylinder between extension and OUT 2.5 ± 0.3 3.1
retraction stroke ends.
aFor measuring posture, see Fig.
J at end of this section. CURL 2.4 ± 0.3 3.0
• Run engine at full throttle.
• Hydraulic oil temperature: 45 –
Bucket speed 55°C
• Measure time required to move
cylinder between extension and DUMP 2.0 ± 0.3 2.6
retraction stroke ends.
Blade speed
• Measure time required to move
cylinder between position at
which blade is in contact with LOWER 1.0 ± 0.3 1.6
ground and maximum blade
raising position.
aFor measuring posture, see Fig. Swing
L at end of this section. boom to 7.0 ± 1.5 10
• Run engine at full throttle. LEFT
Boom swing • Hydraulic oil temperature: 45 –
speed 55°C
• Measure time required to move Swing
cylinder between extension and boom to 7.0 ± 1.5 10
retraction stroke ends. RIGHT
aFor measuring posture, see Fig. M at
end of this section.
• Run engine slow.
• Hydraulic oil temperature: 45 – 55°C
Boom time lag • Set arm to OUT stroke end, bucket to Max. 2 Max. 3.9
DUMP stroke end, and boom at RAISE
stroke end. Then, lower bucket and
measure time required to raise machine
after bucket touches ground. sec
Work equipment
Leakage from
Max. 2 10
each cylinder • Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle. cc/min
Leakage from • Relieve circuit to be measured.
center swivel — —
joint
Performance of
— See section of PERFORMANCE OF HYDRAULIC PUMP.
hydraulic pump
is relieved range
• Engine coolant temperature: Within oper-
rpm
ating range
Speed when 2 • Relief of 1 pump: Relieve bucket circuit.
• Relief of 2 pumps: Relieve bucket and Min. 2,040 Min. 2,040
pumps are relieved
swing circuits.
N o CURL,
Bucket control lever 80 ± 10 80 ± 10
DUMP
Stroke of control lever and pedal
N o Swing to
Swing control lever 80 ± 10 80 ± 10
LEFT, RIGHT
• Stop engine. N o Swing
Boom swing control • Measure at center of boom to LEFT, 25 ± 5 25 ± 5
pedal lever grip. RIGHT
• Measure at pedal tip. mm
• Read max. value to N o RAISE,
Blade control lever 50 ± 5 50 ± 5
stroke end (excluding LOWER
neutral play). N o FOR-
Travel control lever WARD, 100 ± 10 100 ± 10
REVERSE
SLOW i
o FULL
Fuel control lever 160 ± 20 160 ± 20
THROTTLE
Work equip-
Max. 5 Max. 5
ment, swing
Play of control lever
Travel Max. 5 Max. 5
+ 0.98 + 0.98
26.0 – 0.49 26.0 – 0.49
Arm relief pressure + 10 + 10
{265 – 5 } {265 – 5 }
• Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle and measure 26.0
+ 0.98
26.0
+ 0.98
Bucket relief pres- – 0.49 – 0.49
relief pressure (Relieve only circuit to be
sure + 10
{265 – 5 }
+ 10
{265 – 5 }
measured).
• Measure pump outlet pressure.
19.6 ± 0.98 19.6 ± 0.98
Swing relief pressure MPa {200 ± 10} {200 ± 10}
Oil pressure
{kg/cm2}
Target + 0.98 + 0.98
Boom swing relief 26.0 – 0.49 26.0 – 0.49
value
pressure (Range) + 10
{265 – 5 }
+ 10
{265 – 5 }
+ 0.98 + 0.98
21.6 – 0.49 21.6 – 0.49
Raise + 10 + 10
{220 – 5 } {220 – 5 }
Blade relief pressure
+ 0.98 + 0.98
21.6 – 0.49 21.6 – 0.49
Lower + 10 + 10
{220 – 5 } {220 – 5 }
+ 0.98 + 0.98
26.0 – 0.49 26.0 – 0.49
Travel relief pressure + 10 + 10
{265 – 5 } {265 – 5 }
Bucket cylinder
(Retraction of • Measure hydraulic drift every 5 minutes Max. 20 30
cylinder) for 15 minutes.
mm
• Stop engine
• Hydraulic oil temperature: 45 – 55°C
• Bucket: Rated load
Boom swing cyl- (Rated load: 1,422 N {145 kg})
inder (Retraction • Set machine in above position on slope Max. 20 30
and extension of of 15 degrees with upper structure at
cylinder) right angle to its body and measure
retraction and extension of cylinder for
15 minutes.
Work equipment
• Stop engine
Blade (Hydraulic • Hydraulic oil temperature: 45 – 55°C
drift of blade tip) • Measure hydraulic drift of blade tip from Max. 30 45
maximum raising height for 15 minutes.
aFor measuring posture, see Fig.
H at end of this section.
• Run engine at full throttle. RAISE 2.6 ± 0.3 3.2
• Hydraulic oil temperature: 45 –
55°C
Boom speed • Measure time required to move
cylinder between extension
stroke end and position at which LOWER 2.6 ± 0.3 3.2
bucket tooth is in contact with
Work equipment speed
ground.
aFor measuring posture, see Fig.
I at end of this section. IN 2.8 ± 0.3 3.4
• Run engine at full throttle.
• Hydraulic oil temperature: 45 – sec
Arm speed 55°C
• Measure time required to move
cylinder between extension and OUT 2.5 ± 0.3 3.1
retraction stroke ends.
aFor measuring posture, see Fig.
J at end of this section. CURL 2.6 ± 0.3 3.2
• Run engine at full throttle.
• Hydraulic oil temperature: 45 –
Bucket speed 55°C
• Measure time required to move
cylinder between extension and DUMP 1.9 ± 0.3 2.5
retraction stroke ends.
Blade speed
• Measure time required to move
cylinder between position at
which blade is in contact with LOWER 1.0 ± 0.3 1.6
ground and maximum blade
raising position.
aFor measuring posture, see Fig. Swing
L at end of this section. boom to 7.5 ± 1.5 10
• Run engine at full throttle. LEFT
Boom swing • Hydraulic oil temperature: 45 –
speed 55°C
• Measure time required to move Swing
cylinder between extension and boom to 7.5 ± 1.5 10
retraction stroke ends. RIGHT
aFor measuring posture, see Fig. M at
end of this section.
• Run engine slow.
• Hydraulic oil temperature: 45 – 55°C
Boom time lag • Set arm to OUT stroke end, bucket to Max. 2 Max. 3.9
DUMP stroke end, and boom at RAISE
stroke end. Then, lower bucket and
measure time required to raise machine
after bucket touches ground. sec
Work equipment
Leakage from
Max. 2 10
each cylinder • Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle. cc/min
Leakage from • Relieve circuit to be measured.
center swivel — —
joint
Performance of
— See section of PERFORMANCE OF HYDRAULIC PUMP.
hydraulic pump
is relieved range
• Engine coolant temperature: Within oper-
rpm
ating range
Speed when 2 • Relief of 1 pump: Relieve bucket circuit.
• Relief of 2 pumps: Relieve bucket and Min. 1,955 Min. 1,955
pumps are relieved
swing circuits.
N o CURL,
Bucket control lever 80 ± 10 80 ± 10
DUMP
Stroke of control lever and pedal
N o Swing to
Swing control lever 80 ± 10 80 ± 10
LEFT, RIGHT
• Stop engine. N o Swing
Boom swing control • Measure at center of boom to LEFT, 25 ± 5 25 ± 5
pedal lever grip. RIGHT
• Measure at pedal tip. mm
• Read max. value to N o RAISE,
Blade control lever 50 ± 5 50 ± 5
stroke end (excluding LOWER
neutral play). N o FOR-
Travel control lever WARD, 100 ± 10 100 ± 10
REVERSE
SLOW i
o FULL
Fuel control lever 160 ± 10 160 ± 10
THROTTLE
Work equip-
Max. 5 Max. 5
ment, swing
Play of control lever
Travel Max. 5 Max. 5
+ 0.98 + 0.98
26.0 – 0.49 26.0 – 0.49
Arm relief pressure + 10 + 10
{265 – 5 } {265 – 5 }
• Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle and measure 26.0
+ 0.98
26.0
+ 0.98
Bucket relief pres- – 0.49 – 0.49
relief pressure (Relieve only circuit to be
sure + 10
{265 – 5 }
+ 10
{265 – 5 }
measured).
• Measure pump outlet pressure.
MPa 19.6 ± 0.98 19.6 ± 0.98
Swing relief pressure
Oil pressure
+ 0.98 + 0.98
21.6 – 0.49 21.6 – 0.49
Raise + 10 + 10
{220 – 5 } {220 – 5 }
Blade relief pressure
+ 0.98 + 0.98
21.6 – 0.49 21.6 – 0.49
Lower + 10 + 10
{220 – 5 } {220 – 5 }
+ 0.98 + 0.98
26.0 – 0.49 26.0 – 0.49
Travel relief pressure + 10 + 10
{265 – 5 } {265 – 5 }
Bucket cylinder
(Retraction of • Measure hydraulic drift every 5 minutes Max. 16 24
cylinder) for 15 minutes.
mm
• Stop engine
• Hydraulic oil temperature: 45 – 55°C
• Bucket: Rated load
Boom swing cyl- (Rated load: 1,765 N {180 kg})
inder (Retraction • Set machine in above position on slope Max. 20 30
and extension of of 15 degrees with upper structure at
cylinder) right angle to its body and measure
retraction and extension of cylinder for
15 minutes.
Work equipment
• Stop engine
Blade (Hydraulic • Hydraulic oil temperature: 45 – 55°C
drift of blade tip) • Measure hydraulic drift of blade tip from Max. 30 45
maximum raising height for 15 minutes.
aFor measuring posture, see Fig.
H at end of this section.
• Run engine at full throttle. RAISE 2.9 ± 0.3 3.5
• Hydraulic oil temperature: 45 –
55°C
Boom speed • Measure time required to move
cylinder between extension
stroke end and position at which LOWER 2.9 ± 0.3 3.5
bucket tooth is in contact with
Work equipment speed
ground.
aFor measuring posture, see Fig.
I at end of this section. IN 2.8 ± 0.3 3.4
• Run engine at full throttle.
• Hydraulic oil temperature: 45 – sec
Arm speed 55°C
• Measure time required to move
cylinder between extension and OUT 2.5 ± 0.3 3.1
retraction stroke ends.
aFor measuring posture, see Fig.
J at end of this section. CURL 2.7 ± 0.3 3.3
• Run engine at full throttle.
• Hydraulic oil temperature: 45 –
Bucket speed 55°C
• Measure time required to move
cylinder between extension and DUMP 2.0 ± 0.3 2.6
retraction stroke ends.
Blade speed
• Measure time required to move
cylinder between position at
which blade is in contact with LOWER 1.2 ± 0.3 1.6
ground and maximum blade
raising position.
aFor measuring posture, see Fig. Swing
L at end of this section. boom to 7.3 ± 1.5 10
• Run engine at full throttle. LEFT
Boom swing • Hydraulic oil temperature: 45 –
speed 55°C
• Measure time required to move Swing
cylinder between extension and boom to 7.1 ± 1.5 10
retraction stroke ends. RIGHT
aFor measuring posture, see Fig. M at
end of this section.
• Run engine slow.
• Hydraulic oil temperature: 45 – 55°C
Boom time lag • Set arm to OUT stroke end, bucket to Max. 2 Max. 3.9
DUMP stroke end, and boom at RAISE
stroke end. Then, lower bucket and
measure time required to raise machine
after bucket touches ground. sec
Work equipment
Leakage from
Max. 2 10
each cylinder • Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle. cc/min
Leakage from • Relieve circuit to be measured.
center swivel — —
joint
Performance of
— See section of PERFORMANCE OF HYDRAULIC PUMP.
hydraulic pump
is relieved range
• Engine coolant temperature: Within oper-
rpm
ating range
Speed when 2 • Relief of 1 pump: Relieve bucket circuit.
• Relief of 2 pumps: Relieve bucket and Min. 2,100 Min. 2,100
pumps are relieved
swing circuits.
N o CURL,
Bucket control lever 85 ± 10 85 ± 10
DUMP
Stroke of control lever and pedal
N o Swing to
Swing control lever 85 ± 10 85 ± 10
LEFT, RIGHT
• Stop engine. N o Swing
Boom swing control • Measure at center of boom to LEFT, 25 ± 5 25 ± 5
pedal lever grip. RIGHT
• Measure at pedal tip. mm
• Read max. value to N o RAISE,
Blade control lever 50 ± 5 50 ± 5
stroke end (excluding LOWER
neutral play). N o FOR-
Travel control lever WARD, 100 ± 10 100 ± 10
REVERSE
SLOW i
o FULL
Fuel control lever 160 ± 20 160 ± 20
THROTTLE
Work equip-
Max. 5 Max. 5
ment, swing
Play of control lever
Travel Max. 10 Max. 10
+ 10 + 10
{kg/cm2} {220 – 5 } {220 – 5 }
Blade relief pressure
Target + 0.98 + 0.98
value 21.6 – 0.49 21.6 – 0.49
Lower + 10 + 10
(Range) {220 – 5 } {220 – 5 }
+ 0.98 + 0.98
26.5 – 0.49 26.5 – 0.49
Travel relief pressure + 10 + 10
{270 – 5 } {270 – 5 }
swinging
• Hydraulic oil temperature: 45 – 55°C
• Measure time required to swing 5 turns
after swinging 1 turn.
aFor measuring posture, see Fig. C at
end of this section.
• Max. reach
• Stop engine.
• Hydraulic oil temperature: 45 – 55°C
• Fill bucket with rated load or dirt and
sand.
• Rated load
Hydraulic drift of deg. 0 0
PC40MR-2: 2,245 N {230 kg}
swing (mm) (0) (0)
PC50MR-2: 2,450 N {250 kg}
• Stop machine on slope of 15 degrees
and set its upper structure at 45 degrees
upward.
• Make match marks on swing circle outer
race and track frame.
• Measure shifting distance of match
marks in 15 minutes.
• Run engine at full throttle.
Leakage from swing • Hydraulic oil temperature: 45 – 55°C
cc/min — —
motor • Relieve swing circuit and measure leak-
age in 1 minute.
aFor measuring posture, see Fig.
D at end of this section. Low 25.7 ± 2 25.7 ± 4
• Run engine at full throttle. speed (27.7 ± 2) (26.9 ± 4)
• Hydraulic oil temperature: 45 – 55°C
Travel speed • After approach run of at least 10 sec
m on flat ground, measure time
required to travel 20 m. High 15.7 ± 2 15.7 ± 4
• ( ): Machine with steel shoe speed (16.7 ± 2) (16.7 ± 4)
specification
Travel
0 0
with sprocket on upper side.
• Measure hydraulic drift of travel in 5 min-
utes.
• Stop engine
Blade (Hydraulic • Hydraulic oil temperature: 45 – 55°C
drift of blade tip) • Measure hydraulic drift of blade tip from Max. 30 45
maximum raising height for 15 minutes.
aFor measuring posture, see Fig.
H at end of this section.
• Run engine at full throttle. RAISE 3.0 ± 0.3 3.6
• Hydraulic oil temperature: 45 –
55°C
Boom speed • Measure time required to move
cylinder between extension
stroke end and position at which LOWER 3.0 ± 0.3 3.6
bucket tooth is in contact with
Work equipment speed
ground.
aFor measuring posture, see Fig.
I at end of this section. IN 3.1 ± 0.3 3.4 ± 0.3 3.7 4.0
• Run engine at full throttle.
• Hydraulic oil temperature: 45 – sec
Arm speed 55°C
• Measure time required to move
cylinder between extension and OUT 2.7 ± 0.3 2.8 ± 0.3 3.3 3.4
retraction stroke ends.
aFor measuring posture, see Fig.
J at end of this section. CURL 3.0 ± 0.3 3.6
• Run engine at full throttle.
• Hydraulic oil temperature: 45 –
Bucket speed 55°C
• Measure time required to move
cylinder between extension and DUMP 2.2 ± 0.3 2.8
retraction stroke ends.
Blade speed
• Measure time required to move
cylinder between position at
which blade is in contact with LOWER 1.3 ± 0.3 1.9
ground and maximum blade
raising position.
aFor measuring posture, see Fig. Swing
L at end of this section. boom to 7.0 ± 1.5 10
• Run engine at full throttle. LEFT
Boom swing • Hydraulic oil temperature: 45 –
speed 55°C
• Measure time required to move Swing
cylinder between extension and boom to 7.0 ± 1.5 10
retraction stroke ends. RIGHT
aFor measuring posture, see Fig. M at
end of this section.
• Run engine slow.
• Hydraulic oil temperature: 45 – 55°C
Boom time lag • Set arm to OUT stroke end, bucket to Max. 2 Max. 3.9
DUMP stroke end, and boom at RAISE
stroke end. Then, lower bucket and
measure time required to raise machine
after bucket touches ground. sec
Work equipment
Leakage from
Max. 2 10
each cylinder • Hydraulic oil temperature: 45 – 55°C
• Run engine at full throttle. cc/min
Leakage from • Relieve circuit to be measured.
center swivel — —
joint
Performance of
— See section of PERFORMANCE OF HYDRAULIC PUMP.
hydraulic pump
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
a Fig. G a Fig. J
a Fig. H a Fig. K
a Fig. I a Fig. L
a Fig. M a Fig. P
a Fig. N
a Fig. O
PC40MR-2
32.5 26.5
PC50MR-2
a Fig. Q
a Fig. R
a Fig. S
a Fig. T
Symbol
Q’ty
Testing/Adjusting item Part No. Part Name Remarks
Measuring engine speed A 799-205-1100 Tachometer kit 1 Degital display: 6.0 – 99,999.9 rpm
D Commercially
Adjusting valve clearance available Feeler gauge 1 —
3 795-101-1571 Joint 1 —
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 kit (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Measuring engine oil pres- F Oil pressure gauge
sure 790-261-1204 kit (Digital) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 kit (Analog) 1 {25, 60, 400, 600 kg/cm2}
Measuring and adjusting 1
oil pressures in work Oil pressure gauge
equipment, travel, boom G 790-261-1204 kit (Digital) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
swing, swing, and blade
circuits 799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1 —
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 kit (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge
790-261-1204 kit (Digital) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
799-101-5002 Oil pressure gauge 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
kit (Analog) {25, 60, 400, 600 kg/cm2}
1
Measuring control circuit oil 790-261-1204 Oil pressure gauge 1 Pressure gauge: 58.8 MPa {600kg/cm2}
pressure (oil pressure J kit (Digital)
reduced by self pressure)
799-401-3100 Adapter 1 Face seal type (#02)
2 Both male and female: 9/16-18UNF
02896-11008 O-ring 1 (Female: PT1/8)
Symbol
Q’ty
Testing/Adjusting item Part No. Part Name Remarks
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 kit (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Testing and adjusting con- Oil pressure gauge
trol pump circuit oil pres- K 790-261-1204 kit (Digital) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
sure
799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1 —
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 kit (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge
Measuring solenoid valve L 790-261-1204 kit (Digital) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
output pressure
799-401-3100 Adapter 1 Face seal type (#02)
2 Both male and female: 9/16-18UNF
02896-11008 O-ring 1 (Female: PT1/8)
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 kit (Analog) 1 {25, 60, 400, 600 kg/cm2}
1
Measuring PPC valve out- Oil pressure gauge
put pressure and swing M 790-261-1204 kit (Digital) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
holding brake release pres-
sure 799-401-3100 Adapter 1 Face seal type (#02)
2 Both male and female: 9/16-18UNF
02896-11008 O-ring 1 (Female: PT1/8)
a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, List of T-boxes
and T-adapters.
MEASURING ENGINE SPEED 1) Measuring low idle and high idle speeds:
Set the fuel control lever to the low idle and
high idle positions and measure the engine
a Measuring instruments for engine speed
speed.
Symbol Part No. Part name 2) Measuring pump relief engine speed:
A 799-205-1100 Tachometer kit Lock the work equipment or travel system to
relieve the main pump, run the engine at full
throttle, and measure the engine speed.
a Measure the engine speed under the following
condition.
• Engine coolant temperature:
Within operating range
• Hydraulic oil temperature : 45 – 55°C
MEASURING COMPRESSION
5. Disconnect connector E3 (2) of the engine stop
PRESSURE motor.
TESTING AND ADJUSTING 3. Stick injection angle adjustment seal (8) to the
gear case, matching its center line to stamped
FUEL INJECTION TIMING line (5) of the fuel injection pump body.
• Seal (8) number: YM158090-51990
TESTING
Open the engine side cover and check mounting nut
(1) of the fuel injection pump for looseness.
ADJUSTING
a The injection timing of the fuel injection pump
used engine cannot be adjusted like the former
models. Accordingly, adjust the injection angle
instead of measuring the injection timong.
1. Before removing fuel injection pump (2), remove
the cover in front of the timing gear case and
make match marks on the meshing parts of
pump drive gear (3) and idle gear (4).
(Example)
5. Read the "injection angle i" recorded on the 8. Tighten the fuel injection pump mounting nut.
fuel injection pump to be installed and calucu-
lated the difference between it and the "injection REMARK
angle i" of the removed fuel injection pump. Injection angle i is the difference between the
a When the same fuel injection pump is cam angle at which injection is started and the
installed again, the angle difference is 0. cam angle at which the plunger lift is 2.5 mm
a Injection angle difference (Cam angle) = while the fuel injection pump unit is driven with a
(Injection angle i of fuel injection pump to motor.
be installed) – (Injection angle i of removed Actual injection angle i is measured for each
fuel injection pump) fuel injection pump and recorded on the pump
body.
6. Install the fuel injection pump temporarily and
tighten the nut at the shaft end.
See Removal, installation of fuel injection pump.
ADJUSTING
a If the belt deflection is not normal, adjust it
according to the following procedure.
PC40, 50MR-2
ADJUSTING
a If the deflection of the belt is abnormal, adjust it
according to the following procedure.
1. Loosen nut (3) of idler pulley (2).
TESTING AND ADJUSTING 2) To check that the tension is normal, run the
engine at low idle and move the machine for-
TRACK SHOE TENSION ward by the length of track on ground, then
stop slowly.
TESTING 3) Test the track shoe tension again. If it is ab-
1. Run the engine at low idle and move the ma- normal, adjust it again.
chine by the length of track on ground, then stop
slowly.
ADJUSTING
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
MEASURING
a Hydraulic oil temperature for measurement:
45 – 55°C
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank and set the safety lever in
the LOCK position.
a Remove the triangular cover from the left rear of
the machine.
2) Install nipple G2 and connect oil pressure
1. Measuring oil pressures in work equipment, gauge G1 (39.2 MPa {400 kg/cm2}) by hose
travel, and boom swing circuits [1].
1) Remove main pump circuit oil pressure pick- Example of PC27, 30MR-2
up plug (1).
a You may remove either plug from PC35,
40, 50MR-2.
PC27, 30MR-2
PC40, 50MR-2
• Applicable model: PC35, 40, 50MR-2 2. Adjusting main relief valves of swing and
1) Loosen locknut (4) of main relief valve (6) blade circuits
and turn adjustment screw (5). a The set pressure of the safety valve of the
a If the adjustment screw is swing motor is lower than that of the main
• Turned to the right, the pressure is in- relief valve. Accordingly, the relief pressure
creased. of only the blade circuit is obtained.
• Turned to the left, the pressure is de- 1) Loosen locknut (4) of relief valve (6) and turn
creased. adjustment screw (5).
a Amount of adjustment per turn of adjust- a If the adjustment screw is
ment screw: 19.6 MPa {200 kg/cm2} • Turned to the right, the pressure is in-
2) After adjusting, tighten locknut (4). creased.
3 Locknut: 39 – 49 Nm {4 – 5 kgm} • Turned to the left, the pressure is de-
creased.
3) Referring to the section of measuring, check a Amount of adjustment per turn of adjust-
the relief pressure again.
ment screw: 19.6 MPa {200 kg/cm2}
PC35MR-2
2) After adjusting, tighten locknut (4).
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
3) Referring to the section of measuring, check
the relief pressure again.
PC40, 50MR-2
3 Locknut:
2) After adjusting, tighten locknut (7).
PC40, 50MR-2
MEASURING
a Remove the triangular cover from the left rear of
the machine.
PC35MR-2
Applicable model: PC40, 50MR-2 5. Run the engine at full throttle and measure the
1. Disconnect hydraulic hoses (3) and (4). LS pressure under the condition for measure-
ment with the differential pressure gauge.
a Read the pointer accurately from its front
side.
ADJUSTING
a If the LS differential pressure is abnormal, adjust
the LS valve according to the above procedure.
2. Install adapters H4 and H5 to the discharge side 1. Loosen locknut (12) of LS valve (11) and turn
of the pump and LS pressure side respectively. adjustment screw (13).
a If the adjustment screw is
3. Install nipples [2] of oil pressure gauge kit H1 to • Turned to the right, the pressure is in-
H4 and H5 and connect pressure gauge H1 creased.
(39.2 MPa {400 kg/cm2}) by hoses [1]. • Turned to the left, the pressure is decreased.
a Use a pressure gauge having divisions of
2. After adjusting, tighten locknut (12).
3 Locknut: 27.4 – 34.3 Nm {2.8 – 3.5 kgm}
0.98 MPa {10 kg/cm2}.
ADJUSTING PC VALVE
a While the pump discharge pressure and LS dif-
ferential pressure are normal, if the following
faults occur, adjust the PC valve.
• When the load is increased, the engine speed
lowers.
• The engine speed is normal but the work equip-
ment speed is low.
a The PC valve is installed in the servo piston.
MEASURING CONTROL
CIRCUIT OIL PRESSURE (OIL
PRESSURE REDUCED BY
SELF PRESSURE)
Applicable model: PC27, 30MR-2
a Measuring instruments for control circuit oil pres-
sure
MEASURING
a Hydraulic oil temperature for measurement:
45 – 55°C
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank and set the safety lever in
the LOCK position.
MEASURING AND
ADJUSTING CONTROL PUMP
CIRCUIT OIL PRESSURE
Applicable model: PC35, 40, 50MR-2
a Measuring instruments for control pump circuit
oil pressure
MEASURING ADJUSTING
a Hydraulic oil temperature for measurement: a If the control circuit oil pressure is abnormal,
45 – 55°C adjust control relief valve according to the follow-
a Remove the triangular cover from the left rear of ing procedure.
the machine. a Tilt up the floor frame.
For details, see How to open and close (tilt) floor.
1. Remove oil pressure pickup plug (1) of the con-
trol pump outlet hose. 1. Loosen locknut (3) of relief valve (2) and turn
adjustment screw (4).
a If the adjustment screw is
• Turned to the right, the pressure is in-
creased.
• Turned to the left, the pressure is decreased.
a Amount of adjustment per turn of adjustment
screw: 0.92 MPa {9.4 kg/cm2}
PC40, 50MR-2
MEASURING
a Hydraulic oil temperature for measurement:
45 – 55°C PC40, 50MR-2
a Measure the pressure at the outlet of each sole-
noid valve.
Lock lever:
OFF 0{0}
LOCK
1 PPC lock
+ 0.49
Lock lever: 2.94 – 0.1
ON
FREE +5
{30 – 1 }
2nd travel
speed selection OFF 0{0}
2nd travel pedal: OFF
2 speed
selection 2nd travel + 0.49
2.94 – 0.1
speed selection ON +5
pedal: ON {30 – 1 }
• PC40, 50MR-2
Solenoid Measurement Operation Oil pressure
No.
valve conditions of solenoid (MPa{kg/cm2})
Lock lever:
OFF 0{0}
LOCK
1 PPC lock
+ 0.29
Lock lever: 3.33 0
ON
FREE +3
{34 0 }
2nd travel
speed selection OFF 0{0}
2nd travel pedal: OFF
2 speed
selection 2nd travel + 0.39
3.72 – 0.1
speed selection ON +4
pedal: ON {38 – 1 }
MEASURING
a Measure the PPC valve output pressure when
the work equipment speed or swing speed is low a The connection diagram of the PPC valve
or the work equipment does not move. and control valve is shown on the next page.
a Hydraulic oil temperature for measurement:
45 – 55°C
• P27MR-2
• PC30, 35MR-2
• PC40, 50MR-2
MEASURING
a Hydraulic oil temperature for measurement:
45 – 55°C
TESTING ADJUSTING
1. Set the machine to the travel posture. Note) Do not perform the following procedure for
a Extend the bucket cylinder and arm cylinder PC27, 30MR-2.
to the stroke end and set the boom angle to a If the machine deviates, it can be corrected by
45 degrees. partially draining the oil discharged more from
the pump through the adjustment plug. (If the
travel deviation is corrected by this method, how-
ever, the pump discharge is reduced. As a
result, the travel speed, work equipment speed
in compound operation, and relief pressure may
lower.)
a If the machine deviates in the same direction
regardless of the travel direction, correct it
according to the following procedure.
a Only when the travel deviation is 200 mm or less,
it can be corrected by the following method.
k If the adjustment plug is loosened more than
the adjustment limit, high-pressure oil will spout
1. Check the locations of adjustment plugs (1) and 6. Check the travel deviation again according the
(2) of the main pump. above described testing procedure. If it is not
• (1): Right deviation adjustment plug corrected completely, adjust it again.
• (2): Left deviation adjustment plug a Do not adjust more than the adjustment limit
Example of PC35MR-2 of the adjustment plug (2 turns/720 degrees).
3 Adjustment plug:
plug fully, and then adjust it again.
MEASUREMENT OF OIL 2. Disconnect the hose on the head side and plug
the hose on the chassis side.
LEAKAGE FROM WORK • Hose (1): Boom cylinder
EQUIPMENT CYLINDER • Hose (2): Arm cylinder
• Hose (3): Bucket cylinder
k Take care not to disconnect the hose on the
a Measuring instruments for oil leakage from work
equipment cylinder cylinder bottom side.
Symbol Part No. Part name
1. Fully extend the rod of the cylinder to be mea- PC27, 30, 35MR-2
sured and stop the engine.
Posture for measuring boom cylinder
PC40, 50MR-2
1 2 3 4 5 6 7
Note: Bleed air from the swing motor and travel motor only after the oil in the motor cases is drained.
PC35MR-2
RELEASING RESIDUAL
PRESSURE FROM
HYDRAULIC CIRCUIT
k Since an accumulator is not installed, the resid-
ual pressure in the piping between the main
control valve and each hydraulic cylinder or
swing motor cannot be released even if the
control levers are operated.
When removing the above piping, observe the
following points.
RELEASING RESIDUAL
PRESSURE FROM
HYDRAULIC TANK
k The hydraulic tank is enclosed and pressurized.
When remove a hose or a plug connected to
the hydraulic tank, release the residual pres-
sure from the hydraulic tank according to the
following procedure.
PRESSURIZING HYDRAULIC
TANK
a If the oil filler cap is removed from the hydraulic
tank, pressurize the hydraulic tank according to
the following procedure.
2. Stop the engine and open the oil filler cap of the
hydraulic tank and tighten it again.
PC40, 50MR-2
PC40, 50MR-2
7. Open cover (4). 10. After the floor rises, push up knob (6) until lock
a Perform this step for only PC27, 30, 35MR-2 pin (7) is fitted to lock groove (a) of lock plate (8).
with cab specification. a When the lock pin moves to the lock groove,
the 1st locking is completed.
PC27 • 30 • 35MR-2
2. While pulling floor lock release lever (5) toward
the rear of the machine with the left hand, hold
knob (6) with the right hand and push down the
floor toward the rear of the machine.
k Do not put any part of your body under the
floor while opening or closing the floor.
a While checking that the wiring and piping are
not caught or damaged, push down the floor
slowly.
PC40 • 50MR-2
PC40 • 50MR-2
3 Fixing bolt:
156.8 – 196 Nm {16 – 20 kgm}
INSPECTION PROCEDURES
FOR DIODE
a Check an assembled-type diode (8 pins) and sin-
gle diode (2 pins) in the following manner.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
Mode Contents
E-mode Troubleshooting for electric system
H-mode Troubleshooting for hydraulic and mechanical system
M-mode Troubleshooting for monitor panel
S-mode Troubleshooting for engine unit
Troubleshooting
No. Possible fault
E-mode H-mode M-mode S-mode
Troubleshooting
No. Possible fault
E-mode H-mode M-mode S-mode
Troubleshooting
No. Possible fault
E-mode H-mode M-mode S-mode
F14 DT-T 2 PPC lock switch (Right) (Canopy specification) (*1) G-5 —
F21 DT-T 2 Rotary lamp (If equipped for canopy specification) K-9 —
Address of connector
Connector Number arrangement drawing
Type Location
No. of pins Canopy Cab
specification specification
M2 X 2 Fuel level sensor A-8 M-8
R6 R 5 — — —
Address of connector
Connector Number arrangement drawing
Type Location
No. of pins Canopy Cab
specification specification
T-F6 Terminal 1 Starting switch terminal R2 H-8 T-8
V1 DT 12 — — —
PC40, 50MR-2 (*1): Except PC40MR-2, Serial No. 11933 and up, and PC50MR-2, Serial
No. 8550 and up for North America.
Address of connector
Connector Number arrangement drawing
No. Type of pins Location
Canopy Cab
specification specification
A2 X 2 Travel pressure switch AD-3 —
F14 DT-T 2 PPC lock switch (Right) (Canopy specification) (*1) AE-5 —
F21 DT-T 2 Rotary lamp (If equipped for canopy specification) AI-9 —
Address of connector
Connector Number arrangement drawing
Type Location
No. of pins Canopy Cab
specification specification
FB1 – – Fuse box AJ-3 AV-3
M17 DT-T 2 2nd travel speed selection solenoid relay AD-3 AP-3
R6 R 5 — — —
Address of connector
Connector Number arrangement drawing
Type Location
No. of pins Canopy Cab
specification specification
T-F4 Terminal 1 Starting switch terminal C AE-9 AQ-9
V1 DT 12 — — —
PC40, 50MR-2
Canopy specification
PC40, 50MR-2
Cab specification
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
16 799-601-7320
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)
17 799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
— —
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
4 —
— —
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820T (normal type) Part No.: 08192-1810T (normal type)
08192-2820T (fine wire type) 08192-2810T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920T (normal type) Part No.: 08192-1910T (normal type)
08192-2920T (fine wire type) 08192-2910T (fine wire type)
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
[The pin No. is also marked on the connector (electric wire insertion end)]
24 799-601-9360
40
799-601-9350
(A)
40
799-601-9350
(B)
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Type of connector No. of pins
—
799-601-2600 Box for measurement Econo-21P Q Q Q Q Q Q
799-601-3100 Box for measurement MS-37P Q
799-601-3200 Box for measurement MS-37P Q
799-601-3300 Box for measurement Econo-24P Q
799-601-3360 Plate For MS box
799-601-3370 Plate For MS box
799-601-3380 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Type of connector No. of pins
—
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Type of connector No. of pins
—
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD24 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Box for measurement For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For fuel, boost
799-601-9420 3P Q
pressure
799-601-9430 PVC socket 2P Q
Safety relay
Fuel pump
2 10A
PPC lock solenoid relay
Horn switch
Monitor
Room lamp
Radio
6 20A
Wiper motor
Radio
9 — (Spare)
—
10 — (Spare)
<Content Included>
• Standard value in normalcy by which to pass "Good" or "No good"
judgement over the presumed cause
1
• Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>
• Disconnection
There is a faulty contact at the connector or disconnection of wiring
harness occurred.
• Defective grounding
A wiring harness that is not connected with a grounding circuit has
2
a contact with the grounding circuit.
• Short-circuiting
A wiring harness that is not connected with a 12 V electric circuit
Presumed cause Cause that presumably trig- has a contact with the electric circuit.
and standard value gered failure in question
<Precaution for Troubleshooting>
in normalcy (The assigned No. is for filing
1) Connector No. display method and handling of T-adapter
purpose only. It does not
stand for any priority) Insert or connect T-adapters in the following manner before start-
ing troubleshooting unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific con-
nector No., disconnect the connector and insert the T-adapter
into both male and female sides.
• If there is an indication of "male" or "female" in a specific con-
3 nector No., disconnect the connector and connect the T-adepter
with only one side of either "male" or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a cir-
cuit tester in the following manner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the
front or the wiring harness.
• Connect the negative (–) lead with the pin No. indicated at the
front or the wiring harness.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
Failure information • Engine does not start (Starting motor does not rotated)
• Since the engine starting circuit has a locking function, the engine cannot start if the PPC lock lever
(lock lever) is not in the LOCK position.
Relative information
• The lock lever is installed to the right and left side of the canopy specification and to the left side of the
cab specification.
PC40, 50MR-2 (*1): Except PC40MR-2, Serial No. 11933 and up, and PC50MR-2, Serial
No. 8550 and up for North America.
Failure information • Engine does not start (Starting motor does not rotated)
• Since the engine starting circuit has a locking function, the engine cannot start if the PPC lock lever
(safety lock lever) is not in the LOCK position.
Relative information
• The lock lever is installed to the right and left side of the canopy specification and to the left side of the
cab specification.
PC40, 50MR-2
a For the related circuit diagram, see 1).
Failure information • Engine does not start (Fault in engine stop solenoid)
Relative information • The starting motor rotates but the engine does not start.
PC40, 50MR-2
Failure information • Engine does not stop
Relative information
PC40, 50MR-2
• When work equipment lock (PPC basic pressure lock) lever is set in LOCK position, work equipment
Failure information
still moves
Relative information
PC40, 50MR-2
Failure information • Windshield washer does not operate
• Before starting troubleshooting, check the liquid level in the tank.
Relative information • The windshield wiper operates. (If the windshield wiper does not operate, carry out troubleshooting E-
4 first.)
2) Air does not blow out or air flow rate does not change
Trouble • Air does not blow out or air flow rate does not change
Related informa- • Check in advance that the fuse is normal and the continuity of the wiring harnesses between the con-
tion nectors is normal.
Defective temperature a Prepare with starting switch OFF, then carry out troubleshooting
1 without turning starting switch.
regulator switch
Temperature regulator
switch connector (2) Operation of knob Resistance
(Switch side)
COOL-MAX o Approx. 2.3 kz o
Middle position Max. 1 z
Y/W – Y/B
Middle position o
Max. 1 z
HOT-MAX
COOL-MAX o
Approx. 2.3 kz
Middle position
Y/W G/W
Middle position o Approx. 2.3 kz o
HOT-MAX Max. 1 z
Possible causes a Prepare with starting switch OFF, then turn starting switch ON and
and standard val- carry out troubleshooting.
ue in normal state a Turn blower switch ON (Set it to the 1, 2, or 3 position) and carry out
troubleshooting.
Rod operates according to operation of temperature regula-
Operation
tor switch.
2 Defective water valve
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Condition becomes Water valve assembly is
Replace water valve normal. defective.
assembly with normal
one. Condition does not be- Water valve assembly is
come normal. normal.
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness (Disconnection in wir- without turning starting switch.
3
ing harness or defective Referring to the circuit diagram, check the con- Resis-
contact in connector) Max. 1 z
tinuity between connectors. tance
a Prepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch.
ground in wiring harness
4 Referring to the circuit diagram, check the insu-
(Contact with ground cir- Resis-
cuit) lation between each connector and chassis Min. 1M z
tance
ground. (Do not check the ground circuit.)
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Condition becomes Control amplifier is
5 Defective control amplifier
Replace control ampli- normal. defective.
fier with normal one. Condition does not Control amplifier is
become normal. normal.
8) Water leaks
Trouble • Water leaks.
Related informa-
—
tion
2
Cause for presumed
failure <Contents>
Presumed cause
(The attached No. for • The standard values in normalcy by which to judge "good" or "no
and standard value 3
filing and reference good" about presumed causes.
in normalcy
purpose only. It does not • References for making judgement of "good" or "no good"
stand for any priority)
4
: Normal
: Low in speed or power
Whole Trouble-
work Travel Swing Blade shooting
equipment item
Go to 1)
Go to 2)
Go to 3)
Go to 4)
Go to 5)
Go to 6)
1) Speed or power of whole work equipment, travel, swing, and blade is low
Failure information • Speed or power of whole work equipment, travel, swing, and blade is low
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Relative information
• Before starting troubleshooting, check that the electric system (solenoid circuit) is normal.
• If a phenomenon disappears as the engine speed is increased, it is not a fault.
Failure information • Speed or power of whole work equipment and travel is low
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative information • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
• If a phenomenon disappears as the engine speed is increased, it is not a fault.
3.2±0.49MPa
PC40, 50MR-2
Presumed cause {33±5kg/cm2}
and standard value a Prepare with engine stopped, then run engine at full throttle and carry
in normalcy out troubleshooting.
Differential pressure
Oil pressure to be measured Curl bucket with no
Set all levers in
load (Move lever to
neutral
stroke end)
Defective adjustment or mal- Difference pres- PC27, 3.9 + 0.98
0 MPa 1.57±0.1MPa
3
function of LS valve sure between 30MR-2 {39.6 + 10
0 kg/cm 2} {16±1kg/cm2}
+ 0.98
pump discharge 3.2 0 MPa 1.41±0.1MPa
PC35MR-2
pressure and LS {33 + 10 2
0 kg/cm } {14.4±1kg/cm2}
valve input pres- PC40, 3.2±0.49MPa 1.57±0.1MPa
sure
50MR-2 {33±5kg/cm2} {16±1kg/cm2}
If the oil pressure ratio does not become normal after adjustment, the LS
valve may have a malfunction or a defect in it. Check it directly.
Referring to TESTING AND ADJUSTING, Adjusting PC valve, adjust the
Defective adjustment or mal-
4 PC valve. If the oil pressure does not become normal after adjustment,
function of PC valve
the PC valve may have a malfunction or a defect in it. Check it directly.
5 Malfunction of servo piston The servo piston may have a malfunction. Check it direction.
If any problem is not detected by the above checks, the cause may be
6 Defective piston pump lowering of performance, malfunction, or internal defect of the piston
pump.
Malfunction of sequence If the fault does not disappear when the engine speed is increased, the
7
valve (PC27, 30MR-2) sequence valve may have a malfunction. Check it directly.
Failure information • Speed or power of whole work equipment and blade is low
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative information • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
• If a phenomenon disappears as the engine speed is increased, it is not a fault.
: Normal
: Does not work
Whole Trouble-
work Travel Swing Blade shooting
equipment item
Go to 1)
Go to 2)
Go to 3)
Go to 4)
Go to 5)
Go to 6)
1) Whole work equipment, travel system, swing system, and blade do not work
Failure information • Whole work equipment, travel system, swing system, and blade do not work
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative information • When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
• Before starting troubleshooting, check that the electric system (solenoid circuit) is normal.
Failure information • Whole work equipment and travel system do not work
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Presumed cause Cause Standard value in normalcy and references for troubleshooting
and standard value Malfunction of control valve The suction valve (head side) of the control valve may have a malfunc-
in normalcy 1
(suction valve) tion. Check it directly.
2) Machine deviates when it starts (It does not deviate during ordinary travel)
Failure information • Machine deviates when it starts (It does not deviate during ordinary travel)
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Failure information • Travel motors on both sides do not work (PC35, 40, 50MR-2)
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
[Remarks]
Relationship between defect of PPC circuit check valve and "Travel motor does not work"
PPC circuit check valves A – D are installed as shown in the following figure to take out the signal pressure for
changing the pump merge valve from the travel PPC pressure.
If the checking function of check valves A – D is lost, the travel motors may not work.
Failure information • Travel motor on only one side does not work
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
Relative information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Failure information • Hydraulic drift of swing is large (when swing holding brake is applied)
• When the control levers on the swing and arm IN side are in neutral, the swing holding brake operates
Relative information
and the upper structure is fixed by the disc brake.
Failure information • Hydraulic drift of swing is large (while swing holding brake is released)
• If the arm is moved IN, the swing brake is released and the upper structure is held by only hydraulic
Relative information
pressure.
If the oil pressure does not become normal after adjustment, the relief
valve may have a malfunction or a defect in it. Check it directly.
aPrepare with engine stopped, then run engine at full throttle and car-
ry out troubleshooting.
Blade control lever PPC valve output pressure
Set in neutral 0MPa {0kg/cm2}
Presumed cause 2 Malfunction of PPC valve
and standard value PC27, 30, 2.94 +– 0.49
0.1 MPa
in normalcy Operate to raise or lower 35MR-2 {30 +– 51 kg/cm2}
blade 3.72 +– 0.39
0.1 MPa
PC40, 50MR-2
{38 +– 41 kg/cm2}
Malfunction of blade control The blade control valve spool may have a malfunction. Check it direct-
3
valve spool ly.
aPrepare with engine stopped, then run engine at full throttle and car-
ry out troubleshooting.
4 Defective blade cylinder
Blade cylinder Leakage from cylinder
Relieve by lowering blade 10 cc/min
Malfunction of load check The load check valve in the control valve spool may have a malfunc-
5
valve in control valve spool tion. Check it directly.
The suction valve of the control valve may have a malfunction. Check
Malfunction of suction valve it directly.
6
of control valve * The suction valve is installed on the LOWER side of PC27, 30MR-2
and on both sides of PC35, 40, 50MR-2.
Safety relay
Fuel pump
2 10A
PPC lock solenoid relay
Horn switch
Monitor
Room lamp
Radio
6 20A
Wiper motor
Radio
9 — (Spare)
—
10 — (Spare)
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
PC40, 50MR-2
M-1 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT
OPERATE
• When the starting switch is turned from OFF to ON, the following faults occur in the self-check of the
monitor panel.
1) The warning lamps and indicators do not light up (for 3 seconds).
Failure information
2) The buzzer does not sound (for 1 second).
• The fuel level gauge and coolant temperature gauge do not operate even a while after the starting
switch is turned ON.
Relative information • Before starting troubleshooting, check that fuses No. 3 and No. 7 and fusible link are not broken.
Presumed cause Cause Standard value in normalcy and references for troubleshooting
and standard value See STRUCTURE AND OPERATION, Maintenance standard, "Moni-
in normalcy 1 Defective monitor panel
tor system".
• When the starting switch is turned from OFF to ON, the self-check buzzer does not sound (for 1 sec-
ond).
Failure information
• When the starting switch turned ON and the 2nd travel speed selection switch and light switch are
pressed, the selection sound (a short sound) is not heard.
• Before starting troubleshooting, check that fuse No. 3 is not broken.
Relative information
• Refer to troubleshooting M-1, too.
PC40, 50MR-2
• The monitor panel performs the following operations to notify abnormal charge level while the engine
is running.
Failure information
1) The charge level caution lamp flashes.
2) The buzzer sounds.
• Check that the belt tension is normal.
• When the starting switch is turned from OFF to ON, the monitor panel performs the following opera-
Relative information tions. This does not indicate a fault.
1) The engine oil pressure caution lamp and charge level caution lamp light up.
2) The buzzer does not sound.
PC40, 50MR-2
• When the starting switch is set to HEAT, the following preheating system of the monitor panel does not
operate.
Failure information
1) The preheating indicator flashes (for about 18 seconds).
2) The buzzer sounds at start and end of preheating.
• Check that the fusible link is not broken.
Relative information
• Refer to troubleshooting M-1, too.
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from C on the panel.
• Check that the coolant temperature is normal.
Relative information • While the starting switch is in OFF, the pointer does not move from C. This is not abnormal.
• Refer to troubleshooting M-1, too.
PC40, 50MR-2
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from C on the panel.
• Check that the coolant temperature is normal.
Relative information • While the starting switch is in OFF, the pointer does not move from C. This is not abnormal.
• Refer to troubleshooting M-1, too.
2) The pointer of the gauge does not move from H on the panel
PC27, 30, 35MR-2
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from H on the panel.
• Check that the coolant temperature is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
PC40, 50MR-2
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from H on the panel.
• Check that the coolant temperature is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
• When the starting switch is turned ON, the temperature indicated by the gauge is very different from
Failure information
the actual temperature.
• Check that the coolant temperature is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
PC40, 50MR-2
• When the starting switch is turned ON, the temperature indicated by the gauge is very different from
Failure information
the actual temperature.
• Check that the coolant temperature is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from E on the panel.
• Check that the fuel level is normal.
Relative information • While the starting switch is in OFF, the pointer does not move from E. This is not abnormal.
• Refer to troubleshooting M-1, too.
PC40, 50MR-2
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from E on the panel.
• Check that the fuel level is normal.
Relative information • While the starting switch is in OFF, the pointer does not move from E. This is not abnormal.
• Refer to troubleshooting M-1, too.
2) The pointer of the gauge does not move from F on the panel
PC27, 30, 35MR-2
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from F on the panel.
• Check that the fuel level is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
PC40, 50MR-2
Failure information • When the starting switch is turned ON, the pointer of the gauge does not move from F on the panel.
• Check that the fuel level is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
3) Fuel level indicated by gauge is very different from actual oil level
PC27, 30, 35MR-2
• When the starting switch is turned ON, the fuel level indicated by the gauge is very different from the
Failure information
actual temperature.
• Check that the fuel level is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
PC40, 50MR-2
• When the starting switch is turned ON, the fuel level indicated by the gauge is very different from the
Failure information
actual temperature.
• Check that the fuel level is normal.
Relative information
• Refer to troubleshooting M-1, too.
a For the related circuit diagram and panel gauges, see 1).
• Service meter (Operating hour integrator) does not operate Engine oil pressure and charge does not
Failure information
while engine is running warning
• While the engine is running, the service meter operates even if the machine does not move at all.
• While the engine is stopped, the service meter does not operate.
Relative information • Refer to troubleshooting M-1, too.
a If the service meter still does not work after the troubleshooting for M-4 and M-5, the possible cause
is as follows.
Presumed cause Cause Standard value in normalcy and references for troubleshooting
and standard value If any abnormality is not detected by 1) and 2), the monitor panel is de-
in normalcy 2 Defective monitor panel
fective.
• When the 2nd travel speed selection switch is pressed while the engine is running, the monitor panel
does not make the following responses.
Failure information
1) Turning ON/OFF of 2nd travel speed indicator
2) Changing sound by buzzer (Short sound)
Relative information
Failure information • Monitor panel responds but 2nd travel speed is not selected.
Relative information • Refer to troubleshooting M-1, too.
PC40, 50MR-2
Failure information • Monitor panel responds but 2nd travel speed is not selected.
Relative information • Refer to troubleshooting M-1, too.
• When the starting switch is turned ON and the lamp switch is pressed, the monitor panel does not
make the following responses.
Failure information
1) Turning ON/OFF of monitor back light
2) Changing sound by buzzer (Short sound)
Relative information
Failure information • Monitor panel responds but 2nd travel speed is not selected.
Relative information • Refer to troubleshooting M-1, too.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba- Causes
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
Causes
Replace
Replace
Replace
Clean
Adjust
Adjust
Adjust
Remedy
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cylinder head:
(3) Clogged, seized fuel injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item
marked . The Remedy is given as [Clean], so
carry out cleaning, and the exhaust gas color
should return to normal.
Defective alternator
Defective regulator
– 10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value for the
Starting aid
charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the
value for the charging rate of 75% in the above table.
Confirm recent repair history
Degree of use of machine Operated for long period EEE E
Gradually became worse w w Q Q Q
Ease of starting
Starts when warm w w
w
Questions
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
w
* Adjust
Replace Defetive injection pump (rack, plunger stuck)
q
w
w
Q
Q
Correct Leakage, clogging, air in fuel piping
q
Q w
Causes
Clean Clogged air breather hole in fuel tank
q
w Q
Q
PC30 – 50MR-2
TROUBLESHOOTING
(1)
20-607
S-1
TROUBLESHOOTING S-2
Remedy —
1) No fuel comes out even when fuel filter air bleed plug is
loosened w Q Q Q
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened w w w
Rust and water are found when fuel tank is drained Q Q
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
(3) Exhaust smoke comes out but engine does not start
(Fuel is being injected)
found to be clogged
When feed pump gouze filter is inspected directly, it is found to
be clogged q
When air cleaner is inspected directly, it is found to be clogged q
Heater mount does not become warm q
Either specific gravity of electrolyte or voltage of battery is low q
When feed pump is operated, there is no response, or
operation is too heavy q
Speed does not change when operation of certain cylinders is stopped q
When fuel tank cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
Operation Manual
Non-specified fuel is being used w w w w
Engine oil must be added more frequently w
Rust and water are found when fuel tank is drained w w
Dust indicator lights up w
Engine pick-up suddenly became poor Q Q Q
Blue under light load Q w
Color of exhaust gas
Black w w Q
Clanging sound is heard from around cylinder head w
Mud is stuck to fuel tank cap w
Check items
clogged
Speed does not change when operation of certain cylinders
is stopped q
When control rack is pushed, it is found to be heavy, or does not return q
When compression pressure is measured, it is found to be low q q
When valve clearance is checked directly, it is found to be
outside standard value q
When fuel tank cap is inspected directly, it is found to be clogged q
When feed pump is operated, operation is too light or too heavy q
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
Clean
Clean
Clean
Remedy
Add
to be clogged
Speed does not change when operation of certain cylinders
is stopped q
When control rack is pushed, it is found to be heavy, or
does not return q
When valve clearance is checked directly, it is found to be
outside standard value q
When fuel dial is placed at FULL position, lever does not contact stopper q
When feed pump is operated, operation is too light or too heavy q
When fuel tank cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Replace
Replace
Replace
Adjust
Adjust
Adjust
Clean
Remedy
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Replace
Replace
Replace
Clean
Clean
Remedy —
stopped
When control rack is pushed, it is found to be heavy, or does not
return q
Remove feed pump and inspect directly q
When engine speed is measured, low idle speeds are found to be
high q
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Remedy
Suddenly increased Q
Oil level
Gradually increased Q
Hard water is being used as coolant
q
shooting
Trouble-
Replace
Remedy
Operation Manual
Non-specified oil is being used Q Q
Oil pressure monitor lights up w Q
Lights up at low idle w Q
Condition when oil Lights up at low, high idle w w w w w Q Q Q
pressure caution lamp
lights up Lights up on slopes w
Sometimes lights up w w Q
Check items
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy —
Add
Replace
Correct
Remedy
Lack of coolant
Confirm recent repair history
Degree of use of machine Operated for long period EE E
Questions
Suddenly overheated w Q Q
Condition of overheating
Always tends to overheat w w Q Q
Coolant temperature Rises quickly w Q
gauge Does not go down from red range w
Fan belt whines under sudden load w
Cloudy white oil is floating on coolant w
Coolant flows out from overflow hose w
Excessive air bubbles inside radiator, water spurts back w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found in oil filter w w
Metal particles are found when oil is drained w w
Oil pressure is low at low idle Q Q
Vibration occurs at mid-range speed Q Q
Check items
Replace
Correct
Adjust
Remedy
• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing part
kind of information are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
t: Special tools which cannot be substi- are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Speciall tools which are very useful if stand for the following.
k
available, can be substituted with com-
This mark indicates safety-related pre-
mercially available tools.
cautions, which must be followed when
2) Distinction of new and existing special tools. doing the work.
N: Tools with new part numbers, newly a This marks gives guidance or precau-
developed for this model. tions when doing the procedure.
5
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the spe- This mark indicates an amount of oil or
cial tool is presented in the section of water to be added.
Sketches for Special Tools.
a Part No. of special tools starting with 79*T SKETCHES OF SPECIAL TOOLS
means that they are locally made parts and as
such not interchangeable with those made by • Various special tools are illustrated for the con-
Komatsu in Japan e.g. 79*T---×××---××××. venience of local manufacture.
REMOVAL OF PARTS
SPECIAL TOOLS
5
for other models.
Blank: Tools already available for other models, This mark indicates an amount of oil or
used without any modification. water to be added.
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of SKETCHES OF SPECIAL TOOLS
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T 1) Vartious special tools are illustrated for the
means that they are locally made parts and convenience of local manufacture.
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T---×××--
-××××.
DISASSEMBLY
C. If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
PC27,30,
796T-126-1210 Wrench t 1 N Q 35MR-2 Removal,
1 installation
796T-126-1410 Wrench t 1 N Q PC40,50MR-2 of nut
790-101-5151 • Plate 1
PC27,30,
35MR-2
790-101-5021 • Grip 1
01010-50816 • Bolt 1
2 Press fitting
of oil seal
790-101-5201 Push tool KIT t 1
790-101-5251 • Plate 1
PC40,50MR-2
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5271 • Plate 1
PC27,30,
35MR-2
Disassembly, assembly of 790-101-5221 • Grip 1
swing motor and swing F
machinery assembly 01010-51225 • Bolt 1 Press fitting
3 of outer
790-101-5201 Push tool KIT q 1 race (small)
790-101-5311 • Plate 1
PC40,50MR-2
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5331 • Plate 1
PC27,30,
35MR-2
790-101-5221 • Grip 1
790-101-5341 • Plate 1
PC40,50MR-2
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
PC27,30,
796-760-9110 Push tool t 1
35MR-2 Press fitting
5 of bearing
Disassembly, assembly of 796-465-1120 Push tool t 1 PC40,50MR-2 (small)
swing motor and swing F
PC27,30,
machinery assembly 790-445-3810 Push tool t 1
35MR-2 Press fitting
6 of bearing
795-765-1110 Push tool t 1 PC40,50MR-2 (large)
790-101-5081 • Plate 1
1 Press fitting of bushing
Disassembly, assembly of
idler assembly 790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5081 • Plate 1
Press fitting of ball bearing
5 and cap
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly, assembly of
carrier roller
790-101-5001 Push tool KIT q 1
790-101-5111 • Plate 1
6 Press fitting of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly, assembly of Disassembly, assembly of
recoil spring assembly M 792-371-1400 Sleeve t 1 recoil spring assembly
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly, assembly
of center swivel joint T 791-112-1180 • Nut 1 Separation of rotor and swivel
joint
assembly
790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly, assembly 4 790-201-1731 • Push tool 1 Press fitting of bushing
of hydraulic cylinder
assembly U
790-201-1751 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1560 • Plate 1
790-201-1550 • Plate 1
790-201-1570 • Plate 1
PC27MR-2
boom, swing
PC30MR-2
boom,arm,swing
6 790-720-1000 Expander q 1 PC35MR-2
boom,arm Installation
PC50MR-2 of piston
bucket ring
796-720-1630 Ring q 1
PC27MR-2
7
bucket
07281-00709 Clamp q 1
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
PC27MR-2
796-720-1640 Ring q 1 boom, swing
PC30MR-2
boom,arm,swing
PC35MR-2
boom,arm
07281-00909 Clamp q 1 PC50MR-2
bucket
796-720-1660 Ring q 1
PC40, 50MR-2
blade
07281-00159 Clamp q 1
8. Remove nut (13) from the end of the fuel injec- • Sample of identification mark
tion pump drive shaft. [*3]
a Take care not to drop the nut into the case.
a Never loosen mounting bolts (14) of pump
drive gear (3) and flange. (If the flange and
pump drive gear move from each other, it
becomes very difficult to adjust the injection
timing.)
[*2]
a Referring to the following figure, install the fuel
tube.
a The cylinder of the engine on the flywheel side is
the No. 1 cylinder.
PC27, 30, 35MR-2
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a When installing the fan, line up the match marks.
a Check that the identification mark (M) of the fan
is on outside.
Identification PC40, 50MR-2
Machine model Engine type
mark (M)
PC27MR-2 3D82AE T
PC30MR-2 3D84E YA
S3D84E YA
PC35MR-2
3D88E YA
PC40MR-2 4D88E KS
PC50MR-2 4D88E KS
REMOVAL AND INSTALLATION 6. Open the rear cover of the machine and right
side cover. Remove all the mounting bolts of
OF RADIATOR AND plate (9) on the right side of the engine, and then
HYDRAULIC OIL COOLER raise the plate toward the front of the machine
ASSEMBLY and secure it with ropes, etc.
REMOVAL
1. Release the air pressure in the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing air in hydraulic tank.
6 Coolant: 3.3 l
7. Remove air hose (10) and air cleaner case and
bracket assembly (11).
4. Remove cover (7). 8. Remove reservoir tank hose (12).
5. Remove all the mounting bolts of plate (8) on the 9. Remove battery (13).
left side of the engine.
a Since the plate cannot be removed, set it so
that it can be removed.
10. Disconnect tube (14). 14. Loosen alternator belt (20). [*1]
11. Disconnect hoses (15) and (16) from the hydrau- 15. While leaning the radiator toward this side,
lic oil cooler. remove cooling fan (21).
a Return the radiator.
5 Coolant: 3.3 l
REMOVAL
1. Release the air pressure in the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing air in hydraulic tank.
6 Coolant: 7.3 l
4. Open cover (7) and remove cover (8). 7. Disconnect air duct (11) and hose (12). [*1]
10. Loosen the alternator belt. [*2] 14. Remove reservoir tank (20).
17. Sling the radiator and hydraulic oil cooler assem- 19. Lift off radiator and hydraulic oil cooler assembly
bly temporarily. (27).
a Remove the radiator and hydraulic oil cooler
18. Remove mounting bolts (24), (25), and (26) (2 assembly without removing the fan shroud.
pieces). [*3] a When removing the radiator and hydraulic oil
cooler assembly, take care not to damage
the core.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
a Adjust the belt tension. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting
alternator belt tension.
[*3]
3 Mounting bolts
(24): 59 – 74 Nm {6 – 7.5 kgm}
(25), (26): 98 – 123 Nm {10 – 12.5 kgm}
5 Coolant: 7.3 l
4 Canopy 77 kg
PC35MR-2
6 Coolant: 3.3 l
5 Coolant: 3.3 l
• Bleeding air
a Bleed air. For details, see TESTING AND ADJUST-
ING, Bleeding air from each part.
REMOVAL
1. Tilt up the floor frame.
For details, see TESTING AND ADJUSTING,
How to open and close (tilt) floor.
k Disconnect the cable from the negative (–)
terminal of the battery.
6 Coolant: 7.3 l
6 Hydraulic oil: 20 l
7. Remove clamp (11) and 2 air cleaner case
mounting bolts (12).
4. Open cover (7) and remove cover (8).
9. Remove air cleaner case and hose assembly 13. Remove alternator belt. [*3]
(14). [*1]
14. Remove plate (20).
12. Remove fan guard (19). 16. Remove fuel control cable (22). [*4]
18. Remove and shift the clamp of fuel control cable 23. Remove exhaust manifold cover (42), muffler
(22). (43), and exhaust tube (41). [*5]
[*1]
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
3 Radiator hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*3]
a Adjust the belt tension. For details, see
TESTING AND ADJUSTING, Testing and
adjusting alternator belt tension.
27. Sling the engine and hydraulic pump assembly
temporarily. [*4]
a Adjust the cable tension. For details, see
28. Remove 4 mounting nuts (50). [*6] TESTING AND ADJUSTING, Testing and
adjusting fuel control lever.
[*5]
2 Muffler bracket mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
[*6]
2 Mounting nut: Adhesive (LT-2)
3 Mounting nut: 59 – 74 Nm {6 – 7.5 kgm}
29. Lift off engine and hydraulic pump assembly • Refilling with water
(51). a Add water through the water filler to the specified
a Check that all the wires and pipes have been level. Run the engine to circulate the water
disconnected. through the system. Then, check the water level
a When removing the engine and hydraulic again.
pump assembly, take care that it will not 5 Coolant: 7.3 l
interfere with other parts.
4 Engine and hydraulic pump assembly: • Refilling with oil (Hydraulic tank)
250 kg a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
• Bleeding air
a Bleed air. For details, see TESTING AND ADJUST-
ING, Bleeding air from each part.
REMOVAL AND INSTALLATION 4. Sling track shoe assembly (3) and pull it out
toward this side.
4 Rubber shoe
OF TRACK SHOE ASSEMBLY
REMOVAL PC27MR-2: 120 kg
PC30, 35MR-2: 130 kg
1. Swing the upper structure by 180° and raise the PC40, 50MR-2: 250 kg
machine by using the work equipment and blade.
Double grouser shoe
2. Loosen valve (1) to discharge grease and loosen PC27MR-2: 160 kg
the track shoe tension. [*1] PC30, 35MR-2: 170 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a Adjust the track shoe tension. For details,
see TESTING AND ADJUSTING, Testing
and adjusting track shoe tension.
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5001 Push tool KIT q 1
790-101-5081 • Plate 1
1
L 790-101-5021 • Grip 1
01010-50816 • Bolt 1
2 791-430-3230 Installer t 1
3. Using tool L2, install floating seals (7) to support
a In this section, only the assembly procedure is (3) and (6).
explained. a Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
ASSEMBLY a Coat the sliding surface of the floating seal
with engine oil (EO30-CD) before installing,
1. Using tool L1, press fit 2 bushings (10) to idler and be careful not to let any dirt or dust stick
(9). to it.
2. Using tool L2, install 2 floating seals (8) to idler 4. Fit O-ring and install shaft (5) to support (6).
(9).
a Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
a Coat the sliding surface of the floating seal
with engine oil (EO30-CD) before installing,
and be careful not to let any dirt or dust stick
to it.
3 Mounting bolt :
98 – 123 Nm {10.0 – 12.5 kgm}
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
M 792-371-1400 Sleeve t 1
DISASSEMBLY
1. Piston
1) Remove valve (1).
2) Remove piston (2).
3. Cylinder ASSEMBLY
1) Remove snap ring (8), then remove spacer
(9) from cylinder (10). 1. cylinder
2) Remove dust seal (11) 1) Install O-ring (12) to cylinder (10).
3) Remove O-ring (12). 2) Install dust seal (11).
3) Fit spacer (9) and secure with snap ring (8).
2. Recoil spring
1) Assemble cylinder assembly (7), spring (6),
and stopper (5).
2) Using tool M, set recoil spring to press. a After assembling the recoil spring, check that
k The recoil spring is under large installed
the out-of -parallel between surface a of cyl-
inder (7) and surface b of stopper (5) is less
load, so be sure to set the tool properly.
than 0.5 mm.
Failure to do this is dangerous.
a The figure shows PC27, 30, 35MR-2 as
3) Apply hydraulic pressure slowly to compress
an example.
spring, then fit nut (4) and install screw (3).
a Installed height of spring:
PC27, 30, 35MR-2: 188 mm
PC40, 50MR-2
Rubber shoe specification: 202.2 mm
Steel, road liner specification: 238.2 mm
a Installed height of spring:
PC27, 30, 35MR-2: 30.9 kN {3,153 kgm}
PC40, 50MR-2
Rubber shoe specification:
42.4 kN {4,326 kgm}
Steel, road liner specification:
26.9 kN {2,748 kgm}
3. Piston
1) Tighten plug (1) temporarily.
a Grease will come out from grease hole c,
so tighten completely, then turn back
approx. 2 turns.
2) Add approx. 120 cc of grease (G2-LI) inside
cylinder.
3) Assembly cylinder (2) and push in until
grease come out from grease hole c.
4) When grease come out, tighten valve (1).
a After tightening the valve, check that the
grease fitting is facing the outside (just
beside) of the chassis.
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5001 Push tool KIT q 1
790-101-5051 • Plate 1
(PC27, 30, 35MR-2)
3 790-101-5081 • Plate 1
(PC40, 50MR-2)
L 790-101-5021 • Grip 1
3. Set the floating seal (4) in the collars (1) and (2)
01010-50816 • Bolt 1
by using the tool L4.
Installer
791-434-1660
(PC27, 30, 35MR-2) t 1 a Clean the O-ring and the O-ring contact sur-
4 face to degrease completely and dry them.
Installer
791-430-3230 (PC40, 50MR-2) t 1
a Apply engine oil (EO30-CD) to the floating
seal sliding surface and keep it free from
a In this section, only the assembly procedure is
dust.
explained.
ASSEMBLY
1. Press fit two pieces of the bushing (7) in the
roller (6) using the tool L3.
4. Set the O-ring and install the shaft (3) in the roller.
5 Roller inside:
PC27, 30, 35MR-2:
Approx. 50cc (EO30-CD)
PC40, 50MR-2: Approx. 135cc (EO30-CD)
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5001 Push tool KIT q 1
790-101-5081 • Plate 1
5
790-101-5021 • Grip 1
01010-50816 • Bolt 1
3. Fill the inside of the roller with grease.
L
2. Using tool L6, press fit dust seal (4) to roller (5).
REMOVAL AND INSTALLATION 5. Remove lever (12) from the center swivel joint.
[*1]
OF CENTER SWIVEL JOINT
ASSEMBLY
PC27, 30, 35MR-2
REMOVAL
1. Release the air pressure in the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing air in hydraulic tank.
REMOVAL
1. Release the air pressure in the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing air in hydraulic tank.
[*1]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
153 – 190 Nm {15.5 – 19.5 kgm}
6. Remove lever (16) from the center swivel joint. 9. Remove elbow (27) and center swivel joint
[*1] assembly.
[*1]
2 Lever mounting bolt: Adhesive (LT-2)
3 Lever mounting bolt:
153 – 190 Nm {15.5 – 19.5 kgm}
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
DISASSEMBLY AND ASSEMBLY 4. Remove dust seal (6), 3 plugs (7), and 4 plugs
(8) from the swivel shaft (5).
OF CENTER SWIVEL JOINT a PC40, 50MR-2 has 1 plug (7) at the center.
ASSEMBLY
5. Remove ring (10), O-ring (11), backup ring (12),
SPECIAL TOOLS and 7 slipper seals (13) from rotor (9).
a Only PC27, 30, 35MR-2 has backup ring
New/Remodel
(12).
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
T 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2660 • Adapter 2
DISASSEMBLY
1. Remove bolts (1) and plate (2).
ASSEMBLY
1. Install O-ring (11), backup ring (12), and 7 slipper
seals (13) to rotor (9).
a Install backup ring (12) to only PC27, 30,
35MR-2.
a PC40, 50MR-2 has 8 slipper seals (13).
REMOVAL AND INSTALLATION 4. Remove floor mat (2) and bar (3).
a Perform this step for only the model with the
OF FLOOR FRAME ASSEMBLY canopy specification.
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
4 Canopy 77 kg
8. Remove cover (5a). 11. Disconnect 4 travel PPC hoses (9). [*3]
a Identification type colors of hoses
(PC27MR-2): Right front: "Black, yellow"
Right rear: "Yellow, green"
Left front: "Yellow, brown"
Left rear: "Yellow, orange"
a Identification marks of hoses
(PC30, 35MR-2): Right front: "1"
Right rear: "2"
Left front: "3"
Left rear: "4"
a Identification tape colors of hoses
(PC40, 50MR-2): Right front: "Black, yellow"
Right rear: "Green, yellow"
Left front: "Brown, yellow"
9. Remove work equipment PPC hoses (6) and (7), Left rear: "Yellow"
8 pieces in total. [*1]
a Hose band colors 12. Disconnect 2 swing PPC hoses (10). [*4]
PC27MR-2: a Identification tape colors of hoses
Hoses (6) on this side from above: (PC27MR-2): Right side: "Blue, white"
Black, yellow, blue and red Left side: "Red, white"
Hoses (7) on the deeper side from above: a Identification marks of hoses
Brown, green, white and orange (PC30, 35MR-2): Right side: "A"
PC30, 35MR-2: Left side: "B"
Hoses (6) on this side from above: a Identification tape colors of hoses
White, green, brown, and orange (PC40, 50MR-2): Right side: "White, blue"
Hoses (7) on the deeper side from above: Left side: "White, red"
Blue, yellow, red, and black
13. Disconnect hose (11).
PC40, 50MR-2:
Hoses (6) on this side from above:
Brown, green, white, and orange
Hoses (7) on the deeper side from above:
Blue, yellow, red, and black
14. Disconnect connectors (12) – (15) in front of the 17. Loosen 2 bolts (17) gradually and alternately to
revolving frame. disconnect damper (18).
PC27, 30, 35MR-2
19. Remove right and left bolts (20) and pull out pin
(21).
PC40, 50MR-2
20. Lift off canopy and floor frame (operator's cab 21. Lift off floor frame assembly (23).
and floor frame) assembly (22). (Only for PC27MR-2, Serial No. 17902 and up,
Except PC27MR-2, Serial No. 17902 and up, and PC35MR-2, Serial No. 9242 and up for
and PC35MR-2, Serial No. 9242 and up for North America with the canopy specification.)
North America. a Check that all the wires and pipes have been
a Check that all the wires and pipes have been disconnected.
disconnected. a When removing the assembly, take care of
a When removing the assembly, take care of its balance.
4 Floor frame assembly: 190 kg
its balance.
a Do not remove the canopy singly.
a The operator's cab and the floor frame are
made in 1 unit.
4 Canopy and floor frame assembly:
290 kg
Cab and floor frame assembly: 400 kg
Canopy specification
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a When connecting, check the identification
Cab specification colors.
[*2]
a Adjust the cable tension. For details, see
TESTING AND ADJUSTING, Testing and
adjusting fuel control lever.
[*3], [*4]
a When connecting, check the identification
marks and colors.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
DISASSEMBLY AND ASSEMBLY a The figures in this section show PC27, 30,
35MR-2. Although PC40, 50MR-2 has dimen-
OF SWING MOTOR AND sions and shapes a little different from these fig-
SWING MACHINERY ASSEMBLY ures, the disassembly and assembly procedures
are the same.
SPECIAL TOOLS
DISASSEMBLY
PC27, 30, 35MR-2
a Since an oil drain plug is not installed, prepare
New/Remodel
an oil pan, etc. to receive oil flowing out of the
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
PC27, 30, 35MR-2:Approx. 0.9 l
1 796T-126-1210 Wrench t 1 N Q
PC40, 50MR-2: Approx. 1.3 l
790-101-5001 Push tool KIT t 1
790-101-5151 • Plate 1 1. Swing motor assembly
2
790-101-5021 • Grip 1 Set the swing motor and swing machinery
01010-50816 • Bolt 1 assembly to block [1] and remove swing motor
790-101-5201 Push tool KIT q 1
assembly (1).
790-101-5271 • Plate 1
3
F 790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5201 Push tool KIT q 1
790-101-5331 • Plate 1
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
5 796-760-9110 Push tool t 1
6 790-445-3810 Push tool t 1
PC40, 50MR-2
2. No. 1 sun gear
New/Remodel
Necessity
assembly
1 796T-126-1410 Wrench t 1 N Q 1) Remove No. 1 planetary carrier and No. 2
790-101-5201 Push tool KIT t 1 sun gear assembly (3).
790-101-5251 • Plate 1
2
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5201 Push tool KIT q 1
790-101-5311 • Plate 1
3
F 790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5201 Push tool KIT q 1
790-101-5341 • Plate 1
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
5 796-465-1120 Push tool t 1
6 796-765-1110 Push tool t 1
2) Remove snap ring (4), thrust washer (5), No. 3) Remove No. 2 planetary carrier and bearing
1 planetary gear (6), needle roller bearing assembly (19).
(7), spacer (8), and thrust washer (9). a Using a press, etc., push the end of pin-
3) Remove snap ring (10), and then remove ion shaft (24) to remove the No. 2 pinion
No. 1 planetary carrier (11) from No. 2 sun shaft and bearing assembly.
gear (10a).
3) Using tool F1, tighten nut (18). 5) Install thrust washer (17), spacer (16), nee-
2 Nut: Adhesive (LT-2)
dle roller bearing (15), No. 2 planetary carrier
3 Nut
(14), thrust washer (13), and snap ring (12).
a Check that there is no play in the No. 2
PC27, 30, 35MR-2: planetary gear.
245 – 294 Nm {25 – 30 kgm}
PC40, 50MR-2:
392 – 441 Nm {40 – 45 kgm}
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
k When aligning the pin holes, never insert
your fingers in them.
2 Sliding surfaces of pin and boom:
Molybdenum disulfide grease (LM-P)
2 Greasing after installation:
Grease (Hyper white grease)
a Adjust the shim so that clearance a between
boom cylinder head (7) and boom (8) will be
less than 1 mm. (PC40, 50MR-2)
• Set shim thickness: 1 mm
[*2]
k When aligning the pin holes, never insert
your fingers in them.
2 Sliding surfaces of pin and swing bracket:
Molybdenum disulfide grease (LM-P)
2 Greasing after installation:
Grease (Hyper white grease)
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
4 Boom cylinder
and remove mounting bolts (13). [*3]
a Leave 2 bolts each on the front and rear
PC27, 30, 35MR-2: 30 kg sides.
PC40, 50MR-2: 45 kg
[*3]
2 Revolving frame assembly mounting bolt:
Adhesive (LT-2)
3 Revolving frame assembly mounting bolt
PC27, 30, 35MR-2:
117.6 – 137.2 Nm {12 – 14 kgm}
PC40, 50MR-2:
98 – 123 Nm {10 – 12.5 kgm}
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
3 Mounting bolt
REVOLVING FRAME ASSEMBLY.
PC40, 50MR-2
New/Remodel
Symbol
Necessity
Part No. Part name a Take care not to damage the packings, dust
Sketch
seals, O-rings, etc.
Q'ty
790-502-1003 Cylinder repair stand t 1 a Clean each part thoroughly. After assembling,
1
790-101-1102 Hydraulic pump t 1 close the piping ports and pin inserting holes so
2 790-330-1100 Wrench assembly t 1 that dirt will not enter them.
Commercially Socket (Width across
t 1
available flats: 41 mm) a Do not insert each backup ring forcibly, but warm
Commercially Socket (Width across it in water at 50 – 60°C and then insert it.
available flats: 46 mm) t 1
Socket
790-302-1390 (Width across flats: t 1 1. Cylinder
46 mm, long type) 1) Fit the O-ring and install elbow (25) to cylin-
Socket (Width across der (3).
3 790-302-1270 flats: 50 mm) t 1
a Perform this step for only the arm cylin-
Socket
790-302-1490 (Width across flats: t 1 der of PC35, 40, 50MR-2.
3 Elbow
50 mm, long type)
Socket (Width across
790-302-1280 flats: 55 mm) t 1 PC35MR-2:
Socket 84 – 132 Nm {8.5 – 13.5 kgm}
790-302-1470 (Width across flats: t 1 PC40, 50MR-2:
55 mm, long type)
128 – 186 Nm {13 – 19 kgm}
790-201-1702 Push tool KIT t 1
2) Press fit bushing (24).
790-101-5021 • Grip 1
3) Press fit 2 dust seals (23).
01010-50816 • Bolt 1
4 790-201-1731 • Push tool 1
790-201-1751 • Push tool 1
U
790-201-1741 • Push tool 1
790-201-1761 • Push tool 1
790-201-1500 Push tool KIT t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 790-201-1540 • Plate 1
790-201-1560 • Plate 1
790-201-1550 • Plate 1
790-201-1570 • Plate 1
6 790-720-1000 Expander q 1
796-720-1630 Ring q 1
07281-00709 Clamp q 1
796-720-1640 Ring q 1
07281-00909 Clamp q 1
796-720-1740 Ring q 1
7
07281-00809 Clamp q 1
796-720-1650 Ring q 1
07281-01029 Clamp q 1
796-720-1660 Ring q 1
07281-00159 Clamp q 1
4. Piston assembly
1) Install cushion plunger (10) to piston rod (6).
a Boom cylinder only
2) Set the piston ring (9) on tool U6 and turn the 7) Set piston rod assembly (2) to tool U1.
handle 8 to 10 times to expand the ring. 8) Using tool U3, install piston nut (4).
a Width across flats of piston nut :
(Unit: mm)
Model Boom Arm Bucket Swing Blade
PC27MR 46 46 36 41 50
PC30MR 46 46(*) 46 41 50
PC35MR 46 50(*) 46 55 50
PC40MR 50 55(*) 50(*) 55 55
PC50MR 50 55(*) 50(*) 55 55
6. Piping
Install cylinder piping.
3 Sleeve nut:
PC27, 30, 35MR-2 (Bucket cylinder):
46.1 – 61.8 Nm {4.7 – 6.3 kgm}
PC40, 50MR-2 (Boom cylinder):
84 – 123 Nm {8.5 – 12.5 kgm}
PC40, 50MR-2 (Arm cylinder):
128 – 172 Nm {13 – 17.5 kgm}
PC40, 50MR-2 (Bucket cylinder):
84 – 123 Nm {8.5 – 12.5 kgm}
REMOVAL AND INSTALLATION 2) Pull up the front window. When it stops mov-
ing backward, push up grips (2) until they are
OF AIR CONDITIONER UNIT locked securely.
ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
799-703-1200 Service tool KIT t 1
Vacuum pump
799-703-1100 (100 V) t 1
Vacuum pump
X 1 799-703-1110 (220 V) t 1
Vacuum pump
799-703-1120
(240 V) t 1
799-703-1401 Gas leak detector t 1 3. Remove front window (lower side) (4).
a Hold knobs (5) and pull up and remove the
window, and then store it at the rear of the
REMOVAL operator's seat in the operator's cab.
k Stop the machine on a level place, lower the
work equipment to the ground, and set the work
equipment lock lever in the LOCK position.
k Disconnect the cable from the negative (–) ter-
minal of the battery.
13. Remove 4 air conditioner unit assembly mount- a When installing, check that the O-ring is fitted to
ing bolts (20). each joint of the air conditioner hoses.
a Check that each O-ring is free from damage and
deterioration.
[*1]
a Using tool X1, charge the air conditioner circuit
with refrigerant (R134a).
[*2]
a Apply compressor oil (ND-OIL8) to the
threaded part of each refrigerant pipe and
tighten the pipe with double spanner.
3 M16 x 1.5 thread of tube:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
M24 x 1.5 thread of tube:
14. Tilt down the floor frame. 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
a On the 5 faces of the operator's cab, including (1) Right sash window glass assembly
the ceiling, panes (1) - (9) are stuck. (Ceiling (9) (2) Right front lower triangular window glass
is a clear plate.) (3) Right rear window glass
a When replacing front window glass (8), remove (4) Rear window glass
front window assembly. (It is impossible to (5) Left rear window glass
replace only the front window glass while the (6) Door upper window glass
front window assembly is installed to the oper- (7) Door lower window glass
ato’s cab.) (8) Front window glass
a For the procedure for replacing the front window (9) Clear plate
assembly, see REMOVAL AND INSTALLATION (10) Both-sided adhesive tape
OF FRONT WINDOW ASSEMBLY. (11) Center trim seal
a Precautions for removing and installing glass (The figure shows the operator's cab of a
• When removing and installing the glass, be wheel loader.)
sure to put on protective goggles.
• When using primer or degreasing solvent,
take care of fire and ventilation extremely.
• If a shock is given to an edge of the glass,
the glass is broken easily. Handle the glass
with care.
• If primer, caulking material, or adhesive gets
in your eye, wash you eye with much water,
and then consult an eye doctor.
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Pipe
a Install the both-sided adhesive tape from the end
of the round part of each corner of the pipe.
Sliding sash
a Install the both-sided adhesive tape along the
periphery of the sticking face of the sash.
• Bottom frame
• Dimension (c): 2.4 mm
5. Apply adhesive.
a The using limit of the adhesive is 6 months
after the date of manufacture. Do not use the 3) Set adhesive cartridge (17) to caulking gun
adhesive after this limit. [7].
a Keep the adhesive in a dark place where the a An electric caulking gun is more efficient.
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (18) of the outlet of
adhesive cartridge (17) and install the noz-
zle.
2 Adhesive:
cab.
a Apply adhesive (20) higher than both- 5) Install sliding sash assembly (1) to operator's
sided adhesive tape (10). cab (13).
a Apply the adhesive evenly. a Press the sash assembly firmly to elimi-
nate clearance from its periphery.
a If the adhesive is projected, wipe it off
immediately before it is set.
(The figure shows the operator's cab of a When caulking, neatly arrange the form
PC200-7.) of the adhesive at the right and left ends
2 Adhesive:
with a rubber spatula.
2 Caulking material:
• Dimension (w): 3 mm a Apply caulking material all around the
glass to fill part (x) between the glass
GE TOSHIBA SILICONE TOS SEAL and center trim seal.
381
REMOVAL
5. Holding the handle, release the latch and
1. Lower the front window assembly.
remove the front window assembly (6).
2. Remove wiper motor (1) and wiper blade (2).
a Remove the coiled cable for the wiper from
the sash and secure it in the operator's cab.
INSTALLATION
3. Remove rollers (3) (right and left) from the bot- • Carry out installation in the reverse order to
tom of the sash. removal.