SEBM025000 SIO” MIAVNTUA\ Ls KOMATSU PCO3-2 MACHINE MODEL _ SERIAL No. PC03-2 21587 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. + PC03-2 mount the 2D68E-3A engine. © 2001 KOMATSU All Rights Reserved Printed in Japan 05-01(03) 00-101 10 20 30 40 91 CONTENTS STRUCTURE AND FUNCTION.........ccssssssssscsseeeeseesneeneenteene TESTING AND ADJUSTING........ccsscssessesssesessseeneesteenesntennees DISASSEMBLY AND ASSEMBLY ................. MAINTENANCE STANDARD..............::ccsseese ENGINE No. of page seen O11 10-1 20-1 ee 91-1 Pco3-2take the necessary actions to deal AX important SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. ‘The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu'for the 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 ith the situation. A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1.Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear foose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. * Always wear safety glasses when grinding parts with a grinder, ete. 3.f welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4.When carrying out any operation with two ‘or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. PCO3-2 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for ‘smoking. Never smoke while working. PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the contro! levers and hang warning signs on them, 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine If it is impossible to use the handrails, ladders or steps, use 2 stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- tying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to 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 00-4 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘© When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track. PCo3-2FOREWORD. 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 chapters for each main group of components; these chapters are further divided into the following sections, 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. Contact your KOMATSU distributor for the latest information. Pco3-2 00-5HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as ‘one volume to cover all models Engine volume: Electrical volume: Attachments volume These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work. FILING METHOD 1, See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volumel: 10-3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): Unit number (1. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) {Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-4-1 12-203-1 10-4.2 }~Added pages £4 9.203-2 10-5 12-204 00-6 REVISED EDITION MARK (O@O® When a manual is revised, an-edition mark is recorded on the bottom outside corer of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. ‘SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. symbol | Item Remarks ‘Special safety precautions are necessary when performing the work, A | soto ‘Special technical precautions fr other precautions for preserving standards are necessary when performing the work, | action Weight of pars or systems Coulton necessary when Selecting hosting wie, pr wien working posture if important et Weight Places that require special attention for the tightening torque during assembly. Tighten- ing torque| Places to be coated with Coat | adhesives and lubricants, ete. Places where oll, water or i, water | fuel must be added, and the capacity. ce) oz Ds @ Places where oil or water must be drained, and quantity to be drained. whey | Drain PCo3-2HOISTING INSTRUCTIONS Ad Heavy parts (25 kg or more) must be lifted with a hoist etc. in the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with the symbol <> 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: ‘= Check for removal of all bolts fastening the part to the relative parts. = Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1)Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S" twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 2 14 128 16 14 22 16 28 18 36 20 44 224 56 30 10.0 40 18.0 50 28.0 60 40.0 Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. 100% BH 78H 1% aH, 50064 3)Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. AB. Sirsing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result ina dangerous accident. 4)Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can’ be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. A A rm The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. PCO3-2 2000} i f= 00-7STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. niwees Halas eae 1 of bolt actoss flat ‘en (eam) kam ii 6 10 1.35+0.15, 13.2214 8 13, 3.2403 31.4229 10 7 6.707 65.7268 em 19 115+1.0 112+9.8 14 22 18.0+2.0 177419 16 24 28.5+3 279429 18 27 3944 383439 20 30 56+6 549+58 22 32 7648 745*78 24 36 94.5410 927498 27 41 135415 13204140 30 46 175+20 1720+190 33 50 (225+25 2210+240 36 55 (280+30 (2750+290 39 60 335435 3280+340 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque. * Nm (newton meter): 1Nm = 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque of bolt across flats (mm) (mm) kgm Nm 10 14 6740.7 65.7468 12 17 112298 16 22 27929 00-8 Pco3-2—s C24 es 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. C4 == Thread diameter | Width across flats Tightening torque ‘of nut part ‘of nut part - (ram) (om) kgm Nm. 14 19 2.5205 245449 18 24 8+2 492196 22 27 8x2 7854196 24 32 1423 13734294 30 36 183 176.5:29.4 33 a 20*5 196.1249 36 46 2545 245.249 42 55 30+5 294.2449 COATING MATERIALS ‘The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. ee cine os laa eo oi erg Sa Bate apSE Don Taped SOS TOE w iT-4 mating portion of she Tat | ten gato part moves aang oct Sealant gasket — and exhaust png a ea Taio eT ees pon Wings weed erev ag a ape \G-5 screw fittings in hydraulic circuit tool less than 50 mm in: ‘dometer TES | Son bse typ uedin combination wih LG and .G-4 \e-7 to peel off. eee eee to! Js and taper shafts to facilitate press-fitting and to ER aT cane) Reid wears tao a brat eg Se ee — ee ams [to oti bts erlfoncoroin *LT-2is also called LOCTITE inthe shop manuals, Pco3-2 00-9eA In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires, ELECTRIC WIRE CODE 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 15 cry “0.45 13.36 70 59 ‘Starting (Glow plug) eens eee CLASSIFICATION BY COLOR AND CODE Creve i | cima ccraring | Ground | staring | Ligning | tastument | signa otner ee = 3 7 Y @ T rma T Cotor| White Black Black Red ‘Yellow Green Blue Code] wa = aw iw ve ew ow e Color] White & Red - Black & White | Red & White | Yellow &Red | Green & White | Blue & White cose] we 7 w Fa ve GJ = * | sz. | Cor] Wane 8 eich | — [Bock Yetow | Reda eck | Yerow kack | Geant fed | Oue® Red ary \Coge wu = ‘BR RY YG cy uy . Color] White & Blue - Black & Red | Red & Yellow | Yellow & Green | Green & Yellow | Blue & Yellow cove] we 7 = Re we J rc : Color | White & Green = = Red & Green | Yellow & Blue | (Green & Black) | (Blue & Black) Cons = = m ww oy = . Cotor | - - - Red & Blue | Yellow & White | (Green & Blue! = 00-10 Pco3-2CONVERSION TABLE Method of using the Conversion Table ‘The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example + Method of using the Conversion Table to convert from millimeters to inches 1. Convert 56 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal tine from ®. {2) Locate the number 5 in the row across the top, take this as @, then draw 8 perpendicular line down from © {3) Take the point where the two lines cross as ©. This point © aives the value when converting ‘rom millimeters to inches. Therefore, 56 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. ~ (2) Carry out the came 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 650 mm = 21.65 inches. Millimeters to inches 1 mm = 0.03937 in ° 1 2 3 4 5 ° 0.039 | 0.079 | 0.118 | 0.157 | 0.197 '| 0.236 | 0.276 | 0.315 | 0.354 10 | 0304 | 0433 | 0472 | a5t2 | 0551 | 0591 1] 0.630 | 0.669 | 0.709 | 0.748 20 | 0787 | 0827 | 086s | 0906 | 094s | ogea) 1.024 | 1.063 | 1.102 | 1.142 30 | 121 | 1.220 | 1.260 | 1.209 | 1339 | 1.3781] 1.417 | 1.457 | 1.496 | 1.536 ao | 1575 | 1614 | 1.654 | 1.693 | 1.732 | 1.772 |] 1.811 | 1.850 | 1.890 | 1.929 2205 | 2.244 | 2283 | 2.923 “2480 2559 | 2598 | 2638 | 2677 | 2.717 2a35 | 2874 2.953 | 2.992 | 3.032 | 3071 | 3.110 3228 | 3268 3.346 | 3.386 | 3.425 | 3.465 | 3504 3.622 | 3661 3.740 | 3.760 | sere | aas8 | 3898 PCo3-2 00-11Millimeters to Inches 0 7 2 Sle | 5 ef ectaa t 1 + ‘ oO ; 0.039 | 0079 | 0.118 | 0.157 | 0.197 | 0236 ' 0276 | 0315 } 0.354 10 ase | 0493 | oa72 | astz | 0861 | ose1 | 0690 | 0682 | 0709 | 0748 | i i i 20 0787 | 0.827 | 0866 | 0906 | 0945 | oe 1028! 1.069 | 102 | 1.142 vo | ase | azz0 | 1200 | 1.209 | rave | sare | air | nasr | sa96 | 530 40 1575 | 1614 | 1654 | 1.693 | 12792 | 1.772 | "1.811 ' 3.850 | 1.890 | 1.929 | j i : i poof 50 +960 | 2008 | 2047 | 2087 | 2.26 | 2185 | 2205 | 2248 | 2203 | 2323 6 2262 | 2402 | 2441 | 2480 | 2520 | 2569 | 2598 | 2638 | 2677 | 2.717 70 2786 | 2.795 | 2895 | 2.874 | 29:3 | 2053 | 2.992 | 3032 | | ano ! 1 1 20 aaso | 3199 | 3228 | 3268 | 9.207 | 2346 | 3386 | 3425 | 3.508 0 asas | 3503 | 3622 | 3661 | 3701 | 3740 | 3700 | 3819 3.808 ! i i L L | | L L L Kilogram to Pound Vika = 2.2046 Ib | i 220} 441) 661] sez | 1102 | 1323 | 1543 | 17.64. 1984 10 22.05 | 2425 | 2646 | 2865 | 2086 | a307 | 25.27 | 748 | 3968 41.99 20 4409 | 4630 | 4250 | 50.71 | sir | 55.12 | 5732 | 5953: 6173! 6393 i ! 20 eos | oat | 7055 | 7275 | 7496 | 77.16 | 707 | ers? | e378) e508 40 88.18 | 90.38 | 92.59 | 94.80 | 97.00 | 99.21 joa | 103.62 : 105.82 ° 108.03 i | | i ' 50, 110.23 | 112.44 | 114.66 | 116.85 | 119.05 | 121.25 j 12346 | tse | 127.87; 130.07 0 132.28 | 13448 | 196.69 | 198.89 | 141.10 | 143.30 | 145.51 | 147.71 | 14990 | 152.12 70 184.32 | 156.53 | 158.73 | 160.94 | 163.14 | 165.35 | 16755 ; 16976 | 171.96 © 174.17 80 176.37 | 17857 | 180.78 | 182.98 | 185.19 | 187.39 | 189.60 | 191.80 ' 194.01 196.21 | i 90} 19842 | 20062 | 20283 | 205.03 | 207.24 | 20844 | 211.64 | 71385 | 21605 . 21826 | : 1 L L ab 00-12 PCO3-2r to U.S. Gallon, 180.2642 US. Gal eee 02 | 0526] o703| 1057] 1321] 1505] 1200 | 212] 2978 10 | 2602| 2906| 2170) 3438] 3608) 2963] 4227] aan| 4755| sor0 20 | 5263| ssee| serz| so7e| 6240] seor| oa0a| 7123/7297 | 7.661 30 7925| 9199] 8454] 8.718] 8982] 9.246] 9510] 9.774! 10.039 10.303 40 | 10567 | 10.831 | 11.095 | 11.360 | 11.624 | 11.980 | 12.152 | 12416 | 12.680 | 12984 | | so | 19200 | 12.479 | 19.737 | 14001 | 14265 | 14520 | 14.795 | 15050 | 15.222 | 15596 co — | 15.250 | 16.115 | 16379 | 16.683 | 16907 | 17.171 | 17.425 | 17700 | 17.964 | 10228 20 | se4se | 10.756 | 19.020 | 19205 | 10549 | 102812 | 20.077 | 20:24: | 20.605 | 20.70 co | 21.10 | 21.308 | 21.662 | 21926 | 22100 | 22485 | 22.719 | 22,983 | 23247 | 23511 co | 23.775 | 24040 | 24308 | 24508 | 24.832 | 25006 | 25.261 | 25.625 | 25.089 | 26.153 | | Liter to U.K. Gatton. 1&= 0.21997 U.K. Gal 0220| 0440 | 0660| 0890) 1.100| 120) 1510] 1.760] 1.980 10 | 2200] 2420} 2640) 2860} 3090) 2200) 3520| 3740] 3950| 4.179 20 | 4290| <610| 4030] sose| 279] s4oo| sz19| S920] 150] 6379 x | 6500| aro | 7030| 7250] 2479| 7960] 7919] e120| e350) 570 40 3799} 9.019] 9239] 9.459] 9.679} 9.899] 10.119] 10.339) 10.559) 10.778 so | r0908| 11.261 | 11438 | 11.4680 | 1176 | 12090 | 12.918 | 12828 | 12.758 | 12.978 co | 998} 13418 | 13638 | 13.888 | 14078 | 14290 | 14518 | 14798 | 14.980 | 16.178 70 | 15296 | 15.618 | 16.38 | 16058 | 16.278 | 16400 | 16.718 | 16938 | 17.158) 17.378 eo | 7800 17910 | 16037 | 10257 | 18477 | 18607 | 12.017 | 19397 | 10:57 | 19577 co | 19707 | 20007 | 20.237 | 20.487 | 20.677 | 20.807 | 24.117 | 21397 | 21557 | 21.77 PCO3-2kgm to ft.lb 1 kg.m = 7.233 feb ° 1 2 3 4 5 6 7 8 9 72| 145| 217} 289 | 362] 434] sos | 579 10 723 | 796| 868 | 940] 1013 | 108s | 1157 | 1230 | 1302 20 1447 | 1519 | 159.1 | 1664] 1736 | 1208 | 1881 | 1953 | 2025 30 2170 | 2242 | 2315 | 2387 | 2459 | 25632 | 2604 | 2676 | 2789 40 2893 | 2066 | 3038 | a110 | 3183 | 3255 | 3327 | 3400 | 347.2 | 50 3617 | 3689 | 3761 | 3834 | 3906 | 3978} 4051 | 4123 | 4195 | 4268 60 4340 | 4412 | 4485 | 4557 | 4629 | 4702 | 4774 | 4846 | aor8 | 490, 70 5063 | 5135 | 5208 | 5280 | $352 | 5426 | S407 | 5569 | 5642 | 5714 80 5786 | 5859 | 5931 | 6003 | 6076 | 6148 | 6220 | 6293 | 6365 | 6437 0 eso | e502 | cosa | 672.7 | e709 | 697.1 | 6044 | 7016 | 7098 |- 7161 100 7233 | 7308 | 7378 | 7450 | 7522 | 7505 | 7687 | 7739 | 7012 | 7e04 110 | 7956 | 8029 | at0.1 | 8173 | 8246 | axe | e900 | 2463 | e535 | 8607 120 8680 | 875.2 | 8824 | 8897 | 8969 | 904.1 | 9114 | 9186 | 9258 | 9331 130 9403'| 9475 | 9548 | 9620 | 9692 | 9765 | 9837 | 9909 | 998.2 | 1005.4 140 | 10126 | 10199 | 1027.1 | 1034.3 | 1015 | 1048.8 | 1056.0 | 1063.2 | 10708 | 1077.7 150 | 10849 | 1092.2 | 1099.4 | 1106.6 | 11139 | 1121.1 | 11283 | 11356 | 11428 | 1150.0 veo | 11573 | 1645 | 11717 | 11790 | 11862 | 1193.4 | 1200.7 | 12079 | 1215.1 | 12224 10 | 11296 | 12368 | 1244.1 | 1251.3 | 12585 | 1265.8 | 12730 | 1280.1 | 12875 | 1294.7 120 | 13019 | 1309.2 | 13164 | 13236 | 13509 | 1338.1 | 1345. | 13826 | 1969.8 | 1367.0 190 | 1374.3 | 13015 | 13887 | 1396.0 | 14032 | 1410.4 | 1417.7 | 14249 | 1492.1 | 14394 00-14 PCO3-2kg/cm? to thin? Vkglem? = 14.2235 to/in? PCo3-2 — ° 1 2 3 4 5 6 7 8 9 va2| 284] a7] seo] 711 | 853] 996] 1138 | 1280 10 1422 | 1865 | 1707 | 1849 | 1991 | 2134 | 2276 | 2418 | 2560 | 2702 20 204s | 2087 | 3129 | 327.1 | 3414 | 3656 | 3698 | seo | 3989 | 4125 30 4267 | 4409 | 455.1 | 469.4 | 4836 | 497.8 | 5120 | 5263 | s4os | 9547 40 sso | 5832 | so7a | 6116 | 6258 | 640.1 | 6543 | 6685 | 6827 | 696.9 50 riz | 7254 | 7396 | 7538 | 768.1 | 7823 | 7965 | 810.7 | e250 | 8392 60 2534 | 8676 | gs18 | 96.1 | 9103 | 9245 | 9387 | 9530 | 967.2 | 9814 70 995.6 | 1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 80 taza ftis2 | 1166 aver | 1195 | 1209 | 1229 | 1257 | 1252 | 1266 20 yzeo | 1208 1909 | 1929 | 1337 | 1351 | 1968 | 1380 | 1394 | 1408 100 422 razr | 1451 | t46s | 1479 | 1493 | 1508 | 1522, | 1536 | 1850 110} 1565 | 1579 | 1593 | 1607 | 1621 | 1636 | 1650 | 1664 | 1678 | 1699 120 fa707 favar | 4735 | avag | 1764 | 1778 | 1792 | 1806 | 1821 | 1895 130 J 1849 J 1863 | 1877 | 1892 | 1906 | 1920 | 1934 | 1949 | 1963 | 1977 yao }.1991 | 2008 | 2020 | 2034 | 2048 | 2062 | 2077 | 2001 | 2105 | 2119 150 2134 |2rag | 2162 [2176 | 2190 | 2208 | 2219 | 2233 | 2247 | 2262 reo} 2276 | 2290 | 2904 |2318 | 2333 | 2347 | 2361 | 2375 | 2389 | 2404 170 | zara | 2432 | 246 | 2460 | 2475 | 2489 | 2503 | 2518 | 2592 | 2546 1a | 2560 | 2574 | 2589 | 2603 | 2617 | 2631 | 2646 | 2660 | 2674 | 2688 190 2702 2717 2731 | 274s | 2759 | 2773 | 2788 | 2802 | 2816 | 2830 200 | 2985 | 2859 | 2873 | 2887 | 2901 | 2016 | 2930 | 2944 | 2988 | 2973 210 | 2987 | 3001 |3015 | 3030 | 3044 | 2068 | 3072 | 3086) 3101 | 3115 220 | 3129 | ara farsa 3172 | 3186 | 3200 | 3214 | 3220 | 3243 | 3257 230 | 3271 | 3286 | 3300 | sara | 3328 | 3043 | 3357 | 371 | 3385 | 3390 240 | a4ra | nana | 34az | aase | 3470 | 3485 | 3499 | 3513 | 9527 | 3542 dE 00-15‘Temperature Fahrenheit-Centigrade Conversion. A simple way to convert a Fahrenheit temperture reading into a Centigrade temperature reading oF 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 itis 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 tc “ © | ce *c oa | a | woo] -u72 |v | sis | 7a | a | sae | a2 | or | re sara | -as | -a10 | -ra | v2 | sas | 02 | a7 | rr56 | ae | oe | 1796 -ua | -20 | -220 | 105 | 12 | ssa | o9 | a | tree | 202 | o | rea oa | -2 | -120 | -100 | 4 | 522 | 94 | 49 | 102 | 29 | o | rez -2a3 | -20 | -40 | -04 | 15 | s90 | wo | so | 1220 | 204 | 05 | 1250 =a | -19 | -22 | -29 | w | cos | ws | si | 1238 | 200 | 06 | 1058 me | -1e | -o4 | -22 | 7 | e26 | ma | s2 | 1256 | 206 | or | r906 cra | | 1a | 78 | se | esa | arr | so | rz | ara | os | 904 27 | 16 | 22] -22 | 19 | os2 | 122 | se | r202 | arr | oo | t022 -261 | -15 | so | -67 | 20 | eo | 122 | ss | 10 | 322 | 9 | 1040 ss | 4 | oa | 1 | 1 | oo | 122 | so | roe | aa | a | 059 so | -12 | es | -s6 | 22 | ne | 129 | s7 | ise | oa | 2 | t976 waa | -12 | 104 | -so | 22 | 7aa | rea | sa | 136e | a9 | 92 | t094 ene | - | 22] 1a | 2 | 752 | 150 | so | 1302 | aoa | oe | zore ona uo | -29 | 25 | 70 | 16 | 60 | woo | a0 | os | 2020 -ma| -2 | we | -22 | 2 | rs | ter | or | vs | ase | os | one -22 | -8 | 16 | -28 | 2» | os | w7 | oz | rss | 61 | 97 | 2006 ny | -7 | 14 | -22 | 2 | exe | 72 | 63 | rasa | 367 | 98 | 2004 ena | -6 | a2 | 17 | 2 | sz | a | oa | rez | a72 | 99 | 202 wos | -s | m0 | -11 | 30 | oo | wea | os | mao | are | 100 | a1z0 -200 | «| 22 | -o6 | a | are | reo | o6 | s508 | 406 | 105 | 2210 ssa | 2 | 2s | 0 | a2 | sos | 194 | 7 | 1526 | 3 | s10 | 2200 “isa | -2 | 224 | o6 | as | ora | 200 | eo | tea | aes | vs | 2290 sea | -1 | 202 | ss | ae | on2 | oe | 9 | 1962 | 409 | 120 | 2an0 =a | o | 220] 17 | a5 | 950 | 2a | 7 | asco | siz | 25 | 2570 -7a | 1 | me] 22 | a6 | oss | 27 | m | asa | sea | 120 | 2050 ser | 2 | ase | 28 | a7 | oes | 22 | 72 | sors | sx2 | 125 | 2750 sex | 3 | ara | as | se | 10a | zze | 72 | 1024 | coo | 40 | 2000 ass | «| 292 | a9 | 29 | 122 | m3 | 7 | 1652 | o27 | us | 2020 sso | s | ao | 44 | ao | roo | 29 | 75 | wero | ose | 150 | acz0 wa | 6 | aa] so | ar | rose | 24 | 76 | rooe | oa | 155 | ano -9 | 7 | as | se | a2 | sors | 250 | 77 | 1706 | m2 | 160 | 2200 =a | 2 | asa] 61 | a2 | to0a | 256 | 72 | 1724 | 709 | 6s | 2200 se | 9 | «a2 | 67 | as | sa | ar | 79 | 172 | 707 | 190 | s300 122 | 10 | soo | 72 | 4s | 0 | 267 | a | 160 | 794 | 15 | sar 00-16 Pco3-201 GENERAL General assembly drawing ... Specifications .. Weight table List of lubricant and water. Co3-2 01-1GENERAL ASSEMBLY DRAWING Oversit tenath 2790 (9! 2") 01-2 soot a") 1440 (661 i076") ao") 450117") (extencedd 12000) q 00 2" 9°) Qveratt wigth 90042" 11") a . = Uisetalatntre eae teal oss e1 5351/97) (Retrctedl PCO3-2SPECIFICATIONS Machine model PC03-2 STD Variable gauge Serial number 21587 and up Operating weight (kg) 820 900 Bucket capacity (m®) 0.02 Max. digging depth (mm) 1,500 1,490 Max. vertical wall depth (mm) 1,170 1,160 g | Max. digging reach (mm) 2,840 2,840 2 | Max. reach at ground level (mm) 2,760 2,760 | Mox. digging height (mm) 2,790 2,800 = | Max. dumping height (mm) 1,990 2,000 g | = | Bucket offset (mm) | Left: 460/Right: 390 | Left: 460/Right: 390 : Max. blade lifting height (mm) 155 155 g Max. blade lowering depth (mm) 175 175 © | Max. digging force (KN (kg) 10.5 {1,075} 10.5 (1,075) ‘Swing speed (rpm) 83 a3 Max. slope angle for swinging (deg.) 28 28 Travel speed (km/h) 24 24 Gradeability (deg.) 30 30 Ground pressure (standard shoe width) (MPa {kg/em’}) | 0.025 (0.25 (180 mm)} | 0.026 (0.27 (180 mm) Overall length (for transport) (mm) 2,770 2,790 Overall width (mm) 800 800 Overall height (for transport) (mm) 2,090 2,015 Overall height (mm) 2,090 2,015 Ground clearance, counterweight (mm) 350 350 2 | Min. ground clearance (mm) 170 110 5 | Tail swing radius (mm) 870 870 2 | Min. swing radius of work equipment (mm) 1,050 1,050 © | Height of work equipment at min. (mm) 2,150 2,150 swing radius Length of track on ground (mm) 900 900 Track gauge (mm) 620 620 Overall length of track (mm) 1,222 1,222 Blade width x height (mm) 800 x 220 800 x 220 01-3Machine model PCO3-2 STD Variable gauge Serial number 21587 and up Model 2D68E-3B Type ‘Acycle, water cooled, vertical, pre-combuscion ‘chamber, diesel engine No. of cylinders - bore x stroke (mm) 2-68 x72 Piston displacement (ec) 523 firing order - 2 | Flywhee! horsepower (eW(HPyrpm) 6.0 (8.19/2,200 B | Max. torque (Nmtkgmy/rpm) 32.3 (3.3)1,600 Max. speed at no load (rpm) 2,380 Min. speed at no load (rom) 900 Min. fuel consumption (g/kWhig/HPh)) 235 (173) Starting motor 12V, 0.8 KW Alternator 12V, 204, Battery 12V, 35Ah 2 | Upper guide 1 por side 8 | Track roller 2 per side & | Track shoe One-piece rubber truck Typex no. Gear type 2-tandem pump x 1 Delivery (e/miny 11.3 x2 Set pressure for travel, (MPa(kg/em?)) 16.7 (160) work equipment Set pressure for swing (MPatkg/cm*)) 6.4 (65) £ B| Be | Tooxno. 9-spool type x 1 2 88} control method Mechanically operated g 35 Travel motor Piston type (with brake valve, reduction gear) x 2 EE | swing motor Goar type (orbit) x 1 Hydraulic sylinder Hydraulic tank Hydraulic oil filter Reciprocating piston Box-shaped, sealed Tank return side 01-4 PCo3-2WEIGHT TABLE Machine model Serial number Engine ass'y + Engine +PTO + Hydraulic pump Revolving frame Canopy Operator's seat Fuel tank Hydraulic tank 9-spool control valve Ss Swing motor Center swivel joint circle Track frame ass'y + Track frame + Idler + Track roller + Sprocket + Track shoe Travel motor Boom swing bracket ass'y Boom ass'y ‘Arm ass'y Bucket ass'y Blade ass'y Boom cylinder ass'y ‘Arm cylinder ass'y Bucket cylinder ass'y Boom swing cylinder Blade cylinder Variable gauge oylinder : Variable gauge PCO3-2 Unit: kg PCO3-2 21587 and up 73.8 65 169.0 (221.0) 81.2 (133.2) 13.5 x 2 224 40x2 22.0 x2 14.0 x2 13.8 216 14.2 14.0 30.2 (36.1) 9.2 19 15 14 48 = (4.8)LIST OF LUBRICANT AND WATER KIND OF wo |-22 -4 14 Lost =30__-20 __-10 RESERVOIR AMBIENT TEMPERATURE 2 CAPACITY (2) so 6888 10H Soo $0 $88 THE Specified] Refill we | 1688 0.42 US gal 0.42 US gat 0.35 UK gall 0.35 UK gal Engine oi os3e | osse 0.09 Us gal] 0.09 US gal 0.07 UK gal] 0.07 UK gal Hydraulic system wsse | 10.06 4.09 US gall 2.64 US gal 3.41 UK gall 220 UK gal Idler (each) Trach roller (1 piece) Grease cows | oor 0.0037 US gal] 0.0037 US gat 0.0031 UK gal] 0.0091 UK gal 1308 Fuel tank 1343 US gal] — ; 2.86 UK gal 38: ASTM DOTS No. 1 REMARK + When fuel sulphur content is tess than 0.5%, change cil in the oil pan every periodic main- tenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Fuel sulphur content | Change interval of oil engine oil pan 10 1.0% 12 of regular interval Above 1.0% 1.4 of regular interval + When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAEIOW, SAE10W-30 and ‘SAE15W-40, even though an atmospheric tern- erature goes up to 10°C more or less in the day time. + Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to halt. 01-6 + There is no problem if single grade oil is mixed with multigrade oil (SAETOW-30, 15W- 40), but be sure to add single grade oil that ‘matches the temperature in the table. + We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equip- ‘ment applications. Specified capacity: Total amount of oil including oil for components and oil piping. Amount of oil needed to refill system during normal inspec- tion and maintenance. Refill capacity: ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API; American Petroleum Institute PCO3-2PCO3-2 10 STRUCTURE AND FUNCTION Engine mount 10-2 Power train .. 10-3 ‘Swing circle 4 Track frame... 5 Idler. it Track roller i. Hydraulic piping 10- 8 Hydraulic diagram 10-12, Hydraulic tank ssn 10-16 Hydraulic pump.. 10-18 9-spool control valve 10-19 ‘Swing motor 10-21 Center swivel joint 10-22 Travel motor 10-23, Valve contro! 10-24 Hydraulic cylinder . 10-26 Work equipment 10-28 10-30 10-1ENGINE MOUNT Engine Reservoir tank Radiator Drain cock Engine mount Hydraulic pump Coupling Mogeers 10-2 Specifications radiator Core type: cr42 Heat dissipation area: 3.475 m? Fin pitch: 4.0/2P Pressure valve cracking pressure: 88.3kPa (0.9kg/om*) Vaccume valve cracking pressure: =4.9kPa (-0.05kg/cm’) Water volume: 1.20 PCO3-2POWER TRAIN 1. Idler 2. Swing motor 3. Hydraulic pump 4, Travel motor PCO3-2 Faysaz001 5. Engine 6. Center swivel joint 7. $-spool control valve 9. Swing circle 10-3SWING CIRCLE aiscooz002 1. Swing circle inner race (teeth: 89) ‘SPECIFICATION 2. Ball bearing on 3. Swing circle outer race + Reduction ratio: $5 = 4.944 10-4 PCO3-2TRACK FRAME 1c0020003, 7. Track tension adjustment bolt 1. Idler 2. Track frame 8. Track shoe 3. Upper guide 9. Idler guide 4, Sprocket 5. Travel motor 6. Track roller PCO3-2 10-5TRACK FRAME VARIABLE GAUGE Idler Track frame Upper guide Sprocket Travel motor Track roller Track tension adjustment bolt Track shoe Idler guide Variable gauge cylinder Seer ggaens 10-6 supossit PCO3-2IDLER 1. Idler 2. Ball bearing 3. Shaft 4, Floating seal axsco0z008 TRACK ROLLER 1 1. Idler 2. Ball bearing 3. Shaft 4. Floating seal 23sc002005 PCO3-2 10-7HYDRAULIC PIPING |. Bucket cylinder . Arm cylinder . Boom cylinder Boom swing cylinder . 9-spool control valve . RH. travel motor Hydraulic tank . Hydraulic filter . Engine 10. Hydraulic pump 11. LH. travel motor 12. Swing motor 13. Center swivel joint 14, Blade cylinder CONSE RONS 10-8 P0352 + Pco3-2HYDRAULIC PIPING VARIABLE GAUGE 1, Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Boom swing cylinder 5. 9-spool control valve 6. R.H. travel motor 7. Hydraulic tank 8. Hydraulic filter 9. Engine 10. Hydraulic pump 11. LH. travel motor 12. Swing motor 13. Center swivel joint 14, Blade cylinder 15. Variable gauge cylinder + swpossi 10-10 Pco3-2PCo3-2 10-11HYDRAULIC DIAGRAM nor Wain geuiFe vaLve | SEV PRESSURE! 15 64Ps Uiebka/on put ee al = peti SS FaTRavEL | A a) | Cr0ko/en | 8.OMPa, [flea ! es i ‘a CTR ! 10-12 to 54900516 Pco3-2ANORABLIC_ Ta SET PRESSURE Tanepat. Ska/ea?) ia HrORAUTE POR TRAVEL NOTOR A) PRESSURE GAUGE GowwecT oN PORT "Ravel WoToR LH) LOE evLTNGER 10 50908817 10-13 Pco3-2HYDRAULIC DIAGRAM VARIABLE GAUGE WAIN REL VE. SET PRESSURE da! | a i i i BUCKET CYLINDER euenee oe a co Boaw CYLINDER i swing GycTHDER ! jservice | i joe up reaver to PR ie a6, cia) 6 oye, 1 feet 10-14 n S0P08515 Pco3-2SET PRESSURE TkPa (1. bkaZemt PRESSURE GAUGE CONNECTION PORT CENTER SWIVEL JOINT TRAVEL MOTOR (a. HyoRAULIC TANK TRAVEL WOTOR i VARIABLE GAUGE CYLINDER PCo3-2 supoasia 10-15HYDRAULIC TANK suP08520 10-16 Pco3-21. Hydraulic tank 2. Suction strainer 3. Sight gauge 4, Oil filter plug 5. Drain plug C03-2 oq o-0 syp08521 Specifications Tank capacity: Approx 13.0 ¢ Oil level: Approx. 10.0 ¢ 10-17HYDRAULIC PUMP y \ LL Be 10 9 xo 1, Pump cover Specifications 2! Side plate Type: FBRO-5.0150 3. Drive gear Theoretical delivery: 4.99+4.99cc/rev. 4. Body Rated flo\ 11.3+11.3¢/min (at 2,350rpm) 5. Coupling 6. Pump cover T. Drive gear 8. Body 9. Driven gear 10. Driven gear 10-18 PCO3-29-SPOOL CONTROL VALVE T port (to tank) A9 port (to bucket cylinder head) {AB port (to boom cylinder bottom) ‘AT port (to R.H. travel motor B port) . AB port (to boom swing cylinder bottom) f. AS port (service oil pressure outlet) Ad port (to blade cylinder head) ‘A port {to LH. travel motor A port) |. AZ port (to swing motor B port) ‘Al port (to arm cylinder bottom) ae ee re we Fe PCo3-2 aenepessor Ana assroaooe PR port (from front pump) B1 port (to arm cylinder head) B2 port (to swing motor A port) 83 port (to LH. travel motor A port) 184 port (to blade cylinder bottom) 6 port (to boom swing cylinder head) B7 port (to RH. travel motor A port) 8 port (to boom cylinder head) . BY port (to bucket cylinder bottom) PL port (from rear pump) 10-198-8 1. Travel balance valve 2. Check valve 3. Spring 4, Main relief valve (for rear pump) 5. Spool (bucket) 6. Spool (boom) 7. Spool (R.H. travel) 10-20 Ww Bo a 3. 10. " 2 13. 1“ 5 ‘Spool (boom swing) ‘Spool (service) ‘Spool (blade) ‘Spool (LH. travel) ‘Spool (swing) Spool (arm) Main relief valve for front pump) _28F02006 18. Spool return spring 16. Safety valve 17. Suction valve 18. Spring PCo3-2SWING MOTOR Cover ‘Swing pinion Flange . Check valve . Check valve spring . Housing opens PCo3-2 7. Spacer 8 Giroller ring 9. Giroller 10. End cap 11. Drive shaft 12, Output shaft aisrowon ‘SPECIFICATIONS ‘+ Type : S-280AM2U2-K ‘+ Theoretical delivery : 277 cc/rev 10-21CENTER SWIVEL JOINT 10-22 ce. " a2: |. Shaft Dust seal . Body . Cover : 2. 3. 4 Fe 82 2102006 : From 9-spool control valve B7 port : To RH. travel motor A port From 9-spool control valve B3 port : To LH. travel motor B port From 9-spool control vaive A7 port To R.H. travel motor B port From 9-spool control valve A3 port : To LH. travel motor A port From 9-spool control valve B4 port To blade cylinder bottom end From 9-spool control valve A4 port : To blade cylinder head end Pco3-2TRAVEL MOTOR 4 1. Cover 2. No.2 planetary gear 3. No. 1 planetary gear Ring gear Housing Piston Cylinder Valve plate Brake valve 10. Center spring 4 5. 6 7 8. 9. PCO3-2 nO 4 asazo02 SPECIFICATIONS 11. Swash plate 12. Output shaft (No. 2 sun gear) 18. No. 1 sun gear 14, No. 2 planetary carrier 16. Drain check valve 16. Spring 17. Return spring 18. Spool 19. Check valve 20. Spring + Type : PHD-75-378-9-8097A + Theoretical delivery : 7.8 co/rev ‘+ Reduction ratio : 36.96 10-23VALVE CONTROL ack UM 00m RAISE Fight Sind pm ‘Boom LOWER “SS Bucket CURL, | Btade LOWER kos 2ysFo2008 1. 9-spool control valve 5. LH. work equipment control lever 2. Travel control lever 6. Fuel contro! dial 3. Blade control lever 7. Boom swing control pedal 4. RH. work equipment control lever 10-24 Pco3-2HYDRAULIC CYLINDER + The diagram shows the boom cylinder. 1 3 assro2ooe 1. Head bushing 6. Cylinder head 11. Piston ring 2. Head tube 7. Rod packing 12. Wear ring 3. Bottom bushing 8, Cylinder 13, Piston 4, Bottom tube 8. Cushion plunger 14, Piston nut 5. Piston rod 10. Spacer ‘SPECIFICATIONS Unit: mm Item | Outside diameter] Inside diameter Wiath across flat Cylinder ‘of piston rod ‘of cylinder Stroke | Max. stroke | Min. stroke | “of piston nut Boom 25 50 330 930 600 24 Arm 25 50 350 935 585 2 Bucket 25 50 292 840 548 27 Boom swing 5 50 280 780 500 27 Blade 25 50 70 370 300 2 10-26 PCO3-2HYDRAULIC CYLINDER VARIABLE GAUGE + The diagram shows the boom cylinder. 2102008 1. Head bushing 6. Cylinder head 11. Piston ring 2. Head tube 7. Rod packing 412, Wear ring 3. Bottom bushing 8. Cylinder iston 4, Bottom tube 9. Cushion plunger iston nut 5, Piston rod 10. Spacer ‘SPECIFICATIONS Unit: mm Item | Outside diameter | Inside diameter i Width across flat ovina ‘a ponrod. | “etoylinder Stroke | Max. stroke | Min. stroke | Wirt.azess t Boom 25 50 330 930 600 24 Arm 25 50 350 935 585 27 Bucket 25 50 292 840 548 a7 ‘Boom swing 5 50 280 780 500 27 Blade 25 50 65 365 300 27 Variable gauge| 25 50 70 370 300 27 10-27 PCO3-2WORK EQUIPMENT 6. Boom cylinder 1. Bucket 2. Bucket cylinder 7. Boom swing cylinder 3. Arm 8. Boom swing bracket 4. Arm cylinder 9. Blade cylinder 5. Boom 10. Blade 10-28 Pco3-2WORK EQUIPMENT VARIABLE GAUGE 1. Bucket 2. Bucket cylinder ‘oan sve08s22 4, Arm cylinder 5. Boom 6. Boom cylinder 7, Boom swing cylinder 8. Boom swing bracket 9. Blade cylinder 10. Blade 11. Variable gauge cylinder PCo3-2 10-29ELECTRICAL CIRCUIT DIAGRAM Ho Te | oa woe piano V1 HLL 134 NON’ we W0 GKLL 133 NONE tan CURRENT LIMITER Tas Wye senna = jan _ z ansaid a = : 0 Se 5 3 yee zara rd WW SONS | (ore Jetoa viet ino Lie FUSE 80K STARTING swiTo FUSE 80x PCO3-2 sip08s23 10-30BarTERY ee Tea A © = a : i (6 j : one | BG | YS an Si? i i : a i $ $ ; : ‘ 4 i * an ‘i % 7. apie ‘ ee ee a 4 1435 ! i nr cure FAA eure Tel*|*]ew-r10 fae co fenrin | TAMER GLOW ah i a oc maim ner suon9 | it | ai i a i a2 ‘ — nae ; i suroasae C032 10-3120 TESTING AND ADJUSTING Standard value table for engine-related parts Standard value table for chas parts Tools for testing, adjusting, and troubleshooting . Measuring engine speed Measuring engine oil pressure Adjusting valve clearance ... Measuring compression pressure Testing and adjusting fuel injection timing Testing and adjusting oll pressure in work ‘equipment, swing, and travel circuits ....20-15 Testing locations causing hydraulic drift of work equipment Bleeding air from hydraulic cylinders 10-16 10-17 4 The following precautions are necessary when using the STANDARD VALUE TABLE for testing and ad- justing, or for troubleshooting. 1. The values in the table are for new machines, and are obtained from reference values at delivery from the factory. Therefore, they should be used as target values for judging the progress of wear, or when repairing the machine. 2. The values for judging failures are based on standards at machine delivery from the factory, and on the results of various tests. These values should be used as a reference together with the repair condi- tion and operating record of the machine to make judgements on failures. 3. The values in the table should not be used for judging claims. (A. When carving out testing, adjusting or woubleshocting stp the machine on lve ground, instal he tafety pine and block the racks, A. When working in groups, use agreed signals and do not allow unauthorized persons near the mee chine. A. Becareful not to get caught inthe fon or other rotating parts Pco3-2 20-1STANDARD VALUE TABLE FOR ENGINE-RELATED PARTS Engine 2D68E-3B Item Measurement conditions unit —_ | Standard value for | service limit value High idling rem 2,380 ~ 2,450 = Engine speed Low idling rom 1,000 ~ 1,100 - Rated speed rom 2,180 2.250 = Valve clearance Intake valve mm 0.2 a (normal temperature) | exhaust valve mm 02 = Compression pressure | Oll temperatura: 6 | MPa tkgicm’) 3.2 (83) 3.2 (33) (SAESO oll) Engine speed (rpm) (250) (250) ‘At rated speed MPa filo) | Min. 020-028 20-80)] Min, 020 (20) Olt pressure (SAE30 oil] At low idling (SAE30) | MPa tio 015 (15) 018 (18) At low idling (SAE10W) | MPa (kolem? 015 08 01 (15) Olt temperature __| Wle spaed range c Max. 120 Max. 120 Fuel injection timing | Before top dead centor 7 13-16 - 20-2 PCo3-2STANDARD VALUE TABLE FOR CHASSIS-RELATED PARTS ‘Applicable model Pcoa.2 lea Item leasurement conditions init | Standard value fF | Service limit value gory : Me te Unit) Sew machine |" deri z Waa epg ature: 60° 3 | actoumpceli’ |. Hydraulie oil temperature: 45 ~ 55°C 2,360 2,000 3 Pin Sine z $8 cpr om | EV pezpumprene [epume ret guar belo? a aie + 2:pump relief: Bucket + arm relief 2,300 710 a a [ob Boom control valve - pase 4 frm eontalae Bucket cont vate g & | Swing contro! valve fie mm] 20.3} 5 5 |203] 5 5 8 | Boom swing control 3 | faee Blade convo ate eae Lat wave cont va FH tavel enolate = Coir comeontoliner | "eam, RAISE, LOWER 2 -fsimoe Tmeonvotiver | valuetyond W—m,OUT 2 Sve sucket control r + Engine 7 ucerconvoioer | "E88, cURL OUMP 2 § | Swing control ever N~ left swing, right swing] 52 3 | Boor nin eon Weboom i, 8 | pedal ahtboom svting 2 5 i 2 ede cont ver NAGE, LOWER « 2 [Tevet cont nvr N= FORWARD REVERSE 3 Fool conte da Cow ing — Hing “ Boom == Bk WM. 20 Ply of con ever san Swing ox. 20 CO3-2 20-3Applicable model Pco3-2 oe Item Measurement cont Unit |ormew machine| value Boom control lever | * Engine at full throtle 10-20 Min. 3 + Olitemperatre: 45 55°C Blam contot ver |"iaerinobto messi 10-20 Min. 3 2 + Measure max. value © end of travel E | Bucket control lever 0-20 Min. 3 3 | swing contro! lever 10-20 Min. 3 5 io 8 | Boor swing control [Bean Win 6 z Blade control lever 13-25 Min, 35 B | Travel control lever 19-37 Min. 45 é Fuel control dial Min. 8 Boom + Oil temperature: 45 ~ 55% 157 ~ 162 + Rolief pressure with engine at full penned Stee au thot. 157-162 | 157-162 {Raliof only circuit to be measured) (60-165) |_ (160 165) 157-162 | 157-162 Bucket (60-165) |_(160~ 165) : 64-69 64-69 swing 60-70) {60-70 s 157-162 | 157-102 g | Boom swing wea |__160~ 165) | 607 185) eles lustm| 157-162 | 157-162 G60" 165 | (160~ 368) 2 les 157-162 | 157-162 cee 60165) | (160 168) = 157-162 | 15.7162 RH. travel (iso= 40 | (60~ 165 : 157-162 | 157-162 Variable gauge {60-163 | {160 tee * Hydauli ol temperature: 45 ~ 5510 * Difference betwoen relltprescure with Drop in hyrauic |" Ergin tt tee an ait pres wrnin 10 | within 10 Sure at 1/2 of rated engine speed. (rele pressure is -pump pressure) 20-4 Pco3-2Applicable mode! PC03-2 Gee em leasurement conditions nit | Stondard value for | Service limit value oy te Measurement conditior Unit | St2ndard valve f0r| Service limit val ‘Work equipment posture Max, reach ‘Overrun when stoppit swing af Deg, 20 ofesto4 + Engine at full throttle {+ Hydraulic oll temperature: 45 — 55°C + Stop after swinging one turn and mea~ ure distance that swing circle moves. ‘Work equipment posture Max. reach 20° 20 Time taken to start Sec. swinging 2085104 + Engine at full throttle ‘+ Hydraulic oil temperature: eer ere 25 — 55°C +. Time taken to swing 90° and 2 180° from starting position. é Work equipment posture Max. reach Time taken to swing ec.] Max. 37 + Engine at full throttle + Hydraulic oll temperature: 45 — 55°C + Swing one turn, and measure time taken to swing next S turns. Posture when measuring 2ones105 ‘Swing hydraulic drift’ | « Engine stopped mm] Max. 315 + Hydraulic oll temperature: 45 — 85°C + Set machine on 15° slope, and set ‘upper structure at 90° to the side. + Make match marks on swing circle ‘outer race and track frame. “+ Measure distance that match marks, move apart after 15 minutes. PCO3-2 20-5Applicable model P02 onl leasurement condition ni | Standard value for | Service limit value C4 trem Measurement conditions Uni | Stendard value for | Service 2 + Engine at fll throttle | Leslgaetrom wine |< ijcraue tempera 45 — 56°C en + Relieve swing eu Posture when measuring iN Travel speed (1) Max. 24 Max. 31 7A 100 + Engine at ful throttle + Hydraulic ol temperature: 45 — 55°C + Raise track on one side at atime rotate one tur, then measure time taken for next 5 turns with no load. Posture wien measuring Travel speed (2) sec. Max. 36 Max. 41 + Engine a full throtle + Hydraulic oil temperature: 45 — 55°C + Fun up for at least 10 m, and measure time taken to travel next 20 m on fat ground. Posture when measuring + Engine at fl throttle + Hydraulic ol temperature: 45 ~ 55°C Travel deviation {+ Run up for atleast 10m, and measure | mm 500 550 deviation when traveling next 20m fon flat ground, +x Use a hard horizontal surace. 20m 10m soso “Measure dimension x 20-6 PCO3-2Applicable mode! Pc0s.2 el em jeasurement condi nie} Standard valve f0r | Service im cao ie Measurement o Unit] Standard value for | service fimit value Posture when measuring Travel hydraulic drift mam 200 2enes108 é + Engine stopped £ + Hydraulic ol temperature: 45 — 55° + Stop machine on 15° slope with sprocket facing straight up the slope. «+ Measure the dlstance the machine moves in 5 minutes + Engine at full throttle Leakage rom wavel | grout ol temperature: 45 ~ 55°C i + Lock shoes and relieve travel circuit. skage from ewiver | 7 HYSraulic ol temperature: 45 — 55°C Leakage tom envel_| 7 Appelt presser to pot being fn measured Posture when Total work measuring equipment {ydrautic art ot Meee 380 bucket teeth tip) = | Boom cylinder § | tomount ot 2 E | vinder retraction) 3/3 + Place in above posture and measure z|= : extension or retraction ofeach S| oe cylinder and downward movement at Z| S| @mountot | bucket teeth tip. mm 10 E| S| gyinderemten- | Horizontal fat ground z\= + Bucket Rated load (36 kg) 3 + Levers at neutral 3 + Engine stopped 5 + Hydraulic oll temperature: 45 — 85°C | Bucketeyinder | Starrmeasring immediately eter 10 (amount of ootng, evlinder retraction] « Measure hydraulic drift every § minutes, and judge from results for "5 minuies. + ("When bucket is not loaded Blade (hydraulic | Set blade at maximum lifting height ‘and measure downward movernent Of blade for 15 minutes. Pcos-2 20-7Applicable model C032 Cate m leasurement conditions init | Standard value for | Service limit value sory a ep me Het new mactinert| cee uns Posture when measuring Boom 4 Bucket teeth in z Max. 2.5 Max. 2.8 ‘contact with a round | Cynder fly & ‘extended + Engine at full throttle 2 Max. 2.5 Max. 2.8 {yet o temperature: 8 —s5rc Posture when measuring an z Moco | Max. 43 3 Eftnde uty reves AE ! oad if Fully extended id + Engine at full throttle 3 Max. 3.0 Max. 3.3 yee ol temperetre ssc a Posure when measuring =| 8) ova 8] | moss | moss E| 2 | cylinder fully 8| &| rosea é See Hi &| 2 | Fully extended g els laee + Engine at full throttle 3 Max. 2.7 Max. 3.0 = ‘+ Hydraulic oil temperature: = ssc Posture when measuring Blade 2 Max. 15 Max. 18 Blade in contact = an grosed . ! com) = Blade (uly raised & _ ++ Engine at full throttle 5 Max. 15, Max. 18 1 hyeroute of tempertu g “se Posture when messarng : Beam swing : woc3a | Mex 42 Epi y 4 feasted Fully extended . + Engine ot full throttle : Max. 4.2 Max. 4.5 1 iyaeut ol temperature: z sero] @ 20-8 PCO3-2Applicable model Pc03-2 cate] oo Measurement conditions: Unit Standard value for andard value 0F | service limit value Posture when measuring (Ya Bore Engine at low idling Hydraulic ol temperature: 45 — 95°C Lower boom and measure time taken from point where bucket contacts {ground to point where chassis rises From ground. ° Max. 1 Posture when ‘measuring + Engine at low idling aoe 1 Hydraulic ol! temperature: 45 ~ 55°C 1 Stttop surface of boom horizontal, tract bucket eylinder fully, then ‘extend arm eylinder and measure time taken for arm to start moving again after stopping at Botom. Work equipment Bucket Posture when measuring at low idling zoresnis + Hydraulic oll temperature: 45 ~ 55°C + Set top surface of boom horizontal, retract arm cylinder fully, then extend bucket eyinder and measure time taken for arm to start moving again after stopping at bottom. ° Max.1 Blade Posture when ‘measuring 2oresti9 + Engine at low idling Hydraulic oll temperature: 45 ~ 55°C 1 Measure the time it takes for the rear ‘of the machine to be lifted off the ‘ground, starting from the time the Blade contacts the ground. ° Max. Leakage from cylinder + Hydraulic oil temperature: 45 ~ 55°C + Apply tlie pressure to cylinder to be measured ia C03-2 20-9TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Check or measurement item |Symbol] Part No. Part Name Remarks Digital display Engine speed ‘A__| 799-208-9000 | Multi-tachometer : 60 — 2,000 1pm Hi: 60 — 19,999 rpm Oil temperature B | 799-101-1502 | Praia temperature | 59 _ 1.200% , | 738-101-8002 | Hydraulic tester rea cae a Oil pressure c Pressure gauge: p 790-261-1203 | Digital hydraulic tester "700 kg/em* 2 | 799-401-2320 | Hydraulic gauge 10 kg/om* 0 — 70 kg/em? Compression pressure D_ | 795-502-1580 | Compression gauge | Kit Part No. '95-502-1205 Valve clearance E | Commercially | Footer gauge Blowby pressure F _| 799-201-1504 | Blowby checker 0 — 500 mmHz0 79A-264-0020 0—30kg Operating force s Push-pull scale 79A-264-0090 0—30kg Stroke, hydraulic drift H | Commercially | scale Work equipment speed 1 | Commercially | sropwatch Measuring voltage and Peeunre oles 79A-264-0210 | Tester Pump performance | 790-303-1002 | Flowmeter kit 20-10 PCO3-2MEASURING ENGINE SPEED + Tho engine speed is to be measured under the following conditions. + Engine cooling water temperature: To be within the operating range + Hydraulic oil temperature: Anywhere between 45 - 55°C 1. Remove clamp (1) for installing a sensor lo- cated on the injection pipes. 2. Install sensor @ of multi-tachometer A on in- jection pipe (2), then connect it with the main body of multi-tachometer A. 3. Start the engine and measure the engine speed under a given set condition with amplifier @ set at the dial "4", 1) Measurement of the engine speed at a low idling speed and at a high idling speed: Measure the engine speed with the fuel control lever set at the low idling posi- tion and at the high idling position. 2) Measurement of the engine speed at the time of fuel pump pressure relief: Measure the engine speed, when the fuel pump pressure is relieved, while keeping the running at the fullest speed. MEASURING ENGINE OIL PRESSURE * The engine lubrication oil pressure is to be measured under the following conditions. + Engine cooling water temperature: To be within the operating range 1. Remove hydraulic switch (1) and install con- necting plug @ included in the oil pressure gauge kit. 2. Fix oil pressure gauge C2 (10 kg/cm?) to con- necting plug @. 3. Start the engine and measure the engine oil pressure both at a low idling speed and at a high idling speed. PCo3-2 8700818 00817 Beroosis 20-11ADJUSTING VALVE CLEARANCE 1. Remove the cylinder head cover. 2. Romove cap (A) of the flywheel housing. 3. Align the pointer (1) on the flywheel housing with mark (2) on the flywheel, while normally rotating the crankshaft and watching the valve movernent. * Mark (2) is provided at two points on the periphery of the flywheel. Adjust each cyl inder referring to each mark No. + Mark No. 1: Cylinder on the flywheel side (No. 2 cylinder) + Mark No, 2: Cylinder on the co side (No. 1 cylinder) 19 fan * When the crankshaft is rotating and the corresponding cylinder is at the top dead center, the valve does not move. If the valve is found moving, rotate the crankshaft by ‘one more tum, and align pointer (1) and mark (2). 4, For the valve clearance adjustment, insert filler gauge D in between rocker lever (3) and valve stem (4), then adjust the clearance with adjust- ing screw (5) to the extent that filler gauge D can be slightly moved, and tighten lock nut (6). = Lock Nut: 22.6 - 28.4 Nm {2.3 - 2.9 kgm) 20-12 0702483 ceroiza7 PCO3-2MEASURING COMPRESSION PRESSURE MExercise good care, while taking measuring ‘compression pressure, so that hands will not, get burnt by inadvertently touching the exhaust manifold or any other heated part of the en- gine, or get the working clothes caught with a rotating part like the cooling fan and the fan belt. 1. Adjust the valve clearance correctly, referring to the section, "Valve Clearance Adjustment’, in this shop manual. 2. Run the engine for warming up until the en- gine oil temperature rises to 40 ~ 60 3, Remove nozzle holder ass'y (1) for the cylinder to be measured. * Take care so that no dust or foreign ob- jects get in the cylinder. * Replace the seat gasket, when removing the nozzle holder assemblies. 4. Install adaptor E2 to the end of the nozzle holder, and connect it with compression gauge Et. Goa=) Adaptor: 49 ~ 53 Nm (5.0 ~ 5.4 kgm} + Disconnect connector ES for the engine stop solenoid, then measure the engine compres- sion pressure by rotating the engine with the engine starting motor. %* Read the measurement value, only after the needle of the pressure gauge stops swaying. Install nozzle holder ass'y (1) after taking meas- urement of the compression pressure. Pco3-2 aevoosze 20-13TESTING AND ADJUSTING FUEL INJECTION TIMING 1. Disconnect fuel injection pipe (1) for the No. 2 cylinder. 2. Remove cap (A) of the flywheel housing, 3. Rotate the crankshaft normally, using the crank pulley-securing nut. Stop the crank- shaft, as soon as the oil surface swells on the tip of delivery valve holder (2). 4. While maintaining this condition, check that pointer (3) on the flywheel housing is matched with injection timing mark (4) on. the flywheel. 5. Ifthe injection timing is found improper, dis- ‘mantle the fuel injection pump, and adjust it by either increasing or decreasing the number of shims (5) between the fuel injec- tion pump and the timing gear case. + Increase of shims: The injection timing tends to be retarded + Decrease of shims: The injection timing tends to be advanced * When making the adjustment, pay at- tention to the following points. @ A shim of 0.5 mm thickness is the standard shim for the injection tim- ing adjustment. ® With thinner, wipe off oil on both sides of the shims and the fuel pump installing surface, since shims used for the injection timing adjustment are silicone coated. © 0.1 mm in shim thickness causes a change of approx. 1° either way. There are two kinds of shims for this application. One is of 0.2 mm and the other of 0.3 mm. 6. After adjusting, install the fuel injection pipe aw. GE Sleeve Nut: 29.45 - 34.35 Nm (3.0 - 3.5 kgm) 20-14 seroos23 } ospozass PCcO3-2TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIP- MENT, SWING, AND TRAVEL CIRCUITS A 1 2 Lower the work equipment completely to the ‘ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler plug slowly to release the pressure inside the hydraulic tank Measuring 1) Remove pressure pickup plugs (1) or (2) from the circuit to be measured, then install oil pressure gauge C1 (200 kg/cm2). + Plug(1): For bucket, boom, R.H. travel, boom swing + Plug (2): For L.H. travel, arm, blade, (swing) 2). Start the engine, run itat full throttle, then op- erate the control lever of the circuit to be measured, and measure the relief pressure. %& For the swing circuit, measure the relief pressure of the safety valve. (The set pressure of the safety valve is lower than the pressure of the main relief valve, so the main relief valve is not actuated.) +k When relieving the swing circuit, place the bucket against a pillar or block to pre- vent swinging. ‘When relieving the travel circuit, fit block © between the track shoe and sprocket to lock the track, and measure one side at atime. Adjusting & If the result of the inspection shows that there is an abnormality in the set pressure, adjust the set pressure of the main relief valve as follows. 1) Loosen locknut (6) of main relief valve (3) or (4) to be adjusted, then turn adjustmnet screw (6) to adjust the set pressure. + Valve (3): For bucket, boom, RH. travel, boom swing + Valve (4): For LH. travel, arm, blade, (swing) + Adjust the pressure with the adjustment screw as follows. To INCREASE pressure, turn clockwise To DECREASE pressure, turn counter- clockwise + One turn of the adjustment screw adjusts the pressure by 7.6 MPa (78 kg/cm). GED Locknut: 11.274 1.47 Nm (1.18 0.15 kgm) + After.adjusting, repeat the procedure in ‘Step 1 to check the set pressure again. PCo3-2 eae AE EI 4 / Cofotalotal © (OXOKCLOIOKO) 10) OCOOO® ‘i 5 Stor eta zisozaze 20-15TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT Hf there is any hydra ‘ment (cylinders), check as follows to determin drift in the work equi the cause is in the cylinder packing or in the con- trol valve. 1. Checking for defective cylinder packing ” 2 * Checking boom and bucket cylinders i) Set in the same posture as when mea- suring hydraulic drift, and stop the en- gine. ii) Operate the boom control lever to RAISE or the bucket control lever to CURL. + If the lowering speed increases, the packing is defective. + If there is no change, the control valve is defective. Checking arm cylinder i) Operate the arm cylinder to move the arm in fully, then stop the engine. ii) Operate the control lever to arm IN. ‘+ If the lowering speed increases, the packing is defective. + If there is no change, the control valve is defective. + Set the safety lock lever to the RE- LEASE position. If it is difficult to judge the condition, fill the bucket with sand or apply the rated load. [Reference] If the cause of the hydraulic drift is in the pack- 1g, and the above operat is carried out, the downward movement becomes faster for the fol- lowing reasons. v 2 3) If the work equipment is set to the above posture (holding pressure applied to the bot- tom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. When the internal pressure at the head end \ereases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by re- peating this procedure. ‘When the pressure is balanced, the down- ward movement becomes slower. If the lever then operated according to the procedure given above, the circuit at the head end is ‘opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster. 20-16 Posture for checking boom, bucket 2orron195 2oreov196 Pco3-2BLEEDING AIR FROM HYDRAULIC CYLINDERS + After replacing or installing hydraulic cylinders or hydraulic piping, bleed the air from the hydraulic cylinders as follows: 1. Start the engine and run at idling for about § minutes. 2. Run the engine at low idling, and raise and lower the boom 4 — 5 times. Stop the piston rod about 100 mm from the end of the stroke. Never operate it to the re- lief position. 3. Run the engine at full throttle and repeat the above procedure. Then run the engine at low idling and operate the piston rod to the end of, the stroke to relieve the circuit, 4, Repeat the procedure in Steps 2 and 3 for the arm and bucket also. Pco3-2 20-17TROUBLESHOOTING . 20-102 see 20-103 - 20-104 20-112 20-113 Points to remember when troubleshooting Sequence of events in troubleshooting Precautions when carrying out maintenance .. Checks before troubleshooting Method of using troubleshooting charts Troubleshooting of hydraulic and mechanical systems (H mode) Troubleshooting of machine monitor system (M mode) Troubleshooting of electrical system (E mode) - 20-129 - 20-135 Pco3-2 20-101POINTS TO REMEMBER WHEN TROUBLESHOOTING + Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. + When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. + Be extremely careful not to touch any hot parts or to get caught in any rotating parts. + When disconnecting wiring, always disconnect the negative (~) terminal of the battery first. + When removing the plug of cap from a location which is under pressure from oil or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. ‘The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swittly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and func- tion. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: + Parts that have no connection with the fail- ure or other unnecessary parts will be dis- assembled. + Itwill become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also ose the confidence of the user or operator. For this reason, when carrying out trouble- shooting, it is necessary to carry out through prior investigation and to carry out trouble- shooting in accordance with the fixed proce- dure. Points to ask user or operator 1) Have any other problems occured apart from the problem that had been reported? 2) Was there anything strange about the ma- chine before tha failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what condi cur? 5) Had any repairs been carried out before the failure? ‘When were these repairs carried out? 6) Has the same kind of failure occurred be- fore? Check before troubleshooting 1). Were there abnormal symptoms about the machine? 2) Check checking items before starting. 3) Check other checking items. ns did the failure oc- 20-102 4) Other maintenance items can be checked externally, so check any item that is con- sidered to be necessary. 4, Confirming failure Confirm the extent of the failure yourself, ‘and judge whether to handle it as a real failure or as a problem with the method of operation, etc. +k When operating the machine to reen- act the troubleshooting symptoms, do not carry out any investigation or mea- surement.that may make the problem worse. Troubleshooting + Use the results of the investigation and it spection in Items 2 — 4 to narrow down the causes of failure, then use the trouble: shooting flowchart to locate the position of the failure exactly. + The basic procedure for troubleshoot- ing is as follows. 1). Start from the simple points. 2). Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure + Even if the dailure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occured. Then, remove the root cause. PCOS-2SEQUENCE OF EVENTS IN TROUBLESHOOTING LE) sovsite », Go 20-103PRECAUTIONS WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine cover a long period, and to prevent failures or other troubles before they occur, correct op- eration, maintenance and inspection, trouble- shooting, and repairs must be carried out. This section deals particularly with correct re- pair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric. equipment” (particularly hydraulic oil) 1. PRECAUTIONS WHEN HANDLING ELEC- ‘TRIC EQUIPMENT 1) Handling wiring harnesses and connec- tors Wiring harnesses consist of wiring connecting ‘one component to another component, con- nectors used for connecting and disconnecting ‘one wire from another wire, and protector or tubes used for protecting the wiring. Com- pared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations they are frequently removed and installed again, so they are likely to suffer deformation or dam- age. For this reason, it is necessary to be ex- tremely careful when handling wiring har- nesses. Main failures occuring in wiring harness (1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female con- Rector, or because one or both of the con: nectors is deformed or the position is not correctly aligned, or because there is cor- rosion or oxidization of the contact sur- faces. (2) Defective composition or soldering of con- nectors The pins of the male and female connec- tors are in contact at the compressed ter- minal or soldered portion, but there cessive force on the wiring, and the plat- ing peels to cause improper correction or breakage. 20-104 20505201 Improper inspection 20505202 F56103079 PCo3-2(3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the com- pression of the connector may be lost, or the soldering may be damaged, or the wir- ing may be broken, 20808204 (4) High pressure water entering connector The connector is disigned to make it diffi- cult for water to enter (drip-proof struc- ture), but if high-pressure water is sprayed directly on the connector, water may enter the connector depending on the direction of the water jet. ‘The connector is designed to prevent wa- ter from entering, but at the same time, if ‘the water does enter, itis difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short- circuited by the water, so if any water gets in, immediately dry the connector or take ‘other appropriate action before passing ae electricity through it. 6) If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, ‘so there will be defective contact. If there is oil or grease or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with air, and spray it with a con- tact restorer. + When wiping the mating portion of the connector, be careful not to use exces- sive force deform the pins. +k If there is water or oil in the air, it will increase the contamination of the 20505206 points, so clean with air from which all the water and oil has been removed. PCO3-2 20-1052) Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors (1) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors ond not the wires, then fe ress lghty, Tease the tock ond pullin poral! with both ‘ Lock stopper—_ 0 hands. For connectors held by ascrew, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. aoa For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. + Never try to pull out with one hand. (2) When removing the connectors from the clips, pull the connector in a parallel direc- tion to the cf ok If the connector is twisted to the left and right or up and down, the housing Yi, may break. (3) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, di il, or water from getting in the connector portion. + When especially disassembled ma- chine is maintained for long time, that action certainly does. Because defective contacts are likely to occure. 20805208 20-106 PCO3-2Conneeting connectors (1) Check the connector visually. ‘a. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). b. Check that there is no deformation, defective contact, corrosion, or dam- ‘age to the connector pins. c. Check that there is no damage or breakage to the outside of the connec- tor. If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wir- ing with a dryer, but be careful not to make it too hot as this will cause short circuits. 4k If there is any damage or breakage, re- place the connector. CCliks into position (2) Fix the connector securely. Align the position of the connector cor- rectly, then insert it securely. For connectors with lock stopper Push in the connector until the stopper clicks into position. 20505209 (3) Correct any protrution of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the 1, adjust it to its cor- rect position. Ifthe clamp cannot adjust its correct position easily, it disconnects and trois. raosos2%0 (4) When the wiring harness clamp of the connector has been removed, always re- turn it to it original condition and check that there is no looseness of the clamp. q& PCO3-2 20-107Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. (1) Disconnect the connector and wipe off the water with a dry cloth. ok If the connector is blown dry with air, there is the risk that oil in the air may cause defective contact, so avoid ‘side of the connector with a If water gets inside the connector, use a dryer to dry the connector. > Hot air from the dryer can be used, but be careful not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. (3) Carry out a continuity test on the connec- tor. After drying, leave the wiring harness dis- connected and carry out a continuity test to check for any short circuits between pins caused by water. + After completery drying the connector, blow it with contact restorer and reassemble. 20-108 20505211 F20505212 Tadapter 20508213 PCo3-23) Handling control box (1) The control box contains a microcomputer and electronic control circuits. ‘These control all of the electronic circuits on the machine, so be extremely careful when hadling the control box. (2) Do not open the cover of the control box unless necessary. (3) Do not place objects on top of the control box. (4) Cover the control connectors with tape or vinyl bag. Never touch joints of connectors. 20505216 (5) During rainy weather, do not leave the control box in a place where it is exposed to rain. (6) Do not place the contro! box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand) (7) Precautions when carrying out are welding When carrying out arc welding on the body, disconnect all wiring harness con- nectors connected to the control box. Fit {an are welding ground close to the weld- ing point. 20505216 roe 20-1092. POINTS TO REMEMBER WHEN HAN- DLING HYDRAULIC EQUIPMENT With the increse in pressure and precision of hy- draulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic cir- cuit. When adding hydraulic oil, or when disas- sembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic cil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried ‘out on hydraulic equipment in the field, there is danger of dust entering the equipment. [tis also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic ‘equipment should be carried out in a specially Prepared dustproof workshop, and the perfor- ‘mance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the ‘openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from en- tering. If the opening is left open or is blocked with a rag, there is danger of dirt ent of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal. 4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oll. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to fil- ter out the dirt that has collected during stor- ‘age, so this is an even more effective method. 20-110 20505217 20505218 20505219 PCO3-25) Change hydraulic oil when the tempera- ture is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, ‘as much as possible of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic ol 6) Flushing operations After disassembling and assembling the ‘equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: pri mary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic cil 20505220 7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, ete.) or when running the machine, carrry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. ‘The oil cleaning equipment is used to remove the ultrafine (about 3p) particles that the filter built into the hydraulic equipment cannot re- move, s0 itis an extremely effective device. 20805221 ae 20-111CHECKS BEFORE TROUBLESHOOTING tern vademest | Remedy 1. Check fuel level, type : Add fuet 2. Check for dirt or water in fuel - Clean, drain 3 | 3 Check hydraulic oil level - ‘Add oil E | 4. check hydrauiic oil strainer - Clean, drain 6. Shack engin ae av of on ol pan : ‘Add oi 7. Check hydraulic ol filter Replace 1. Check for loose or corroded battery terminals . Tighten or replace EH 2. Check for loose oF corroded alternator terminals . Tighten or replace EZ | 3. check or loose or corroded starting motor ace . Tighten or replace 3 41. Check for abnormal noise or odor 7 Repair 5S 2. check for oil leakage - Repair £38 | 3. Blood air from system = Bleed air 1. Check battery voltage (engine stopped) 20—30V Replace a | 2 Checkleveof baton tectrove - ‘Add or replace = 3. Check for discolored, burnt, or bare wiring - Replace E | 4. checkfor missing wiring clamps, hanging wires 7 Repair 3 | 5. check for water leaking onto wiring (check care- . connestor and dry & | tly for water at connectors and terminals) connection - 6. Check for broken or corroded fuses - Replace 7. Check alternator voltage After running for (engine running at over half throttle) ee ee 20-112 PCO3-2METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number Troubleshooting Code No. Component H-00 ‘Troubleshooting of hydraulic, mechanical system MOO Troubleshooting of machine monitor system 2. Method of using troubleshooting table for each troubleshooting mode 1) Troubleshooting code number and problem. ‘The title of the troubleshooting chart gives the troubleshooting code, and failure mode (problem with the machine). (See Example (1)) 2). Distinguishing conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for exemple, a)), 60 go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. (See Example (2)) 3) Method of following troubleshooting chart + Check or measure the item inside and according to the answer follow either the YES line or the NO line to go to the next [-—]. (Note: The number written at the top right corner of the [1 is an index number i does not indicate the order to follow.) + Following the VES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right._ (See Example (3)) + Bolow the [1] there are the methods for inspection or measurement, and the judgement values. Ifthe judgement values below the [1] are correct or the answer to the question inside the [__] is YES, follow the YES line; if the judgement value is not correct, or the an- swer to the question is NO, follow the NO line. + Below the L——] is given the preparatory work needed for inspection and measurement, and the judgement values. if this preparatory work is neglected, or the method of operation or handling is. mistaken, there is danger that it may cause mistaken judgement, or the equip- ment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from ftem 1). 4) General precautions ‘When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at the top of the page and marked with x. (See Example (4)) ‘The precautions marked % are not given in the [__], but must always be followed when carry- ing out the check inside the [___]. 5) Troubleshooting tools ‘When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. 6) Installation position, pin number ‘A diagram or chart is given for the connector type, installation position, and connector pin number ‘connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem). Pco3-2 20-113 H-8 When machine is traveling, it deviates naturally to one side @ a) Deviates in same direction in both forward and reverse Oiection of, Seviation does Roses between, potchense } No] ewe! jorw one travel motor sre necrenanged? NO @ + When the travel speed is normal. 20-114 PCO3-2TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) H-1_ Speeds of all work equipment, traveling, swinging are slow or lack power . sevens 20116 H.2 There is excessive drop in engine speed, or engine stalls Work equipment, traveling, swinging do not function or are extremely slow .. . 20-116 H-3 Abnormal noise generated (from around pump) - 20-117 H-4 Control lever is heavy 20-117 HS” Work equipment (boom, arm, bucket) is slow Excessive hydraulic drift 20-118 H-6 Work equipment (boom, arm, bucket) lacks power 20-118 20-118 H-7 Excessive time lag... H-8 When machine is traveling, it deviates naturally to one side a) Deviates in same direction in both forward and reverse .. b)Deviates in different directions in forward and reverse H-9 Travel lacks power (or speed is stow) H-10 Machine does not move (one side only) H-11 Does not swing, H-12 Swing speed is slow or acceleration is poor . H-13 Excessive overrun when stopping swing H-14 Excessive shock when stopping swing .. H-18 Excessive abnormal noise when stopping swing .. H-16 Excessive hydraulic drift of swins H-17_ Excessive hydraulic drift of boom swing .. Table of failure modes and causes... PCO3-2 20-115H-1 Speed of work equipment, traveling, swinging are slow or lack power cue toma 2 ves Seam, a ves) esas fee | Snore 1 | [see % evtmine shops | ite esse esate 3 Detective aiarmentot Lajas arpa — | [Peseraacg, beer azhw, [|r || BESS” 00] Sec, baa “valve is adjusted? ie ete min eet [ence H-2. There is excessive drop in engine speed, or engine stalls Work equipment, traveling, swinging do not function, or are ex- tremely slow couse Remedy 1 ves ‘Does condition Detective pump Replace ‘ecarne normal vren pume LH Feptaeds See Engine Shop Manuat | — 20-116 PCo3-2H-3 Abnormal noise generated (from around pump) come ene 2 Sssaay TE Seis \ v0 | Saar ves ohne oveaveoume |e ees Wed som, sits, os 1] Bera aes oi ommesterz nine | Res Sereatcamaraee, [isan volgen nm Ia taka agama H-4 Control lever is heavy com er 1 ves ee ee Sara earasmemen* tees er ssa oc “ bsxaassrar wescenicnt, lnoote L Geeta ate (pat PCO3-2 20-1171-5 Work equipment (boom, arm, bucket) is slow Excessive hydraulic drift + When the travel and swing are normal. couse Remedy a) Detective operation of | Replace contrat contrat waive spo! ave seserty| i hydraulic dit of Slow evinder Defective cylinder piston [Replace histo packing psdking mm | [isteakage normal ‘nen ere Televed st end of hydrouté cylinder Stoke? etecve ster (suction) + 12 edmin are interchanged? Detective oitightnees of | Reptsce control nO. eantrol valve sp001 shee sem H-6 Work equipment (boom, arm, bucket) lacks power +k When hydraulic drift is normal. came feed : osecive operation ot |peplae contra SRO aot end eanectekespol [eSB aS peters Reeder tom ed Sy tone ene ony pete ste uesend | aenace H-7_ Excessive time lag Ifthe work equipment speed is normal (if the speed is slow, go first to H-5). Cause Remedy Time ag (see Detective operation of ucaon walee Replace * Engine stow ra 20-118 PCO3-2H-8 When machine is traveling, it deviates naturally to one side + When the travel speed is normal. Deviates in same direction in both forward and reverse 2s ves Brees 2 []acemeivis ieee [aera | ote cleved, No ase" [HERES Bat im 1 ves See : sarge beeen F ‘Are metal park akan aa See aH rakes Se ieee oe Tl — [Does direction of Eee ; Lies 7 nolsemveljomeere’” | | [Does aveqgon ot ] = Direction of Is stroke of eee: when left and right Seana] eae. iia abso, vo sec a | + 520.5 mm eee NO = 'b) Deviates in different direction in forward and reverse (See Fig. 1) com oy 2 ms a ves epee 1 [| Seoetnormary = k Pseraaeree ore motor is relieved, + 520.5 mm ial pool ers Psrinegornwest (age erie wb are [ag 20-120 agedcause Remedy Se epace 2 NNN vito . ov in at press of fins kristy ace font tina cia | apa or "iat eee eee eee eee eRe eee ese ene rn never err ESE nd PO feetace Sg ee em pee na =, dct travel motor | ence Eavlgvortntagese | Re Seectve operation of | reslace ecmrel see 00) Fig. 1 Locations of defective swivel joint packing and direction of travel deviation ‘Sate nase) Forward - {Lettreverse only |i / annevenae| Let ‘ Forward Reverse ts Left fowardand__ foe revns Cae ee {reeves e [Eronvarol_ Let forward and Reverwe Forward le ogre Tightreverse | {fight vero oniy, | WORN noche 1 cover Reverie rns In forward ang revere, deviates nGieronedresion th drection of heavier load aistozmza Pco3-2 20-121H-9 Travel lacks power (or speed is slow) + When there is no travel deviation. (When there is travel deviation, carry out troubleshooting first for H-8 When machine is traveling, it deviates naturally to one side.) cone ‘ont avs er So [Bees condition oe ined YES | when pump H sere a | [sx C soe tncine shoo Manat | ves) a, iter ne 4 yes etacie aiesenent of | aajet Ter wee es rai rote vave ms trees hneen [| exergy | + etton” 5) Brae ‘SB SRN, tte man tte Repace esesiescramiers! In saimigedt dna Lo somerceemaes | sete ssa H-10 Machine does not move (one side only) + When the work equipment and swing are normal. cause Remedy 3 ves Repaic or a {5 any frsign| ves | inact founein {| eitdraned trom al ee? Travel motor brake sragoing _ oe ves | ent aes +157 MPe nese ee + Engine at high ‘ding te stoke of contra Vai normal Defective travel motor [Replace + S05 mm Defective operation of, 08 frvelleverintage or |Repsicor Wwooperaton ot [replace NO. Contrel vaive spool 20-122 PCo3-2H-11 Does not swing 4 When the work equipment and travel are normal. Cause Remedy 3 yes| Defective swing motor | Replace Does contro YES | Vawe spocl move 2 [sacostee teracretonet Irene er cet ein] _| een svinge aojeonateteest |e Serpootewing] | wheverait L | aca Sees oan ceca + 53205 MPa Detective safety valve | Replace seem - eat, seen . — | Detective safety vaive [Replace Wien oe nat oe Detone |—| seeitetraes' ree cate wees _I] steve swing motor | epee PCO3-2 20-123H-12 Swing speed is slow or acceleration is poor +& When the work equipment and travel are normal. (if there is also deviation (to left) during normal travel, go first to H-8 "When machine is traveling, it deviates naturally to one side") couse Remeoy 2 ves. Excessive leakage insice |pepiace [tpg oes contra wae | el conse i no Sotho a he, 4 th ie and vg YES | prop in set pressure of ae Sion dnt oe ease a YES] Become normal + Tipe ten o sae 3 |] ehensatcyvahe gaing teociev00": a is adjus x Wren and Detective sateryvaive [Replace + Tinetaten or | fone direction Wohtesiey vanes] | ~ Forstanaara — nO} oa | seirctanged: L] * sSiserSSe em maae® aie] Rigen + Ets ation tevenest ca 2 itis also possible Defe motor Replace is also pose fective swing eoace foresee me hiyarauite pres NO Beta ioioe + sa es feessaem « eeet aay H-13 Excessive overrun when stopping swing Ifthe speed is slow or the acceleration is poor, go first to H-12. cue Remedy a aoe Leakage inside motor | Replace Seteuanice Sedaphe or ma Stein } octetvesatey vane |renice 20-124 PC03-2