‘SEBM019903 SHOW? IMCAINTUA\ IL KOMATSU CD60R-1 MACHINE MODEL SERIAL NUMBER CD60R-1 1801 and UP This shop manual may contain attachments and optional equipment that are not avail- able in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice CDEOR-1 mounts the $6D102E-1-A engine. For details of the engine, see the 102-1 Series Engine Shop Manual, ©2000 MomaYsU All Rights Reserved Printed in USA 00-0801 10 20 30 90 00-2 CONTENTS No. of page GENERAL . 01-1 STRUCTURE AND FUNCTION........ beeen eee 10-1 TESTING AND ADJUSTING....................-+- 20-1 DISASSEMBLY AND ASSEMBLY ................ - 30-1 OTHERS. cDs0R.The affected pages ate indicated by using the following marks. | yar, ‘naleation ‘ation itis requested that nacossary actions be taken to these pages | Required according tothe able below 9 | New pageto be added | Add © | Page 1 be replaced oplace () | Page to be deleted Discard Pages having no marks are not revised at this time LIST OF REVISED PAGES wank Pages ROBOT ark Pages RNR ark Pages POSEN an Pages PeNSOM|Mank Pooes Revon eT @ | OE 1038 D7 @ eB) 202 @ 10s 10-40 ne @ 20128 @ 2 021 @ 04 1041 20.128 @ © 022 o 105 1042 20101 @ 20128 @ 003 108 10-43 20-02 © 004 107 0-4 2003 @ 2021 @ 005 ws 10-45 z-108 @ | 2202 @ 008 0 @ 1046 2105 @ | 2203 @ 007 10-10 047 204108 @ 20208 @ 008 ton 04s 20.107 ® 20205 @ 009 1012 049 20-108 @ 20206 @ 00-10 0-13 1080 20-08 @ 20207 @ oot to i051 200 @ 20208 @ oo.r2 tos 1082 2m @ 20209 @ oo3 1016 1053 © 2020 00-14 10417 1054 2-101 220 @ 00-15 wow oss ww © 22 © oo.16 1019 1056 20-03 @ 2213 oo? 1020 1087 20-108 @ ne vos 021 1058 20-05 @ 20215 @ 00-19 1022 1059 @ 20-106 @ 226 0020 023 1060 20-107 @ 2217 @ 0-21 10-24 1081 20-08 @ 2ne 00-22 1025 1062 20-109 @ 228 10:26 083 20-10 @ 20220 @ on 10-27 1068 2m @ 20221 @ a2 10-28 10485 212 @ 2022 os 10-29 1066 20-13 © on 10:30 10-67 20-18 20201 @ ons 1031 1068 2-15 20202 ors 1032 2-18 @ 20203 @ or 10-33 20-1 @ nT @ 20-204 ons 034 202 @ 20-18 @ 20205 @ os 10235 23 2-19 @ 20208 @ orto 1036 04 @ 20-120 @ 20207 @ 037 205 @ 20.121 @ 20208 @ 10 1038 25 20422 @ 20209 @ cDBOR-100-2-2 [Mark Pages EMEOM|iark Pages Ren Revieonlark Pages TVSO" [Mark Pages Rovner BIO WEG ow Go wT @ (] zn @ ras @ |r @ |o D8 o 2022 © 007 @ | o37 @ | 5 06 @ 2021 @ ros @ [owe @ | 065 @ 224 @ 20008 @ | 5 3019 @ | 9 3068 @ 20215 @ wan @ | 220 @ |5 267 @ 2218 © war @ | 5502 @ | 5 3068 @ 20217 @ mar @ | 22 @ |> 30 @ 20218 @ wars @ | 502 @ [590 @ 20219 @ nae @ | 202 @ 20220 @ was @ | 9 02 @ 404 2021 @ nas @ | 202 @ 402 22m © nar @ | 9027 @ 403 20223 @ > 02 @ aoa 22 © ns @ | 902 @ 405 202 @ ns @ | 39 @ 406 i 22 @ 20503 @ | > 3031 407 2027 @ ns @ | 38 @ 408 20228 © 250 @ | > 3033 @ 209 2029 @ 2506 @ | 33 @ 40-10 20200 @ 20507 @ | > 2038 @ aon 20231 @ 2508 @ | > 3038 4on2 2502 @ | 037 @ 403 20301 @ ws @ | 3038 o aoa 20302 © wen @ | 3039 @ 4015 2003 @ ws @ | > 39040 @ 40-6 20208 @ 52 @ | > 24 @ 4017 ee) ws @ | > 942 @ 40.18 20208 @ 2515 @ | 5308 @ 40-19 20307 @ 516 @ | > 304 @ 40-20 20208 @ 2517 @ | 3 3048 @ 2009 @ 58 @ | > 3046 @ 901 2030 @ > 2047 @ 903 van @ |o 91 @ | > 3048 @ 905 nar @ | 902 @ | > 3049 @ 233 @ | 93 @ | > 2050 @ ra @ [oe @ | 53081 @ vas @ [995 @ | we @ vas @ (os @ | 52053 @ nar @ |o907 @ | > 3058 @ wa @ [os @ | > 95 @ na @ |o 9 @ | ww @ > 310 @ | 32087 @ nar @ [os @ | > 2088 @ rae @ |os2 @ | 205 © 203 @ [os @ | 20 @ roe @ [osm @ | 2081 @ ‘co60R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 specially designed by Komatsu for the specific purpose. To prevent injury to workers the symbol dls is used to mark safety precautions inthis manual. The cautions accompanying these symbols should always be followed care. fully. f any dangerous etuation arises or may possibly arse, fiat consider eafety, and take the necessary actions to deal with the situation GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing, = Always wear safety glasses when hi parts with a hammer. + Always wear safety glasses when grind- ing parts with a grinder, etc. ing 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. Qn and learn 5. Keep all tools in good condi the correct way to use them. 6. Decide 2 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. Jisassembling 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 oi! 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 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 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. 14, When 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- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under i 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 fon the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. ing heavy components, use a hoist 19. 20. 2. 22. 23, 24, SAFETY NOTICE Be sure to assemble all parts again in thei 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. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits, Also, check that connecting parts are correctly installed. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check ‘that they are installed correctly. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. cary technical information for operations performed in 2 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 the latest date.FOREWORD HOW TO READ THE SHOP MANUAL VOLUMES: ‘Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models Electrical volume: Attachments volume: ‘These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , itis 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): B-5 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 0-4-1 12-203-1 30.421 Added pages —[_19.203.2 105 12-208 00-6 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When @ manual is revised, an edition mark (OOO...) 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 | tem Remarks ‘Special safety precautions are necessary when performing the work Safety Caution serving standards are neces- sary when performing the work. Weight of parts of systems. Caution necessary when se- lecting hoisting wire, or when, working posture is important, Weight Places that require spec tention for the tight torque during assembly Places to be coated with ad- hesives and lubricants, etc {Tightening} torque Coat Places where ol, water or fuel must be added, and the ca- pacity. il, water Places where oil or water must be drained, and quan- tity to be drained Drain be | Eb | + [>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 indicated 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 ithout galvanizing) Rope diameter Allowable load mm kN. tons 10 98 10 n2 137 1a 125 187 16 1“ 216 22 16 25 28 18 36.3 36 20 48.41 rey 22.4 549 56 30 98.1 10.0 40 765 18.0 50 246 28.0 60, 292.2 40.0 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. $4449 100% © 88% 79% «= 71% «41% 3) Do not sling 2 heavy load with one rope ‘alone, but sling with two or more ropes ‘symmetrically wound onto the load. B Singing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding Position on the load, which can 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 hoisting is made with two ropes, each of which is allowed to sling up to 9.8 KN (1000 kg) vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN (2000 kg) of total weight can be suspended. This weight becomes 9.8 kN (1000 kg) when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN (4000 kg) if they sling a 19.6 KN {2000 kg) load at a lifting angle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, s0 see the table below when disassembling and connecting the coupler. Tweet ‘Type? » 2) sembly 3) Hold the mouthpiece of the tighteni fion and push body (2) in straight until stid- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male ond. r ie cvrossst Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end. = cnPosaes Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect > a cwvosnes 1) Hold the mouthpiece of the tightening por- tion and push body (2) in straight until stid- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male end, - : cwPossa2 2) Hold in the condition in Step 1), and turn. lever (4) to the right (clockwise). Le - cnvosaee 3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. 1 cxvosnesFOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Tyee ‘Type2 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. cvrosa + Hold the mouthpiece of the tightening por- tion and push body (2) in straight until stid- ing prevention ring (1) contacts contact sur- face a of the hexagonal portion at the male end to connect it 1 cxPosneeFOREWORD COATING MATERIALS COATING MATERIALS The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in tt list. Category | Komatsu code| PartNo. | Q'ty _| Container Main applications, features = Used to prevent rubber gaskets, rubber ut-14— |790-129-9090] 1509 | Tube |” cushions, and cock plug from coming out. Used in places requiring an immediately | etoctive strong adhesive. Used for plas- ut-18 [790-128-8060] 20.2 |Poyerene| ses (except polvethylene, polyprophylene, pes) | container | tetraftuoroethiene and vinyl chloride), rub ber, metal and non-metal > Features: Resistance to heat and chem- Povvethviene|” cals tr-2—[oge4o-c0020 | 50.8 |" coiainer | Used for antiloosening and sealant pur- | pose for bolts and plugs. [790-129-060 Adhesive: |- Used as adhesive or sealant for metal, glass (Set of adhe-| 1 ko | and plastic urs | siveand [Hardening] can hardening | agent: agent) | 5009 Adhesives Lr |700-128-0040] 250 9 [Polvethvlene|+ Used as sealant for machined holes. cara te, [roozesrao] 78a | toe | Vena | + Quick hardening type adhesive Three bona payetnene|s corse ane oo ton 1735 790-128-0140) S09 ‘container |* Used mainly for adhesion of metals, rub- ee anes ees ouch nrdenig wpe adhesio tte re ka 3 min onatone |rso-zeore| 25 Pavemlone|” ste + ain er adhesin of ber ae Tenures Reincs ohn cherie oe 794-129-9110} 50 cc Polyethylene |. Used at joint portions subject to high tem- es sneer dae on ote ize S010 | 200/e) Tube ‘and packing of power train case, etc. [ Fonuro: essance not ed aren rt cao eed uc-3 |790-129-9070) 1 ko Can to prevent seizure, + Used as sealant for heat resistance gasket for high temperature locations such as en- gine precombustion chamber, exhaust pipe, ete. 00-10FOREWORD COATING MATERIALS Category |Komatsucode| PartNo. | a'y | Container Main applications, features |- Features: Resistance to water, ol + Used as sealant for flange surface, thread. Les Tube |* Also possible to use as sealant for flanges 790-128-8020) 200.9 with large clearance. | + Used as sealant for mating surfaces of fi- tal drive case, transmission case. J+ Used as sealant for various threads, pipe Polyethylene] joints, flanges. UGS 790-129-9080) 19 |" container |* Used a sealant for tapered plugs, elbows, nipples of hydraulic piping. + Features: Silicon based, resistance to heat, Gasket cold sealant 16-6 | 09940-00011 250g | Tube |. Used as sealant for lange surface, tread. |+ Used as sealant for oil pan, final drive case, ete. + Features: Silicon based, quick hardening type LG-7 | 09920-00150 | 1509 | Tube |. Used as sealant for flywheel housing, in- take manifold, oll an, thermostat housing, etc, Three bond |. Used as heat-resisting sealant for repairing | Ths re"? |790-128-2090] 1009 | Tube |” reme + Used as lubricant for sliding partion (to pre: Mohtde Lm-c | 09940-00051 | 60 9 Can aaa ene disulphi + Used to prevent seizure or scut lubricant Lmp | 09840-00040 | 2009 | Tube | thread when press fiting or shrink fiting |+ Used as lubricant for linkage, bearings, etc. Isvc2-4o0u! + General purpose type 'syG2-350u! G21 |SYG2-400L-A | Various | Various |sya2-t60u! [SYGA-160CNL| [+ Used for normal temperature, light load se fsva240oca bearing at places in contact with water or ore Isvo2-asoca ae G2ca {SYG2400CA-A] Various | Various Isya2-r60ca ISvGa-t600NcAl Molybdenum 400 9 |+ Used for places with heavy load disulphide | S¥G2-400M | (10 per |Belows type| ad | “tuprieane case)FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) struction, tighten to the torque + Inthe case of metric nuts and bolts for which there is no speci given in the table below. Trend dares] wi sggemem) ee, | ®@ @ i we 6 10 wate 13520.15 8 3 3123 32403 10 v7 66:7 67207 2 19 113210 5=1 1“ 2 177219 iee2 6 2 279230 23523 8 2 382239 3924 20 30 54959 5626 2 32 74583 76285 24 36 927 103, 9452105 7 a 1320 140 135415 30 6 1720 190 375420 33 50 2210 240 225225 36 55 2750290 280230 39 60 i 3290 340 335235 Thread diameter width (0) of bolt ‘across flats DF oon mm mm Nm kgm 6 70 7.85" 195 oa202 8 3 136248 19405 10 “4 40.2259 41408 12 a 82.352 7.85 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. Thread diameter | Width across flat Tightening torque mm mm Nm kom Ty 8 2a5z49 25205 8 2 492196 522 2 2 785+ 196 822 26 32 13732294 14s3. 30 36 1765229.4 183 33 a 196.1 49 205 36 6 245.22 49 2525 2 55 204.249 i 3025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 0 1% ea7268 er207 2 ” 112298 11541 16 2 279129 28533 ‘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. Nominal No, [thread Width across flat Tightening torque mm mm Nm kgm 2 “ 3a3249 35205 03, 08 20 \Varies depending on| 931298 = | a5 05, 06 2 type of connector. vazizi9g = | 1452 10, 12 33 42142588 4326 4 2 877.12132.3 29.52 135 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ‘Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Nominal No. | thread diameter [ Width across flat Tightening torque mm mm Nm kgm 08 8 4 7352147 0.7520.15 10 10 7 a7 147 1520.5 2 2 19 18202 “ “ 2 23202 16 16 m4 3205 8 8 2 4205 20 20 30 ts 5205 Ey 2 32 68.6298 721 30 30 32 30782147 nei a 3 = 127-42 19.6 1332 36 36 36 15192245, 185225 2 2 = 21072294 21523 52 52 = 323.45 44.1 33245FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter mm Nm. kgm. 6 1042 1.02 + 0.20 8 mst 245 £0.81 0 4326 4384061 2 ne 7.85 +122 TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter Tightening torque mm Nm kgm 6 e22 081 +020 8 1022 11.02 + 0.20 10 1222 1.22 £0.20 2 m4 245 £0.81 u 3625 3.67 £051 TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine. ‘Thread diameter Tightening torque inch Nm kgm 16 Frsy 031 £0.10 8 et2 01 £0.20 4 1222 1.22 £020 3/8 1542 153 £0.41 2 mea 245 £0.41 3/4 36 +5 3.67 £0.51 1 oo =9 6.12 = 082 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: 5W8 indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS. Copper wire number Number of [ia of sean ross secon Cable 0.0. |Current ratig | Applicable circuit oss | on ox 088 2a 32__ | Starting, lighting, signal et, 2 26 02 209 a4 20 | Lighting, signal ete. 5 6 oz 523 46 a7_| Charging and signal 5 e 045 13.36 10 59 | Starting (Glow plug) #6 0.80 an | ta 135__| Staring a 127 0.80 e384 136 178 | Staring 100 27 oa | 1091 176 720 | staring CLASSIFICATION BY COLOR AND CODE Ground | staring | Lighting | instrument | signat | other @ 8 R Y é u Black | Black Red__| vetow | Green | Ble — Bw RW YR ow ow White & Red] _— _ [elack & write|Red & white [Velow & Red Green & White[Biue & White we = ay 8 ve oR iF [white & Bick] — [lack & Vetow| Red & Black [Yelow & Back|Green & Red] Blue & Red we = aR RY Ye ov wv ‘ [White & Blue] _— | Black & Red fied & Vellowfielow & Greenfreen & Volowlue & Yellow ; WG = S aG we oe we White & Greed] — —__ [Rea & Groen etow & BuofGreen & Blok] Bive & Black S = = = aL w a S = = —__[ Red & bive fetow & wntefGreen & Blue] _—FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE ‘The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE, «Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @. (2) Locate the number 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 85 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. {3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. Millimeters to inches 1mm = 0.03937 in ° 1 2 3 4 7 8 9 0.276 | 0.315 | 0.354 0.669 | 0.709 | 0.748 1.063 | 1.102 | 1.142 1487 | 1.496 | 1.536 11850 | 1.890 | 1.929 2244 | 2.283 | 2.323 2638 | 2.677 | 2.717 3.032 | 3.071 | 3.110 3.425 | 3.465 | 3.504 3819 | 3.858 | 3.698 00-16FOREWORD CONVERSION TABLE +L mm = 0.03937 in ° 1 2 3 4 5 6 7 e | 9 ° ° 0.039 | 0.079 | 0.118 | 0.157 | 0.197 | 0.236 | 0.276 | 0.315 | 0.354 10 0.394 | 0.433 | 0.472 | 0.512 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748 20 0.787 | 0.827 | 0.2866 | 0.906 | 0.945 | 0.984 | 1.024 | 1.069 | 1.102 | 1.142 30 1.181 | 1.220 | 1.260 | 1.299 | 1.339 | 1.978 | 1.417 | 1.457 | 1.496 | 1.536 40 1.875 | 1.614 | 1.654 | 1.693 | 1.732 | 1.772 | 1.811 | 1.850 | 1.890 | 1.929 60 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 | 2.659 | 2.598 | 2638 | 2.677 | 2.717 70 2.756 | 2.795 | 2835 | 2874 | 2.913 | 2.953 | 2.992 | 3.032 | 3.071 | 3.110 80 3.150 | 31e9 | 3228 | 3268 | 3.307 | 3.346 | 3.386 | 3.425 | 3.465 | 3.504 90 3.543 | 3583 | 3622 | 3661 | 3.701 | 3740 | 3.780 | 319 | 3.858 | 3.898 Kilogram to Pound 11kg = 2.2046 Ib ° 1 2 3 4 5 6 7 8 9 ° o 220} 441! 661| 8e2| 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] 57.92] 69.63] 61.73| 63.99 30 66.14] 68.34| 70.55] 72.75] 7496] 77.16| 79.37| 81.57] 8378| 8598 40 98.18 90.39) 92.59] 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 | 125.68 | 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 | 196.53 | 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 1198.42 | 200.62 | 202.83 | 205.03 | 207.24 | 209.44 | 211.64 213.85 | 216.08 | 218.26FOREWORD Liter to U.S. Gallon CONVERSION TABLE 1 = 0.2642 US. Gat of +f2]sfefs}e]7]e)s © fo | oase| osze | 0769 | 1057 | 1321] 1505 | 1900 | 2119 | 2278 10 | 26e2| 2906 | 3.170 | ace | aese | 2.900 | 4227 | aasr | 4755 | sors 20 | 5293 | 5548] ser2| 6076 | 6340 | 6.00 | soso | 7120 | 7297 | 7001 30 | 7925 | 8.1a9 | e0se | arte | 2902 | 9.205 | ost0 | 9.774 | 1039 | 10.03 10 | 0587 | 08st | 11.095 | 12.250 | 11526 | re | 12152 | 12.416 | 12680 | 12.944 so | 13209 | 13.73 | 19737 | 14.00 | 14268 | 14.529 | 14795 | 15.058 | 15322 | 15.586 c0 | rsaso | 16.115 | re.av | 042 | n6907 | 7.171 | 7435 | 17700 | 17966 | 13.228 20° | re4s2 | 18.788 | 1.000 | 19.288 | 1549 | 12.019 | 20077 | 20:31 | 20.505 | 20.870 eo | 21.194 | 21.98 | 21.060 | 21.206 | 22.190 |22.ss | 22-710 | 22,989 | 23.247 | 2351 20 [25775 | 24.040 | 2404 | 24560 | 24.922 | 2.006 | 25:61 | 5.65 | 2.0 | 20.158 Liter to UK. aon tes 021987 UX. Gal o fs fa2fefefs]oe}7fel]e © | | e220) oso] asso | osa0| 1300] 1320) 1540] 1760 | 1980 to | 2200| 2420| 2640| 2860) 2000] 2200] 2520] a740| 3950] 4.173 20 | 4380 | sete | MPa {kg/em*) kPa (mmH:0} kPa (mmHg) kwirpm {HPirpm) g/kwh {g/HPh) 00-22OI GENERAL General assembly drawin; Specifications ... Weight table. . Table of oil and coolant capacities CDEOR-1 01-1GENERAL GENERAL ASSEMBLY DRAWING GENERAL ASSEMBLY DRAWING CD6OR-1A Unit: am + FOR HULL TYPE DUMP BODY sxzo2216 01-2 ‘CDEOR-1GENERAL GENERAL ASSEMBLY DRAWING + FOR BOX TYPE DUMP BODY Unit: mn sxto2217 ‘CD6OR-1 01-3GENERAL SPECIFICATIONS SPECIFICATIONS ‘Machine model 080-14 Serial number 1601 and up | operating weight kg 8,450 | max. payload ko 6,000 3 ~ 20 : - 32 ‘Swing speed tom 4 Travel speed km Lo:60/Hi:85 g Empty deg 30 x deg 6 4) Loaded 8 Front eg 8 | hear eo 5 8/3] Lon og 2 2/7 | ion eo 20 : E | around preseure + No load Ka tiatoma 2160022) + Loaded KPa tale 27231028) Swing machinery + Reduction ratio ‘om _ + Swing reduction rato rom _ + Swing speed fom _ + Lubrication oil amount om _ COveraliength mm aes overall width mm 2515 Overall neight mm 2778 Ground clearance, botom of 2 | Soper swore mm 20 © | in. ground clearance mm a E| tat ewing radius mm 2.690 Length of rack on ground mm 3190 Track gauge mm 1.790 Length of track om 3.840 Track shoe width (standarc vm 600 01-4 cD60R-1‘SPECIFICATIONS Machine mode! (cD 60R-1 Serial number 1801 and up Name ‘S6D102E-1-A ‘Type of engine 4-cycle, water-cooled, in-line type, direct injection with turbocharger No.of cylinders bore xstroke | mm 6- 102% 120 Piston displacement e102) 5999 (5.683) Fiywnee! horsepower WP vrpm 99 (12) / 2,000 Max. torque Nenegrrpm 359 (57/1250 Max. speed at no load rom 2.2002 $0 Min. speed at no load om 110002 50, 2 | Min. fuet consumption ratio |grtvm ign) 2171162) 2 | starting motor 2av, 45kW Alternator 24,354 Battery 42V, 190An «2 (115E4IR) Radiator + Core type cries + Fin pitch 35mm + Heat dissipation area 34m! + Water capacity 780 + Pressure valve cracking pressure 49.0 Pa (05 kglom) + Vacuum valve cracking pressure = 4.9 KPa (0.05 kglem Carver roller (each sided ow a 8 | rock rote coon ie) ow 3 8 | Track shoe (1-piece rubber shoe) $+ No.of shoes on ach side a 5] pitch mm 100 + Track shoe wiath (standard) mm 600 2] se No Variable piston ype x2 gear type x3 | Discharge amount min Variable piston type: 112 x 2 | Discharge: " as Gear type: 50, gear type: 45, gear type: 13 2} cot preseur a Voriable piston type: 3.3 (370) x2 E | Set pressure Patten) Gear type: 17% (17S) gear type: 2.8 (30) x2 E IBe| type, wo. 2-sp00! ype x1 5 [88| comtroi methos Hydraulic assist Variable displacement piston 3 [aa] vel motor (with brake valve, parking brakel = 2 SIE] swing motor Fixed displacement piston type ERE) swing moto ‘with brake valve, swing shaft bee) 1 Hydraulic tank Hydraulic filter Hydraulic cooler Box shape open type Tank return side Air cooled (34-CS) cD6OR-1GENERAL ‘SPECIFICATIONS Mactine model a Serial umber 1801 and up Inside diameter of yindar Double-acting piston ype |< Forhulrype ump body | mm 120 Z| rerboxnpeaumptedy | mm 0 e meter of piston rod mm 55 2 sure on Pa 6 | Max. distance between pins mm 988 Min. distance between pins | mm oe? 2] Mex night aboveground 2) Fornulltype dump body | mm 4380 B/E | rorvoxpecumebody| mm 380 2 || in nigt above ground BB) - Ferhat type ump body | mm 20 é ‘+ For box type dump body mm 645 : Body dump angle mm 58 =| | soayaepth = + For hull type dump body mm (2,725 B| |< fortorsypedump body | mm im 5 | Body width 8 | rorhulltypedump body | — mm 2.085 | < rorboxtype dump body | mm 2.085 © | Body height ~Forhulltype dump body | mm 00 + Forboxtype dump body | mm 00 01-6 ‘CDEOR-1(GENERAL WEIGHT TABLE WEIGHT TABLE Bi This weight table isa guide for use when transportiong or handing components. Unite kg ‘Machine model (cD6OR-18 ‘Serial Number 1801 and up Engine assembly (excl. water, oi) 530) Dumper assembly 5 Radiator, oll cooler assembly 6 Revolving frame 1,040 Operator's cab 195 ops (With rops function) 210 Operator's seat 20 Fue! tank (excl. fuel) 50 Hydraulic tank (excl. hydraulic oil) 48 Hydraulic pump assembly 104 Control vaive 6 ‘Swing circle assembly 704 ‘Swing machinery assembly 43 ‘Swing motor assembly 2 Center swivel joint 43 “Track frame assembly + Track frame 1,050 + Idler assembly (each) 7 ‘Idler cushion assembly (each) 89 += Cartier roller assembly (each) 7 ‘Track roller, Bogie assembly + Bogie assembly (each) WS: 110, SS: 100 + Track roller assembly (each) w:365, ‘Travel motor (one sede) 147 + Sprocket (one sede) 18 “Track shoe assembly (one sede) + piece rubber shoe (600 mm) 75 + Road liner (600 mm) - + Road liner (450 mm) = Dump body assembly 910 Dump eylinder assembly (each) 46 01-8 CDEOR-1GENERAL TABLE OF OIL AND COOLANT CAPACITIES TABLE OF OIL AND COOLANT CAPACITIES nese xinp oF | SELECTION ACCORDING TO AMBIENT TEMPERATURE | _GAPACITY 1) FLUID {30-20-10 o 10 20 30 40 _s0°C|Specified| Refill Engine oil pan 23 | 190 1g machinery 1s | 15 BST CERES Final drive case 2a | 2a Engine ot tater 0.05 | 006 Track roller z oss | 033 Cartier roller oot | oo Hydraulie system 6 | as Hydraulic or — Diese Fuel tank Pig _ 130 | | Boay fale —lgrease | Lithium base grease -|- Cooling system |cootant | Add antifreeze 2» | — CDEOR-1 01-9(GENERAL 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%. Change interval of ollin Fuel sulphur content nge interval or 05 to 1.0% 1/2 of regular interval ‘Above 1.0% 1/4 of regular interval, (2) When starting the engine in an atmospheric tem- perature of lower than 0'C, be sure to use engine il of SAE 10W, SAE 10W-30 and SAE15W-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 haf. (4) There is no problem if single grade oil is mixed with multigrade oil (SAE1OW-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. %1 For the HO46-HM, use the oil recommended by Komatsu, ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Specified capacity: Total amount of for components and oil . Refill capacity: Amount of oil needed to refill system during normal inspection and main- tenance. il including 01-10 LIST OF LUBRICANT AND WATER D60R-110D6OR-1 10 STRUCTURE AND FUNCTION Engine control ....- : Power train system diagram Swing circle ‘Swing machinery .. Track frame Idler cushion Track roller bogie .. Track frame Hydraulic piping dra Valve control Hydraulic tank Hydraulic pump Work equipment control vaive Swing MOtOF wn Center swivel joint.. Travel motor Dump body PPC vaive Swing PPC valve.. Travel PPC valve. Solenoid valve .. PPC accurnulato Timer valve .. DA valve : Work equipment. Actual electrical wiring diagram screen 10-61 Machine monitor system. 10-1STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER Reservoir tank Engine Fan guard Radiator Oil cooler Shroud Fan Drain valve exe aeNe 10-2 ‘SPECIFICATIONS Radiator + Cracking pressure of pressure valve 49.0 kPa (0.5 kg/cm’ + Cracking pressure of vacuum valve: 4.9 kPa {-0.05 kg/cm* RADIATOR AND OIL COOLER 100197 Oil cooler + Type of core: 3A-CS Fin pitch: 3.5 mm_ + Total heat dissipation area: 12.27 m? Quantity of oit: 3.0 2 ‘cD60R-1STRUCTURE AND FUNCTION DAMPER COUPLING DAMPER COUPLING sxz00740 1. Input shaft (for piston pump) OUTLINE 2. Rubber + The coupling reduces the torsional vibration, 3. Bolt caused by fluctuation of the engine torque 4. Pin to protect the drive system after the engine 5. Clamping hub from the torsional vibration. 6. Clamping screw + The engine power is transmitted from the fly- wheel to rubber (2) of the coupling which at ‘sorbs the torsional vibration, then transmit- ted through clamping hub (5) to the main pis ton pump. ‘CD6OR-1 10-3STRUCTURE AND FUNCTION ENGINE CONTROL ENGINE CONTROL eupooise Fuel control lever Governor lever Cable Cable Spring Loose spring 7. Decelerator pedal 10-4 ‘CDEOR-1STRUCTURE AND FUNCTION ENGINE CONTROL oeeelerator © 8 Poel Tovar’ > Pou suzoanie LEVER PosmioN OUTUNE ©: Lo. idling + When the engine is stopped, the si ®: Hic idling the starting switch actuates the engine stop solenoid to carry out contol. PEDAL POSITION + Control of the engine speed is carried out with @ : Deceleration ON fuel control lever (1). @ : Deceleration OFF + Decelerator pedal (7) can be used to reduce the engine speed, regardless of the position of fuel control lever (1).. ‘CDEOR-1 10-5STRUCTURE AND FUNCTION POWER TRAIN SYSTEM DIAGRAM POWER TRAIN SYSTEM DIAGRAM 000000 1. Travel motor 2. Engine 3. Hydraulic pump 4. Control valve 5. Idler 6. Travel solenoid valve 10-6 W ‘sxz00742, 7. Swing brake solenoid valve 8. Swing motor 9. Center swivel joint 10. Swing machinery 11. Swing circle cD60R-1STRUCTURE AND FUNCTION SWING CIRCLE 1. Swing circle outer race 2. Ball bearing 3. Swing circle inner race ‘SPECIFICATIONS Reduction ratio : 80/10 = 8.00 Amount of grease : 5 £ (Grease G2-LI) D6OR- SWING CIRCLE sopornee a. Soft zone of outer race b. Soft zone of inner race 10-7‘STRUCTURE AND FUNCTION SWING MACHINERY SWING MACHINERY = Ann r 1. Swing pinion (tooth: 10) 8. Oillevel gauge 2: Housing 10. Oilfiler port 3: No-2 planetary gear 11. No- 1 planetary gear (tooth: 23) 4 No.2 sun gear (tooth: 19) 12, No. 2 planetary gear (tooth : 24) 5. Ring gear (tooth : 68) 1. Bearing greasing nipple 6. No-1 planetary gear 14, Drain plug 7. No.1 sun gear (tooth: 22) 46. Swing cirle (tooth : 80) 8. Swing motor 10-8 coorSTRUCTURE AND FUNCTION. TRACK FRAME TRACK FRAME sezooves 5 een Type of tack roller and positioning of bogie 2. Sprocket 3. Carer roller sogeNo [1] 2 [3] @ 4 ler Troek over |S WS] [Ww] S| Ws 5. Track rome 6. Track olor 7. Track lle bogie OUTLINE + The track roller bogie is employed to increase the actual ground contact area of the track shoe (on unfinished ground for larger traction force. CDEOR-1 10-9STRUCTURE AND FUNCTION IDLER CUSHION IDLER CUSHION 1. Lubricator 2. Grease cylinder 3. Piston 4, Recoil spring 5. Fork 10-10 6. Spring seat 7. Nut & Oil seat 9. O-ring (D6OR-1STRUCTURE AND FUNCTION TRACK ROLLER BOGIE TRACK ROLLER BOGIE 1200950 1. Bogie OUTLINE 2. Track roller + Track roller (2) is installed to bogie (1) to re- 3. Nut duce separation of the track roller and track 4. Pin shoe. 5. Bushing ‘CD6OR-1 10-11STRUCTURE AND FUNCTION TRACK FRAME TRACK FRAME sur007s2 1. Floating seal 2. Oil filler plug 3. Seal cover 4. Bushing 5. Shaft 6. Roller 10-12 ‘CD6OR-1STRUCTURE AND FUNCTION HYDRAULIC PIPING DIAGRAM HYDRAULIC PIPING DRAWING sua00200 1. Oil cooler 11. Dump body PPC valve 2. Swing PPC valve 12. Travel motor (R.H.) 3. Hydraulic pump. 18. Hydraulic tank 4, Dump cylinder 14. Hydraulic line filter 5. Swing motor 18. PPC lock solenoid valve 6. Center swivel joint 16. Swing brake solenoid valve T. Control valve 17. DA valve 8. Accumulator 18, Timer valve 9. Travel motor (LH.) 19. Emergency stop solenoid valve 10. Travel PPC valve CD6OR-1 10-13,STRUCTURE AND FUNCTION VALVE CONTROL VALVE CONTROL storm LEVER POSITION 1. Travel PPC valve @: Neutrat 2. Dump body PPC valve ® : Dump body (RAISE) 3. Dump body contro! pedal @: Dump body (LOWER) 4, Travel control lever (LH.) @: Neutral 5. Travel control lever (R-H.) ©: Swing (RIGHT) 6. Swing PPC valve © : Swing (LEFT) T. Swing control lever @: Neutral 8. Hydraulic pump © : Travel (REVERSE) 9. PPC lock solenoid valve @ : Travel (FORWARD) 10. Control valve @: Lock 11. Safety lock lever @: Free 10-14 ‘CD6OR-1‘STRUCTURE AND FUNCTION HYDRAULIC TANK HYDRAULIC TANK c-c a-8 ‘1000201 1. Oil filler cap OUTLINE 2. Drain plug Tank capacity: 65 ¢ 3. Element push spring Quantity of oil in tank: 45 ¢ 4, Hydraulic filter element Cracking pressure of pressure valve: 5. Safety valve 38.2 + 14.7 kPa {0.39 + 0.18 kglern’} 6. Hydraulic oil strainer Cracking pressure of vacuum valve: ~4.§ — 0 kPa {-0.046 — 0 kg/em*) Operating pressure of safety valve: (0.1 MPa {1.05 kg/em?) ‘CDEOR-1 10-15STRUCTURE AND FUNCTION HYDRAULIC PUMP HYDRAULIC PUMP MODEL: A4VG56HD+A4VG5GHD+GPX0-25+GSP2H-22+G1-06 Tr Yar 13. Yaz Faz 83 BABB yer Bt yer yey Pet Ye2 Pez supoorso Al. To port B (LH. Travel motor) ‘83. From hydraulic tank ‘A2. To port A(R. H. Travel motor) ‘84. From hydraulic tank B1. To port (L. H. Travel motor) Ti. To hydraulic tank B2. To port B (R. H. Travel motor) 3. To hydraulic tank B3. To port P (Control valve) YA1. From port 4 (Travel PPC valve} B4. To port Fa? (Hydraulic pump} YA2. From port 2 (Travel PPC valve) BS. To port P (2-spool solenoid valve) YB1. From port 3 (Travel PPC valve) Fa2. From port B4 (Hydraulic pump) ‘YB2. From port 1 (Travel PPC valve) P31. From port A (2-spoo! solenoid valve) Ys1. From port PP (Timer valve) P52. From port A (2-spool solenoid valve) Ys2. From port PP (Timer vaive) 10-16 CD6OR-1STRUCTURE AND FUNCTION HYDRAULIC PUMP 1. HD contro 6. PPC pump 2. High-pressure selector 7. Low-pressure relief valve 3. High-pressure relief valve 8. Rear piston pump 4. Wark equipment pump 8. Front piston pump 5. Charging pump CD6OR-1 10-17,STRUCTURE AND FUNCTION HYDRAULIC PUMP ‘SPECIFICATIONS 5 Fiston pump 8] Gear pump © | Gear pumpO | Gear pump E yee ‘A4VG56HD- GXPO-25 GSP2H-22 G1-06 Capacity cxlev 6 253 a o Theoretical discharge | _e/min 710 50 5 8 Gil pressure Paige] ssaa7o | wai | rams 23830) 10-18 D6OR-1STRUCTURE AND FUNCTION OUTLINE + The A4VG is a swash plate variable displace- ment piston pump for the closed circuit. The HD regulator, which controls the direction and flow of the discharge, a high- pressure relief valve, and a charge relief valve are built into it + Two piston pumps and 2 or 3 gear pumps are stalled to the same shaft. Pump A: For right travel Pump B: For left travel Pump C: For dump body, swing Pump D: For charge Pump E: For pilot OPERATION + Cylinder block (2) is interconnected with drive shaft (1) and rotates. + Piston (3), which is assembled to cylinder block (2), follows hanger (4) (swash plate) and car- ries out a double- acting movement, so a change in volume occurs inside the cylinder to carry out the suction and discharge action of the pump. + Piston (3) carries out a suction and discharge stroke each time cylinder block (2) rotates, so by rotating drive shaft (1), the 9 pistons carry ‘out continuous suction and discharge. D60R-1 ENGINE HYDRAULIC PUMP sup00i76 sxzo2220 10-19STRUCTURE AND FUNCTION HYDRAULIC PUMP HD-REGULATOR VALVE 1200782 1. Angled piston 2. Feedback arm 3. Hanger 4. Pin OUTLINE Pitot eressuce + The displacement volume of the pump wre changes steplessly between 0% and 100% in proportion to the pilot pressure. + The relationship between the pilot pressure and the displacement volume is shown in the diagram on the right. suro721 10-20 CD6OR-1‘STRUCTURE AND FUNCTION OPERATION Neutral ‘When the pilot pressure is lower than the in- stalled load of control spring (6), spool (7) does not move from the neutral position, and pres- sure is not sent to tilt piston (1). + Tilt piston (1) is connected to hanger (3) by pin (4). Return spring (6) is built into tilt pis: ton (1), and when the pressure does not act on it (when the pressure is lower than the i stalled load of return spring (5}), itis held at the neutral position (0 discharge condition). + The pressure equivalent to the installed load of control spring (6) is called the control start pressure. CONNECTING PILOT PRESSURE ‘When the pilot preseure becomes higher than. the control start pressure, spool (7) moves in the direction of the arrow. At the same time, the pressure acting on tilt cylinder (8) connects the other tiltcylinder (9) to the tank (inside the housing). + Control spring (6) extends and generates a load in the direction to oppose the pilot pres- sure. ‘cD6OR-1 Of pat — 1 ‘TRAVEL MOTOR x 12 pez ofo Se o, 6) 2 | oreo! © S Oho. supoorss 10-31STRUCTURE AND FUNCTION (2/2) 1. No. 1 planetary gear 2. Ring gear 3. No. 2 planetary gear 4. Output shaft 5. Brake piston 6. Brake spring 7. Piston 8 Cylinder 9. Plate 10. Disc 11. No. 2 planetary carrier 12, No. 2 sun gear 13, No. 1 planetary carrier 14, No. 1 sun gear 10-32 TRAVEL MOTOR susnoise 5. Plug . Piston Spring 3. Servo spool lot valve spring . Adjusting sorew | Control piston . Connecting rod . Valve body Relief spring . Spool return spring Shuttle valve spring Check valve CD6OR-1STRUCTURE AND FUNCTION ‘SPECIFICATIONS Model | AsvesHiAL Motor capacity carey | 40-687 Pressure used MPatkgiom? | 3431350) Relief set pressure | MPatkgiem’) | 37.885) Brake release pressure | MPatka/em) | 23023) OUTLINE + This motor has a built-in parking brake and HST circuit that automatically controls the travel torque to match the travel resistance. + Under normal conditions, a large tilt is given priority, and the tilt is automatically controlled according to the increase or decrease in the motor load and high-low speed pilot pressure. cDéoR-1 ‘TRAVEL MOTOR 10-33STRUCTURE AND FUNCTION OPERATION OF PISTON MOTOR PRINCIPLE ‘As shown in Fig. 1, the shaft of a disc is sup- ported to allow the disc to rotate freely. Ifforce F is applied to this disc at an angle, as shown in Fig. 2, this force F can be divided into force F1 applied at a right angle to the face of the dise and force F2 applied in the direction of the circumference of the disc. Force F1 pushes the disc in the axial directi tates the disc in a clockwise direction. If force F’is applied to the disc instead of force F, the force can be divided in the same way into forces F’1 and F'2, and force F'2 will rotate the disc in a counterclockwise direction. ‘OUTLINE OF STRUCTURE ‘The structure of the piston motor is as shown in Fig. 2. Seven pistons are installed with a spherical connection to the disc portion of ‘output shaft (7). Pistons (9) are at a certain angle to the output shaft and are fitted inside cylinder block (10). In addition, the cylinder block and valve plate (1) are guided by the center shaft. The rote- tion of the cylinder block to the axis of the cen- ter shaft is free, but the valve plate is fixed to the end cover by bolts. OPERATION ‘As shown in Fig. 3, when the oil flows into the left port of the valve plate and flows out of the right port, pressure is applied to the back of the piston, which is connected to the left port. ‘As explained in the section on the principle, ‘the output shaft then rotates clockwise. In addition, when this happens, the piston slides. inside the cylinder block and rotates clockwise together with the cylinder block with the same rotation as the output shaft. It passes the top. position of the output shaft and connects with the outlet port of the valve plate. When itcon- nects with the outlet port, the pressure at the back face of the piston is released, and the force acting on the output shaft is lost. For this reason, the piston is now rotated by the ‘output shaft, and the piston slides inside the cylinder block and drains the oil at the back face of the piston to the tank. The same ac- tion is repeated by all seven pistons, and the output shaft rotates clockwise. In addition, when the inlet and outlet ports of the valve plate are reversed, the above action is completely reversed, so the rotation be- comes counterclockwise as explained in the 10-34 Find ignite ‘TRAVEL MOTOR sxzoa28 srzozn30 foQo AEA as) sxzoz231 D60R-1‘STRUCTURE AND FUNCTION TRAVEL MOTOR OPERATION OPERATION OF MOTOR [At low speed at high load (motor swash plate angle at maximum) st 0 “ —— > é t ny fy + The oil pressure from the high-pressure side (PA or PB) of the circuitis sent by shuttle valve (26) inside valve body (23) as the high-pres- sure side pilot pressure from oil passage P1 through servo spool (18) to the small diam- eter port of control piston (21). + Servo spool (18) is actuated by the pilot pres- sure, and it tries to move towards pilot valve spring (19). + At the same time, servo spool (18) receives the movement towards pilot valve spring (19) from the force of spring (17) and external pilot pressure X. + If the set pressure of pilot valve spring (19) is {greater than these forces acting on servo spool (18), the passage to oil passage P2 is kept closed by servo spool (18), and the oil pres- sure acting on port $1 moves control piston (21) to the motor capacity maximum side. cp6oR-1 is u sxtonna2 10-35STRUCTURE AND FUNCTION At high speed (motor swash plate angle at minimum) TRAVEL MOTOR + When the pilot pressure from port X rises and the pressure acting on servo spool (18) be- ‘comes greater than the set pressure of con- trol valve spring (19), servo spool (18) over- ‘comes the reaction of control valve spring (18), moves down, and oil passage P2 opens. + The motor circuit pressure passes through oil passage P2, enters port S2 at the large diam- eter end of Control piston (21), and acts on the: end face at the large diameter end of control piston (21). + Asa result, the propulsion force generated by the difference in area (S1 - $2) moves control piston (21) in the direction of the minimum mo- tor capacity. 10-36 Ploy ne 2 suao2nss ‘When this happens, pilot valve spring (19) is compressed by the movement of control pis- ton (21) and tries to push back servo spool! (18) The circuit pressure, which varies according to the pilot pressure from port X and the load ‘on the motor, acts on servo spool (18), and it moves to a position where the pressure is bal- anced with pilot valve spring (19). Because of this pressure balance, control pi ton (21) automatically controls the swash plate angle according to the load. cD6OR-1STRUCTURE AND FUNCTION Operation of parking brake When operating travel When the travel lever is operated, the timer valve acts to allow the pressure oil used to release the parking brake to flow into the parking brake cir- cuit just before the drive oll pressure acts on the motor. The oil pressure from the pump flows into cham- ber a of brake piston (1) and pushes brake piston (1) to the right. As a result, the force of spring (4) pressing plate {2) and disc (3) together is lost, and plate (2) and disc (3) separate to release the braking force. When travel is at neutral When the travel lever is at neutral, the timer valve ‘acts to shut off the pressure oil in the brake circuit from the pump to actuate the parking brake just after the drive oil pressure of the motor is cut. ‘The pressure oil in chamber a of brake piston (1) is shut off, and piston (1) is pushed fully to the left by spring (4). ‘As a result, plate (2) and disc (3) are pushed to- gether and the brake is applied. cD6oR-1 TRAVEL MOTOR sup0ores 10-37,STRUCTURE AND FUNCTION DUMP BODY PPC VALVE DUMP BODY PPC VALVE | © @l9 1. Spool 2. Metering spring 3. Centering spring 4, Piston 5. Lever 6. Plate 7. Retainer 8. Body 9. Filter 10-38 P2. AA savocors T: Totank P: From port A (2-spool solenoid valve) P1: Dump body LOWER. P2: Dump body RAISE D60R-1‘STRUCTURE AND FUNCTION OPERATION 1. Atneutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1) 2. Fine control (neutral to fine control) When piston (4) starts to be pushed by disc (6), retainer (7) Is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the control pump is sent from port A through fine control hole f to port P1. When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At al- most the same time, it is connected to drain chamber D, so the pressure at port P1 es- capes. As a result, spool (1) moves up and down tuntil the force of metering spool (2) is bal- ‘anced with the pressure of port P1 ‘The relationship of the positions of spool! (1) and body (8) (fine contro! hole f ic in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (7) contacts spool (1). Therefore, metering spring (2) is com- pressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the con- trol lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the con- trol valve spool are balanced. (Fig. 2) CDEOR-1 DUMP BODY PPC VALVE 4 Pr Pa control valve 4 » sxpor2%4 sxpov29s 10-39STRUCTURE AND FUNCTION 3. Fine control (control lever returned) When disc (6) starts to be returned, spool! (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is con- nected to drain chamber D, and the pressur- ized oil at port P1 is released. If the pressure at port P1 drops too much, ‘spool (1) is pushed up by metering spring (2), s0 fine control hole f is shut off from drain chamber D. At almost the same time, itis connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drai chamber D flows in from fine control hole f* of the valve on the side that is not moving. It passes through port P2 and goes to cham- ber B to charge the oil. (Fig. 3) 4) Attull stroke Dise (5) pushes down piston (4), and re- tainer (7) pushes down spool (1). Fine con- trol hole f is shut off from drain chamber D, and is connected to pump pressure cham- ber PP. Therefore, the pilot pressure oil from the control pump passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool. ‘The return oil from chamber B passes from port P2 through fine control hole f* and fiows to drain chamber D. (Fig. 4) 10-40 DUMP BODY PPC VALVE suvonase 5 ‘ _ ° alt —T le t oo y ce Pr contro! vatve 4g fina 5 4 o ° 2 pr Pa control vaive Pgs ine sxvo7287 €D6OR-1STRUCTURE AND FUNCTION SWING PPC VALVE SWING PPC VALVE suv00038 P: From A port (2-spool solenoid valve) T: Totank PI: Plug P2: Plug P3: Swing (RH.) Pa: Swing (LH.) CD6OR-1 10-41STRUCTURE AND FUNCTION 1. Spool 2. Mastering spring 3. Centering spring 4, Piston 5. Disc 6. Nut (For connecting lever) 10-42 ‘SWING PPC VALVE saPo0a74 @P z D6OR-1STRUCTURE AND FUNCTION SWING PPC VALVE OPERATION 1) Atneutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve ere connected to drain chamber D through fine controle hole fin spool (1). (Fig. 1) a rae Urn E ze > '~| Ae y b 1 iy Le Pe} 2) During fine control (neutral to fine control) H H ‘When piston (4) starts to be pushed by dise A | (5), retainer (9) is pushed; spool (1) is also gM contear vaive ge pushed by metering spring (2), and moves down. fied When this happens, fine control hole f is shut off from drain chamber D, and at al- most the same time, it is connected to pump pressure chamber PP, so pilot pres- sure oil from the control pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pres- sure chamber PP. At almost the same time, it is connected to drain chamber D to re- lease the pressure at port P1. When this happens, spool (1) moves up or down so that the force of metering spring (2) is bal- anced with the pressure at port P1. The re- lationship in the position of spool (1) and body (10) (fine contro! hole f is at a point midway between drain hole D and pump pressure chamber PP} does not change until retainer (9) contacts spool! (1). Therefore, metering spring (2) is com- pressed proportionally to the amount of movement of the control lever, so the pras- sure at port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber A (the same Fie as the pressure at port P1) and the force of the control valve spool return spring are balanced. (Fig. 2) sevonse8 sevons70 CD6OR-1 10-43STRUCTURE AND FUNCTION 3) During fine contro! (when control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pres- sure oil at port P1 is released. If the pressure at port Pt drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber 1. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is sup- plied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. ‘When the spool of the control valve returns, il in drain chamber D flows in from fine control hole fin the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil. Fig. 3) 4) Atfull stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spoo! (1), fine con- trol hole f is shut off from drain chamber D, land is connected with pump pressure cham- ber PP. Therefore, the pilot pressure from the control pump passes through fine con- trol hole f and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f and flows to drain chamber D. (Fig. 4) 10-44 SWING PPC VALVE Ir Control valve Fie ® sepons7t — Contre! valve eae seronsna cD60R-1STRUCTURE AND FUNCTION TRAVEL PPC VALVE TRAVEL PPC VALVE P: From control pump T: Totank PI: Reverse (LH.) euyooa! P2: Forward (LH.) P3: Reverse (R.H.) Pa: Forward (LH.) 10-46 CDEOR-1STRUCTURE AND FUNCTION TRAVEL PPC VALVE 1. Plate suvoos22 5. Metering spring 6. Centering spring 7. Valve ‘CD6OR-1 10-47‘STRUCTURE AND FUNCTION OPERATION 1 ‘At neutral Ports A and B of the control valve and ports 1 and P2 of the PPC valve are connected to drain chamber D through fine contro! hole f in spool (1). (Fig. 1) 2. Fine control (neutral to fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure ‘of the control pump is sent from port A through fine control hole f to port Pt. ‘When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At al- most the same time, itis connected to drain chamber D, so the pressure at port P1 es- capes. As a result, spool (1) moves up and down Until the force of metering spool (2) is bal- anced with the pressure of port P1. ‘The relationship of the positions of spool! (1), and body (10) (fine contro! hole f is in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (8) contacts spool (1). Therefore, metering spring (2) is com- pressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the con- trol lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the con- trol valve spool are balanced. (Fig. 2) 10-48 TRAVEL PPC VALVE suns ‘ a Zi . L ‘ TREE Te, ea. I YE PP Kamm CD6OR-1STRUCTURE AND FUNCTION. 3. Fine control (control lever returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is con- ected to drain chamber D, and the pressur- ized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring (2), 80 fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. ‘When the control vaive returns, oil in drain ‘chamber D flows in from fine contro! hole f* of the valve on the side that is not moving, It passes through port P2 and goes to cham- ber B to charge the oil. Fig. 3) 4) At full stroke Disc (5) pushes down piston (4), and re- ier (9) pushes down spool (1). Fine con- trol hole fis shut off from drain chamber D, and is connected to pump pressure cham- ber PP. Therefore, the pilot pressure oil from the control pump passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool. ‘The return oil from chamber B passes from port P2 through fine control hole f* and flows to drain chamber D. (Fig. 4) D60R-1 TRAVEL PPC VALVE fins sxz02236 con sxz0n237 10-49STRUCTURE AND FUNCTION ‘SOLENOID VALVE SOLENOID VALVE FOR PPC LOCK AND SWING BRAKE 1 yey sunoo708 1. For PPC lock Control relief valve ‘A: To PPC valve 2. For swing parking brake '&. Lock nut B: To port B (Swing motor) 8, Adjusting screw P: From pilot pump Solenoid valve 40. Shim T: To hydraulic tank 3. Solenoid 11. Spring G: Pressure pick-up port 4, Push pin 12. Spool 5. Spool 6. Return spring 7. Valve body 10-50 ‘CDEOR-1STRUCTURE AND FUNCTION OPERATION When solenoid is de-energized ‘When the signal current does not flow, sole- noid (3) is de-energize For this reason, spool (5) is kept pushed up in the direction of the arrow by spring (7) As a result, port P is closed, and no pressure oil flows from the control pump to the actua- tor. At the same time, the oil from the actuator flows from port A to port T and is drained to the tank. When solenoid is energized ‘When the signal current flows to solenoid (3), solenoid (3) is energized. For this reason, spool (5) is pushed down by push pin (4). As a result, the pressure oil from the control pump passes from port P through the inside ‘of spool (5), flows to port A and then flows to the actuator. At the same time, port T is closed, so the oil does not flow to the tank. cD60R-1 SOLENOID VALVE A f Aetanter c T oe cide sutoz238 fxeitee poten T I pt 10-51STRUCTURE AND FUNCTION SOLENOID VALVE FOR EMERGENCY STOP | —» > 1. Solenoid ‘A: To hydraulic tank 2. Pushpin P: To hydraulic tank 3. Spool TT: From port B (Timer valve) 4. Guide 5. Return spring 6 Valve body 10-52 CDEOR-1STRUCTURE AND FUNCTION. OPERATION ‘When solenoid is de-energized (circuit shut off) + When the signal current from the emergency stop switch is shut off, solenoid (1) is de-ener- gized. As a result, spool (3) is pushed up by spring 5). + When this happens, port T and port A open, and the pressure oil from the timer valve that was actuating the parking brake circuit of the travel motor flows from port T to port A, and is drained to the tank. + Therefore, the pressure oil in the parking brake circuit of the travel motor is released and the parking brake is applied. ‘energized (circuit connected) + When the signal current from the emergency stop switch flows, solenoid (1) is energized. ‘Asa result, spool (3) is pushed down by push pin (2) + When this happens, port T is closed, and the pressure oil from the timer valve actuates the parking brake circuit of the travel motor, and the brake is released. + Therefore, the parking brake is released by the pressure oil in the parking brake circuit of the travel motor. p60R-1 SOLENOID VALVE sxzorzae e{_& sxzoa2e1 10-53PPC ACCUMULATOR STRUCTURE AND FUNCTION. PPC ACCUMULATOR 1 P 3 ‘ 5 ' -_ ssp00250 1. Gas plug ‘SPECIFICATIONS 2. Shell ‘Type of gas : Nitrogen gas 3. Poppet Gas volume :0.3 ¢ 4. Holder ‘Min, actuating pressure : 1.18 MPa(12 kg/om*} (at 80°C) 5. Bladder ‘Max. actuating pressure : 6.86 MPa{70 kg/cm’) 6. Oil port 10-54 peor:STRUCTURE AND FUNCTION ‘TIMER VALVE TIMER VALVE TRAVEL SPEED SELECTER sxzoo77? T: To hydraulic tank Br: To port PB (LH/R. travel motor) PG : From port A (2-spool solenoid valve) PM : To port X (LH/R. travel motor) PP: From port YS1/YS2 (Main pump) (CDéOR-1 10-55STRUCTURE AND FUNCTION. TIMER VALVE sur0or76 1. Guide 7. Guide 2. Poppet 8. Plug 3. Guide 9. Spool 4. Body 10. Spring 5. Guide 11. Solenoid 6. Orifice 10-56 ‘CDEOR-1STRUCTURE AND FUNCTION OPERATION +The control of the travel motor parking brake is carried out by the HD control pilot pressure ‘combined with the travel lever. + Each of the front and rear HD regulator covers has a built-in shuttle valve to output the high pressure from either of the two pilot pressures (FORWARD, REVERSE). + The front and rear (left and right on the ma- chine) pilot pressures have the high pressure selected further by the timer valve, and are connected to the spool. + The highest of the front, rear, left, and right is used as the signal, so if the lever for any one of these is operated, a signal pressure is gen- erated. The pressure for the tilt operation then connected to the brake port of the travel motor, and the brake is quickly released. + When all the levers are at neutral, the signal, goes down and the spool is switched. The brake port oil passes through the orifice and is drained to the tank. The parking brake i actuated after the HST brake is actuated, and this is effective in improving the service life of the parking brake. + Asolenoid vaive is built into the timer valve, and this controls the tilting of the travel mo- tor. + When no electricity Is flowing, the HD signal pressure is connected to the 1st fixed circuit of the motor. When the travel lever is at neu- tral (machine stopped), the motor is at maxi- ‘mum tit (1st); and when the lever is operated, there is automatic control of the load pres- sure sensing. + When the solenoid is energized, the pressure ofthe 1st fixed circuit is connected to the tank, ‘and the motor is set to maximum tilt (1st. ‘st fixed circuit pressure: PX PX < 0.5 MPa {6 kgicm*} motor at maximum, tilt PX > 0.5 MPa {5 kg/om*} automatic control D60R-1 TIMER VALVE sxtoand2 10-57STRUCTURE AND FUNCTION DA VALVE DA VALVE — : z 4 1 femal tl 1 x, 5 7 ‘ i 1 x 8 AoA x xi sezoo78o 1. Blind cap T: To hydraulic tank 2. Pressure adjustment screw X1: From rear gear pump port Bé (charge pre 3. O-ring sure inlet port) 4. Locknut X2:: To solenoid valve port P (charge pressure out- 5. DAcartridge let port) 6. Spring X3 : Plug (control pressure) 7. Body X@ : To travel PPC valve portP (HD command con- 8. Orifice trol pressure) 10-58 CD6OR-1STRUCTURE AND FUNCTION FUNCTION ‘The gear pumps used for pump tilt control are ‘connected to the same shaft, and the discharge flow from the gear pump is increased or de- creased in proportion to the engine speed. + All of this oil flow passes through the orifice of the DA valve and goes to the tilt actuating circuit + The pressure difference on both sides of the orifice caused by the difference in the oil flow is used as the signal, and the tilt actuating pres- sure is reduced to change the control pressure, + Inother words, itis possible to generate a con- ‘rol pressure that is almost proportional to the engine speed, ESP+P2+A+P3+B-P1+A=0 = (P1—P2)+ AB - FSPIB Atthe same time, P1~P2=f(Q),0 P3 =f (N) -FSP (ny Constant output contro! +The pump pressure controlled by the DA valve Is Used as the pilot pressure supplied to the travel PPC valve. This makes it possible to prevent the engine from stopping under over- load. + When load is applied to the engine and the engine speed drops, the DA valve lowers the control pressure. This reduces the displace- ment volume and makes the pump absorption torque smaller. + The displacement volume is balanced at the point where it matches the engine torque. +The pump automatically carries our tilt con- trol to match the slight drop in the engine speed when there is an increase in the load. This means that the engine torque can be used effectively without the engine stopping, CD6OR-1 DA VALVE {HD coaeand otessere) 4 Xp05 9 Fron Cate. aressure Pri Pyoe) Pye) Yew ° Da? 7 nh OG GH Ge 10-59STRUCTURE AND FUNCTION WORK EQUIPMENT WORK EQUIPMENT + The diagram shows the box type dump body. srto2a4s Dump body Dump cylinder Rear gate Dump body support bar Rear gate lock booster 10-60 CD6OR-1STRUCTURE AND FUNCTION ACTUAL ELECTRICAL WIRING DIAGRAM ACTUAL ELECTRICAL WIRING DIAGRAM (1/2) i 10 snes 1. Horn switch 9. Travel speed selector switch 2. Monitor panel 10. PPC lock limit switch 3. Starting switch 11. Glow resistance 4, Fuse box 12. Heater 5. Relay 18. Swing holding brake controller 6. Swing holding brake cancel switch 14, Alarm buzzer 7. Wiper switch’ 15. Flasher 8. Swing lock switch CD6OR-1 10-61STRUCTURE AND FUNCTION ACTUAL ELECTRICAL WIRING DIAGRAM (2/2) 10-62STRUCTURE AND FUNCTION 16. Front lamp 17. Right swing pilot lamp 18. Washer tank 19. Heater relay 20. Room lamp 21. Centering detection proximity switch 22. Reverse travel detection proximity switch 23. Travel alarm 24. Fusible link 25. Battery 26. Battery relay 27. Fuel level sensor 28. Cooler unit (OPT) 29. Swing pressure switch 30. Left swing pilot lamp 31. Wiper motor 32. Fuel electric pump 33. Horn 34. Alternator 35. Coolant temperature sensor 36. Electrical Intake air heater 37. Starting motor 38. Engine oil pressure sensor 39. Engine stop solenoid 40. Airconditioner compressor (OPT) 41. Travel alarm relay 42. HST charge pressure switch 43. PPC lock solenoid valve 44, Swing brake solenoid valve 45, Travel pressure switch 46. Travel speed solenoid valve 47. Emergency stop solenoid valve 48, Tachometer 49, HST charge pressure warning lamp 50. Brake switch 51. Brake pilot lamp 52. Center pilot lamp 53, Reverse travel pilot lamp cD60R-1 ACTUAL ELECTRICAL WIRING DIAGRAM 10-63STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM +The monitor system uses sensors installed to, all parts of the machine to observe the condi- tion of the machine. It then quickly processes the information and displays iton the panel to inform the operator of the condition of the ma- chine. + The panel displays can be broadly divided as follows: 1. Monitor portion (which issues warnings when any abnormality is found in the ma- chine) 10-64 MACHINE MONITOR SYSTEM SS suaozeas 2. Pilot portion (which displays the con: ‘of the machine when the machine is oper- ated) 3. Gauges (which always display the condi- tion) There are also switches for the electrical equip- ‘ment installed inside the monitor panel. D60R-1STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM MONITOR PANEL AMPo4o-16P kesi-aP (1) KESI-4P (2) ‘OUTLINE +The monitor panel carries out the monitor dis- play function, gauge display function, service meter function, and switch functions for elec- sunoozes trical equipment. + Ithas a built-in CPU (Central Processing Unit) to process the data and output the display. + Liquid crystal displays are used for the gauge displays. + Lamps are used for the monitor displays. Inputoutput signals ‘AMPO40-16P (CN-P1) Ne. Name of signal Input/Output No. Name of signal InpuvOutput 1_| Power source (2av S 3. | Engine oll pressure Taput 2_| Power source (24V) = 10 | Battery charge Taput 3 | GND = 11 | Spare avi = [GND = 32 | Swing lock input &_| Stan signal Tnput 13 | Preheating Input 6 | Coolant temperature Tnput af = 7_| Fuel level Input 15 | Alarm buzzer Output e[— = 16 | Night ighting Input KES1-4P(1) (CN-P2) KES1-4P(2) (CN-P3) No. Name of signal InpuvOutput No. Name of signal InpuvOutput f= = e[— = 2 | Working lamp Output 10 | Heater Hi Output 3_| Night lighting Output TH | Heater to Output @ po 28v = 72 | GND. = ‘CD6OR-1 10-65STRUCTURE AND FUNCTION FUNCTION MACHINE MONITOR SYSTEM s ‘ ? ‘ ‘s suonente Display | Display Display methox Display | Remar Nol category | item” | range elon coior’_| Remarks ‘Counts tine when engine fs running (when Glock 1 Service meter | 0-g00089h | Sum are wae closely — time iRernator fs generating electiciy) Est ‘Aplcabie segment (i place) Tigh 5 Cootam _|see sketen | Miher temperature enter top evel above fermperoure| above | $050) ony segment Hashes ana buzer 7 soun aul Gauges Rppleable sopmentand all segments below | "4° | erystal 5 Fuel lever |Seesketen | lian up sSove "| ttten temperature enters bottom level empty) ani. segment flashes! 11: Monitor panel ights up 4 Lamp switen] — [2 Monitor panel s¥rontlamp + working | — | tarp ight up Switches 5 Heater — | bo Heater fan tow Switch Hi Heater fan high -|- Tights up for spprax 30 sononde when, 5 reheating |When [staring suites turned to MEAT ten ashes | Gregn Droheating | for approx 10 seconds, and goes out to reer a Giapley completion of prehestng When 7 swing tock | swing is | Lights up when swing lock switch is ON toons wr ‘Airave lights up when staring switch i ot ‘ame 2 ays lights up when starting switch i 8 Barry — [Wetting is ON Goortutwnenenaneresened | Res roe |detective | Display Caution When normal: OFF ° Engine oil | o£4 Hoenn | renee ig any abnormality when en (05 kgf re ig any abnormality when engine is pressure | (OS em? | running, buzzer sounds) 10-66 cDs0R-1STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM SENSOR ‘The signal from the sensor is input directly to the panel. ‘There are two types of sensors: contact type and resistance type. ‘One side of the contact type sensors is always connected to the chassis ground. Display category | Type ofsensor | Sensor method ‘When normal When abnormal Caution Engine oil pressure Contact OFF (open) ON (closed Coolantremperature| Resistance = = Gauge Fue! level Resistance = = ENGINE OIL PRESSURE SENSOR Structure of clea 1. Pup 4. Diatvagm 2 Contact sng ®: Spring 3 Comat &: Tormeal COOLANT TEMPERATURE SENSOR \ 3 im Soe =f) 1. comnectr 2 Bey 3. Thermistor ‘CD6OR-1 10-67‘STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM FUEL LEVEL SENSOR i ' Aca sus 1. Float 3. Cover 2. Connector 4. Variable resistance 10-68 (CDEOR-120 TESTING AND ADJUSTING ‘STANDARD VALUE TABLE Standard value table for engine FB1ALCE PANS vernninrr 20-2 Standard value table for chassis, related parts : semen 20 3 Standard value table for electrical parts ..20- 8 TESTING AND ADJUSTING 20-101 TROUBLESHOOTING 20-201 Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting, 1. The standard value for a new machine given in the table is the value used when shipping the ma- chine from the factory and is given for reference. Itis used asa guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. Itis used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims. A. Wien carrying out testing, adjusting, oF troubleshooting, park the machine on level ground, inset the safety pins. and use blocks to prevent the machine from moving. A. When carrying out work together with other workers, always use signals and do not let uneutho- tied people nesr the machine. By Wien checking the water level, always wait for the water to cool down. If the radiator cap is re- moved when the water is still hot, the water will purt out and cause burns, By Be careful not to get caught in the fan fan belt or other rotating pars. cD6OR-I y eSTESTING AND ADJUSTING ‘STANDARD VALUE TABLE FOR ENGINE RELATED PARTS STANDARD VALUE TABLE FOR ENGINE RELATED PARTS Applicable model cosor-t Engine SEDTO2E-1-A tem Measurement conditions vunit | Standard yaiue, | Servic mit av sudeen acceleration Beser | Max 5.0 1s At high iting Bosch | pax. 05 20 Intake vave mm | 025 - eon Exhaust vate mm | 081 - (Diterence be- Compression pressure | Oil temperature: 40 - 60°C MPa Min. 2.4 tween cylinder) SRNR IY | RhgtneSpacd 265 ogenn | ain zie) 18, Blow-by pressure |(Watertemperatue: Operating range) | pa | Max. 4g0 x0 Barigecane | Ateh eee wba] tes 53 oer temperature: Operating range) wpe, | 032-058 02s it pressure wpem) 85-85) 2B wpe, | Min-o.12 08 At tow iting (SAE WO) seta] Bip 932 208 Cittemperature | Whole speed range inside ci pan) © | e010 120 Before compression top dead center Fuslinjetion timing [Bforecompression tondeadcenter fy | yyy wet Fan pulley. \uto-tension: - Ldieaineay tension pulley aaa rence wit inger Fan beltension [pressed with inger ecutive | ee conpresson 1-18 12-18 sen 20-2 CD6OR-1TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ‘Applicable model PCE Serial No 7801 and up oe Standard value | Service limit s] tem Measurement conditions unit] Standard valve | Service i 3 High idling + Hydraulic oil temperature: 45 - 55° 2,200 + 60 & n | Engine water temperature: Within |) s.999 g |Lowiating operating range me i = B | at -pump reliet + pump relief: Swing clit Engine must not eta > £ ato Dump body contra | vse 2 | ; mmlafelelale|s Swing contro valve | it [Duma body pedal__| «Center of ever knob 3025 3025 ‘Measure max. value wo end of ravet | | fF" ¢¢ [Swing controttever | “Engine stopped 3210 | 95270 & + Excluding neutral play & [Travel controltever |" mousing neutral play wore | 10278 [Fuel control ever 1 +t + 8 [{Slow — Full) mm eae) 1802 15 3 [play ot controliever | E | -Oump body, swing | Max.5 Max. 5 Travel lever Max. 10 Max. 10 Fuel contol ever 2022 Dump body pedal e {Ointempersture: 45 55°C se = raise |“ Pestle camer of con Max seg | Max 588 + Mesbre max value to end of travel Max. 58.8 Max. 58.8 Ged N Max. 6.0) (Max. 6.0) 9) Wax. 138 Max. 198 Swing ‘Max 2.0) {Max 20) zg | Max. 24.5 Max. 24.5 Travel (Max. 2.5) (Max. 2.5) & | Fuel control lever Max. 68.6. ‘Max. 68.6 S | stow Ful) | {idee} | (Maxi?) $ | Dump body + Relief pressure with engine at full w.23%175°3) | 17.280752) gemeee throm eee only lac ove 5 | swing + Oil temperature: 45 ~ 55°C ty seats) | 17.2:28075"%) 3 [ Tevet (roieton one sien] ®™? | 38.3.8,670.%) | 96:9°980370%8) = | Control pump 2.9 - 3.9 {30 - 40} | 2.9-3.9 {30-40} ‘co6oR-1 20-3 ®TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model PC6OR-1 cas oe tem Measurement conditions ‘Standard value Unit) fornew machine Service limit value’ Time taken to start swing sm 1 Engine at fll throne 1 Hiydtautic ol emportire: 5 sec “ime taken to swing 80° ftom starting postion sec| ass04 a7 Time taken to swing ‘swing 1100695, Empty Engine at full throtle ‘Hydraulic ol temperature: 45 ~ 55°C + Swing one turn, then measure time taken to swing next 5 turns Sec.| 8020 20220 Hydraulic drift of swing | + Engine stopped | + Hydraulic olf temperature: 45 ~ 95°C | | Set machine on 15° slope with upper structure to front. + Make counter marks on swing circle Outer face and track frame + Measure distance that counter marks move apart after 15 minutes. (ea. a 0) Leakage from to start swing Engine at high idling “Hydraulic olf temperature: 45 ~ 55°C + Swing lock switch ON ‘Relieve swing circuit, lenin] Max. 3.5 70 Travel speed Trav Low we12 See. 4 + Hyrauioll emperature: abn gare High Run up fe atleast om, and_ [speed ‘measure time taken to tie 20 m on fiat ground: a5 209 10 cp60R-1TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model PCeOR-A cen Measurement conditions te sure ‘Unit| Standard value ‘Service limit fornew machine value |-Empwy + Engine a full theowie \yoraulic oll temperature: 45 ~ 55°C ravel speed at Hi ‘Run up for atleast 10 m, and mes- sure deviation when traveling next 20 |™™ mon flat ground + Use shard horizontal surface. “Travel deviation ‘Max. 100 Max. 110 ‘s#Measure dimension & eee AS rae co “8 spe Travel mm ° Leakage of travel = ee lie 2 ez0063¢ | + Engine at high iating + Hyaraulle oi temperature: 45 - 55° 1 dee shoes and relieve travel circu. CD6OR-1 20-7‘TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS STANDARD VALUE TABLE FOR ELECTRICAL PARTS Sys 4 [Connector] "Bae Measurement pone’ fon Judgement tabl ST Name of component [Nee "Ban Judgement table peers If the condition is as shown in the table | 1)Turn starting z | Below i tenorm | caieh OFF | | ayBisconnect Pra. £ | [Engine oi! | Engin ol pressure pis | |[pretste | pexween [No continuity santor 8 | |Rormats_| terminal — |_| [Engine ot chassis, E | forsatire' | stouid| continiy «= | When engine is running (72 throttle or | Stan engine g | above ner “295 Alternator ms | 88 | S°iFthe battery is ld or ater starting in old areas, the voltage may not se for 38 SSme'tme © | ithe condition is as shown in the table | 1/Tur starting & | below iis norma! Switch OFF 5 aybiecannect Engine water 2 = ‘Approx ‘connector K1 temperature sensorr n 2 2c Between 40k Z ce] 0) Approx | = {Loe sigs B | If the condition is as shown in the table | 1)Turn starting 5 below, it is normal! ‘switch OFF. 3 aibisconnest es | & |r aprox ]| “connectors P5 - | Fue level sensor ge | eB if Fu | perween | AR connec z e le PRET tps (male) - 2 es [[emmry | Potmat ge 5 i | B88 5 = || lfthe condition is as shown in the table | 1)Turm staring = = | below, it is normall ‘switch OFF” ee aBiaconnet 2 [Sei connector XS. Swing look switch xs | 8 | SH] ceuween [No continuity = [swims ] (0-0 2 Lae Continuity Ifthe condition is a shown inthe table | 1/Tur startin below, it is normal! ‘switch ore aibisconnest [Switen | Bewween No connector P2 OE |e | continuity Lamp switch P2 Berween iswinen 1] 83888" | Continuity Berween switch 2] Beeyee™,. [Continuity Ifthe condition is as shown inthe tabi | 1)Turn stenting B | below iis norma Butch OF Z ||Se" |.,.883 cw loom] | venecerr Heater switch P3 5 |e (0-2-1) continuity © |ISwich | Between leon, | B {ito (3)~ (4) tinuity: 5 ||swich | Between | 7 egweee [continuity 20-8 osor-tTESTING AND ADJUSTING Tools for testing, adjusting, and troubleshooting 20-102 Measuring exhaust COlOF ninnnnnnnnannnennnnn . 20-103 Adjusting valve clearance 20-104 Measuring compression pressure .. 20-105 Measuring blow-by pressure wun sone 20-108 Testing and adjusting fuel injection timing... ss 20-107 Measuring engine oil pressure : 20-108 Testing and adjusting air conditioner compessor belt tension 20-108 Testing and adjusting engine stop solenoid linkage 20-110 ‘Testing and inspecting HST hydraulic pressure 20-112 Testing control pump circuit pressure 20-116 Testing solenoid valve output pressure nnn 20-118 Measuing PPC valve output pressure (for swing) 20-120 Adjusting PPC valve (for swing) 20-120 Testing travel deviation. 20-121 Measuring oil leakage 1 20-122, Releasing remaining pressure in hydraulic circuit, 20-124 Testing clearance of swing circie bearing Testing and adjusuing track shoe tension Bleeding air... ‘CD6OR-1 20-101TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ( TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Check oF measure- 4] PartNo. ae a peor imass symbot] Part N Part Remark 7 | 799-203-9000 | Mutt-tachometer Diialdeplay [60-200 9m Engine speed a ++ Measure with ahometr ne 2 [795-790-2500 | Adapter Le eames Costantandoirtempers: |g |7e9-103-1502 | Digital temperature gauge | 29.9 — +1.266%0 Saar sono eoas oer Pressure gauge; 2553 02508 MPa 1 [7382075002 _| Hyctrauti tost See it kaon 780-261-1203 | Digital hydraulic tester | Pressure gauge: 49 MPa (500 kglem?) Oit pressure c [2 |ree-401-2320 | Hydraulic gauge Pressure gauge: 10 MPa 0 en? 12x 15 (female PT V8) for pa both male and female s 18x 15 female PT U8) for 790-261-1321 both male and female ' 1 [795-502-1590 | Compression gauge 0-69MP3 0-79 kolem* Compression pressure | 0 }—+ |__| 0. 6 8 MPa 0-7 kalems) 2 [795-502-1700 [Adapter 799-201-1504 | Blow-by checker 0-49 MPa (0-500 mmHiO) Blow-by pressure e 796-780-1950 | Too! For 102 series engine Vanve clearance F_ [SommECIV | Fester gouge = 1 [798-201-8000 [Handy Smoke Checker _| Discoloration O- Tose Exhaust color 6 7 [Commercial | smnoxe moter (Discoloration % «1/10 vate Bosch ingen 798-264-0021 | o-296N(0- 2049) Operating effort 4 Push-pull scale 798-264-0091 [0-490N (0-50K9) Stroke, hydraulic aft, 1_[Svatapie [Seale | = Workeauipmentspeed | a _[Sammercialy | Stop watch = 799-601-8000 _| Adapter assembh Ss Troubleshooting of wiring | [SESOrSH—O | ASeP! ~ hamesses and sensors aaa ee ] = meatuneevaeees S| t [ranzeeoor | Tester = 20-102 ‘CDEOR-1TESTING AND ADJUSTING MEASURING EXHAUST COLOR * ‘When measuring in the field where there is no air or electric power supply, use Handy Smoke Checker G1; when recording formal data, use ‘Smoke Meter G2. Raise the coolant temperature to the operating range before measuring By be careful not to touch any hot parts wien re- moving or installing the measuring tools. Measuring with Handy Smoke Checker G1. 1) Install filter paper to Handy Smoke Checker Gt 2) Insert the exhaust gas suction port into the exhaust pipe. 3) Accelerate the engine suddenly, and operate the handle of Handy Smoke Checker G1 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. ssuring with Smoke Meter G2 1) Insert the probe of Smoke Meter G2 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 G2. Koop the preesure of the air cupply bolow 1.47 MPal15 kg/em’) 3) Connect the power cord to the AC socket. % 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. % Fitthe filter paper securely so that the ex- haust gas cannot leak 5) Turn the power switch of Smoke Meter G2 ON, 6) Accelerate the engine suddenly, and depress the accelerator pedal of Smoke Meter G2 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 un- used filter paper inside the filter paper holder, and read the value shown.

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