PC12R 8

SEBM013103
MACHINE MODEL SERIAL NUMBER

PC12R-8 10001 and up
PC15R-8 10001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• PC12R-8, PC15R-8 mount the 3D68E-3 engine.

For details of the engine, see the 68 Series Engine Shop Manual.
© 2000 1
All Rights Reserved 00-1
Printed in Japan 09-00(02) 3
CONTENTS
No. of page
01 GENERAL ............................................................................................................ 01-1
10 STRUCTURE AND FUNCTION ............................................................ 10-1
20 TESTING AND ADJUSTING ................................................................. 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40 MAINTENANCE STANDARD ............................................................... 40-1
90 OTHERS ............................................................................................................... 90-1
00-2 PC12R, 15R-8

2
PC12R, 15R-8 00-2-1
3
00-2-2 PC12R, 15R-8
3
SAFETY SAFETY NOTICE
SAFETY
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 A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first 20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit. tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before 21. When assembling or installing parts, always
carrying out any work on the oil or water use the specified tightening torques. When
circuits. installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage. 23. When measuring hydraulic pressure, check
Always use lifting equipment which has that the measuring tool is correctly assem-
ample capacity. bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate 24. Take care when removing or installing the
slowly to prevent the component from hit- tracks of track-type machines.
ting any other part. Do not work with any When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
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 mini-
mum of gasoline when washing electrical
parts.
00-d.
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.
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.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....I is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one
Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
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
See the page number on the bottom of the Symbol 1 Item Remarks
page. File the pages in correct order.
A/
Special safety precautions are
Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3 or other precautions for pre-
Item number (IO. Structure

and Function)
* I Caution serving standards are neces-
sary when performing the
work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
TT T Places that require special at-
Tightenin:
Unit number (I. Engine) tention for the tightening
w torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for & Coat
+ hesives and lubricants, etc.
each item.
Places where oil, water or fuel
must be added, and the ca-
Additional pages: Additional pages are indi- pacity.
cated by a hyphen 6) and number after the
Places where oil or water
page number. File as in the example. must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
10-4-I -
> Added pages -c~~~~~~::
1O-4-2
1o-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to sult in a dangerous accident.
the table below:
4) Do not sling a heavy load with ropes form-
Wire ropes
ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
Rope diameter l- Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN {IO00 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2 to 19.6 kN (2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 (1000 kg) when two ropes make a 120”
4.4 hanging angle. On the other hand, two

20 43.1
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN (2000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
50 274.6 28.0
60 392.2 40.0
Ir The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
L I I I I I
2) Sling wire ropes from the middle portion 30 60 90 120 150
of the hook. Lifting mole (deereel SAD00480
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTlNG 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 Type 2
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 (I) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
CWPOfi391 CWPO6392
2) Hold in the condition in Step I), and push 2) Hold in the condition in Step I), and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
CWPO6393 CWPO6394
Hold in the condition in Steps 1) and 21, and 3) Hold in the condition in Steps 1) and 21, and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
CWPO6395 CWPO6396
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Me 2
l Hold the mouthpiece of the tightening por- l 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 (I) contacts contact sur- ing prevention ring (I) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
S
‘L
:
E
8
CWP06391 CWP06392
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
* The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
* For coating materials not listed below, use the equivalent of products shown in this list.
Category :omatsu cods, Part No. Q’W Container Main applications, features
v Used to prevent rubber gaskets, rubber

LT-1A 790-l 29-9030 150 g Tube
cushions, and cock plug from coming out.
9 Used in places requiring an immediately

effective, strong adhesive. Used for plas-
790-129-9050 20 9 blyethylene
LT-IB tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
1 Features: Resistance to heat and chemi-

blyethylene cals
LT-2 0994040030 50 g container 1 Used for anti-loosening and sealant pur-
pose for bolts and plugs.
i 790-l 29-9060 id hesive: 1 Used as adhesive or sealant for metal, glass

/I-Set of adhe- 1 kg and plastic.
LT-3 sive and lardening Can
hardening agent:
agent) 500 g
Adhesives
olyethylene 1 Used as sealant for machined holes.
LT-4 i~90-129-9040 2wg container
Holtz n Used as heat-resisting sealant for repair-

i ‘90-1269120 75 g Tube
MH 705 ing engine.
p Quick hardening type adhesive

Three bond olyethylene ) Cure time: within 5 sec. to 3 min.
7'90-129-9140 50 g
1735 container b Used mainly for adhesion of metals, rub-
bers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength after 30 min-
Aron-alpha olyethylene
'90-129-9130 29 utes)
201 container
Used mainly for adhesion of rubbers, plas-
tics and metals.
Features: Resistance to heat, chemicals

Loctite olyethylene
‘9A-129-9110 50 cc Used at joint portions subject to high tem-
648-50 container peratures.
Used as adhesive or sealant for gaskets

LG-1 ’ ‘90-129-9010 200 g Tube
and packing of power train case, etc.
Features: Resistance to heat

Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant
LG-3 790-I 29-9070 Can to prevent seizure.
1 kg
Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-10
FOREWORD COATING MATERIALS
Q’W Container Main applications, features
l Features: Resistance to water, oil

l Used as sealant for flange surface, thread.
200 g Tube l Also possible to use as sealant for flanges
with large clearance.
l Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe

Polyethylene joints, flanges.
790-129-9080 1 kg container l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
l Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940~0011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
l Features: Silicon based, quick hardening

type
09920-00150 150 g Tube
I I
LG-7 l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
l Used as heat-resisting sealant for repairing

/ 100 g Tube engine.
l Used as lubricant for sliding portion (to pre-

LM-G 09940-00051 60 g rlane 1 vent from squeaking). _
Molybde-
num
disulphide l Used to prevent seizure or scufflrng of the
lubricant LM-P 09940-00040 200 g thread when press fitting or shrink fitting.
I l Used as lubricant for linkage, bearings, etc.
SYG2-4OOLI l General purpose type

SYG2-35OLI
G2-LI SYG2-4OOLI-A Various
SYG2-16OLi
SYGA-16OCNLI
l Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease
I SYG2-350CA steam.
GS-CA SYG2-4OOCA-A Various Various
I I
SYG2-EOCA
SYGAl6OCNGa
400 g l Used for places with heavy load

1 M;zE: 1 SYG2-400M (IO per Belows type
case)
00-l1
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

of bolt across flats
mm mm Nm bm
6 10 13.2+ 1.4 1.35f0.15
8 13 31+3 3.250.3
10 17 66f7 6.7kO.7
12 19 113+10 11.5&l
14 22 177f19 18+2
16 24 279+30 28.5+3
18 27 382f39 39+4
20 30 549+59 56f6
22 32 745f83 76f8.5
24 36 927+103 94.5f 10.5
27 41 1320f140 135+15
30 46 1720+190 175+20
33 50 2210f240 225+25
36 55 2750f290 280+30
39 60 3290f340 335+35
Thread diameter Width

of bolt across flats
mm mm Nm bm
6 10 7.85f1.95 0.8f0.2
8 13 18.6f 4.9 1.9+ 0.5
10 14 40.2k5.9 4.1f0.6
12 27 82.35k7.85 8.4+0.8
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 1 Tighteni g torque

mm mm Nm knm
14 19 24.5f4.9 2.5kO.5
18 24 49f 19.6 5f2
22 27 78.5f 19.6 8+2
24 32 137.3f29.4 14+3
30 36 176.5k29.4 18+3
33 41 196.1+49 20f5
36 46 245.2+49 25+5
42 55 294.2+49 30f5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Ir 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
IO 14 65.7f6.8 6.7kO.7
12 17 112k9.8 11.5&l
16 22 279f29 28.5f3
TABLE OF TlGHTENtNG TORQUES FOR O-RING BOSS PIPING JOtNTS

Ir Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Nominal No.
mm mm Nm kgm
02 14 34.3f 4.9 3.5kO.5
03,04 20 Varies depending on 93.1k9.8 9.5fl
05,06 type of connector. 142.1f19.6 14.5+2
10.12 ;: 421.4zk58.8 43+6
14 42 877.1f132.3 89.5f13.5
TABLE OF TtGHTENtNG TORQUES FOR O-RING BOSS PLUGS

Ir Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Nominal No.
mm mm Nm kgm
08 8 14 7.35+ 1.47 0.75f0.15
10 IO 17 11.27f 1.47 1.15+0.15
12 12 19 17.64k1.96 1.8f0.2
14 14 22 22.54k1.96 2.3kO.2
16 16 24 29.4f 4.9 3zko.5
18 18 27 39.2k4.9 4kO.5
20 20 30 49f4.9 5kO.5
24 24 32 68.6k9.8 7fl
30 30 32 107.8f 14.7 llf1.5
33 33 - 127.4f19.6 13+2
36 36 36 151.9+24.5 15.5f2.5
42 42 - 210.7f29.4 21.5+3
52 52 - 323.4f44.1 33+ 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 10+2 1.02 + 0.20
8 24 f 4 2.45 f 0.41
10 43 If:
6 4.38 f 0.61
12 77 +12 7.85 + 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
6 8+2 0.81 + 0.20
8 10 f2 1.02 f 0.20
10 12 f2 1.22 zk0.20
12 24 + 4 2.45 f 0.41
14 36 f 5 3.67 + 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
l/l6 3+1 0.31 f 0.10
'II8 8k2 0.81 + 0.20
l/4 12 f 2 1.22 +-0.20
318 15f2 1.53 rf:
0.41
l/2 24 + 4 2.45 f 0.41
314 36 f 5 3.67 + 0.51
1 * 60 + 9 6.12 f 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
Applicable circuit
Starting, lighting, signal etc.
Lighting, signal etc.
Charging and signal
Starting (Glow plug)
Starting
Starting
Starting
CLASSIFICATION BY COLOR AND CODE
II22
Circuits
Chazng 1 Gr;d 1 Starg Lighting Instrument Signal Other
p%r- Classi-
rcation
R Y G L
White Black Black Red Yellow Green Blue
WR - BW RW YR GW LW
White & Red - Black &White Red & White Yellow & Red Green & White Blue & White
WB - BY RB YB GR LR
White & Black1 - IBlack & Yellow Red & Black Yellow & Black Green & Red Blue & Red
WL - Bf? RY YG GY LY
4
White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
WG 1 - 1 - RG YL GB LB
White & Green1 - 1 - Red & Green Yellow & Blue Green & Black Blue & Black
RL WV GL -
Red & Blue Yellow&White Green & Blue -
00-15
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
l 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 @I, then draw a perpendicular line
down from @I.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches j 1 mm = 0.03937 in
0 1 2 3 4 5; 6 7 8 9
0 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 0.512 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
0 i
50 1.969 2.008 2.047 2.087 2.126
.... .... .... .... .......... ................... ........ ............. .. ...... ...... ... (2.1651 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.736 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 0.866 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 7.457 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 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
\
0 0 2.20 4.41 6.61 8.82 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 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Literto U.S. Gallon

le = 0.2642 U.S. Gal
2 3 5 6 7 8 9
0 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
so 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Literto U.K. Gallon

le = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
\
0 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 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 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
so 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 606.3 607.6 614.8 622.0 629.3 636.5 643.;
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm* to lb/in*
lkg/cm2 = 14.2233 lb/in2
A
0 1 2 3 4 5 6 7 8 9
\
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

IO 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F
“C “F “C “F “C “F . “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 92 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 46 118.4 28.3 93 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 94 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 95 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 96 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 97 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 99 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 59 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -6 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 29 82.4 17.2 63 145.4 36.7 99 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 66 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 39 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 166 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 79 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 90 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with lnternatinal System of units WI.
As for reference, conventionally used Gravitational System of units are indicated in parentheses { I.
Example:
N {kg)
Nm {kgml
MPa {kg/cm21
kPa immHz01
kPa immHg1
kw/rpm {HP/rpml
glkwh {g/HPhI
00-22
GENERAL
01 GENERAL
General assembly drawing .......................... 01- 2

Specifications ............................................... 01- 6
List of lubricant and water ........................... 01-10
PC12R, 15R-8 01-1

GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

PC12R-8 CANOPY SPECIFICATION
01-2 PC12R, 15R-8

PC12R-8 CAB SPECIFICATION
PC12R, 15R-8 01-3

PC15R-8 CANOPY SPECIFICATION
01-4 PC12R, 15R-8

PC15R-8 CAB SPECIFICATION
PC12R, 15R-8 01-5

GENERAL SPECIFICATION
SPECIFICATIONS
PC12R-8
PC12R-8
Machine model
Canopy specification Cab specification
Serial number 10001 and up
Operating weight kg 1,300 [1,340] 1,390 [1,430]
Bucket capacity m3 0.04 0.04
Max. digging depth mm 1,900 1,900
Max. vertical wall depth mm 1,505 1,505
Max. digging reach mm 3,515 3,515

Working ranges
Max. reach at ground level mm 3,425 3,425
Max. digging height mm 3,335 3,335
Max. dumping height mm 2,335 2,445

Performance
Bucket offset mm 390 (L.H.)/590 (R.H.) 390 (L.H.)/550 (R.H.)
Max. blade lifting amount mm 175 175
Max. blade lowering amount mm 155 155
Max. digging force kN{kg} 12.9 {1,315} 12.9 {1,315}
Swing speed rpm 8.7 8.7
Swing max. slope angle deg. 25 25
Travel speed (Hi/Lo) km/h 4.0/2.1 4.0/2.1
Gradeability deg. 30 30
Ground pressure
(standard shoe width: 200 mm) kPa{kg/cm2} 28.4 {0.29} 30.4 {0.31}
Overall length (for transport) mm 3,495 3,495
Overall width mm 1,000 1,000
Overall height (for transport) mm 2,240 [2,230] 2,455 [2,445]
Overall height (to top of canopy) mm 2,240 [2,230] 2,455 [2,445]

Ground clearance of
counterweight mm 435 435
Dimensions
Min. ground clearance mm 205 205
Tail swing radius mm 1,070 1,070

Min. swing radius of work
equipment (at boom swing) mm 1,310 [960] 1,530 [1,320]
Height of work equipment at min.

swing radius mm 2,615 2,615
Length of track on ground mm 1,020 [1,005] 1,020 [1,005]
Track gauge mm 800 800
Track length mm 1,395 [1,375] 1,395 [1,375]
Blade width x height mm 1,000 x 250 1,000 x 250
[ ] : Steel shoe specification
01-6 PC12R, 15R-8

PC12R-8
Machine model
Model 3D68E-3G
Type 4-cycle, water cooled, in-line, turbulence chamber
No. of cylinders - bore x stroke mm 3 – 68 x 72
Piston displacement l {cc} 0.78 {784}
Firing order 3–1–2
Flywheel horsepower kW/rpm{HP/rpm} 10.3/2,450 {13.8/2,450}

Performance
Maximum torque Nm/rpm{kgm/rpm} 47.1/1,800 {4.8/1,800}

Engine
High idling speed rpm 2,600
Low idling speed rpm 1,350
Min. fuel consumption ratio g/kWh{g/HPh} 265 {197.8}
Starting motor 12V, 1.0 kW
Alternator 12V, 20A
Battery 12V, 45Ah
Radiator type CD-2

Undercarriage
Sliding plate 1 on each side
Track roller 3 on each side
Track shoe Rubber crawler [assembly type, double grouser,

32 each side]
Type x no. Gear type 3–pump x 1
Hydraulic pump
Delivery l /min 26.4 + 10.8 + 6.5

Set pressure
• Travel, work equipment MPa{kg/cm2} 19 {193.8}
2
• Swing MPa{kg/cm } 12.5 {127.5}
• PPC MPa{kg/cm2} 3.5 {35.7}
Hydraulic system
Type x no. 9–spool type x 1

Control
valve
Hydraulic assist type (boom, arm, bucket, swing)

Control method Direct control type (travel, brade, boom swing)
Hydraulic
Travel motor Piston type x 2

motor
Swing motor Orbit-roll type x 1
Hydraulic cylinder Reciprocating piston

Hydraulic tank Box-shaped, close
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled
PC12R, 15R-8 01-7

PC15R-8
PC15R-8
Machine model
Operating weight kg 1,455 [1,495] 1,545 [1,585]
Bucket capacity m3 0.044 0.044
Max. digging depth mm 2,155 2,155
Max. vertical wall depth mm 1,560 1,560
Max. digging reach mm 3,675 3,675

Working ranges
Max. reach at ground level mm 3,590 3,590
Max. digging height mm 3,455 3,365
Max. dumping height mm 2,470 2,385

Performance
Bucket offset mm 390 (L.H.)/590 (R.H.) 390 (L.H.)/550 (R.H.)
Max. blade lifting amount mm 280 280
Max. blade lowering amount mm 155 155
Max. digging force kN{kg} 12.9 {1,315} 12.9 {1,315}
Swing speed rpm 8.7 9.0
Swing max. slope angle deg. 25 25
Travel speed (Hi/Lo) km/h 4.7/2.5 4.7/2.5
Gradeability deg. 30 30
Ground pressure
(standard shoe width: 230 mm) kPa{kg/cm2} 27.5 {0.28} 29.4 {0.30}
Overall length (for transport) mm 3,535 3,535
Overall width mm 1,030 1,030
Overall height (for transport) mm 2,240 [2,230] 2,455 [2,445]
Overall height (to top of canopy) mm 2,240 [2,230] 2,455 [2,445]

Ground clearance of
counterweight mm 435 435
Dimensions
Min. ground clearance mm 205 205
Tail swing radius mm 1,070 1,070

Min. swing radius of work
equipment (at boom swing) mm 1,340 [980] 1,520 [1,270]
Height of work equipment at min.

swing radius mm 2,750 2,750
Length of track on ground mm 1,020 [1,005] 1,020 [1,005]
Track gauge mm 800 800
Track length mm 1,395 [1,375] 1,395 [1,375]
Blade width x height mm 1,030 x 250 1,030 x 250
01-8 PC12R, 15R-8

PC15R-8
Machine model
Model 3D68E-3H
Type 4-cycle, water cooled, in-line, turbulence chamber
No. of cylinders - bore x stroke mm 3 – 68 x 72
Piston displacement l {cc} 0.78 {784}
Firing order 3–1–2
Flywheel horsepower kW/rpm{HP/rpm} 11.2/2,600 {15.2/2,600}

Performance
Maximum torque Nm/rpm{kgm/rpm} 47.1/1,600 {4.8/1,600}

Engine
High idling speed rpm 2,775
Low idling speed rpm 1,350
Min. fuel consumption ratio g/kWh{g/HPh} 265 {197.8}
Starting motor 12V, 1.0 kW
Alternator 12V, 20A
Battery 12V, 45Ah
Radiator type CD-2

Undercarriage
Sliding plate 1 on each side
Track roller 3 on each side
Track shoe Rubber crawler [assembly type, double grouser,

32 each side]
Type x no. Variable poston type x 1 + gear type x 1
Hydraulic pump
Delivery l /min 40.8 + 6.9

Set pressure
• Travel, swing, work MPa{kg/cm2} 18.6 {190}
equipment
• PPC MPa{kg/cm2} 2.9 {30}
Hydraulic system
Type x no. 9–spool type x 1

Control
valve
Hydraulic assist type (boom, arm, bucket, swing)

Control method Direct control type (travel, brade, boom swing)
Hydraulic
Travel motor Piston type x 2

motor
Swing motor Orbit-roll type x 1
Hydraulic cylinder Reciprocating piston

Hydraulic tank Box-shaped, close
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled
PC12R, 15R-8 01-9

GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER
AMBIENT TEMPERATURE CAPACITY

RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104°F
–30 –20 –10 0 10 20 30 40°C Specified (l) Refill (l)
PC12R PC15R PC12R PC15R
SAE 30
SAE 10W
Engine oil pan 3.0 3.0 3.0 3.0
SAE 10W-30
Engine oil SAE 15W-40
Final drive case

(each)
SAE 30 0.3 0.3 0.3 0.3
Track roller
(each)
Idler (each) 0.044 0.044 — —

Carrier roller Grease NOK SEALU S-1 or equivalent
(each) 0.036 0.036 — —
Hydraulic SAE 10W 24 24 12.7 12.7

system Engine oil
ASTM D975 No. 2

Fuel tank Diesel fuel 19 19 — —
k1
Cooling system Water Add antifreeze 3.4 3.4 — —
k1: ASTM D975 No. 1
REMARK
• When fuel sulphur content is less than 0.5%, • There is no problem if single grade oil is mixed
change oil in the oil pan every periodic main- with multigrade oil (SAE10W-30, 15W-40), but
tenance hours described in this manual. be sure to add single grade oil that matches
Change oil according to the following table if the temperature in the table on the left.
fuel sulphur content is above 0.5%. • We recommend Komatsu genuine oil which
has been specifically formulated and ap-
Change interval of oil proved for use in engine and hydraulic work
Fuel sulphur content
in engine oil pan equipment applications.
0.5 to 1.0 % 1/2 of regular interval
Specified capacity: Total amount of oil including
Above 1.0 % 1/4 of regular interval oil for components and oil in
piping.
• When starting the engine in an atmospheric Refill capacity: Amount of oil needed to re-
temperature of lower than 0°C, be sure to use fill system during normal in-
engine oil of SAE10W, SAE10W-30 and spection and maintenance.
SAE15W-40 even though an atmospheric tem-
perature goes up to 10°C more or less in the ASTM: American Society of Testing and Mate-
day time. rial
SAE: Society of Automotive Engineers
• Use API classification CD as engine oil and if API: American Petroleum Institute
API classification CC, reduce the engine oil
change interval to half.
01-10 PC12R, 15R-8

10 STRUCTURE AND FUNCTION
Power train.. .................................................. IO- 2

Swing circle .................................................. IO- 3
Track frame and recoil spring.. .................... IO- 4
Hydraulic piping ........................................... IO- 5
Hydraulic tank.. ............................................. IO- 6
Hydraulic pump.. .......................................... IO- 8
Control valve (PC12R) .................................. IO-12
CLSS (PC12R). ............................................... IO-20
Control valve (PC15R) .................................. IO-44
CLSS (PC15R). ............................................... IO-52
Center swivel joint.. ...................................... 1O-73
Swing motor.. ............................................... IO-75
Travel motor ................................................. IO-77
Valve control ................................................. 1O-80
PPC valve ...................................................... 1 O-82
Work equipment ........................................... IO-86
Machine monitor system ............................. IO-87
PC1 2R, 15R-8 10-l

0
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
- Swine control
SXPO7341
1. Idler 6. Engine
2. Control valve 7. Hydraulic pump
3. Center swivel joint 8. Travel Hi/Lo selector valve
4. Swing motor 9. Swing circle
5. Travel motor
1o-2 PC 12R, 15R-8

0
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
ii
D-D LA
SDP03305
1. Swing circle outer race

2. Ball bearing
3. Swing circle inner race
PC1 2R, 15R-8 1o-3

0
STRUCTURE AND FUNCTION TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING
l This drawing shows the machine of steel shoe

specification.
El SDP03306
1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Sliding plate 8. Recoil spring
4. Travel motor 9. Spacer
5. Sprocket 10. Gard
1o-4 PC1 2R, 15R-8
0
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
SEP03307
I. Bucket cylinder 7. Hydraulic oil tank

2. Arm cylinder 8. Travel motor
3. Boom cylinder 9. Swing1 motor
4. Boom swing cylinder 10. Center swivel joint
5. Hydraulic oil filter 11. Control valve
6. Hydraulic pump 12. Blade cylinder
PC 12R, 15R-8 1o-5

0
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
A-A
SDP03308
1. Hydraulic tank Specifications

2. Side gauge Capacity: 21.6 e
3. Drain plug Oil level: 12.7 .Q
4. Strainer
5. Filler cap
1 O-6 PC1 2R, 15R-8
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
PC15R-8
Pl P2
PLS
SDP03309
1. Main pump Specifications

2. Control pump Type: PVK-OB-16
Capacity: 16 ~~12.75 cc
a: Port PI (to control valve) Set pressure: Main pump: 18.6 MPa (190 kg/cm*}
b: Port P2 (to control valve) Control pump: 2.9 MPa (30 kg/cm*}
c: Port Sl (from hydraulic tank)
d: Port PLS (from control valve LS port)
1 O-8 PC12R, l!.iR-8

0
HYDRAULIC PUMP
A-A SDP02958
I. Input shaft
2. Rocker pin
3. Swash plate
4. Piston
5. Cylinder block
6. Valve plate
7. Spring
8. Control piston
PC1 2R, 15R-8

1o-9
0
1. Operation
. This pump has the functions of load response con-
trol and constant horsepower control.
There are nine pistons (2) assembled inside cyl-
inder block (I), and the end face is in contact with
valve plate (3). Suction port A and discharge port
B are provided in valve plate (3). In this structure,
swash plate (4) is secured to the body at a certain
angle, and pistons (2) rotate along swash plate
(4).
. By rotating shaft (5), cylinder block (I) rotates, and
pistons (2) assembled inside cylinder block (1)
move in a reciprocal motion following swash plate
(4). This movement performs the suction and dis-
charge action of the pump.
. Each of the nine pistons (2) performs one suction stroke I
and discharge stroke for each rotation of cylinder 3 SEP04125
block (I), so the rotation of shaft (5) provides con-
tinuous suction and discharge.
The volume of the stroke of piston (2) depends
on the angle of swash plate (41, so by changing
the angle of swash plate (4) it is possible to change
the amount of the discharge flow.
I- HI SOP02960
2. Constant horsepower control

. Rocker pin (6) is assembled to swash plate (41,
and it is installed to the body to make it possible
to change the swash plate angle. In addition,
swash plate (4) is equipped with spring (7) and
cylinder block piston (21, which acts in the oppo-
site way to spring (7), and the discharge pressure
of PI acts on piston (2).
. When the discharge pressure is lower than the
set value of spring (7), the angle of swash plate
(4) is held at the maximum position by spring (7).
When the discharge pressure becomes greater
than the setvalue of spring (71, the angle of swash
plate (4) is made smaller by total piston force Fl
x a and is held at the position where the discharge
pressure is balanced with the force of the spring.
10-10 PC1 2R, 15R-8

0
. If the discharge pressure rises further, the angle

of swash plate (4) becomes smaller. When this
happens, the length of the arm applying total pis-
ton force Fl is reduced from a to a’, so a larger
force Fl is needed for the angle of swash plate
(4).
. In this way, curve P-Q becomes a curve (constant

horsepower control) which gives effective use of Characteristics of P-Q
(cc/rev)
the engine horsepower.
10.6 16.6
11101 11901
Discharse oi I Pressure Pi MPa(kdctil) SxPO7342
3. Load response control

. When carrying out load response control, the sig-
nal pressure from the LS valve is transmitted to
control piston (81, and control piston (8) pushes
swash plate (4). The angle of swash plate (4)
changes to a point where this force is balanced
with the total force of the spring and piston, so
the discharge amount changes.
. Constant horsepower control is carried out with
priority over load response control, so the dis-
charge amount changes in the range below the
flow at constant horsepower control.
SOP04128
PC 12R, 15R-8 10-11

0
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
PC12R-8
Outline
Ir The sketch shows the standard valve.
Ir The control valve is an add-on type where one
service valve each can be added, so it is pos-
sible to add valves or remove valves if neces-
sary.
Ir The service valve is added on between the
8th, 9th valve (swing, breaker) and cover sub-
assembly.
* The cross section of the service valve is the
same as the bucket valve of the standard
valve.
Names of ports
,I? Pump port (from main pump F) TS. Sealed drain port (to tank)
P2. Pump port (from main pump R) LS. LS port (To pump LS valve)
T. Tank port (to tank P2) Pil. From pilot pump
C. Cooler port (to cooler) Pi2.To PPC valve port P
S. Swing motor suction port Pi3.To travel motor
(to swing motor port S) Br. To swing brake
Al. To arm cylinder head (swing holding brake cancel port)
A2. To swing motor PAl. From arm OUT PPC valve
A3. To travel motor PA2. From right swing PPC valve
A4. To travel motor PA5. From boom RAISE PPC valve
A5. To boom cylinder bottom PA6. From bucket CURL PPC valve
A6. To bucket cylinder bottom PA9. From breaker PPC valve
A7. To blade cylinder head PBI. From arm IN PPC valve
A8. To boom swing cylinder head PB2. From left swing PPC valve
A9. To breaker PB5. From boom LOWER PPC valve
Bl. To arm cylinder bottom PB6. From bucket DUMP PPC valve
B2. To swing motor
B3. To travel motor
B4. To travel motor
B5. To boom cylinder head
B6. To bucket cylinder head
B7. To blade cylinder bottom
B8. To boom swing cylinder bottom
10-n PC1 2R, 15R-8
0
Pi2 Pi3 Pi 1
PA9
A9
PB6
PB5
PA5
P2
PA2
PB2
PA1
PBl
TS
SDP03311
PC12R, 15R-8 10-13

0
CONTROL VALVE
A-A SDP033 12
1. Sefety valve
2. Suction valve (boom, bottom)
3. Suction valve (swing, bottom)
4. Suction valve (boom, head)
5. Suction valve (arm, bottom)
PC1 2R, 15R-8

10-14
0
SOP03313
1. Spool (arm) 6. Spool (bucket)

2. Spool (swing) 7. Spool (blade)
3. Spool (L.H. travel) 8. Spool (swing)
4. Spool (R.H. travel) 9. Main relief valve
5. Spool (boom)
PC12R, 15R-8 10-15

0
CONTROL VALVE
SDP03314
1. Lift check valve 9. Spool (breaker)

10. Pressure compensation valve R
2. Unload valve
3. Pressure compensation valve F (arm) (boom swing, blade)
valve F (L.H. travel) 11. Pressure compensation valve R (bucket)
4. Pressure compensation
valve F (R.H. travel) 12. Pressure compensation valve R (boom)
valve F (boom) 13. Pressure compensation valve R (R.H. travel)
valve F (bucket) 14. Pressure compensation valve R (L.H. travel)
valve F 15. Pressure compensation valve R (arm)
(boom swing, blade) 16. Cooler check valve
lo-16 PC1 2R, 15R-8
0
I- D-D .2 5 E-E
,9
13
F-F
\
‘IO
G-G SDP03315
1. Lift check valve 8. Suction valve (arm)

2. Cooler check valve 9. Pilot pressure check valve
3. Safety valve 10. Pressure compensation valve R (arm)
4. Main relief valve 11. Pressure compensation valve F (arm)
5. Unload valve 12. Spool (swing)
6. Spool (arm) 13. Pilot pressure check valve
7. Check valve 14. Pilot pressure check valve
PC1 2R, 15R-8 10-17

0
L
H-H J-J ‘7
K-K
SOP03316
1. Spool (travel) 9. Spool (boom)

2. Pressure compensation valve R IO. Spool (bucket)
(travel) 11. Pressure compensation valve R
3. Pressure compensation valve F (bucket)
(travel) 12. Pressure compensation valve F
4. Suction valve (boom) (bucket)
5. Check valve 13. Spool (blade)
6. Suction valve (boom) 14. Pressure compensation valve R
7. Pressure compensation valve R (blade, swing)
(boom) 15. Pressure compensation valve F
8. Pressure compensation valve F (blade, swing)
(boom)
lo-18 PC1 2R, 15R-8

0
N-N
1. Spool (swing)
2. Suction valve
3. Spool (breaker)
4. Pressure relief plug
5. Cover assembly
6. Pilot relief valve
7. Travel Hi/Lo selector valve
8. PPC pressure lock valve
PC1 2R, 15R-8

10-19
0
STRUCTURE AND FUNCTION CLSS
CLSS
PClZR-8
1. OUTLINE
FEATURES
The term “CLSS” stands for the “Closed center Load Sensing System” which has the following fea-
tures.
1) Fine-controllability not affected by loads
2) Controllability enabling digging even in the fine control mode
3) Complex operability ensured by flow distribution determined according to the opening areas of
spools during complex operation
STRUCTURE
l The CLSS consists of a gear pump, control valve and actuators.
PLS
.____________--------~ Control valve
PP
-----------
i----------- t
Unload valve -
SXG00597
1O-20 PC1 2R, 15R-8
0
2. BASIC PRINCIPLE
1) Unload valve flow control

. The unload valve is controlled so that LS dif-
ferential pressure APLS, which is the differ-
ential pressure between punp discharge pres-
sure PP and LS pressure PLS (the load of the
actuator ) at the control valve outlet port, be-
comes constant.
(LS differential pressure APLS = Pump dis-
charge pressure PP - LS pressure PLS)
. When the LS differential pressure becomes
lower than the set pressure, the unload valve
reduces the amount of oil drained to the cir-
cuit; when it becomes higher, it increases the
amount of oil.
* For details, see the section on the unload
valve.
Actuator
i i
Pump Passage j j
4 , _____-__----------------~
l-------------___________i I
j /
=-qm
Fixed throttle
PP
:‘> SXG00598
PC1 2R, 15R-8 10-21

0
2) Pressure compensation control

l Valves (pressure compensation valves) are installed at the inlet port side of the spools of the
control valves to balance the loads.
When the actuators are complex-operated, the pressure differences AP at the upstream (inlet)
and downstream (outlet) are made equal by these valves.
In this way, the flow from the pump are distributed in proportion to the opening areas Sl and S2
of each valve.
Load
Load
Actuator
ion
w Unload
valve
6 Pump
SXPO7343
1o-22 PC1 2R, 15R-8
0
3. Functions and operation of each valve

Names of hydraulic circuits and valves
Pi2 Pi3 TS
L
Pi1
A9 Breaker
+& Baom swine cylinder 1. Unload valve

(LS differential pressure +
1.6 MPa {I 6 kg/cm2))
2. Safety valve
+& Blade cylinder (20.6 MPa (210 kg/cm*})
valve
4. Suction valve
5. Main relief valve
.--- Bucket cylinder (18.6 MPa (190 kg/cm2})
PBS
6. Back pressure check valve
(cracking pressure:
0.45 MPa (4.5 kg/cm2})
7. Cooler bypass valve
Boom CY I inder
(cracking pressure:
0.45 MPa (4.5 kg/cm2))
84 (REVERSEI
(2.9 MPa (30 kg/cmY
9 R.H. travel motor
9. PPC basic pressure lock
~4 (FORWARD)
valve
10. Travel Hi-Lo selector valve
83 (REVERSE) 11. Swing holding brake cancel
0 L.H. travel motor check valve
A3 (FORWARD)
$7J Swing motor

._--
PB2
.-KC.
+& Arm cylinder

.---
PBl
SDP04143
PC1 2R, 15R-8 1o-23

0
1. Unload valve
Function
1) In the case of a fixed displacement pump sys-
tem, the unload valve has the functions pro-
vided by a variable displacement pump and
LS valve in a variable displacement pump
system.
l It acts to send pump discharge amount Q
to the tank circuit when the control valve
is at neutral.
. It acts to send oil to the accumulator in
accordance with the size of the opening
of the spool when the control valve is
operated.
. It acts to make LS differential pressure
APLS variable according to the engine
speed (Engine revolution sensing func-
tion).
To actuators
SXPO7344
Operation
When control valve is in neutral
. Pump pressure PP2 is applied to area Sl of l If pump discharge pressure PPI rises, spool
the left end of spool (I), and pressure PPI and (1) moves to the right to the place at which
LS pressure are applied to areas S2 and S3 of PP2xSl=PPlxS2+Loadofspring(2),and
the right end respectively. The load of spring pump circuits PPI and PP2 are connected
(2) is also applied to the right end. through the drilled holes of spool (I) to tank
. Pump pressure PPI and pump pressure PP2 circuit T.
are different because of pressure loss APP l At this time, the differential pressure (LS dif-
made when pump discharge amount Q passes ferential pressure) between pump discharge
through fixed throttle (3) of spool (1). PPI is pressure PPI and LS pressure PLS is set to
equal to PP2 + APP. 1.6 MPa {I 6 kg/cm?
l When the control valve is in neutral, LS pres-
sure PLS is not generated. Accordingly, pump
discharge pressures PPI and PP2 and the load
of spring (2) are applied to spool (I).
1 O-24 PC1 2R, 15R-8

0
2) When the control valve is operated, pump dis-

charge pressure PPl is set to LS pressure PLS
+ 1.6 MPa {I 6 kg/cm2}.
I
\ PP2 T PP1 PLS s3 s2
To actuators
SXPO7345
Operation
. If the control valve is stroked, LS pressure PLS
is generated and applied to area S3 of the
right end of spool (1).
l If the differential pressure between pump dis-
charge pressure PPl and LS pressure PLS
reaches 1.6 MPa (16 kg/cm2}, spool (1) moves
to the left, then the oil, all of which is drained
into circuit T while the control valve is in neu-
tral, is sent to the actuator side.
l This valve operates similarly when the con-
trol valve is operated for fine control and
when the stroke of the control valve is fixed.
l When multiple spools are operated simulta-
neously and the discharge amount required
by those actuators exceeds the pump dis-
charge amount, spool (1) moves further to the
left stroke end, then pump circuits PPI and
PP2 and tank circuit T are shut off, and the all
pump discharge amount flows in the actua-
tors.
PC1 2R, 15R-8 1o-25

0
1
\ PP2 T PPl PLS S3 s2
To actuators
SXPO7346
3) Engine revolution sensing function

. All of pump discharge amount Q passes
through fixed throttle (3) of spool (I). In the
case of a fixed displacement pump system,
the engine speed is in proportion to pump
discharge amount 0, that is, when the engine
speed is high, more amount is discharged,
and when the engine speed is low, less
amount is discharged.
. Accordingly, the amount of oil flowing

through fixed throttle (3) of spool (1) varies
with the engine speed, and pressure loss APP
varies, too.
. The balance of the unload valve is expressed MPa(ka/cm'I

as (PP2 x Sl) = (PPI x S2) + (PLS x S3) + Load 2 A
of spring (2). If this expression is expanded, " ,, 6{,6) .------_--------------____

LS differential pressure APLS = PPI - PLS can z
:
be expressed as PPI - PLS = “‘$ ” + Load "
a
z
.-
of spring. Accordingly, LS differential pres-
i 0. 7(,) .________----/
sure APLS varies with APLS, or with the en- I
ax
z I
gine speed. .- I
I
4 I b
. LS differential pressure APLS varies as shown 0 1300 2800 rpm
Engine speed SXPO7347
in the figure.
1 O-26 PC1 2R, 15R-8

0
2. Introduction of LS pressure
Function
l The LS pressure is the actuator load pressure l With the boom swing and blade valves, pump
at the outlet port end of the control valve. pressure PP is reduced to the same pressure
. It actually reduces pump pressure PP at re- as actuator circuit pressure A by one reduc-
ducing valve (3) of the pressure compensa- ing valve (3) used for both systems, and the
tion valve to the same pressure as actuation pressure is sent to the LS circuit PLS.
circuit pressure A, and sends it to the LS cir- l With the breaker valve, actuator circuit pres-
cuit PLS. sure A is taken directly to the LS circuit PLS.
A T
@ To PPC
valve
From PPC
valve f+
SXPO7348
Operation
1) Boom, arm, bucket, travel valve (4) (see the section on the LS bypass plug).
l When spool (I) is operated, pump pressure l Actuator circuit pressure PA (=A) acts on the
PP flows from flow control valve (2) and notch left end of reducing valve (3); the reduced
a in spool (I) through bridge passage b to ac- pump pressure PP acts on the other end.
tuator circuit A. l As a result, reducing valve (3) is balanced at a
l At the same time, reducing valve (3) also position where actuator circuit pressure PA
moves to the right, so pump pressure PP has and the pressure of spring chamber PLSI are
its pressure reduced by the pressure loss at the same. Pump pressure PP reduced at notch
notch C. It is introduced to LS circuit PLS, C becomes actuator circuit pressure A and is
and then goes to spring chamber PLSI. taken to LS circuit PLS.
l When this happens, LS circuit PLS is con-
nected to tank circuit T from LS bypass plug
PC1 2R, 15R-8 lo-27

0
A b
SDP02998
a Boom swing, blade valve (6), then goes through passage d, and acts on
. When blade spool (I) is operated, pump pres- the left end of piston (7). Piston (7) and re-
sure PP is reduced by reducing valve (3) in ducing valve (3) then move to the right.
the same way as in Item I), and is sent to the As a result, pump pressure PP is reduced at
LS circuit PLS. notch d, becomes the actuator circuit pres-
. When boom swing spool (5) is operated, sure, and is sent to LS circuit PLS.
pump pressure PP flows from flow control * The boom swing and blade valves are differ-
valve (2), passage e, and notch a in boom ent from the boom, arm, bucket, and travel
swing spool (5) through bridge passage b to valves: they share one pressure compensa-
actuator circuit A. tion valve and bring in the LS pressure.
. At the same time, the actuator circuit pres-
sure passes through notch f in breaker spool
1 O-28 PC12R, 15R-8

0
3) Breaker valve
l When breaker spool (6) is operated, pump
pressure PP flows through flow control valve
(2), passage e, and notch a in breaker spool
(6) to actuator circuit A.
l At the same time, actuator circuit pressure PA
passes through check valve (8) and is inter-
connected with the LS circuit PLS.
J, The breaker circuit is different from the other
circuits: actuator circuit pressure PA goes di-
rectly to LS circuit PLS.
PC1 2R, 15R-8 1O-29

0
3. LS bypass plug
Function
. It releases the residual pressure of LS pres-
sure PLS.
. It makes the speed of the rise in pressure of
LS pressure PLS more gentle. In addition,
with this discarded throttled folw, it creates a
pressure loss in the throttled flow of the spool
or shttle valve, and increases the stability by
lowering the effective LS differential pressure.
SDP03326
Operation PP: Pump circuit

. The pressurized oil for LS circuit PLS passes PLS: LS circuit
from clearance filter a (formed by the clear- T: Tank circuit
ante between LS bypass plug (1) and the valve A: To valves
body) through orifice b and flows to the tank
circuit T.
1O-30 PC1 2R, 15R-8

0
4. Pressure compensation valve

Function
. During compound operations, if the load
pressure becomes lower than the other ac-
tuator and the oil flow tries to increase, com-
pensation is received. (When this happens,
the other actuator being used for compound
operation (right side) is at a higher load than
the actuator on this side (left side).)
Side receiving compensation Side providing compensation
A 6 a PPA a
pis
SXPO7349
Operation
. If the load pressure of the other actuator (right . Flow control valve (2) and reducing valve (1)
side) becomes higher during compound op- are balanced in position where the difference
erations, the oil flow in actuator circuit A on in pressure between PLS and PA acting on
this side (left side) tries to increase. both ends of reducing valve (2) and the pres-
. If this happens, the LS pressure PLS of the sure loss between PP and PPA on both sides
other actuator acts on spring chamber PLSl, of flow control valve (2) are the same.
and reducing valve (I) and flow control valve . In this way, the pressure difference between
(2) are pushed to the left. upstream pressure PPA and downstream
. Flow control valve (2) throttles the area of pressure PA of both spools used during com-
opening between pump circuit PP and spool pound operations is the same, so the pump
upstream PPA, and pressure loss is generated flow is divided in proportion to the area of
between PP and PPA. opening of notch a of each spool.
PC1 2R, 15R-8 10-31

0
5. Area ratio of pressure compensation valve

Function
l The pressure compensation valve determines
the compensation characteristics by carrying
out fine adjustment of the area ratio (S2ISl)
between area S2 of reducing valve (1) and
area Sl of flow control valve (2) to match the
characteristics of each actuator.
r
Sl: Area of flow control valve (2) - area of
piston (3)
S2: Area of reducing valve (I) - area of pis-
ton (3)
PP
PA
SDP03002
Area ratio (Sl:S2) and compensation characteristics

l When ratio is 1.00: [pump pressure PP - spool notch upstream pressure PPAI L:.[LS circuit
pressure PLS - actuator circuit pressure PA (=A)] and oil flow is divided
in proportion to area of opening of spool.
l When ratio is more than 1 .OO: PP - PPA r PLS - PA (=A) and oil flow to side receiving compensation is
divided in a proportion less than area of opening of spool.
l When ratio is less than 1 .OO: PP - PPA c PLS - PA (=A) and oil flow to side receiving compensation
is divided in a proportion more than area of opening of spool.
Valve Ratio of area Valve

Arm 0.98 Boom swing
Travel 1.oo Blade
Boom 1 0.95 ( Service 1 1.oo
Bucket / 1 .oo I
1 O-32 PC12R, 15R-8

0
6. Throttling LS introduction of pressure

compensation valve
Function
. If the other actuator is relieved during com-
pound operations, LS introduction throttle b
of reducing valve (1) divides the flow and
sends more oil to the side receiving compen-
sation.
Side receiving compensation Side Providing compensation

(relief side)
@I ////n/N/
B PPA a
SXPO7350
Operation
. If the other actuator (right side) is relieved dur-
ing compound operations, each circuit pres-
sure (PPA, PA) of the other actuator becomes
the same as the pump circuit pressure (PP =
relief pressure).
. In this case, spring chamber PLS2 of the other
actuator (right side) becomes the same as
pump circuit pressure PP because of the bal-
ance of reducing valve (1).
l PLS2 passes through LS introduction throttle
b of reducing valve (1)and becomes PLS. PLS
is connected to the tank circuit from LS by-
pass plug (4), so pressure loss is generated at
LS introduction throttle b (the condition be-
comes PLS c PLSP).
l As a result, even if the other actuator is re-
lieved, a pressure differential is created be-
tween PP and PLS, so more oil flows to ac-
tuator circuit A on this side (left side).
PC1 2R, 15R-8 1o-33

0
7. L.H., R.H. travel junction circuit

Function
l To compensate for any difference in the oil . When steering the machine, the difference in
flow in the left and right travel circuits when the load pressure returns the reducing valve
traveling in a straight line, the junction circuit of the travel valve on the inside of the turn
opens when the left and right travel spools and the opening of the notch in the travel junc-
are operated. tion valve spool becomes smaller, so the ma-
In this way, the flow of oil to the left and right chine can be steered.
travel motors is almost the same when trav-
eling in a straight line, so there is no travel
deviation.
Left travel Right travel
n -
PAR T
4 I
ll :: SXPO7351
Operation
When traveling in a straight line
When left and right travel spools (IL, IR) are
operated, the pump discharge flows from
pump circuit PP and circuits PAL and PAR to
actuator circuits AL and AR.
When traveling in a straight line, to make ac-
tuator circuits PAL and PAR equal, left and
right reducing valves (2) are pushed to the
right by the same amount, and notch a and
the travel junction circuit are opened.
In this way, the left and right travel actuator
circuits are interconnected by the travel junc-
tion circuit, so if any difference occurs in the
flow of oil to the left and right travel motors,
the compensation is carried out to prevent
any deviation in travel.
1o-34 PC1 2R, 15R-8
0
Left travel Rioht travel

n
PAL
b SXPO7352
Steering when traveling

l When traveling in a straight line, if left travel
spool (IL) is returned to the neutral position
and the steering is operated, a difference (AR
> AL) is generated in the load pressure of left
and right travel actuator circuits PALand PAR,
and LS pressure PLS becomes the same pres-
sure as AR (the side with the high load pres-
sure).
l As a result, flow control valve (3) on the left
travel side is pushed to the left by LS circuit
PLS. Because of this, the opening of the left
notch a is made smaller, so it becomes pos-
sible to operate the steering when traveling.
l Damper b is provided in the circuit to dampen
any excessive characteristics in the opening
or closing of the travel junction circuit if the
spool is operated suddenly.
PC1 2R, 15R-8 1o-35

0
8. Swing valve (Open center valve)

Functions
. The swing section of PC1 2R is an open center
system of a fixed displacement pump, which
has the same functions as that on a current
mini-excavator.
From swine
PPC valve
From swing
PPC valve
SXPO7353
Operation
. If pressurized oil from the PPC valve flows in
port PA2, spool (1) moves to the right, and
the oil from the pump pushes load checkvalve
(2A) open through port P, then flows through
port A2 to the swing motor.
. If pressurized oil from the PPC valve flows in
port PB2, spool (1) moves to the left and the
oil from the pump pushes load check valve
(2B) open through port P, then flows through
port B2 to the swing motor.
1 O-36 PC1 2R, 15R-8

0
9. Swing holding brake cancel system

Function
l The system uses the swing PPC pressure and
the arm IN PPC pressure as a signal to cancel
the shaft brake of the swing motor.
From swing
PPC valve
To swine motor
holding brake
Br
SXPO7354
Operation
. The left and right swing PPC pressure and the
arm IN PPC pressure each pass through check
valve (2) inside spring case (I), are output to
port Br, and the swing holding brake is can-
celed. (The highest pressure is output to port
Br.)
l The arm and swing are connected by the pi-
lot circuit inside the control valve.
PC12R, 15R-8 1o-37

0
10. Pilot relief valve, PPC basic pressure lock

valve, Hi-Lo travel speed selector valve
Function
l These valves set the pilot pressure of the pi-
lot pump. (2.9 MPa (30 kg/cm*})
. These valves switch the PPC basic pressure
lock and Hi-Lo travel selector pilot pressure
signal.
To PPC valve To travel motor
Pi lot
Dump
Operation PPC basic lock valve, Hi-Lo travel speed

Pilot relief valve selector valve
l The discharge pressure from the pilot pump l The diagram above shows the condition when
entering chamber A acts on the bottom of pi- the valve is ON. The PPC basic pressure is
lot relief valve (I 1. The pilot pump discharge connected to the PPC valve, and the PPC valve
pressure is set to 2.9 MPa 130 kg/cm*} by the is actuated. The Hi-Lo travel speed selector
spring load of spring (2). pressure is connected to the travel motor and
the travel is set to high speed.
l When the PPC basic pressure lock or low
speed travel are operated, PPC basic pressure
lock valve (3) or Hi-Lo travel speed selector
valve (4) rotate and the pressure is shut off
from port A.
l As a result, the actuation of the PPC valve is
stopped and the travel is switched to low
speed.
1 O-38 PC1 2R, 15R-8
0
11. OPERATION OF THE SYSTEM AS A WHOLE
PC12R-8
20
;;
“17
*I,:,,
;:;;;;
,,,,,,
,,,,,,,, ::
G=
/I
====A-I
PC12R, 15R-8
1. Hydraulic tank 11. Boom swing, breaker valve

2. Hydraulic pump assembly 1 IA. Boom swing spool
2A. Main gear pump 11 B. Breaker spool
2B. Gear (swing) pump 12. Unload valve
2C. Gear (pilot) pump 13. Main relief valve
3. LS bypass plug 14. Safety valve
4. Arm valve 15. Lift check valve
4A. Spool 16. Cooler check valve
4B. Pressure compensation valve (flow 17. Pilot relief valve
control valve) 18. PPC basic pressure lock valve
4C. Pressure compensation valve (reducing 19. Travel Hi-Lo selector valve
valve) 20. Pressure release plug
4D. Suction valve 21. Bucket cylinder
5. Swing valve 22. Arm cylinder
5A. Spool 23. Boom cylinder
6. L.H. travel valve 24. R.H. travel motor
6A. Spool 25. L.H. travel motor
6B. Pressure compensation valve (flow 26. Swing motor
control valve) 27. Blade cylinder
6C. Pressure compensation valve (reducing 28. Boom swing cylinder
valve)
7. R.H. travel valve
7A. Spool
78. Pressure compensation valve (flow
control valve)
7C. Pressure compensation valve (reducing
valve)
8. Boom valve
8A. Spool
8B. Pressure compensation valve (flow
control valve)
va Ive)
8D. Suction valve
9. Bucket valve
9A. Spool
control valve)
control valve)
10. Blade valve
IOA. Blade spool
1OB. Pressure compensation valve (flow
control valve)
IOC. Pressure compensation valve (reducing
valve)
PC12R, 15R-8 10-41

0
l Operation of whole system 4) When both travel spools are operated si-
1) When all control valves are in neutral multaneouslv
l All of discharge amount 01 of main If both travel spools (6A) and (7A) are
gear pump (2A) flows from unload operated, pump discharge amount Q
valve (12) to tank (1). flows to both travel motors (24) and
l Since any spool (each A of the valve) (251, then LS pressure PLS is gener-
is not operated, LS pressure PLS is not ated and unload valve (12) moves in
generated at all. the closing direction.
l Since LS pressure PLS is connected At this time, pressure reducing valves
through LS bypass plug (3) to the seal (6C) and (7C) of both travel valves
drain circuit, it is set to the tank pres- move to the right to open the travel
sure. interconnection circuit to prevent
l Discharge amount 02 of swing gear travel deviation.
pump (2B) flows through the swing Even if the opening ratio of both travel
spool to (open center) tank (1). spools (6A) and (7A) is lOO%, the
2) When only swing spool is operated pump discharge amount does not in-
l If the swing spool is operated, dis- crease to 100%. Accordingly, LS dif-
charge amount Q2 of the gear pump ferential pressure APLS becomes
flows from swing spool (5A) to the equal to the set LS pressure of unload
swing motor. valve (121, then the unload valve
l All of discharge amount 01 of the drains the excessive oil for the travel
main gear pump flows from unload circuit into tank (1).
valve (12) to tank (1). 51 When multiple actuators are operated (As
3) When only one actuator is operated (As an example, simultaneous operation of
an example, operation of the boom is ex- the boom and arm is explained below.)
plained below.) l If boom spool (8A) is operated in the
l If boom spool (8A) is operated, dis- raising direction and arm spool (4A)
charge amount Q of the pump flows is operated in the dumping direction
in boom cylinder (23). As a result, LS simultaneously, pump discharge Q
pressure PLS is generated and unload flows to cylinders (23) and (22).
valve (12) moves in the closing direc- l At this time, since the load pressure
tion. of boom cylinder (23) is larger than
l LS pressure PLS becomes the nega- that of arm cylinder (221, the oil flows
tive pressure of boom cylinder (23). into the arm cylinder where the nega-
In the boom circuit, the difference be- tive pressure is lower, but the pres-
tween pump discharge pressure PP sure on the upper stream side of the
and LS pressure PLS, or LS differen- arm spool (4A) is compensated by
tial pressure APLS is equal to the set pressure compensation valves (8B)
LS pressure of the unload valve, and and (8C) which receive the negative
the unload valve drains the excessive pressure of the boom (= Maximum LS
oil for the boom circuit into tank (I). pressure PLS).
l Since pump pressure PP is led through l By the above operation, the respec-
the drilled holes of flow control valve tive differences between the upper
(8B) to the left end, the spools of boom stream side and lower stream side of
pressure compensation valves (8B) boom spool (8A) and arm spool (4A)
and (8C) move to the right end. become the same. As a result, the
l When any actuator other than the flow from the main gear pump is di-
boom actuator is operated singly, the vided according to the ratio of the
system operates similarly to the above opening area of each spool.
case where the boom actuator is op-
erated, since pump discharge amount
Q does not increase to 100%.
1O-42 PC1 2R, 15R-8

0
l The system is so set that even if the

opening ratios of both boom spool
(8A) and arm spool (4A) are 100% re-
spectively and the pump discharge in-
creases to lOO%, LS differential pres-
sure APLS does not reach the set pres-
sure of unload valve (12). Accordingly,
unload valve (12) drainsthe excessive
oil into tank (1).
l If three actuators of the boom, arm,
bucket, etc. are operated simulta-
neously and the opening ratio of each
actuator is 100% and they require
more than 100% of pump discharge
amount 01, unload valve (12) is closed
and all of pump discharge amount 01
is supplied to the actuator. Pump dis-
charge amount Ql is divided for the
actuators according to the ratio of the
opening area of each spool.
PC1 2R, 15R-8 1o-43

0
CONTROL VALVE
PC15R-8
Outline
The sketch shows the standard valve.
The control valve is an add-on type where one
service valve each can be added, so it is pos-
sible to add valves or remove valves if neces-
sary.
The service valve is added on between the
8th, 9th valve (swing, breaker) and cover sub-
assembly.
The cross section of the service valve is the
same as the bucket valve of the standard
valve.
Names of ports
I? Pump port (from main pump) Pil. From pilot pump
T. Tank port (to tank) Pi2. To PPC valve port P
C. Cooler port (to cooler) Pi3. To travel motor
S. Swing motor suction port Br. To swing brake
(to swing motor port S) (swing holding brake cancel port)
Al. To arm cylinder head PAI. From arm OUT PPC valve
A2. To swing motor PA2. From right swing PPC valve
A3. To travel motor PA5. From boom RAISE PPC valve
A4. To travel motor PA6. From bucket CURL PPC valve
A5. To boom cylinder bottom PA9. From breaker PPC valve
A6. To bucket cylinder bottom PBI. From arm IN PPC valve
A7. To blade cylinder head PB2. From left swing PPC valve
A8. To boom swing cylinder head PB5. From boom LOWER PPC valve
A9. To breaker PB6. From bucket DUMP PPC valve
Bl. To arm cylinder bottom
82. To swing motor
B3. To travel motor
B4. To travel motor
85. To boom cylinder head
B6. To bucket cylinder head
B7. To blade cylinder bottom
B8. To boom swing cylinder bottom
TS. Sealed drain port
LS. LS port (To pump LS valve)
1o-44 PC1 2R, 15R-8

0
A9
Pi3 Pi 1
PB8 PA8
PB7 PA7
PB6 PA6
PA9
PA1
PBl
LL
l--A
B
C
TS
Br
T C SDP02985
PC12R, 15R-8 1o-45

0
A-A SDP0333 1
1. Suction valve (boom, bottom)

2. Suction valve (swing, bottom)
3. Suction valve (boom, head)
4. Suction valve (arm, bottom)
5. Safety valve
1 O-46 PC1 2R, 15R-8

0
‘9
SDP03332
1. Spool (arm) 6. Spool (bucket)

2. Spool (swing) 7. Spool (blade)
3. Spool (L.H. travel) 8. Spool (boom swing)
4. Spool (R.H. travel) 9. Main relief valve
5. Spool (boom)
PC1 2R, 15R-8

1o-47
0
18
SDP03333
1. Lift check valve 11. Pressure compensation valve R

2. Unload valve (boom swing, blade)
3. Pressure compensation valve F (arm) 12. Pressure compensation valve R (bucket)
4. Pressure compensation valve F (swing) 13. Pressure compensation valve R (boom)
5. Pressure compensation valve F (L.H. travel) 14. Pressure compensation valve R (R.H. travel)
6. Pressure compensation valve F (R.H. travel) 15. Pressure compensation valve R (L.H. travel)
7. Pressure compensation valve F (boom) 16. Pressure compensation valve R (swing)
8. Pressure compensation valve F (bucket) 17. Pressure compensation valve R (arm)
9. Pressure compensation valve F 18. LS bypass plug
(boom swing, blade) 19. Cooler check valve
10. Spool (breaker)
1 O-48 PC 12R, 15R-8
0
I D-D 2 E-E ‘5
F-F G-G
\
II
SDP03334
1. Lift check valve 10. Pilot pressure check valve

2. Cooler check valve 11. Pressure compensation valve R (arm)
3. Safety valve 12. Pressure compensation valve F (arm)
4. Main relief valve 13. Spool (swing)
5. LS bypass plug 14. Pilot pressure check valve
6. Unload valve 15. Pressure compensation valve R (swing)
7. Spool (arm) 16. Pressure compensation valve F (swing)
8. Check valve 17. Pilot pressure check valve
9. Suction valve (arm)
PC1 2R. 15R-8 1o-49

0
J-J ‘7
131
15’
K-K
SDP03:
1. Spool (travel) 9. Spool (boom)

2. Pressure compensation valve R 10. Spool (bucket)
(travel) 11. Pressure compensation valve R
3. Pressure compensation valve F (bucket)
(travel) 12. Pressure compensation valve F
4. Suction valve (boom) (bucket)
5. Check valve 13. Spool (blade)
6. Suction valve (boom) 14. Pressure compensation valve R
7. Pressure compensation valve R (blade, swing)
(boom) 15. Pressure compensation valve F
8. Pressure compensation valve F (blade, swing)
(boom)
1O-50 PC1 2R, 15R-8

0
N-N
SDP03336
1. Spool (swing)
2. Suction valve
3. Spool (breaker)
4. Pressure relief plug
5. Cover assembly
7. Travel Hi/Lo selector valve
8. PPC pressure lock valve
PC1 2R, 15R-8 10-51

0
CLSS
PC15R-8
1. OUTLINE
FEATURES
The term “CLSS” stands for the “Closed center Load Sensing System” which has the following fea-
tu res.
1) Fine-controllability not affected by loads
2) Controllability enabling digging even in the fine control mode
3) Complex operability ensured by flow distribution determined according to the opening areas of
spools during complex operation
4) Energy-saving feature using variable pump control
STRUCTURE
l The CLSS consists of a variable displacement single piston pump, control valve and actuators.
l The pump body consists of the main pump, TCC valve and LS valve.
( Actuators )
0
I 1
r______________pL?! Cant roi valve /
TCC valve ------+)
I________-------____ LS valve -------1
&
PO
Servo
piston
SKP04139
1 O-52 PC1 2R, 15R-8

0
2. BASIC PRINCIPLE
1) Control of pump swash plate angle

. The pump swash plate angle (pump discharge amount) is so controlled that the LS differential
pressure APLS, which is the difference between the pump discharge pressure Pp and the LS
pressure PLS at the outlet port of the control valve (actuator load pressure), is maintained at a
constant level.
(LS differential pressure APLS = Pump discharge pressure Pp - LS pressure PLS)
l If the LS differential pressure APLS becomes lower than the setting pressure of the LS valve, the
pump swash plate angle becomes larger, and if it becomes higher, the pump swash plate angle
becomes smaller.
* For the details of this action, refer to the descriptions of “Hydraulic Pump”.
Control valve
-------7
f I PLS I I
0 LS differential f
Pump Pasease
j i Pressure APLS Set differential
II I‘----------7LS I Preseure of LS valve
L__________ SKP04141
Main Pump
7%
PP
Min. Max.
Servo
Piston
bifferential
bressure smal I
(law)
TCC valve
=zGz$
P
lump
jressure low
SKP04140
PC1 2R, 15R-8 1o-53

0
2) Pressure compensation control

l Valves (pressure compensation valves) are installed at the inlet port side of the spools of the
control valves to balance the loads.
When the actuators are complex-operated, the pressure differences AP at the upstream (inlet)
and downstream (outlet) are made equal by these valves.
In this way, the flow from the pump are distributed in proportion to the opening areas Sl and S2
of each valve.
Load
Actuator
I---
AP
Pressure
comoensation
valve
IV Pump
I’ SDP04142
1o-54 PC1 2R, 15R-8

0
3. Functions and operation of each valve

Names of hydraulic circuits and valves
Pi2 Pi3
r
r_-__-__-_--_,___~__-__~.
1. Unload valve
(LS differential pressure +
Breaker
2.9 MPa (30 kg/cm*))
2. Safety valve
(20.6 MPa (210 kg/cm*})
Boom swine cylinder valve
4. Suction valve
(18.6 MPa (190 kg/cm*))
Blade cylinder 6. Back pressure check valve
(cracking pressure:
0.45 MPa (4.5 kg/cm*})
7. Cooler bypass valve
(cracking pressure:
PA6
---.
Bucket cylinder
0.4 MPa (4 kg/cm*))
(2.9 MPa (30 kg/cm*})
9. PPC basic pressure lock
PA5
---. Boom cylinder valve
10. Travel Hi-Lo selector valve
11. Swing holding brake cancel
check valve
R.H travel motor
L.H. travel motor
Swine motor
---PA:
:p Arm cylinder
K?cp~~_-_____-__A C T SXPO7356
PC1 2R, 15R-8 1o-55

0
1. Unload valve
Function
1) When the control valve is at HOLD, pump dis-
charge amount Q discharged by the minimum
swash plate angle is released to the tank cir-
cuit. When this happens, pump discharge
pressure PP is set to 2.9 MPa (30 kg/cm? by
spring (2) inside the valve.
(LS pressure PLS: 0 MPa (0 kg/cm*})
SDP02994
Operation
When control valve is at HOLD
l At the left end of spool (I), pump pressure PP PP: Pump circuit
is acting on area Sl, and at the right end of PLS: LS circuit
spool (1); pump pressure PP is acting on area T: Tank circuit
S2, and LS pressure PLS is acting on area S3. A: To valves
l When the control valve is at HOLD, LS pres- B: To pump LS valve
sure PLS is not generated, so only pump dis-
charge pressure PP has any effect, and PP is
set by the load of spring (2).
. As pump discharge pressure PP rises and
reaches the PP x Sl = PP x S2 + spring force
of spring (21, spool (I) is moved to the right.
Pump circuit PP is then connected to tank cir-
cuit T through the drill hole.
. In this way, pump discharge pressure PP is
set to 2.9 MPa (30 kg/cm?.
1O-56 PC1 2R, 15R-8

0
2) During fine control of the control valve, when

the demand flow for the actuator is within the
amount discharged by the minimum swash
plate angle of the pump, pump discharge
pressure PP is set to LS pressure PLS + 2.9
MPa (30 kg/cm*).
When the difference in pressure between
pump discharge pressure PP and LS pressure
PLS reaches the load of,spring (2) (2.9 MPa
(30 kg/cm*}), the unload valve opens, so LS
differential pressure APLS becomes 2.9 MPa
(30 kg/cm2).
SDP02995
Operation
Durina fine control of control valve PP: Pump circuit
Widen fine control is carried out on the con- PLS: LS circuit
trol valve, LS pressure PLS is generated and T Tank circuit
acts on area S3 at the right end of spool (1). A: To valves
When this happens, the area of the opening B: To pump LS valve
of the control valve spool is small, so there is
a big difference between LS pressure PLS
and pump discharge pressure PP.
When the difference in pressure between
pump discharge pressure PP and LS pressure
PLS reaches the load of spring (21, spool (I)
moves to the right, and pump circuit PP and
tank circuit T are connected.
In other words, pump discharge pressure PP
is set to a pressure equal to the force of spring
(2) (2.9 MPa (30 kg/cm?) + LS pressure PLS,
and LS differential pressure APLS becomes
2.9 MPa (30 kg/cm2}.
PC1 2R, 15R-8 1o-57

0
3) When the control valve is being operated and

the demand flow for the actuator becomes
greater than the pump discharge from the
minimum swash plate angle, the flow of the
oil out to tank circuit T is shut off, and all of
pump discharge amount 0 flows to the
actuator circuit.
SDP02996
OPERATION
Control valve operated PP: Pump circuit
When the control valve is operated to a larger PLS: LS circuit
stroke, LS pressure PLSis generated and acts T: Tank circuit
on area S3 at the right end of spool (I 1. When A: To valves
this happens, the area of the opening of the B: To pump LS valve
control valve spool is large, so the difference
between LS pressure PLS and pump dis-
charge pressure PP is small.
Forthis reason, the difference in pressure be-
tween pump discharge pressure PP and LS
pressure PLS does not reach the load of spring
(2) (2.9 MPa (30 kg/cm*)), so spool (I) is
pushed to the left by spring (21.
As a result, pump circuit PP and tank circuit T
are shut off, and all the pump discharge
amount 0 flows to the actuator circuit.
lo-58 PC1 2R, 15R-8

0
2. Introduction of LS pressure
Function
l The LS pressure is the actuator load pressure . With the boom swing and blade valves, pump
at the outlet port end of the control valve. pressure PP is reduced to the same pressure
l It actually reduces pump pressure PP at re- as actuator circuit pressure A by one reduc-
ducing valve (3) of the pressure compensa- ing valve (3) used for both systems, and the
tion valve to the same pressure as actuation pressure is sent to the LS circuit PLS.
circuit pressure A, and sends it to the LS cir- . With the breaker valve, actuator circuit pres-
cuit PLS. sure A is taken directly to the LS circuit PLS.
TO
PPC
valve
From
PPC
valve
K4 SDP04144
Operation
1) Boom, arm, bucket, travel valve (4) (see the section on the LS bypass plug).
l When spool (1) is operated, pump pressure Actuator circuit pressure PA (=A) acts on the
PP flows from flow control valve (2) and notch left end of reducing valve (3); the reduced
a in spool (1) through bridge passage b to ac- pump pressure PP acts on the other end.
tuator circuit A. As a result, reducing valve (3) is balanced at a
l At the same time, reducing valve (3) also position where actuator circuit pressure PA
moves to the right, so pump pressure PP has and the pressure of spring chamber PLSI are
its pressure reduced by the pressure loss at the same. Pump pressure PP reduced at notch
notch C. It is introduced to LS circuit PLS, C becomes actuator circuit pressure A and is
and then goes to spring chamber PLSI. taken to LS circuit PLS.
l When this happens, LS circuit PLS is con-
nected to tank circuit T from LS bypass plug
PC 12R, 15R-8 1o-59

0
5
A b I
SDP02998
2) Boom swing, blade valve (6), then goes through passage d, and acts on
. When blade spool (1) is operated, pump pres- the left end of piston (7). Piston (7) and re-
sure PP is reduced by reducing valve (3) in ducing valve (3) then move to the right.
the same way as in Item I), and is sent to the As a result, pump pressure PP is reduced at
LS circuit PLS. notch d, becomes the actuator circuit pres-
. When boom swing spool (5) is operated, sure, and is sent to LS circuit PLS.
pump pressure PP flows from flow control * The boom swing and blade valves are differ-
valve (2), passage e, and notch a in boom ent from the boom, arm, bucket, and travel
swing spool (5) through bridge passage b to valves: they share one pressure compensa-
actuator circuit A. tion valve and bring in the LS pressure.
. At the same time, the actuator circuit pres-
sure passes through notch f in breaker spool
1O-60 PC1 2R, 15R-8
0
CLSS
3) Breaker valve
l When breaker spool (6) is operated, pump
pressure PP flows through flow control valve
(Z), passage e, and notch a in breaker spool
(6) to actuator circuit A.
l At the same time, actuator circuit pressure PA
passes through check valve (8) and is inter-
connected with the LS circuit PLS.
* The breaker circuit is different from the other
circuits: actuator circuit pressure PA goes di-
rectly to LS circuit PLS.
PC1 2R, 15R-8 1O-61

0
3. LS bypass plug
Function
. It releases the residual pressure of LS pres-
sure PLS.
. It makes the speed of the rise in pressure of
LS pressure PLS more gentle. In addition,
with this discarded throttled folw, it creates a
pressure loss in the throttled flow of the spool
or shttle valve, and increases the stability by
lowering the effective LS differential pressure.
I
B
sDPo3ooo
Operation PP: Pump circuit

l The pressurized oil for LS circuit PLS passes PLS: LS circuit
from clearance filter a (formed by the clear- T: Tank circuit
ante between LS bypass plug (1) and the valve A: To valves
body) through orifice b and flows to the tank B: To pump LS valve
circuit.
1O-62 PC1 2R, 15R-8

0
4. Pressure compensation valve

Function
. During compound operations, if the load
pressure becomes lower than the other ac-
tuator and the oil flow tries to increase, com-
pensation is received. (When this happens,
the other actuator being used for compound
operation (right side) is at a higher load than
the actuator on this side (left side).)
Side receiving compensation Side providing compensation
El El
PiS SDP04145
Operation
. If the load pressure of the other actuator (right . Flow control valve (2) and reducing valve (1)
side) becomes higher during compound op- are balanced in position where the difference
erations, the oil flow in actuator circuit A on in pressure between PLS and PA acting on
this side (left side) tries to increase. both ends of reducing valve (2) and the pres-
. If this happens, the LS pressure PLS of the sure loss between PP and PPA on both sides
other actuator acts on spring chamber PLSI, of flow control valve (2) are the same.
and reducing valve (I) and flow control valve l In this way, the pressure difference between
(2) are pushed to the left ( 1. upstream pressure PPA and downstream
. Flow control valve (2) throttles the area of pressure PA of both spools used during com-
opening between pump circuit PP and spool pound operations is the same, so the pump
upstream PPA, and pressure loss is generated flow is divided in proportion to the area of
betweenPPandPPA. opening of notch a of each spool.
PC1 2R, 15R-8 1O-63

0
5. Area ratio of pressure compensation valve

Function
l The pressure compensation valve determines
the compensation characteristics by carrying
out fine adjustment of the area ratio (WSl)
between area S2 of reducing valve (1) and
area Sl of flow control valve (2) to match the
characteristics of each actuator.
Sl: Area of flow control valve (2) - area of
piston (3)
S2: Area of reducing valve (1) - area of pis-
ton (3)
PP
SDP03002
Area ratio (Sl:S2) and compensation characteristics

l When ratio is 1.00: [pump pressure PP - spool notch upstream pressure PPAI +[LS circuit
pressure PLS - actuator circuit pressure PA (=A)] and oil flow is divided
in proportion to area of opening of spool.
l When ratio is more than 1 .OO: PP - PPA r PLS - PA (=A) and oil flow to side receiving compensation is
divided in a proportion less than area of opening of spool.
l When ratio is less than 1.00: PP - PPA < PLS - PA (=A) and oil flow to side receiving compensation
is divided in a proportion more than area of opening of spool.
lo-64 PC1 2R, 15R-8
0
6. Throttling LS introduction of pressure

compensation valve
Function
. If the other actuator is relieved during com-
pound operations, LS introduction throttle b
of reducing valve (I) divides the flow and
sends more oil to the side receiving compen-
sation.
Side receiving compensation Side providing comoensation

(relief side)
lLfELLu
PPA
,a B I ra
PP
&3
SDP04146
Operation
If the other actuator (right side) is relieved dur-
ing compound operations, each circuit pres-
sure (PPA, PA) of the other actuator becomes
the same as the pump circuit pressure (PP =
relief pressure).
In this case, spring chamber PLS2 of the other
actuator (right side) becomes the same as
pump circuit pressure PP because of the bal-
ance of reducing valve (I 1.
PLS2 passes through LS introduction throttle
b of reducing valve (1) and becomes PLS. PLS
is connected to the tank circuit from LS by-
pass plug (4), so pressure loss is generated at
LS introduction throttle b (the condition be-
comes PLS < PLSZ).
As a result, even if the other actuator is re-
lieved, a pressure differential is created be-
tween PP and PLS, so more oil flows to ac-
tuator circuit A on this side (left side).
PC 1 2R, 15R-8 1 O-65

0
7. L.H., R.H. travel junction circuit

Function
l To compensate for any difference in the oil l When steering the machine, the difference in
flow in the left and right travel circuits when the load pressure returns the reducing valve
traveling in a straight line, the junction circuit of the travel valve on the inside of the turn
opens when the left and right travel spools and the opening of the notch in the travel junc-
are operated. tion valve spool becomes smaller, so the ma-
In this way, the flow of oil to the left and right chine can be steered.
travel motors is almost the same when trav-
eling in a straight line, so there is no travel
deviation.
n n
-/
1L R
PLS
2 \ 2
PP
SDP04147
Operation
When traveling in a straight line
When left and right travel spools (IL, IR) are
operated, the pump discharge flows from
pump circuit PP and circuits PAL and PAR to
actuator circuits AL and AR.
When traveling in a straight line, to make ac-
tuator circuits PAL and PAR equal, left and
right reducing valves (2) are pushed to the
right by the same amount, and notch a and
the travel junction circuit are opened.
In this way, the left and right travel actuator
circuits are interconnected by the travel junc-
tion circuit, so if any difference occurs in the
flow of oil to the left and right travel motors,
the compensation is carried out to prevent
any deviation in travel.
1O-66 PC1 2R, 15R-8

0

n
PP
b SDP04148
Steering when traveling

When traveling in a-straight line, if left travel
spool (IL) is returned to the neutral position
and the steering is operated, a difference (AR
> AL) is generated in the load pressure of left
and right travel actuator circuits PAL and PAR,
and LS pressure PLS becomes the same pres-
sure as AR (the side with the high load pres-
sure).
As a result, flow control valve (3) on the left
travel side is pushed to the left by LS circuit
PLS. Because of this, the opening of the left
notch a is made smaller, so it becomes pos-
sible to operate the steering when traveling.
Damper b is provided in the circuit to dampen
any excessive characteristics in the opening
or closing of the travel junction circuit if the
spool is operated suddenly.
PC1 2R, 15R-8 1 O-67

0
8. Swing holding brake cancel system

Function
l The system uses the swing PPC pressure and
the arm IN PPC pressure as a signal to cancel
the shaft brake of the swing motor.
‘\ /’
From From
swine Qa swing
PPC "a PPC valve
To swing motor brake
PPC valve
SDP04149
Operation
l The left and right swing PPC pressure and the
arm IN PPC pressure each pass through check
valve (2) inside spring case (1 I, are output to
port Br, and the swing holding brake is can-
celed. (The highest pressure is output to port
Br.)
l The arm and swing are connected by the pi-
lot circuit inside the control valve.
1O-68 PC1 2R, 15R-8
0
9. Pilot relief valve, PPC basic pressure lock

valve, Hi-Lo travel speed selector valve
Function
l These valves set the pilot pressure of the pi-
lot pump. (2.9 MPa (30 kg/cm*))
l These valves switch the PPC basic pressure
lock and Hi-Lo travel selector pilot pressure
signal.
To PPC valve port P 9 To travel motor

/PC3
Operation PPC basic lock valve, Hi-Lo travel speed

Pilot relief valve selector valve
l The discharge pressure from the pilot pump l The diagram above shows the condition when
entering chamber A acts on the bottom of pi- the valve is ON. The PPC basic pressure is
lot relief valve (1). The pilot pump discharge connected to the PPC valve, and the PPCvaive
pressure is set to 2.9 MPa (30 kg/cm*} by the is actuated. The Hi-Lo travel speed selector
spring load of spring (21. pressure is connected to the travel motor and
the travel is set to high speed.
l When the PPC basic pressure lock or low
speed travel are operated, PPC basic pressure
lock valve (3) or Hi-Lo travel speed selector
valve (4) rotate and the pressure is shut off
from port A.
l As a result, the actuation of the PPC valve is
stopped and the travel is switched to low
speed.
PC1 2R, 15R-8 1O-69

0
10. OPERATION OF THE SYSTEM AS A WHOLE
PC15R-8
20
If?-,
I 28
I I
I
27
-
9
3
:
1 3
25
:
II II
in
1O-70 PC12R, 15R-8

0
1. Hydraulic tank 10. Blade valve

2. Hydraulic pump assembly IOA. Blade spool
2A. Main pump IOB. Pressure compensation valve (flow
2B. Gear (pilot) pump control valve)
2C. Servo piston IOC. Pressure compensation valve (reducing
2D. LS valve valve)
3. LS bypass plug 11. Boom swing, breaker valve
4. Arm valve 1 IA. Boom swing spool
4A. Spool 11 B. Breaker spool
4B. Pressure compensation valve (flow 12. Unload valve
control valve) 13. Main relief valve
4C. Pressure compensation valve (reducing 14. Safety valve
valve) 15. Lift check valve
4D. Suction valve 16. Cooler check valve
5. Swing valve 17. Pilot relief valve
5A. Spool 18. PPC basic pressure lock valve
58. Pressure compensation valve (flow 19. Travel Hi-Lo selector valve
control valve) 20. Pressure release plug
5C. Pressure compensation valve (reducing 21. Bucket cylinder
valve) 22. Arm cylinder
6. L.H. travel valve 23. Boom cylinder
6A. Spool 24. R.H. travel motor
6B. Pressure compensation valve (flow 25. L.H. travel motor
control valve) 26. Swing motor
6C. Pressure compensation valve (reducing 27. Blade cylinder
valve) 28. Boom swing cylinder
7. R.H. travel valve
7A. Spool
control valve)
valve)
8. Boom valve
8A. Spool
control valve)
valve)
8D. Suction valve
9. Bucket valve
9A. Spool
control valve)
valve)
PC1 2R, 15R-8 10-71

0
IlC. Operation of system as a whole

1) When all control valves are at HOLD When this happens, reducing valves (6C)
Operation and (7C) of the left and right travel valves
Pump discharge amount Q all flows from move to the right, the travel junction cir-
unload valve (12) to tank (I ). cuit is interconnected, and this prevents
None of the spools (each spool A of the any deviation in travel.
valves) is being operated, so the LS pres- When left and right travel spools (6A) and
sure PLS is not generated. (7A) are 100% open, the pump discharge
At the same time, the LS pressure PLS is amount Q does not become lOO%, so LS
connected to the tank circuit by the LS by- differential pressure APLS becomes the
pass plug, so it is the tank pressure. same pressure as the LS set pressure of
In this condition, LS differential pressure LS valve (2D), and the swash plate angle
APLS becomes the unload pressure-tank of main pump (2A) is kept at a point mid-
pressure, and becomes higherthan the LS way between the minimum and maxi-
set pressure of LS valve (2D), so main mum angles.
pump (2A) is set to the minimum swash 4) Compound operation of actuators (ex-
plate angle. ample: boom + arm operated at same time)
2) When actuator is operated independently If boom spool (8A) is operated to RAISE
(example: boom) and arm spool (4A) is operated at the
l When boom spool (8A) is operated, pump same time to OUT, pump discharge
discharge amount Q flows to boom cylin- amount Q flows to each cylinder (22) and
der (23). At the same time, LS pressure (23).
PLS is generated and unload valve (12) When this happens, the load pressure of
closes. boom cylinder (23) is greaterthan the load
LS pressure PLS becomes the load pres- pressure of arm cylinder (22), so the oil
sure of boom cylinder (23). tries to flow to arm cylinder (22), where
. In the boom circuit, the difference be- the load pressure is low. However, the
tween pump discharge pressure PP and pressure on the upstream side of arm
LS pressure PLS (in other words, LS dif- spool (4A) is compensated by pressure
ferential pressure APLS) becomes the compensation valves (8B) and (8C), which
same as the LS set pressure of the LS receive the load pressure of the boom (=
valve. maximum LS pressure PLS).
l As a result, the swash plate angle of main In this way, the pressure difference be-
pump (2A) is kept at a point midway between the upstream pressure and down-
tween the minimum and maximum stream pressure of boom spool (8A) and
angles. arm spool (4A) becomes equal, so the flow
. Pump pressure PP passes through the drill of oil from main pump (2A) is divided in
hole in flow control valve (88) and goes proportion to the area of opening of each
to the left end, so boom pressure com- spool.
pensation valves (86) and (8C) move fully If the area of opening of boom spool (8A)
to the right. and arm spool (4A) is lOO%, even if pump
l When the other actuators are operated in- discharge amount Q becomes lOO%, LS
dependently, pump discharge amount Q differential pressure APLS is set so that it
does not become lOO%, so the operation does not reach the set pressure of LS valve
is the same as for the boom. (2D), so main pump (2A) is held at the
3) When left and right travel are operated at maximum swash plate angle.
same time If the total demand flow of boom spool
l When left and right travel spools (6A) and (8A) and arm spool (4A) is lessthan lOO%,
(7A) are operated, pump discharge pump discharge amount Q, pump dis-
amount Q flows to left and right travel charge amount Q is controlled in accor-
motors (24) and (25) and at the same time, dance with the area of opening of the
LS pressure PLS is generated and unload spools by LS differential pressure APLS.
valve (12) closes.
1 O-72 PC1 2R, 15R-8

0
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

PC12R-8
Al
Gl
A-A
1. Cover
2. Body
3. Slipper seal
4. Shaft
Al: From R.H. travel control D2: To L.H. travel motor port A
valve port B El: From blade control valve port
A2: To R.H. travel motor port A A
Bl: From L.H. travel control E2: To blade cylinder bottom end
valve port B Fl: From blade control valve port D2 82
B2: To L.H. travel motor port B B
Cl: From R.H. travel control F2: To blade cylinder head end
valve port A Gl : From travel Hi-Lo speed
C2: To R.H. travel motor port B selector valve port Pi3
Dl: From L.H. travel control G2: To L.H., R.H. travel motor port s0P03010
valve port A P
PC12R, 15R-8 1 o-73

0
CENTER SWIVEL JOINT
PC1 5R-8
A
n m-7 n
El
Gl
A-A
A4
1. Cover
2. Body
3. Slipper seal
4. Shaft
Al: From R.H. travel control D2: To L.H. travel motor port A
valve port 6 El: From blade control valve port
A2: To R.H. travel motor port A B
Bl: From L.H. travel control E2: To blade cylinder head end
valve port B Fl: From blade control valve port ~2
B2: To L.H. travel motor port B A
Cl: From R.H. travel control F2: To blade cylinder bottom end
valve port A Gl : From travel Hi-Lo speed
C2: To R.H. travel motor port B selector valve port Pi3 c2
Dl: From L.H. travel control G2: To L.H., R.H. travel motor port B-B SDP03010
valve port A P
1o-74 PC1 2R, 15R-8
0
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
C d b a
D
0 0
0
0 0
sDPo3o11
a. Port A (from control valve port A2) Specifications

b. Port B (from control valve port B2) l Type: 2PD20C0305-A
c. Port P (from control valve port Pi2) l Theoretical discharge: 195 cc/rev
d. Port R (from control valve port Br)
e. T port (to tank)
PC1 2R, 15R-8 1o-75

0
STRUCTURE AND FUNCTION SWING MOTOR
1. Output shaft 11. Valve

2. Front bearing 12. Valve housing
3. Housing 13. Pin
4. Clutch plate 14. Balancing plate
5. Clutch disc 15. Ball
6. Ring 16. Valve drive
7. Piston 17. Geroller
8. Spring 18. Geroller star
9. Main drive shaft 19. Rear bearing
10. Valve plate
1O-76 PC1 2R, 15R-8

0
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
b c
Oil level
% The sketch shows the PCl5R-8.
SXPO7358
Specifications
a. Port PP (from control valve port Pi31
b. Port A (from travel control valve) PC12R-8 PC1 5R-8
c. Port B (from travel control valve)
Model PHX-100
d. Port DR (to tank)
Capacity (Hi/Lo) cc/rev 1 8.66/18.2 1 10.5/22.1
Speed switching pressure

l.O{lO)
M Pa{kg/cm*)
Reduction ratio 19.66
PC12R, 15R-8 1o-77

0
PC20R-8
SEP03024
1. Cover 13. No. 1 sun gear

2. No. 2 planetary gear 14. No. 2 planetary carrier
3 Ring gear 15. No. 2 sun gear
4. No. 1 planetary gear 16.2nd spool
5. Housing 17. Plug
6. Piston 18. Check valve spring
7. Cylinder 19. Spool return spring
8. Valve plate 20. Plug
9. Brake valve 21. Check valve
10. Center spring 22. Counterbalance valve spool
11. Swash plate
12. Output shaft
1 O-78 PC1 2R, 15R-8

0
CHANGE OF TRAVEL SPEED

Outline
. Ports A and B of valve plate (1) consist of in-
dependent two respective ports (Al, A2, and
Bl, B2).
l The travel speed is changed by changing the
supply of pressurized oil to each port.
Operation
1) In low speed range
If the 2nd travel speed changeover pedal is
released, the pump circuit of 2nd travel speed
changeover valve (3) is closed and the pres-
surized oil does not flow in port PP.
Since all of the pressurized oil from the travel
control valve is supplied to Al and A2 (or Bl
and B2) by the above operation, the piston of
the motor acts through the distance from the
top dead center to bottom dead center. As a
result, the capacity of the motor is increased
but the travel speed is lowered.
l!-!l SXPO7359
2) In high speed range

If the 2nd travel speed changeover pedal i s
depressed, the pump circuit of 2nd travel
speed changeover valve (3) is opened and the
pressurized oil flows in port PP to change
regulator valve (2).
The pressurized oil from the travel control

_._
/J
valve to port A2 (or B2) is cut out by the above
I
operation, and it is supplied to only port Al I .L
r L
-i I
(or Bl). I
I
IL I
I
Accordingly, the piston of the motor acts in I -L

’ &I I
only a part of its stroke. As a result, the ca- II
v--------
0;
pacity of the motor is decreased but the travel
speed is heightened.
~ IT- -1 I
II
‘I I II
I I.--------- --------- II
/I I
LtP_E)_:
T------- ------7
r
LL/fYTj&q 3
SXPO7360
PC1 2R, 15R-8 1o-79

0
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
Blade RAISE
Blade LOWER
SXPO7361
1. R.H. PPC valve 8. R.H. Travel control lever

2. Work equipment lock lever 9. L.H. PPC valve
3. Blade control lever 10. Travel Hi/Lo selector lever
4. R.H. travel control lever (boom, bucket) 11. 9-spool control lever
5. L.H. travel control lever (arm, swing) 12. Boom swing control pedal
6. Work equipment lock lever 13. Boom swing lock plate
7. L.H. travel control lever
1O-80 PCl2R, 15R-8

0
STRUCTURE AND FUNCTION PPC VALUE
PPC VALVE
LEFT: arm, swing
RIGHT bucket, boom
a B-d ‘b
H SYD00313
a. Port P (from PPC basic pressure lock valve) d. PortP4

b. Port T (to tank) (L.H.: Swing LEFT/R.H.: bucket CURL))
c. Port P2 (L.H.: arm OUTA3.H.: boom LOWER) e. Port PI (L.H.: arm IN/R.H.: boom RAISE)
f. Port P3 (L.H.: swing RIGHT/bucket DUMP)
1O-82 PC1 2R, 15R-8
0
STRUCTURE AND FUNCTION WC VALUE
L_.JL-..J
A-A B-B
D-D
E-E
sYDoo314
1. Spool 7. Joint
2. Measuring spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for lever connection)
PC1 2R, 15R-8

1 O-83
0
STFHJCTURE AND FUNCTION PPC VALVE
Operation
1) At neutral
Ports A and B of the control valve and ports
PI and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
Fig. 1) Si3PO1472
21 Duming fine control (neutral + fine control)
When piston (4) starts to be pushed by disc
(51, retainer (9) is pushed; spool (I) is also
pushed by metering spring (21, and moves
down.
When this happens, fine control hole f is shut
off from drain chamber D, and at almost the
same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the
control pump passes through fine control hole
f and goes from port PI to port A.
When the pressure at port Pl becomes higher,
spool (I) is pushed back and fine control hole
f is shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D to release the pressure at
port PI. When this happens, spool (1) moves
up or down so that the force of metering
spring (2) is balanced with the pressure at port
PI. The relationship in the position of spool
(I) and body (IO) (fine control 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 compressed
proportionally to the amount of movement of
the control lever, so the pressure at port PI
also rises in proportion to the travel of the CONTROL
control lever. In this way, the control valve (Fig. 2) SBPO1473
spool moves to a position where the pressure
in chamber A (the same as the pressure at
port PI) and the force of the control valve
spool return spring are balanced. (Fig. 2)
1O-84 PC1 2R, 15R-8

0
STRUCTURE AND FUNCTION PPC VALVE
3) Duming fine control

(when control lever is returned)
When disc (5) starts to be returned, spool (1 I
is pushed up by the force of centering spring
(3) and the pressure at port Pl.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure
oil at port Pl is released.
If the pressure at port PI drops too far, spool
(1) is pushed down by metering spring (21,
and fine control hole f is shut off from drain
chamber Pl. At almost the same time, it is
connected to pump pressure chamber PP, and
the pump pressure is supplied until the pres-
sure at port Pl recovers to a pressure that
corresponds to the lever position.
When the spool of the control valve returns,
oil in drain chamber D flows in from fine con-
trol hole f’ in 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)
(F i 9. 3) SBP01474
4) At full stroke
When disc (5) pushes down piston (41, and
retainer (9) pushes down spool (I), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure from the
control pump passes through fine control hole
f and flows to chamber A from port PI, 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)
(Fig.41 SBPO1475
PC1 2R, 15R-8 1 O-85

0
WORK EQUIPMENT
WORK EQUIPMENT
SEP03344
1. Bucket
6. Boom cylinder
2. Bucket cylinder
7. Boom swing cylinder
3. Arm
8. Boom swing bracket
4. Arm cylinder
9. Blade cylinder
5. Boom
10. Blade
lo-86
PC 12R, 15R-8
0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM

1. MONITOR PANEL
SOP03345
1. Service meter
2. Coolant temperature caution lamp
3. Fuel level
4. Engine oil pressure caution lamp
5. Preheating pilot lamp
6. Charging level caution lamp
PC12R, 15R-8 1O-87

0
STRUCTUREAND FUNCTION MACHINE MONITOR SYSTEM
Display Symbol Display item Display range Display method

category
Engine oil 3elow 0.05 MPa jO.5 kg/cm21

pressure
Displayed while starting switch is in ON
When there is defective position and engine is running.
Battery charge Goes off in normal state
zharging l
SDPO334i l Lights up in abnormal state.
Coolant
temperature Wore than 105’C
a
SOPO334S
Displayed while starting switch is in ON

Fuel level position.
l Indicates the remaining fuel level
with a pointer.
SOP03340
Displayed while starting switch is in

HEAT position.
l Lights up while engine is preheated
Preheating Nhen preheating (For about 15 set).
l Goes off when preheating is com-
SDPO3361
pleted.
2. SENSOR
. The signals from the sensors are input directly
to the monitor panel.
One of the contact points of the sensors with
contacts is always connected to the chassis
GND.
Classification Normal Abnormal

Type of sensor Sensing type
of indication
CAUTION Engine oil pressure Contact type OFF (open) ON (close)
Coolant temperature Resistance type - -

GAUGE
Fuel level Resistance type - -
1O-88 PC1 2R, 15R-8

0
MACHINE MONITOR SYSTEM
FUEL LEVEL SENSOR
FULL 1. Float
2. Variable resistance
3. Brucket
EMPTY
2 3
SDP03352
PC12R, 15R-8
1O-89
0
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

Standard value table for engine
related parts ............................................ 20- 2
Standard value table for chassis
related parts ............................................ 20- 4
Standard value table for electrical
parts ........................................................ 20- 19
TESTING AND ADJUSTING ...................... 20-101
TROUBLESHOOTING ................................ 20-201
s 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 machine
from the factory and is given for reference. It is used as a guideline for judging the progress of wear
after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
b When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
b When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
b When 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 spurt out and cause burns.
b Be careful not to get caught in the fan, fan belt or other rotating parts.
PC12R, 15R-8 20-1

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicable model PC12R-8
Engine 3D68E-3G
Standard value for Service limit

Item Measurement conditions Unit new machine value
High idling rpm 2,600 ± 50 2,600 ± 50

Engine speed Low idling rpm 1,350 ± 50 1,350 ± 50
Rated speed rpm 2,450 2,450
At sudden acceleration Bosch index Max. 5.5 7.5

Exhaust gas color
At high idling Bosch index Max. 1.0 2.0
Valve clearance Intake valve mm 0.20 —

(normal temperature) Exhaust valve mm 0.20 —
Compression pressure Oil temperature: 40 – 60°C MPa {kg/cm2} 3.2 {33} 2.5 {26}
(SAE30 oil) (engine speed) (rpm) (250) (250)
(Water temperature:
Blow-by pressure Operating range) kPa — —
{mmH2O} {—} {—}
(SAE 30 oil) At high idling
(Water temperature:
Operating range)
MPa 0.29 Min. 0.2
At high idling {kg/cm2} {3.0} {Min. 2.0}
Oil pressure (SAE30 oil) MPa Min. 0.06 Min. 0.06
At low idling (SAE30) {kg/cm2} {Min. 0.6} {Min. 0.6}
MPa
At low idling (SAE10W) {kg/cm2} — —
Whole speed range

Oil temperature °C Max. 120 Max. 120
(inside oil pan)
Before top dead center

Fuel injection timing deg. 14 ± 1 —
(B • T • D • C)
Deflection when pressed with

Fan belt tension finger force of approx. 58.8 N mm 10 – 15 —
{6 kg}.
20-2 PC12R, 15R-8

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
PC15R-8
3D68E-3H
Standard value for Service limit

new machine value
2,775 ± 50 2,775 ± 50
1,350 ± 50 1,350 ± 50
2,600 2,600
Max. 5.5 7.5
Max. 1.0 2.0
0.20 —
0.20 —
3.2 {33} 2.5 {26}
(250) (250)
— —
{—} {—}
0.29 Min. 0.2

{3.0} {Min. 2.0}
Min. 0.06 Min. 0.06

{Min. 0.6} {Min. 0.6}
— —
Max. 120 Max. 120
14 ± 1 —
10 – 15 —
PC12R, 15R-8 20-3

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

egory
Standard value Service limit

Cat-
Item Measurement conditions Unit

for new machine value
• Hydraulic oil temperature: 45 – 55°C
Engine speed
• Engine oil pressure:

Within operating range
At pump relief • Engine water temperature: rpm 2,450 ± 100 Min. 2,100
Within operating range
• Bucket relief
Boom control valve l a b l a b
Arm control valve
Bucket control valve 30 6 6 30 6 6
Swing control valve

Spool stroke
Breaker control valve

mm
Boom swing control
valve
Blade control valve

20 6 6 20 6 6
L.H. travel control
valve
R.H. travel control

valve
Boom control lever • Center of lever N → CURL, DUMP 105 ± 11 105 ± 20

knob
• Tip of pedal
Arm control lever • Read max. N → IN, OUT 105 ± 11 105 ± 20
value to end of
travel (exclud-
Bucket control lever ing play) N → CURL, DUMP 105 ± 11 105 ± 20
• Engine stopped
N → left, right
Travel of control levers
Swing control lever 105 ± 11 105 ± 20

swing
Boom swing control N → left, right
pedal boom swing 16 ± 2 16 ± 4
mm
Blade control lever N → RAISE,LOWER 70 ± 10 70 ± 20
Travel control lever N → FORWARD,

REVERSE (left, right) 65 ± 7 65 ± 14
Fuel control lever Low idling ↔

full throttle
Work equipment,
swing Max. 6 Max. 12
Play of control lever
Travel Max. 20 Max. 40
20-4 PC12R, 15R-8

PC15R-8

2,450 ± 100 Min. 2,100
l a b l a b
30 6 6 30 6 6
20 6 6 20 6 6
105 ± 11 105 ± 20
105 ± 11 105 ± 20
105 ± 11 105 ± 20
105 ± 11 105 ± 20
16 ± 2 16 ± 4
70 ± 10 70 ± 20
65 ± 7 65 ± 14
Max. 6 Max. 12
Max. 20 Max. 40
PC12R, 15R-8 20-5


egory

Cat-

Boom control lever • Engine at full throttle 16.7 ± 2.9 16.7 ± 5.8
• Oil temperature: 45 – 55°C {1.7 ± 0.3} {1.7 ± 0.3}
• Fit push-pull scale to center of control
Arm control lever lever knob to measure 16.7 ± 2.9 16.7 ± 5.8
• Fit push-pull scale to tip of pedal to {1.7 ± 0.3} {1.7 ± 0.3}
measure
Operating force of control levers
Bucket control lever • Measure max. value to end of travel 16.7 ± 2.9 16.7 ± 5.8
{1.7 ± 0.3} {1.7 ± 0.3}
Swing control lever 16.7 ± 2.9 16.7 ±5.8

{1.7 ± 0.3} {1.7 ± 0.3}
Boom swing control N 61.7 ± 9.8 61.7 ± 19.6

lever {kg} {6.3 ± 1} {6.3 ± 2}
Blade control lever 15.7 ± 2 15.7 ± 4

{1.6 ± 0.2} {1.6 ± 0.4}
Travel control lever 16.7 ± 4.9 16.7 ± 9.8

{1.7 ± 0.5} {1.7 ± 1}
Low idling ↔ 39.2 ± 19.6 39.2 ± 39.2

Fuel full throttle {4 ± 2} {4 ± 4}
control
lever Full throttle ↔ 39.2 ± 19.6 39.2 ± 39.2
low idling {4 ± 2} {4 ± 4}
• Oil temperature: 45 – 55°C • All levers
2.0 +1.0 2.0 +1.0
Unload pressure 0
• Engine at full throttle at HOLD 0
• Pump outlet pressure {20 +10
0 } {20 +10
0 }
• Oil temperature: 45 – 55°C 18.1 ± 0.25 18.1 ± 0.25

Boom • Engine at full throttle {185 ± 2.5} {185 ± 2.5}
• Pump outlet pressure
• Relieve only circuit to be measured 18.1 ± 0.25 18.1 ± 0.25
Arm
{185 ± 2.5} {185 ± 2.5}
Bucket 18.1 ± 0.25 18.1 ± 0.25

{185 ± 2.5} {185 ± 2.5}
Hydraulic pressure
MPa 11.8 +0.49 11.8 +0.49

Swing {kg/
0 0
{120+50 } {120 +50 }
cm2}
Boom swing 11.8 +0.49
0 11.8 +0.49
0
{120+50 } {120 +50 }
Blade 11.8 +0.49

0 11.8 +0.49
0
{120+50 } {120 +50 }
Travel 11.8 +0.49

0 11.8 +0.49
0
{120+50 } {120 +50 }
Control 2.9 +0.49

0 2.9 +0.49
0
{30 +50 } {30 +50 }
• Hydraulic oil
temperature: 2.0 +1.0
0 2.0 +1.0
0
45 – 55°C All levers at HOLD {20 +10 {20 +10
0 } 0 }
LS differential pressure • Engine at full
throttle
¡LS differential
pressure = Travel rotating
freely, travel lever 1.57 1.57
Pump discharge
pressure at half-way position {16} {16}
- LS pressure
20-6 PC12R, 15R-8

3
PC15R-8

16.7 ± 2.9 16.7 ± 5.8

{1.7 ± 0.3} {1.7 ± 0.3}
16.7 ± 2.9 16.7 ± 5.8

{1.7 ± 0.3} {1.7 ± 0.3}
16.7 ± 2.9 16.7 ± 5.8

{1.7 ± 0.3} {1.7 ± 0.3}
16.7 ± 2.9 16.7 ±5.8

{1.7 ± 0.3} {1.7 ± 0.3}
61.7 ± 9.8 61.7 ± 19.6

{6.3 ± 1} {6.3 ± 2}
15.7 ± 2 15.7 ± 4
{1.6 ± 0.2} {1.6 ± 0.4}
16.7 ± 4.9 16.7 ± 9.8

{1.7 ± 0.5} {1.7 ± 1}
39.2 ± 19.6 39.2 ± 39.2

{4 ± 2} {4 ± 4}
39.2 ± 19.6 39.2 ± 39.2

{4 ± 2} {4 ± 4}
+1.0
2.0 0 2.0 +1.0
0
{20 +10
0 } {20 +10
0 }
18.1 ± 0.25 18.1 ± 0.25

{185 ± 2.5} {185 ± 2.5}
18.1 ± 0.25 18.1 ± 0.25

{185 ± 2.5} {185 ± 2.5}
18.1 ± 0.25 18.1 ± 0.25

{185 ± 2.5} {185 ± 2.5}
11.8 +0.49
0 11.8 +0.49
0
{120 +50 } {120 +50 }
11.8 +0.49
0 11.8 +0.49
0
{120 +50 } {120 +50 }
11.8 +0.49
0 11.8 +0.49
0
{120 +50 } {120 +50 }
11.8 +0.49
0 11.8 +0.49
0
{120 +50 } {120 +50 }
+0.49 +0.49
2.9 0 2.9 0
{30 +50 } {30 +50 }
2.0 +1.0
0 2.0 +1.0
0
{20 +10
0 } {20 +10
0 }
1.57 1.57
{16} {16}
PC12R, 15R-8 20-7

3

egory

Cat-

Overrun when Deg. Max. 30 Max. 40

stopping swing (mm) (Max. 120) (Max. 160)
• Engine at full throttle
• Stop after swinging one turn and measure
distance that swing circle moves
• ( ): Distance of movement on outside cir-
cumference of swing circle
90° Max. 2 Max. 2.2
Time taken to start Sec

swing

• Hydraulic oil temperature: 45 – 55°C 180° — —
• Time taken to swing 90° and 180°
from starting position
Swing
Time taken to swing Sec 35 ± 1.5 Max. 42

• Swing one turn, and measure time taken
to swing next 5 turns
Rated load:
706N {72 kg}
Hydraulic drift of Deg. 0 0

swing (mm) (0) (0)
• Engine stopped
• Bucket at rated load or filled with soil.
• Set machine on 15° slope, and set upper
structure at 45° to the front.
• Make counter marks on swing circle outer
race and track frame.
• Measure distance that counter marks move
apart after 15 minutes.

Leakage from swing • Hydraulic oil temperature: 45 – 55°C cc/
motor min — —
• Relieve swing circuit.
20-8 PC12R, 15R-8

PC15R-8

Max. 30 Max. 40
(Max. 120) (Max. 160)
Max. 1.8 Max. 2.0
— —
29 ± 1.5 Max. 36
Rated load:
785N {80 kg}
0 0
(0) (0)
— —
PC12R, 15R-8 20-9


egory

Cat-

Low speed
22 ± 2 22 ± 4
Travel speed (1) Sec
High speed
• Hydraulic oil temperature:
45 – 55°C 11.5 ± 2 11.5 ± 4
• Raise track on one side at a time,
rotate one turn, then measure
time taken for next
Low speed
Travel speed (2) Sec

High speed
45 – 55°C
• Run up for at least 10 m, and mea-
sure time taken to travel next 20
Travel
m on flat ground.
• ( ): Steel shoe specification ma-
chine

• Run up for at least 10 m, and mea-
sure deviation when traveling next 20
Travel deviation m on flat ground. mm Max. 500 Max. 550
• Use a hard horizontal surface.
20m
10m BKP00107
s Measure dimension χ
20-10 PC12R, 15R-8

PC15R-8

20.5 ± 2 20.5 ± 4
10.5 ± 2 10.5 ± 4
Max. 500 Max. 550
PC12R, 15R-8 20-11


egory

Cat-

Hydraulic drift of travel mm Max. 200 Max. 240

Travel
• Engine stopped
• Stop machine on 30° slope with
sprocket on uphill side.
• Measure the distance the machine
moves in 5 minutes.

Leakage of travel • Hydraulic oil temperature: 45 – 55°C l/
motor mm — —
• Lock track and relieve travel circuit.
Total work Rated load:

equipment 706 N {72 kg}
 hydraulic drift 
 at tip of  Max. 300 Max. 600
 bucket teeth 
Boom cylinder
 amount of  Max. 20 40
 retraction of 
 cylinder  • Place in above posture and measure
extension or retraction of each cylin-
Hydraulic drift of work equipment
der and downward movement at tip

Arm cylinder of bucket teeth.
 amount of  • Horizontal, flat ground
 extension of  • Bucket: Rated load Max. 25 50
 cylinder 
Work equipment
• Levers at neutral
• Engine stopped
Bucket cylinder • Start measuring immediately after
setting.
 amount of  • Measure hydraulic drift every 5 min- Max. 10 20
 retraction of  utes, and judge from results for 15
mm
 cylinder  minutes.
• Engine stopped
Boom swing • Hydraulic oil temperature: 45 – 55°C
cylinder • Bucket: Rated load
• Using same posture as above, set ma-
 retraction,  chine on 15° slope with upper struc-
Max. 15 30
 extension of  ture at 90° to the side. Measure re-
 cylinder  traction and extension of cylinder for
15 minutes.
Blade • Engine stopped

• Hydraulic oil temperature:45 – 55°C
 downward  • Raise blade to max. height, then mea- — —
 movement at  sure downward movement at tip of
 tip of blade  blade for 15 minutes.
20-12 PC12R, 15R-8

PC15R-8

Max. 200 Max. 240
— —
Rated load:
785 N {80 kg}
Max. 300 Max. 600
Max. 20 40
Max. 25 50
Max. 10 20
Max. 15 30
— —
PC12R, 15R-8 20-13


egory

Cat-

RAISE
Boom
1.9 ± 0.3 1.9 ± 0.6
Bucket teeth in
contact with
ground
↔
LOWER
Cylinder fully 1.9 ± 0.3 1.9 ± 0.6
extended • Engine at full throttle
45 – 55°C
Arm IN 2.5 ± 0.3 2.5 ± 0.6
Cylinder fully
retracted
↔
OUT
Fully extended 2.5 ± 0.3 2.5 ± 0.6

45 – 55°C
Work equipment speed
CURL
Bucket 2.3 ± 0.3 2.3 ± 0.6

Work equipment
Cylinder fully
retracted Sec
↔
DUMP
Fully extended 2.7 ± 0.3 2.7 ± 0.6

45 – 55°C
RAISE
Blade 0.9 ± 0.3 0.9 ± 0.6
Blade in contact
with ground
LOWER
↔
Blade fully raised 1.4 ± 0.3 1.4 ± 0.6

45 – 55°C
Left swing
5.8 ± 1.0 5.8 ± 2.0

Boom swing
Cylinder fully
retracted
Right swing
↔
Fully extended
6.1 ± 1.0 6.1 ± 2.0
45 – 55°C
20-14 PC12R, 15R-8

PC15R-8

1.6 ± 0.3 1.6 ± 0.6
1.7 ± 0.3 1.6 ± 0.6
2.3 ± 0.3 2.3 ± 0.6
2.4 ± 0.3 2.4 ± 0.6
2.3 ± 0.3 2.3 ± 0.6
2.3 ± 0.3 2.3 ± 0.6
1.3 ± 0.3 1.3 ± 0.6
1.6 ± 0.3 1.6 ± 0.6
6.3 ± 0.3 6.3 ± 0.6
6.9 ± 0.3 6.9 ± 0.6
PC12R, 15R-8 20-15


egory

Cat-

Boom Max. 3 Max. 4
• Engine at low idling

• Retract arm and bucket cylinders fully and set
boom at max. height. Lower boom and measure
time taken from point where bucket contacts
ground to point where chassis rises from ground
Arm Max. 2 Max. 3

• Set top of boom horizontal and retract
Time lag
Work equipment
bucket cylinder fully. Then extend cylin-

der and measure time taken for arm to stop
at bottom and then start again Sec
Bucket Max. 1 Max. 2

• Set top of boom horizontal and retract arm
cylinder fully. Then extend cylinder and
measure time taken for bucket to stop at
bottom and then start again
Blade Max. 1 Max. 2

• Raise blade to max. height. Then lower
blade and measure time taken from point
where blade contacts ground to point
where chassis rises from ground
• Hydraulic oil temperature: 45 – 55°C Max. 1.2 Max. 2
Internal
leakage
Cylinders cc/
• Apply relief pressure to circuit to be min
Center swivel joint
20-16 PC12R, 15R-8

PC15R-8

Max. 3 Max. 4
Max. 2 Max. 3
Max. 1 Max. 2
Max. 1 Max. 2
Max. 1.2 Max. 2
PC12R, 15R-8 20-17

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sys- Connector Inpsec-

tion
Measurement
tem Name of component No. method
Judgement table conditions
If the condition is as shown in Table 1 and Table 2, the 1) Connect
monitor panel is normal. T-adapter
Table 1 (CHECK, CAUTION section)
Monitor item Measurement Sensor
(input connector) conditions Display signal input
Engine water tem- Engine ON Max. 1 V

perature C2 (10) started OFF 10 – 16 V
CHECK, CAUTION
section Battery charge Engine ON Max. 1 V
C2 (3) started OFF 10 – 16 V
Engine oil pressure Engine ON Max. 1 V
C2 (4) started OFF 10 – 16 V
Monitor panel
Preheating Engine ON 10 – 16 V
C2 (2) stopped OFF Max. 1 V
Table 2 (Gauges) 1) Turn starting

switch OFF,
Display level resistance insert dummy
Position of gauge
display  Monitor panel input resistance, or
 resistance  measure
resistance of
Machine monitor system
Starting switch ON Starting switch OFF sensor.

Gauges 2) Turn starting
Measure switch ON,
resistance E 80 ± 0.1 Ω and check
between display.
fuel level
gauge C2
(female) F 10 ± 0.1 Ω
(6) – (7)
If the condition is as shown in the table 1) Turn starting

below, it is normal switch OFF.
resistance
Measure
2) Disconnect
Coolant temperature E6 (male) Normal temperature (25°C) Min. 1 MΩ connector E6.
sensor
Above 110°C Max. 1 Ω
If the condition is as shown in the table 1) Turn starting

below, it is normal switch OFF.
resistance
Measure
M6 (male) 2) Disconnect
Fuel level sensor M5 (male) Full 10 ± 0.1 Ω connectors
M6 – M5 M6 and M5.
Empty 80 ± 0.1 Ω
If the condition is as shown in the table 1) Disconnect

below, it is normal connector E7.
2) Start engine.
resistance
Measure
Engine oil pressure Above 68.6 kPa

E7 {Above 0.7 kg/cm2} Min. 1 MΩ
sensor
Below 49.0 kPa
{Below 0.5 kg/cm2} Max. 1 Ω
PC12R, 15R-8 20-19

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sys- Connector Inpsec-

tion Measurement
tem Name of component No. method
Judgement table
conditions
Machine monitor
If the condition is as shown in the table 1) Disconnect

below, it is normal connector E3.
resistance
Measure
2) Start engine.
system
Between (1)(2) – chassis 13.5 – 14.5 V 3) Measure with

Alternator E3 (male)
AC range.
• When engine is running
(1/2 throttle or above)
20-20 PC12R, 15R-8

Tools for testing, adjusting, and troubleshooting ................................................................................ 20-102

Measuring engine speed ..................................................................................................................... 20-102-1
Measuring exhaust color .................................................................................................................... 20-102-2
Adjusting valve clearance ................................................................................................................... 20-102-3
Measuring compression pressure ...................................................................................................... 20-102-4
Testing and adjusting fuel injection timing ........................................................................................ 20-102-5
Measuring engine oil pressure ........................................................................................................... 20-102-6
Testing and adjusting fan belt tension ............................................................................................... 20-102-7
Testing and adjusting fuel control lever ................................................................................................ 20-103
Measuring sprocket wear ....................................................................................................................... 20-104
Testing and adjusting track shoe tension ............................................................................................. 20-105
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit .......................... 20-106
Testing and adjusting LS differential pressure (PC15R) ....................................................................... 20-111
Adjusting PC valve spring ...................................................................................................................... 20-113
Testing and adjusting control circut pressure ...................................................................................... 20-114
Measuring output pressure of PPC lock valve and travel boost valve ................................................ 20-116
Testing PPC valve output pressure and swing holding brake inlet port pressure ............................. 20-117
Adjusting work equipment, swing PPC valve ....................................................................................... 20-119
Testing and adjusting travel deviation ............................................................................................... 20-119-1
Measuring oil leakage inside work equipment cylinder ................................................................... 20-119-2
Releasing remaining pressure from hydraulic circuit .......................................................................... 20-120
Releasing remaining pressure from hydraulic tank ............................................................................. 20-120
Pressurizing hydraulic tank .................................................................................................................... 20-120
Bleeding air ............................................................................................................................................. 20-121
PC12R, 15R-8 20-101

3
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measure- Symbol Part No. Part Name Remarks

ment item
1 799-203-9000 Multi-tachometer
Engine speed Digital display L:60 – 2,000rpm
A
2 • 799-203-8901 • Clamp set H:60 – 19,999rpm
Water and oil temperatures B 799-101-1502 Digital temperature gauge – 99.9 – + 1,299°C
799-101-5002 Hydraulic tester Pressure gauge : 2.5,5.9,39.2,

58.8 MPa{25,60,400,600 kg/cm2}
1
790-261-1203 Digital hydraulic tester Pressure gauge :
68.6 MPa {700 kg/cm2}
2 • 799-101-5160 • Nipple PT1/8
C
• 790-261-1340 10 × 1.25 (female PT 1/8)
for both male and female
• 790-261-1311 14 × 1.5 (female PT 1/8)

Oil pressure for both male and female
3 • Adapter
• 790-261-1321 18 × 1.5 (female PT 1/8)
• 790-261-1331 22 × 1.5 (female PT 1/8)

4 799-401-2320 Hydraulic gauge 1.0 MPa {10kg/cm2}
5 799-401-2701 Differential pressure gauge
07040-11007 Plug 10 × 1.25

6
07002-11023 O-ring
1 795-502-1205 Compression gauge 0 – 6.9 MPa {0 – 70kg/cm2}
Compression pressure D 2 795-111-1110 Adapter

3 • 795-101-1571 • Joint
E Commercially Feeler gauge

Valve clearance available
1 799-201-9000 Handy smoke checker Discoloration 0 – 70%
Exhaust color F (with standard color)
2 Commercially Smoke meter (Discoloration % x 1/10 .=.
available Bosch index)
Operating effort G Commercially Push-pull scale

available
Stroke, hydraulic drift H Commercially Scale
available
Work equipment speed J Commercially Stop watch
available
Measuring voltage and Commercially
resistance values K Tester
available
Troubleshooting of wiring
harnesses and sensors L 799-601-8000 T-adapter kit
Measuring wear of
sprocket M 796-127-1130 Wear gauge
20-102 PC12R, 15R-8

TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

b Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
¡ Measure the engine speed under the following
conditions.
• Cooling water temperature: Within operating
range
• Hydraulic oil temperature : 45 – 55°C
1. Install clamp set A2 of multi-tachometer to fuel

injection tube (1), then connect to multi-tachom-
eter A1.
2. Start the engine, and measure the engine speed

when it is set to the conditions for measuring.
1) Measuring low idling and high idling speed:
Measure the engine speed with the fuel con-
trol lever set to low idling and high idling.
2) Measuring speed at 1-pump relief:
Run the engine at full throttle, operate the
bucket control lever, and measure the engine
speed when the bucket CURL is relieved.
3) Measuring speed at 2-pump relief:
Run the engine at full throttle, operate the
bucket and swing control levers, and measure
the engine speed when the bucket CURL and
swing are relieved.
b For the swing, use the work euipment
and lock securely.
PC12R, 15R-8 20-102-1

3
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

• When measuring in the field where there is no air
or electric power supply, use Handy Smoke
Checker F1; when recording formal data, use
Smoke Meter F2.
¡ Raise the coolant temperature to the operating
range before measuring.
b Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
1. Measuring with Handy Smoke Checker F1.

1) Install filter paper to Handy Smoke Checker
F1.
2) Insert the exhaust gas suction port into the
exhaust pipe.
3) Accelerate the engine suddenly, and operate
the handle of Handy Smoke Checker F1 at the
same time to collect the exhaust gas on the
filter paper.
4) Remove the filter paper and compare it with
the scale supplied to judge the condition.
2. Measuring with Smoke Meter F2

1) Insert the probe of Smoke Meter F2 into the
outlet port of the exhaust pipe, and tighten
the clip to secure it to the exhaust pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter F2.
¡ Keep the pressure of the air supply below
1.47 MPa {15 kg/cm2}.
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.
¡ Fit the filter paper securely so that the ex-
haust gas cannot leak.
5) Turn the power switch of Smoke Meter F2 ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter F2 at
the same time to collect the exhaust gas color
on the filter.
7) Place the filter paper used to catch the exhaust
gas color on top of at least 10 sheets of un-
used filter paper inside the filter paper holder,
and read the value shown.
20-102-2 PC12R, 15R-8

3
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

1. Remove air cleaner (1), then remove the cylinder
head cover.
2. Remove cap (2) of the flywheel housing.
3. Rotate the crankshaft in the normal direction to

align the No. 1 line b on the flywheel with line a
on the housing. When rotating, check the move-
ment of the valves of the No. 1 cylinder (flywheel
end).
¡ Cylinder No. 1 is the cylinder at the flywheel
end of the engine.
¡ When the crankshaft is rotated, the valves of
the cylinder at top dead center do not move.
If the valves are moving, rotate the crankshaft
one more turn and align the lines.
¡ Rotate the crankshaft 240° each time and
adjust the valve clearance of each cylinder
according to the firing order.
• Firing order : 1—3—2
¡ There is a line on the flywheel for the top dead
center of each cylinder.
4. To adjust the valve clearance, loosen locknut (6),

then insert feeler gauge E between rocker lever
(3) and valve stem (4), and turn adjustment screw
(5) until the clearance is a sliding fit. Then tighten
locknut (6) to hold the adjustment screw in posi-
tion.
9 Locknut : 25.48 ± 2.94 Nm {2.6 ± 0.3 kgm}
¡ After tightening the locknut, check the clear-
ance again.
PC12R, 15R-8 20-102-3

3
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
b When measuring the compression pressure, be
careful not to touch the exhaust manifold or muf-
fler, or to get your clothes caught in the fan, fan
belt or other rotating parts.
1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine to make the oil temperature

40 – 60°C.
3. Remove nozzle holder assembly (1) from the cyl-

inder to be measured.
4. Install adapter D2 and joint D3 to the mount of

the nozzle holder, then connect compression
gauge D1.
9 Adapter mounting nut:
50.96 ± 1.96 Nm {5.2 ± 0.2 kgm}
5. Set multi-tachometer A in position.
6. Disconnect engine stop solenoid connector E5 (1).
7. Close the fuel filter stop valve.
8. Crank the engine with the starting motor and mea-

sure the compression pressure.
¡ Measure the compression pressure at the
point where the compression gauge indica-
tor remains steady.
¡ When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
¡ After measuring the compression pressure, install

the nozzle holder assembly.
9 Nozzle holder mounting nut:
50.96 ± 1.96 Nm {5.2 ± 0.2 kgm}
20-102-4 PC12R, 15R-8

3
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
Testing
1. Disconnect fuel injection pipe (1) of the No. 1 cyl-

inder.
¡ Engine cylinder No. 1 is the cylinder at the fly-
wheel end.
2. Remove cap (2) of the flywheel housing.
3. Turn the crankshaft in the normal direction, and

stop the crankshaft at the point where the surface
of the fuel at the tip of delivery valve holder (3)
begins to rise.
4. In this condition, check that line a on the flywheel

housing is aligned with line b on the flywheel.
Adjusting
¡ If the lines are not aligned, adjust as follows.
1. Remove the fuel injection pump assembly.

¡ For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF FUEL INJECTION PUMP
ASSEMBLY.
2. Adjust the thickness of shim (4) between the fuel

injection pump and gear case to adjust the tim-
ing.
• INCREASE shim to RETARD injection timing
• DECREASE shim to ADVANCE injection tim-
ing
¡ Be careful of the following points when ad-
justing.
(1) The standard for the injection timing ad-
justment shim is 0.5 mm.
(2) The adjustment shim has a silicon coat-
ing, so use thinner to remove all the oil
and grease from both faces of the shim
and the fuel injection pump mounting
surface.
(3) A shim thickness of 0.1 mm changes
approx. 1°.
There are two types of shim thickness: 0.2
mm and 0.3 mm.
3. After adjusting, install the fuel injection pump as-

sembly.
¡ For details, see DISASSEMBLY AND ASSEM-
BLY, INSTALLATION OF FUEL INJECTION
PUMP ASSEMBLY.
PC12R, 15R-8 20-102-5

3
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRES-

SURE
¡ Measure the engine oil pressure under the follow-
ing conditions.
• Cooling water temperature: Within operating
range
1. Remove engine oil pressure switch (1).
2. Install nipple C2, then connect oil pressure gauge

C4 (1.0 MPa {10 kg/cm2}).
3. Start the engine, and measure the oil pressure

with the engine at low idling and high idling.
20-102-6 PC12R, 15R-8

3
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN

BELT TENSION
Testing
1. Measure deflection a of the fan belt when pressed
with a force of approx. 58.8 Nm {approx. 6 kg} at a
point midway between the fan pulley and the al-
ternator pulley.
• Belt deflection a: 10 – 15 mm
Adjusting
¡ If the deflection is not normal, adjust as follows.
1. Loosen the alternator mounting bolts and adjust-

ment bolt (1).
2. Using a bar, move alternator (2) towards the out-

side to adjust the belt tension.
3. Tighten adjustment bolt (1), then tighten the al-

ternator mounting bolts.
PC12R, 15R-8 20-102-7

3
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL CONTROL LEVER
TESTING AND ADJUSTING FUEL CONTROL LEVER
1. Before connecting yoke (1), adjust with nut (3)

so that operating effort of fuel control lever (2) is
standard value shown below.
• Operating effort : 2.5 – 3.5 kg
s Measure the operating effort at the center of
the lever knob.
s After adjusting, connect yoke (1).
2. Set fuel control lever (2) at the low idling posi-

tion.
3. Connect inner cable (4) of the wire to governor

lever (5).
s Check that the governor lever is in contact
with the low idling stopper.
4. Start the engine, move fuel control lever (2) to

the high idling position, then adjust the high
idling speed with adjustment bolt (6).
• High idling speed : 2,600 ± 50 rpm (PC12R)
2,775 ± 50 rpm (PC15R)
• Standard dimension a of stopper bolt (refer-
ence) : 20 mm
PC12R, 15R-8 20-103

TESTING AND ADJUSTING MEASURING SPROCKET WEAR
MEASURING SPROCKET WEAR
1. Remove the track shoe assembly.

s For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF RUBBER SHOE ASSEM-
BLY or REMOVAL OF STEEL SHOE ASSEM-
BLY.
2. Align wear gauge M with the sprocket.

s Align the standard line, then align the wave
shape of the sprocket with the wave shape of
the wear gauge.
3. Judge the sprocket wear.

s If the wave shape of the sprocket is above the
wear limit line:
It is possible to continue to use the sprocket.
s If the wave shape of the sprocket has reached
the wear limit line:
Replace the sprocket with a new part.
20-104 PC12R, 15R-8

TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
Testing
1. Move the machine forward or backward to set
the connection of the track shoe (M mark) at the
top at the center of the track between the idler
and sprocket.
s Rubber shoe specification machine only.
2. Using the boom and arm, push up the track on

the side being inspected.
3. Measure clearance a between the tread of the

track roller and the top surface of the track link.
s Measure at the following position.
• PC12R, 15R: 2nd track roller from sprocket
• Standard clearance (tension)
Rubber shoe : 10 – 15 mm
Steel shoe : 10 – 20 mm
Adjusting
s If the track shoe tension is not within the stan-
dard value, adjust as follows.
1. If tension is too tight

Slowly loosen valve (1) and release grease.
b There is danger that the valve may fly out
under the high internal pressure of the
grease, so never loosen the valve more than
1 turn.
s If the grease does not come out easily, move
the machine backwards or forwards slowly.
2. If tension is too loose

Pump in grease through grease fitting (2).
s If the grease does not come out easily, move
the machine backwards or forwards slowly.
PC12R, 15R-8 20-105

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT (PC12R)

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT (PC12R)
Measuring
s Oil temperature when measuring: 45 – 55°C
b Before removing the oil pressure measurement
plug, release the pressure inside the hydraulic
tank. For details, see RELEASING REMAINING
PRESSURE FROM HYDRAULIC TANK.
b After installing the oil pressure gauge, pressur-
ize the hydraulic tank. For details, see PRESSUR-
IZING HYDRAULIC TANK.
1. Measuring unload oil pressure

1) Remove pressure measurement plug (1) (PT1/
8).
2) Fit nipple C2, then install oil pressure gauge
C1 (39.2 MPa {400 kg/cm2}).
3) Run the engine at full throttle and measure
the oil pressure with all levers at HOLD.
2. Measuring work equipment, and travel relief pres-

sure
1) Remove pressure measurement plug (1) (PT1/
8).
C1 (39.2 MPa {400 kg/cm2}).
the oil pressure with each actuator operated
to the end of its stroke.
b For the work equipment, set each cylin-
der to the end of its stroke.
b For the travel, lock the track by fitting
block 1 under the track shoe grouser or
by fitting block 2 between the sprocket
and frame.
20-106 PC12R, 15R-8

3. Measuring swing relief pressure

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

C1 (39.2 MPa {400 kg/cm2}).
b For the swing, use the work equipment
and lock securely.
Adjusting
s The unload valve cannot be adjusted.
1. Adjusting main relief valve
s If the work equipment and travel relief pres-
sure is not normal, adjust the main relief valve
as follows.
1) Loosen locknut (3) and turn adjustment screw
(4) to adjust.
s Turn the adjustment screw to adjust as fol-
lows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
s Amount of adjustment for one turn of ad-
justment screw : 12.6 MPa {128 kg/cm2}
2) After adjusting, tighten locknut (3).
3 Locknut : 59 ± 10 Nm {6 ± 1 kgm}
s After completion of adjustment, use the mea-
surement procedure above to check the oil
pressure again.
PC12R, 15R-8 20-107

TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT (PCIPR)
3. Measuring swing relief pressure

1) Remove oil pressure measurement plug (2)
(PT1/8).
ELPO2192

Cl (39.2 MPa I400 kg/cm2}).
the oil pressure with ‘each actuator operated
g For the swing, use the work equipment

and lock securely.
’ / BLPO2193
Adjusting
* The unload valve cannot be adjusted.
* If the work equipment and travel relief pres-
sure is not normal, adjust main relief valve
(8) as follows.
1) Remove cover (7) from the lower part of the

revolving frame.
(4) to adjust.
* Turn the adjustment screw to adjust as fol- TXP0.2118
lows.
. To INCREASE pressure, turn CLOCK-
WISE
. To DECREASE pressure, turn COUN-
TERCLOCKWISE
* Amount of adjustment for one turn of ad-
justment screw : 12.6 MPa I128 kg/cm*}
m Locknut : 59 5 10 Nm {S + 1 kgm}
* After completion of adjustment, use the mea-

pressure again.
4) Install cover (7). BKP02195
PC1 2R, 15R-8 20-107

0
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT (PCIZR)
2. Swing motor safety valve

* If the swing relief pressure is not normal, ad-
just the swing motor safety valve as follows. Swine motor safet
1) Remove nut (5).

(7) to adjust.
* Turn the adjustment screw as follows.
l To INCREASE pressure, turn CLOCK-
WISE
l To DECREASE pressure, turn COUN-
TERCLOCKWISE
4) After adjusting, install nut (5).
pressure again.
I BLPO2197
20-108 PC1 2R, 15R-8

TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT (PCISR)

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT (PCl5R)
Measuring
* Oil temperature when measuring: 45 - 55°C
a Before removing the oil pressure measurement

plug, release the pressure inside the hydraulic
tank. For details, see RELEASING REMAINING
PRESSURE FROM HYDRAULIC TANK.
g After installing the oil pressure gauge, pressur-
ize the hydraulic tank. For details, see PRES-
SURIZING HYDRAULIC TANK.
1. Measuring unload oil pressure

1) Remove pressure measurement plug (1) (PTII
8).
Cl (39.2 MPa {400 kg/cm2)).
the oil pressure with all levers at HOLD.
2. Measuring work equipment, swing and travel re-

lief pressure
1) Remove pressure measurement plug (I) (PTV
8).
Cl (39.2 MPa I400 kg/cm21).
a For the work equipment, set each cylin-

der to the end of its stroke.
For the swing, use the work equipment
and lock securely.
For the travel, lock the track by fitting
block @ under the track shoe grouser or
by fitting block @ between the sprocket
and frame. BLPDOl70 BLP00171
PC1 ZR, 15R-8 20- 109

Adjusting
n
* The unload valve cannot be adjusted.
* If the work equipment and travel relief pres-
sure is not normal, adjust main relief valve
(8) as follows.
1) Remove cover (7) from the lower part of the
revolving frame.
(3) to adjust.
* Turn the adjustment screw to adjust as
follows. TXP02118
. To INCREASE pressure, turn CLOCK-
WISE
l To DECREASE pressure, turn COUN-
TERCLOCKWISE
* Amount of adjustment for one turn of ad-
justment screw: 12.6 MPa {I 28 kg/cm*)
w Locknut: 59 f 10 Nm 16 + 1 kgm}

pressure again.
4) Install cover (7).
I BKP02045
2. Swing motor safety valve

* Ifihe swing relief pressure is not normal, ad-
just the swing motor safety valve as follows.
1) Remove nut (4).
(6) to adjust.
* Turn the adjustment screw as follows.
l To INCREASE pressure, turn CLOCK-
WISE
. To DECREASE pressure, turn COUN-
TERCLOCKWISE
4) After adjusting, install nut (4).
pressure again.
BLPO2201
20-110 PC1 2R, 15R-8

a
TESTING AND ADJUSTING LS DIFFERENTIAL
TESTING AND ADJUSTING PRESSURE (PC15R)
TESTING AND ADJUSTING LS

DIFFERENTIAL PRESSURE (PC15R)
Measuring
1. Measuring with differential pressure gauge
1) Remove oil pressure measurement plugs (1)
and (2) (PT1/8).
2) Fit nipple C2, then install differential pressure
gauge C5.
¡ Connect pump discharge pressure (1) to
the high-pressure side of the differential
pressure gauge and LS pressure (2) to the
low-pressure side.
3) Using the work equipment, push up the track
on one side.
4) Run the engine at full throttle, set to the con-
ditions in the table, and measure the LS dif-
ferential pressure.
Table
LS differential
Travel lever pressure Remarks
(MPa{kg/cm2})
+1.0
2.0 0 LS differential pressure
Neutral becomes same as
{20 +10
0 } unload pressure
Half 1.57
travel rotates
 freely  {16}
2. Measuring with oil pressure gauge

¡ The differential pressure at its maximum is
less than 1.96 MPa {20 kg/cm2}, so measure
with the same pressure gauge.
1) Remove oil pressure measurement plugs (1)
and (2) (PT1/8).
C1 (39.2 MPa {400 kg/cm2})
¡ Use a gauge with a scale in units of 1.0
MPa {10 kg/cm2}.
3) Using the work equipment, push up the track
on one side.
ditions in the table, and measure the pump
discharge pressure.
¡ Read the gauge indicator accurately from
directly in front of it.
ditions in the table, and measure the LS pres-
sure.
¡ Read the gauge indicator accurately from
directly in front of it.
6) Calculate the LS differential pressure from the
pump discharge pressure and the LS pressure.
PC12R, 15R-8 20-111

3
TESTING AND ADJUSTING LS DIFFERENTIAL
TESTING AND ADJUSTING PRESSURE (PC15R)
Adjusting
1. Adjusting LS valve
s If the LS differential pressure is not normal,
adjust the LS valve as follows.
1) Disconnect hose (3).
(5) to adjust.
s Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
s Amount of adjustment for one turn of adjust-
ment screw:
1.3 MPa {13 kg/cm2} (LS differential pressure)
3 Locknut :
30.85 ± 3.45 Nm {3.15 ± 0.35 kgm}
s After completion of adjustment, repeat the
measurement procedure above to check the
set pressure again.
20-112 PC12R, 15R-8

TESTING AND ADJUSTING ADJUSTING PC VALVE
ADJUSTING PC VALVE
s If the load becomes high and the engine speed
drops, or the engine speed remains normal and
the work equipment becomes slower, when the
pump discharge pressure and the LS differential
pressure are normal, adjust the pump PC valve
as follows.
1. Loosen locknut (1) and turn adjustment screw (2)

to adjust.
• If the work equipment speed is slow:
To INCREASE pump absorption torque,
turn CLOCKWISE
• If the engine speed drops:
To DECREASE pump absorption torque,
turn COUNTERCLOCKWISE
s Turn the adjustment screw within a range of
180° to the left and right.
2. After adjusting, tighten locknut (1).
PC12R, 15R-8 20-113

TESTING AND ADJUSTING CONTROL
TESTING AND ADJUSTING CIRCUIT PRESSURE (PC12R)

CONTROL CIRCUIT PRESSURE
(PC12R)
Measuring
1. Remove pressure measurement plug (1) (PT1/8).
2. Fit adapter C2, then install oil pressure gauge C1

(5.9 MPa {60 kg/cm2}).
3. Measure the oil pressure with the engine at full

throttle and the control levers at HOLD.
Adjusting
1. Loosen locknut (2) and turn adjustment screw
(3) to adjust.
CLOCKWISE
ment screw: 5.49 MPa {56 kg/cm2}

3 Locknut:
22.05 ± 2.45 Nm {2.25 ± 0.25 kgm}
20-114 PC12R, 15R-8

TESTING AND ADJUSTING CONTROL
TESTING AND ADJUSTING CIRCUIT PRESSURE (PC15R)

CONTROL CIRCUIT PRESSURE
(PC15R)
Measuring
1. Remove pressure measurement plug (1) (PT1/8).
2. Fit adapter C2, then install oil pressure gauge C1

(5.9 MPa {60 kg/cm2}).
3. Measure the oil pressure with the engine at full

throttle and the control levers at HOLD.
Adjusting
1. Loosen locknut (2) and turn adjustment screw (3)
to adjust.
CLOCKWISE
ment screw: 5.49 MPa {56 kg/cm2}

3 Locknut:
22.05 ± 2.45 Nm {2.25 ± 0.25 kgm}
PC12R, 15R-8 20-115

MEASURING OUTPUT PRESSURE OF PPC
TESTING AND ADJUSTING LOCK VALVE AND TRAVEL BOOST VALVE
MEASURING OUTPUT PRESSURE

OF PPC LOCK VALVE AND
TRAVEL BOOST VALVE
* Oil temperature when measuring: 45 - 55°C
1. Disconnect outlet hose (I 1or (2) from the valve to
be measured.
l (1) : PPC lock valve
l (2) : Travel boost valve
2. Fit adapter C3 and nipple C2, then install oil pres-

sure gauge Cl (5.9 MPa (60 kg/cm*)).
3. Run the engine at full throttle, set to the condi-

tions in Table 1, and measure the output pressure.
Table 1
“i
2 Travel boost
Et peda’ r:1
Boost pedal 2.9 +8.@
ON (30 ‘“01
.PO22 16
20-116 PC12R, 15R-8

0
TESTING PPC VALVE OUTPUT PRESSURE AND SWING
TESTING AND ADJUSTING HOLDING BRAKE INLET PORT PRESSURE
TESTING PPC VALVE OUTPUT

PRESSURE AND SWING
HOLDING BRAKE INLET PORT
PRESSURE
1. Measuring PPC valve output pressure
1) Disconnect PPC hose (1) of the circuit to be
measured.
s For details of the hose to disconnect, see
the circuit diagram on the next page.
2) Install adapter C3 and plug and O-ring C6 to

the hose, and block the circuit.

C1 (5.9 MPa {60 kg/cm2}).
4) Measure the output pressure with the engine

at full throttle and the control lever operated.
s The standard value is the same as the con-
trol circuit pressure (when the control le-
ver is operated fully).
2. Measuring swing holding brake inlet port pres-

sure
1) Disconnect hose (2).
2) Fit adapter C3 and nipple C2, then install oil
pressure gauge C1 (5.9 MPa {60 kg/cm2}).
3) Measure the inlet port pressure with the en-
gine at full throttle and the control lever oper-
ated to left swing, right swing, or arm IN.
s The standard value is the same as the con-
trol circuit pressure (when the control le-
ver is operated fully).
PC12R, 15R-8 20-117

TESTING PPC VALVE OUTPUT PRESSURE AND SWING
TESTING AND ADJUSTING HOLDING BRAKE INLET PORT PRESSURE
<Reference>
• If the PPC valve output pressure is normal for all
of left swing, right swing, and arm IN, and the
swing holding brake inlet port pressure is not
normal for any of these operations, it can be
judged that the PPC shuttle valve for the abnor-
mal system is defective.
• The PPC shuttle valve is assembled inside the con-
trol valve spring case.
20-118 PC12R, 15R-8

TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIPMENT,

SWING PPC VALVE
s If there is excessive play in the work equipment
or swing lever, adjust as follows.
1. Remove the PPC valve.
s For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF PPC VALVE ASSEMBLY.
2. Remove boot (1).
3. Loosen locknut (2), then screw in disc (3) to a po-

sition where it contacts the heads of 4 pistons
(4).
s When doing this, do not move the piston.
4. Fix the position of disc (3), then tighten locknut

(2) to the specified torque.
3 Locknut : 113±15Nm {11.5±1.5kgm}
5. Install boot (1).
s With the above adjustment, the clearance be-

tween disc (3) and piston (4) becomes 0.
PC12R, 15R-8 20-119

TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION

TRAVEL DEVIATION
¡ When traveling on flat ground
1. Set the machine in the travel posture.
¡ When setting the machine in the travel pos-
ture, extend the bucket and arm cylinder rod
fully, and hold the boom at an angle of 45°.
2. Travel for 10m, then measure the deviation when

traveling for the next 20m.
¡ Measure with the engine at full throttle.
¡ Install the oil pressure gauge and measure the
pump discharge pressure at the same time.
20-119-1 PC12R, 15R-8

3
TESTING AND ADJUSTING MEASURING OIL LEAKAGE INSIDE WORK EQUIPMENT CYLINDER
MEASURING OIL LEAKAGE IN-

SIDE WORK EQUIPMENT CYL-
INDER
¡ Oil temperature when measuring: 45 – 55°C
¡ If the hydraulic drift of the work equipment ex-
ceeds the standard value, measure the leakage
inside the cylinder as follows to check if the cause
of the hydraulic drift is in the control valve or the
cylinder.
• If the leakage is within the standard value, the
control valve is the cause.
• If the leakage is not within the standard value, the
cylinder is the cause.
1. Fully extend the rod of the work equipment cylin-

der to be measured, then stop the engine.
2. Disconnect the hose (1) at the head end and block

the hose at the chassis end with a blind plug.
b Be careful not to disconnect the piping at the

bottom end.
3. Start the engine, run at full throttle, and apply re-

lief pressure to the bottom end of the cylinder.
¡ Boom cylinder: Operate to RAISE
Arm cylinder: Operate to IN
Bucket cylinder: Operate to CURL
4. Wait for 30 seconds, then measure the leakage

for the next one minute.
PC12R, 15R-8 20-119-2

3
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK
TESTING AND ADJUSTING PRESSURIZING HYDRAULIC TANK
RELEASING REMAINING RELEASING REMAINING

PRESSURE FROM PRESSURE FROM
HYDRAULIC CIRCUIT HYDRAULIC TANK
b There is no accumulator installed, so the re- b The hydraulic tank is a sealed type, so it is
maining pressure in the piping between the pressurized.
control valve and hydraulic cylinder or swing When removing the hoses or plugs installed
motor cannot be released by operating the to the hydraulic tank, release the remaining
control levers. pressure in the hydraulic tank as follows.
When the above piping is removed, be care-
ful of the following points. 1. Lower the work equipment to the ground and
stop the engine.
1. Run the engine at low idling, operate the hy-
draulic cylinders so that as far as possible the 2. Loosen the oil filler plug slowly to release the
pressure is not relieved at the end of the stroke, pressure inside the hydraulic tank.
lower the work equipment to the ground, then
stop the engine.
s If the engine is stopped with the hydraulic
circuit relieved and the hydraulic cylinder
at the end of its stroke, do not carry out
any work for 5 to 10 minutes.
2. When removing the piping, loosen the piping

sleeve nut gradually to release the pressure
remaining in the piping slowly, then remove
the piping after the oil stops spurting out. PRESSURIZING HYDRAULIC
TANK
s If the oil filler plug of the hydraulic tank has
been removed, pressurize the hydraulic tank
as follows.
1. Run the engine at low idling and set the work

equipment to the pressurizing posture.
2. Stop the engine, open the hydraulic tank oil

filler plug, then tighten it again.
s This operation pressurizes the hydraulic
tank.
3. Start the engine and lower the work equipment

to the ground.
20-120 PC12R, 15R-8

TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
Air bleeding procedure
Air bleeding item
1 2 3 4 5 6 7
Bleeding air Start Bleeding air Bleeding air Bleeding air Pressurizing Start
Nature of work from pump engine from from swing from travel hydraulic operations
cylinder motor motor tank
• Change hydraulic oil

• Clean strainer
(Note) (Note)
• Replace return filter element
• Replace, repair pump

• Remove suction piping
• Replace, repair control valve
• Replace, repair cylinder

• Remove cylinder piping
• Replace, repair swing motor

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

• Remove travel motor, swivel piping
Note : Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained.
1. Bleeding air from pump

1) Loosen air bleed plug (1) and add engine oil
through the plug hole.
2) Tighten plug (1).
s Precautions when starting the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for approx. 10 minutes.
PC12R, 15R-8 20-121

TESTING AND ADJUSTING BLEEDING AIR
2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, and raise and
lower the boom 4 – 5 times in succession.
s Operate the piston rod to approx. 100 mm
before the end of its stroke. Do not re-
lieve the circuit under any circumstances.
3) Run the engine at full throttle and repeat Step
2). After that, run the engine at low idling,
and operate the piston rod to the end of its
stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm, bucket, boom swing, and blade cyl-
inders.
3. Bleeding air from swing motor

1) Run the engine at low idling and swing 3 times
to the left.
2) Next, swing 3 times to the right.
4. Bleeding air from travel motor

1) Run the engine at low idling and use the work
equipment to raise the track on the left side.
2) Run the engine at low idling, and rotate the
track on the left side under no load for
approx. 30 seconds.
3) Repeat Steps 1) and 2) for the track on the
right side.
5. Pressurizing hydraulic tank

1) Before pressurizing the hydraulic tank, check
the hydraulic oil level.
2) Pressurize the hydraulic tank. For details, see
PRESSURIZING HYDRAULIC TANK.
20-122 PC12R, 15R-8

TROUBLESHOOTING
TROUBLESHOOTING
Type of connector and position of intallation ....................................................................................... 20-203

Connection table for connector pin numbers ....................................................................................... 20-206
Troubleshooting of engine electrical system (E mode) ....................................................................... 20-301
Troubleshooting of hydraulic, mechanical system (H mode) ............................................................. 20-401
Troubleshooting of machine monitor system (M mode) ..................................................................... 20-501
PC12R, 15R-8 20-201

TROUBLESHOOTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
Con- No. Con- No.

nector Connec-
tor type of Place of use
Add- nector Connec-
tor type of Place of use
Add-
No. ress No. ress
pins pins
C1 2 Service meter B8
C2 10 Monitor panel D7
C3 2 Starting switch A7
C4 6 Starting switch A8
C5 2 Lamp switch A8
D1 — 2 Diode (engine stop solenoid circuit) L5
E1 2 Fuel feed pump L7
E2 — 1 Starting motor L3
E3 2 Alternator L4
E4 — 1 Glow plug L7
E5 3 Engine stop solenoid L6

E6 — 1 Coolant temperature sensor L8
E7 — 1 Engine oil pressure switch L5
M5 — 1 Fuel level sensor K2

M6 — 1 Fuel level sensor K2
M7 — 1 Horn H6
M8 — 1 Horn H6
M9 — 1 Horn switch J1
M10 — 1 Horn switch J1
M11 — 1 Intermediate connector I1
M12 — 1 Intermediate connector I1

M13 — 1 Working lamp G6
M14 — 1 Working lamp G6
P1 3 Fusible link K2
P2 4 Fuse box A6
P3 6 Fuse box A6
P4 6 Safety relay C4
P5 — 1 Current limiter D7
P6 6 Current limiter D6
P7 4 Glow timer B4
P8 6 Intermediate connector D5
P9 4 Charge indicator D4
P10 4 Engine stop timer B4

P11 — 4 Engine stop relay A5
P12 4 Bulb check timer B4
S1 14 Intermediate connector D5
PC12R, 15R-8 20-203

20-204 PC12R, 15R-8

PC12R, 15R-8 20-205

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

s The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.
No. X type connector

of
pins Male (female housing) Female (male housing)
1
1
2
2
TEW00221 TEW00222
1 3 3 1
2 2
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-206 PC12R, 15R-8

No. SWP type connector

of
1 4 4 1
3 6
6 3 BLP00033
TEW00235
1 5 5 1
4 8 8 4
TEW00237 TEW00238
4 1
1 4
12
8 5
5 8
12 9 9 12
BLP00034 BLP00035
1 4 8 11 11 8 4 1
14
3 7 10 14 14 10 7 3
TEW00239 TEW00240
4 1 4
1
8 5
5 8
16
12 9 9 12
16 13
BLP00036 13 16 BLP00037
PC12R, 15R-8 20-207

No. M type connector

of
2 2
1 BLP00038 1 BLP00039
2 3 3 2
1 1
TEW00243 TEW00244
1 3 3 1
2 4 4 2
TEW00245 TEW00246
1 4 4 1
3 6 6 3 TEW00248
TEW00247
4 1 4
1
8 5
BLP00040
5 8 BLP00041
20-208 PC12R, 15R-8

No. S type connector

of
1 5 5 1
4 8 TEW00249 8 4 TEW00250
6 1
1 6
10
(White)
5 10 10
TEW00251 5 BLP00042
12
(White)
16
(White)
PC12R, 15R-8 20-209

No. S type connector

of
10
(Blue)
1 6 6 1
12
(Blue)
5 12
BLP00043 12 5 TEW00254
1 8
8 1
16
(Blue)
7 16 BLP00044 16 7 TEW00256
20-210 PC12R, 15R-8

No. MIC type connector

of
3 1
1 3
4 5 4
5
5
BLP00045 BLP00046
1 5 5 1
9 9 6
6
9
BLP00047 BLP00048
7 7 1
1
13 13 8
8
13
BLP00049 BLP00050
1 9 9 1
10 17
17 10
17
BLP00051 BLP00052
1 11
11 1
12 21
21 12
21
TEW00259 TEW00260
PC12R, 15R-8 20-211

No. AMP040 type connector

of
4 8
8 4
1 5
5 1 BLP00054
BLP00053
6 12 12 6
12
1 7
BLP00055 7 1 BLP00056
8 16
16 8
16
9 1
1 9
BLP00057 TEW00232
10 20
20 10
20
1 11 11 1
BLP00058 TEW00234
20-212 PC12R, 15R-8

No. AMP070 type connector

of
1 7 7 1
6 14 14 BLP00060
BLP00059 6
9 1
1 9
12
8 18 18 BLP00062
BLP00061 8
PC12R, 15R-8 20-213

No. L type connector

of
1 1
2
2 2
TEW00257 TEW00258
20-214 PC12R, 15R-8

No. KES1 (automobile) connector

of
2 2
1 1
BLP00063 BLP00064
1
1
3 2
2 3 BLP00065 BLP00066
1 2 2 1
4 3
3 4 BLP00067 BLP00068
1 1 3
3
4 6
6 4 BLP00069 BLP00070
4 1 1 4
5 8
8 5 BLP00071 BLP00072
PC12R, 15R-8 20-215

TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL
SYSTEM
(E MODE)
E-Mode related electrical circuit diagram ............................................................................................. 20-302

E-1 Engine does not start .................................................................................................................... 20-303
a) When starting motor does not turn (starting system) ........................................................ 20-303
b) When starting motor turns (engine stop solenoid system) ............................................... 20-305
E-2 Engine does not stop .................................................................................................................... 20-307
PC12R, 15R-8 20-301

TROUBLESHOOTING E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-302 PC12R, 15R-8

TROUBLESHOOTING E-1
E-1 Engine does not start

a) When starting motor does not turn (starting system)
s Check that fuse 2 is normal (if it is blown, check for a short circuit with the ground in the circuits related
to fuse 2).
s Before carrying out troubleshooting, check that all the related connectors are properly inserted.
s Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective starting motor Replace
2
Is voltage between
YES starting motor Defective contact or discon-
terminal B and nection in wiring harness
chassis ground 3 YES Repair or
between starting motor
normal? replace
Is voltage between terminal B and battery
• Turn starting battery terminal (+) terminal (+)
switch to OFF NO and chassis ground
1 • 10 – 14 V normal?
Defective battery Replace
Is voltage between • Turn starting NO
E2 (female) and switch to OFF
chassis ground • 10 – 14 V
normal? 6 YES
Go to A
• Disconnect E2. Is voltage between
• Turn starting YES P4 (female) (1) and
switch to START. 5 chassis ground
• 10 – 14 V normal?
Is resistance bet- Go to B
YES ween P4 (female) • Disconnect P4. NO
(1) and chassis • Turn starting
ground normal? switch ON. Defective contact or discon-
4 • Max. 1 V nection in wiring harness Repair or
• Turn starting
Is voltage between switch OFF. NO between P4 (female) (4) – replace
P8 (2) – chassis ground
P4 (female) (6) and • Disconnect P4.
NO chassis ground • Max. 1 Ω Defective contact or discon-
normal? YES nection in wiring harness Repair or
between P4 (female) (6) –
• Disconnect P4. 7 replace
P3 (2) – fuse 2 – P2 (2) – C3
• Turn starting Is voltage between (1) – starting switch
switch ON. starting switch terminal C
• Max. 1 V terminal C and
NO 8 YES Replace
chassis ground Defective starting switch
normal? Is voltage between
starting switch
• Turn starting terminal B and Defective contact or discon-
switch to START. NO chassis ground nection in wiring harness
• 10 – 14 V normal? Repair or
between starting switch
• Turn starting NO terminal B – C3 (2) – P1 replace
switch to OFF (2)(1) – battery
• 10 – 14 V
9 YES
Defective safety relay Replace
Does engine start
A
when safety relay
is replaced? Defective contact or discon-
nection in wiring harness Repair or
• Turn starting NO between P4 (female) (2) and replace
switch to START. E2 (female)
10 YES
Defective current limiter Replace
Is voltage between
B P4 (female) (1) and
chassis ground
normal when P6 is Short circuit with power
disconnected? source in wiring harness Repair or
• Disconnect P4. NO between P4 (female) (1) and replace
• Turn starting P6 (female) (6)
switch ON.
• Max. 1 V
PC12R, 15R-8 20-303

TROUBLESHOOTING E-1
E-1 a) Related electrical circuit diagram
20-304 PC12R, 15R-8

TROUBLESHOOTING E-1
b) When starting motor turns (engine stop solenoid system)

s Check that fuse 4 is normal (if it is blown, check for a short circuit
with the ground in the circuits related to fuse 4).
Cause Remedy
s Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
s Always connect any disconnected connectors before going on
the next step. 3 YES Defective engine stop
Replace
Is resistance bet- solenoid
YES ween E5 (female)
(3) and chassis
Defective contact or discon-
2 ground normal? Repair or
nection in wiring harness
Is voltage between • Turn starting NO between P5 (female) (3) – replace
YES E5 (1) and chassis switch OFF. P8 (1) – chassis ground
ground as shown • Disconnect E5. Defective contact or discon-
in table? • Max. 1 Ω 4 YES nection in wiring harness Repair or
between E5 (female) (1) –
Is voltage between replace
P3 (4) – fuse 4 – P2 (3) – C4
starting switch
terminal ACC and (6) – starting switch ACC
NO chassis ground
normal?
Defective starting switch Replace
• Turn starting NO
switch ON.
1 • 10 – 14 V
7 YES Defective engine stop
Is voltage between Replace
E5 (2) and chassis
relay
Does engine start
ground as shown YES
when P11 (C) and
in table? Defective contact or discon-
(D) are connected?
6 nection in wiring harness Repair or
Is voltage • Turn starting NO between E5 (female) (2) and replace
YES between P11 (C) switch to START. P11 (D)
and chassis Defective contact or discon-
ground normal? 8 YES nection in wiring harness Repair or
between P11 (C) – P3 (4) – replace
• Disconnect P11. Is voltage between
fuse 4 – P2 (3) – C4 (6) –
• Turn starting starting switch
5 terminal ACC and
starting switch ACC
switch ON. NO chassis ground
Is voltage • 10 – 14 V normal?
between P11 (A) Defective starting switch Replace
NO and (B) as shown • Turn starting NO
in table? switch ON.
• 10 – 14 V Defective contact or discon-
• Disconnect P11. nection in wiring harness Repair or
YES
9 replace
P11 (A) or P10 (female) (2) –
Is voltage P11 (B)
between P10 (1)
NO and (2) as shown 10 YES
in table? Go to A
Is voltage between
P10 (4) and chassis
NO ground as shown
in table?
Go to B
• Disconnect P10. NO
• Turn starting
switch ON.
11 YES • 10 – 14 V Defective engine stop Replace
Is resistance between timer
A P10 (female) (3) and
chassis ground Defective contact or discon-
normal? nection in wiring harness Repair or
• Turn starting NO between P10 (female) (3) – replace
switch OFF. P8 (1) – chassis ground
• Disconnect P10. Defective contact or discon-
• Max. 1 Ω 12 YES nection in wiring harness
Repair or
Is voltage between P3 (4) – fuse 4 – P2 (3) – C4 replace
B starting switch
terminal BR and
(6) – starting switch ACC
chassis ground
normal?
switch ON.
• 10 – 14 V
PC12R, 15R-8 20-305

TROUBLESHOOTING E-1
Table
E5 P11 P10 Starting switch ON
10 – 14 V for 1 second, then
Between (2) – chassis Between A – chassis Between (1) – (2) less than 1 V 1 second later
Between (1) – chassis Between B – chassis Between (4) – chassis 10 – 14 V (connected)
E-1 b) Related electrical circuit diagram
20-306 PC12R, 15R-8

TROUBLESHOOTING E-2
E-2 Engine does not stop

Cause Remedy
Short circuit with power

source in wiring harness
2 YES between starting switch
Repair or
terminal ACC – C4 (6) – S1
Is voltage between (12) – P2 (3) – fuse 4 – P4 (4) replace
YES starting switch – P10 (4) or D1 (1), (2) – E5
terminal ACC and
1 (female) (2)
chassis ground
normal?
Does engine stop Defective starting switch Replace
when E5 is • Turn starting NO
disconnected? switch OFF.
• Max. 1 V
Defective engine stop
Replace
NO solenoid
E-2 Related electrical circuit diagram
PC12R, 15R-8 20-307

TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes ........................................................................................................ 20-402

H- 1 Speeds of all work equipment, swing, travel are slow or lack power ...................................... 20-406
H- 2 There is excessive drop in engine speed, or engine stalls ........................................................ 20-408
H- 3 No work equipment, travel, swing move .................................................................................... 20-409
H- 4 Abnormal noise generated (from around pump) ....................................................................... 30-410
H- 5 Fine control ability is poor or response is poor (PC15R) ........................................................... 20-410
H- 6 Boom is slow or lacks power ....................................................................................................... 20-411
H- 7 Arm is slow or lacks power .......................................................................................................... 20-411
H- 8 Bucket is slow or lacks power ...................................................................................................... 20-412
H- 9 Boom swing is slow or lacks power ............................................................................................ 20-412
H-10 Blade is slow or lacks power ........................................................................................................ 20-413
H-11 Boom, arm, bucket do not move (boom swing, blade, travel and swing are normal) ............ 20-413
H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade) ......................................... 20-414
a) Boom, bucket, boom swing, blade ...................................................................................... 20-414
b) Arm ......................................................................................................................................... 20-414
H-13 Excessive time lag (engine at low idling) .................................................................................... 20-414
a) Boom, arm ............................................................................................................................. 20-414
b) Bucket ..................................................................................................................................... 20-414
H-14 In compound operations, work equipment with larger load is slow ........................................ 20-415
H-15 Travel deviation ............................................................................................................................. 20-416
a) Deviation in normal travel .................................................................................................... 20-416
b) Deviation when starting ........................................................................................................ 20-416
H-16 Travel speed is slow or lacks power ............................................................................................ 20-417
H-17 Steering does not turn easily ....................................................................................................... 20-417
H-18 Travel speed does not switch ....................................................................................................... 20-418
H-19 Travel does not move (one side only) ......................................................................................... 20-418
H-20 Swing speed is slow or lacks power ........................................................................................... 20-419
a) Speed is slow or lacks power in both directions ................................................................ 20-419
b) Speed is slow or lacks power in one direction only (left or right) ..................................... 20-419
H-21 Does not swing ............................................................................................................................. 20-420
a) Does not swing in either direction ....................................................................................... 20-420
a) Does not swing in one direction (left or right) .................................................................... 20-420
H-22 Swing acceleration is poor ........................................................................................................... 20-421
a) Acceleration is poor in both directions ................................................................................ 20-421
b) Acceleration is poor in one direction only (left or right) .................................................... 20-421
H-23 Excessive overrun when stopping swing ................................................................................... 20-422
a) Overrun when stopping is excessive in both directions .................................................... 20-422
b) Overrun when stopping is excessive in one direction only (left or right) ......................... 20-422
H-24 Excessive shock when stopping swing (in one direction only) .................................................. 20-422
H-25 Excessive abnormal noise when stopping swing ....................................................................... 20-423
H-26 Excessive hydraulic drift of swing ................................................................................................ 20-423
PC12R, 15R-8 20-401

TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES

PC12R
Hydraulic
pump Control valve
Parts causing failure
Pressure compensation valve
Back pressure check valve

Central safety valve
Control relief valve
Cooler check valve
Travel boost pedal

PPC shuttle valve
Main relief valve
Hydraulic pump
PPC lock valve

Control pump
Unload pump
Suction valve
Swing pump
Check valve
PPC valve
Damper
Strainer
Failure mode
Speeds of all work equipment, swing, travel are slow or lack power B B B B B B B
All work equipment,
travel, swing
There is excessive drop in engine speed, or engine stalls B

No work equipment, travel, swing move B B B B B B
Abnormal noise generated (around pump) B B B B
Fine control ability is poor or response is poor
Boom is slow or lacks power B B B B B
Arm is slow or lacks power B B B B B
Bucket is slow or lacks power B B B B B
Boom swing is slow or lacks power B B B
Blade is slow or lacks power B B
Work equipment
Boom does not move B B

Arm does not move B B
Bucket does not move B B
Boom B
Arm B B B
Excessive
hydraulic drift
Bucket B
Boom swing B
Blade B
Excessive time lag (engine at low idling) B
Other equipment moves when single circuit is relieved B
Deviation during normal travel B B
Travel system
Travel deviation
Deviation when starting
Travel speed is slow or lacks power B
Steering does not turn easily B B
Travel speed does not switch B
Travel does not move (one side only)
Swing speed is slow or Both left and right B
lacks power One direction only B B
Both left and right
Does not swing
Swing system
One direction only B B B

Swing acceleration is Both left and right
poor or swing speed is
slow One direction only B B B
Excessive overrun when Both left and right
stopping swing One direction only B B
Excessive shock when stopping swing (one direction only) B B
Excessive abnormal noise when stopping swing B
Excessive hydraulic drift of swing
20-402 PC12R, 15R-8

Swing motor Travel motor

Counterbalance valve
Speed selector servo
Trouble-
Center swivel joint
Hydraulic cylinder shooting

mode
Control linkage
Engine system
Remote valve
Parking brake
Suction valve
Motor proper
Motor proper
Safety valve
Check valve
Final drive
H- 1
B B H- 2
H- 3
H- 4
H- 5
B H- 6
B H- 7
B H- 8
B B H- 9
B B H-10
H-11
B
B
B H-12
B
B
H-13
H-14
B B B B
H-15
B
H-16
B H-17
B H-18
B B B H-19
B
H-20
B B
B B B
H-21
B B B
H-22
B B
B
H-23
B B
H-24
B B H-25
B B H-26
PC12R, 15R-8 20-403

PC15R
Hydraulic pump Control valve
Parts causing failure
Pressure compensation valve
Back pressure check valve

Central safety valve
Control relief valve
Cooler check valve

PPC shuttle valve
PC valve (spring)
Main relief valve
Suction valve
Unload valve
Servo piston
Piston pump
Check valve
Gear pump
LS valve
Damper
Strainer
Spool
Failure mode
Speeds of all work equipment, swing, travel are slow or lack power B B B B B B
All work equipment,
travel, swing
There is excessive drop in engine speed, or engine stalls B

No work equipment, travel, swing move B B B B
Abnormal noise generated (around pump) B B
Fine control ability is poor or response is poor B B B
Boom is slow or lacks power B B B B
Arm is slow or lacks power B B B B
Bucket is slow or lacks power B B
Boom swing is slow or lacks power B B B
Blade is slow or lacks power B B
Work equipment
Boom does not move B

Arm does not move B
Bucket does not move B
Boom B
Arm B B B
Excessive
hydraulic drift
Bucket B
Boom swing B
Blade B
Excessive time lag (engine at low idling) B
Other equipment moves when single circuit is relieved B
Deviation during normal travel B B
Travel system
Travel deviation
Deviation when starting
Travel speed is slow or lacks power B B
Steering does not turn easily B B
Travel speed does not switch
Travel does not move (one side only)
Swing speed is slow or Both left and right B
lacks power One direction only B
Both left and right
Does not swing
Swing system
One direction only B B

Swing acceleration is Both left and right B
poor or swing speed is
slow One direction only B B
Excessive overrun when Both left and right
stopping swing One direction only B
Excessive shock when stopping swing (one direction only) B
Excessive abnormal noise when stopping swing B
Excessive hydraulic drift of swing
20-404 PC12R, 15R-8

Control Swing motor Travel motor

valve
Counterbalance valve
Speed selector servo

Trouble-
shooting
Center swivel joint
Travel boost pedal
Hydraulic cylinder
mode
Control linkage
Engine system
PPC lock valve
Remote valve
Parking brake
Suction valve
Motor proper
Motor proper
Safety valve
Check valve
Final drive
PPC valve
B H- 1
B H- 2
B H- 3
H- 4
H- 5
B B H- 6
B B H- 7
B B H- 8
B B H- 9
B B H-10
B
B H-11
B
B
B
B H-12
B
B
H-13
H-14
B B B B
H-15
B
H-16
B H-17
B B H-18
B B B H-19
B
H-20
B B B
B B B
H-21
B
B B B
H-22
B B
B
H-23
B B B
B H-24
B B H-25
B B H-26
PC12R, 15R-8 20-405

TROUBLESHOOTING H-1
H-1 Speeds of all work equipment, swing, travel are slow or lack power
s If the speed is slow or there is lack of power in the actuators of 2 or more systems at the same time,
carry out this troubleshooting.
PC12R
Cause Remedy
Defective hydraulic pump

or swing pump (pump Replace
2 where speed is slow)
Is work equip-
YES
ment relief YES Defective unload valve Replace
pressure normal? 3
• Engine at high Does condition
become normal
idling
when unload valve 4 YES Defective adjustment of
• Bucket relieved Adjust
is replaced? Does condition main relief valve
1
become normal
Is PPC lock valve when main relief
NO valve is adjusted?
output pressure Defective main relief Replace
normal? NO valve
• Engine at high
idling
• Safety lock lever YES Replace
Defective PPC lock valve
: Free
5
Is control relief
YES Defective adjustment of
NO pressure normal? control relief valve
Adjust
6
idling become normal
NO when control relief 7 YES Defective control relief
Replace
valve is ad-justed? Does condition valve
become normal
NO when control relief
valve is adjusted?
Defective control pump Replace
NO
20-406 PC12R, 15R-8

TROUBLESHOOTING H-1
PC15R
Cause Remedy

PC valve Adjust
3
Does condition
YES become normal
when PC valve is 4 YES Defective PC valve, servo
adjusted? piston Replace
Does condition
become normal
2 NO when PC valve
spring is replaced?
Is work equip- Defective piston pump Replace
YES NO
ment relief
pressure normal?
• Engine at high YES Defective unload valve Replace

idling 5
• Bucket relieved
Does condition
become normal
1 NO when unload 6 YES Defective adjustment of
valve is replaced? main relief valve Adjust
Is PPC lock valve Does condition
become normal
output pressure when main relief
normal? NO valve is adjusted?
Defective main relief Replace
• Engine at high NO valve
idling
• Safety lock lever:
Free YES
Defective PPC lock valve Replace
7
Is control relief
NO pressure normal? control relief valve
Adjust
8
become normal
idling when control
NO relief valve is ad- 9 YES Defective control relief
Replace
justed? Does condition valve
become normal
when control
NO relief valve is
replaced?
Defective gear pump Replace
NO
PC12R, 15R-8 20-407

TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed, or engine stalls

PC12R
Cause Remedy
YES Repair or
Defective engine system
2 replace
YES Is swing relief

pressure normal? 3 YES Defective adjustment of
Adjust
Does condition swing motor safety valve
become normal
• Engine at high when swing motor
1 NO
idling safety valve is
Is work adjusted? Defective swing motor Repair or
equipment, travel safety valve replace
NO
relief pressure
normal?
• Engine at high 4 YES Defective adjustment of
Adjust
idling Does condition main relief valve
become normal
NO when main relief
valve is adjusted? Defective main relief Repair or
NO valve replace
PC15R
Cause Remedy
YES Defective adjustment of Replace

PC valve
1
Does condition
become normal
when PC valve is
2 YES
Defective PC valve spring Replace
adjusted? Does condition
become normal
NO when PC valve
spring is replaced? Repair or
Defective engine system
NO replace
20-408 PC12R, 15R-8

TROUBLESHOOTING H-3
H-3 No work equipment, travel, swing move

s If there is no movement in the actuators of 2 or more systems at the same time, carry out this trouble-
shooting.
PC12R
Cause Remedy
YES Defective PPC lock valve Replace

2
YES Is control relief

pressure normal? YES Defective adjustment of
Adjust
3 control relief valve
become normal
idling
1 valve is adjusted? Replace
Does condition valve
Does oil come out
become normal
when piston pump
pressure NO when control relief
measurement plug valve is replaced?
is removed? Defective control pump Replace
NO
• Crank engine by
hand.
5 YES Defective hydraulic pump Repair or
and swing pump replace
Does damper
NO rotate?
Repair or
Defective damper
• Remove pump. NO replace
• Crank engine
by hand.
PC15R
Cause Remedy
YES Defective PPC lock valve Replace

2
YES Is control relief

pressure normal? YES Defective adjustment of Adjust
3 control relief valve

become normal
idling
1 valve is adjusted? Replace
Does condition valve
Does oil come out
become normal
when pump oil
pressure NO when control relief
measurement plug valve is replaced?
is removed? Defective gear pump Replace
NO
• Remove 2 plugs
at engine end.
• Crank engine by
5 YES Repair or
hand. Defective piston pump
replace
Does piston
pump shaft
NO rotate?
Repair or
Defective damper
• Remove gear NO replace
pump.
• Crank engine by
hand.
PC12R, 15R-8 20-409

TROUBLESHOOTING H-4, H-5
H-4 Abnormal noise generated (from around pump)

Cause Remedy
3 YES Go to Trouble-
shooting No. 4
Do bubbles
YES disappear when
engine is
stopped?
2 Improper hydraulic oil Change
NO hydraulic oil
YES Are there bubbles
inside hydraulic
tank? YES Suction strainer clogged
by external foreign Remove
4 material (cloth, etc.)
Is suction strainer
1 clogged with
NO external foreign 5 YES
Repair or
material? Is suction strainer Defect inside pump
replace
k
Is hydraulic tank clogged with metal
oil level correct? External foreign particles or other for-
material: cloth, NO eign material, or are
there metal particles Inspect again
etc. Operate for a short time
stuck to drain plug? (according to
and look for any change in
NO the condition change in
condition)
Add hydraulic
Lack of hydraulic oil
NO oil
H-5 Fine control ability is poor or response is poor (PC15R)
Cause Remedy
2 YES Clogged unload valve Clean

orifice
YES Is unload valve
orifice clogged?
1 Repair or
Defective servo piston replace
NO
Is LS differential
pressure normal?
3 YES Defective adjustment of Adjust
• See TESTING AND Does condition LS valve
ADJUSTING. become normal
NO when LS valve is
adjusted? Correct or
Defective LS valve replace
NO
20-410 PC12R, 15R-8

H-6 Boom is slow or lacks power
Cause Remedy
4 YES Defective boom cylinder Repair or

packing replace
Does pressure
YES compensation
3 valve move
smoothly? Defective operation of
pressure compensation Repair or
YES Does control NO valve replace
valve spool move
2 smoothly?
Is output Defective operation of Repair or

YES pressure of PPC
NO control valve spool replace
valve normal?
1 • Engine at high
Repair or
idling Defective PPC valve
Is boom relief NO replace
pressure normal?
• Engine at high 5 YES Repair or

Defective suction valve replace
idling
Is arm relief
NO pressure normal?
Defective central safety Replace
idling
H-7 Arm is slow or lacks power

Cause Remedy
4 YES Defective arm cylinder Repair or

packing replace
Does pressure
YES compensation
3 valve move
smoothly? Defective operation of Repair or
Does control pressure compensation
YES NO valve replace
valve spool move
2 smoothly?

YES pressure of PPC
valve normal?
1 • Engine at high
Repair or
Is arm IN relief NO replace
pressure normal?
• Engine at high 5 YES Repair or

Defective suction valve replace
idling Is boom LOWER
relief pressure
NO normal?
Defective central safety Replace
idling
PC12R, 15R-8 20-411

H-8 Bucket is slow or lacks power
Cause Remedy
3 YES Defective boom cylinder Repair or

packing replace
Does pressure
YES compensation
2 valve move
smoothly? Defective operation of
pressure compensation Repair or
YES Does control NO valve replace
valve spool move
1 smoothly?
Is output pressure Defective operation of Repair or

of PPC valve NO control valve spool replace
normal?
• Engine at high Repair or

NO replace
H-9 Boom swing is slow or lacks power
Cause Remedy
YES Defective operation of Repair or

pressure compensation
3 valve replace
YES Is blade also

slow? 4 YES Defective operation of Repair or
check valve inside control
replace
Is boom swing valve spool
2 cylinder leakage
NO normal?
Defective boom swing Repair or
YES Is control pedal
stroke normal? • 2.0 cc/min. NO cylinder packing replace
1
• 16 ± 4 mm
5 YES Defective adjustment of
Is left boom control pedal linkage Adjust
swing relief Is stroke of
pressure normal? control valve
NO spool normal?
• Engine at high Defective operation of Repair or
idling NO control valve spool replace
• 6 mm
Repair or
Defective suction valve
NO replace
20-412 PC12R, 15R-8

H-10 Blade is slow or lacks power
Cause Remedy
YES Defective operation of Repair or

2 valve replace
YES Is boom swing

also slow? 3 YES Defective operation of Repair or
check valve inside control
replace
valve spool
Is blade cylinder
1
NO leakage normal?
Defective blade cylinder Repair or
Is control lever
• 2.0 cc/min. NO packing replace
stroke normal?
• 70 ± 20 mm. 4 YES Defective adjustment of

Adjust
control lever linkage
Is stroke of
control valve
NO spool normal?
Defective operation of Repair or
• 6mm.
H-11 Boom, arm, bucket do not move

(boom swing, blade, travel and swing are normal)
s When boom, arm, or bucket are operated independently.
Cause Remedy
1 YES Defective operation of Repair or

control valve spool replace
Is output
pressure of PPC
valve normal?
Repair or
Defective PPC valve replace
• Engine at high NO
idling
PC12R, 15R-8 20-413

H-12 Excessive hydraulic drift (boom, arm, bucket, boom swing, blade)
a) Boom, bucket, boom swing, blade
Cause Remedy
1 YES Defective oil tightness of Repair or

control valve spoo replace
Is hydraulic
cylinder leakage
normal?
Defective cylinder piston Repair or
• Max. 20 cc/min NO packing replace
• Engine at high
idling
b) Arm
Cause Remedy
2 YES Repair or
Defective suction valve
Does condition
replace
become normal
One side only
when suction valve
1 is replaced? Defective central safety
Replace
NO valve
Is there hydraulic
drift on one side
or on both sides?
2 YES Defective oil tightness of Repair or
control valve spool replace
Is hydraulic
Both sides cylinder leakage
normal?
Defective cylinder piston Repair or
• Max. 20 cc/min NO packing replace
• Engine at high
idling
H-13 Excessive time lag (engine at low idling)

s When work equipment speed is normal.
a) Boom, arm
Cause Remedy
Defective suction valve Repair or

replace
b) Bucket
s Carry out troubleshooting for H-8 Bucket is slow or lacks power.
20-414 PC12R, 15R-8

TROUBLESHOOTING H-14
H-14 In compound operations, work equipment with larger load is slow
Cause Remedy
Defective operation of
Replace
valve on side where load
is light
Combination for
compound operation Side with larger load Side with lighter load
1 Boom RAISE + arm IN Boom RAISE Arm IN

2 Boom RAISE + arm OUT Arm OUT Boom RAISE
3 Boom RAISE + bucket CURL Boom RAISE Bucket CURL
4 Arm OUT + bucket CURL Arm OUT Bucket CURL
5 Boom LOWER + arm OUT Arm OUT Boom LOWER
PC12R, 15R-8 20-415

H-15 Travel deviation

a) Deviation in normal travel
Cause Remedy
YES Repair or
Defective final drive
3 replace
Are metal
YES particles in oil
drained from final
drive on side 4 YES Repair or
Defective travel motor replace
which deviates? Does counter-
2 balance valve on
Does pressure side which
NO deviates move
YES compensation smoothly?
valve on side Defective counterbalance Repair or
which deviates NO valve replace
move smoothly?
1
Is distance of Defective operation of
Repair or
movement of left pressure compensation
and right travel NO valve replace
control levers
normal?
• 65±14 mm 5 YES Defective adjustment of
travel control lever linkage Adjust
Is stroke of
control valve
NO spool normal?
• 6 mm NO control valve spool replace
b) Deviation when starting
Cause Remedy

counterbalance valve replace
20-416 PC12R, 15R-8

H-16 Travel speed is slow or lacks power

s When there is no travel deviation (if there is travel deviation,
go to H-15 Travel deviation).
s When the work equipment speed is normal. Cause Remedy
PC12R
Does condition main relief valve
become normal
when main relief
valve is adjusted? Repair or
Defective main relief valve replace
NO
PC15R
Cause Remedy
2 YES Defective adjustment of PC Adjust

valve
Does condition
YES become normal
when PC valve is
1 adjusted?
Defective PC valve spring Replace
NO
Is travel relief
pressure normal?
3 YES Defective adjustment of
main relief valve Adjust
idling become normal
NO when main relief
valve is adjusted? Repair or
Defective main relief valve
NO replace
H-17 Steering does not turn easily

s When there is no travel deviation (if there is travel deviation,
go to H-15 Travel deviation). Cause Remedy
2 YES Defective center swivel Repair or

Does pressure joint replace
YES compensation
valve on inside of
1 steering move
Does control pressure compensation
NO replace
valve spool move valve
smoothly?

PC12R, 15R-8 20-417

H-18 Travel speed does not switch
Cause Remedy
1 YES Defective travel motor Repair or

speed selector servo replace
Is output pressure
of travel boost
valve normal?
Defective travel boost Repair or
• Engine at high NO valve replace
idling
H-19 Travel does not move (one side only)
Cause Remedy
YES Repair or
Defective final drive
1 replace
Is any foreign
material found in
oil drained from 2 YES Defective counterbalance Repair or
final drive? valve replace
Does counter-
balance valve
NO move smoothly?
Repair or
Defective travel motor
NO replace
20-418 PC12R, 15R-8

H-20 Swing speed is slow or lacks power

s When the work equipment speed is normal.
a) Speed is slow or lacks power in both directions
PC12R
Cause Remedy
1 YES Replace
Defective swing pump
Does condition
become normal
when hydraulic
pump assembly is
replaced? Repair or
Defective swing motor
NO replace
PC15R
Cause Remedy
1 YES Repair or
Does pressure replace
compensation
valve move
NO replace
valve
b) Speed is slow or lacks power in one direction only

Cause Remedy
(left or right)

Does condition swing motor safety valve
YES become normal
when swing motor
3 safety valve is
Is problem reversed adjusted? Defective swing motor Repair or
YES when left and right NO safety valve replace
swing motor safety
2 valves are
interchanged?
Does control Defective swing motor Repair or
YES valve spool move suction valve replace
NO
smoothly?
1
pressure of PPC NO control valve spool replace
valve normal?
• Engine at high
Repair or
NO replace
PC12R, 15R-8 20-419

H-21 Does not swing

a) Does not swing in either direction
PC12R
Cause Remedy
2 YES Defective swing motor Repair or

Does condition remote valve replace
YES become normal
when swing motor
1 remote valve is
Defective swing motor or
Does oil come out replaced? Repair or
when swing pump defective swing holding
NO replace
oil pressure brake
measurement plug
is removed?
• Crank engine by Defective swing pump Replace
hand. NO
PC15R
Cause Remedy

become normal
when swing motor
remote valve is Defective swing motor or
replaced? Repair or
defective swing holding
NO replace
brake
a) Does not swing in one direction (left or right)

Cause Remedy
2 YES Defective operation of Repair or

PPC shuttle valve inside
replace
Does control control valve
YES valve spool move
1 smoothly?
Is output pres- control valve spool replace
NO
sure of PPC valve
normal?
• Engine at high Repair or

Defective PPC valve
idling NO replace
20-420 PC12R, 15R-8

H-22 Swing acceleration is poor

a) Acceleration is poor in both directions
PC12R
Cause Remedy

become normal
when swing motor
remote valve is Defective swing motor or
replaced? Repair or
NO replace
brake
PC15R
Cause Remedy

YES become normal
when swing motor
1 remote valve is Defective swing motor or
Does pressure replaced? Repair or
compensation NO replace
brake
valve move
smoothly?
Defective actuation of
Repair or
NO replace
valve
b) Acceleration is poor in one direction only

Cause Remedy
(left or right)

Is problem reversed safety valve replace
YES when left and right
swing motor safety
3 valves are
Does PPC shuttle interchanged? Defective swing motor Repair or
YES valve inside NO suction valve replace
control valve move
2 smoothly?
Defective operation of
Does control Repair or
YES valve spool move PPC shuttle valve inside
NO replace
control valve
smoothly?
1
pressure of PPC NO control valve spool replace
valve normal?
• Engine at high
Repair or
NO replace
PC12R, 15R-8 20-421

H-23 Excessive overrun when stopping swing

a) Overrun when stopping is excessive in both directions
Cause Remedy
Repair or
replace
b) Overrun when stopping is excessive in one direction only (left or right)
Cause Remedy
YES Defective swing motor Repair or

2 safety valve replace
Is problem reversed
YES when left and right
swing motor safety
valves are 3 YES Defective swing motor Repair or
interchanged? Is problem reversed suction valve replace
1 when left and right
swing motor suction
Does control NO valves are
valve spool move interchanged? Repair or
smoothly? Defective PPC valve
NO replace

H-24 Excessive shock when stopping swing (in one direction only)
Cause Remedy
1 YES Repair or
Defective PPC valve
replace
Does control
valve spool move
smoothly?
20-422 PC12R, 15R-8

H-25 Excessive abnormal noise when stopping swing
Cause Remedy
YES Defective swing motor Replace

safety valve
1
Does condition
become normal
when swing motor 2 YES Defective swing motor
safety valve is Clean
Does condition suction valve
replaced? become normal
when swing motor
NO suction valve is
Defective back-pressure
cleaned? Repair or
check valve of control
NO replace
valve
H-26 Excessive hydraulic drift of swing
Cause Remedy

become normal
when swing motor
remote valve is
replaced? Defective swing holding Repair or
NO brake replace
PC12R, 15R-8 20-423

TROUBLESHOOTING
TROUBLESHOOTING OF MACHINE MONITOR

SYSTEM
(M MODE)
Electrical circuit diagram for M Mode related parts ............................................................................20-502

M-1 Abnormality in engine oil pressure caution lamp system ......................................................... 20-503
a) Lamp does not light up when starting switch is turned ON .............................................. 20-503
b) Lamp lights up when engine is running (engine oil pressure is normal) ......................... 20-503
M-2 Abnormality in charge caution lamp system .............................................................................. 20-505
a) Lamp does not light up when starting switch is turned ON .............................................. 20-505
b) Lamp lights up when engine is running (battery charge is normal) ................................. 20-505
M-3 Abnormality in engine water temperature caution lamp system ............................................. 20-507
a) Lamp does not stay lighted up for 3 seconds when starting switch is turned ON ........... 20-507
b) Lamp does not go out after starting switch has been at ON for 3 seconds ...................... 20-507
c) Lamp lights up when engine is running (engine water temperature is normal) .............. 20-508
M-4 Abnormality in preheating pilot lamp ......................................................................................... 20-509
a) Lamp does not light up when starting switch is turned to HEAT ...................................... 20-509
b) Lamp does not go out when starting switch is at HEAT and preheating time
(approx. 18 sec.) is completed .............................................................................................. 20-509
c) Lamp lights up when starting switch is at position other than HEAT ............................... 20-510
M-5 Abnormality in fuel gauge system .............................................................................................. 20-511
a) Gauge does not go up from E when fuel is added to fuel tank ......................................... 20-511
b) Gauge does not go down from F even when there is no fuel in fuel tank ........................ 20-511
c) Fuel level does not match gauge display ............................................................................ 20-512
M-6 Abnormality in service meter system ......................................................................................... 20-513
a) Service meter does not advance when starting switch is at ON ....................................... 20-513
b) Service meter advances when starting switch is at OFF .................................................... 20-513
c) Pilot lamp does not flash when service meter is advancing .............................................. 20-513
M-7 Abnormality in night lighting system .......................................................................................... 20-515
a) Night lighting does not light up when lamp switch is turned ON ..................................... 20-515
b) Night lighting lights up when lamp switch is turned OFF .................................................. 20-515
PC12R, 15R-8 20-501

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE RELATED PARTS
20-502 PC12R, 15R-8

TROUBLESHOOTING M-1
M-1 Abnormality in engine oil pressure caution lamp system

a) Lamp does not light up when starting switch is turned ON

s Check that fuse 3 is normal
(if it is blown, check for a short circuit with the ground in the circuits related to fuse 3).
Cause Remedy

3 YES nection in wiring harness Repair or
between C2 (female) (4) – replace
Is resistance
S1 (5) – E7 (harness end)
YES between E7 (switch
2 end) and chassis
ground normal? Defective engine oil
Is resistance bet- Replace
YES ween C2 (female) • Turn starting NO pressure switch
(4) and chassis switch OFF.
ground normal? • Disconnect E7.
1 • Max. 1 Ω
• Turn starting Defective monitor panel Replace
Is voltage between
C2 (female) (8) and switch OFF. NO
chassis ground • Disconnect C2.
normal? • Max. 1 Ω Defective contact or discon-
4 YES between starting switch Repair or
• Disconnect C2.
Is voltage between terminal ACC – C4 (6) – S1 replace
• Turn starting starting switch (12) – P2 (3) – fuse 3 – P3 (3) –
switch ON. terminal ACC and S1 (2) – C2 (female) (8)
• 10 – 14 V NO chassis ground
normal?
switch ON.
• 10 – 14 V
b) Lamp lights up when engine is running

(engine oil pressure is normal)
Cause Remedy
YES Defective engine oil

Replace
pressure switch
1
When E7 is
disconnected,
does lamp go 2 YES
Defective monitor panel Replace
out? When E7 is discon-
nected, is resistance
. Start engine. between C2 (female)
NO (4) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
. Turn starting NO between C2 (female) (4) – replace
switch OFF. S1 (5) – E7 (harness end)
. Disconnect C2.
. Min. 1 MΩ
PC12R, 15R-8 20-503

TROUBLESHOOTING M-1
M-1 Related electrical circuit diagram
20-504 PC12R, 15R-8

TROUBLESHOOTING M-2
M-2 Abnormality in charge caution lamp system

s Always connect any disconnected connectors before going on the next
step.
Cause Remedy
a) Lamp does not light up when starting switch is turned ON
s Check that fuse 3 is normal (if it is blown, check for a short circuit with
the ground in the circuits related to fuse 3).
2 YES Replace
Defective monitor panel
Is resistance bet-
YES ween C2 (female)
(7) and chassis Defective contact or discon-
ground normal? nection in wiring harness
Repair or
between C2 (female) (7) –
• Turn starting NO S1 (1) – P8 (4) – chassis replace
1
switch OFF. ground
Is voltage between • Disconnect C2.
C2 (female) (3) and • Max. 1 Ω YES Repair or
chassis ground nection in wiring harness
normal? between C2 (female) (3) – replace
S1 (4) – P9 (female) (3)
• Disconnect C2.
• Turn starting 3
switch ON. Is voltage 5 YES
Go to A
• 10 – 14 V between P9 (3) Is resistance bet-
NO and chassis YES ween P9 (female)
ground normal? (1) and chassis Defective contact or discon-
4 ground normal? nection in wiring harness Repair or
• Disconnect P9.
• Turn starting Is voltage bet- • Turn starting NO between P9 (female) (1) – replace
switch ON. ween P9 (female) switch OFF.
• 10 – 14 V NO (4) and chassis • Disconnect P9. Defective contact or discon-
ground normal? • Max. 1 Ω 6 YES nection in wiring harness Repair or
• Disconnect P9. terminal ACC – C4 (6) – S1
• Turn starting starting switch (12) – P2 (3) – fuse 3 – P3 (3)
terminal ACC and – P9 (female) (4)
• 10 – 14 V normal?
switch ON.
• 10 – 14 V
7 YES
Defective charge indicator Replace
Is voltage between
A P9 (female) (2) and
chassis ground Defective current limiter, or
normal? short circuit with power
Repair or
source in wiring harness
• Disconnect P9. NO replace
between P9 (female) (2) and
• Turn starting P5 (male)
switch ON.
• Max. 1 V
b) Lamp lights up when engine is running

Cause Remedy
(battery charge is normal)
YES Replace
1
Is voltage between 3 YES
Defective charge indicator Replace
C2 (female) (3) and Is voltage between
chassis ground YES P9 (female) (2) and
normal? chassis ground Defective current limiter, or
2 defective contact or
• Disconnect C2. normal?
disconnection in wiring Repair or
• Start engine. When P9 is dis- • Disconnect P9. NO replace
harness between P9
• Max. 1 V connected, does • Start engine. (female) (2) and P5 (male)
NO lamp go out?
• 10 – 14 V Short circuit with power
• Start engine. source in wiring harness Repair or
NO between C2 (female) (3) – replace
S1 (4) – P9 (female) (3)
PC12R, 15R-8 20-505

TROUBLESHOOTING M-2
20-506 PC12R, 15R-8

TROUBLESHOOTING M-3
M-3 Abnormality in engine water temperature caution lamp system

a) Lamp does not stay lighted up for 3 seconds when starting switch is turned ON
s Check that fuses 2, 3, and 5 are normal (if they are blown, check for a
short circuit with the ground in the circuits related to the fuse). Cause Remedy
YES Defective monitor panel Replace
2
Is resistance bet- 4 YES
Go to A
YES ween C2 (female) Is resistance bet-
(10) and chassis
YES ween P12 (female)
ground normal? (3) and chassis
3 Defective contact or discon-
• Disconnect C2. ground normal? nection in wiring harness Repair or
Is voltage between
• Turn starting P12 (female) (1) • Turn starting NO between P12 (female) (3) – replace
1 switch OFF. P8 (5) – chassis ground
NO and chassis ground switch OFF.
Is voltage between • Max. 1 Ω normal? • Disconnect P12.
C2 (female) (8) and (for 3 sec. after • Max. 1 Ω nection in wiring harness Repair or
chassis ground turning ON) • Disconnect P12.
normal? • Turn starting NO between C2 (female) (10) – replace
switch ON. S1 (8) – P12 (female) (1)
• Disconnect C2. • 10 – 14 V Defective contact or discon-
• Turn starting nection in wiring harness
5 YES Repair or
switch ON. between starting switch
• 10 – 14 V terminal ACC – C4 (6) – S1
starting switch
(12) – P2 (3) – fuse 3 – P3 (3)
terminal ACC and
NO – S1 (2) - C2 (female) (8)
chassis ground
normal?
switch ON.
• 10 – 14 V
YES
Defective bulb check Replace
6 timer
Is voltage between
A P12 (female) (4) Defective contact or discon-
and chassis ground 7 YES nection in wiring harness Repair or
normal? Is voltage between between starting switch replace
starting switch terminal ACC – C4 (5) – S1
• Disconnect P12. terminal ACC and (11) – P2 (4) – fuse 5 – P3 (5)
• Turn starting NO chassis ground – P12 (female) (4)
switch ON. normal?
• 10 – 14 V Replace
• Turn starting NO Defective starting switch
switch ON.
• 10 – 14 V
b) Lamp does not go out after starting switch has been at ON

Cause Remedy
for 3 seconds
YES Defective engine water

Replace
temperature switch
1
Does lamp go out
when E6 is YES Defective bulb check
disconnected? Replace
2 timer
. Turn starting Does lamp go out

switch ON. when P12 is
NO disconnected? 3 YES
Is resistance between
. Turn starting C2 (female) (10) and
chassis ground Short circuit with chassis
switch ON. NO normal when E6 and
ground in wiring harness
P12 are disconnected? Repair or
. Turn starting NO S1 (8) – E6 (female) – P12
replace
switch OFF. (female) (1)
. Disconnect C2.
. Min. 1 MΩ
PC12R, 15R-8 20-507

TROUBLESHOOTING M-3
c) Lamp lights up when engine is running (engine water temperature is normal)
Cause Remedy
YES Defective engine water

Replace
temperature switch
1
Does lamp go out
when E6 is YES Defective bulb check
disconnected? Replace
2 timer
. Turn starting Does lamp go out

switch ON. when P12 is
NO disconnected? 3 YES
Is resistance between
. Turn starting C2 (female) (10) and
chassis ground Short circuit with chassis
switch ON. NO normal when E6 and
ground in wiring harness
P12 are disconnected? Repair or
. Turn starting NO S1 (8) – E6 (female) – P12
replace
switch OFF. (female) (1)
. Disconnect C2.
. Min. 1 MΩ
20-508 PC12R, 15R-8

TROUBLESHOOTING M-4
M-4 Abnormality in preheating pilot lamp

a) Lamp does not light up when starting switch is turned to HEAT
Cause Remedy
2 YES Replace
Is resistance be-
YES tween C2 (female)
between C2 (female) (7) – Repair or
1
switch OFF. ground
Is voltage between
• Disconnect C2. Defective contact or discon-
C2 (female) (2) and
chassis ground • Max. 1 Ω YES nection in wiring harness Repair or
normal? between C2 (female) (2) – replace
S1 (3) – P7 (female) (1)
• Disconnect C2.
3
• Turn starting
switch to HEAT. Is voltage 5 YES
between P7 (1) Defective glow timer Replace
• 10 – 14 V Is voltage bet-
NO and chassis YES ween P7 (female)
ground normal?
4 (4) and chassis
• Turn starting ground normal?
Is voltage bet- Go to A
switch to HEAT. • Disconnect P7. NO
ween P7 (female)
• 10 – 14 V • Turn starting
NO (3) and chassis
ground normal? switch to HEAT. Defective contact or discon-
• 10 – 14 V nection in wiring harness Repair or
• Turn starting
NO between P7 (female) (3) – replace
switch OFF.
• Disconnect P7.
• Max. 1 Ω Defective contact or discon-
6 YES nection in wiring harness Repair or
between starting switch replace
Is voltage between
terminal R1 – C4 (3) – S1
A starting switch
(10) – P7 (female) (4)
terminal R1 and
chassis ground
normal? Replace
Defective starting switch
switch to HEAT.
• 10 – 14 V
b) Lamp does not go out when starting switch is at HEAT and preheating time (approx. 18 sec.) is
completed
Cause Remedy
Defective glow timer Replace
PC12R, 15R-8 20-509

TROUBLESHOOTING M-4
c) Lamp lights up when starting switch is at position other than HEAT
Cause Remedy
YES
1
Is voltage between Short circuit with power
C2 (female) (3) and YES source in wiring harness Repair or
chassis ground between C2 (female) (2) – replace
normal? 2 S1 (3) – P7 (female) (1)
. Disconnect C2. Is voltage
. Turn starting between P7 (1)
YES Replace
switch ON. NO and chassis 3
Defective glow timer
. Max. 1 V ground normal?
Is voltage between
. Turn starting Short circuit with power
P7 (female) (4) and
switch ON. source in wiring harness
NO chassis ground 4 YES Repair or
. Max. 1 V between starting switch
normal? Is voltage between replace
terminal R1 – C4 (3) – S1
starting switch
. Disconnect P7. (10) – P7 (female) (4)
terminal R1 and
. Turn starting NO chassis ground
switch ON. normal?
. Max. 1 V . Turn starting NO
switch ON.
. Max. 1 V
20-510 PC12R, 15R-8

TROUBLESHOOTING M-5
M-5 Abnormality in fuel gauge system

a) Gauge does not go up from E when fuel is added to fuel tank

s Check that fuse 3 is normal
(if it is blown, check for a short circuit with the ground in the circuits related to fuse 3).
Cause Remedy

Is resistance bet- 4 YES nection in wiring harness Repair or
YES ween C2 (female) Is resistance between C2 (female) (6) – replace
(6) and chassis S1 (6) – M6 (female)
YES between M5 (male)
ground normal? and chassis ground
• Turn starting normal? nection in wiring harness Repair or
Is resistance
switch OFF. between M5 • Turn starting NO between M5 (male) – P8 (5) replace
1 • Disconnect C2. – chassis ground
NO (female) and M6 switch OFF.
Is voltage between • 10 – 80 Ω (male) normal? • Disconnect P5.
C2 (female) (1) and • Max. 1 Ω
chassis ground • Turn starting Defective fuel level sensor Replace
normal? switch OFF. NO
• Disconnect M5 and M6.
• Disconnect C2. Defective contact or discon-
• 10 – 80 Ω
• Turn starting nection in wiring harness
5 YES between starting switch Repair or
switch ON.
Is voltage between terminal ACC – C4 (6) – S1 replace
• 10 – 14 V
starting switch (12) – P2 (3) – fuse 3 – P3 (3)
terminal ACC and – S1 (2) – C2 (female) (8)
NO chassis ground
normal?
switch ON.
• 10 – 14 V
b) Gauge does not go down from F even when there is no fuel in fuel tank
Cause Remedy
YES Defective fuel level sensor Replace

1
When M6 is
disconnected,
does level go 2 YES Defective monitor panel Replace
down? When M6 is discon-
nected, is resistance
. Turn starting between C2 (female)
switch ON. NO (6) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
. Turn starting NO between C2 (female) (6) – replace
switch OFF. S1 (6) – M6 (female)
. Disconnect C2.
. Min. 1 MΩ
PC12R, 15R-8 20-511

TROUBLESHOOTING M-5
c) Fuel level does not match gauge display
Cause Remedy
1 YES
Is resistance bet-
ween M5 (female)
and M6 (male) as
shown in the table?
Defective fuel level sensor Replace
• Check sensor as
individual part.
Table
Float position Resistance value(Ω)
+1.0
Top end 10 –0.5
Top 1/4 (19)
1/2 (middle) 32±3
Bottom 1/4 49.5
Bottom end 80 +12
+ 2
ß Figures in ( ) are reference values.
20-512 PC12R, 15R-8

TROUBLESHOOTING M-6
M-6 Abnormality in service meter system

a) Service meter does not advance when starting switch is at ON

to fuse 3).
Cause Remedy
2 YES
Is voltage between
YES C1 (female) (1) and Defective contact or discon-
chassis ground
1 normal? Repair or
Is voltage bet- . Disconnect C1. NO S1 (1) – P8 (4) – chassis replace
ween C1 (female) . Turn starting ground
(2) and chassis switch ON. Defective contact or discon-
ground normal? . Max. 1V 3 YES nection in wiring harness Repair or
. Disconnect C1. Is voltage between replace
terminal ACC – C4 (6) – S1
starting switch
. Turn starting (12) – P2 (3) – fuse 3 – P3 (3)
terminal ACC and
– S1 (2) – C1 (female) (2)
. 10 – 14 V normal?
. Turn starting NO
switch ON.
. 10 – 14 V
b) Service meter advances when starting switch is at OFF

Cause Remedy

1
Is voltage bet- Short circuit with power
ween C1 (female) source in wiring harness
(2) and chassis 2 YES between starting switch Repair or
ground normal? Is voltage between terminal ACC – C4 (6) – S1 replace
starting switch (12) – P2 (3) – fuse 3 – P3 (3)
. Turn starting terminal ACC and – S1 (2) – C1 (female) (2)
switch OFF. NO chassis ground
. Disconnect C1. normal?
. Max. 1 V . Turn starting NO
switch OFF.
. Disconnect ACC
terminal wiring harness.
. Max. 1 V
c) Pilot lamp does not flash when service meter is advancing

Cause Remedy
PC12R, 15R-8 20-513

TROUBLESHOOTING M-6
20-514 PC12R, 15R-8

TROUBLESHOOTING M-7
M-7 Abnormality in night lighting system

a) Night lighting does not light up when lamp switch is turned ON

to fuse 3).
Cause Remedy
2 YES
Is resistance bet-
YES ween C2 (female)
between C2 (female) (7) – Repair or
switch OFF. ground
1 • Disconnect C2. Defective contact or discon-
• Max. 1 Ω YES nection in wiring harness Repair or
Is voltage between
between C2 (female) (9) and replace
C2 (female) (9) and 4
chassis ground C5 (female) (1)
Is voltage between
normal? YES C5 (female) (2) and Defective contact or discon-
• Disconnect C2. chassis ground 5 YES nection in wiring harness Repair or
between starting switch replace
• Turn starting normal? Is voltage between
3 terminal ACC – C4 (6) – S1
switch ON. starting switch
• Disconnect C5. (12) – P2 (3) – fuse 1 – P3 (1)
Is resistance terminal ACC and
• Turn lamp switch • Turn starting NO chassis ground
– S1 (13) – C5 (female) (2)
ON. between C5 switch ON. normal?
• 10 – 14 V NO (male) (1) and (2) Defective starting switch Replace
• 10 – 14 V • Turn starting NO
normal?
switch ON.
• Turn starting • 10 – 14 V
switch OFF.
• Disconnect C5. Defective lamp switch Replace
• Switch OFF: NO
Min. 1 MΩ
• Switch ON: Max. 1 Ω
b) Night lighting lights up when lamp switch is turned OFF
Cause Remedy

1
Is voltage bet-
ween C2 (female) Short circuit with power
(9) and chassis 2 YES source in wiring harness Repair or
ground normal? Is resistance between C2 (female) (9) and replace
between C5 C5 (female) (1)
• Disconnect C2.
• Turn starting NO (male) (1) and (2)
normal?
switch ON. Defective lamp switch Replace
• Turn lamp switch • Turn starting NO
OFF. switch OFF.
• 10 – 14 V • Disconnect C5.
• Switch OFF: Min. 1 MΩ
• Switch ON : Max. 1 Ω
PC12R, 15R-8 20-515

TROUBLESHOOTING M-7
20-516 PC12R, 15R-8

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL.. ................. 30- 3 SWING MOTOR

PRECAUTIONS WHEN CARRYING Removal and Installation.. ........................ 30-29
OUT OPERATION ...................................... 30- 4 REVOLVING FRAME
SPECIAL TOOL LIST.. .................................. 30- 6 Removal ..................................................... 30-30
STARTING MOTOR Installation ................................................. 30-31
Removal and Installation.. ........................ 30- 7 SWING CIRCLE
ALTERNATOR Removal and Installation.. ........................ 30-32
Removal and Installation.. ........................ 30- 8 IDLER
FUEL INJECTION PUMP Removal and Installation.. ........................ 30-33
Removal and Installation .......................... 30- 9 Disassembly.. ............................................. 30-34
NOZZLE HOLDER Assembly ................................................... 30-35
Removal and Installation.. ........................ 30-10 IDLER CUSHION (Rubber shoe)
WATER PUMP Removal and Installation.. ........................ 30-36
Removal and Installation.. ........................ 30-I 1 Disassembly and assembly.. .................... 30-37
THERMOSTAT IDLER CUSHION (Steel shoe)
Removal and Installation .......................... 30- 12 Disassembly .............................................. 30-38
ENGINE FRONT SEAL Assembly ................................................... 30- 39
Removal and Installation.. ........................ 30-13 TRACK ROLLER
ENGINE REAR SEAL Removal and Installation.. ........................ 30-40
Removal ..................................................... 30- 14 Disassembly and assembly.. .................... 30-41
Installation ................................................. 30-15 RUBBER SHOE
CYLINDER HEAD Removal and Installation .......................... 30-42
Removal ..................................................... 30- 16 STEEL SHOE
Installation ................................................. 30-17 Expansion and Installation ....................... 30-43
RADIATOR HYDRAULIC TANK
Removal ..................................................... 30- 18 Removal ..................................................... 30-44
Installation ................................................. 30-19 Installation ................................................. 30-45
ENGINE, HYDRAULIC PUMP HYDRAULIC OIL COOLER
Removal ..................................................... 30-20 Removal and Installation.. ........................ 30-46
Installation ................................................. 30-22 HYDRAULIC PUMP
FUEL TANK Removal and Installation.. ........................ 30-47
Removal and Installation.. ........................ 30-23 CONTROL VALVE
DAMPER Removal ..................................................... 30-48
Removal and Installation.. ........................ 30-24 Installation ................................................. 30-49
CENTER SWIVEL JOINT Disassembly .............................................. 30-50
Removal and Installation .......................... 30-25 Assembly ................................................... 30- 55
Disassembly and assembly.. .................... 30-26 PPC VALVE
TRAVEL MOTOR Removal and Installation.. ........................ 30-62
Removal and Installation.. ........................ 30-27 Disassembly .............................................. 30- 63
SPROCKET Assembly ................................................... 30- 64
Removal and Installation.. ........................ 30-28
PC12R, 15R-8 30-l

0
BOOM CYLINDER
Removal . . . .. . . . . .. . . .. . .. . . . .. .. . . . . . . . .. . . . .. .. . .. . . . .. .. . . 30-65
Installation . . . . . . . .. .. . . .. . . .. . .. . .. . . . ..._................. 30-66
ARM CYLINDER
Removal .. . .. . . . . .. . . . .. . . . . .. . . . . . . . . .. . . . . . .. . . . .. . . . . .. . .. 30- 67
Installation . . . .. . . .. . .. . . . .._............................... 30-68
BUCKET CYLINDER
Removal . . . . . . . .._............_.............................. 30-69
Installation . . .. . . . . . .. . . . .. . .. . . .. . .. .. . . .. . .. .. . . . . .. . . .. . . 30-70
SWING CYLINDER
Removal . . . .. . .. . . . . .. . . .. . . . .. . . . .. . . .. .. . . . . . .. . . .. . . . .. . . . 30-71
Installation . . . .. . . .. . .. .. . . . .. . .. . . .. . .. . . . . . . .. . . . .. . . .. . . . 30-72
BLADE CYLINDER
Removal and Installation . . . .. . . . . .. . .. . . .. . . .. . . .. 30-73
HYDRAULIC CYLINDER
Disassembly .. . . . . .. . . .. . .. . . . .. .. . .. .. . . . . .. . . .. . . . .. . . .. 30-74
Assembly .. . . . . . .. . . . .. .. .. . .. . . . . . . . .. . . . . . .. . .. . .. . . . .. .. . 30-77
WORK EQUIPMENT
Removal . . .. . . . .. . . . . . .. . .. .. . . . . . . .. . . . . . . . .. . . .. . . . . . .. . .. . 30-81
Installation . . . .. .. .. .. . .. .. . . . . . .. .. . .. . . . .. . .. .. . . . .. . . .. . . 30-82
BUCKET
Removal and Installation .. . . . . . . .. .. .. . . . . .. . . . .. . 30-83
ARM
Removal . .. . . .. . . .. . . . .. . .. .. . . . . . . .. . . . . . . .. . . . .. . .. . . . . .. . . 30-84
Installation . . . . . .. . . . .. .. .. . . . . . .. .. . . . . . .. . .. .. . . . . .. . . .. . . 30-85
BUCKET, ARM
Removal . . . .. . .. . . . . . .. . . .. . . . .. . .. . . . .. .. .. . . . .. . . .. . . . . .. . . 30-86
Installation . .. . . . . .. . .. . .. . . .. . .. . . . . . .. . . . . . .. .. . . . . . .. . . . . 30-87
BOOM
Removal . . .. . . . .. . . . . . .. . .. .. . . . . . . .. . . . . . . .. . . . .. . . .. . . . .. . . 30-88
Installation . . .. . .. . . .. . .. .. . . . . . . . .. . . . . . .. . . . .. . . . . .. . . .. . . 30-89
SWING BRACKET
Removal . . . . . . . .. . . . . .. . . .. .. . . . . . .. . . . . . . . .. . . .. . .. . . . . .. .. . 30-90
Installation . . .. . . . . .. . . . .. . . . . . .. .. . . . . . . .. . . . .. . . . . .. . . .. . . 30-91
BLADE
Removal and Installation . . . . .. . . . . . .. . . . .. .. . . . .. . 30-92
CANOPY
Removal and Installation . . . .. . . . . . .. . .. . . . ._. . . .. . 30-93
30-2 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked a, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 0 ASSEMBLY . . . . .. . . . .. . Title of operation
a . .. .. . .. . . . . .. .. . .. . . . .. .. . .. . . .. . .. . . .. . . .. . . . . . ... . . .. .. . . . . . . . . Precautions related to safety when carrying out the
operation
1. xXxX(1) . ..... ........ .................................... Step in operation
* . . .. .. . . . .. . . . . .. . . . .. . .. . . .. . . . .. . . .. . . . .. . . . .. . . . . . .. . .. . . . . Technique or important point to remember when re-
moving XxXx (1).
2. AAAA (2) . . .. .. . .. . . . . . .. . . .. . . .. . . . . . .. . . . . . .. . . . . . . . . a Indicates that a technique is listed for use dur-
ing installation
3. q OCICI assembly (3)
. . . .. . . . .. . . . . .. . .. . . .. . . . . .. . .. .. . .. . . . .. .. . . . . .. . .. . .. See Lubricant and Coolant Table
INSTALLATION OF 0 0 0 0 ASSEMBLY . . ..Trtle of operation

. Carry out installation in the reverse order to removal.
m ................ ........................ ........... Technique used during installation
* . . . .. . . .. . . . .. .. .. . . . . .. . .. . . .. . . .. . .. . ... . .. . .. . . . . . . . . Technique or important point to remember when in-
stalling AAAA (2).
. Adding water, oil . . .. .. . . . .. . . .. . .. . . . . .. .. . .. . Step in operation
* . . .. .. . .. . .. . . .. . . . . . .. . . . . . ... . .. . .. . . . .. .. . . . . .. . . . . . . Point to remember when adding water or oil
% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these
precautions when carrying out the operation.
3. Listing of special tools

(1) FoTdetails of the description, part number, and quantity of any tools (Al, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
(2) The tools marked Q in the SPECIAL TOOLS LIST are not available as an assembly.
(3) Items listed as 79OT- 0000 - 0000 in the SPECIAL TOOL LIST are tools prohibited for supply.
(4) The items marked in the Sketch Column of the SPECIAL TOOL LIST are special tools with sketches
introduced in this Shop Manual, but Komatsu cannot accept any responsibility for special tools
manufactured according to the sketch.
PC1 2R, 15R-8 30-3

0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out rem&al work

. If the coolant contains antifreeze, dispose of it correctly.
. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when install-
ing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
* Precautions when handling piping during disassembly

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nommal number Plug (nut end) Sleeve nut (elbow end): Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
IO 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal number I-lange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-I 0400 0737 I-30400
05 07379-00500 07378-I 0500 0737 I-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
1
I
Taper l/8
8" ______-_-_---
:
DEW00401
30-4 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

. Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
. Install the hoses without twisting or interference.
. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
. Bend the cotter pin or lock plate securely.
. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
. When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
. Clean all parts, and correct any damage, dents, burrs, or rust.
. Coat rotating parts and sliding parts with engine oil.
. When press fitting parts, coat the surface with anti-friction compound (LM-P).
. After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them in fully,
and align the direction of the hook.
. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps
and other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times in
succession, stopping 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
* When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

l If the coolant has been drained, tighten the drain valve, and add water to the specified level.
Run the engine to circulate the water through the system. Then check the water level again.
l If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level again.
l If the piping or hydraulic equipment has been removed for repair, always bleed the air from the
system after reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
l Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
PC1 2R, 15R-8 30-5

0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

* Tools with part number 79OT-000-0000 cannot be supplied (they are items to be locally manu-
factured).
* Necessity: n .. . . .. . . . Cannot be substituted, should always be installed (used)
l ....... .. Extremely useful if available, can be substituted with commercially available
part
New/remodel: N . .. . .. . . . Tools with new part numbers, newly developed for this model
R . .. . .. . . . Tools with upgraded part numbers, remodeled from items already available
for other models
Blank . . Tools already available for other models, used without any modification
* Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Component
Disassembly, assembly Press fitting of bearing

of idler assembly
Disassembly, assembly
of track roller assembly
M 792-371-1400 Sleeve Installation of spring
of recoil spring assembly Hll I I
Removal, installation o
of hydraulic cylinder l 790-101-5021 l Grip
assembly
l 01010-50816 l Bolt
Fitting
of
piston
ring
Application *I : Boom, arm, blade, PC12R 15R swing, bucket

l
“2 : PC15R boom, arm, blade

*3 : PC12R arm, PC12R/15R bucket
‘4 : PC12R blade, PC15R arm, PC12R 15R boom, swing
l
30-6 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
minal of the battery.
Open the operator’s seat, then remove storage

box (I).
Disconnect wiring connector E2 (2) and battery

terminal (3).
Remove starting motor assembly (4).
I - 3 I
INSTALLATION OF STARTING
MOTOR ASSEMBLY
. Carry out installation in the reverse order to re-
moval.
PC12R, 15R-8 30-7

0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
A Disconnect the cable from the negative
(-1 ter-
1. Open the operator’s seat, then remove storage

box (I).
2. Disconnect wiring connector E3 (2).
3. Loosen the mounting nut and adjustment bolt,

then remove fan belt (3) from the pulley. jl
4. Remove alternator assembly (4).
INSTALLATION OF
ALTERNATOR ASSEMBLY
l Carry out installation in the reverse order to re-
moval.
+ Adjust the fan belt tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
justing fan belt tension.
30-8 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION PUMP

ASSEMBLY
4h Disconnect the cable from the negative H ter-
1. Disconnect fuel feed hose (I 1, return hose (21, and

spill hose (3).
2. Remove fuel injection tube (4). m
3. Remove cover (5).
4. Pull out pin (6) to disconnect the rod.

* Block the gaps with cloth, etc. to prevent the
pin from failing in the pump housing.
5. Remove fuel injection pump assembly (7). m
5
CBPO3306 CBPO3307
NSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
moval.
w Fuel injection tube sleeve nut :

31.85 f 2.45 Nm (3.25 * 0.25 kgml
Ir Adjust the fuel injection timing. For details,

see TESTING AND ADJUSTING, Testing and
adjusting fuel injection timing.
PC1 2R, 15R-8 30-9

a
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER

ASSEMBLY
1. Remove air intake hose and air cleaner assembly
(I).
2. Remove air cleaner case bracket (2).
3. Remove fuel injection tube (3). m
4. Remove blow-by hose (4).
5. Disconnect spill .hose (5).
6. Remove nozzle holder assembly (6). m
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
moval.
QGI Fuel injection tube sleeve nut :

31.85 + 2.45 Nm I3.25 f 0.25 kgm}
m Nozzle holder :
50.96 f 1.96 Nm {5.2 + 0.2 kgm}
30-10 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
&h Disconnect the cable from the negative (-) ter-
1. Drain the cooling water.
2. Remove the engine hood.

(1).
4. Remove air cleaner case bracket (2).
5. Disconnect radiator inlet hose (3) and outlet hose

(4).
6. Disconnect water temperature sensor wiring con-

nector E6 (5).
7. Remove fan guard (6).
8. Disconnect fan shroud (7) and move it toward the

engine.
9. Loosen the fan belt. For details, see REMOVAL

OF ALTERNATOR ASSEMBLY. m
IO. Remove fan (8), then remove fan belt (9).
11. Disconnect alternator adjustment bar (IO) from the

alternator.
12. Remove water pump assembly (1 I).
INSTALLATION OF WATER
PUMP ASSEMBLY
moval.
* Adjust the fan belt tension. For details, see

. Refilling with water

Add water through the water filler to the speci-
fied level. Run the engine to circulate the water
through the system. Then, check the water level
again.
PC1 2R, 15R-8

DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY

(1).
3. Disconnect radiator inlet hose (2).
4. Remove cover (31, then remove thermostat as-

sembly.
INSTALLATION OF

moval.

again.
30-12 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
I. Remove the radiator assembly. For details, see
REMOVAL OF RADIATOR ASSEMBLY.
2. Loosen the mounting bolt and adjustment bolt of

the alternator, and loosen the fan belt.
3. Remove fan belt (I).
4. Remove the crank pulley mounting bolt.
5. Remove crank pulley (2) with pulier 0.
6. Remove engine front seal (3).
INSTALLATION OF ENGINE
FRONT SEAL
moval.
* Adjust the fan belt tension. For details, see

m Crank pulley mounting bolt :

88.2 ? 4.9 Nm (9 ? 0.5 kgm}
M
* When installing the crank pulley, match it to
the dowel pin of the crankshaft.
& Oil seal lip : Engine oil (E030-CD)
PC 12R, 15R-8 30-l 3

0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove the damper assembly. For details, see
REMOVAL OF DAMPER ASSEMBLY.
2. Remove flywheel (1). m
3. Remove seal case (2).

* Insert screwdrivers, etc. in the cuts on both
ends of the seal case, and pry up.
CBPO3322
Remove engine rear seal (3) from the seal case.

m
CBP03323
30-l 4 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
INSTALLATION OF ENGINE
REAR SEAL
moval.
& Seal fitting face of seal case and oil seal

lip : Engine oil (E030-CD)
* Press fit the oil seal until it is flush with the
seal case.
& Fitting face of seal case:

Gasket sealant (LG-7)
a
* Tighten the flywheel mounting bolts in the or-
der shown at right.
w Flywheel mounting bolt :

93.3 f 2.94 Nm I8.5 f 0.3 kgm}
After installing the flywheel, check it for facial

runout and radial runout with dial gauge 0.
. Facial runout : 0.20 mm max.
. Radial runout : 0.20 mm max.
CKP02631
PC1 2R, 15R-8 30-l 5

0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
&b Disconnect the cable from the negative (-) ter-
1. Remove the water pump assembly. For details,

see REMOVAL OF WATER PUMP ASSEMBLY.
2. Disconnect fuel filter (1) and move it toward the

counterweight.
3. Remove 3 fuel tubes (2). m

125
4. Remove blow-by hose (3).
5. Remove exhaust pipe (4) and muffler (5).

Sr After removing the exhaust pipe and muffler
as an assembly, separate them from each
other, then take out of the engine room.
6. Remove air intake manifold (6).
7. Remove exhaust manifold (7).
8. Disconnect 3 spill hoses (8).
9. Remove 3 nozzle holder assemblies (9). m
10. Remove glow plug harness (IO).
CBP03328
30-16 PC1 2R, 15R-8

a
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
11. Remove glow plugs (II).
12. Remove cylinder head cover (12).
13. Remove rocker shaft and rocker arm assembly

(13). /x
Sr Loosen the locknut, then loosen adjustment
screw by 2 - 3 turns.
14. Remove 6 push rods (14).
15. Remove cylinder head assembly (15). m
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
0 Carry out installation in the reverse order to re-
moval.
w Fuel injection tube sleeve nut :

31.85 f 2.45 Nm I3.25 k 0.25 kgm)
w Nozzle holder :
50.96 i 1.96 Nm 15.2 ? 0.2 kgm}
w Glow plug :
17.15 + 2.45 Nm Il.75 * 0.25 kgm1
m
* Tighten the mounting bolts from the central
one to outer ones in order.
* Check that the ball of the adjustment screw is

fitted to the socket of the push rod.
* Adjust the valve clearance. For details, see

TESTING AND ADJUSTING, Adjusting valve
clearance.
a
* Tighten the mounting bolts of the cylinder
head assembly in the order shown at right.
A : Cam side
B : Fuel injection pump side
C : Flywheel side
I D : Gear case side
m Cylinder head assembly mounting bolts :

39.2 ? 1.96 Nm (4 k 0.2 kgm} DXP00901
PC1 ZR, 15R-8 30-l 7

DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
2. Remove engine hood (I 1.
3. Lift off right protector (2).
fblkg Right protector : 30 kg
4. Remove air intake hose (3).
5. Disconnect radiator inlet hose (4) and outlet hose

(5).
6. Disconnect reservoir tank hose (6).
7. Remove fan guard (7).
8. Disconnect fan shroud (8) and move it toward the

engine.
9. Disconnect hydraulic oil cooler assembly (9) from

the radiator bracket.
* Do not disconnect the piping.
CBP03334
30-l 8 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY RADIATOR
10. Remove radiator assembly (IO).

* Remove the 4 mounting bolts on both sides
of the radiator bracket, then pull out the ra-
diator assembly toward the rear of the ma-
chine.
INSTALLATION OF RADIATOR
ASSEMBLY
moval.

again.
PC1 2R, 15R-8 30-19

0
DISASSEMBLY AND ASSEMBLY ENGINE, HYDRAULIC PUMP
REMOVAL OF ENGINE,
HYDRAULIC PUMP ASSEMBLY
A Release the pressure from the hydraulic circuit
and hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing remaining pressure
from hydraulic circuit and Releasing remaining
pressure from hydraulic tank.
A Disconnect the cable from the negative (-1 termi

nal of the battery.
2. Drain the hydraulic oil.
- : Hydraulic tank : Approx. 12.7 t
3. Remove left floor cover (I) and engine hood (2).
4. Lift off both protectors (3).
r+ ks Both protectors : 30 kg each
5. Lift off countemeight (4).
&I ks Counterweight : 55 kg
hT-f=d CBPO3337
6. Remove both hood stays (5) and reservoir tank

bracket assembly (6).
7. Remove air intake hose (7).
3338
8. Disconnect radiator outlet hose (8) and inlet hose

(9).
9. Disconnect water temperature sensor wiring con-

nector E6 (IO).
10. Remove fan guard (I I).
11. Disconnect fan shroud (12) and move it toward

the engine.
30-20 PC1 2R, 15R-8
0
12. Disconnect fuel control cable (13). m
13. Disconnect fuel feed hose (14) and return hose

(15).
Jr Remove the clamp from the frame, then move
the hoses toward the rear of the machine.
14. Disconnect engine ground wire (16).
15. Disconnect
E7 (17).
engine oil pressure switch terminal
1
16. Disconnect glow plug wiring connector E4 (18).
17. Disconnect engine stop solenoid connector E5 (19).
IO CBP03341
/ \‘I
CBPO3342
18. Disconnect starting motor wiring
I$
connector E2
(20) and battery terminal (21).
19. Disconnect alternator wiring connector E3 (22).
20. Disconnect 2 hydraulic hoses (23).
21. Remove hydraulic oil filter (24).
CBP03345
PC1 2R, 15R-8 30-21

0
PCIZR
22. Disconnect 4 hydraulic hoses (25).
23. Lift off engine and hydraulic pump assembly (26).

J, Check that the all piping and wiring have been
disconnected and the assembly will not inter-
fere with any part.
r9 kg Engine and hydraulic pump assembly :

130 kg
PC15R
INSTALLATION OF ENGINE,
HYDRAULIC PUMP ASSEMBLY
moval.
* Adiust the fuel control linkage. For details,

see TESTING AND ADJUSTING, Adjusting
fuel control lever.
Refilling with water

again.
Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
I& Hydraulic tank :

Approx. 12.7 4 (EOIOW-CD)
CEPO3348
30-22 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
kh Disconnect the cable from the negative H ter-
1. Drain the fuel.
- : Fuel tank : Approx. 19 1 (When full)
2. Remove operator’s seat (I 1 and right floor cover

(2).
3. Remove the storage box under the operators seat,

and disconnect wiring connectors Sl, S2, and S3
(3) under the monitor panel.
4. Remove fuel control lever knob (41, fuel filler cap

(51, and hydraulic oil filler cap.
5. Remove center cover (6).
CBPO3350 CBPO3351
6. Disconnect fuel hoses (7) and (8).

j, Put tags, etc. to the disconnected hoses.
7. Disconnect fuel level sensor connectors M5 and

M6 (9).
8. Remove fuel tank band (IO).
9. Remove fuel tank assembly (II).
INSTALLATION OF FUEL TANK CBPO3352

ASSEMBLY
moval.
w Band mounting nut: 6.37 Nm (0.65 kgm1
. Filling with fuel (Fuel tank)

Add fuel to the fuel tank.
l Pressurizing (Hydraulic tank)

Apply pressure to the hydraulic tank. For details,
see TESTING AND ADJUSTING, Pressurizing hy-
draulic tank.
PC1 2R, 15R-8

DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Remove the hydraulic pump assembly. For de-
tails, see REMOVAL OF HYDRAULIC PUMP AS-
SEMBLY.
2. Remove cover (1).
3. Remove damper assembly (2). a
INSTALLATION OF DAMPER
ASSEMBLY
moval.
& Threads of damper assembly

mounting bolt : Liquid adhesive (LT-2)
* Take care that the adhesive will not stick to

the rubber part of the coupling.
& Spline of damper assembly :

Grease (LM-G)
30-24 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
g Release the pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING, Re-
leasing remaining pressure from hydraulic tank.
1. Remove the floor plate.
2. Remove the track frame undercover.
3. Disconnect the hoses above the swivel joint from

the control valve, and move them.
Ir Put tags, etc. to the disconnected hoses.
4. Disconnect 8 upper hoses (I ).

* Plug the drain hose (at the center of the swivel
joint).
* Put tags, etc. to the disconnected hoses.
5. Remove stopper (2).
6. Disconnect 8 side hoses (3) and 2 lower hoses

(4).
+r Put tags, etc. to the disconnected hoses.
7. Remove down center swivel joint assembly (5).
INSTALLATION OF CENTER
SWIVEL JOINT
moval.
. Refilling with oil (Hydraulic tank)

. Bleeding air
Bleed air from the travel motor. For details, see
TESTING AND ADJUSTING, Bleeding air.
PC1 2R, 15R-8 30-25

a
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY OF CENTER
SWIVEL JOINT
1. Remove plate (1).
2. Remove snap ring (2).
3. Remove shaft assembly (3).
4. Remove dust seal (4) from shaft assembly (3).
5. Remove 3 plugs (5) and 4 plugs (6) from shaft

assembly (3).
6. Remove 8 O-rings (7) and 2 backup rings (8) from

the swivel rotor (9).
ASSEMBLY OF CENTER SWIVEL

JOINT ASSEMBLY
1. Fit8 O-rings (7) and 2 backup rings (8) to the swivel
rotor (9).
2. Fit 3 plugs (5) and 4 plugs (6) to shaft assembly

(3).
* Degrease and dry the threads of the plugs and
shaft completely, then apply liquid adhesive
(LOCTITE 542) all over the threads of the
plugs.
m Plug (5): 5.88 * 0.98 Nm (0.6 f 0.1 kgm1

Plug (6) : 18.23 f 6.37 Nm {I .35 + 0.65 kgm1
3. Fit dust seal (4) to shaft assembly (3).
& Lip of dust seal and its fitting faces against

rotor and shaft : Grease (G2-LI)
CAP03053
4. Install shaft assembly (3).

* Take care not to damage the O-rings.
5. Install spacer (9) and secure it with snap ring (2).
6. Install plate (I).
w Mounting bolt :
13.23 + 1.4 Nm Il.35 + 0.15 kgm1
30-26 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR

1. Remove the sprocket. For details, see REMOVAL

OF SPROCKET.
2. Remove cover (I).
3. Disconnect drain hose (2), pilot hose (3). and 2

main hoses (4).
Sr Plug the drain hose.
4. Remove union (5) from the travel motor.

f Do not remove the union for the pilot hose.
5. Remove travel motor assembly (6). a
INSTALLATION OF TRAVEL
4 CBPO3359

moval.
& Threads of travel motor assembly mount-

ing bolt : Liquid adhesive (LT-21
If
m Travel motor assembly mounting bolt :
66.15 f 7.35 Nm 16.75 f 0.75 kgm}
l Refilling with oil (Hydraulic tank)

. Bleeding air
Bleed air from the travel motor. For details, see
PC1 2R, 15R-8 30-27

0
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
ASSEMBLY
1. Remove the track shoe assembly. For details, see
REMOVAL OF RUBBER SHOE ASSEMBLY or EX-
PANSION OF STEEL SHOE ASSEMBLY.
2. Remove sprocket (1).
INSTALLATION OF SPROCKET
ASSEMBLY
moval.
30-28 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING MOTOR

ASSEMBLY
A Release the pressure from the hydraulic tank.
1. Remove the floor plate.
2. Open the operator’s seat and remove the storage

box.
3. Disconnect drain hose (1).
* Plug the drain hose adapter of the hydraulic

tank.
4. Disconnect 4 hoses (2).

5. Remove swing motor assembly (3).
&I kg Swing motor assembly : 28 kg
INSTALLATION OF SWING
MOTOR ASSEMBLY
moval.
l Refilling with oil (Hydraulic tank)

. Bleeding air
Bleed air from the swing motor. For details, see
PC1 2R, 15R-8 30-29

0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
g Release the pressure from the hydraulic tank. For
details, see TESTING AND ADJUSTING, Releas-
ing remaining pressure from hydraulic tank.
1. Remove the canopy assembly. For details, see

REMOVAL OF CANOPY ASSEMBLY.
2. Remove the work equipment assembly. For de-

tails, see REMOVAL OF WORK EQUIPMENT AS-
SEMBLY.
3. Remove the swing motor assembly. For details,

see REMOVAL OF SWING MOTOR ASSEMBLY.
4. Sling boom cylinder assembly (1) temporarily.
5. Disconnect 2 hoses (21, then pull out pin (3) to

remove boom cylinder assembly (1). m
6. Disconnect the hoses above the swivel joint from

the control valve, and move them.
7. Disconnect 8 hoses (4) above the swivel joint.

* Plug the drain hose (in front of the machine
body).
8. Remove stopper (6).
9. Disconnect grease tube (6) and remove grease

connector (7).
CBPO3365
30-30 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
10. Remove the engine hood.
11. Sling revolving frame assembly (8) temporarily.

* After slinging temporarily, remove the mount-
ing bolts, leaving 2 - 3 ones each on the front
and rear sides. a
12. Remove the mounting bolts to remove revolving

frame assembly (8). m
+ Balance the revolving frame assembly in each
direction with lever blocks, etc., then remove
the rest of the mounting bolts.
* When removing the revolving frame assem-
bly, take care not to hit it against the center
swivel joint.
&I kg Revolving frame assembly : 600 kg
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
moval.
A When aligning the pin holes, never insert your

fingers in them.
6 Lubrication of pin and sliding surfaces

for assembly :
Lubricant containing molybdenum disul-
fide (LM-PI
& Lubrication after assembly :

Lubricant containing molybdenum disul-
fide (LM-G)
* Reduce clearance a between the bottom of
cylinder (I 1 and swing bracket (8) to 1 mm or
less with shim.
l Shim thickness : 1 mm
m(Fq
& Revolving frame assembly

mounting bolt : Liquid adhesive (LT-2)
m Revolving frame assembly

mounting bolt :
56.15 C 7.35 Nm I6.75 f 0.75 kgm}
PC1 2R, 15R-8 30-31

0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
CIRCLE ASSEMBLY
1. Remove the revolving frame assembly. For de-
tails, see REMOVAL OF REVOLVING FRAME AS-
SEMBLY.
2. Lift off swing circle assembly (I) by using hang-

ing bolts 0. m
1 71r\ CBPO3368
CIRCLE ASSEMBLY
moval.
m
* Install the swing circle assembly so that soft
zone S mark @ will be on the right side of the
track frame.
& Swing circle assembly mounting bolt :

Liquid adhesive (LT-2)
m Swing circle assembly mounting bolt :

66.15 + 7.35 Nm (6.75 If: 0.75 kgm}
& Tooth surface of inner race:

Grease (G2-LI)
DXP00903
30-32 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL OF IDLER ASSEMBLY

1. Remove the track shoe assembly. For details, see
REMOVAL OF RUBBER SHOE ASSEMBLY or EX-
PANSION OF STEEL SHOE ASSEMBLY.
2. Remove idler assembly (I).

Jc The idler assembly and idler cushion are sepa-
rate from each other in the rubber shoe speci-
fication, but are made as one unit in the steel
shoe specification.
CBPO3369
INSTALLATION OF IDLER
ASSEMBLY
moval.
PC1 2R, 15R-8 30-33

0
DISASSEMBLY OF IDLER
ASSEMBLY
1. Disconnect idler cushion assembly (in the steel
shoe specification).
2. Remove plate (I 1.
3. Remove support (2).
4. Remove oil seal (3).
5. Remove snap ring (4). then remove shaft (5).

CAP03441
6. Remove 2 bearings (6) from idler (7).
CAP03442
CAP03443
30-34 PC1 2R, 15R-8

0
ASSEMBLY OF IDLER
ASSEMBLY
1. Using tool Ll, press fit 2 bearings (6) to idler (7).
Ir Fill the bearings with grease (G2-LI).
CAP03060
2. Install shaft (5) and secure it with snap ring (4).
CAP03061
3. Using tool L2, fit oil seal (3) to the idler.

* Fill the oil seal lip with grease (G2-LI) and take
care that dust will not stick to it.
Ir After fitting the oil seal to one side, fill the
inside of the idler with grease.
% Inside of idler : Approx. 36cc (G2-LI)
CAP03062
4. Install support (2).

& Mounting bolt : Liquid adhesive (LT-21
5. Install plate (I).
6. Install idler cushion assembly. (Steel shoe speci-

fication)
CAP03441
PC1 2R, 15R-8 30-35

0
DISASSEMBLY AND ASSEMBLY IDLER CUSHION
REMOVAL OF IDLER CUSHION

ASSEMBLY (Ruber shoe)
1. Remove the idler assembly. For details, see RE-
MOVAL OF IDLER ASSEMBLY.
2. Pull out and remove idler cushion assembly (I).
INSTALLATION OF IDLER
CUSHION ASSEMBLY
(Ruber shoe)
moval.
30-36 PC1 2R, 15R-8

0
DISASSEMBLY OF IDLER CUSH-

ION ASSEMBLY (Rubber shoe)
1. Remove grease fitting (I) and valve (2) from rod
(3).
2. Remove rod (3) from cylinder (4).
3. Remove dust seal (5), backup ring (6), and O-ring

(7) from cylinder (4) in order.
ASSEMBLY OF IDLER CUSHION

ASSEMBLY (Rubber shoe)
1. Fit O-ring (7), backup ring (6), and dust seal (5) to
cylinder (4) in order.
O-ring, backup ring, dust seal: Grease (G2-LI)
CAP03444
2. Fill the cylinder with grease (G2-LI).
3. Install valve (2) and grease fitting (1) to rod (3).

* After tightening the valve, loosen it about two
turns.
4. Install rod (3) to cylinder (4) and push grease out

of the valve to bleed air from the cylinder.
5. Tighten valve (2).
w Valve : 66.15 ? 7.35 Nm I6.75 f 0.75 kgml
PC1 2R, 15R-8 30-37

0
DISASSEMBLY OF IDLER CUSH-

ION ASSEMBLY (Steel shoe)
1. Piston
I) Remove grease fitting (I) and valve (2) from
rod (3).
2) Remove rod (3) from cylinder assembly (4).
2. Recoil spring
1) Remove cotter pin (5) from the nut.
2) Using tool M, set the recoil spring to a press.
a Since
. the installing load of the spring is
high and dangerous, set it securely.
3) Apply hydraulic pressure gradually to com-

press the spring and remove nut (6).
* Compress the spring until the nut is loos-
ened.
* nstalling load of spring : 6860 Nm {700 kg}
4) Release the hydraulic pressure gradually to

let the spring expand, then remove stopper
(7) and spring (8) from the cylinder assem-
bly.
Ir Free length of spring: 200 mm
3. Cylinder CAP03445
. Remove dust seal (IO), backup ring (I I), and

O-ring (12) from cylinder (9) in order.
30-38 PC1 2R, 15R-8

0
ASSEMBLY OF IDLER CUSHION

ASSEMBLY (Steel shoe)
1. Cylinder
. Fit O-ring (121, backup ring (1 I), and dust seal
(IO) to cylinder (9) in order.
& O-ring, backup ring, dust seal :
i
Grease (G2-LI)
*
2. Recoil spring
1) Assemble cylinder assembly (4), spring (81,
and stopper (7).
2) Using tool M, set the recoil spring to the press.
A Since the installing load of the spring is

high and dangerous, set it securely.
3) Apply hydraulic pressure gradually to com-

press the spring to installing dimension a,
then install nut (I).
* Spring installing dimension a :
168 + 0.5 mm
4) Secure the nut with cotter pin (5).
3. Piston
1) Fill the cylinder with grease (G2-LI).
2) Install valve (2) and grease fitting (1) to rod
(3). CAP0344!
j, After tightening the valve, loosen it about

two turns.
3) Insert rod (3) in cylinder (4) and push grease
out of the valve to bleed air from the cylinder.
4) Tighten valve (2).
PC1 2R, 15R-8

DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Loosen valve (1) to loosen the track roller. /I
A Since the pressure in the idler cushion cyl-

inder is very high, do not loosen the valve
more than one turn.
* If the grease does not flow out well, move the

machine forward and in reverse.
2. Swing the upper structure by 90 degrees and lift

up track frame (2) by using the work equipment.
* Raise the blade in advance.
3. Remove track roller assembly (3).
CBP03371
INSTALLATION OF TRACK
ROLLER ASSEMBLY
moval.
m
* Adjust the track shoe tension. For details, see
justing track shoe tension.
30-40 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
1. Remove plates (1).
2. Remove oil seals (2).
3. Remove snap rings (3), then remove shaft (4).
4. Remove bearings (5) from track roller (6).
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
I. Using tool L3, press fit bearings (5) to track roller
(6).
* Fill the bearings with grease (G2-LI).
2. Install shaft (4) and secure it with snap ring (3).
3. Using tool L4, install oil seals (2) to track roller

(6). I CAP03447
* Apply engine oil (E030-CD) to the sliding sur-

face of the oil seal and take care that dust will
not stick to it.
Ir After fitting the oil seal to one side, fill the

inside of the track roller with grease.
22 Inside of track roller :

Approx. 44cc (G2-LI)
4. Install plates (I).
I 1 J L J CAP03448
CAP03449
PClZR, 15R-8 30-4 1

0
DISASSEMBLY AND ASSEMBLY RUBBER SHOE
REMOVAL OF RUBBER SHOE

ASSEMBLY
1. Loosen valve (I) to loosen the track roller. a
g Since the pressure in the idler cushion cyl-

inder is very high, do not loosen the valve
more than one turn.
Sr If the grease does not flow out well, move

the machine forward and in reverse.
2. Swing the upper structure by 90 degrees and lift

up track frame a little by using the work equip-
ment.
1: Raise the blade in advance.
3. Remove rubber shoe assembly (3) by using steel

pipes, bars, etc. 0.
j, Catch pipes, bars, etc. @ in the rubber shoe
and turn the latter in reverse. If the rubber
shoe is separated from the idler, slide and
remove it sideways.
& k9 Rubber shoe assembly: 45 kg
CBPO3372
INSTALLATION OF RUBBER
SHOE ASSEMBLY
moval.
m
t Adjust the track shoe tension. For details, see
30-42 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY STEEL SHOE
EXPANSION OF STEEL SHOE

ASSEMBLY
1. Loosen valve (I) to loosen the track shoe. m
g Since the pressure in the recoil spring cylin-

der is very high, do not loosen the valve
more than one turn.
* If the grease does not flow out well, move the

machine forward and in reverse.
2. Bring the master pin to the front of the machine

and set block @ to the track shoe.
* Move the machine forward or in reverse so
that the master pin will be at the top of the
idler.
3. Straighten either side of lock pin (2) and remove

it. m
4. Remove master pin (3).
5. Expand steel shoe assembly (4).
g Start the engine and move the machine in

reverse slowly to expand the steel shoe as-
sem bly.
CLPO3109
r+ kg Steel shoe assembly : 120 kg
INSTALLATION OF STEEL SHOE

ASSEMBLY
moval.
Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and ad- CLP03110
After inserting the lock pin, bent it.
PC1 2R, 15R-8 30-43

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK
1. Drain hydraulic oil.
- : Hydraulic tank : Approx. 12.7 .k?
2. Remove operator’s seat (1) and left floor cover

(2).
3. Remove the storage box under the operator’s

seat, and disconnect wiring connectors Sl, S2,
and S3 (3) under the monitor panel.
4. Remove fuel control lever knob (4), fuel filler cap

(5), and hydraulic oil filler cap.
5. Remove center cover (6).
lojT \
CBPO3350 CBP0335 1
6. Disconnect 3 hoses (7) on the right side of the

hydraulic tank.
7. Disconnect 2 hoses (8) at the rear of the hydrau-

lic tank.
8. Remove reservoir tank (9).
9. Disconnect 2 hoses (10) under the hydraulic tank.
cap03374
CBPO3376
30-44 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
IQ. Remove hydraulic tank assembly (II).
INSTALLATION OF HYDRAULIC
TANK
Carry out installation in the reverse order to re-
moval.

Add oil through the oil fillerto the specified level.
I&? Hydraulic tank :

Approx. 12.7 e (EOlOW-CD)
Bleeding air
Bleed air from the hydraulic circuit. For details,
see TESTING AND ADJUSTING, Bleeding air.
PC1 2R, 15R-8 30-45

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL OF HYDRAULIC OIL

COOLER ASSEMBLY
a Release the pressure from the hydraulic tank. I
- : Hydraulic tank : Approx. 12.7 4?
2. Remove engine hood (1).

2
3. Lift off right protector (2).
-
&I kg Right protector : 30 kg
5. Remove hydraulic oil cooler assembly (4).
OIL COOLER ASSEMBLY

moval.

Hydraulic tank :
. Bleeding air
30-46 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL OF HYDRAULIC
PUMP ASSEMBLY
a Release the pressure from the hydraulic tank.
- : Hydraulic tank : Approx. 12.7 e
2. Remove left floor cover (1).
3. Lift off left protector (2). CBPO3379
& kg Left protector : 30 kg

PCIZR
4. Disconnect inlet hose (3) and outlet hoses (4), (51,

and (6) (PC12R).
Disconnect inlet hose (3), outlet hoses (4) and (5),

and pilot hose (6) (PC15R).
5. Remove hydraulic pump assembly (7). m
CLP03420
PC15R
PUMP ASSEMBLY
moval.
,=$& Spline of shaft :

Molybdenum disulfide lubricant (LM-G)
Refilling with oil (Hydraulic tank]

Q Hydraulic tank :
Bleeding air
PC1 2R, 15R-8 30-47

0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL VALVE

ASSEMBLY
dk Release the pressure from the hydraulic circuit
and hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing pressure from hy-
draulic circuit and Releasing remaining pressure
from hydraulic tank.
1. Remove right floor cover (I) and floor plate (2).
2. Disconnect horn wiring connectors M9 and Ml0

(3).
3. Disconnect hose (4) on the control valve side.

m
* Do not disconnect hose connected to the PPC
valve. (It shall be disconnected in step 9.)
* The hoses which are on the sides or bottom
and cannot be disconnected easily shall be
disconnected when the control valve is re-
moved.
4. Sling the lever stand and control valve assembly

(5).
r3 kg Lever stand and control valve assembly :

50 kg
5. With the lever stand and control valve slung, dis-

connect the hoses (6) which are still connected.
6. Remove the lever stand and control valve assem-

bly (5).
' CBP03384 CBP03385
30-48 PC 12R, 15R-8

0
7. Place the lever stand and control valve assembly

on block @ with the travel lever side up.
8. Remove iever stand cover (7).
9. Disconnect IO hoses (8). m

10. Disconnect 3 cables (9) and 4 yokes (IO).

+ Record the connecting dimensions of the
7
cabies.
A Put tags, etc. to the disconnected cables. CBPO3386
11. Using hanging bolts 0, lift off control valve as

sembly (II).
& kg Control valve assembly : 40 kg
INSTALLATION OF CONTROL
VALVE ASSEMBLY
moval.
m
m Taper seal hose :
Nominal size Tightening torque

Hydraulic tank :
Approx. 12.7 f? (EOlOW-CD)
Bleeding air
PC12R,15R-8 30-49
0
DISASSEMBLY OF CONTROL VALVE ASSEMBLY

UPPER SECTION OF CONTROL VALVE (l/2)
B 0
28w
Q/3! f&13
0
33 Q
---I
, gJ-14
IO
4l--@_d w”?T I
53
52
m
41y&
qso 32--+? &37
e _ ,f
CAP03456
30-50 PCl2R, 15R-8

0
* Do not remove the lower connecting bolt (longer 6. Blade and breaker control valve
one) of the control valve. Remove the upper con- 1) Remove case (27) and plate (28).
necting bolt (shorter one) of the control valve 2) Remove bolt (29).
when installing an additional service valve. * Loosen the bolt while the spool is
* Since the spools and pressure compensation in the valve.
valves (both flow control valves and pressure re- 3) Remove retainer (30), spring (311, and
ducing valves) are not interchangeable among the retainer (32).
blocks, mark them when removing them. 4) Remove spool (33).
* Do not remove the plug from each spool end. 5) Remove plug (341, then remove spring
* Do not disassemble the centralized safety valve, (35), piston (36), valve (37), and spacer
since its pressure cannot be set while it is (38).
mounted on the machine. 6) Remove plug (39), then remove valve
(40).
1. Upper cover 7) Remove 2 seals (41).
1) Remove plug (1).
Ir Loosen the plug slowly, since some pres- 7. Bucket control valve
sure may be still left in the centralized 1) Remove cases (42) and (43).
safety valve. 2) Remove retainer (44).
Ir Remove the O-ring and backup ring. 3) Remove bolt (45).
* Loosen the bolt while the spool is
2. Pilot relief valve in the valve.
Loosen locknut (2), then remove adjustment screw 4) Remove retainer (46), spring (471, and
(3). spring (4), and valve (5). retainer (48).
* If the adjustment screw is loosened, the set 5) Remove spool (49).
pressure changes. Accordingly, measure how 6) Remove plug (50), then remove spring
much the adjustment screw is projected from (511, piston (521, and valve (53).
the nut before removing the valve. 7) Remove plug (54), then remove valve
(55) and spring (56).
3. PPC lock valve
Remove plate (6), then remove valve (7). 8. Boom control valve
1) Remove cases (57) and (58) and retainer
4. Travel booster valve (59).
Remove plate (81, then remove valve (9). 2) Remove bolt (60).
Jr Loosen the bolt while the spool is
5. Swing control valve in the valve.
1) Remove block (IO). 3) Remove retainer (61), spring (621, and
2) Remove case (11) and plate (12). retainer (63).
3) Remove case (13) and plate (14). 4) Remove spool (64).
4) Remove bolt (15). 5) Remove plug (651, spring (66), piston
* Loosen the bolt while the spool is in the (671, and valve (68).
valve. 6) Remove plug (69), valve (70), and
5) Remove retainer (161, spring (171, and retainer spring (71).
(18). 7) Remove 2 suction valve assemblies
6) Remove spool (19). (72).
7) Remove bolt (20). 8) Remove plug (731, then remove spring
* Loosen the bolt while the spool is in the (74) and valve (75).
valve.
8) Remove retainer (211, spring (221, and retainer
(23).
9) Remove spool (24).
IO) Remove 2 seals (25).
11) Remove suction valve assembly (26).
PC1 2R‘ 15R-8 30-51

a
LOWER SECTION OF CONTROL VALVE (2/2)
PC1
& ‘18
______________-__-__-__
CAP03458
30-52 PC12R, 15R-8

0
9. Right travel control valve and left travel con- 13. Centralized safety valve
trol valve Remove centralized safety valve assembly
Ir Disassemble both travel control valves ac- (50).
cording to the same procedure. Sr Remove the O-ring and backup ring.
5) Remove plate (13.
2) Remove case (2) and plate (3). 14. Unload valve
3) Remove bolt (4). 1) Remove plug (51), then remove spring
* Loosen the bolt while the spool is in (52).
the valve. * Remove the O-ring and backup ring.
4) Remove retainer (5), spring (6), and re- 2) Remove plug (53), then remove spool (54).
tainer (7).
Remove spool (8). 15. Cooler check valve
Remove 2 seais (9). Remove plug (55), then remove spring (56)
Remove plug (IO), then remove piston and valve (57).
(II), spring (12), and valve (13).
8) Remove plug (14), then removevalve (15). 16. Back pressure check valve
Remove plug (58), then remove spring (59)
10. Swing control valve and valve (60).
* Steps 6) and after are for only PCISR.
1) Remove block (16). 17. Upper cover
2) Remove cases (17) and (18). Ir When installing an additional service
3) Remove bolt (19). valve, remove cover (61).
* Loosen the bolt while the spool is in
the valve.
4) Remove retainer (20), spring (21), and re-
tainer (22).
6) Remove plug (24), then remove spring
(25), piston (26), and valve (27).
7) Remove plug (28), then remove valve (29).
11. Arm control valve

1) Remove cases (30) and (31).
2) Remove retainer (32).
3) Remove bolt (33).
+r Loosen the bolt while the spool is in
the valve.
4) Remove retainer (34), spring (35), and re-
tainer (36).
6) Remove plug (38), then remove spring
(39), piston (40), and valve (41).
7) Remove plug (42), then remove valve (43)
and spring (44).
8) Remove suction valve assembly (45).
9) Remove plug (46), then remove spring (47)
and valve (48).

Remove main relief valve assembly (49).
* For disassembly of the sub assembly, see
DISASSEMBLY OF SUB ASSEMBLY OF
MAIN RELIEF VALVE ASSEMBLY.
PC12R, 15R-8 30-53

a
DISASSEMBLY OF SUB ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
If the adjustment screw is loosened, the set pres-
sure changes. Accordingly, measure how much
the adjustment screw is projected from the nut
before disassembling the sub assembly.
Remove nut (I ).
Remove screw (2), then remove spring (3) and

puppet (4).
Remove ring (51, then remove valve (6) and spring

(7) from sleeve (8).
30-54 PC1 2R, 15R-8

0
ASSEMBLY OF CONTROL VALVE ASSEMBLY

LOWER SECTION OF CONTROL VALVE (l/2)
CAP03458
PC12R, 15R-8 30-55

0
* Since the spools and pressure compensation Ir For assembly of the sub assembly, see AS-
valves (both flow control valves and pressure SEMBLY OF SUB ASSEMBLY OF MAIN
reducing valves) are not interchangeable RELIEF VALVE ASSEMBLY.
among the blocks, match their marks made
when they were removed. 7. Arm control valve
1) Install valve (48) and spring (471, then in-
1. Upper cover stall plug (46) together with the O-ring.
* If the upper cover has been removed, in-
m Plug : 22.05 f 2.45 Nm
stall it by the following method.
I2.25 f 0.25 kgm)
Fit the O-ring to the block side, then install 2) Install suction valve (45).
cover (61).
QGI Suction valve assembly :
w Mounting bolt : 44.1 f 4.9 Nm 14.5 ? 0.5 kgm)
33.35 k 1.95 Nm I3.4 k 0.2 kgm1
3) Install spring (44) and valve (43), then in-
stall plug (42) together with the O-ring.
2. Back pressure check valve
Install valve (60) and spring (59), then install w Plug : 52.95 k 5.85 Nm
plug (58) together with the O-ring. 15.4 f 0.6 kgml
w Plug : 4) Install valve (41), piston (401, and spring

139.75 f 22.05 Nm I14.25 + 2.25 kgm1 (39), then install plug (38) together with
the O-ring.
3. Cooler check valve
m Plug : 52.95 + 5.85 Nm
Install valve (57) and spring (56), then install
I5.4 i: 0.6 kgm1
plug (55) together with the O-ring.
5) Install spool (37).
w Plug :
* Take care of the installing direction.
139.75 + 22.05 Nm I14.25 k 2.25 kgml
6) Install retainer (361, spring (35), and re-

4. Unload valve
tainer (34) to the spool, then install bolt
1) Install spool (54), then install plug (53) to-
(33).
gether with the O-ring.
j, Tighten the bolt while the spool is in
w Plug : the valve.
139.75 f 22.05 Nm j14.25 + 2.25 kgm}
w Bolt : 8.35 ? 1.45 Nm
2) Install spring (521, then install plug (51) IO.85 + 0.15 kgml
together with the O-ring and backup ring.
7) Install retainer (321, then install cases (31)
w Plug : and (30) together with the O-rings.
139.75 * 22.05 Nm I14.25 + 2.25 kgml
m Mounting bolt : 11.25 + 1.45 Nm
Il.15 f 0.15 kgml
5. Centralized safety valve
Install centralized safety valve assembly (50)
together with the 0;ring and backup ring.
w Centralized safety valve assembly :

147 f IO Nm {I5 f 1 kgm}

Install main reliefvalve assembly (49) together
with the O-ring.
w Main relief valve assembly :

53.9 rf:4.9 Nm I5.5 f 0.5 kgml
30-56 PC1 2R, 15R-8

0
8. Swing control valve 5) Install retainer (7), spring (6), and retainer
* Steps 1) and 2) are for only PC15R. (5) to the spool, then install bolt (4).
1) Install valve (29), then install plug (28) to- f Tighten the bolt while the spool is in
gether with the U-ring. the valve.
m Plug : 22.05 k 2.45 Nm m Bolt : 8.35 + 1.45 Nm

12.25 + 0.25 kgm} IO.85 f. 0.15 kgm}
2) lnstali valve (27), piston (26), and spring 6) Install plate (3) and case (2).
i25), then install plug (24) together with
m Mounting bolt :
the Q-ring.
11.25 f 1.45 Nm(1.15 I: 0.15 kgm}
D Plug : 22.05 + 2.45 Nm
7) Install case (I).
12.25 & 0.25 kgm}
m Mounting bolt :
3) install spool (23).
11.25 + 1.45 NmI1.15 f 0.15 kgm}
4) Install retainer (22), spring (21), and re-

(19)
Ir Tighten the bolt while the spool is in
the valve.
m Bolt : 8.35 + 1.45 Nm

IO.85 i 0.15 kgm1
5) Install cases (18) and (17) together with

the O-rings.
m Mounting bolt :
‘81.25? 1.45 Nm{l.l5f 0.15 kgm}
6) Install block (16) togetherwith the O-ring.
QEI Mounting bolt :

11.25 i: 1.45 Nm(1.15 f 0.15 kgm}
9. Right travel control valve and left travel con-

trol valve
* Assemble both travel control valves ac-
cording to the same procedure.
1) Install valve (15), then install plug (14) to-

gether with the O-ring..
m Plug : 22.05 ? 2.45 Nm

i2.25 f 0.25 kgm}
2) Install valve (13), spring (12), and piston

(II), then install plug (IO) together with
the O-ring.
QFQ Plug : 22.05 + 2.45 Nm

I2.25 ? 0.25 kgm)
3) Press fit 2 seals (9).

PCl2R, 15R-8 30-57

0
UPPER SECTION OF CONTROL

__- VALVE
. ._.~ 12/2)
. .
CAP03456
30-58 PC1 2R,15R-8

0
IO. Boom control valve 4) Install retainer (48), spring (47), and re-
1) Install valve (75) and spring (74), then in- tainer (46) to the spool, then install bolt
stall plug (73) together with the O-ring. (45).
* Tighten the bolt while the spool is in
w Plug : 22.05 f 2.45 Nm
the valve.
(2.25 + 0.25 kgm1
m Bolt : 8.35 & 1.45 Nm
2) Install 2 suction valve assemblies (72) to-
IO.85 f 0.15 kgm}
gether with the O-rings.
5) Install retainer (44), then install cases (43)
w Suction valve assembly :
and (42) together with the O-rings.
44.1 f 4.9 Nm I4.5 f 0.5 kgm}
w Mounting bolt : 11.25 f 1.45 Nm
3) Install spring (71) and valve (70), then in-
{1.15? 0.15 kgm1
w Plug: 12. Blade and breaker control valve

52.95 + 5.85 Nm 15.4 f 0.6 kgm} 1) Press fit 2 seals (41).
4) Install valve (68), piston (67), and spring
2) Install valve (40), then install plug (39) to-
(66), then install plug (65) together with
the O-ring.
w Plug : 52.95 + 5.85 Nm
m Plug :
{5.4 f 0.6 kgm1
52.95 k 5.85 Nm I5.4 + 0.6 kgm}
3) Install spacer (38), valve (37), piston (36),
and spring (35), then install plug (34) to-
6) Install retainer (63), spring (62), and re-
tainer (61) to the spool, then install bolt m Plug : 52.95 f 5.85 Nm
(60). t5.4 f 0.6 kgm1
j, Tighten the bolt while the spool is in
the valve.
Ir Take care of the installing direction.
w Bolt : 8.35 f 1.45 Nm 5) Install retainer (32), spring (31), and re-
IO.85 f 0.15 kgm1 tainer (30) to the spool, then install bolt
(29).
7) Install retainer (59), then install cases (58)
and (57) together with the O-rings.
the valve.
w Mounting bolt :
w Bolt : 8.35 + 1.45 Nm
11.25 f 1.45 Nm11.15 f 0.15 kgm1
IO.85 f 0.15 kgm1
1 I. Bucket control valve 6) Install plate (28) and case (27).

1) Install spring (56) and valve (55), then in- w Mounting bolt :
11.25f 1.45Nm~1.15+0.15kgmI
w Plug :
52.95 & 5.85 Nm 15.4 ? 0.6 kgm1
2) Install valve (53), piston (52), and spring

(51), then install plug (50) together with
the O-ring.
m Plug :
52.95 + 5.85 Nm 15.4 f 0.6 kgm1

PC12R,15R-8 30-59
0
13. Swing control valve 15. PPC lock valve

1) Install suction valve assembly (26) to- Install valve (7), then install plate (6) together
gether with the O-ring. with the O-ring.
QZ Suction valve assembly : m Mounting bolt :

44.1 + 4.9 Nm 14.5 + 0.5 kgm} 11.25 + 1.45 NmI1.15 IO.15 kgm}
2) Press fit 2 seals (25). 16. Pilot relief valve

3) nstall spool (24). * To obtain the set pressure before disassem-
bly, project the adjustment screw from the nut
4) Install retainer (231, spring (22), and re-
by the length measured when it was removed.
After installing the control valve assembly to
(20). the machine body, check the set pressure
again according toTESTING AND DJUSTING.
the valve.
1) Install valve (5) and spring (4), then install
w Bolt : 8.35 + 1.45 Nm adjustment screw (3) and locknut (2) to-
IO.85 + 0.15 kgm) gether with the O-ring.
2) Tighten locknut (2).
4) Install re5) Install spool (19).
* Take care of the installing direction. m Locknut : 22.05 f 2.45 Nm
6) Install retainer (18), spring (171, and re- j2.25 + 0.25 kgml
tainer (16), then install bolt (15).
* Tighten the bolt while the spool is in 17. Upper cover
the valve. install plug (I) together with the O-ring and
backup ring.
w Bolt : 8.35 + 1.45 Nm
iO.85 + 0.15 kgml m Plug : 39.2 + 4.9 Nm 14 + 0.5 kgml
7) llnstall plate (14) together with the O-ring.
m Mounting bolt:
11.25 f 1.45 NmI1.15 + 0.15 kgml
8) Install case (13) together with the O-ring.
m Mounting bolt:
11.25 + 1.45 NmI1.15 + 0.15 kgm1
9) Install plate (12) together with the O-ring.
N Mounting bolt :
11.25 f 1.45 Nm{1.15? 0.15 kgm}
IO) Install case (I I) together with the O-ring.
w Mounting bolt :
11.25 * 1.45 Nmi1.15 f 0.15 kgml
11) Install block (lO).together with the O-ring.
m Mounting bolt :
11.25 + 1.45 Nm{1.15? 0.15 kgml
14. Travel booster valve

Install valve (91, then install plate (8) together
with the O-ring.
w Mounting bolt :
11.25 + 1.45 NmI1.15 k 0.15 kgm}
30-60 PC 12R, 15R-8
0
ASSEMBLY OF SUB ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
To obtain the set pressure before disassembly,
project the adjustment screw from the nut by the
length measured when it was removed.
After instailing the control valve assembly to the
machine body, check the set pressure again ac-
cording to TESTING AND DJUSTING.
install spring (71 and valve (6) to sleeve (81, then

secure them with ring (5).
Instaii puppet (41 and spring (31, then install screw

(2) together with the O-ring.
Install nut (I ).
QZI Nut : 68.7 f 9.8 Nm I7 f 1 kgm}
CAP03098
PC1 2R, 15R-8 30-61

0
DISASSEMBLY AND ASSEMBLY PPC VALVE
REMOVAL OF PPC VALVE

ASSEMBLY
g Disconnect the cable from the negative (-1 ter-

1. Remove covers (I), (21, and (3).
2. Remove floor plate (41, then disconnect horn

switch connectors M9 and Ml0 (5).
BP03389
j, Perform this work for only the right lever.
3. Remove levers (6).
4. Disconnect 6 hoses (7) on each side. m

5. Remove PPC valve assembly (8).
Y CBPO3390
INSTALLATION OF PPC VALVE
ASSEMBLY
moval.
m P-port eye joint :

39.2 + 4.9 Nm 14 ? 0.5 kgm}

30-62 PC1 2R, 15R-8

0
DISASSEMBLY OF PPC VALVE

ASSEMBLY
1. Remove nut (I), then remove disc (2) and boot
(3).
2. Remove joint (4).
3. Remove plate (5)
4. Remove seals (6) and collars (7).
5. Remove pistons (8).
6. Remove valve assemblies (9).
7. Remove retainers (IO), then disassemble springs

(II), shims (121, and valves (13).
* Record the thickness and quantity of the
shims.
8. Remove springs (14).

* Springs of two types are used. Record their
locations.
9. Remove 2 plugs (15) from body (16).
r
/‘O
I I1
9712
113
CAP03087
PC1 2R, 15R-8 30-63

0
ASSEMBLY OF PPC VALVE

ASSEMBLY
1. Install 2 plugs (15) to body (16).
m Plug : 6.86 k 1.96 Nm IO.7 & 0.2 kgm}
2. Install springs 14.

* Springs of two types are used. Check the
number of turns of each of them.
Position Number Position Number
of port of turns of port of turns
PI l P2 9 P3 l P4 10.5
3. Install shims (12) and springs (II) to valves 13,

then secure them with retainers (IO).
* Install the springs with the smaller diameter
side directed to the shims.
. Smaller inside diameter :

0 4.9 mm, Larger inside diameter : 0 5.5 mm
4. Install valve assemblies (9) to the body.
5. Install pistons (8).
& Outside of piston and inside of body :

Grease (G2-LI)
6. Install collars (7) together with the O-rings.
7. Fit seals (6).
8. Install plate (5).
m Mounting bolt:
13.23 f 1.47 Nm Il.35 f 0.15 kgm}
9. Install joint (4).

+ Degrease and dry the threads of the joint and
body completely, then apply liquid adhesive
(LOCTITE 262) one drip each to two parts of U
CAP03087
the threads of the body.
m Joint : 44.1 k 4.9 Nm I4.5 f 0.5 kgm}
10. Install boot (3) and disc (2), then install nut (I I.
* Tighten the disc until it touches the 4 pistons,
then secure it by tightening the nut. (Do not
move the pistons with the disc.)
m Nut : 112.7 f 14.7 Nm ill.5 i- 1.5 kgm}
30-64 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

ASSEMBLY
A Start the engine and extract the arm cylinder and
bucket cylinder fully, then lower the work equip-
ment to the ground.
1. Sling the boom cylinder assembly temporarily

and remove pin (1) on the head side. m
* If any shim is inserted, record its quantity and
location.
A Start the engine and retract the piston rod,

then bind it with wires, etc. so that it will not
come out.
A Release the pressure from the hydraulic cir-

cuit. For details, see TESTING AND AD-
JUSTING, Releasing remaining pressure
from hydraulic circuit.
3. Remove pin (3) on the bottom side, then remove

boom cylinder assembly (4). m
+ If any shim is inserted, record its quantity and
location.
03394
PC1 2R, 15R-8 30-65

0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
moval.
a When aligning the pin holes, never insert

your fingers in them.
& Lubrication of pin and sliding surfaces

for assembly :
Lubricant containing molybdenum DXP00906
disulfide (LM-PI

for assembly :
Lubricant containing molybdenum
disulfide (LM-G)
Ir Reduce clearance a between the head of cyl-
inder (4) and boom (5) to 1 mm or less with
shim.
A When aligning the pin holes, never insert


for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)
* Reduce clearance b between the bottom of
cylinder (4) and swing bracket (6) to 1 mm or
less with shim.

Bleeding air
Bleed air from the boom cylinder. For details, see
30-66 PC12R,15R-8
0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
A Start the engine and lower the work equipment
to the ground with the bucket back in horizontal
position.
1. Sling the arm cylinder assembly temporarily and

remove pin (I) on the head side m
location.

’
/ CBPO3395
come out.

cuit. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure from hy-
draulic circuit.

arm cylinder assembly (4). m
location.
PC1 2R, 15R-8 30-67

0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM
CYLINDER ASSEMBLY
moval.
g When aligning the pin holes, never insert


for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)
j, Reduce clearance a between the head of cyl-
inder (4) and arm (5) to 1 mm or less with
shim.
A When aligning the pin holes, never insert u

your fingers in them. b DXP00907

for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)
* Reduce clearance b between the bottom of
cylinder (4) and boom (6) to 1 mm or less with
shim.

. Bleeding air
Bleed air from the arm cylinder. For details, see
30-68 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
g Start the engine and lower the work equipment
to the ground with the bucket back in horizontal
position.
1. Set block (I) between the bucket cylinder and arm,

and remove pin (I) on the head side. m
t If any shim is inserted, record its quantity and
location.
a Start the engine and retract the piston rod,

COP03396
come out.

draulic circuit.
2. Sling the arm cylinder assembly temporarily.

bucket cylinder assembly (4). m
Ir If any shim is inserted, record its quantity and CBPO3397
I
location.
PC1 2R, 15R-8 30-69

0
DISASSEMBLY AND ASSEMBLY BUCKET CYUNDER
IINSTALLATION OF BUCKET
CYLINDER ASSEMBLY
moval.
A When aligning the pin holes, never

insert

for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-G)
* Reduce clearance a between the head of cyl-
inder (4) and bucket link (5) to 1 mm or less
with shim.
l Shim thickness: 1 mm
* Reduce clearance b between bucket links (5)
and (6) to 1 mm or less with shim.
l Shim thickness 1: 1 mm
DXP00909
m

for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-GI
* Reduce clearance c between the bottom of
cylinder (4) and arm (7) to 1 mm or less with
shim.

Bleeding air
Bleed air from the bucket cylinder. For details,
30-70 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY SWING CYLINDER
REMOVAL OF SWING
CYLINDER ASSEMBLY
g Start the engine and swing the work equipment
to the left and stop just before the stroke end,
then lower the work equipment to the ground.
1. Remove the right floor cover.
2. Remove pin (I) on the head side. m

location.

come out.

ING, Releasing pressure from hydraulic cir-
cuit.
4. Sling the swing cylinder temporarily and remove

pin (3) on the bottom side, then remove swing
cylinder assembly (4). m
* If any shim is inserted, record its quantity and - CBPO3399
location.
PC1 2R, 15R-8 30-71

0
DISASSEMBLY AND ASSEMBLY SWING CYLINDER
CYLINDER ASSEMBLY
moval.
a When aligning the pin holes, never insert


for assembly :
DXP00910
disulfide (LM-PI

for assembly :
disulfide (LM-G)
* Reduce clearance a between the head of cyl-
inder (4) and swing bracket (5) to 1 mm or
less with shim.
. Shim thickness : 1 mm
* Reduce clearance b between bucket links (5)
and (6) to I mm or less with shim.
m DXPOOS 11


for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-GI
Ir Reduce clearance b between the bottom of
cylinder (4) and revolving frame (6) to 1 mm
or less with shim.

. Bleeding air
Bleed air from the swing cylinder. For details, see
30-72 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER
REMOVAL OF BLADE CYLINDER

ASSEMBLY
a Start the engine and swing the work equipment
by 90 degrees, then lower it to the ground.
1. Remove the cylinder cover.
2. Sling the blade cylinder assembly temporarily,

and remove pin (I) on the bottom side. a
a Start the engine and retract the piston rod, then

bind it with wires, etc. so that it will not come
out.
A Operate the blade control lever two -three times

to release the pressure from the piping.
4. Remove pin (3) on the head side, then remove

blade cylinder assembly (4). m
INSTALLATION OF BLADE
CYLINDER ASSEMBLY
moval.
/II fi2j


for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)

Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
. Bleeding air
Bleed air from the blade cylinder. For details, see
PC1 2R, 15R-8 30-73

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piping
Remove the cylinder piping.
2. Piston rod assembly

1) Set cylinder assembly (I) to tool Ul.
2) Using tool U2, loosen the cylinder head.
CLPO3114
3) Remove piston rod assembly (2) from cylin-

der (3).
CKP031 15
3. Piston assembly
1) Set piston rod assembly (2) to tool Ul to re-
move piston nut (4).
* Remove the blade cylinder of PC15R with
tool u3.
* Width across flats of piston nut:
Unit:(mm)
Model Boom Arm Bucket Swing Blade
PC12R
PCISR
30
32
32
32
32
32
32
32
32
41 77 CLPO3116
2) Remove piston assembly (5) from piston rod

(6).
CKPO3117
30-74 PC1 2R, 15R-8

0
4) Disassemble piston assembly according to

the following procedure.
i) Remove wear ring (7) from piston (8).
ii) Remove piston ring (9).
CKP03118
,
5) Remove cushion plunger (IO) from piston rod
(6).
* Perform this work for only the boom cyl-
inder.
Sr Remove the spacer between the piston
and cushion plunger (on only PC12R).
CKP03119
6) Remove spacers (11) and (12) from piston rod

(6).
* Perform this work for only the blade cyl-
inder of PC15R.
7) Remove O-ring (13) from spacer (12).
CEPO3450
4. Cylinder head assembly

1) Remove cylinder head assembly (14) from pis-
ton rod (6).
CAP03451
PC1 2R, 15R-8 30-75

0
2) Disassemble the cylinder head assembly ac-

cording to the following procedure.
22 17 15 16
i) Remove O-ring (15) and 2 backup rings
(16) from cylinder head (17).
* Perform this work for only the boom
cylinder.
ii) Remove O-ring (18) and backup ring (19).
iii) Remove snap ring (20) with snap ring pli-
ers.
iv) Remove dust seal (21).
VI Remove rod packing (22).
20 21 19 18
5. Piston rod
1) Remove 2 dust seals (23) from piston rod (6).
2) Remove bushing (24).
CAP03453
6. Cylinder
1) Remove 2 dust seals (25) from cylinder (3).
2) Remove bushing (26).
CAP03454
PC1 2R, 15R-8

ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Cylinder
I j Press fit bushing (26) to cylinder (3).
2i Press fit 2 dust sea!s (25).
CAP03454
2. Piston rod
1) Press fit bushing (24) to piston rod (6).
2) Press fit 2 dust seals (23).
23 CAP03453
3. Cylinder head assembly

1) Assemble the cylinder head assembly accord-
. ing to the following procedure.
i) Using tool U4, press fit dust seal (21) to
piston (14).
ii) Using snap ring pliers, install snap ring
(20).
iii) Fit rod packing (22).
iv) Fit O-ring (18) and backup ring (19).
1: Fit these rings in the direction shown
at right.
v) Fit O-ring (15) and 2 backup rings (16). CAP03455
* Perform this work for only the boom

cylinder.
I 26 Id CAP03452
PC12R, 15R-8 30-77

0
2) Install cylinder head assembly (14) together

with the O-ring to piston rod (6).
CAP03451
4. Piston assembly
1) Fit O-ring (13) to spacer (12).
inder of PC15R.
2) Install spacers (11) and (12) to piston rod (6).
inder of PC15R.
CBPO3450
3) Install cushion plunger (IO) to piston rod (6).

inder.
* Fit the spacer between the piston and
cushion plunger (on only PC12R).
CKP03119
4) Assemble the piston assembly according to

the following procedure. U6 7
i) Using tool U5, expand piston ring (9).
Ir Set the piston ring to tool U5 and turn
the handle by eight-ten turns to ex-
pand.
ii) Fit piston ring (9) to piston (8).
iii) Using tool U6, tighten piston ring (9).
iv) Fit wear ring (7).
CAP03093 CAP03094
30-78 PC1 2R, 15R-8

0
5) Install piston assembly (5) to piston rod (6).
6) Set piston rod assembly (2) to Ul, then install CKP03117

piston nut (4).
Ir Use tool U3 for only the blade cylinder of
PC1 5R.
* Width across flats of piston nut:
Unit:(mm)
& Piston nut : Adhesive(LOCTITE 262 or
m
equivalent)
Piston nut : See the following table.

97 CLPO3116
m Tightening torque for piston nut

Unit:(Nm {kgm})
Model Boom Arm Bucket Swing Blade
245f24.5 324k32.5 324f32.5 343f34 324k32.5

“‘IZR {25*2.5} {33+3.3} i33f3.31 i35f3.51 i33k3.3)
324k32.5 412?41 324k32.5 343+34

PC15R {33*3.3} {42?4.2} 133k3.31 I35k3.5) &%!:I
5. Piston assembly
1) Install piston rod assembly (2) to cylinder (3).
PC1 2R, 15R-8

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

3) Using tool U2, tighten cylinder head.
m Cylinder head :
See the following table.
m lightening torque for cylinder head

Unit:(Nm {kgm})
CLPO3114
6. Piping
Install the cylinder piping.
w Sleeve nut : 49 + 19.6 Nm I5 f 2 kgm}
30-80 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
Start the engine and extract the arm cylinder and
bucket cylinder fully, then lower the work equip-
ment to the ground.
A Release the pressure from the hydraulic circuit.

leasing remaining pressure from hydraulic cir-
cuit.
a Disconnect the cable from the negative

H ter-
1. 3emove floor plate (I).
2. Disconnect 2 head lamp connectors Ml1 and Ml2

(2), and pull out them toward the workequipment.
3. Sling the boom cylinder temporarily and remove

pin (3) on the head side. m
location.
* After removing the pin, start the engine and
retract the piston rod and lower it to the blade.
4. Disconnect 4 hoses (4) on the cylinder side, and

pull them out of the boom.
CBPO3405
!sling the work equipment assembly temporarily

3nd remove boom foot pin (5). a
k If any shim is inserted, record its quantity and
location.
_ift off work equipment assembly (6).
53kg Work equipment assembly : 150 kg
CBPO3406
PC1 2R, 15R-8 30-81

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
a4
moval.
p%lJ
A When aligning the pin holes,

never insert
,$& Lubrication of pin and sliding surfaces

for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-G)
Reduce clearance a between the head of
boom cylinder (7) and boom (8) to 1 mm or
less with shim.

never insert
DXPOOS

for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-G)
* Reduce clearance b between boom (8) and
swing bracket (9) to 1 mm or less with shim.

Bleeding air
Bleed air from the arm cylinder and bucket cylin-
der. For details, see TESTING AND ADJUSTING,
Bleeding air.
30-82 PC12R,15R-8
0
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET
ASSEMBLY
a Start the engine and lower the work equipment
to the ground with the bucket back down.
1. Remove link pin (1). a
2. Start the engine and retract the bucket cylinder.
3. Remove arm top pin (2). m
4. Start the engine and raise the work equipment to

remove bucket assembly (3). CBPO3021
6 kg Bucket assembly : 30 kg
INSTALLATION OF BUCKET
ASSEMBLY
moval.


for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-G)
* Reduce clearance a between bucket (3) and
link (4) to 1 mm or less with shim.
m a--l--

5,
for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-G)
* Reduce clearance b between bucket (3) and
DXP00915
arm (5) to 1 mm or less with shim.
PC12R, 15R-8 30-83

0
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY

1. Remove the bucket. For details, see REMOVAL
OF BUCKET ASSEMBLY.
2. Remove 2 hoses (I).
3. Set block @ between the arm cylinder and boom.
4. Remove pin (2) on the head side. m

Ir If any shim is inserted, record its quantity and
location.
A Start the engine

der.
and retract the arm cylin-
AL cuit.
Release the pressure from the hydraulic cir-
For details, see TESTING AND ADJUST-
draulic circuit.
5. Sling the arm assembly temporarily and remove

boom top pin (3). m
location.
6. Lift off arm assembly (4).
& kg Arm assembly : 45 kg

CEPO3408
30-84 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY ARM
NSTALLATION OF ARM
ASSEMBLY
. a-i-
movai.
v
4
#fEL3 Lubrication of pin and sliding surfaces
for assembly :
5
disulfide (LM-PI

for assembly :
Lubricant containing molybdenum -b
disulfide (LM-G)
* Reduce clearance a between the head of arm
shim.
- Shim thickness : 1 mm

never insert
4
4 u DXP00917

for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-G)
Ir Reduce clearance b between arm (4) and
boom (6) to 1 mm or less with shim.

. Bleeding air
PC1 2R, 15R-8 30-85

0
DISASSEMBLY AND ASSEMBLY BUCKET AND ARM
REMOVAL OF BUCKET AND

ARM ASSEMBLY
A Start the engine and lower the work equipment
to the ground with the bucket back down.
1. Disconnect 2 hoses (I 1.
2. Set block @ between the arm cylinder and boom.
3. Remove pin (2) on the head side. m

Jr If any shim is inserted, record its quantity and
location.
CBPO3409
A Start the engine and retract the arm cylin-
der.

cuit. For details, see TESTING AND ADJUST
draulic circuit.
4. Sling the bucket and arm assembly temporarily

and remove boom top pin (3). If
location.
5. Lift off bucket and arm assembly (4).
& k9 Bucket and arm assembly : 80 kg
30-86 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY BUCKET AND ARM
NSTALLATION OF BUCKET AND

ARM ASSEMBLY
moval.


for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)
* Reduce clearance a between the head of arm
shim.
a
A When aligning the pin holes, never
insert

for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)
Ir Reduce clearance b between arm (4) and
boom (6) to 1 mm or less with shim.

l Bleeding air
PC1 2R, 15R-8 30-87

0
DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL OF BOOM
ASSEMBLY
A Disconnect
. the cable
from the negative (-1 ter-
1. Remove the bucket and arm assembly. For de-

tails, see REMOVAL OF BUCKET AND ARM AS-
SEMBLY.
2. Set the work equipment.
A Start the engine and lower the boom onto

block 0. CBPO13411
3. Remove floor plate (I).
4. Disconnect 2 head lamp connectors Ml1 and Ml2

(2), and pull out them toward the work equipment.
5. Sling the boom cylinder temporarily and remove

pin (3) on the head side. m
Ir If any shim is inserted, record its quantity and
location.
A Start the engine and retract the boom cylin-

der and lower it to the blade.
CBPO3412
30-88 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY BOOM
7. Sling the boom assembly temporarily and remove

foot pin (5). m
* Ifany shim is inserted, record its quantity and
location.
8. Lift off boom assembly (6).
& Boom assembly : 65 kg
INSTALLATION OF BOOM
ASSEMBLY
CBP03413


for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)
+ Reduce clearance a between the head of
DXP00918
boom cylinder (7) and boom (6) to 1 mm or
less with shim.
When aligning the pin holes, never insert


for assembly :
disulfide (LM-PI

for assembly :
disulfide (LM-G)
* Reduce clearance b between boom (6) and
swing bracket (8) to 1 mm or less with shim.
PC12R, 15R-8 30-89

0
DISASSEMBLY AND ASSEMBLY SWING BRACKET
REMOVAL OF SWING BRACKET

ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
1. Remove the work equipment assembly. For de-

tails, see REMOVAL OF WORK EQUIPMENT AS-
SEMBLY.
2. Sling the boom cylinder assembly temporarily.

CBP03365
4. Pull out pin (2) and remove boom cylinder assem-
bly (3). a
5. Remove pin (4) on the head side of the swing cyl-

inder. a
+ If any shim is inserted, record its quantity and
location.
A Start the engine and retract the swing cylin-

der.
6. Remove pin (5). m

location.
7. Lift off swing bracket assembly (6).
&I kn Swing bracket assembly : 30 kg
30-90 PC1 2R, 15R-8

0
DISASSEMBLY AND ASSEMBLY SWING BRACKET
BRACKET ASSEMBLY
moval.
m
for assembly :
disulfide (LM-P)
for assembly :
disulfide (LM-G)
* Reduce clearance a between the bottom of
boom cylinder (3) and swing bracket (6) to 1
mm or less with shim.
m
for assembly :
disulfide (LM-P)
for assembly :
disulfide (LM-G)
* Reduce clearance b between the head of
swing cylinder (7) and swing bracket (6) to 1
mm or less with shim.
m
& Lubrication of pin and sliding surfaces DXPO0922
for assembly :
disulfide (LM-P)
for assembly :
disulfide (LM-G)
* Reduce clearance c between the swing bracket
(6) and revolving frame (8) to 1 mm or less
with shim.
. Bleeding air
Bleed air from the boom cylinder. For details, see
PC1 2R, 15R-8 30-91

0
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE
ASSEMBLY
g Start the engine and lower the blade to the
ground.
Sling the blade cylinder temporarily and remove

pin (I). m
A Start the engine and retract the blade cylin-

der, then lower it to the ground.
Sling the blade assembly temporarily and remove

2 blade pins (2). m
Sling blade assembly (3).
&I kg Blade assembly : 55 kg
INSTALLATION OF BLADE
ASSEMBLY
i
CBPO3041
l
moval.


for assembly :
disulfide (LM-P)

for assembly :
disulfide (LM-G)
30-92 PC1 2R, 15R-8
0
DISASSEMBLY AND ASSEMBLY CANOPY
REMOVAL OF CANOPY
1. Lift off canopy assembly (1).
E3kg Canopy assembly : 25 kg
INSTALLATION OF CANOPY
moval. CBP03416
PC1 2R, 15R-8 30-93

0
MAINTENANCE STANDARD
40 MAINTENANCE STANDARD
Swing circle ................................................. 40- 2

Track frame, recoil spring ........................... 40- 3
Idler .............................................................. 40- 4
Track roller ................................................... 40- 5
Track shoe .................................................... 40- 6
Hydraulic pump (PC15R-8) .......................... 40- 8
Control valve (PC12R-8) .............................. 40- 9
Control valve (PC15R-8) .............................. 40-15
Center swivel joint ....................................... 40-21
Swing motor ................................................ 40-22
PPC valve ..................................................... 40-23
Hydraulic cylinder ....................................... 40-24
Work equipment .......................................... 40-26
PC12R, 15R-8 40-1

MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

1 Bearing axial clearance Replace
0.03 – 0.15 0.25
40-2 PC12R, 15R-8

MAINTENANCE STANDARD TRACK FRAME, RECOIL SPRING
TRACK FRAME, RECOIL SPRING
Unit: mm
Standard size Repair limit

Track Rebuild
Vertical width frame 103 106
1
of idler guide
Idler Rebuild or
support 100 93 replace
Track
Horizontal frame 161 164 Rebuild
2 width of idler
guide Idler Rebuild or
support 158 155
replace
Free length Installed length Installed load Free length Installed load
3 Recoil spring Replace
6,865 kN 5,997 kN
200 168 {700 kg} 195.6
{611.5 kg}
PC12R, 15R-8 40-3

MAINTENANCE STANDARD IDLER
IDLER
Unit: mm
Standard clearance Repair limit

Outside diameter of
1 protruding portion
266 259.5
2 Outside diameter of tread 227 221

Rebuild or
Width of protruding replace
3 portion 23 17
4 Overall width 60 55
5 Width of tread 18.5 21.5
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
6 Clearance between idler Replace
and bearing +0.030 +0.030 bushing
62 0 0 0 – 0.030 1.5
Clearance between shaft 0 +0.039

7 30 – 0.025 0 0 – 0.064 1.5 Replace
and support
40-4 PC12R, 15R-8

MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
Standard clearance Repair limit

Outside diameter of
1 protruding portion
96 90
2 Outside diameter of tread 80 74 Rebuild or

replace
3 Width of tread 31 34
Width of protruding
4 portion 26 23
Tolerance Standard
Standard size
Shaft Hole clearance
Interference between shaft
5 and bearing
0 – 0.20 Replace
25 0.179 – 0.40 bushing
– 0.021 – 0.40
Interference between roller +0.40 +0.039

6 and bearing 35 0.161 – 0.40
+0.20 0
PC12R, 15R-8 40-5

MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
RUBBER SHOE
Unit: mm

1 Wear of lug height
23 5
Wear of roller guard Replace

2 portion 30 33
Standard size Tolerance Repair limit

Wear of meshing portion
3 of sprocket +1.5
23 27
0
40-6 PC12R, 15R-8

MAINTENANCE STANDARD TRACK SHOE
STEEL SHOE
Unit: mm
Standard size Repair limit Replace

bushing and
1 Link pitch pin or link as-
90 92
sembly
2 Height of grouser 15 5
3 Height of link 46 41
4 Outside diameter of 22 18
bushing
Tolerance
Standard Standard Interference
size Shaft Hole interference limit Replace
5 Interference between link
and regular pin
14 +0.155 +0.050 0.100 – —
+0.150 0 0.105
Interference between link 22 +0.154 +0.050 0.100 – —

6 and bushing +0.150 0 0.104
Tolerance
Standard Standard Clearance
Clearance between mas- size Shaft Hole clearance limit
7 ter pin and bushing
– 0.020 +0.050 0.020 –
14 – 0.050 0 0.100 0.8
PC12R, 15R-8 40-7

MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
PC15R-8
40-8 PC12R, 15R-8

MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
PC12R-8
PC12R, 15R-8 40-9

40-10 PC12R, 15R-8

Unit: mm

Free length Installed Installed Installed
× O.D. length Free length load When dam-
1 Spool return spring load
(travel, blade, boom swing) age or defor-
98 N 78.4 N mation is
46.2 × 20 25.4 {10 kg} — {8 kg} found, re-
place the
22.6 N 18.1 N spring
Spool return spring
2 (arm, swing, boom, bucket) 29 × 17.5 28.5 {2.3 kg} — {1.84 kg}
PC12R, 15R-8 40-11

Unit: mm

× O.D. length Free length load
(breaker)
22.6 N 18.1 N
29 × 17.5 28.5 {2.3 kg} — {1.84 kg}
Pressure compensation 6.86 N 5.49 N When dam-

2 valve spring 20 × 8.4 12 {0.7 kg} — {0.56 kg} age or defor-
mation is
Pressue compensation 7.64 N 6.11 N found, re-
3 valve spring 16.9 × 8.4 15 {0.78 kg} — {0.62 kg} place the
spring
28.8 N 23.1 N
4 Unload valve spring 38.5 × 17.7 18 {2.94 kg} — {2.36 kg}
78.8 N 63.0 N
5 Cooler check valve spring 27.2 × 13.2 21 {8.04 kg} — {6.43 kg}
Back pressure check valve 15.3 N 12.2 N

6 spring 29 × 13.3 21 — {1.25 kg}
{1.56 kg}
40-12 PC12R, 15R-8

Unit: mm
Standard size Repair limit When dam-

Free length Installed Installed Installed age or defor-
× O.D. length Free length load mation is
1 Check valve spring load
(arm, boom) found, re-
1.96 N 1.57 N place the
21.9 × 5 15.8 {0.2 kg} — {0.16 kg} spring
PC12R, 15R-8 40-13

Unit: mm

1 Pilot relief valve spring load
found, re-
32.4 × 10.4 27 {8.5 kg} — {6.8 kg} spring
40-14 PC12R, 15R-8

CONTROL VALVE
PC15R-8
PC12R, 15R-8 40-15

40-16 PC12R, 15R-8

Unit: mm

× O.D. length Free length load When dam-
(travel, blade, boom swing) age or defor-
98 N 78.4 N mation is
46.2 × 20 25.4 {10 kg} — {8 kg} found, re-
place the
22.6 N 18.1 N spring
Spool return spring
2 (arm, swing, boom, bucket) 29 × 17.5 28.5 {2.3 kg} — {1.84 kg}
PC12R, 15R-8 40-17

Unit: mm

(breaker)
22.6 N 18.1 N
29 × 17.5 28.5 {2.3 kg} — {1.84 kg}
Pressure compensation 6.86 N 5.49 N

2 valve spring 20 × 8.4 12 {0.7 kg} — {0.56 kg}
Pressue compensation 7.64 N 6.11 N When dam-

3 valve spring 16.9 × 8.4 15 {0.78 kg} — {0.62 kg} age or defor-
mation is
found, re-
Pressue compensation 30.5 N 24.4 N
4 valve spring 23.61 × 8.4 17 {3.11 kg} — {2.49 kg}
place the
spring
82.4 N 65.9 N
5 Unload valve spring 29.1 × 18.7 18 {8.4 kg} — {6.7 kg}
78.8 N 63.0 N
6 Cooler check valve spring 27.2 × 13.2 21 {8.04 kg} — {6.43 kg}
Back pressure check valve 15.3 N 12.2 N

7 spring 29 × 13.3 21 {1.56 kg} — {1.25 kg}
40-18 PC12R, 15R-8

Unit: mm

1 Check valve spring load
(arm, boom) found, re-
21.9 × 5 15.8 {0.2 kg} — {0.16 kg} spring
PC12R, 15R-8 40-19

Unit: mm

1 Pilot relief valve spring load
found, re-
32.4 × 10.4 27 {8.5 kg} — {6.8 kg} spring
40-20 PC12R, 15R-8

MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
Unit: mm
Standard size Standard clearance Clearance limit

Clearance between rotor Replace
1 and shaft 45 0.055 – 0.085 0.090
PC12R, 15R-8 40-21

MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
40-22 PC12R, 15R-8

MAINTENANCE STANDARD PPC VALVE
PPC VALVE
kgm 11.28±14.7Nm
(11.5±1.5kgm)
kgm 13.2±1.5Nm
(1.35±0.15kgm)
1
kgm 44.1±4.9Nm
(4.5±0.5kgm)
A–A C–C
kgm 39.2±4.9Nm
(4.0±0.5kgm)
kgm 12.7±2.9Nm
(1.3±0.3kgm)
2 D–D
3 kgm 6.8±1.9Nm
(0.7±0.2kgm)
B–B
E–E
SBP00434
Unit: mm

1 Centering spring load
(for P3, P4) When dam-
55.9 N 45.1 N
50.4 × 15.5 34 {5.7 kg} — {4.6 kg} age or defor-
mation is
found, re-
Centering spring 29.4 N 23.5 N place the
2 (for P1, P2) 44.4 × 15.5 34 {3.0 kg} — {2.4 kg} spring
16.7 N 13.7 N
3 Measuring spring 26.5 × 8.2 24.9 {1.7 kg} — {1.4 kg}
PC12R, 15R-8 40-23

MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
PC12R-8
Unit: mm
Standard Tolerance Standard

Cylinder Clearance
– 0.020 +0.033 0.020 –

Boom 30 – 0.072 0 0.105 0.405
Clearance be- – 0.020 +0.033 0.020 –

Arm 30 – 0.072 0 0.105 0.405 Replace
tween piston rod
1 and cylinder cylinder
head – 0.020 +0.033 0.020 – head
Bucket 30 – 0.072 0 0.105 0.405
Boom – 0.020 +0.033 0.020 –

swing 30 – 0.072 0 0.105 0.405
– 0.020 +0.033 0.020 –

Blade 30 – 0.072 0 0.105 0.405
+0.134
Boom 35 — +0.072 — 1.0
+0.099
Arm 30 — +0.040 — 1.0
Clearance be-
tween piston rod +0.099
2 support shaft Bucket 30 — — 1.0
+0.040
and bushing
Boom +0.099
swing 30 — +0.040 — 1.0
+0.134
Blade 35 — +0.072 — 1.0
Replace
bushing
+0.134
Boom 35 — +0.072 — 1.0
+0.099
Arm 30 — +0.040 — 1.0
Clearance be-
tween cylinder +0.099
3 bottom shaft and Bucket 30 — — 1.0
+0.040
bushing
Boom +0.099
swing 30 — +0.040 — 1.0
+0.134
Blade 35 — +0.072 — 1.0
40-24 PC12R, 15R-8

MAINTENANCE STANDARD HYDRAULIC CYLINDER
PC15R-8
Unit: mm
Tolerance
Cylinder Standard Standard Clearance
– 0.025 +0.039 0.025 –

Boom 35 – 0.087 0 0.126 0.426
– 0.025 +0.039 0.025 –

Clearance be- Arm 35 0.126 0.426
tween piston rod – 0.087 0 Replace
1 and cylinder cylinder
head – 0.020 +0.033 0.020 – head
Bucket 30 – 0.072 0 0.105 0.405
Boom – 0.020 +0.033 0.020 –

swing 30 – 0.072 0 0.105 0.405
– 0.025 +0.039 0.025 –

Blade 35 – 0.087 0 0.126 0.426
+0.134
Boom 35 — +0.072 — 0.1
+0.099
Arm 30 — +0.040 — 0.1
Clearance be-
tween piston rod +0.099
2 support shaft Bucket 30 — — 0.1
+0.040
and bushing
Boom +0.099
swing 30 — +0.040 — 0.1
+0.134
Blade 35 — +0.072 — 0.1
Replace
bushing
+0.134
Boom 35 — +0.072 — 0.1
+0.099
Arm 30 — +0.040 — 0.1
Clearance be-
tween cylinder +0.099
3 bottom shaft and Bucket 30 — — 0.1
+0.040
bushing
Boom +0.099
swing 30 — +0.040 — 0.1
+0.134
Blade 35 — +0.072 — 0.1
PC12R, 15R-8 40-25

MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
40-26 PC12R, 15R-8

MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
Standard Tolerance Standard Clearance

Clearance between bushing size clearance limit
and mounting pin of boom Shaft Hole
1 swing bracket and revolving
frame 50 – 0.01 +0.230 0.070 – 1.0
– 0.05 +0.060 0.280
Clearance between
bushing and pin of boom 35 – 0.01 +0.134 0.082 – 1.0
2 – 0.05 +0.072 0.184
foot pin
Clearance between bushing
and mounting pin of arm 30 – 0.01 +0.134 0.082 – 1.0
3 – 0.05 +0.072 0.184
and boom
and mounting pin of link 30 – 0.01 +0.134 0.082 – 1.0 Replace
4 – 0.05 +0.072 0.184
and link
and mounting pin of bucket 30 –0.090 +0.117 0.170 – 1.0
5 –0.130 +0.080 0.247
and link
6 and mounting pin of link 30 – 0.01 +0.134 0.082 – 1.0
and arm – 0.05 +0.072 0.184
7 and mounting pin of bucket 30 –0.090 +0.117 0.170 – 1.0
and arm – 0.130 +0.080 0.247
8 and mounting pin of track – 0.01 +0.099 0.073 – 1.0
30 +0.062 0.149
frame and blade – 0.05
PC12R, 15R-8 40-27

90 OTHERS
Hydraulic circuit diagram PC12R-8 .................. 90-3

Hydraulic circuit diagram PC15R-8 .................. 90-5
Electric circuit diagram PC12R,15R-8 ............... 90-7
PC12R, 15R-8 90-1

PC12R 8

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PC12R 8

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SEBM013103

MACHINE MODEL SERIAL NUMBER

• PC12R-8, PC15R-8 mount the 3D68E-3 engine.

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

10 STRUCTURE AND FUNCTION ............................................................ 10-1

20 TESTING AND ADJUSTING ................................................................. 20-1

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

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

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

00-2 PC12R, 15R-8

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Item number (IO. Structure

. If a part cannot be smoothly removed from

A Slinging with one rope may cause

4.4 hanging angle. On the other hand, two

Ir The allowable load value is estimated to

METHOD OF DISASSEMBLING, CONNECTlNG PUSH-PULL TYPE COUPLER

v Used to prevent rubber gaskets, rubber

9 Used in places requiring an immediately

1 Features: Resistance to heat and chemi-

i 790-l 29-9060 id hesive: 1 Used as adhesive or sealant for metal, glass

Holtz n Used as heat-resisting sealant for repair-

p Quick hardening type adhesive

Quick hardening type adhesive

Features: Resistance to heat, chemicals

Used as adhesive or sealant for gaskets

Features: Resistance to heat

Q’W Container Main applications, features

l Features: Resistance to water, oil

l Used as sealant for various threads, pipe

l Features: Silicon based, resistance to heat,

l Features: Silicon based, quick hardening

l Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

SYG2-4OOLI l General purpose type

l Used for normal temperature, light load

400 g l Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width

Thread diameter Width

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat 1 Tighteni g torque

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TlGHTENtNG TORQUES FOR O-RING BOSS PIPING JOtNTS

Thread diameter Width across flat Tightening torque

TABLE OF TtGHTENtNG TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)