Komatsu PC15MR-1 Hydraulic Excavator Shop Manual

SEBM019002

MACHINE MODEL

SERIAL NUMBER

PC15MR-1

10001 and up

•

This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require.

Materials and specifications are subject to change without notice.

•

PC15MR-1 mounts the 3D68E-3KJ engine.

For details of the engine, see the 68E-88E Series Engine Shop Manual.

© 2003 1 All Rights Reserved Printed in Japan 06-03(02)

00-1 (2)

CONTENTS No. of page

01

GENERAL ............................................................................................................ 01-1

10

STRUCTURE AND FUNCTION

20

TESTING AND ADJUSTING

30

DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

40

MAINTENANCE STANDARD ............................................................... 40-1

90

OTHERS

00-2 1

........................................................... 10-1

................................................................ 20-1

............................................................................................................... 90-1

PC15MR-1

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PC15MR-1

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PC15MR-1

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model

Engine speed

Category

Item

Pump relief

PC15MR-1

Measurement conditions

Unit

Standard value for new machine

Service limit value

• Hydraulic oil temperature: 45 – 55°C • Engine oil pressure: Within operating range • Engine water temperature: Within operating range

rpm

2,360 ± 100

Min. 1,800

¬

a

b

¬

a

b

30

6

6

30

6

6

20

6

6

20

6

6

Boom control valve Arm control valve

Spool stroke

Bucket control valve Swing control valve Breaker control valve

mm

Boom swing control valve Blade control valve L.H. travel control valve R.H. travel control valve Boom control lever

Travel of control levers stroke

Arm control lever Bucket control lever Swing control lever Boom swing control lever

• Center of N → RAISE, LOWER lever knob • Tip of pedal • Read max. value to end N → CURL, DUMP of travel (Excluding N → CURL, DUMP play) • Engine stopped N → Left, right swing N → Left, right boom swing

80 ± 8

80 ± 16

80 ± 8

80 ± 16

80 ± 8

80 ± 16

80 ± 8

80 ± 16

18 ± 2

80 ± 4

mm Blade control lever

N → RAISE, LOWER

55 ± 6

55 ± 12

Travel control lever

N → FORWARD, REVERSE (left, right)

80 ± 8

80 ± 16

Fuel control lever

Min. ←→ Max.

80 ± 8

80 ± 16

Work equipment, swing

Max. 10

20

Travel

Max. 20

40

Play of control lever

PC15MR-1

20-3 (2)

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

Applicable model

Standard value for new machine

Service limit value

15.7 ± 2.9 {1.6 ± 0.3}

15.7 ± 5.9 {1.6 ± 0.6}

15.7 ± 2.9 {1.6 ± 0.3}

15.7 ± 5.9 {1.6 ± 0.6}

14.7 ± 2.9 {1.5 ± 0.3}

14.7 ± 5.9 {1.5 ± 0.6}

14.7 ± 2.9 {1.5 ± 0.3}

14.7 ± 5.9 {1.5 ± 0.6}

58.8 ± 9.8 {6.0 ± 1.0}

58.8 ± 19.6 {6.0 ± 2.0}

Blade control lever

27.5 ± 2.9 {2.8 ± 0.3}

27.5 ± 5.9 {2.8 ± 0.6}

Travel control lever

14.7 ± 2.9 {1.5 ± 0.3}

14.7 ± 5.9 {1.5 ± 0.6}

Min. → Max.

20.6 ± 9.8 {2.1 ± 1.0}

20.6 ± 9.8 {2.1 ± 1.0}

Max. → Min.

20.6 ± 9.8 {2.1 ± 1.0}

20.6 ± 9.8 {2.1 ± 1.0}

2.0 +1.0 0 {20 +10 0 }

2.0 +1.0 0 {20 +10 0 }

21.6 ± 0.5 {220 ± 5}

21.6 ± 0.5 {220 ± 5}

21.6 ± 0.5 {220 ± 5}

21.6 ± 0.5 {220 ± 5}

Bucket

21.6 ± 0.5 {220 ± 5}

21.6 ± 0.5 {220 ± 5}

Swing

14.2␣ +1.0 0 {145␣ +10 0 }

14.2␣ +1.0 0 {145␣ +10 0 }

21.6 ± 0.5 {220 ± 5}

21.6 ± 0.5 {220 ± 5}

Blade

21.6 ± 0.5 {220 ± 5}

21.6 ± 0.5 {220 ± 5}

Travel

21.6 ± 0.5 {220 ± 5}

21.6 ± 0.5 {220 ± 5}

2.9␣ +0.5 –0 {30␣ +50 }

2.9␣ +0.5 –0 {30␣ +50 }

2.0␣ +1.0 0 {20␣ +10 0 }

2.0␣ +1.0 0 {20␣ +10 0 }

1.57 ± 0.1 {16 ± 1.0}

1.57 ± 0.1 {16 ± 1.0}

Category

Item Boom control lever

Operating effort of control levers

Arm control lever Bucket control lever

Measurement conditions • Engine at full throttle • Oil temperature: 45 – 55°C • Fit push-pull scale to center of control lever knob to measure • Fit push-pull scale to tip of pedal to measure • Measure max. value to end of travel

N {kg}

Boom swing control lever

Unload pressure

Boom Arm

• • • •

Oil temperature: 45 – 55°C Engine at full throttle All levers at neutral Pump outlet port pressure

• • • •

Oil temperature: 45 – 55°C Engine at full throttle Pump outlet port pressure Relieve only circuit to be measured

MPa {kg/ cm2}

Boom swing

Control pump • Oil temperature: 45 – 55°C • Engine at full throttle LS differential pressure flLS differential pressure = Pump outlet port pressure – LS pressure

20-4 1

Unit

Swing control lever

Fuel control lever

Hydraulic pressure

PC15MR-1

All levers at hold Travel under no load, travel lever at halfway position

PC15MR-1

TESTING AND ADJUSTING

TESTING AND ADJUSTING Tools for testing, adjusting, and troubleshooting ............................................................................... 20- 102 Measuring engine speed ....................................................................................................................... 20- 103 Measuring exhaust color ....................................................................................................................... 20- 104 Adjusting valve clearance ...................................................................................................................... 20- 105 Measuring compression pressure ........................................................................................................ 20- 106 Testing and adjusting fuel injection timing .......................................................................................... 20- 107 Measuring engine oil pressure ............................................................................................................. 20- 108 Testing and adjusting fan belt tension ................................................................................................. 20- 109 Adjusting fuel control lever ................................................................................................................... 20- 110 Measuring sprocket wear ...................................................................................................................... 20- 111 Testing and adjusting track shoe tension ............................................................................................. 20- 112 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ........................ 20- 113 Testing and adjusting LS differential pressure .................................................................................... 20- 115 Adjusting PC valve spring ...................................................................................................................... 20-117 Testing and adjusting control circuit pressure ...................................................................................... 20-118 Testing PPC lock valve ............................................................................................................................ 20-119 Testing PPC valve output pressure and swing holding brake inlet port pressure ............................. 20-120 Adjusting work equipment, swing PPC valve ....................................................................................... 20-122 Testing and adjusting travel deviation .................................................................................................. 20-123 Measuring oil leakage inside work equipment cylinder ...................................................................... 20-124 Releasing remaining pressure from hydraulic circuit .......................................................................... 20-125 Releasing remaining pressure from hydraulic tank ............................................................................. 20-126 Pressurizing hydraulic tank .................................................................................................................... 20-126 Bleeding air .............................................................................................................................................. 20-127

PC15MR-1

20-101 1

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Check or measurement item Engine speed

Symbol

Part No.

Part Name

799-203-9000

Multi-tachometer

2

• 799-203-8901

• Clamp set

799-101-1502

Digital temperature gauge

–99.9 — +1,299˚C

799-101-5002

Hydraulic tester

Pressure gauge: 2.5,5.9,39.2,58.8 MPa {25,60,400,600 kg/cm2}

790-261-1203

Digital hydraulic tester

Pressure gauge: 68.6MPa{700 kg/cm2}

• 799-101-5160

• Nipple

PT1/8

• Adapter

10 x 1.25 (female PT 1/8) for both male and female 14 x 1.5 (female PT 1/8) for both male and female 18 x 1.5 (female PT 1/8) for both male and female 22 x 1.5 (female PT 1/8) for both male and female 1.0 MPa {10 kg/cm2}

B

1

2

• 790-261-1340 • 790-261-1311 3 Oil pressure

Digital display L : 60 – 2,000 rpm H: 60 – 19,999 rpm

1 A

Coolant and oil temperatures

Remarks

C

• 790-261-1321 • 790-261-1331 4

790-401-2320

Hydraulic gauge

5

799-401-2701

Differential pressure gauge

07040-11007

Plug

07002-11023

O-ring

795-502-1205

Compression gauge

10 x 1.25

6

1

0 – 6.9 MPa {0 – 70 kg/cm2}

795-111-1120 Compression pressure

D

Adapter

2 795-111-1110 3 E

Valve clearance

1 Exhaust color

F

Feeler gauge

799-201-9000

Handy Smoke Checker

L

799-601-8000

T-adapter kit

M

796-127-1111

Wear gauge

G

Stroke, hydraulic drift

H

Work equipment speed

J

1

Commercially available

K

Operating effort

20-102

• Joint

Commercially available Commercially available Commercially available Commercially available Commercially available

2

Measuring voltage and resistance values Troubleshooting of wiring harnesses and sensors Measuring wear of sprocket

• 795-101-1571

Smoke meter

Discoloration 0 – 70% (with standard color) .

(Discoloration % × 1/10 = .

Bosch index)

Push-pull scale Scale Stop watch Tester

PC15MR-1

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

MEASURING ENGINE SPEED ¤

Be careful not to touch any hot parts when removing or installing the measuring tools. fl Measure the engine speed under the following conditions.

• Cooling water temperature: Within operating range • Hydraulic oil temperature : 45 – 55°C 1. Install clamp set A2 of multi-tachometer to fuel injection tube (1), then connect to multi-tachometer A1.

2. Start the engine, and measure the engine speed when it is set to the conditions for measuring.

1) Measuring low idling and high idling speed: Measure the engine speed with the fuel control lever set to low idling and high idling.

2) Measuring speed at the pump relief: Run the engine at full throttle, operate the bucket control lever, and measure the engine speed when the bucket CURL is relieved.

3) Measuring speed at 2-pump relief: Run the engine at full throttle, operate the bucket control lever, and measure the engine speed when the bucket CURL and swing are relieved.

¤

PC15MR-1

For the swing, use the work equipment and lock securely.

20-103 1

TESTING AND ADJUSTING

MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR •

When measuring in the field where there is no air or electric power supply, use Handy Smoke Checker F1; when recording formal data, use Smoke Meter F2. fl Raise the coolant temperature to the operating range before measuring. ¤ Be careful not to touch any hot parts when removing or installing the measuring tools.

1. Measuring with Handy Smoke Checker F1.

1) Install filter paper to Handy Smoke Checker F1.

2) Insert the exhaust gas suction port into the exhaust pipe.

3) Accelerate the engine suddenly, and operate the handle of Handy Smoke Checker F1 at the same time to collect the exhaust gas on the filter paper.

4) Remove the filter paper and compare it with the scale supplied to judge the condition.

2. Measuring with Smoke Meter F2 1) Insert the probe of Smoke Meter F2 into the outlet port of the exhaust pipe, and tighten the clip to secure it to the exhaust pipe.

2) Connect the air hose and the socket of the probe hose and accelerator switch to Smoke Meter F2. fl Keep the pressure of the air supply below 1.47 MPa {15 kg/cm2}.

3) Connect the power cord to the AC socket. fl When connecting the cord, check that the power switch of the smoke meter is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. fl Fit the filter paper securely so that the exhaust gas cannot leak.

5) Turn the power switch of Smoke Meter F2 ON. 6) Accelerate the engine suddenly, and depress the accelerator pedal of Smoke Meter F2 at the same time to collect the exhaust gas color on the filter.

7) Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets of unused filter paper inside the filter paper holder, and read the value shown.

20-104 1

PC15MR-1

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE 1. Remove air cleaner (1), then remove the cylinder head cover. fl Remove air cleaner bracket.

2. Remove cap (2) of the flywheel housing.

3. Rotate the crankshaft in the normal direction to align the No. 1 line b on the flywheel with line a on the housing. When rotating, check the movement of the valves of the No. 1 cylinder (flywheel end). fl Cylinder No. 1 is the cylinder at the flywheel end of the engine. fl When the crankshaft is rotated, the valves of the cylinder at top dead center do not move.

If the valves are moving, rotate the crankshaft one more turn and align the lines. fl Rotate the crankshaft 240° each time and adjust the valve clearance of each cylinder according to the firing order.

• Firing order : 1 — 3 — 2 fl There is a line on the flywheel for the top dead center of each cylinder.

4. To adjust the valve clearance, loosen locknut (6), then insert feeler gauge E between rocker lever (3) and valve stem (4), and turn adjustment screw (5) until the clearance is a sliding fit. Then tighten locknut (6) to hold the adjustment screw in position.

9 Locknut : 25.5 ± 2.9 Nm {2.6 ± 0.3 kgm} fl After tightening the locknut, check the clearance again.

PC15MR-1

20-105 1

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE ¤

When measuring the compression pressure, be careful not to touch the exhaust manifold or muffler, or to get your clothes caught in the fan, fan belt or other rotating parts.

1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEARANCE. 2. Warm up the engine to make the oil temperature 40 – 60°C. 3. Remove nozzle holder assembly (1) from the cylinder to be measured.

4. Install adapter D2 and joint D3 to the mount of the nozzle holder, then connect compression gauge D1.

9 Adapter mounting nut: 51.00 ± 1.96 Nm {5.2 ± 0.2 kgm} 5. Set multi-tachometer A in position.

6. Disconnect engine stop solenoid connector (2).

7. Close the fuel filter stop valve.

8. Crank the engine with the starting motor and measure the compression pressure. fl Measure the compression pressure at the point where the compression gauge indicator remains steady. fl When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. fl After measuring the compression pressure, install the nozzle holder assembly.

9 Nozzle holder mounting nut: 51.00 ± 1.96 Nm {5.2 ± 0.2 kgm}

20-106 1

PC15MR-1

TESTING AND ADJUSTING

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING Testing fl If the fuel injection pump has been removed and installed again, check as follows.

1. Disconnect fuel injection pipe (1) of the No. 1 cylinder. fl Engine cylinder No. 1 is the cylinder at the flywheel end.

2. Remove cap (2) of the flywheel housing.

3. Turn the crankshaft in the normal direction, and stop the crankshaft at the point where the surface of the fuel at the tip of delivery valve holder (3) begins to rise.

4. In this condition, check that line a on the flywheel housing is aligned with line b on the flywheel.

Adjusting fl If the lines are not aligned, adjust as follows.

1. Remove the fuel injection pump assembly.

2. Adjust the thickness of shim (4) between the fuel injection pump and gear case to adjust the timing.

• INCREASE shim to RETARD injection timing • DECREASE shim to ADVANCE injection timing fl Be careful of the following points when adjusting.

(1) The standard for the injection timing adjustment shim is 0.5 mm.

(2) The adjustment shim has a silicon coating, so use thinner to remove all the oil and grease from both faces of the shim and the fuel injection pump mounting surface.

(3) A shim thickness of 0.1 mm changes approx. 1°.

There are two types of shim thickness: 0.2 mm and 0.3 mm.

3. After adjusting, install the fuel injection pump assembly.

PC15MR-1

20-107 1

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE fl Measure the engine oil pressure under the following conditions. • Cooling water temperature: Within operating range 1. Remove engine oil pressure switch (1).

2. Install nipple C2, then connect oil pressure gauge C4 (1.0 MPa {10 kg/cm2}).

3. Start the engine, and measure the oil pressure with the engine at low idling and high idling.

20-108 1

PC15MR-1

TESTING AND ADJUSTING

TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION Testing 1. Measure deflection a of the fan belt when pressed with a force of approx. 58.8 Nm {approx. 6 kg} at a point midway between the fan pulley and the alternator pulley.

• Belt deflection a: 10 – 15 mm

Adjusting fl If the deflection is not normal, adjust as follows.

1. Loosen the alternator mounting bolts and adjustment bolt (1).

2. Using a bar, move alternator (2) towards the outside to adjust the belt tension.

3. Tighten adjustment bolt (1), then tighten the alternator mounting bolts .

PC15MR-1

20-109 1

TESTING AND ADJUSTING

ADJUSTING FUEL CONTROL LEVER

ADJUSTING FUEL CONTROL LEVER 1. Set fuel control lever (1) at the low idling position.

2. Connect inner cable (2) of the wire to governor lever (3). fl Check that the governor lever is in contact with the low idling stopper.

3. Start the engine, move fuel control lever (1) to the high idling position, then adjust the high idling speed with adjustment bolt (4).

• High idling speed: 2,780 ± 50 rpm • Standard dimension a of stopper bolt (reference): 22 mm

20-110 1

PC15MR-1

TESTING AND ADJUSTING

MEASURING SPROCKET WEAR

MEASURING SPROCKET WEAR

1. Remove the track shoe assembly. fl For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF RUBBER SHOE ASSEMBLY or REMOVAL OF STEEL SHOE ASSEMBLY. 2. Align wear gauge M with the sprocket. fl Align the standard line, then align the wave shape of the sprocket with the wave shape of the wear gauge.

3. Judge the sprocket wear. fl If the wave shape of the sprocket is above the wear limit line: It is possible to continue to use the sprocket. fl If the wave shape of the sprocket has reached the wear limit line: Replace the sprocket with a new part.

PC15MR-1

20-111 1

TESTING AND ADJUSTING

TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. Move the machine forward or backward to set the connection of the rubber shoe (M mark) at the top at the center of the track between the idler and sprocket. fl Rubber shoe specification machine only.

2. Using the boom and arm, push up the track on the side being inspected.

3. Measure clearance a between the tread of the track roller and the top surface of the track link. fl Measure at the 2nd track roller from the sprocket.

• Standard clearance (tension) Rubber shoe : 10 – 15 mm Steel shoe : 10 – 20 mm

Adjusting fl If the track shoe tension is not within the standard value, adjust as follows.

1. If tension is too tight Slowly loosen valve (1) and release grease.

¤

There is danger that the valve may fly out under the high internal pressure of the grease, so never loosen the valve more than 1 turn. fl If the grease does not come out easily, move the machine backwards or forwards slowly.

2. If tension is too loose Pump in grease through grease fitting (2). fl If the track tension does not increase easily, move the machine backwards or forwards slowly.

20-112 1

PC15MR-1

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT Measuring fl Oil temperature when measuring: 45 – 55°C ¤ Before removing the oil pressure measurement plug, release the pressure inside the hydraulic tank. For details, see RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK. ¤ After installing the oil pressure gauge, pressurize the hydraulic tank. For details, see PRESSURIZING HYDRAULIC TANK. 1. Measuring unload oil pressure 1) Remove oil pressure measurement plug (1) (PT1/8).

2) Fit nipple C2, then install oil pressure gauge C1 (39.2 MPa {400 kg/cm2}).

3) Run the engine at full throttle and measure the oil pressure with all levers at HOLD. 2. Measuring work equipment and travel relief pressure 1) Remove oil pressure measurement plug (1) (PT1/8).

2) Fit nipple C2, then install oil pressure gauge C1 (39.2 MPa {400 kg/cm2}).

3) Run the engine at full throttle and measure the oil pressure with each actuator operated to relief. ¤ For the work equipment, operate each cylinder to the end of its stroke. ¤ Using with work equipment, lock the boom swing. ¤ For the travel, lock the track by fitting block 1 under the track shoe grouser or by fitting block 2 between the sprocket and frame.

PC15MR-1

20-113 1

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

Adjusting fl The unload valve cannot be adjusted.

1. Adjusting main relief valve fl If the work equipment and travel relief pressure is not normal, adjust the main relief valve as follows.

1) Loosen locknut (2) and turn adjustment screw (3) to adjust. fl Turn the adjustment screw to adjust as follows.

• To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Amount of adjustment for one turn of adjustment screw: 12.6 MPa {128 kg/cm2} 2) After adjusting, tighten locknut (2).

9 Locknut: 69 ± 10 Nm {6 ± 1 kgm} fl After completion of adjustment, repeat the measurement procedure above to check the oil pressure again.

2. Adjusting swing motor safety valve fl If the swing relief pressure is not correct, adjust swing motor safety valve (7) as follows.

1) Remove nut (4).

2) Loosen locknut (5), then turn adjustment screw (6) to adjust. fl Turn the adjustment screw to adjust as follows.

• To INCREASE pressure, turn CLOCKWISE. • To DECREASE pressure, turn COUNTERCLOCKWISE. 3) After adjusting, tighten locknut (5).

4) Install nut (4). fl After completion of adjustment, repeat the measurement procedure above to check the oil pressure again.

20-114 1

PC15MR-1

TESTING AND ADJUSTING

TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE

TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE Measuring 1. Measuring with differential pressure gauge 1) Remove oil pressure measurement plugs (1) and (2) (PT1/8).

2) Fit adapter C3 and nipple C2, then install differential pressure gauge C5. fl Connect pump discharge pressure (1) to the high-pressure side of the differential pressure gauge and LS pressure (2) to the low-pressure side.

3) Using the work equipment, push up the track on one side.

4) Run the engine at full throttle, set to the conditions in the table, and measure the LS differential pressure.

Table Travel lever

LS differential pressure MPa{kg/cm2}

Neutral

2.0 0 {20 +10 0 }

Half (travel rotates freely)

1.57 Âą 0.1 {16 Âą 1.0}

+1.0

Remarks LS differential pressure becomes same as unload pressure

2. Measuring with oil pressure gauge fl The differential pressure at its maximum is less than 1.96 MPa {20 kg/cm2}, so measure with the same pressure gauge.

1) Remove oil pressure measurement plugs (1) and (2) (PT1/8).

2) Fit adapter C3 and nipple C2, then install oil pressure gauge C1 (39.2 MPa {400 kg/cm2}). fl Use a gauge with a scale in units of 1.0 MPa {10 kg/cm2}.

3) Using the work equipment, push up the track on one side.

4) Run the engine at full throttle, set to the conditions in the table, and measure the pump discharge pressure. fl Read the gauge indicator accurately from directly in front of it.

5) Run the engine at full throttle, set to the conditions in the table, and measure the LS pressure. fl Read the gauge indicator accurately from directly in front of it.

6) Calculate the LS differential pressure from the pump discharge pressure and the LS pressure.

PC15MR-1

20-115 1

TESTING AND ADJUSTING

TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE, ADJUSTING TCC VALVE

Adjusting 1. Adjusting LS valve fl If the LS differential pressure is not normal, adjust the LS valve (3) as follows.

1) Disconnect hose (4).

2) Loosen locknut (5) and turn adjustment screw (6) to adjust. fl Turn the adjustment screw as follows.

• To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Amount of adjustment for one turn of adjustment screw: 127 MPa {13 kg/cm2} (LS differential pressure) 3) After adjusting, tighten locknut (5).

9 Locknut : 30.85 ± 3.45 Nm {3.15 ± 0.35 kgm} fl After completion of adjustment, repeat the measurement procedure above to check the set pressure again.

20-116 1

PC15MR-1

TESTING AND ADJUSTING

ADJUSTING PC VALVE SPRING

ADJUSTING PC VALVE SPRING fl If the load becomes high and the engine speed drops, or the engine speed remains normal and the work equipment becomes slower, but the pump discharge pressure and the LS differential pressure are normal, adjust PC valve (1) as follows.

1. Loosen locknut (2) and turn adjustment screw (3) to adjust. fl Turn the adjustment screw as follows.

• If speed is slow, turn CLOCKWISE (pump absorption torque is increased) • If engine speed drops, turn COUNTERCLOCKWISE (pump absorption torque is decreased) fl Turn the adjustment screw within a range of 180° to the left or right.

2. After adjusting, tighten locknut (2).

PC15MR-1

20-117 1

TESTING AND ADJUSTING

TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE

TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE Measuring fl Oil temperature when measuring: 45 – 55°C 1. Remove pressure measurement plug (1) (PT 1/8).

2. Fit a nipple, then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).

3. Measure the oil pressure with the engine at full throttle and the control levers at HOLD.

Adjusting 1. Loosen locknut (2) of control relief valve (4) and turn adjustment screw (3) to adjust. fl Turn the adjustment screw as follows.

• To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Amount of adjustment for one turn of adjustment screw: 5.49 MPa {56 kg/cm2} 2. After adjusting, tighten locknut (2).

9 Locknut: 22.05 ± 2.45 Nm {2.25 ± 0.25 kgm}

20-118 1

PC15MR-1

TESTING AND ADJUSTING

TESTING PPC LOCK VALVE

TESTING PPC LOCK VALVE fl Oil temperature when measuring: 45 – 55°C 1. Disconnect outlet hose (1) from the valve to be measured.

• (1): PPC lock valve 2. Fit adapter C3 and nipple C2, then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).

3. Measure the oil pressure with the engine at full throttle and the control levers at HOLD. Table No.

1

Valve

Mesurement conditions MPa{kg/cm2}

Oil pressure MPa{kg/cm2}

Lock lever at [Lock]

0 {0}

Lock lever at [Free]

2.9 0 {30 +50 }

PPC rock

PC15MR-1

+0.5

20-119 1

TESTING AND ADJUSTING

TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE

TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE fl Oil temperature when measuring: 45 – 55°C 1. Measuring PPC valve output pressure 1) Disconnect PPC hose (1) of the circuit to be measured. fl For details of the hose to disconnect, see the circuit diagram on the next page.

2) Fit adapter C3 and nipple C2, then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).

3) Run the engine at full throttle, operate the control lever of the circuit to be measured, and measure the output pressure. fl The standard value is the same as the control circuit pressure (when the control lever is operated fully).

2. Measuring swing holding brake inlet port pressure 1) Disconnect hose (2).

2) Fit adapter C3 and nipple C2, then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).

3) Measure the inlet port pressure with the engine at full throttle and the control lever operated to left swing, right swing, or arm IN. fl The standard value is the same as the control circuit pressure (when the control lever is operated fully).

20-120 1

PC15MR-1

TESTING AND ADJUSTING

TESTING PPC VALVE OUTPUT PRESSURE AND SWING HOLDING BRAKE INLET PORT PRESSURE

<Reference> •

•

If the PPC valve output pressure is normal for all of left swing, right swing, and arm IN, and the swing holding brake inlet port pressure is not normal for any of these operations, it can be judged that the PPC shuttle valve for the abnormal system is defective.

The PPC shuttle valve is assembled inside the control valve spring case.

PPC valve and swing holding brake diagram

PC15MR-1

20-121 1

TESTING AND ADJUSTING

ADJUSTING WORK EQUIPMENT, SWING PPC VALVE

ADJUSTING WORK EQUIPMENT, SWING PPC VALVE fl If there is excessive play in the work equipment or swing lever, adjust as follows. ¤ Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Then put the safety lock lever in the LOCK position.

1. Remove the PPC valve. fl For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF PPC VALVE ASSEMBLY. 2. Remove boot (1).

3. Loosen locknut (2), then screw in disc (3) to a position where it contacts the heads of 4 pistons (4). fl When doing this, do not make the piston move.

4. Fix the position of disc (3), then tighten locknut (2) to the specified torque.

9 Locknut : 113 ± 15Nm {11.5 ± 1.5 kgm} 5. Install boot (1). fl With the above adjustment, the clearance between disc (3) and piston (4) becomes 0.

20-122 1

PC15MR-1

TESTING AND ADJUSTING

TESTING AND ADJUSTING TRAVEL DEVIATION

TESTING AND ADJUSTING TRAVEL DEVIATION fl When traveling on flat ground 1. Set the machine in the travel posture. fl When setting the machine in the travel posture, extend the bucket and arm cylinder rod fully, and hold the boom at an angle of 45°.

2. Travel for 10m, then measure the deviation when traveling for the next 20m. fl Measure with the engine at full throttle. fl Install the oil pressure gauge and measure the pump discharge pressure at the same time.

PC15MR-1

20-123 1

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER

MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER fl Oil temperature when measuring: 45 – 55°C fl If the hydraulic drift of the work equipment exceeds the standard value, measure the leakage inside the cylinder as follows to check if the cause of the hydraulic drift is in the control valve or the cylinder.

• If the leakage is within the standard value, the control valve is the cause.

• If the leakage is not within the standard value, the cylinder is the cause.

1. Fully extend the rod of the work equipment cylinder to be measured, then stop the engine.

A : Measuring posture of boom cylinder B : Measuring posture of arm and buckt cylinder 2. Disconnect the hose at the head end and block the hose (1), (2) and (3) at the chassis end with a blind plug.

¤ Be careful not to disconnect the piping at the bottom end.

(1) : For boom cylinder hose (2) : For arm cylinder hose (3) : For bucket cylinder hose 3. Start the engine, run at full throttle, and apply relief pressure to the bottom end of the cylinder.

Boom cylinder : Operate to RAISE Arm cylinder : Operate to IN Bucket cylinder: Operate to CURL 4. Wait for 30 seconds, then measure the leakage for the next one minute.

20-124 1

PC15MR-1

TESTING AND ADJUSTING

RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT

RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT ¤

There is no accumulator installed, so the remaining pressure in the piping between the control valve and hydraulic cylinder or swing motor cannot be released by operating the control levers.

When the above piping is removed, be careful of the following points.

1. Run the engine at low idling, operate the hydraulic cylinders so that as far as possible the pressure is not relieved at the end of the stroke, lower the work equipment to the ground, then stop the engine. fl If the engine is stopped with the hydraulic circuit relieved and the hydraulic cylinder at the end of its stroke, do not carry out any work for 5 to 10 minutes.

2. When removing the piping, loosen the piping sleeve nut gradually to release the pressure remaining in the piping slowly, then remove the piping after the oil stops spurting out.

PC15MR-1

20-125 1

TESTING AND ADJUSTING

RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK, PRESSURIZING HYDRAULIC TANK

RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK ¤

The hydraulic tank is a sealed type, so it is pressurized.

When removing the hoses or plugs installed to the hydraulic tank, release the remaining pressure in the hydraulic tank as follows.

1. Lower the work equipment to the ground and stop the engine.

2.

Loosen the hydraulic tank oil filler plug slowly to release the pressure inside the hydraulic tank.

PRESSURIZING HYDRAULIC TANK fl If the oil filler plug of the hydraulic tank has been removed, pressurize the hydraulic tank as follows.

1. Run the engine at low idling and set the work equipment to the pressurizing posture.

A : Hydraulic tank pressurizing posture 2. Stop the engine, open the hydraulic tank oil filler plug, then tighten it again. fl This operation pressurizes the hydraulic tank.

3. Start the engine and lower the work equipment to the ground.

20-126 1

PC15MR-1

TESTING AND ADJUSTING

BLEEDING AIR

BLEEDING AIR Order for operations and procedure for bleeding air Air bleeding item Nature of work • Change hydraulic oil • Clean strainer • Replace return filter element • Replace, repair pump • Remove suction piping

1

Air bleeding procedure 3 4 5

2

Bleeding air from pump

Start engine

6

Bleeding air Bleeding air Bleeding air Pressurize from from swing from travel hydraulic tank cylinder motor motor

7 Start operations

→ → → → → → (Note)

(Note)

→ →

→ → → →

• Replace, repair control valve

→ → →

• Replace, repair cylinder • Remove cylinder piping

→ → →

• Replace, repair swing motor • Remove swing motor piping

→ → →

• Replace, repair travel motor, swivel • Remove travel motor, swivel piping

→ → →

Note : leed the air from the swing motor and travel motor only when the oil inside the motor case has been drained.

1. Bleeding air from pump 1) Loosen air bleed plug (1), and bleed the air from the plug hole.

2) Tighten air bleed plug (1). fl Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low idling for 10 minutes.

PC15MR-1

20-127 1

TESTING AND ADJUSTING

BLEEDING AIR

2. Bleeding air from hydraulic cylinders A : Boom cylinder 1) Start the engine and run at idling for approx.

5 minutes.

2) Run the engine at low idling, and raise and lower the boom 4 â&#x20AC;&#x201C; 5 times in succession. fl Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances.

3) Run the engine at full throttle and repeat Step 2). After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit.

4) Repeat Steps 2) and 3) to bleed the air from the arm, bucket, boom swing, and blade cylinders.

3. Bleeding air from swing motor B : Swing motor 1) Run the engine at low idling and swing 3 turns to the left.

2) Next, swing 3 turns to the right.

4. Bleeding air from travel motor C : Travel motor 1) Run the engine at low idling and use the work equipment to raise the track on the left side.

2) Run the engine at low idling, and rotate the track on the left side under no load for approx.

30 seconds.

3) Repeat Steps 1) and 2) for the track on the right side.

5. Pressurizing hydraulic tank 1) Before pressurizing the hydraulic tank, check the hydraulic oil level.

2) Pressurize the hydraulic tank. For details, see PRESSURIZING HYDRAULIC TANK.

20-128 1

PC15MR-1

TROUBLESHOOTING

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-mode related electrical circuit diagram ............................................................................................. 20-302 E-1

Engine does not start ................................................................................................................... 20-304 a) When starting motor does not turn (starting system) ......................................................... 20-304 b) When starting motor turns (engine stop solenoid system) ................................................. 20-306

E-2

Engine does not stop ................................................................................................................... 20-308

E-3

Work equipment does not move even when work equipment lock lever is canceled ........... 20-309

E-4

Work equipment moves even when work equipment lock lever is locked ............................. 20-311

E-5

Travel alarm does not sound ....................................................................................................... 20-312

PC15MR-1

20-301 (2)

TROUBLESHOOTING

E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ENGINE START/STOP SYSTEM

20-302 1

PC15MR-1

TROUBLESHOOTING

E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

PPC LOCK, TRAVEL BOOST SOLENOID VALVE SYSTEM Serial No.: 10001 â&#x20AC;&#x201C; 10634

Serial No.: 10635 and up

PC15MR-1

20-303 (2)

TROUBLESHOOTING

E-1

E-1 Engine does not start a) When starting motor does not turn (starting system) fl Check that fuse 2 is normal (if it is blown, check for a short circuit with the ground in the circuits related to fuse 2). fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.

Cause

YES 2 Is voltage YES between starting motor terminal B and chassis ground normal?

• Turn starting switch OFF. NO • 10 – 14 V

Is voltage between battery terminal (+) and chassis ground normal?

• Turn starting switch OFF. • 10 – 14 V

1 Is voltage between E2 (female) and chassis ground normal?

• Disconnect E2.

• Turn starting switch to START. • 10 – 14V

Is resistance between P4

9 YES Does engine A start when safety relay is interchanged?

NO

10 YES

1

• Disconnect P4.

• Turn starting switch ON. • Max. 1 V

chassis ground normal?

• Disconnect P4.

• Turn starting switch ON. • Max. 1 V

20-304

Is voltage YES between P4 (female) (1) and 5 chassis ground normal?

YES (female) (1) and

4

Is voltage between P4 (female) B (1) and chassis ground normal when P6 is disconnected?

• Disconnect P4.

• Turn starting switch ON. • Max. 1 V

NO

6 YES

Is voltage between P4 (female) (6) and NO chassis ground normal?

• Turn starting switch to START.

3 YES

NO

• Disconnect P4.

• Turn starting switch OFF. • Max. 1 Ω

NO

Replace

Defective contact or disconnection in wiring harness between starting motor terminal B and battery terminal (+)

Repair or replace

Defective battery

Replace

Go to A

Go to B

Defective contact or disconnection in wiring harness between P4 (female) (6) – fuse 2 – C3 (1) – starting switch terminal C

YES 7 Is voltage between starting switch terminal C and NO chassis ground normal?

Defective starting motor

Defective contact or disconnection in wiring harness between P4 (female) (4) and chassis ground

NO

Remedy

8 YES

Defective starting switch Is voltage between starting switch terminal B • Turn starting Defective contact or switch to START. NO and chassis disconnection in wiring ground normal?

• 10 – 14 V harness between starting • Turn starting NO switch terminal B – C3 (2) switch OFF. – P1 (2)(1) – battery • 10 – 14 V

Repair or replace

Repair or replace

Replace

Repair or replace

Defective safety relay

Replace

Defective contact or disconnection in wiring harness between P4 (female) (2) and E2 (female)

Repair or replace

Defective current limiter

Replace

Short circuit with power source in wiring harness between P4 (female) (1) and P6 (female) (6)

Repair or replace

PC15MR-1

TROUBLESHOOTING

E-3

E-3 Work equipment does not move even when work equipment lock lever is canceled Serial No.: 10001 – 10634 fl Check that fuse 3 is normal (if it is blown, check for a short circuit with the ground in the circuits related to fuse 3). fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.

Remedy

Cause

YES

Defective hydraulic system

3

—

Is voltage M3 YES between (female) (2) and

4 YES

chassis ground normal?

2 YES Is voltage between M2 (female) (2) and chassis ground normal?

1 Is resistance between M3 (female) (1) and (2) normal?

• Disconnect M2.

• Turn starting switch ON. • 10 – 14 V

• Disconnect M3.

• Turn starting switch OFF. • 5 – 25 Ω

Is resistance • Work equipment between M2 (1) – lock lever: FREE NO (2) normal?

• Disconnect M3.

• Turn starting • Work equipment switch ON. lock lever: FREE • 10 – 14 V • Disconnect M2.

• Turn starting switch OFF. • Max. 1 Ω

5 YES

Is voltage between starting switch terminal NO ACC and chassis ground normal?

• Turn starting switch ON. • 10 – 14 V

NO

6

YES

Is resistance M3 A between (female) (1) and chassis ground normal?

• Disconnect M3.

• Turn starting switch OFF. • Min. 1 MΩ

E-3

NO

NO

NO

Go to A

Defective PPC lock switch or defective installation

Defective contact or disconnection in wiring harness between starting switch terminal ACC – fuse 3 – M3 (female) (2)

Repair or replace

Repair or replace

Defective starting switch

Replace

Defective PPC lock solenoid

Replace

Defective contact or disconnection in wiring harness between M2 (female) (1) – M3 (female) (2)

Repair or replace

Defective contact or disconnection in wiring harness between M2 (female) (2) – chassis ground

Repair or replace

Related electric circuit diagram

PC15MR-1

20-309 (2)

TROUBLESHOOTING

E-3

Serial No.: 10635 and up fl Check that fuse 3 is normal (if it is blown, check for a short circuit with the ground in the circuits related to fuse 3). fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.

Remedy

Cause

YES

Defective hydraulic system

3

—

Is voltage M3 YES between (female) (2) and

4 YES

chassis ground normal?

2 YES Is voltage between M2 (female) (2) and chassis ground normal?

1 Is resistance between M3 (female) (1) and (2) normal?

• Disconnect M2.

• Turn starting switch ON. • 10 – 14 V

• Disconnect M3.

• Turn starting switch OFF. • 5 – 25 Ω

Is resistance • Work equipment between M2 (1) – lock lever: FREE NO (2) normal?

• Disconnect M3.

• Turn starting • Work equipment switch ON. lock lever: FREE • 10 – 14 V • Disconnect M2.

• Turn starting switch OFF. • Max. 1 Ω

5 YES

Is voltage between starting switch terminal NO ACC and chassis ground normal?

• Turn starting switch ON. • 10 – 14 V

NO

6

YES

Is resistance M3 A between (female) (1) and chassis ground normal?

• Disconnect M3.

• Turn starting switch OFF. • Min. 1 MΩ

E-3

NO

NO

NO

Go to A

Defective PPC lock switch or defective installation

Defective contact or disconnection in wiring harness between starting switch terminal ACC – fuse 3 – M3 (female) (2)

Repair or replace

Repair or replace

Defective starting switch

Replace

Defective PPC lock solenoid

Replace

Defective contact or disconnection in wiring harness between M2 (female) (1) – M3 (female) (2)

Repair or replace

Defective contact or disconnection in wiring harness between M2 (female) (2) – chassis ground

Repair or replace

Related electric circuit diagram

20-310 (2)

PC15MR-1

TROUBLESHOOTING

E-4

E-4 Work equipment moves even when work equipment lock lever is locked fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.

Cause

2 YES Is resistance YES between M2 (male) (1) and 1 chassis ground normal?

Is resistance • Work equipment NO between M3 lock lever: LOCK (male) (1) and • Disconnect M2. chassis ground • Turn starting switch OFF. normal ?

• Min. 1 MΩ • Disconnect M3.

• Turn starting NO switch OFF. • Min. 1 MΩ

E-4

Defective hydraulic system

Remedy

See H mode

Defective PPC lock switch

Replace

Defective PPC lock solenoid

Replace

Related electric circuit diagram

Serial No.: 10001 – 10634

Serial No.: 10635 and up

PC15MR-1

20-311 (2)

TROUBLESHOOTING

E-5

E-5 Travel alarm does not sound fl Check that fuse 1 is normal (if it is blown, check for a short circuit with the ground in the circuits related to fuse 1). fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step.

Cause

3 YES Is resistance between CA1 YES (female) (1) and chassis ground normal?

2 Is voltage YES between CA1 (female) (2) and chassis ground normal?

• Disconnect CA1.

• Max.1 Ω

NO

4 YES

Is resistance between CL1 lever to FORWARD (male) (1) – (2), (REVERSE) NO CL2 (male) (1) – position.

(2) normal?

• Disconnect CA1.

• Disconnect CL1 • Turn starting and CL2. switch ON. • 1.5 Ω • 10 – 14 V

1 • Operate travel Is voltage between CL1 (female) (1) – chassis ground, CL2 (female) (1) – chassis ground normal?

• Disconnect CL1 and CL2.

• Turn starting switch ON. • 10 – 14 V NO

5 YES Is voltage between starting switch terminal ACC and chassis ground normal?

• Turn starting switch ON. • 10 – 14 V

E-5

NO

NO

Remedy

Defective travel alarm

Replace

Defective contact or disconnection in wiring harness between CA1 (female) (1) and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between CL1 (2), CL2 (2) – CA1 (2)

Repair or replace

Defective limit switch

Replace

Defective contact or disconnection in wiring harness between starting switch terminal ACC – C4 (6) – fuse 1 – CL1, CL2 (1)

Repair or replace

Defective starting switch

Replace

Related electric circuit diagram

20-312 (2)

PC15MR-1

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

REMOVAL OF ENGINE AND HYDRAULIC PUMP ASSEMBLY ¤ Release the remaining pressure in the hydraulic circuit and hydraulic tank.

For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit and Releasing remaining pressure in hydraulic tank.

¤ Disconnect the cable from the negative (–) terminal of the battery.

1. Drain coolant.

2. Drain oil from hydraulic tank.

6 Hydraulic tank: Approx. 14 ¬

3. Drain fuel.

6 Fuel tank: Approx. 19 ¬ (full)

4. Lift off canopy assembly (1).

5. Remove left and right covers (2) and open engine hood (3).

6. Remove operator’s seat assembly (4).

7. Remove left and right PPC valve control levers (5).

8. Disconnect connector wiring (6) at bottom right of seat bracket, then remove seat bracket (7).

9. Disconnect blade control cable (8). fl Check the installation dimension, then disconnect.

10. Disconnect 2 intake hoses (9), then remove air cleaner assembly (10).

11. Disconnect water temperature wiring connector E6 (11).

12. Disconnect engine stop solenoid wiring connector E5 (12).

13. Disconnect glow plug wiring connector E4 (13).

14. Disconnect fuel supply hose (14) and return hose (15).

PC15MR-1

30-7 1

DISASSEMBLY AND ASSEMBLY

15. Disconnect fuel control cable (16).

ENGINE AND HYDRAULIC PUMP

1

16. Disconnect engine oil pressure switch terminal E7 (17).

17. Disconnect alternator wiring connector E3 (18).

18. Disconnect wiring connectors M2, P4, P5, P6, P7, P10, P11, and P12 (19), then remove bracket (20). fl Make marks to distinguish.

19. Disconnect battery (+) terminal (21).

20. Disconnect horn wiring connector M7 (22).

21. Disconnect 8 PPC hoses (23). fl After disconnecting the hoses, fit tags to distinguish them.

30-8 1

PC15MR-1

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

22. Disconnect working lamp wiring connectors M11 and M12 (24).

23. Remove selector valve (25).

24. Disconnect 4 PPC lock valve hoses (26). fl After disconnecting the hoses, fit tags to distinguish them.

25. Disconnect 2 solenoid valve hoses (27). fl After disconnecting the hoses, fit tags to distinguish them.

26. Disconnect starting motor wiring E2 (28) and battery terminal (29).

27. Disconnect 2 hoses (31) from fuel tank assembly (30), then disconnect fuel level gauge wiring connector M5.

28. Remove fuel tank assembly (30).

29. Disconnect 2 ground wires (32).

30. Disconnect 5 hoses (33) from hydraulic tank assembly.

31. Remove reservoir tank.

32. Lift off hydraulic tank assembly (34) and frame (35). fl Check that all pipes and wires are disconnected, and remove the assembly carefully so that it does not hit any other parts.

33. Remove exhaust pipe (36) from muffler.

PC15MR-1

30-9 1

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

34. Disconnect hydraulic oil cooler inlet hose (37) and outlet hose (38), then remove hydraulic oil cooler assembly (39).

35. Disconnect radiator inlet hose and outlet hose, then remove radiator assembly (40).

36. Remove fan (41).

37. Remove fan shroud (42).

38. Disconnect 3 hoses (43) from hydraulic pump assembly. fl After disconnecting the hoses, fit tags to distinguish them.

39. Lift off engine and hydraulic pump assembly (44).

2 fl Check that all pipes and wires are disconnected, and remove the assembly carefully so that it does not hit any other parts.

0 Engine, hydraulic pump assembly: 130 kg

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY •

When installing the assembly, reverse the removal procedures.

1 fl Adjust the fuel control linkage. For details, see TESTING AND ADJUSTING, adjusting fuel control lever.

2 8 Mounting bolt : Liquid adhesive (LT-2) fl Use care to keep the adhesive away from the rubber cushion.

9 Mounting bolt : 63.74 – 73.55 Nm {6.5 – 7.5 kgm} •

Refilling with fuel (fuel tank) Add fuel to the fuel tank.

5

•

Fuel : Approx. 19 ¬

Refilling with oil (hydraulic tank) 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.

5

Hydraulic tank : Approx. 14 ¬ (EO10-CD)

•

Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

•

Bleeding air Bleed the air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Bleeding air.

PC15MR-1

30-11 1

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY ¤ Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic tank.

1. Remove swing motor and swing machinery assembly. For details, see REMOVAL OF SWING MOTOR, SWING MACHINERY ASSEMBLY. 2. Remove track frame undercover.

3. Disconnect 8 top hoses (1). fl After disconnecting the hoses, fit blind plugs in them. fl After disconnecting the hoses, fit tags to distinguish them.

4. Remove stopper (2).

5. Disconnect 5 hoses (3) on the left side. fl After disconnecting the hoses, fit tags to distinguish them.

6. Disconnect 5 hoses (4) on the right side. fl After disconnecting the hoses, fit tags to distinguish them.

7. Lower center swivel joint assembly (5) and remove.

INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY •

Carry out installation in the reverse order to removal.

•

Refilling with oil (hydraulic tank) 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 Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air.

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DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1.

2.

3.

4.

Remove the plate (1).

Remove the snap ring (2).

Remove the shaft assembly (3).

Remove the dust seal (4) from the shaft assembly (3).

5. Remove 3 pieces of the plug (5) and 4 pieces of the plug (6) from the shaft assembly (3).

6. Remove 9 pieces of the O-ring (7) and backup ring (8) from the swivel rotor (9).

ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1. Set 9 pieces of the O-ring (7) and 2 pieces of the backup ring (8) in the swivel rotor (9).

2. Set 3 pieces of the plug (5) and 4 pieces of the plug (6) in the shaft assembly (3). fl Degrease and dry the plug screws and shaft female screws completely and apply the liquid adhesive (Loctite 542) around the plug screws.

9 Plug (5): 4.90 – 6.86 Nm {0.5 – 0.7 kgm} 9 Plug (6): 11.8 – 24.7 Nm {1.2 – 2.5 kgm} 3. Set the dust seal (4) in the shaft assembly (3).

8 Contact surfaces with dust seal lip, rotor and shaft : Grease (G2-LI) 4. Install the shaft assembly (3). fl Be careful not to damage the O-rings in installing the shaft assembly.

5. Install the spacer (9) and fix it with the snap ring (2).

6. Install the plate (1).

9 Mounting bolt : 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

PC15MR-1

30-13 1

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

REMOVAL OF SWING MOTOR ASSEMBLY ¤ Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic tank.

1. Remove floor plate.

2. Remove canopy, seat, and bracket under seat.

3. Disconnect drain hose (1). fl Fit a blind plug in the drain hose.

4. Disconnect 4 hoses (2). fl After disconnecting the hoses, fit tags to distinguish them.

5. Lift off swing motor assembly (3).

0 Swing motor assembly : 25 kg

INSTALLATION OF SWING MOTOR ASSEMBLY •

Carry out installation in the reverse order to removal.

•

Refilling with oil (hydraulic tank) 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 Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air.

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

REMOVAL OF REVOLVING FRAME ASSEMBLY ¤ Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic tank.

1. Lift off canopy assembly.

2. Sling boom cylinder assembly (1), then remove head pin and lower on top of blade.

1 3. Disconnect working lamp wiring connectors (M13 and M14) (2).

4. Disconnect 4 hoses (3), then pull out pin (4) and lift off work equipment assembly (5).

5. Sling boom cylinder assembly (1).

6. Disconnect 2 hoses (6), then pull out pin (7) and remove boom cylinder assembly (1).

2 7. Remove engine main pump assembly. For details, see REMOVAL OF ENGINE MAIN PUMP ASSEMBLY, 8. Remove swing motor assembly. For details, see REMOVAL OF SWING MOTOR ASSEMBLY.

9. Disconnect 8 swivel joint top hoses (8). fl After disconnecting the hoses, fit tags to distinguish them.

10. Remove stopper (9).

11. Disconnect grease tube (10) and remove grease connector (11).

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DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

12. Remove engine hood.

13. Sling revolving frame assembly (12), then remove mounting bolts (13). fl Leave 2 or 3 mounting bolts each at the front and rear.

3 14. Remove remaining mounting bolts, then lift off revolving frame assembly (12).

4 fl Using a lever block, adjust the balance of the revolving frame assembly to the left, right, front, and rear, and lift off. fl Be careful not to hit the swivel joint when removing.

0 Revolving frame assembly : 470 kg

INSTALLATION OF REVOLVING FRAME ASSEMBLY •

Carry out installation in the reverse order to removal.

1

¤ When aligning the position of the pin hole, never insert your fingers in the pin hole.

8 Pin, sliding surface when assembling : Molybdenum disulphide lubricant (LM-P) 8 Greasing after assembling: Molybdenum disulphide lubricant (LM-G) fl Adjust with shims so that the clearance between the head of cylinder (1) and boom (2) is less than 1 mm.

• Shim thickness : 1 mm 2

¤ When aligning the position of the pin hole, never insert your fingers in the pin hole.

8 Pin, sliding surface when assembling : Molybdenum disulphide lubricant (LM-P) 8 Greasing after assembling: Molybdenum disulphide lubricant (LM-G) fl Adjust with shims so that the clearance between the bottom of cylinder (1) and swing bracket (3) is less than 1 mm.

• Shim thickness : 1 mm 34 8 Revolving frame assembly mounting bolt : Thread tightener (LT-2) 9 Revolving frame assembly mounting bolt : 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

SWING CIRCLE

REMOVAL OF SWING CIRCLE ASSEMBLY 1. Remove the revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY. 2. Lift the swing circle assembly (1) by using the eyebolt 1 and remove it.

1 0 Swing circle assembly : 25 kg

INSTALLATION OF SWING CIRCLE ASSEMBLY •

When installing the assembly, reverse the removal procedures.

1 fl Install the assembly so that the S mark on the inner race soft zone comes to the left side of the track frame.

8 Swing circle assembly mounting bolt : Liquid adhesive (LT-2) 9 Swing circle assembly mounting bolt: 66.15 ± 7.35 Nm {6.75 ± 0.75 kgm} 8 Inner race tooth surface : Grease (G2-L1)

PC15MR-1

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DISASSEMBLY AND ASSEMBLY

IDLER

ASSEMBLY OF IDLER ASSEMBLY 1. Using tool L1, press fit 2 bearings (6) to idler (7). fl Fill the inside of the bearing with grease (G2LI).

2. Install shaft (5) and secure with snap ring (4).

3. Using tool L2, install oil seal (3) to idler. fl Fill the oil seal lip with grease (G2-LI) and be careful not to let any dirt or dust get stuck to it. fl After installing the oil seal on one side, fill the inside of the idler with grease.

5

Inside idler : Approx. 36 cc (G2-LI)

4. Install support (2).

8 Mounting bolt : Thread tightener (LT-2) 5. Install plate (1).

6. Install idler cushion assembly. (Steel shoe specification)

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

ASSEMBLY OF TRACK ROLLER ASSEMBLY 1. Using tool L3, press fit bearing (5) to track roller (6). fl Fill the inside of the bearing with grease (G2LI).

2. Install shaft (4) and secure with snap ring (3).

3. Using tool L4, install 2 oil seals (2) to track roller (6). fl Coat the sliding surface of the oil seal with engine oil (EO30-CD), and be careful not to let any dirt or dust get stuck to it. fl After installing the oil seal on one side, fill the inside of the track roller with grease.

5

Inside track roller : Approx. 44 cc (G2-LI)

4. Install washer (1).

PC15MR-1

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DISASSEMBLY AND ASSEMBLY

RUBBER SHOE

REMOVAL OF RUBBER SHOE ASSEMBLY 1. Loosen the valve (1) to reduce tension of the track shoe.

1

¤

Since the pressure in the recoil spring cylinder is very high, never turn the valve more than once to loosen it. fl When the grease is not pushed out smoothly, move the machine forward and reverse.

2. Swing the upper structure 90° and lift the track frame (2) a bit by using the work equipment. fl Lift the blade above beforehand.

3. Remove the rubber shoe assembly (3) by using the pipe 1. fl Twine the pipe round the rubber shoe and turn the rubber shoe to the reverse side. When the rubber shoe is raised from the idler, slide the rubber shoe aside to remove it.

0 Rubber shoe assembly : 55 kg

INSTALLATION OF RUBBER SHOE ASSEMBLY •

When installing the rubber shoe assembly, reverse the removal procedures.

1 fl Adjust tension of the track shoe. For details, see TESTING AND ADJUSTING, testing and adjusting track shoe tension.

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

DISASSEMBLY OF CONTROL VALVE Control valve bottom (1/2)

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DISASSEMBLY AND ASSEMBLY

fl Do not remove the long connecting bolt at the bottom of the control valve.

Remove the short connecting bolt at the top of the control valve when adding a service valve. fl The spools and pressure compensation valves (both the flow control valves and reducing valves) are not interchangeable between blocks, so be sure to mark them when disassembling. fl Do not remove the plug at the end of the spool. fl The pressure of the central safety valve cannot be set when it is mounted on the machine, so do not disassemble it.

1. Top cover 1) Remove plug (1). fl In some cases there is pressure remaining in the central safety valve circuit, so loosen the plug slowly. fl Remove the O-ring and backup ring.

2) Remove 2 plugs (2).

2. Boom swing & breaker control valve 1) Remove block (3).

2) Remove case (4) and plate (5).

3) Remove plug (6), case (7), retainer (8), and plate (9).

4) Remove bolt (10). fl Loosen the bolt with the spool still assembled inside the valve.

5) Remove retainer (11), spring (12), and retainer (13).

6) Remove spool (14).

7) Remove bolt (15). fl Loosen the bolt with the spool still assembled inside the valve.

8) Remove retainer (16), spring (17), and retainer (18).

9) Remove spool (19).

10) Remove 2 seals (20).

11) Remove suction valve assembly (21).

CONTROL VALVE

4. Bucket control valve 1) Remove cases (37) and (38).

2) Remove retainer (39).

3) Remove bolt (40). fl Loosen the bolt with the spool still assembled inside the valve.

4) Remove retainer (41), spring (42), and retainer (43).

5) Remove spool (44).

6) Remove plug (45), then remove spring (46), piston (47), and valve (48).

7) Remove plug (49), then remove valve (50) and spring (51).

8) Remove suction valve assembly (52).

9) Remove plug (53).

5. Boom control valve 1) Remove cases (54) and (55) and retainer (56).

2) Remove bolt (57). fl Loosen the bolt with the spool still assembled inside the valve.

3) Remove retainer (58), spring (59), and retainer (60).

4) Remove spool (61).

5) Remove plug (62), then remove spring (63), piston (64), and valve (65).

6) Remove plug (66), then remove valve (67) and spring (68).

7) Remove 2 suction valve assemblies (69).

8) Remove plug (70), then remove spring (71) and valve (72).

3. Blade control valve 1) Remove case (22) and plate (23).

2) Remove bolt (24). fl Loosen the bolt with the spool still assembled inside the valve.

3) Remove retainer (25), spring (26), and retainer (27).

4) Remove spool (28).

5) Remove plug (29), then remove spring (30), piston (31), valve (32), and spacer (33).

6) Remove plug (34), then remove valve (35).

7) Remove 2 seals (36).

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

Control valve bottom (2/2)

PC15MR-1

30-23 1

DISASSEMBLY AND ASSEMBLY

6. R.H. travel control valve & L.H. travel control valve fl Disassemble the L.H. and R.H. travel control valves in the same way.

1) Remove plate (1).

2) Remove case (2) and plate (3).

3) Remove bolt (4). fl Loosen the bolt with the spool still assembled inside the valve.

4) Remove retainer (5), spring (6), and retainer (7).

5) Remove spool (8).

6) Remove 2 seals (9).

7) Remove plug (10), then remove piston (11), spring (12), and valve (13).

8) Remove plug (14), then remove valve (15).

CONTROL VALVE

11. Unload valve 1) Remove plug (53), then remove spring (54). fl Remove the O-ring and backup ring.

2) Remove plug (55), then remove spool (56).

12. Cooler bypass valve Remove plug (57), then remove spring (58) and valve (59).

13. Back pressure check valve Remove plug (60), then remove spring (61) and valve (62).

14. Top cover fl When adding a service valve, remove cover (63).

7. Swing control valve 1) Remove block (16).

2) Remove cases (17) and (18).

3) Remove bolt (19). fl Loosen the bolt with the spool still assembled inside the valve.

4) Remove retainer (20), spring (21), retainer (22), spring (23), and retainer (24).

5) Remove spool (25).

6) Remove plug (26), then remove spring (27), piston (28), and valve (29).

7) Remove plug (30), then remove valve (31).

8. Arm control valve 1) Remove cases (32) and (33).

2) Remove retainer (34).

3) Remove bolt (35). fl Loosen the bolt with the spool still assembled inside the valve.

4) Remove retainer (36), spring (37), and retainer (38).

5) Remove spool (39).

6) Remove plug (40), then remove spring (41), piston (42), and valve (43).

7) Remove plug (44), then remove valve (45) and spring (46).

8) Remove suction valve assembly (47).

9) Remove plug (48), then remove spring (49) and valve (50).

9. Main relief valve Remove main relief valve assembly (51). fl For details of further disassembly, see Disassembly of main relief valve assembly.

10. Central safety valve Remove central safety valve assembly (52). fl Remove the O-ring and backup ring.

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

Disassembly of main relief valve assembly fl When the adjustment screw is loosened, the set pressure will change, so before disassembling, measure the protrusion from the nut of the adjustment screw.

1. Remove nut (1).

2. Remove screw (2), then remove spring (3) and poppet (4).

3. Remove ring (5), then remove valve (6) and spring (7) from sleeve (8).

PC15MR-1

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DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

ASSEMBLY OF CONTROL VALVE ASSEMBLY Control valve bottom (1/2)

30-26 1

PC15MR-1

DISASSEMBLY AND ASSEMBLY

fl The spools and pressure compensation valves (both the flow control valves and reducing valves) are not interchangeable between blocks, so when assembling, put the marks made during disassembly into sets.

1. Top cover fl If the top cover was removed during disassembly, install it as follows.

Fit O-ring to block end and install cover (63).

9 Mounting bolt : 29.4 – 34.3 Nm {3 – 3.5 kgm} 2. Back pressure check valve Assemble valve (62) and spring (61), then fit O-ring and install plug (60).

3. Cooler bypass valve Assemble valve (59) and spring (58), then fit O-ring and install plug (57).

4. Unload valve 1) Assemble spool (56), then fit O-ring and install plug (55).

9 Plug : 117.7 – 161.8 Nm {12 – 16.5 kgm} 2) Assemble spring (54), then fit O-ring and backup ring, and install plug (53).

9 Plug : 117.7 – 161.8 Nm {12 – 16.5 kgm}

CONTROL VALVE

3) Assemble spring (46) and valve (45), then fit O-ring and install plug (44).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 4) Assemble valve (43), piston (42), and spring (41), then fit O-ring and install plug (40).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 5) Assemble spool (39). fl Be careful to assemble in the correct direction.

6) Assemble retainer (38), spring (37), and retainer (36) to spool, then install bolt (35). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 7) Assemble retainer (34), then fit O-rings and install cases (33) and (32).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm}

5. Central safety valve Fit O-ring and backup ring, then install central safety valve assembly (52).

9 Central safety valve assembly : 137 – 157 Nm {14 – 16 kgm} 6. Main relief valve Fit O-ring and install main relief valve assembly (51).

9 Main relief valve assembly : 49 – 58.8 Nm {5 – 6 kgm} fl For details of assembly, see Assembly of main relief valve assembly.

7. Arm control valve 1) Assemble valve (50) and spring (49), then fit O-ring and install plug (48).

9 Plug : 19.6 – 24.5 Nm {2 – 2.5 kgm} 2) Install suction valve assembly (47).

9 Suction valve assembly : 39.2 – 49 Nm {4 – 5 kgm}

PC15MR-1

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DISASSEMBLY AND ASSEMBLY

8. Swing control valve 1) Assemble valve (31), then fit O-ring and install plug (30).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 2) Assemble valve (29), piston (28), and spring (27), then fit O-ring and install plug (26).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 3) Assemble spool (25). fl Be careful to assemble in the correct direction.

4) Assemble retainer (24), spring (23), retainer (22), spring (21), and retainer (20) to spool, then install bolt (19). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 5) Fit O-ring and install cases (18) and (17).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 6) Fit O-ring and install block (16).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 9. R.H. travel control valve & L.H. travel control valve fl Assemble the L.H. and R.H. travel control valves in the same way.

1) Assemble valve (15), then fit O-ring and install plug (14).

CONTROL VALVE

5) Assemble retainer (7), spring (6), and retainer (5) to spool, then install bolt (4). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 6) Install plate (3) and case (2).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 7) Install plate (1).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm}

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 2) Assemble valve (13), spring (12), and piston (11), then fit O-ring and install plug (10).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 3) Press fit 2 seals (9).

4) Assemble spool (8). fl Be careful to assemble in the correct direction.

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

Control valve top (2/2)

PC15MR-1

30-29 1

DISASSEMBLY AND ASSEMBLY

10. Boom control valve 1) Assemble valve (72) and spring (71), then fit O-ring and install plug (70).

9 Plug : 19.6 – 24.5 Nm {2 – 2.5 kgm} 2) Fit O-ring and install 2 suction valve assemblies (69).

9 Suction valve assembly : 39.2 – 49 Nm {4 – 5 kgm} 3) Assemble spring (68) and valve (67), then fit O-ring and install plug (66).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 4) Assemble valve (65), piston (64), and spring (63), then fit O-ring and install plug (62).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 5) Assemble spool (61). fl Be careful to assemble in the correct direction.

6) Assemble retainer (60), spring (59), and retainer (58) to spool, then install bolt (57). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 7) Assemble retainer (56), then fit O-rings and install cases (55) and (54).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 11. Bucket control valve 1) Fit O-ring and install plug (53).

9 Suction valve assembly : 39.2 – 49 Nm {4 – 5 kgm} 2) Fit O-ring and install suction valve (52).

9 Suction valve assembly : 39.2 – 49 Nm {4 – 5 kgm} 3) Assemble spring (51) and valve (50), then fit O-ring and install plug (49).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 4) Assemble valve (48), piston (47), spring (46), then fit O-ring and install plug (45).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm}

30-30 1

CONTROL VALVE

5) Assemble spool (44). fl Be careful to assemble in the correct direction.

6) Assemble retainer (43), spring (42), and retainer (41) to spool, then install bolt (40). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 7) Assemble retainer (39), then fit O-rings and install cases (38) and (37).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 12. Blade control valve 1) Press fit 2 seals (36).

2) Assemble valve (35), then fit O-ring and install plug (34).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 3) Assemble spacer (33), valve (32), piston (31), and spring (30), then fit O-ring and install plug (29).

9 Plug : 47.1 – 58.8 Nm {4.8 – 6 kgm} 4) Assemble spool (28).

Be careful to assemble in the correct direction.

5) Assemble retainer (27), spring (26), and retainer (25) to spool, then install bolt (24). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 9.8 Nm {0.7 – 1.0 kgm} 6) Install plate (23) and case (22).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 13. Boom swing & breaker control valve 1) Fit O-ring and install suction valve assembly (21).

9 Suction valve assembly : 39.2 – 49 Nm {4 – 5 kgm} 2) Press fit 2 seals (20).

3) Assemble spool (19). fl Be careful to assemble in the correct direction.

PC15MR-1

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

4) Assemble retainer (18), spring (17), and retainer (16) to spool, then install bolt (15). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 12.7 Nm {1 – 1.3 kgm} 5) Assemble spool (14). fl Be careful to assemble in the correct direction.

6) Assemble retainer (13), spring (12), and retainer (11) to spool, then install bolt (10). fl Tighten the bolt with the spool assembled inside the valve.

8 Bolt : Thread tightener (Loctite No. 638) 9 Bolt : 6.9 – 12.7 Nm {1 – 1.3 kgm} 7) Fit O-ring and install plate (9).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 8) Install retainer (8), case (7), and plug (6).

9 Plug : 19.6 – 24.5 Nm {2 – 2.5 kgm} 9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 9) Fit O-ring and install plate (5).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 10) Fit O-ring and install case (4).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 11) Fit O-ring and install block (3).

9 Mounting bolt : 9.8 – 12.7 Nm {1 – 1.3 kgm} 14. Top cover 1) Fit O-ring and install plug (2).

9 Plug: 34.3 – 44.1 Nm {3.5 – 4.5 kgm} 2) Fit O-ring and backup ring, then install plug (1).

9 Plug: 34.3 – 44.1 Nm {3.5 – 4.5 kgm}

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DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

Assembly of main relief valve fl To make the set pressure the same as before disassembly, set the protrusion from the nut of the adjustment screw to the dimension measured before disassembly.

After installing the control valve assembly to the machine, check the set pressure again.

For details, see TESTING AND ADJUSTING. 1. Assemble spring (7) and valve (6) to sleeve (8), then secure with ring (5).

2. Assemble poppet (4) and spring (3), then fit Oring and install screw (2).

3. Install nut (1).

9 Nut : 58.5 â&#x20AC;&#x201C; 78.5 Nm {6 â&#x20AC;&#x201C; 8 kgm}

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1. Cylinder 1) Press fit bushing (26) to cylinder (3).

2) Press fit 2 dust seals (25).

2. Piston rod 1) Press fit bushing (24) to piston rod (6).

2) Press fit 2 dust seals (23).

3. Cylinder head assembly 1) Assemble cylinder head assembly as follows. i) Using tool U4, press fit dust seal (21) to piston (14).

ii) Using snap ring pliers, install snap ring (20). iii) Install rod packing (22). iv) Install O-ring (18) and backup ring (19). fl Match the direction of installation with the diagram on the right. v) Install O-ring (15) and 2 backup rings (16). fl Boom cylinder only

PC15MR-1

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DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

2) Fit O-ring and install cylinder head assembly (14) to piston rod (6).

4. Piston assembly 1) Install cushion plunger (10) to piston rod (6). fl Boom cylinder only

2) Assemble piston assembly as follows. i) Using tool U5, expand piston ring (9). fl Set the piston ring on tool U5 and turn the handle 8 â&#x20AC;&#x201C; 10 times to expand the ring. ii) Install piston ring (9) to piston (8). iii) Using tool U6, compress piston ring (9). iv) Install wear ring (7).

3) Install piston assembly (5) to piston rod (6).

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PC15MR-1

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

4) Set piston rod assembly (2) to tool U1, and install piston nut (4). fl Width across flats of piston nut : (mm)

Model Boom Arm Bucket Swing Blade Gauge PC15MR

36

41

32

32

36

32

8 Piston nut : Thread tightener (Loctite 262 or equivalent) 9 Piston nut : (Nm {kgm})

Model Boom

Arm

Bucket Swing

Blade

Gauge

422±42.0 618±62.0 324±32.5 343±34 412±41.0 324±32.5

PC15MR {43±4.3} {63±6.3} {33±3.3} {35±3.5} {42±4.2} {33±3.3}

5. Piston assembly 1) Install piston rod assembly (2) to cylinder (3).

2) Set cylinder assembly (1) to tool U1.

3) Using tool U2, tighten cylinder head.

9 Cylinder head : Model Boom

Arm

Bucket Swing

(Nm {kgm})

Blade

Gauge

637±63.5 569±57 539±54 637±63.5 785±78.5 441±44.0

PC15MR {65±6.5} {58±5.8} {55±5.5} {65±6.5} {80±8.0} {45±4.5}

6. Piping Install cylinder piping.

9 Sleeve nut : 49 ± 19.6 Nm {5 ± 2 kgm} PC15MR-1

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90 OTHERS

Hydraulic circuit deagram (Variavle gauge type) ....................... 90Hydraulic circuit deagram (Fixed gauge type) ........................... 90Electric circuit deagram (Serial No.: 10001 â&#x20AC;&#x201C; 10634) .................. 90Electric circuit deagram (Serial No.: 10635 and up) ................... 90-

PC15MR-1

3 5 7 9

90-1 (2)

ELECTRIC CIRCUIT DIAGRAM Serial No.: 10001 â&#x20AC;&#x201C; 10634

PC15MR-1

90-7 (2)

ELECTRIC CIRCUIT DIAGRAM Serial No.: 10635 and up

PC15MR-1

90-9 (2)