‘SEBM000906 SIOWP IMI A\INTUA\IL: KOMATSU PCSOUU-2 MACHINE MODEL SERIAL No. PCS50UU-2 8001 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 re- quire. Materials and specifications are subject to change without notice. + PC5OUU-2 mount the 4D84-2GA and 4D88E-3 engine. For details of the engine, see the 84 Series and 68E-88 Series Engine Shop Manual. © 2002 KOMATSU All Rights Reserved 00-1 Printed in Japan 03-0202) ®01 10 20 30 40 90 08 CONTENTS GENERAL ... STRUCTURE AND FUNCTION ..... TESTING AND ADJUSTING ... DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD OTHERS .. No. of page 01-1 PCSOUU-2‘The affected pages are indicated by the use of the : following marks. It is requested that necessary |_M@rk Indication eeten eules actions be taken to these pages according to the © | Page to be newly added| Add table below. @ | Page tobe replaced | Replace (_) | Pagetobedeleted | Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGES Mack Pone REVO") ata rage Rewton] mk rape Peon] aon Page REV] mark rage Revibon 201 © 1-15 «@ 1039 @ 1082 @ 10-126 @ 02 © O16 6=@ 10-40 © 1083 @ 2 0021 © 0117 @ 10-42 © 184 @ |e 21 © © 00:22 © 10-43 @ 1085 @ 22 © 2 0023 © 01 @ 10-44 © 108 @ 2021 @ 2 0024 © 102 @ 10-46 © 1087 @ 23° @ 00-3 ; 03 @ 1047 © 1089 @ 20-4 00-4 wa @ 10-48 © 1090 @ 25° «@ 00-5 105 @ 10.49 @ 1081 @ 206 00-6 6 86 @ 1050 © 1093 @ 207 00-7 107 @ 1051 © 1094 @ 208 = 8@ 00-8 10-8 @ | ws @ 1095 © 20-9 00-8 109 -@ 1053 @ 1087 @ ® 00-10 10 @ 1054 © 1098 @ ® 00-11 011 @ 1055 @ 1099 @ @ 00-12 012 © 1056 «© 10-100 © ® 00-13 1013 @ 1057 © 10-101 @ @ 00-14 10-14 @ 1058 © 10-102 @ ® 00-15, 1015 @ 1059 © 10-103 @ ® 00-16 10-16 @ 1060 © 10-104 @ 00-17 10-17 @ 1061 © 10-105 @ 00-18 118 © 1062 © 10-108 @ 00-19 10:20 @ 1063 © 10-107 @ 00-20 1021 @ 1064 @ 10-108 @ 00-21 1022 @ 1065 © 10-109 @ ® 00-22 1023 @ 1066 © 10110 @ ® 1024 © 1087 @ 10-111 @ ® 11 1025 © 1068 = © 10-112 @ ® 12 © 1026 @ 1069 © 10113 @ ® 13° «© 1027 @ 1070 @ 10-114 @ @ 14 © 10:28 @ 1071 @ 10-115 @ 15 © 1023 @ 1072 @ 10-116 @ @ 16 86 1030 @ 1073 @ 10117 @ 6 17 «© 1031 © 1074 @ 10-118 @ (20-22-1) 18 8 1032 @ 10-75 © 1119 @ | e 2023 © 1s «6 1033 @ 1076 @ 10120 @® | © 20231 © 01-10 @ 1034 @ 1077 @ 10-121 @ 20232 © 1 1035 @ 1078 @ 10-122 @ 2024 @ O12 @ 1036 @ 1079 @ 10-123 © 20-241 ® 01-13 @ 1037 @ 1080 @ 10-124 @ 2025 © oa 10:38 @ 1081 © 10-125 © 2026 @ PC5OUU-2 00-2-1 ®Merk Page Few'So"! 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wack Page Fevition) naark Page Revision | tae Page Revision 30399 © 3085 @ 30-97-42 © 30:97:97 © 30-115 @ 30-39-10 © 3086 @ 30-97-43 © 30-97-98 © 30-116 @ 30-39-11 © 3087 © 30-97-44 © 30-97-99 © 20-117 @ 30-39-12 © 3088 © 30-97-45 © 30-97-10 ©) 30-118 @ 30-39-13 © 3089 © 30-97-46 © 30-97-1018) 30-119 @ 30-40 © 30-90 @ | 309747 © 30-97-102 © 30-120 @ 3041 @ 3091 © 30-97-48 © 30-97-103 © 30-121 @ 3042 © 3092 © 30-97-49 © 30-97-104 © 30-122 @ 30-43 @ 3093 © 30-97-50 © 30-87-105 © 30-123 @ 30-44 © 3094 @ 30-97-51 © 30-97-106 © 30-124 @ 30-45 @ 3095 @ 30-97-52 © 30-87-107 © 30-125 © 3046 © 3096 @ 30-97-53 © 30-97-108 ©) 30-126 @ 30-47 @ 3097 @ 30-9754 @ 30-97-109 © 30-127 @ 30-48 © 3097-1 @ 30-97-55 © 30-87-110 © 30-128 © 3049 © 30972 © 30-97-56 © 30-97-111© 30-129 @ 30-50 © 30973 @® 30-97-57 © 30-97-12 30-130 @ 3051 @ 3097-4 © 30-97-58 © 30-97-113 ©) 30-131 © 3052 @ 30975 © 30-9769 © 30-97-114@ 30-132 @ 30-53 @ 30976 © 30-97-60 © 30-97-15 @ 30-133 @ 3054 © 3097-7 © 30-97-61 © 30-97-116 © 30-134 © 3055 @ | 30978 © 30-97-62 © 30-97-117 © 30-135 @ 3058 @ | 30979 © 30-97-63 © 30-97-118© 30-138 @ 3057 @ 3097-10 © 30-97-64 © 30-97-1189 © 30-137 © 3058 @ 3097-11 © 30-97-65 © 30-97-120@ 30-59 © 30-97-12 © 30-97-67 © 30-97-121© 40-1 @ 30-60 © 30-97-13 © 30-97-68 © 30-97-12 © 02 © 3061 © 30-97-14 © 30-97-69 © 30-97-123 © 03 @ 3062 © 30-97-15 © 30-97-70 © 30-97-124@ 0-4 © 3063 © 30-97-16 © 3097-71 © 30-97-125 © 05° @ 30-64 @ 30-97-17 ® 3097-72 © 30-97-126 © 46 8 @ "30-65 © 30-97-18 © 30-97-73 © 30-97-127 © 07 @ 30-66 © 30-97-19 © 30-97-74 © 30-97-128 © 408 «@ 30-68 © 30-97-20 ® 30-97-75 ® 30-97-129 ©) 49 © 30-69 © 30-97-21 © 3087-76 © 30-97-130 © 40-10 @ 30-70 © 30-97-22 © 30-97-77 © 30-97-131@ 40-12 @ 30-71 @ 30-97-23 © 30-97-78 © 30-98 @ 4013 @ 30-72 © 30-97-24 ® 30-97-79 © 3099 © 40-14 @ 3073 © 30-97-25 © 30-97-80 © 30-100 @ 4015 @ 30-74 © 30-97-26 © 3097-81 © 30-101 © 4016 @ 30-75 © 30-97-27 © 30-97-82 © 30-102 @ 40-17 @ 30-76 @ 30-97-28 © 30-97-83 © 30-103 @ 40-18 @ 30-77 © 30-97-29 © 30-97-84 © 30-104 © 40-19 @ 3078 © 30-97-30 © 30-97-85 © 30-105 @ 40-20 @ 30-781 © 30-97-31 © 3097-86 © 30-106 @ 4021 © 30-782 © 30-97-32 © 3097-87 © 30-106-1 @ 4022 @ 30-783 © 30-97-33 © 30-97-88 © 30-106-2 @ 40.24 © 30-784 © 30-97-34 © 30-97-89 © 30-107 @ 4025 @ 30-785 © 30-97-35 © 30-97-90 © 30-108 @ 40-26 © 30-786 © 30-97-36 © 3097.91 © 30-109 @ 4027 @ 30-79 © 30-9737 © 30-97-92 © 30-110 @ 40-28 © 3080 © 30-97-38 © 30-97-93 © 30-111 © 40-29 @ 30-82 © 30-97-39 © 30-97-94 © 30-112 @ 4030 @ 3083 © 30-97-40 © 30-97-95 © 30-113 @ 4031 © 3084 © | 3097.41 © 30-97-96 © 30-114 © 40:32 @ PCSOUU-2 00-2-3Mark Page PMC") wk page FMM] Haan rage FM] on Page FOECM] wack Page Reval 40-33 ® 40-34 @ 40-35, @ 40-36 @ 40-37 @ 40-38 @ 40-39 @ 40-40 @ 40-41 @ | 40-42 @ 40-23 @ 4-2: @ 40-<* @ 40-6, @ 40-47 @ 40-48 @ 40-49 @ 40-50 @ 4051 @ 40-52 ® 4054 @© | 40-55, @ 4058 @ 40-57 @ 40-58 @® 4059 @ | 1 @ | 90-3 @® 90-5 @ 90-7 @ 90-9 @® 20-11 @ 90-13 @ 90-15, @ | | 1 0-2-4 PCSOUU-2SAFETY SAFETY SAFETY NOTICE SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools spec designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol 4) is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed car fully. if any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. ly GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. « Always wear safety glasses when hitting parts with a hammer. ‘+ Always wear safety glasses when grind- ing parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- ing work. 4, When carrying out any operation with two or more workers, always agree on the oper- ating procedure before starting. Always in- form your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. ‘Smoke only in the areas provided for smok- ing. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warn- ing signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the ma- chine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug ‘or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13, Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. 14, When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- 19 any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pres- sure, 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 mit mum of gasoline when washing electrical parts. SAFETY NOTICE 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘+ When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is be- ing operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always Use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your \gers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24, Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD. GENERAL GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components. ‘STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Each issued as one ‘Attachments volume: | Volume to cover all models These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is neces- sary that chassis, engine, electrical and attach- ment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the ‘most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10-3 tem number (10. Structure and Function) Consecutive page number for each item, Example 2 (Engine volume): 12-5 l Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indi- cated by a hyphen (-) and number after the Page number. File as in the example. Example: 10-4 12-203 10-41 12-203-1 10-4.2—1— Added pages —[49.293.2 105 12-204 00-6 REVISED EDITION MARK When a manual is revised, an edition mark (@@®....) is recorded on the bottom of the pages. REVISIONS Revised pages are shown in the LIST OF RE- VISED PAGES next to the CONTENTS page. ‘SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quality portions are marked with the following symbols. Symbol | item Remarks Special safety precautions are Ay | Safety | necessary when performing the work. ‘Special technical precautions or other precautions for pre~ Caution | serving standards are neces- sary when performing the work. Weight of parts of systems. ition necessary when se- iecting holting weer hon ‘working posture is important, ete, Places that require special at- [Fiahtening| tention for the tightening torque | torque during assembly. Coat | Places to be coated with ad- hesives and lubricants, etc. - Places where oll, water or fuel il, water] must be added, and the ca- pacity. Places where oil or water Drain | must be drained, and quan- tity to be drained. Ee WB |FOREWORD HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or more,is dicated clearly with the symbol Ifa part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part caus- ing interference with the part to be re- moved. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S* twist ropes without galvanizing) Rope diameter Allowable load mm kN. tons 10 98 1.0 12 137 14 125 157 16 4 21.6 22 16 25 28 8 35.3 36 20 43.1 44 22.4 54.9 56 30 98.1 10.0 40 176.5 18.0 50 274.6 28.0 60 392.2 40.0 * The allowable load value is estimated to be one-sixth or one-seventh of the break- ing strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. HOISTING INSTRUCTIONS Slinging near the edge of the hook may ‘cause the rope to slip off the hook during hoisting, and a serious accident can re- sult. Hooks have maximum strength at the middle portion. dea 100% 88% 79% 71% 41%. 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes ‘symmetrically wound onto the load. QB Siinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding Position on the load, which can re- sult in a dangerous accident. 4) Do not sling a heavy load with ropes form- ing a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allow- able load kN {kg} when hoi made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg) if they sling a 19.6 KN (2000 kg} load at a lifting angle of 150°. A 00-7FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER ‘There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ- ent, so see the table below when disassembling and connecting the coupler. Type 1 Type2 1) Hold the mouthpiece of the tightening por- | 1) Hold the mouthpiece of the tightening por- tion and push body (2) in straight until slid- | __ tion and push body (2) in straight until slid- ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male | __face a of the hexagonal portion at the male end. end. = covroesa1 : wrasse 2) Hold in the condition in Step 1), and push | 2) Hold in the condition in Step 1), and turn until cover (3) contacts contact surface a of lever (4) to the right (clockwise). the hexagonal portion at the male end. pal ee / + cvross93 cewrosaee Disassembly 3) Holdin 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. p+ > » 1 1 cxrosaa5 owossos 00-8FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Type 1 Type 2 Connection + Hold the mouthpiece of the tightening por- tion and push body (2) in straight until slid- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male end to connect it. cwrosset + Hold the mouthpiece of the tightening por- tion and push body (2) in straight until slid ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male end to connect it. cwrosse2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 eq alent of products shown in this list. Category | Komatsu code| Part No. Qty | Container Main applications, features + Used to prevent rubber gaskets, rubber LT-IA — {790-123-0090/ 1609 ed cushions, and cock plug from coming out. + Used in places requiring an immediately effective, strong adhesive. Used for plas- LT-1B 790-129-9050 ee Lebel tics (except polyethylene, polyprophylene, pee cen tetrafluoroethlene and vinyl chloride), rub- ber, metal and non-metal. + Features: Res Polyethylene] cals snce to heat and chemi- ee Ce uae 509 + Used for anti-loosening and sealant pur- pose for bolts and plugs. 730-128-9060 [Adhesive > Used as adhesive or sealant formal glass (Se of adhe | Ep and ples. ura |Shetana” Maraosing] can vordening | agent gent)” | 09 ut-4 |790-129-9040| 250 g Polyethylene]. Used as sealant for machined holes. Comair vote [Used es heating sealant for Foal Whois |no0-1-2120] 750 | Tube |° Ue 8 hs ~ ulck hardening type adhesive ‘Three bond lPotyethylene|* Cure time: within 5 sec. to 3 min. 1738 790-128-9140) 50.9 container |* Used mainly for adhesion of metals, rub- bers, plastics and woods. dui hardening ype adhesive + Gust curetype tse er 0 i Aromaoha lago.sz-or30] 29 /Povtiven|” fray + Used msinly or adhesion of rubbers, ls- tos and metal, ~ Features: Resistance to Rest shemale Loctite Povetnyene|” Features Resistance o heat chemicals sueso [794-129-9110] soce FEST | Used at ott pontons subject o high tem Used os adhesivo or solant for goats red pater eee 200g. ae and packing of power train case, etc. ~ Features Resistance to bot * Ueda seolrt Yor flange surfacos and Gost bots at high temperature tosaons, ved ae uss froo-tze-e070] 149 | can |, toproventseiure. + Used as sealant for heat resistance gasket for high temperature locations such as en- gine precombustion chamber, exhaust pipe, etc.FOREWORD COATING MATERIALS Category [Komatsu code] PartNo. | aty | Container Main applications, features > Features: Resistance to water, ol {Used as sealant for flange surface, thread. 1c4 —fao-19-90m0] 2009 | Tube [+ AO posi to use as ela for tangs + Used a8 sealant for mating surfaces of fi nal drive case, transmission case. > Used as sealant for various threads, pipe Polyethylene] joints, flanges. 4G-S 790-129-8080) 1 ko |" container |* Used as sealant for tapered plugs, elbows, nipples of hydraulic piping + Features: Sticon based, resistance to heat, Gasket cold sealant 16-6 | 09940-00011 | 2509 | Tube |- Used as seatant for flange surface, tread. + Used as sealant for oil pan final drive case, ere + Features: Silicon based, quick hardening type tG-7 | ovszo-00150/ 1509 | Tube |. Used as sealant for fywhee! housing, in- take manifold, oll an, thermostat housing, ete. Three bond Used as heat resisting sealant for repairing Ssre8@ |790-129-9090| 100g | Tube |" (seca : > Used as lubricant for sliding portion (to pre- Molyode- | ‘MG | 09940-00081] 69g | can |" vent trom squeaking). + Used to prevent seizure or soutfling of the uw-p | 09940-00040 | 2009 | Tube | throad when press fitting or shrink fitting. + Used as lubricant for linkage, bearings, et. Isve2-400u1 + General purpose type Isve2-3601 eeu [sve2400L4A | various | various Isve2-160u1 ISYGA-160CNL + Used for normal temperature, light toad Isyc2-4o0ca bearin i ‘with water or Grease ISvG24ooca bearing places in contact with wate G2ca _|SYG2400CA.A} Various | Various Isve260ca ISYGA-160CNCA| Molybdenum 4009 + Used for places with hea disulphide | SYG2-400M | (10 per |Belows type ieee ail teal de lubricant case) 00-11FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) % In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter Width I) @ of bolt across flats ce mm mm Nm kgm 6 10 132214 1.3520.18 8 13 3123 32203 10 7 6627 i 12 19 1132 10 1581 4 2 7219 1822 16 7m 27930 28523 18 a 38239 39:4 20 30 549 459 5626 2 32 745483, 76285 24 36 927103 94.54 10.5 2 a 13204 140, 135215 30 46 17208 190 175: 20 33 50 2210240 225% 25 36 55 2750+ 290 280: 30, 39 60 3290+ 340 335235 Thread diameter Width of bolt across flats oo mm mm Nm kom 6 10 7.85% 1.95 08202 8 3 tase 49 19205 10 4 402259 412086 12 2 82.3527.85 84208 TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. fiameter | Width across flat Tightening torque mm mm Nm kgm 4 19 245449 25205 18 24 494 19.6 542 2 27 7854 19.6 822 24 32 137.3429.4 us3 30 36 176.5429.4 183 33 a 196.1 49 2045 36 46 245.2449 2545 42 55 294.2449 3045FOREWORD STANDARD TIGHTENING TORQUE TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS % In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter Width across flat Tightening torque mm mm Nm kgm 10 4 657468 67207 12 7 112498 1151 16 2 27929, 28543 ‘TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS * Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Thread diameter ‘Width across flat Tightening torque Nominal No. mm’ mm Nm 02 14 343249 03, 04 20 \Varies depending on| 93.1 9.8 05, 06 24 Itype of connector. 142.14 19.6 10, 12 33 421.4588 14 a2 877.14 132.3 89.52 13.5 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ‘* Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Thread diameter Width across flat Tightening torque Nominal No. mm mm Nm kgm 08 8 4 738% 1.47 0.750.185 10 10 a 14.27% 1.47 1.1820.15 12 12 19 17.64% 1.96 18x02 4 4 22 2254+ 23202 16 16 24 29.42 3405 8 18 27 39.24 420! 20 20 30 49s. 5405 24 24 32 686+ 741 30 30 32 107.8+14.7 1415 33 33 = 127-44 196 1322 36 36 36 15192245, 15.5425 a2 a2 a 21074294 21523 52 52 = 323.44 44.1 33245 00-13FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter Tightening torque mm. Nm kgm 6 +2 1.02 + 0.20 8 mee 2.45 + 0.41 10 4326 438 +061 2 Te2 785 £1.22 TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine. ‘Thread diameter Tightening torque mm Nm kgm) 6 B42 0.81 + 0.20 8 1042 1.02 + 0.20 10 1242 1.22 £0.20 12 te 2.45 £0.41 4 365 3.67 + 0.51 TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine. ‘Thread diameter Tightening torque inch Nm kgm) 1716 FFs 0.31 + 0.10 18 B42 0.81 + 0.20 4 1242 1.22 + 0.20 3/8 16 £2 1.53 £0.41 V2 2634 245 = 0.41 314 36 +5 367 = 051 1 09 6.12 + 0.92 00-14FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS i Cable 0.0. | curent rain Number of [Dia. faved Cress seation (mm) ans Applicable circuit 0.85 1 032 0.88 24 12 | Starting, ighting, signal ete. 2 26 032 2.09 34 20 | Lighting, signal ete. 5 65 0.32 5.23 46 37 | Charging and signal 15 24 045 13.36 70 59 | Starting (Glow plug) “0 85 0.80 4273 W4 135 | Starting 60 127 0.80 oae4 136 178 | starting 100 27 0.280 109.1 176 230 | starting CLASSIFICATION BY COLOR AND CODE os Ground | Staring | Lighting | instrument | signal | other fication + |p, Jeesel —w 8 B R Y 6 c cotor| White | Black | Black Red Yellow | Green Blue Code] WR = Bw RW YR cw ww fi [color| White & Red| — __ [Black & White|Red & White [Yellow & Red [Green & White|BIue & White Code] We = By RB Ye oR LR " Color| White & Black] — Black & Yellow] Red & Black [Yellow & Black|Green & Red| Blue & Red [code] wi = BR RY YG Gy wy : Color|White & Blue] — _| Black & Red [Red & YellowfYelow & Green|Green & Yelow/Blue & Yellow code] WG = = RG vL 8 iB : Color|white & Green] — —__ [Red & Green fyetow & Blue|Green & Biack| Blue & Black code] — = = RL w Gt = i color] — = — [Red & Blue [Yelow & White[Green & Bluel _ —FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE + Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @. (2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from ©. (3) Take the point where the two lines cross as ©. This point © gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 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 mim to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches 0 1 2 3 4 5 o jo 0.039 | 0.079 | 0.118 | 0.157 | 0.197 10 | 0.394 | 0.433] 0.472 | 0.512 | 0.551 | 0.591 20 | 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 30 | 1.181 | 1.220| 1.260 | 1.299 | 1.339 | 1.378 40 | 1.575 | 1.614| 1.654 | 1.693 | 1.732 | 1.772 0.276 | 0.315 | 0.354 0.669 | 0.709 | 0.748 1.063 | 1.102 | 1.142 1.457 | 1.496 | 1.536 1.850 | 1.890 | 1.929 | (2.765) 2.559 2.953 3.346 3.740 2.244 | 2.283 | 2.323 2.638 | 2.677 | 2.717 3.032 | 3.071 3.110 3.425 | 3.465 | 3.504 3.819 | 3.858 | 3.898 00-16FOREWORD Millimeters to Inches CONVERSION TABLE 1mm = 0.03937 in 0 1 2 3 4 5 6 7 8 9 ° 0 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.236 | 0.276 | 0.315 | 0.354 10 0.394 | 0.433 | 0.472 | 0.612 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748 20 0.787 | 0.827 | 0.866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.063 | 1.102 | 1.142 30 1.181 | 1.220 | 1.260 | 1.299 | 1.339 | 1.378 | 1.417 | 1.457 | 1.496 | 1.536 40 1.575 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 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 | 2677 | 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 1Lkg = 2.2046 Ib 0 1 2 3 4 5 6 7 8 9 0 0 220| 4.41) 661| 882] 11.02] 13.23) 15.43] 17.64| 19.84 10 22.05 | 24.25 | 26.46| 28.66) 30.86| 33.07) 35.27} 37.48| 39.68| 41.89 20 44.09} 46.30 48.50| 50.71) 51.91| 55.12] 57.32| 59.53] 61.73| 63.93 30 66.14] 68.34| 70.55| 7275| 74.96| 77.16| 79.37| 81.57] 83.78| 85.98 40 88.18 | 90.39] 9259] 94.80] 97.00| 99.21 | 101.41 | 103.62 | 105.82 | 108.03 50 110.23 | 112.44 | 114.64 | 116.85 | 119.05 | 121.25 | 123.46 | 125.66 | 127.87 | 130.07 60 132.28 | 134.48 | 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FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1é= 0.2642 US. Gal ° 1 2 3 4 5 6 7 8 9 ° 0 0.264 | 0.528 | 0.793 | 1.057 | 1.321 | 1.585 | 1.849 | 2.113 | 2.378 10 2.642 | 2.906 | 3.170 | 3.434 | 3.698 | 3.963 | 4.227 | 4.491 | 4.755 | 5.019 20 5.283 | 5.548 | 5.812 | 6.076 | 6.340 | 6.604 | 6.869 | 7.133 | 7.397 | 7.661 30 7.925 | 8.189 | 8.454 | 8.718 | 8.982 | 9.246 | 9.510 | 9.774 | 10.039 | 10.303 40 10.567 | 10.831 | 11.095 | 11.359 | 11.624 | 11.888 | 12.152 | 12.416 | 12.680 | 12.944 50 13.209 | 13.473 | 13.737 | 14.001 | 14.265 | 14.529 | 14.795 | 15.058 | 15.322 | 15.586 60 15.850 | 16.115 | 16.379 | 16.643 | 16.907 | 17.171 | 17.435 | 17.700 | 17.964 | 18.228 70 18.492 | 18.756 | 19.020 | 19.285 | 19.549 | 19.813 | 20.077 | 20.341 | 20.605 | 20.870 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 Liter to U.K. Gallon Me = 0.21997 UK. Gal 0 1 2 3 4 5 6 7 8 9 0 ° 0.220 | 0.440 | 0.660 | 0.880 | 1.100} 1.320] 1.540 | 1.760 | 1.980 10 2.200 | 2.420 | 2.640 | 2.860 | 3.080 | 3.300] 3520] 3.740} 3.950| 4.179 20 4.399 | 4619 | 4.839 | 5.059] 5.279| 5.499 | 5.719| 5.939| 6159| 6.379 30 6599 | 6819 | 7.039| 7.259 | 7.479| 7.969] 7.919] 8.139] 8.359 | 8.579 40 8.799 | 9.019 | 9.239 | 9.459 | 9.679 | 9.899 | 10.119 | 10.339 | 10.559 | 10.778 50 10.998 | 11.281 | 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 | 20.67 | 20.897 | 21.117 | 21.337 | 21.867 | 21.777 00-18FOREWORD CONVERSION TABLE kgm to ft. Ib ‘kgm = 7.233 ft. Ib ° 1 2 3 4 5 6 7 8 9 o ° 72| 145} 217] 289] 362] 434] 506} 579] 65.1 10 723} 796] 868| 940| 1013] 1085 | 115.7 | 123.0} 1302 | 137.4 20 1447 | 151.9 | 169.1] 166.4 | 1736 | 1808 | 188.1 195.3 | 2025 | 209.8 30 217.0 | 224.2 | 2315 | 238.7 | 245.9 | 253.2 | 260.4 | 267.6 | 274.9 | 282.1 40 289.3 | 2966 | 3038 | 311.0 | 3183 | 325.5 | 3327 | 340.0 | 347.2) 354.4 50 361.7 | 368.9 | 376.1 | 383.4 | 3906 | 397.8 | 405.1 | 4123 | 4195 | 4268 60 434.0 | 441.2 | 448.5 | 455.7 | 4629 | 470.2 | 477.4 | 4846 | 491.8 | 499.1 70 506.3 | 5135 | 5208 | 528.0 | 535.2 | 5425 | 549.7 | 556.9 | 564.2 | 571.4 80 578.6 | 585.9 | 593.1 | 600.3 | 607.6 | 6148 | 622.0 | 629.3 | 6365 | 643.7 90 651.0 | 658.2 | 665.4 | 672.7 | 679.9 | 687.1 | 694.4] 701.6 | 7088 | 716.1 100 723.3 | 7308 | 737.8 | 745.0 | 7522 | 759.5 | 766.7 | 7739 | 781.2 | 788.4 110 795.6 | 8029 | 810.1 | 817.3 | 824.6 | 831.8 | 939.0 | 846.3 | 953.5 | 860.7 120 868.0 | 875.2 | 882.4 | 889.7 | 896.9 | 904.1 | 911.4 | 9186 | 9258 | 933.1 130 940.3 | 947.5 | 954.8 | 962.0 | 969.2 | 976.5 | 9837 | 990.9 | 998.2 | 1005.4 140 | 1012.6 | 1019.9 | 1027.1 | 1034.3 | 1041.5 | 1048.8 | 1056.0 | 1063.2 | 10705 | 107.7 150 | 1084.9 | 1092.2 | 1099.4 | 1106.6 | 1113.9 | 1121.1 | 1128.3 | 1135.6 | 1142.8 | 1150.0 160 | 1957.3 | 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 | 1348.3 | 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/em? to Ib/ir Tkglem? = 14.2233 Ibyin? o 1 2 3 4 5 6 7 8 9 0 o 14.2) 284] 427] 569) 71.1! 953] 996) 1138] 128.0 10 142.2 | 156.5 | 170.7 | 1849 | 199.1 | 2134] 227.6 | 241.8 | 266.0 | 270.2 20 284.5 | 298.7 | 3129 | 327.1 | 341.4] 3556 | 3698 | 3e40| 3983 | 4125 30 426.7 | 440.9 | 455.1 | 469.4] 4836 | 4978 | 512.0 | 526.3 | 5405 | 554.7 40 568.9 | 583.2 | 597.4] 611.6] 6258 | 640.1| 6543 | 6685 | 682.7 | 696.9 50 711.2 | 725.4 | 739.6 | 7538 | 768.1 | 7823) 7965 | 810.7 | 825.0| 839.2 60 853.4 | 867.6 | 881.8 | 896.1 | 9103| 9245 | 9387 | 953.0 | 967.2 | 981.4 70 995.6 |1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 80/1138 1152 | 1166 | 1781 | 1195 | 1209 | 1223 | 1237 | 1252 | 1266 90 | 1280 | 1294 | 1309 | 1323 | 1337 | 1351 | 1365 | 1380 | 1304 | 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 | 2753 | 2773 | 2788 | 2802 | 2816 | 2830 200 | 2845 | 2859 | 2873 |2887 | 2901 | 2916 | 2930 | 2044 | 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 | 3957 | 3371 | 3385 | 3399 240 | 3414 | 3428 | 3442 | 3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542FOREWORD CONVERSION TABLE Temperature Fahrenheit Centigrade Conversion ; a simple way to convert a Fahrenheit tamperature reading into @ Centigrade tempere- ture reading or vice versa isto enter the accompanying table inthe center or boldface column of figures. ‘These figures refer tothe temperature in either Fahrenheit of Centigrade degrees. 1 iis desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature inthe column at the lf. If itis desired to conver 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 cee rc oF | ec ore) ec °F 40.4 | 40 7] | sig] 78] 46 | waa] 272 | or | a78 -372 | -35 =i | 12 | 536 | 83} 47 | 166 | 278) #2 | 1796 -344 | -30 tos | 13 | 554] 89 | 48 | 1184 | 283 | a3 | te14 -317 | -25 -100 | 1 | 572 | 94} 49 | t202 | 289] g¢ | 1232 -289 | -20 -94 | 16 | 590 | 100 | 50 | 1220 | 294 | a5 | 1050 -283 | -19 | -22 | -9| 1 | sos | 106 | 51 | 1238 | 300] a6 | 1868 278 | -18 | 04] -23 |) w | 626 | 111 | 52 | 1256] 306 | 87 | 1086 272 | -17 14 | 78] w | es¢] t17 | 63 | 1274 | 311 | ss | 1904 -26.7 | -16 32 | 72} 19 | 662] 122] se | 1292] 317 | 89 | 1922 -26.1 | -15 50 | -67 | 20 | 680 | 128 | 55 | 1310 | 322 | 90 | 1940 -256 | -14 es | 61 | 21 | os | 133) 56 | 1328 | 228 | 91 | 1958 -25.0 | -13 as | 6 / 2 | 716 | 139] 57 | 1366 | 333 | 92 | 1976 -2a| 12 | 104 | 60] 23 | 734] 144] 58 | 1364] 339 | 93 | 1994 -39 | -1 | 122] -44| 24 | 752] 180 | 59 | 1382] 364] 94 | 2012 33 | -10 | 40] -39| 25 | 770 | 156 | 60 | 1400] 350 | 95 | 2030 -28 | -9 | 18] -33| 26 | 708 | 161 | 61 | m8 | 356 | 96 | 2048 -22| @ | w6| -28| 27 | 806 | 167 | 62 | 1436] 361 | 97 | 2066 a7} 7 | 194 | -22] 2 | a4} 2] os | 454 | 367 | 98 | 2084 aa} | 22] -7 | 2 | ez] we} oe | razz] 372] 99 | 202 206 | 5 | 230 | -11} 30 | 960 | 183 | 65 | 1490 | 378 | 100 | 2120 0.0 | «4 | 28 | -06| a1 | 878 | 189 | 66 | 1508 | 406 | 105 | 2210 194 | -3 | 266 | 0 | 32 | a96 | 194| 67 | 1526 | 433 | 110 | 2300 199 | 2 | 284 | 06 | 33 | 914 | 200| 68 | 1544] 461 | 115 | 2390 a3 | + | 302] 11] 34 | 932] 206 | 68 | 1562 | 489 | 120 | 2480 a7} 0 | azo] 17 | 35 | 950] 211] 70 | 1580 | 617 | 125 | 2870 ~72] 1 | 338] 22] 36 | 968 | 217 | 71 | 1508 | 544 | 190 | 2080 -e7 | 2 | 356] 28] 37 | 986 | 222 | 72 | 1616 | 572 | 195 | 2750 ~161) 3 | 374 | 33] 38 | 1004 | 228 | 73 | 1634 | 600 | 140 | 2840 156 | 4 | 392 | 39 | 39 | 1022 | 233 | 74 | 1652 | 627 | 5 | 2930 -150 | 5 | 410 | 44] 40 | 1040 | 2329 | 75 | 1670 | 656 | 150 | 3020 44} 6 | 428 | 50] 41 | 1058 | 244 | 76 | 1638 | 683 | 155 | 3110 ~139 | 7 | a6 | 56] 42 | 1076 | 250] 77 | 1706 | 711 | 160 | 3200 ~133 | 8 | 464] 61 | 43 | 1094] 256] 73 | 1724 | 739 | 165 | 3290 —28 | 9 | 42 | 67 | a | 12 | 261 | 79 | 1742 | 767 | 170 | 3380 122 | 1 | 500} 72} 48 | 1130 | 267 | 80 | 1760 | 794 | 175 | 347.0 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/em?} kPa (mmH20) kPa (mmHg) kw/pm {HP/rpm} g/kwh {g/HPh} 00-2201 GENERAL General assembly dri Weight table...... List of lubricant and water. PCSOUU-2GENERAL GENERAL ASSEMBLY DRAWING GENERAL ASSEMBLY DRAWING CANOPY SPECIFICATION ee Unit: mm Serial No. : 8001 - 14992 gi at | i aT | t © = | | (Se c a WV e 1555) yale [RO | | - 2 a] | a3) gl | a \ ‘f | 8 8 ae Figures in (_ ): Steel shoe specification 01-2 PCSOUU-2GENERAL GENERAL ASSEMBLY DRAWING Serial No. : 14993 - and up gi Unit: mm : 1 : CAR seposs82 Figures in (_) : Steel shoe specification PCSOUU-2 01-3GENERAL CAB SPECIFICATION Serial No. : 8001 - 14992 GENERAL ASSEMBLY DRAWING Unit: mm. °o oF & Figures in (_}: Steel shoe specification Pcsouu-2GENERAL GENERAL ASSEMBLY DRAWING Serial No. : 14993 - and up Unit: mm 1s) 26 ot a1 490 15551 [1800 ___] 1240 (1310) [2000 ___] }_2455(2430) | 'SE03553 00 SEPO3E64 Figures in (_): Steel shoe specification PC5OUU-2 01-5 eGENERAL SPECIFICATIONS SPECIFICATIONS Machine model PCBOUU-2 Serial Number 8001 - 12771 Specifications Canopy specification | Cab specification Cab specification kg '8,10066,150) 5,25015,300) Bucket capacity mm 0.20 0.20 Mex. digging depth mm 4,000 4,000 Mex. vertical wall depth mm 2,620 2,620 «, | Mox digging reach mm 5,660 5,660 § | tox. reach at ground level mm 5.565 5.565 § | ax. loping height 7 300 6300 & | Max. dumping height mm 4,600 4,800 3 fg | © | Bucket offset (letvright) mm s107730 9107730 5 Max. blade lifting height mm 370 370 E 5 Max. blade lowering depth mm 370 370 Max. digging force KN {kg} 34.22 13500) 3432 (3,500) ‘Swing speed rpm 80 80 Max. slope angle for swing des. 3 3 Low: 2.2/Migh:3.8 | Low:2.2/High :3.8 Travel speed h Hache tenn F Low: 2.1 Migh 3.6) | (Low: 2.1/Migh :3.6) Gredeabilty deg. 20 30 Ground pressure iceaal as 31HS10 Ground proseure kPatkgiem’}| 29.4.(0:303(30.410.31)) | 20.4 0.31101.400.32)) Overall length (for transport) mm 5,335 5,335 Overall width mm 2,000 2,000 Overall height (for transport) mm 2,550(2,545) 2,565(2,560) Overall height mm 2,550(2,545) 2,86512,560) Ground clearance of counterweight mm 630 630 @ | Min. ground clearance mm 320 320 5 3 | Tail ewing radius mm 1,000 1,000 E | Min. ewing radius of work equipment mm 1,000 1.000 a Height of work equipment at m rm amo 4mo swing radius Length of track on ground mm 1940(1,910) 1,940(1,910) “Track gauge mm 1,600 1,600 Overall length of track mm 2,485(2,430) 2,885(2,430) Blade width x height mm 2,000X365 2,000X385 Figures in ( ): Steel shoe specification 01-6 PCSOUU-2GENERAL SPECIFICATIONS Machine model PC5OUU-2 Serial Number 8001 - 12771 Specificé Canopy specification Cab specification Model 4084-268 Type ‘cycle, water-cooled, vertical, direct injection No. of eylinders ~ bore x stroke mm 4-24x86 Piston displacement teo 1.906(7,906) Firing order 1-3-4-2 Flywheel horsepower kw ee yepm 28.7/2,70038.4/2,700) Max, torque Nm {kgm} /rpm) 118/2,700(12/1,900} & | Max. speed at no toad rpm 2875 E | Min, speed at no toad ‘om 1,050 Min. fuel consumption lakh cen 237 (077 Starting motor 12v,20 kW Alternator 12v, 40 Battery 12V, 70h Radiator core type cpa & | comer rtler 1 5 | Trackrolter 5 3 Integrated rubber shoe § | Tak shoe (assembly-type triple grouser x 38) Gear type triple pump (SBR14+14+9) x 1 | Type xno. 38 +30 +24 5 | ciscnare can Gear type single pump (PWHC-3A) x1 & | Set pressure for work e & | Set pressure forworkeaui>- Irs remy 206 210) : + Offset blade [MPa tkgiem| 21.6 (20) + Control MPa {kg/cm?} 2.9 {30} £3 | tvexno. 5-spool type (3-spool + 2-spooll x 1, 4-spool type x 1 g leg Hydraulic assist + mechanically operated & [8S] Controt method (travel, blade) 3 [a3] tavetmome Fiton Woe $|88 Mids (with reduction gear, counterbalance valve) x 2 2 (35) swing motor Piston type (with brake valve) x 1 Hydraulic cylinder Duble-acting piston Hydraulic tank Box-shaped, open Hydraulic filter Tank return side Hydraulic cooler Air cooled PCSOUU-2 Figures in ( ) Steel shoe specification 01-7GENERAL SPECIFICATIONS Machine model PCSOUU-2 Serial Number 12772 - 14992 Specifications Canopy specification | Cab specification Cab specification kg 5,10015,150) 5,250(6,300) Bucket capacity m™ 0.20 0.20 Max. digging depth mm 4,000 4000 Max. vertical wal depth mm 2,620 2,620 _, | Max cigaing reach mm 5.660 5,660 8 | sta coach at ground lve 7 ts sss E | sax claging height a e200 6330 ee ce. = a io g | 5 | Bucket ote defriont mm 9107730 910730 5 Max. blade lifting height mm 370 370 z . Max. blade towering depth mm 370 370 © | stax. digging force Ng) 34.32 (3,500), 34:32 (3,500) Swing speed ‘pm n " Max. slope angle for swing de. 8 13 Low:2.6/High:4.3 | Low:26/Migh 4.3 favel speed vn ee (Low: 2.4/Migh : 4.0) | (Low : 2.4/High : 4.0) Gradeability dog. 30 30 Ground pressure c oo 31 tet a KPaikgiema}] 29.4(0.3010.4¢0.31) | 30.4 (0.21181.400:32) (Overall langth (for transport mm 5.338 5:35 Overall width mm 2,000 2,000 Overall height (for transport) mm 2:550(2,545) 2,565(2,560) Overall height mm 2:550(2,545) 2,565(2,560) Ground clearance of counterweight mm 630 630 a | Min. ground clearance mm 320 320 3 | Tot swing radius mm 1,000 1,000 i |e i = é Height of work equipment at min. aa rea ano swing radius Length of track on ground mm 1,94011,910) 1,940(1,910) Track gauge mm 1,600 1,600 Overall length of track mm 2,485(2,40) 248512 490) Blade width x height mm 2,000x365 2,000X365 Figures in ( ): Steel shoe specification PCSOUU-2GENERAL SPECIFICATIONS Machine model PC50UU-2 Serial Number 1272 - 14982 Specifications Canopy specification | Cab specification Model 4D88E-38 Type 4-cycle, water-cooled, vertical, direct injection No. of cylinders - bore x stroke mm 4-88%90 Piston displacement 2c 2.189(2,188) Firing order 1-3-4-2 Flywheel horsepower kW HPY rpm] 29.4/2,400(38.4/2,400) Max. torque Nem tkemt rpm 134/1,400(13.7/1,400) & | Max. speed at no load tpm 2575 iG | Min. speed at no load rpm 1,050 Min. fuel consumption Jaw (otra 237 077} Starting motor 12v, 20 kW Alternator 12V, 404 Battery 12V, 70Ah Radiator core type cpa Carrier roller 1 § | Track roller 5 8 2 Integrated rubber shoe 33/7 (assembly-type triple grouser x 38) Variable displacement piston type + gear pump a | Type xno. (PVO-2B-42L3DFS + SBR(1)14) x1 & 49449434 2 | Discharge timin Gear type single pump (PW1-C-3A) x 1 s 64 3 | Set pressure for work equip- _ E | eck ave! MPa tkgiem’y 206 (210) = + Offset, blade [MPa tkg/em} 21.6 (220) + Control MPa tkglom’} 2.9130) § |B | Type xno. 5-spool type (3-spool + 2-spool) x 1, 4-spool type x 1 & | 8-3] Control mi Hydraulic assist + mechanically operated 3 (Gs cueoues (travel, blade) 8 | 35) Travel motor Piston type. ti (with reduction gear, counterbalance valve) x 2 | 36] swing motor Piston type {with brake valve) x 1 Hydraulic eylinder Double-acting piston Hydraulic tank Box-shaped, open type Hydraulic fiter ‘Tank return side Hydraulic cooler Air cooled Figures in ( ): Steel shoe specification PCSOUU-2 01-9GENERAL SPECIFICATIONS Machine model PC50UU-2 Serial Number 14993 and up. Specifications Canopy specification Cab specification Cab specification 5 5.1006, 150) 5.28015, 300) Bucket capacity 7 020 020 Max digging depth 7 ‘000 1.000 Max verical wall depth mm 2.620 2.820 __ | Max. ioing reach 7 5.660 5.660 § | Max. reach at ground level mm 5.565 5565 § | sax digging height i 6.330 6220 & | tax. dumping heignt mm 4800 44800 og | © | Bucket offer detriono mm 10730 10730 F | | stax ede tting height 7 370 370 E Max. blade lowering depth mm 370 370 é Max. digging force en 3432 (8.500) 3432 6500) Swing speed i n " Max. slope ange for swing en 3 8 Low : 2.6/High : 4.3 Low : 2.6/High : 4.3 Travel rita Ma ed oe (Low : 2.4/Higt 1.0) (Low : 2.4/High : 4.0) Gradesbitty eo, 20 30 Ground pressure kPa tkglem’ | 29.4 0.303(30.4(0.31 4 0.319(31.4(0.32) {shoe width: 400mm) a {kg/cm} | 29.4 {0.30}(30.4{0.31}) 30.4 {0.31}31.4{0.32)) Overallength Wor vanspon) 7 5335 5398 Overall wath 7 2.000 2.000 Overall height or transport) 7 2.550(2546) 2.565(2.560) Overat height 7 2.850258) 2.565(2.560) Ground clearance of counterweight | mm 0 x0 | Min. ground clearance 7 x20 x20 3 | rit ewing radius 7 1.000 1.000 | min. owing radius otwerkequipment | mm 1,000 1.000 é Height cfworkecipmenarmin | ac | He aia Length of track on ground mm 1,940(1,910) 1,940(1,910) Track gouge 7 1.600 1.600 Overall length of rack fe 2.851230 2.486430) Blade wiath x height i 2000x968 2000x985, 01-10 Figures in ( ): Steel shoe specification PCSOUU-2GENERAL SPECIFICATIONS: Machine model PCS0UU-2 Serial Number 14993 and up Specifications Canopy specification | Cab specification Model 4D 88E-3C Type 4-cycle, water-cooled, vertical, direct injection No. of cylinders — bore x stroke mm 4-88x90 Piston displacement eto) 2.18912,189) Firing order 1-3-4-2 Flywheel horsepower kW (HPY/epm| 29.4/2,400(39.4/2,400} Max. torque IN degen fp 134/1,400(13.7/1,400) £ | Max. speed at no load rom 2575 iG | Min. speed at no load ‘pm 1,050 Min. fue! consumption l/mWh {arPh) 237 (17) Starting motor 12V, 20 kW Alternator 12V, 408, Battery 12V, 70h Radiator core type cpa & | cartier otter 1 5 | track roller 5 3 ' Integrated rubber shoe Se (assembiy-type triple grouser x 38) Variable displacement piston type + gear pump ce | Type xno. (PVD-28-42L3DPS + SBR(1)14) x 1 é 49 +494 34 2 | Discharge wen Gear type single pump (PW1-C-3A) x1 g i 64 2 | Reatesave forwerkeauipr lee acm 20.6 (2101 2 + Offset, blade [MPa tkg/ems 21.6 (220) + Control MPa tkglom’} 2.9 (30) & Type x no. 5-spool type (3-sp00l + 2-spooll x 1, 4-spool type x 1 g & fontro! meth Hydraulic assist + mechanically operated 3 Control method (travel, blade) 2 Travel m ton type $ iaeteed (with reduction gear, counterbalance valve) x 2 z Swing motor Piston type (with brake valve) x 1 Hydraulic cylinder Double-acting piston Hydraulic tank Box-shaped, open type Hydraulic filter Tank return side Hydraulic cooler Air cooled Figures in ( ): Steel shoe specification PC5OUU-2 01-11GENERAL WEIGHT TABLE WEIGHT TABLE & This weight table is a guide for use when transporting or handling component. Serial No. : 8001-12771 Unit: kg Machine model PC50UU-2 Serial Number 8001 - 12771 Engine, hydraulic pump assembly 250 + Engine (with mount) 230 + PTO 10 + Piston pump + gear pump. 8 Radiator, oil cooler assembly 24 Fuel tank (without fuel) 82 Hydraulic tank (without oil) 50 Canopy 59 Operator's cab 172 Revolving frame (without counterweight) 1,480 Counterweight 800 Swing circle 66 ‘Swing machinery 24 Track frame assembly (with piping, cover) 890(866) + Track frame 535 + Idler 20x2 + Recoil spring assembly 8x2 (7x2) + Track roller 10x 10 (7 x 10) + Carrier roller 6x2 (4x2) + Sprocket 11.2 (13.2) Track shoe assembly + Road liner (400 mm) 236 x2 + Rubber shoe (400 mm) (296 x 2) + Steel shoe (480 mm) (335 x 2) 5-spool control valve 19 6-spool control valve 21 4-spool control valve nu 01-12 ® Figures in ( ): Steel shoe specification PCSOUU-2GENERAL, WEIGHT TABLE Unit: kg ‘Machine model PcsouU-2 Serial Numbe 8001-12771 5-spool control valve un ‘Swing motor 15 Center swivel joint 2 Travel motor 62x2 Boom assembly + Ist boom 174 + 2nd boom 146 + 3rd bracket 99 + Sub tank "7 ‘Arm assembly 102 Link assembly 40 Bracket assembly 143 Blade assembly 212 Boom cylinder assembly 58 ‘Arm cylinder assembly 53 Bucket cylinder assembly 32 Offset cylinder assembly 35 Blade cylinder assembly 2 Figures in ( ): Steel shoe specification PCSOUU-2 01-13 @®GENERAL WEIGHT TABLE Serial No. : 12772 - and up Unit: kg Machine mode! PCsOUU-2 Serial Number 12772 and up Engine, hydraulic pump assembly 250 + Engine (with mount) 230 + PTO 10 + Piston pump + gear pump 25 Radiator, oil cooler assembly 24 Fuel tank (without fuel) 82 Hydraulic tank (without oil) 50 Canopy 59 Operator's cab 172 Revolving frame (without counterweight) 1,480 Counterweight 800 Swing circle 66 ‘Swing machinery 24 Track frame assembly (with piping, cover) 890(866) + Track frame 535 + Idler 20x2 + Recoil spring assembly 8x2(7x2) + Track roller 10x 10 (7 x 10) + Carrier roller 6x2 (4x2) + Sprocket 1x2 (13 x2) Track shoe assembly + Road liner (400 mm) 2222 + Rubber shoe (400 mm) (296 x 2) + Steel shoe (480 mm) (835 x 2) 5-spool control valve 19 6-spool control valve 2 4-spool control valve " 01-14 @ Figures in ( ): Steel shoe specification PCSOUU-2GENERAL WEIGHT TABLE Unit Machine model PC50UU-2 Serial Numbe 12772 and up 5-spool control valve " ‘Swing motor 6 Center swivel joint 27 Travel motor 62x2 Boom assembly + Ist boom 174 + 2nd boom 146 + 3rd bracket 99 + Sub tank 7 ‘Arm assembly 102 Link assembly 40 Bracket assembly 143, Blade assembly 212 Boom cylinder assembly 58 ‘Arm cylinder assembly 53 Bucket cylinder assembly 32 Offset cylinder assembly 35 Blade cylinder assembly 27 Figures in ( } : Steel shoe specification PCSOUU-2 01-15 @GENERAL LIST OF LUBRICANT AND WATER LIST OF LUBRICANT AND WATER KIND OF AMBIENT TEMPERATURE CAPACITY (2) RESERVOIR FLUID [op 4 ta 3250 gw 108°F Speci gogo to 8B) S5 Ute |SPecifiod| Refill SAE S000) SAE TOWSON Engine oil pan 85 SAE TOWED SAE 1gWa00D % {Swing machinery aS Engine oil Final rive caseleach) i TL TESHE 1505 Idlerieach) : “Track rollerieach) - SAE TOWED. Hydraulic system SAE TOW S0CD 360 SAE 6W-a00D Cartier roller Grease ALBANIA EP . ‘ASTM DOTS Nod Fuel tank Diesel fue! | | - ASTM DOTS Ra Cooling system Coolant | Add antireese - ¥ 1: Swing machinery case is only for serial No. 8001 - 14992. 01-16 PCSOUU-2 @GENERAL LIST OF LUBRICANT AND WATER NOTE: (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic mainte- nance hours described in manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Fuel sulphur content | henge internal of ollin 0.5 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval Q When starting the engine in an atmospheric tem- perature of lower than 0°C, be sure to use engine oil of SAE 10W, SAE10W-30 and SAE1SW-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the tem- perature in the table on the left. (5) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applica- tions. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system, during normal inspection and main- tenance. PCSOUU-2 01-17 ®10 STRUCTURE AND FUNCTION PCSOUU-2 Power train system 10- 2 PTO : 3 ‘Swing machinery 5 ‘Swing circle .. 8 Track frame 9 Hydraulic piping diagram 10-14 Hydraulic tank. 10-18 Main pump.. 10- 20 5-spool control valve 10-24 6-spool control valv 10- 26 4-spool control valve 10- 28 5-spool control valve... 10- 34 Swing motor... 10- 38 Center swivel joint. 10- 53 Travel motor Valve control PPC valve Solenoid valve, EPC valve 10-78 Work equipment. Electric wiring diagram .. Four system (4 system). Machine monitor system Fuel control (one-touch deceleration system) ... oFSTRUCTURE AND FUNCTION POWER TRAIN SYSTEM POWER TRAIN SYSTEM 1. Idler . 5-spool control valve . Center swivel joint |. Swing motor . Travel motor Control pump (PW1-C-3A) . Engine . Main pump =| 6 Serial No. : 8001 - a) (Sertertas [Serato : 12772 and up PVD-28-42L3DPS+SBR(1)14) 1 9, 4-spool control valve 10. Travel speed solenoid valve 11. Swing machinery 12. Swing circle SPNERAEN loco tel 20UF02005 PCSOUU:2 ee vSTRUCTURE AND FUNCTION PTO PTO Serial No. : 8001 - 12771 1. Main pump (SBR14+14+9) 2. Cover 3. Damper 4. Engine PCSOUU-2 10-3STRUCTURE AND FUNCTION PTO Serial No. : 12772 and up saP008¢5 1. Main pump (PVD-28-42L3DPS+SBR(1)14) 2. Cover 3. Damper 4. Engine 10-4 PCSOUU-2‘STRUCTURE AND FUNCTION SWING MACHINERY Serial No. : 8001 - 12771 ‘Swing pinion (No. of teeth: 9) Housing Ring gear (No. of teeth: 97) Oil filler port ‘Swing motor (No. of teeth: 14) Planetary gear (No. of teeth: 41) Planetary carrier Drain plug Swing circle (No. of teeth: 90) PONOMRwNs PCSOUU-2 SWING MACHINERY ‘20uF02007 Specifications Reduction ratio + Machinery : 1487 _ 7.929 14 20 + Circle: 22 = 10 + Total reduction ratio : 7.929 x 10 = 79.29 10-5 @®STRUCTURE AND FUNCTION Serial No. : 12772 - 14992 ‘Swing pinion (No. of teeth: 9) Housing Ring gear (No. of teeth: 97) Oilfiller port ‘Swing motor (No. of teeth: 14) Planetary gear (No. of teeth: 41) Planetary carrier Drain plug Swing circle (No. of teeth: 90) SeNvonnens 10-6 ® ‘SWING MACHINERY ‘ 1 = 4 i iL a i 16 AOA savocees Specifications Reduction ratio + Machinery : “4487 . 7.929 + Circle: 22. ~ 10 + Total reduction ratio : 7.929 x 10 = 79.29 PCSOUU-2STRUCTURE AND FUNCTION Serial No. : 14993 and up Swing motor No.1 sun gear No.1 planetary gear Ring gear No.2 planetary gear ‘Swing pinion . Taper roller bearing ‘Swing machinery case No. 2 sun gear SEN OMAeND PCSOUU-2 SWING MACHINERY =a] AMA s0P03555 Cirle: $9 = 8.18 + Total reduction ratio : 24.10 x 8.18 = 197.14 Lubrication oil amount : 3 £ (E010-CD)STRUCTURE AND FUNCTION ‘SWING CIRCLE SWING CIRCLE 20uF02008 1. Swing circle outer race 2. Ball bearing 3. Swing circle inner race (No. of teeth : 90) a. Positions of the inner race soft zone b. Positions of the outer race soft zone 10-8 PCSOUU-2‘STRUCTURE AND FUNCTION ‘TRACK FRAME TRACK FRAME RUBBER SHOE eae Serial No. : 8001 - 1277 20uF02009 1. Idler 6. Travel motor 2. Track frame 7. Track roller 3. Carrier roller 8. Track shoe 4. Center swivel joint 8. Idler cushion 5. Sprocket PCSOUU-2 10-9STRUCTURE AND FUNCTION ‘TRACK FRAME Serial No. : 12772 - 14992 8 8 1 SAP00847 1. Idler 6. Travel motor 2. Track frame 7. Track roller 3. Center swivel joint 8, Track shoe 4. Carrier roller 9. Idler cushion 5. Sprocket 10-10 PCSOUU-2 @STRUCTURE AND FUNCTION TRACK FRAME Serial No. : 14993 and up 4 1 s0ro3sse 1. Idler 6. Travel motor 2. Track frame 7. Track roller 3. Center swivel joint 8 Track shoe 4. Carrier roller 9. Idler cushion 5. Sprocket PCSOUU-2 10-11 ®STRUCTURE AND FUNCTION TRACK FRAME STEEL SHOE SPECIFICATION Serial No. : 8001 - 14992 Idler ‘Track frame Carrier roller Center swivel joint Sprocket geen 10-12 @ 1 eurozone 6. Travel motor 7. Track roller 8. Track shoe 9. Idler cushion 10. Guard PCSOUU-2‘STRUCTURE AND FUNCTION ‘TRACK FRAME STEEL SHOE SPECIFICATION Serial No. : 14993 and up \\ 0 a 8 1 03557 1. Idler 7. Track roller 2. Track flame 8. Track shoe 3. Carrier roller 9. Idler cushion 4. Center swivel joint 10. Guard 5. Sprocket 6. Travel motor PCSOUU-2 10-13STRUCTURE AND FUNCTION HYDRAULIC PIPING DIAGRAM Serial No. : 8001 ~ 14997 1. Bucket cylinder 2. Arm cylinder 3. Offset cylinder 4. 5-spool control valve 5. Boom cylinder 6. 4-spool control valve 7, Hydraulic tank 8. R.H. work equipment PPC valve I cooler 10. Control pump (PW1-C-3A) 11. R.H. travel motor 12, Main pump Serial No: 8001 - 12771) SBR14+14+9 Serial No.:12772 and up) PVD-2B-42L3DPS+SBR(1)14 13. LH. travel motor 14, LH. work equipment PPC vaive 15. Swing motor 16. Center swivel joint 17. PPC lock solenoid valve 18. Travel boost solenoid valve 19. Boom RAISE stop EPC valve 20. Arm IN stop EPC valve 21. Boom LOWER stop solenoid valve 2. Left offset stop solenoid valve 23. Offset PPC valve 24, Blde cylinder 10-14 ° HYDRAULIC PIPING DIAGRAM ovo PCSOUU-2‘STRUCTURE AND FUNCTIONSTRUCTURE AND FUNCTION Serial No. : 14993 and up 1. Bucket cylinder 2. Arm cylinder 3. Offset cylinder 4. 5-spool control valve 5. Boom cylinder 6. 4-spool control valve 7. Hydraulic tank 8. R.H. work equipment PPC valve 9. Oilcooler 10. Control pump (PW1-C-3A) 11. R.H. travel motor 12. Main pump (PVD-2B-42L3DPS+SBRI1)14) 13, 14, 15. 16. 17. 18, 19, LAH, travel motor LH. work equipment PPC valve . Swing motor . Center swivel joint PPC lock solenoid vaive . Travel boost solenoid valve |. Check valve (swing holding brake release : right swing) 20. Check vaive (swing holding brake release : left swing) 21. Check valve {swing holding brake release : arm IN) 22. Boom RAISE stop EPC valve 23. Arm IN stop EPC valve 24, Boom LOWER stop solenoid valve 25. Left offset stop solenoid valve 26. Offset PPC vaive 27. Blade cylinder 10-16 HYDRAULIC PIPING DIAGRAM svrorsns PCSOUU-2HYDRAULIC PIPING DIAGRAM ‘STRUCTURE AND FUNCTION 10-17 @®STRUCTURE AND FUNCTION HYDRAULIC TANK HYDRAULIC TANK 2ouro2013 1. Safety valve Specifications 2. Filter element Pressure valve 3. Sight gauge + Relief cracking pressure : 4. Suction strainer 38.3214,7 kPa (0.3940.15 kg/cm?) 5. Drain pulg + Suction cracking pressure : 6 Cap ‘0-45 kPa {0 - 0.046 kg/cm’) 7. Pressure valve 8 Tank Safety valve 9. Drain plug + Relief cracking pressure : 0.1 MPa {1.05 kg/em?} 10-18 PCSOUU-2 ®STRUCTURE AND FUNCTION MAIN PUMP PVD-2B-42L3DPS+SBR(1)14 Serial No. : 12772 and up MAIN PUMP ‘og I a+ (Ohi Port $3 (suction port) Port $1 (suction port) Air bleeding port Branch port Port P2 (discharge port) Port P3 (discharge port) Port P1 (discharge port) erpacge Piston pump (PVD-2B-42L3DPS) Gear pump (SBR(1)14) po 10-20 @ i t sAro0850 Specifications item Pvo-28-42L30PS| SBR(14 Capacity (ecirev)| 209 142 Discharge amount ein] 802 aa) Max. discharge pressure(MPatkgiem)| —_20:6(210) | 20.64210) PCSOUU-2‘STRUCTURE AND FUNCTION MAIN PUMP “4 i 2 a ser008s) 1. Shaft 11. Rod P 2. Oil seal 12. Rod G 3. Ball bearing 13. Valve plate 4, Body 14. Control piston 5. Spring T1 15. Piston 6. Spring 2 16. Cylinder 7. Spring 17. Shoe 8. Needle bearing 18. Swash plate 9. Rod K 19. Thrust bushing 10. Coupling PCSOUU-2 10-21 ©‘STRUCTURE AND FUNCTION Operation + This pump is a variable displacement piston pump which can discharge two equal amounts from a single cylinder block. + There are 10 pistons (2) assembled inside cyl- inder block (1), and the end face contacts valve plate (3). For the suction stroke, valve plate (3) has a common suction port A for pumps P1 and P2. For the discharge stroke, it has discharge port B for pump P1 on the outside, and discharge port C for pump P2 on the in- side. + Swash plate (4) is fixed to the housing and is at an angle (swash plate angle a). Piston (2) slides on swash plate (4) while rotating. + When shaft (5) is rotated, cylinder block (1) rotates and piston (2) assembled to cylinder block (1) follows swash plate (4) and moves in a double-acting movement to carry out the suction and discharge action of the pum) + When this happens, the piston in contact discharge port B of valve plate (3) operates as pump P1, and the piston in contact wit discharge port C acts as pump P2. + In this way, the 10 pistons (2) each carry out ‘one suction and discharge cycle for every ro- tation of cylinder block (1). + Therefore, if shaft (5) is rotated continuously, the suction and discharge is carried out con- tinuously. + The displacement of piston (2) depends on swash plate angle « of swash plate (4), 50 by changing swash plate angle « of swash plate (4) itis possible to change the discharge flow. 10-22 ® MAIN PUMP uction M Discharse stroke stroke sxro7279 4 2 1 SS by | ) sr Cy 1 4 saP00853 PC5OUU-2STRUCTURE AND FUNCTION MAIN PUMP Discharge amount control function + This pump changes the displacement by changing swash plate angle a of swash plate (4), but it controls to a constant output with a variable mechanism using simple directional control of the swash plate angle. + Swash plate angle is determined by the bal- ance of hydraulic force F1 applied to contro! piston (6) and tension F2 of springs (7) and (8) installed on the opposite side. + The pressure bearing on control piston (6) consists of the total of two lines of pressure (P1, P2) and pressure (P3) of the gear pump. F1=P1+P2+P3 As each of these pressures becomes higher, F1 becomes larger, deflects springs (7) and (8), and makes swash plate angle a smaller. This decreases the discharge amount and maintains the pressure constant. PCSOUU-2 A Pp a TE fs cg 8 ao Le steauese se/rey Ps=20.6MPa whe ¢ eee Bt 3 ns a 1 73 ae TZ re a ab Pay Lote oressures Pitty aan 10-23STRUCTURE AND FUNCTION 5-SPOOL CONTROL VALVE Al: Az: 93: Aa: AS: Bi: B2 83 To boom cylinder head To bucket cylinder head To R.H. travel motor B To LH. travel motor A To arm cylinder head To boom cylinder bottom To bucket cylinder bottom :To R.H. travel motor A Ba: BS: To LH. travel motor B To arm cylinder bottom 10-24 5-SPOOL CONTROL VALVE 20uF02014 P1: From front pump 2: From center pump b1: From boom PPC valve b2: From bucket PPC valve PCSOUU-2‘STRUCTURE AND FUNCTION 5-SPOOL CONTROL VALVE our02015 1. Spool (boom) 7. Main relief valve 2. Spool (bucket) 8. Spool return spring 3. Spool (R.H. travel) 9. Spool return spring 4. Spool (L.H. travel) 10. Main relief valve 5. Spool (arm) 11. Safety-suction valve 6. Arm regeneration valve 12. Safety valve PCSOUU-2 10-25STRUCTURE AND FUNCTION 6-SPOOL CONTROL VALVE 6-SPOOL CONTROL VALVE FOR SERVICE VALVE CIRCUIT 2auro2016 :To boom cylinder P1 : From front pump ‘To bucket cylinder P2: Center pump To R.H. travel motor B 11: To tank To LH. travel motor A 2: To tank To arm cylinder bottom a1: From boom PPC valve (Service) a2 : From bucket PPC valve To boom cylinder bottom: a5 : From arm PPC valve To bucket cylinder bottom a6 : Service PPC valve To R.H. travel motor A b1: From boom PPC valve To LH. travel motor B b2 : From bucket PPC valve To arm cylinder bottom 5 : From arm PPC valve B6 : (Service) b6 : Service PPC valve 10-26 PCSOUU-2 @‘STRUCTURE AND FUNCTION 1. Spool (boom) 2. Spool (bucket) 3. Spool (R.H. travel) 4, Spool (LH. travel) 5. Spool (arm) 6. Arm regeneration valve 7. Spool (service) PCSOUU-2 6-SPOOL CONTROL VALVE 2ouro2017 8, Main relief valve 9. Spool return spring 10. Spool return spring 11. Main relief valve 12. Safety-suction valve 13. Safety valve 10-27 ®STRUCTURE AND FUNCTION 4-SPOOL CONTROL VALVE 4-SPOOL CONTROL VALVE Serial No. : 8001 - 12771 J BiB eae Bo pa 2ouF02018 Al: To blade cylinder head A2_: To offset cylinder bottom A3_: To swing motor A B11: To blade cylinder bottom To offset cylinder head To swing motor B B4_: To boom cylinder bottom : From swing PPC valve rom boom PPC valve ‘rom offset PPC valve 10-28 PC50UU-2‘STRUCTURE AND FUNCTION 1. Main relief valve 2. Spool (blade) 3. Spool (offset) 4, Spool (swing) 5. Spool (boom boost) PCSOUU-2 4-SPOOL CONTROL VALVE 6. Spool return spring 7. Check vaive 8. Check valve spring 9. Safety-suction valve 10. Suction valve 10-29STRUCTURE AND FUNCTION 4-SPOOL CONTROL VALVE No. : 12772 - 14992 paz Pes Pas a ee Eee a ° 4 a SL a & a a (6 : lt » a BI bE a ee eo - Le Ls Pag PA3 PAA sapooess To blade cylinder head PA2 : From offset PPC valve To offset cylinder bottom PAS : From swing PPC valve To swing motor A PAd : From boom PPC valve To blade cylinder bottom PB2 : From offset PPC valve + To offset cylinder head PBS : From swing PPC valve To swing motor B PBA: To tank :To boom cylinder bottom P : From rear pump T :Totank 10-30 PCSOUU-2‘STRUCTURE AND FUNCTION 4 SPOOL CONTROL VALVE 1. Main relief valve 6. Spool return spring 2. Spool (blade) 7. Check valve 3. Spool (offset) 8. Check valve spring 4. Spool (swing) 9. Safety-suction valve 5. Spool (boom boost) 10. Suction valve PCSOUU-2 S-G sapoosss 10-31STRUCTURE AND FUNCTION 4SPOOL CONTROL VALVE Serial No. : 14993 and up B2, Bt. t | i & Bo or 8 24 1. A o Aa 8 PA PA PAs 80703582 A1 To blade cylinder head PA2: From offset PPC valve A2_ To offset cylinder bottom PAS : From swing PPC valve A3_:To swing motor A PA4: From boom PPC valve B1 :To blade cylinder bottom PB2: From offset PPC valve B2_:To offset cylinder head PB3 : From swing PPC valve B3_ :To swing motor B PB4: To tank B4_: To boom cylinder bottom P_ : From rear pump T :To tank 10-32 PCSOUU-2‘STRUCTURE AND FUNCTION 4-SPOOL CONTROL VALVE 50P03563, 1. Main relief valve 6. Spool return spring 2. Spool (blade) 7. Check valve 3. Spool (offset) 8. Check valve spring 4. Spool (swing) 9. Safety-suction valve 5. Spool (boom boost) 10. Suction valve PCS5QUU-2 10-33 @STRUCTURE AND FUNCTION 5-SPOOL CONTROL VALVE 5-SPOOL CONTROL VALVE FOR PTMA BLADE MACHINE Serial No. 8001 - 12771 PA2 PAS PAM 2o0uF02020 Al: To blade tilt cylinder head PAS : From offset PPC valve A2_:To blade cylinder head PA4 : From swing PPC valve A3_ : To offset cylinder bottom PAS : From boom PPC valve ‘Aa : To swing motor A P83: From offset PPC valve B1 To blade tilt cylinder bottom PB4:: From swing PPC valve B2_: To blade cylinder bottom PBS: To tank B3_: To offset cylinder head P : From rear pump B4_ : To swing motor B T :Totank 10-34 PcSoUU-2‘STRUCTURE AND FUNCTION 5-SPOOL CONTROL VALVE 2our02021 1. Main relief valve 6. Spool return spring 2. Spool (blade tilt) 7. Check valve 3. Spool (offset) 8. Check valve spring 4. Spool (swing) 9. Safety-suction valve 5. Spool (boom boost) 10. Suction valve PCSOUU-2 10-35 @STRUCTURE AND FUNCTION Serial No. : 12772 and up 5-SPOOL CONTROL VALVE Al :To blade tilt cylinder head A2_:To blade cylinder head A3_:To offset cylinder bottom :To swing motor A fo blade cylinder bottom fo offset cylinder head jo swing motor B BS: To boom cylinder bottom 10-36 fo blade tilt cylinder bottom Pad PAS PAS ‘saP00865 PAS : From offset PPC valve PAa: From swing PPC valve rom boom PPC valve rom offset PPC valve PcsouU-25-SPOOL CONTROL VALVE STRUCTURE AND FUNCTION a sAPo0866 z of & Be Eoogs S835 geeak Bsa SeeEs 8338 gees GbEaa Roose = 8 $2 3 S55g5 Zeseers BEEZ 8 s2eces eSSSss §8 S28888 2E8EE5 sided 10-37 PCSOUU-2 @‘STRUCTURE AND FUNCTION SWING MOTOR LMF40-2 Serial No. : 8001 ~ 12771 ie To port T (to tank) Port MA (from control valve) Port MB (from control valve) Port $ (from tank) epee 10-38 @ ir 2 SWING MOTOR 2005013 Specifications Type = LMF40-2 Capacity : 40.8 cc/rev Safety valve set pressure : 20.6 MPa {210 kgicm’} Check valve set pressure : Max. 0.03 MPa {0.3 kg/cm?) PCsoUU-2‘STRUCTURE AND FUNCTION SWING MOTOR ana coe FFAS 1. Output shaft 7. Valve seat 2. Housing 8. End cap 3. Swash plate 9. Center spring 4, Shoe 10. Safety valve 5. Piston 11. Check valve 6. Cylinder 12. Check valve spring 10-39 PCSOUU-2 @STRUCTURE AND FUNCTION SWING MOTOR ‘SAFETY VALVE PORTION 1. Outline The safety valve portion consists of a check 1 valve and safety valve. 2. Funetion When the swing is stopped, the output cir- cuit of the motor is closed by the control valve, ce. EZ cA but the motor continues to rotate because of inertia. For this reason, the pressure at the output side of the motor becomes abnormally high, and this will damage the motor. To pre~ vent this, the oil causing the abnormal hydrau- q lic pressure is allowed to escape from the outlet port (high-pressure side) of the motor A eee to port §, thereby preventing damage to the Nh ea Be motor. ts 3. Operation 1 1) When starting swing + When the swing control lever is operated to left swing, the pressurized oil from the pump passes through the control valve and is supplied to port MA. Because of cro aie ES this, the pressure at port MA rises, start- ad ing torque is generated in the motor, and swro7280 the motor starts to rotate. The oil from the outlet port of the motor passes from Port MB through the control valve and returns to the tank. 2) When stopping swing 8 A When the swing control lever is returned to neutral, no pressurized oil is supplied from the pump to port MA. a The return circuit to the tank is closed by ce the control valve, so the oll from the out- let port of the motor increases in pressure at port MB. Resistance to the rotation of the motor is created, and the brake starts to act. + The pressure at port MB rises to the set pressure of safety valve B, and in this way, i ahigh brake torque acts on the motor, and ag the motor stops. js + When safety valve Bis being actuated, the 4 relief oil from safety valve B and the oil eg from port § pass through check valve CA and are supplied to port MA. This pre- vents cavitation from occurring at port ne a. MB MA cA : ooo MA Control valve 5707281 10-40 PCSOUU-2 @STRUCTURE AND FUNCTION LMF40B-2 Serial No. : a. Port T (to tank) b. Port MA (from control valve) cc. Port MB (from control valve) d. Port $ (from tank) 10-42 ® SWING MOTOR sn700887 Specification Type: LMF40B-2 Capacity : 40.8 ca/rev Safety valve set pressure : 20.6 MPa {210 kg/cm} Check valve set pressure : Max. 0.03 MPa {0.3 kg/em*) PCSOUU-2